Westerbeke 64A FOUR User manual

OPERATORS MANUAL
MARINE DIESEL ENGINES
64 F
PUBLICATION NO.49112
FIRST EDITION
DECEMBER 2003
member WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
- 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
~ TEL: [phone]. FAX: [phone]· WEBSITE: www.WESTERBEKE.COM

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
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
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
Readthis safety manual carefully. Most accidents are
caused by failure to follow fundomental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personne~
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, or when connected to shore
power. 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 handling electrical equipment.
• Remove wristwatch and all 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 generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
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-;njury or 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 of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuellme, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances offire. Wipe up all spilled fuel and engine oil.
• Be aware - diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• 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 servic-
ing. 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.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starling 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 offall electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) 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 of explosive 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 offbefore 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 protec-
tion. Batteries contain sulfuric acid which is destructive.
Ifit comes in contact with your skin, wash it offat 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
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of
approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional 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 sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
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 symp-
toms or signs of carbon monoxide inhalation or poisoning
are:
Vomiting Muscular twitching
Dizziness
Intense. headache
Throbbing
in temples Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situa-
tion 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 or the drive belt's 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 wotlc on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many ofthe preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough 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 ofthe ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government 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 information:
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 of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifoUJ/water injected exhaust elbow is near or below the loaded
water line of the vessel will result in raw water damage to the engine and possible
flooding of the vessel.
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 manufacturer for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
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
Glow Plugs ......................................................... 26
Introduction ............................................................. 3
W"" 0"
iring lagram .. ................................................ 27
Warranty Procedures.........................................3
Serial Number Location ...................................4
Wiring Schematic ............................................. .28
Starter Motor ..................................................... 29
Admiral Control Panel ......................................... 5
Dual Output Alternators ................................... . 31
Captain Control Panel ......................................... 6 Troubleshooting..............................................32
Fuel, Engine Oil and Coolant .............................. 7
Engine Troubleshobting ..................................... 33
Preparations for Initial Start-Up ......................... 8
Engine Adjustments ............................................ .35
Starting/Stopping Procedure ............................... 9
Warning Lights, Alarms and Circuit Breaker .... l0
Engine Break-In Procedure ............................... 11
BeltAdjustment..............................................35
Fuel Injectors .................................................35
11 . E . C .
estmg ngme ompresslOn..........................36
Valve ClearanceAdjustment ..........................36
The Daily Operation ........................................... 12 Idling Speed....................................................37
Maintenance Schedule ..................................... 13
Stop Solenoid..................................................37
Fuel System ....................................................... 15
FuellWater Separator...................................... 15
Fuel Filters...................................................... 15
Oil Pressure ....................................................38
Hurth HSW Transmissions ................................. 39
Specification ................................................... 40
Cooling System .................................................. 16
Changing Coolant...........................................16
Thermostat......................................................
17
Raw Water Intake Strainer..............................17
Raw Water Cooling Circuit............................ 18
Raw Water Intake Strainer..............................18
Raw Water Pump ............................................ 18
Heat Exchanger ..............................................19
Zinc Anode .....................................................19
Engine Lubricating 0i1 .......................................20
. Changing the Oil Filter...................................20
Changing the Oil ...........................................20
Fluid Change .............................................40,41
Shipment.........................................................41
Transmission Fluid.........................................41
Changing Filter...............................................42
Cable Connections...........;..............................43
Couplings....:...................................................43
Transmission Coolers ....................................43
Maintenance....................................................
44
Borg Warner Transmission ............................... .47
Maintenance.....................................................48
Oil Coolers............................................... ~ ....... 49
La dR """
y-up an ecommlsslonmg ........................... 5,0
Remote Oil Filter (Optional) .............................. 21
Metric Conversions Oata ................................... 51
Water Heater ..................................................... 22
Engine Specifications ....................................... 52
Tachometer ........................................................ 23
Suggested ~pare Parts ..................................... 53
DC Electrical System ........................................... 24
Alternator Troubleshooting ............................
24
Battery Care....................................................25
Engines & Generators
1

DC CHARGING
FUEL LIFT PUMP
RAW WATER
FRONT
AIR INTAKE/AIR FILTER
SILENCER .
PREHEAT IiULltNUIU,
ZINC
ANODE
HEAT EXr::HA~IGEFI---
REAR
HBW
HURTH
TRANSMISSION-Q."-'''''''''"III!
TRANSMISSION
SHIFT LEVER
PARTS IDENTIFICATION
20 AMP
CIRCUIT
FLEXIBLE
MOUNT
WATER INJECTED
_EXlrlAU!~T ELBOW
REAR
TRANSMISSION
.jk.~~~~"", ENGINE BLOCK
DRAIN PLUG
LEFT SIDE
FILL
=......--MANIFOLD
I.D. PLATE
ALTERNATOR
FRONT
MOTOR OIL DRAIN HOSE'
AND SOLENOID
BELL HOUSING/FLYWHEEL
ASSEMBLY
RIGHT SIDE
Engines & Generators
2

