Westerbeke 63B FOUR User manual

OPERATOR'S MANUAL
AND
INSTALLATION GUIDE
WESTERBEKE
63(B)&(C) FOUR -71B FOUR -82B FOUR -
108(B) & (C) SIX
MARINE DIESEL
ENGINES
Publication #038922
Edition Three
November 1994

OPERATOR'S MANUAL
AND
INSTALLATION GUIDE
WESTERBEKE
63(B)&(C) FOUR -71B FOUR -82B FOUR -
108(B) & (C) SIX
MARINE DIESEL
ENGINES
Publication #038922
Edition
Three
November 1994

SAFETY PRECAUTIONS
The following symbols appear in this manual to call
attention to and emphasize conditions potentially
dangerous to the operator.
II WARNING II
The above symbol is used in the manual to warn of
possible serious personal injury or loss of life.
ICAUTION I
The above symbol is used in the manual to caution
personnel of possible damage to equipment.
Read the manual carefully and thoroughly before at-
tempting to operate the equipment. Know when
dangerous conditions
can exist and take necessary
precautions to protect personnel and equipment.
Fuels, exhaust gases, batteries, electrical equipment,
and moving and hot parts are potential hazards that
could result in serious personal injury or death. Follow
recommended procedures carefully.
Always operate bilge blowers for at least five minutes
before starting a gasoline-fueled engine; ensure no
gasoline fumes are present before starting.
• Prevent Electric Shock
Shut off electric power before accessing electrical
equipment.
Use insulated mats whenever working on electrical
equipment.
Make sure your clothing is dry, notdamp (particular-
ly shoes), and keep your skin surfaces dry when
handling electrical equipment.
Remove wristwatch and jewelry when working
on
electrical equipment.
Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double-
throw transfer switch. Damage to vessel's AC gen-
erator may result if this
is not done.
Be extremely careful when working on electrical
components. High voltage can cause injury or
death.
• Exhaust Gases Are Toxic
Ensure that the exhaust system is adequate to expel
gases discharged from the engine. Check exhaust
system regularly for leaks and make sure the ex-
haust manifolds are securely attached and no warp-
ing exists.
Be sure the unit and its surroundings are well-ven-
tilated.
• Use Extreme Care When Handling Engine Fuel
(A constant danger 01 explosion or fire exists)
Do not fill fuel tank(s) while the engine is running.
Do not smoke or use an open flame near the engine
or the fuel tank.
• Do Not Alter or Modjfy the Fuel System
Be sure all fuel supplies have a positive shut-off
valve.
Be certain fuel line fittings are adequately tightened
and free of leaks.
Make sure a fire extinguisher is installed nearby and
is properly maintained.
Be familiar with its proper
use. Extinguishers rated ABC by the NFPA are ap-
propriate for all applications encountered
in this
environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye
protection when servicing batteries.
Lead acid batteries emit hydrogen, a highly-ex-
plosive gas, which can be ignited by electrical ar-
cing or by a lighted cigarette, cigar, or pipe.
Do not
smoke orallowan open flame nearthe battery being
serviced. Shut off all electrical equipment
in the
vicinity to prevent electrical arcing during servicing.
• Avoid Moving Parts
Do not service the unit while the unit is running; if a
situation arises
in which it is absolutely necessary
to make operating adjustments, use extreme care
to avoid moving parts and hot exhaust system com-
ponents.
Do notwear loose clothing orjewelrywhen servicing
eqUipment; avoid wearing loose jackets, shirts or
sleeves, rings, necklaces, or bracelets that might be
caught in moving parts.
Make sure all
attaching hardware is properly
tightened. Keep protective shields and guards in
their respective place at all times.
Do not check fluid levels or the drive-belt's tension
while the unit
is operating.
Do not work on the equipment when mentally or
physically incapacitated by fatigue.

