Westerbeke 63B FOUR User manual

OPERATORS MANUAL
638 and 63C FOUR
71 8 and 71 C FOUR
828 FOUR
1088 and 108C SIX
MARINE DIESEL ENGINES
PUBLICATION NO. 038922
EDITION FIVE
OCTOBER 2006
WESTERBEKE CORPORATION' 150 JOHN HANCOCKROAD
MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKECOM

A WARNING
Exhaust gasses contain carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness
- Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.
~---------'
'~ A WARNING DECAL is provided by
X WESTERBEKE and should be nxed to a
CO
bulkhead near your engine or generator.
\ WESTERBEKE also recommends installing
.. .. \ CARBON MONOXIDE DETECTORS in the
WA RNIN GI living/sleeping quarters of your vessel.
'C-enerators Produye CARBON M9NOXIDE. The
u
are ine""ensive and easil
u
Regular M",ntenance Required !''''. ,
l ~~~~~ J obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure tofollow fundamental rules andprecau-
tions. Know when dangerous conditions exist andtake the
necessary precautions
to protectyourself, yourpersonne4
andyour machinery.
The following safety instructions
are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running. Lethal voltage is present at
these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handlipg electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor
by shorting terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Dr
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery
tame
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching
the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Dr death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke orpermit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -Diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area
away from spark-producing
equipment and out of
the reach ofchildren.
• Do 110t fill the fuel.tank(s) while the engine is mnning.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff 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 appropriate
for all applications encountered in this environment.
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
Dr death!
• To prevent accidental starting when servicing the
generator, remove the 8 amp fuse from the control panel.
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it
last.
• Make certain all personnel are clear ofthe engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being
serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment
in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb
the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or
sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
off
at once with water. Acid may splash on the skin or
into
the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) Is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust
manifolds/water-injected elbow L" securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting
in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near
the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from "gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing
in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. Ifa
situation
arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
--
II

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels orthe drive belts tension while
the engine is operating.
• Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss/
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many ofthe preceding safety tips and wamings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and foHow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination of the American Boat and Yacht
Council's (ABYC) standards. These standards are a
combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust Systems
PA Inboard Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABye, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Goverument Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention
be paid to the following infom1ation:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of20" above the vessel's waterline. Failure to use asiphon-break when
the exhaust manifold injection port is ator below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be desigued to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines &Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Remote Oil Filter (Optional) .............................. 21
Introduction ......................................................... 3
Water Heat Connections ................................... 22
Warranty Procedures........................................
.3
Serial Number Location ...................................4
Admiral Control Panel ......................................... 5
Captain Control Panel ......................................... 6
Wiring Diagram ................................................ .26
Wiring Schematic .............................................. 27
Glow Plugs ........................................................ .28
Starter Motor ............. ........................................ 29
Fuel, Engine Oil, and Coolant. ............................ 7
Preparations for Initial Start-Up ......................... 8
The Daily Operation ..... ........................................ 9
Engine Break-In Procedure ............................... 10
Dual Output Alternators .................................... 31
Alternator TestingJTroubleshooting .................. 34
Engine Troubleshooting ..................................... 37
Service Schedule ....... ....................................... .41
Warning Lights, Alarms and Circuit Breaker .... 11
Cylinder Head Torque ....................................42
Maintenance Schedule .................................... .12
Engine Adjustments .......................................... 43
Fuel System .... ................................................... 14 Oil Pressure ....................................................44
FueliWater Separator......................................14
Tachometer ..................................................... 43A
Fuel Filters......................................................14
Engine Specifications ...................................... .45
Cooling System .................................................. 15
ZF Marine Transmission ......... ........................... 49
Changing Coolant........................................... 15
Thermostat......................................................16
Raw Water Intake Strainer..............................16
Borg Warner Transmission ............................... .49
Lay-Up and Recommissioning ........................... 58
Raw Water Pump............................................ 17
Torque Data ....................................................... 60
Heat Exchanger .............................................. 18
Metric Chart ...................................................... 6]
Zinc Anode ..................................................... 18
Engine Lubricating Oil .......................................19
Suggested Spare Parts ...................................... 63
Changing the Oil Filter...................................19
Changing the Oil ............................................19
Engines & Generators
1

PARTS IDENTIFICATION
ASSEMBLY
DC CHARGING
ALTERNATOR
COOlANT
PRESSURE CAP
WMERHtAltK·-------~
CONNECTION
DRIVE BELT
RAWWATERP~
CRANKSHAFT
PULLEY
OIL DRAIN HOSE
FUEL LIFT PUMP
PREHEAT
SOLENOID ----
ZOAMP
CIRCUIT
BREAKER
HBW
HURTH
TRANSMISSION
REAR
(TYPICAL)
LEFT SIDE
SHIFT LEVER
FILL
ENGINE BLOCK
DRAIN PLUG
Engines &Generators
2
WATER INJECTED
EXHAUST ELBOW
Oil PRESSURE
SENDOR
COOLER
Fill
FILTER
AIR INTAKE
SILENCER
REAR
FILTER
FLEXIBLE
MOUNT
THERMOSTAT
_",~"o;;l"'DLY
FRONT
MANIFOLD
1.0. PLATE
ALTERNATOR

INTRODUCTION
This WESTERBEKE Diesel Engine is a product of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your engine, it is
important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this man-
ual carefully and observe an the safety precautions through-
out. Should your engine require servicing, contact your
nearest WESTERBEKE dealer for assistance.
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment, contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days ofsubmitting the Warranty Registry
form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the engine's
serial number and commission date.
Customer Identification Card
/WO/WESTERBEKE
,
Customer Identification
MR. ENGINE OWNER __ _
NUUNSTREET __________ _
HOMETOWN,
Model ____ _ Ser.#
___ _
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BERESPONSIBLE FOR THE
CONTENTOF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE UABLE
FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF
THE FURNISHING OR USE OFSUCH SOF1WARE.
WESTERBEKE customers should keep in mind the time
span between printings ofWESTERBEKE product software
and the unavoidable existence ofearlier WESTERBEKE
product software. The product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively 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 currentness of the
product software being consulted by the customer.
NOTES, CAUTIONS AND. WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, if nDt strictly
observed, can result in the damage Dr destruction of
your engine.
A WARNING: Procedures which, if not properly fol-
lowed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
a nameplate mounted on the side of the engine's manifold.
The engine's serial number can also be found stamped into
the engine block on the flat sutface of the block just above
and inboard of the injection pump. Take the time to enter this
information on the illustration of the nameplate shown below,
as this will provide aquick reference when seeking technical
information andlor ordering repair parts.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the
mechanism is essentially the same. The cylinders
are arranged
above aclosed crankcase. The crankshaft is the
same general type
as a gasoline engine, and the diesel engine
has the same type of
valves, camshaft, pistons, connecting
rods and lubricating
system.
Therefore, to agreat extent, a diesel engine requires the same
preventive
maintenance as a gasoline engine. The most
important factors are proper ventilation and proper mainte·
nance of the fuel, lubricating and cooling systems. Fuel and
lubricating filter elements
must be replaced at the time
periods specified, and frequent checking for contaminant's
(water, sediment,
etc.) in the fuel system is also essential.
Another important factor
is the consistent use ofthe same
brand
of high detergent diesel lubrication oil designed
specifically
for diesel engines.
The diesel engine
does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The
carburetor
and ignition systems are replaced by a single
component -
the fuel injection pump - which performs the
function of
both.
GLOW PLUG,
ENERGIZED BY THE PREHEAT 1TT£'Al""""""",",
l--~- DIESEL FUEL SPRAY
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine model number
and serial number as they appear on
the silver and black nameplate located on the manifold. You
must provide us with this infonnation so we may properly
identify your engine. In addition, include a complete part
description
and part number for each part needed (see the
separately furnished
Parts List). Insist upon WES1ERBEKE
packaged parts because willfit or generic parts are frequently
not made to the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WES1ERBEKE
engine. Your local WES1ERBEKE dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page in this manual. For engine
accessories,
see WESTERBEKE'S ACCESSORIES brochure.
RAW WATER COOLING SYSTEM
Siphon-Break
For installations where the water injected exhaust elbow is
close to or will be below the vessels waterline, provisions
must be made to install a siphon·break in the raw water
supply hose to the water injected exhaust elbow. The siphon·
break provides an air vent in the raw water cooling system to
prevent raw water from filling the exhaust system and the
engine's cylinders when the engine is shutdown.
A CAUTION: Failure to use a siphon-break when
the exhaust manifold injection port isat or below the
load waterline will result in raw water damage to the
engine and possible flooding of the boat.
If you have any doubt about the position of the water·
injected exhaust elbow relative to the vessels waterline under
the vessels various operating conditions, install a siphon-
break. This precaution is necessary to protect your engine.
The siphon·break must be installed in the highest point ofa
hose that is looped a minimum of 20 inches (51cm) above
the vessels waterline. This siphon·break mustalways be
above the waterline during all angles of vessel operation to
prevent siphoning.
NOTE: A siphon·break requires periodic inspection and
cleaning to ensure proper operation. Failure to properly
maintain a siphon-break can result in catastrophic engine
damage. Consult the siphon-break manufacturer for proper
maintenance.
SIPHON-BREAK WITH STAINLESS
LOOP FOR 314" HOSE
PART NO.045368
Engines &Generators
4