FOREWORD
Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are
pleased to have you as a customer.
Read this manual carefully and observe all of the safety precautions indicated. Operating
procedures, periodic preventive maintenance procedures, installation
checks, system descriptions
and minor adjustment procedures are included so you can operate your equipment safely and
properly, maintain the equipment at a high level of efficiency, and expect dependable performance
and long service
life in return.
Product Software Disclaimer
Product software of
all kind; such as brochures, drawings, technical data, operator's and
workshop manuals, parts lists and parts price lists, and other information, instructions and
specifications provided from sources other than Westerbeke, is not within Westerbeke's control
and; accordingly, is provided to Westerbeke customers only as a courtesy and service.
Westerbeke cannot be responsible for the content of such software, makes no warranties
or representations with respect thereto, including the accuracy, timeliness or completeness
thereof, and will in no event be liable for any type of damages
or injury incurred in
connection with, or arising out of, the furnishing or use
of such software.
For
example, components and subassemblies incorporated in Westerbeke's prodUcts and supplied
by others (such
as engine blocks, fuel systems and components, transmissions, electrical
components, pumps
and other products) are generally supported by their manufacturers with
their
own software, and Westerbeke must depend on such software for the design of Westerbeke's
own product software. Such software may
be outdated and no longer accurate. Routine
changes made by Westerbeke's suppliers, of which Westerbeke
rarely has notice in advance,
are frequently not reflected in the supplier's software until after such changes take place.
Westerbeke customers should also keep in mind the time span between printings of Westerbeke
product software
and the unavoidable existence of earlier, non-current, Westerbeke software
editions
in the field. Additionally, most Westerbeke products include customer-requested special
features that frequently do not include complete documentation.
In summation, product software provided with Westerbeke products, whether from Westerbeke
or other suppliers, must not
and cannot be relied upon exclusively as the definitive authority
on the respective product. It not only makes good sense but is imperative that appropriate
representatives of Westerbeke or the supplier
in question be consulted to determine the accuracy
and currency of the product software being consulted by the customer.
1 Westerbeke Diesel Engines

Warranty Procedures
Should your unit require special attention, contact your Westerbeke dealer for assistance. The
Westerbeke Service Organization is trained to provide the support necessary to ensure long-term
dependable performance.
If, within 60 days of submitting the Warranty Registration Form for your unit, you have not
received a Customer Identification
Card, shown below, registering your warranty, please contact
the factory
in writing with model information, including the unit's serial number and commission
date.
Unit 1.0. Plates
"""" .["IRBE!.! COR'ORllI0~
I'O~ 1~1M1~IJL PllII<
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Mall To:
CUSTOMER IDENTIFICATION
•••• ~.;.h
II Mopl. ~ .....
Udo •. U 12134
10,,, .. "llI!1
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Customer Identification Card
For future service, repair or warranty reference, Westerbeke suggests that you fill in the blank
spaces in the diagram below with the information from your machine.
-
o 0
• MODEL SPEC AVON MA USA SER.NO..
Unit 1.0. Plates
Westerbeke Diesel Engines 2

Section
FOREWORD
GENERAL INFORMATION
MODEL PHOTOS
TABLE OF CONTENTS
63B FOUR GENERAL SPECIFICATIONS
63B FOUR SYSTEM SPECIFICATIONS
71B FOUR GENERAL SPECIFICATIONS
71B FOUR SYSTEM SPECIFICATIONS
82B FOUR GENERAL SPECIFICATIONS
82B FOUR SYSTEM SPECIFICATIONS
108B SIX GENERAL SPECIFICATIONS
108B SIX SYSTEM SPECIFICATIONS
INSTALLATIONS & INSTALLATION CHECKS
EXHAUST SYSTEM
RAW WATER INTAKE SYSTEM
OPERATIONS - CAPTAIN'S PANEL
- ADMIRAL'S PANEL
PREPARATIONS FOR STARTING
STARTING PROCEDURE
STOPPING PROCEDURE
ENGINE BREAK-IN PROCEDURES
FUEL SYSTEM
DC CONTROL CIRCUIT WIRING
DIAGRAM: #36467
#36844
#39144
COOLING SYSTEM
LUBRICATION SYSTEM
TRANSMISSIONS
HBW & HSW - HURTH
BORG WARNER
WALTER V-DRIVE
ENGINE TROUBLESHOOTING
MAINTENANCE & ADJUSTMENTS
LAY-UP & RECOMMISSIONINGIWINTERIZING
TABLE OF STANDARD HARDWARE
TORQUE SPECIFICATIONS
SPARE PARTS
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GENERAL INFORMATION
Introduction
This manual contains the equipment operating procedures as well as additional information
needed to help the operator keep the marine equipment in proper working order. Study and
follow the instructions carefully. A planned maintenance program is included in this manual.
Adhering to the program will result in better equipment performance and longer equipment life.
Proper diagnosis of a problem is the most important step to satisfactory repair; therefore, a
troubleshooting table
is included.
Understanding the Diesel Engine
The diesel engine closely resembles the gasoline engine since the mechanism is essentially
the
same. The cylinders are arranged above a closed crankcase; the crankshaft is of the same
general type as that of a gasoline engine; and the diesel engine has the same type of valves,
camshaft, pistons, connecting rods, and lubricating system.
Therefore, to a great extent, a diesel engine requires the same preventitive maintenance as a
gasoline
engine. The most important factors are proper ventilation and proper maintenance of
the fuel lubricating and cooling systems. Replacement of fuel and lubricating filter elements at
the time periods specified is a must, and frequent checking for contamination (that is, water,
sediment, or algae) in the fuel system is also essential. Another important factor is the use of
the
same brand of high detergent diesel lubricating oil designed specifically for diesel engines.
Be careful not to put gasoline in the diesel fuel tank(s). Gasoline does not have the same
lubricating qualities as diesel fuel; consequently, gasoline in the fuel lines will damage components
in the fuel injection pump and fuel injectors.
The diesel engine does differ from the gasoline engine; however, in its handling and firing
of
fuel. The carburetor and ignition systems are done away with and it their place are two
components -the
fuel injection pump and the fuel injectors.
Protecting Your Investment
The five most important steps to insure long engine life are:
1. Proper installation. In particular, the use of an anti-siphon break to preclude raw
water intrusion into the engine via the exhaust elbow is essential.
2. Avoid Overcranking. This can fill the engine with raw water .
3. Change the lubricating oil.
4. Maintain the cooling system.
5. Winterizing your Westerbeke product.
Ordering Parts
Whenever replacement parts are needed, always provide the generator model number designation
(Le. 63B FOUR), engine serial number, and generator serial number as they appear on the
data
plates located on the exhaust manifold and on the generator end. You !111.§1. provide us
with this information so we may properly identify your generator set. In addition, include a
complete part description
and part number for each part needed (see the separately furnished
Parts List). Also, be sure to insist upon Westerbeke factory packaged parts because "will fit"
or generic parts are frequently not made to the same specifications as original eqUipment.
Westerbeke Diesel Engines 4

General Information (continued)
Note that component locations in the manual are referenced from the front of the engine which
is the pulley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides
are deteremined by the engine; imagine straddling the engine and facing in the same direciton
as the front of the engine: the left side is at your left, the right side is at your right.
Westerbeke generator sets are thoroughly checked and given a final run under various load
conditions before leaving the factory. Test running the generator ensures dependable operation,
long service I ite, and a satisfied owner.
Care at the factory during assembly and thorough testing have resulted in a Westerbeke diesel
engine-driven generator capable of many thousands of hours of dependable service. However,
what the manufacturer cannot control
is the manner or location the generator is installed in
the vessel or the manner in which the unit is operated and serviced in the field. That part is
up to the buyer/owner-operator.
5 Westerbeke Diesel Engines

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70' Exhaust Elbow
Zinc Anode
Domestic Water Heater
(Return)-- __
Instrument Panel
Connection ___
Transmission
Shift Lever
Fresh Water Coolant Fill
Optional DC
Charging
Alternator
Domestic Water Heater Connection (To)
63 B FOUR
Lube Oil
Drain Hose
Adjustable Engine Isolator