ADMIRAL CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch and RPM gauge with an ELAPSED TIME
meter which measures the engine's running time in hours and
in 1110 hours. The panel also includes a WA1ER 1EMPER-
ATURE gauge which indicates water temperature in degrees
Fahrenheit, an OIL PRESSURE gauge which measures the
engine's oil pressure in pounds per square inch, and a DC
control circuit VOLTAGE gauge which measures the sys-
tem's voltage. All gauges are illuminated when the key
switch is turned on and remain illuminated while the engine
is in operation. The panel also contains two rubber-booted
pushbuttons, one for PREHEAT and one for START.
RPM GAUGE: REGIS·
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATEO FOR
ACCURACY FROM THE
REAR OF THE PANEL.
HOURMETER:
REGISTERS ELAPSED
TIME, AND SHOULD BE
USED AS A GUIDE FOR
THE MAINTENANCE
SCHEDULE.
WATER TEMPERATURE GAUGE: THIS GAUGE IS
GRADUATED IN DEGREES FAHRENHEIT AND IS
IlWMINATED WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
TEMPERATURE IS 170' -190·F (77" - aa·c).
PREHEAT PRESSED, ENERGIZES THE
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE
FUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS. IT BYPASSES THE ENGINE'S
OIL PRESSURE ALARM SWITCH. IN ADDITION, THIS
BUTTON ENERGIZES THE START BUTTON.
START BUTTON: WHEN PRESSED. ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.
THIS BUTTON WILL NOT OPERATE ELECTRICALLY
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD
AT THE SAME TIME.
When the engine is shut down with the key switch turned off,
the water temperature gauge will continue to register the last
temperature reading indicated by the gauge before electrical
power was turned off. The oil pressure gauge will fall to zero
when the key switch is turned off. The temperature gauge
will once again register the engine's true temperature when
electrical power is restored to the gauge.
Aseparate alarm buzzer with harness is supplied with every
Admiral Panel. The installer is responsible for electrically con-
necting the buzzer to the four-pin connection on the engine's
electrical harness. The installer is also responsible for installing
the buzzer in a location where it will be dry and where it will
be audible to the operator should it sound while the engine is
running. The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engine's oil pressure rises above 15 psi (1.1 kglcm2).
Oil PRESSURE GAUGE: THIS GAUGE IS GRADU-
ATED IN POUNDS PER SQUARE INCH (PSI) AND IS
ILLUMINATED WHILE THE KEY SWITCH IS TURNED
ON. THE ENGINE'S NORMAL OPERATING OIL
PRESSURE RANGES BElWEEN 30 - 60 psi
(2.1 - 4.2 kg/em').
AUTOMATIC ALARM SYSTEM
__ -"'" SWITCH: PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER
DC VOLTMETER:
INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED.
SHOULb SHOW 13VTO 14V.
COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
REACHES 210" F (99"C), THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
Oil PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
FALL TO 5 -10 psi (OA - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND-
ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
SIGNAL
Engines & Generators
5

CAPTAIN CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch, an RPM gauge, PREHEAT and START but-
tons, an JNSTRL'MEI\TT JEST button and three indicator
lamps, one for AL1ERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for high ENGINE COOLANT
1EMPERATURE.
RPM GAUGE: REGISTERS REVOLUTIONS
PER MINUTE OF THE ENGINE AND CAN BE
RECALIBRATED FOR ACCURACY FROM
THE REAR OFTHE PANEL.
Oil PRESSURE ALTERNATOR
ALARM LIGHT ALARM LIGHT
WATER TEMPERATURE
ALARMUGHT
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME
TIME.
The panel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT 1EMPERATURE. The
RPM gauge is illuminated when the KEY switch is turned on
and remains illuminated while the engine is in operation.
ALARM: THE ALARM WILL SOUND IF THE ENG1NE'S OIL PRESSURE FALLS
BELOW 5 -10 psi (0.4 -0.7 kg/em'). IN THIS EVENT, THE ALARM WILL EMIT A
PULSATING SIGNAL. THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
210
aF
(99°C). IN THiS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
PRESSURE REACHES 15 pSi (1.1 kg/em'), THE ALARM WILL SILENCE.
TEST BUTTON: WHEN
PRESSED, TESTS THE
ALTERNATOR, THE OIL
PRESSURE, AND THE
COOLANT TEMPERA-
TURE CONTROL CIR-
CUITS. WHEN PRESSED,
THE ALTERNATOR, THE
OIL PRESSURE, AND
THE WATER TEMPERA-
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND-
ING THE ALARM
BUZZER,
KEY SWITCH: PROVIDES
POWER ONLY TO THE
lNSTRUMErijT PANEL
CLUSTER.
BUTTON: WHEN PRESSED, ENERGIZES THE
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE FUEL
SOLENOID ON THE INJECTION PUMP, AND THE ENGINE'S
GLOW PLUGS, AND BYPASSES THE ENGINE'S OIL PRES-
SURE ALARM SWITCH. IN ADDITION, THIS BUTTON ENER-
GIZES THE START BUTTON.
Engines & Generators
6

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel1hat meets 1he requirements or specification ofClass
2-D (ASTM), and has a cetane rating of #45 or better.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of1he components
in your fuel injection pump is very critical; invisible dirt
particles which might pass through 1he filter can damage
these finely finished parts. It is important to buy clean fuel,
and keep it clean. The best fuel can be rendered
unsatisfactory by careless handling or improper storage
facilities.
To assure that the fuel going into the tank for your
engine's
daily use is clean and pure, the following practice
is advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor500 FG or 900 FG are good examples ofsuch
filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification ofCf
or
CG-4 or better. Change the engine oil after an initial 50
hours of break-in operation, and every 100 hours ofoperation
1hereafter. For recommended oil ,use sAE 15W-40
(oil viscosity) and stay with 1he same brand ofoil thru-out
the life of the engine.
A CAUTION: Do not allow two Dr mDre brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could reacl in the mixture
to produce properties harmful tD your engine.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engin~ surfaces.
The antifreeze performs double duty. It allows the engine to
run at proper temperatures by transferring heat away from
the engine to the coolant, and lubricates and protects the
cooling circuit from rust and corrosion. Look for a good
quality antifreeze 1hat contains Supplemental Cooling
Additives (SCAs) that keep the antifreeze chemically
balanced,
crucial to long term protection.
The distilled water
and antifreeze should be premixed before
being poured
into the cooling circuit.
NOTE: Lookfor the new environmentally-frierully long lasting
antifreeze that is
now available.
PURCHASING ANTIFREEZE
Rather than preparing the mixture, WESTERBEKE
recommends buying the premixed antifreeze so that so that
when adding coolant the mixture will always be correct
There are two common types ofantifreeze, Ethylene Glycol
(green) and Propylene Glycol (red/purple), either can be used
but do not mix the two and if changing from one to another,
flush the engine thoroughly.
Premixed antifreeze for DIESEL Engines:
Specification
#ASTM 5345.
MAINTENANCE
Change the engine coolant every five years regardless of the
number of operating hours as the chemical additives that
protect and lubricate the engine have a limited life.
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each generator.
The purpose of this recovery tank is to allow for engine
coolant expansion and contraction during engine operation,
without the loss ofcoolant and without introducing air into
the cooling system . .
~. II
Engines & Generators
7

PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
Before starting your engine for the first time or after a
prolonged layoff, check the following items:
o Check the engine oil level. Add oil to maintain the level
at the high mark on the dipstick.
o Turn on the fuel supply, then check the fuel supply and
examine the fuel filter/water separator bowl for
contaminants.
o Check the transmission fluid level.
o Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the positive
(+) battery cable is connected to the starter solenoid and
the negative (-) cable is connected to the engine ground
stud (this location is tagged).
o Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: If the engine has notyet beenfilled with coolant,
refer to the COOliNG SYSTEM section of this manual.
D Visually examine the engine. Look for loose or missing
parts. disconnected wires, and unattached hoses. Check
the threaded connections and engine attachments.
D Make certain there is proper ventilation around the
engine. An ample supply is necessary for proper engine
performance.
D Make sure the mounting installation is secure.
D Ensure the propeller shaft is securely attached to the
transmission.
D Open the thru-hull and make certain raw water is primed
to the raw water strainer.
SIDE OIL FILL
(TYPICAL)
Engines & Generators
8
COOlANT
'RECOVERY
TANK
,-""-_- OIL DIPSTICK
PRESS IN TIGHT
/!~_ FULL (MAX)

STARTING - STOPPING PROCEDURE
CHECKLIST
Follow this check list each day before starting your engine.
D Visually inspect the engine for fuel, oil, or water leaks.
D Check the engine oil level (dipstick).
D Check the coolant level in coolant recovery tank.
Periodically check the manifold coolant leveL.
D Check the transmission fluid level.
D Check your fuel supply.
D Look for clean fuel in the fuel filter/water separator
transparent
bowL
Check for loose wires at the alternator and make sure its
mounting is secure.
D Check the starting batteries (weekly)
D Check drive belts for wear and proper tension (weekly).
D Visually inspect the raw water pump for leakage.
STARTING THE ENGINE
1. Place the transmission in neutral, throttle advanced.
NOTE: Hydraulically operated transmissions have a
neutral safety switch
through which the starter solenoid
energizing circuit
passes. This switch is open when the
transmission is in gear so the starter solenoid will not
energize.
2. Tum the KEY SWITCH to the ON position (2 o'clock).
(If the panel is energized, gauges are lit) and the alarm
buzzer will pulse.
3. Press the PREHEAT BUTfON, and hold for 5 to 15
seconds depending how cold it is .. (Thefoellift pump is
priming the engine and the preheat is activated).
4. Continue pressing the PREHEAT BUTTON and press
the START BUTTON. (The starter motor is cranking the
engine).
5. Release the START and PREHEAT BUTTON as the
engine starts. The alarm buzzer should silence as the oil
pressure rises.
6. With the engine running, check the instruments for
proper oil pressure and battery charging voltage. Also
check for overboard discharge ofexhaust water. The
water temperature
will rise slowly until the thermostat
opens. Do not engage the gear shift until the temperature
is close to nonnal.
NOTE: Never attempt to engage the starter while the
engine is ntnning.
It
is important to closely monitor the panel gauges.
Become aware of the normal engine readings and take
immediate action ifthese readings start to vary.
If a "smart" regulator is part of the charging system,
allow about 50 second~ for the RPMgauge to activate.
FAILURE TO START
If the engine fails to start when the start button is pressed for
5 seconds, wait for at least 30 seconds and repeat the starting
procedure. Make certain the transmission control is in th~
neutral position as some engines have a neutral safety SWItch
to prevent starting in gear.
Never run the starter for more then 30 seconds. If the engine
fails to start, refer to the TROUBLESHOOTING CHART in
this manual.
A CAUTION: Prolonged cranking intervals without
the engine starting can result in the engine exhaust
system filling with raw water. This may happen because
the pump is pumping raw water through the raw water
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust system tills. Prevent this
from happening by clOSing the raw water supply
through-hull shutoff, draining the exhaust muffler, and
correcting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
in mind.
STOPPING PROCEDURE
To stop the engine, bring the throttle to an idle position and
place the transmission in neutral. Allow the engine to idle for
a few moments to stabilize temperatures, then shut the
engine down by turning off the key switch.
NOTE: When starting:
A voltage
drop will occur
when
the preheat button
is depressed.
Engines &Generators
9