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Optional Refrigeration Compressor
\ Top Engine
Fuel Injection Pump
Alarm
Oil Pressure Sender
Oil Fill
Preheat Solenoid
Lube Oil Dipstick
Starter with Solenoid
inc Anode
Domestic Water Heater
(Return)
Instrument Panel
Connection
/
,
Battery Ground
Connection
Transmission
Cooler
Adjustable
Engine Isolator
Lube Oil Cooler Transmission Drain

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Domestic Water Heater Connection
Fuel Manual Primer
Preheat Solenoid ________
Zinc Anode
Domestic Water Heater
(Return)-
Heat Exchanger
Marine Transmission
(To) Fresh Water Fill Cap
71 B FOUR
Optional
Refrigeration
Compressor
Optional
DC Alternator

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Fuel Lift Pump
Lube Oil Drain Hose
Oil Pressu re Switch
Lube Oil Cooler
Air Intake Silencer
Fuel Manual Primer
Lube Oil Dipstick /
/
Fuel Filter
inc Anode
Domestic Water Heater
(Return)
Starter with Solenoid
Pressure Sender
Lube Oil Filter

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70° Exhaust Elb
Domestic Water Heater
(Return)
Instrument Panel
Connection
Transmission
Shift Lever
Domestic Water
Fresh Water
Unit I. D. Plate
DC Charging
Alternator
Raw
Water Pump
Lube Oil Drain Hose
(To) Adjustable Engine Isolator
Starter with Solenoid
82 B FOUR

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Fuel Lift Pump
Fuel Injection
Pump
Top Engine Oil Fill
Adjustable Engine Isolator
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Oil Pressure Sender
Preheat Solenoid
Lube Oil Filter
Secondary Fuel Filter
Zinc Anode
Domestic Water Heater
(Return)
Fresh Water Block
Drain Plug
Transmission
Cooler
Transmission Drain
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Domestic Water Heater (To)
90' Exhaust Elbow
Exchanger Air Bleed
Petcock
Transmission Cooler
Transmission
Dipstick
Transmission Vent
Transmission Drain Plug
Fresh Water Fill Cap
Starter with Solenoid
108 B SIX
Top Engine Oil Fill Cap
Lu
DC Charging
Alternator
Oil Drain Hose

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Top Engine Oil Fill Cap
Water Temperature
Alarm Switch
Water
Temperature
Sender
Fresh Water
Circulating
Pump
Adjustable Engine Isolator
Lube Oil r
Secondary Fuel Filter
Oil Pressure
Sender
Fuel Lift Pump
20 A DC
Circuit Breaker
Zinc Anode
Domestic Water Heater
(Return)
Instrument
Panel Connection
il Pressure
Alarm Switch

63(B) & (C) Four Marine Diesel Engine General Specifications
Engine Type
Governor
Valve Mechanism
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque (at 2900 rpm)
Compression Ratio
Compression Pressure
Valve Seat Angle
Valve Clearance
(engine cold)
Dimensions
Inclination
Dry Weight
Engine Speed
Fuel Consumption
Westerbeke Diesel Engines
Diesel, four-cycle, fresh water-cooled, vertical, in-line (63
hp at 3600 rpm maximum)
Integral
of the injection pump, mechanical flyweight type.
Overhead
Swirl chamber type
3.50 x 3.51 inches (88.9 x 89.9 mm)
134.8 cubic inches (2.21 liters)
1-3-4-2
Clockwise, when viewed from the front
93 Ib-ft (10.92 kg-m)
21:1
427 psi (30.0 kg/cm') at 200 rpm
Intake 45° Exhaust 45°
Intake 0.12 inches (OJ mm)
Exhaust 0.012 inches (0.3 mm)
Height: 25.30 inches (642.6 mm)
Width: 21.19 inches (538.2 mm)
Length: 38.75 inches (984.3 mm)
Continuous 14° Temporary 25° (not to exceed 30 min.)
611
lbs (192 kgs)
Idle speed: 750 -1000 rpm
Cruising speed: 2500 -3000 rpm
1.2 US gph (4.5 Iph) running at 2500 rpm (approximate)
when the propeller allows 3600 rpm at full open throttle
while underway
in forward gear.
14