ENGINE BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour of
test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-
ated properly, a break-in time is required. The service life of
your engine
is dependent upon how the engine is operated
and serviced during its initial 50 hours of use.
Breaking-in a new engine basically involves seating the pis-
ton rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
scored,
which is caused by overloading the engine during the
break-in period.
Your new engine requires approximately 50 hours ofinitial
conditioning operation
to break in each moving part in order
to maximize the performance and service life ofthe engine.
Perfonn this conditioning carefully, keeping in mind the fol-
lowing:
1. Start the engine according to the STARTING PROCE-
DURE section. Run the engine at fast idle while checking
that all systems (raw water pump, oil pressure, battery
charging) are functioning.
2. Allow the engine to wann up (preferably by running at
fast idle) until the water temperature gauge moves into
the 130 -140°F (55 - 60°C) range.
3.
While using the vessel, run the engine at various engine
speeds for the first 25 hours. Avoid prolonged periods of
idling.
4. Avoid rapid acceleration, especially with acold engine.
5. Use caution not to overload the engine. The presence ofa
grey or black exhaust and the inability ofthe engine to
reach its full rated speed are signs of an overload.
.6. During the next 25 hours, the engine may be operated at
varying engine speeds, with short runs at full rated rpm.
Avoid prolonged idling during this break-in period.
CHECK LIST
D Monitor the control panel gauges.
D Check for leaks of fuel and engine oil.
D Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
D Confinn exhaust smoke:
When the engine is cold - white smoke.
When the engine is warm -almost smokeless.
When the engine is overloaded - some black smoke and soot
NOTE: See the TRANSMISSION section of this manual for
break-in information on your transmission.
Engines & G€merators
10

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER
ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low discharge
with ared warning light A
low oil pressure alarm switch is located off the engine's
oil gallery. This switch's sensor monitors the engine's oil
pressure. Should the engine's oil pressure fall to 5 -10 psi
(0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.
The Admiral Control Panel uses a voltmeter to monitor the
performance of the alternator.
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing. This switch will activate a continuous alarm if the
coolant's operating temperature reaches approximately
210°F (99°C).
TO CONTROL PANEL
TYPICAL ARRANGEMENT
<
ENGINE CIRCUIT BREAKER
The DC harness on the engine is protected by an engine-
mounted manual reset circuit breaker (20 amps DC).
Excessive current draw or electrical overload anywhere in
the instrument panel wiring or engine wiring will cause the
breaker to trip. In this event most engines will shut down
because the opened breaker disconnects the fuel supply. If
this should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
engine.
COOLANT TFIIIIPFI<llITIIIRI:\
SEND OR
THERMOSTAT
ASSEMBLY
Engines &Generators
11

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many of the following maintenance jobs are simple but others are more
difficult andmay require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY
50 100
250
500
750 1000 1250
MAINTENANCE
0
Diesel No.2 rating of 45 cetane or higher.
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
0
Oil level should indicate between MAX. and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8" to 112" deflection)
weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
0
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tension.
Fuel Filter
0 0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries
0
Every 50 operating hours check electrolyte levels
(and House Batteries) weekly
and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil (and filter)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Heat Exchanger Zinc Anode
0
(]
0 0 0 0
Inspect zinc anode, replace if needed, clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
0 0 0 0 0 0
Change every 200 hours.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check anti-Siphon valve operation. Check
the exhaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary. Check that all connections are tig ht.
Engine Hoses
0
or
0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Engines &Generators
12

SCHEDULED
MAINTENANCE
Raw Water Pump
Coolant System
Electric Fuel lift Pump
Inlet Fuel Filter
DC Alternator
*Fuellniectors
*Starter Motor
*Preheat Circuit
*Englne Cylinder
Compression
*Torque Cylinder Head
Hold-down bolts
MAINTENANCE SCHEDULE
NOTE: Use the engine hour meter gauge to log your engine hours or record your
engine hours by running time.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY
50
100 250 SOD 750
1000 1250
MAINTENANCE
0 0 0
Remove the pump cover and inspect impeller, gas-
ket, cam and cover for wear. Check the bearings
and seals (the shaft can turn, but not wobble).
Lubricate when reassembling.
0
Drain. flush, and refill cooling system with
appropriate antifreeze mixture compatible with
various cooling system metals.
0 0 0 0 0 0
Periodically check the wiring connections and
inspect the fuel line connections.
0 0 0 0 0
Replace.
0 0 0
Check DC charge from alternator. Check the
mounting bracket; tighten electrical connections.
0
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs; check resistance (4-6 ohms).
Reinstall with anti seize compound on threads.
D 0
Check compression pressure and timing
(see Engine Adjustments).
0 0 0
At first 50 hours. then every 500 hours
(see ENGINE ADJUSTMENTS).
*Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances
(see ENGINE ADJUSTMENTS).
"Heat Exchanger
0
Remove. have profeSSionally cleaned and
pressure tested.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
13

FUEL SYSTEM
DIESEL FUEL
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do
not use kerosene or home heating fueL
FUEL FILTER/WATER SEPARATOR
Aprimary fuel filter of the water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.
Most installers include a fuel filter/water separator with the
installation package as they are aware of the problems that
contaminants in 'the fuel can cause.
A typical fuel filter/water separator is il1ustrated below. This
is the Raycor Model 500 MA. Keep in mind that if a water
separator type filter is not installed between the fuel supply
tank and engine-mounted fuel system, any water in the fuel
will affect the fuel pump, engine filter, and injection equip-
ment. The owner/operator is responsible for making certain
the fuel reaching the engine's injection equipment is free of
impurities. This process is accomplished by installing and
maintaining a proper fuel filter/water separator.
TYPICAL
FUEL
FILTER
The fuel injection pump is a very important component of
the diesel engine, requiring the utmost care in handling. The
fuel injection pump has been thoroughly bench-tested and the
owner-operator is cautioned not to attempt to service it. If it
requires servicing, remove it and take it to an authorized fuel
injection pump service facility. Do not attempt to disassem-
ble and repair it.
FUEL LIFT PUMP
Periodically check the fuel connections to and out of the
pump and make sure that no leakage is present and that the
fittings are tight and secure. The DC ground connection at
one of the pump's mounting bolts should be clean and well
securedbi the mounting bolt to ensure proper pump opera-
tions.
When energized thru the preheat circuit, the fuel lift pump
will purge air from the fuel system and provide a continuous
flow of fuel as the engine is running.
INLET FUEL FILTER
To ensure clean fuel enters the fuel lift pump, there is an
in-line filter at the incoming fuel line. This filter should be
replaced every 200 operating hours.
FUEL FILTERS
The fuel injection pump and the fuel injectors are precisely
manufactured and they must receive clean diesel fuel, free
from water and dirt. To ensure this flow ofclean fuel, the fuel
must pass through at least two fuel filters, a fuel filter/water
separator and the engine's spin-on fuel filter. Visually inspect,
clean, and change these filters according to the maintenance
schedule in this manual.
A WARNING: Shut off the fuel valve at the tank
when servicing the fuel system. Take care in catching
any fuel that may spill. DO NOT allow any smoking ,
open flames or other sources of fire near the fuel sys-
tem when servicing. Ensure proper ventilation exists
when servicing the fuel system.
LOOSEN FITTING -----l'-A
WHEN PRIMING
FILL FILTER
Changing The Fuel Filter 0
1. Shut off the fuel supply.
SPIN ON
FUEL FILTER
#24363
2. Loosen the fuel filter, turning counterclockwise with a
filter wrench. Place the used filter in a container for proper
disposal.
3. Using a rag, wipe clean the sealing face on the housing
bracket so the new filter can be seated properly.
4. Lightly oil the sealing O-ring on the new filter. To rein-
staJ], tum the filter assembly counterclockwise carefully
until the a-ring contacts the sealing surface of the housing
bracket. Tum 213 further with the filter wrench.
5. The key-on preheat sequence will operate the fuel lift
pump and quickly fill the new filter. It is also poSsible to
hand prime ~he filter using the lever on the top.
6. Run the engine and inspect the filter for fuel leaks.
Engines &Generators
14