INTRODUCTION
This WESTERBEKE Diesel Engine is a product of
WESTERBEKE's
long years ofexperience 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
manual carefully and observe all the safety precautions
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer
for assistance.
This is your operators manual. Aparts 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
Customer Identification
MR. ENGINE OWNER
MAIN STREET
HOMETOWN, USA
Model 64A FOUR
Expires 3/20/04 Serial Number
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 CANNOTBE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE
FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
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
exclusively as the definitive authority on the respective
product.
It not only makes good sense but is imperative that
appropriate representatives ofWESTERBEKE
or the sup-
plier 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 not strictly
observed. can result in the damage or destruction of
your engine.
A WARNING: Procedures which. if not properly
followed. 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
the nameplate mounted on the side ofthe engine's manifold.
The engine's serial number
is stamped into the engine block
on a flat swface directly above the injection pump. Take the
time to enter this information on the illustration ofthe name-
plate shown below, as this will provide a quick reference
when seeking technical information and/or ordering parts.
Fill in the infol71lationforyour reference. ~
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 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 a great extent, a diesel engine requires the same
preventive maintenance as a gasoline engine. The most impor-
tant factors are proper ventilation and proper maintenance of
the fuel, lubricating and cooling systems. Fuel and lubricating
filter elements must be replaced at the time periods specified,
and frequent checking for contaminants (water, sediment, etc.)
in the fuel system is also essential. Another important factor is
the consistent use of the same brand ofhigh 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 BIlTTON:.e5115'
17"1:a------¥A---IJI~SEL FUEL SPRAY
PRE·COMBUSTION CHAMBER-2~~~~~
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 infor:mation 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 acces-
sories, see WES1ERBEKE'S ACCESSORIES brochure.
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 1/10 hours. The panel also includes a WATER TEMPER-
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
RECALiBRATED 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
ILLUMINATED WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
TEMPERATURE IS 170· -190· F (77" - aa·c).
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 alann buzzer with harness is supplied with every
Admiral Panel. TIle 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 kg/cm2).
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 BETWEEN 30 - 60 psi
(2.1 - 4.2 kg/em').
SWITCH: PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER.
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.
~
DC VOLTMETER:
INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED.
SHOULb SHOW 13V TO 14V.
~
~
" AUTOMATIC ALARM SYSTEM
,. "
COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
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.
!~.: 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 01 L 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 (0.4 - 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 INSTRUMENT TEST button and three indicator
lamps, one for ALTERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for high ENGINE COOLANT
TEMPERATURE.
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
ALARM LIGHT
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS
BunON WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BunON IS PRESSED AND HELD AT THE SAME
TIME.
The panel also includes an alann buzzer for low OIL
PRESSURE or high COOLANT TEMPERATURE. 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 ENGINE'S OIL PRESSURE FALLS
BELOW 5 -10 psi (0.4 - 0.7 kg/cm'). 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°F (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/cm'), THE ALARM WILL SILENCE.
TEST BunON: WHEN
PRESSED, TESTS THE
ALTERNATOR, THE OIL
PRESSURE, AND THE
COOLANT TEMPERA-
TURE CONTROL CIR-
CUITS. WHEN PRESSED,
TH£ 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
INSTRUMENT PANEL
CLUSTER.
PREHEAT BUnON: 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 BUnON ENER-
GIZES THE START BUnON.
Engines &Generators
6

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification of Class
2-D (ASTM), and has a cetane rating of #45 or better.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump is very critical; invisible dirt par-
ticles which might pass through the 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 Raycor 500 FG or 900 FG are good examples of such
filters.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. Change the engine oil after an initial 50
hours ofbreak-in operation, and every 100 hours ofoperation
thereafter. For recommended oil viscosity, see the following
chart:
Operating Temperature Oil Viscosity
Above 68°F (20°C)
SAE 30, 10W-30 or 15W-40
41° - 68°F (5 - 20°C)
SAE 20, 10W-30 or 15W-40
Below 41°F (5°C)
SAE 10W-30 or 15W-40
A CAUTION: 00 not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
Oil Pressure
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 35 and
55 psi (2.5 and 3.9 kglcm2).
NOTE: A newly started, cold engine can have an oil pressure
reading up to 60 psi (4.2 kglcm
2
). A warmed engine can have
an oil pressure reading as low as 25 psi (1.8 kglcm
2
). These
readings will vary depending upon the temperature of the
engine and the loadplaced on the engine.
ENGINE COOLANT
WESTERBEKE reco~ends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine 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 that 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-friendly long lasting
antifreeze that is now available.
The recommended 50/50 mixture will protect the engine
against
the most extreme temperatures. The antifreeze
mixture will also retard rust within the engine and add to the
life of the circulating pump impeller and seals.
Coolant Recovery Tank
Acoolant recovery tank kit is supplied with each
WESTERBEKE diesel engine. The purpose of this recovery
tank is to allow for engine coolant expansion and contraction
during engine operation, without the loss of coolant and
without introducing air into the cooling system. This kit is
provided and must be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at orabove
the level of the engine's manifold, but it
can be located below the level of the engine's manifold if the
particular installation makes this necessary.
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:
D Check the engine oil level. Add oil to maintain the level
at the high mark on the dipstick.
D Turn on the fuel supply, then check the fuel supply and
examine the fuel filter/water separator bowl for
contaminants.
D Check the transmission fluid level.
D 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).
D Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: If the engine has not yet beenfilled with coolant,
refer to the COOUNG 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.
o Make certain there is proper ventilation around the
engine. An ample supply is necessary for proper engine
performance.
o 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.
Engines &Generators
8
COOLANT
RECOVERY
TANK
I~_- OIL DIPSTICK
, PRESS IN TIGHT

STARTING • STOPPING PROCEDURE
STARTING PROCEDURE
1. Place the transmission in neutral and advance the throttle
control
to slightly open.
2. Thrn the KEY SWITCH to the ON position (2 o'clock).
(If the panel is energized, the gauges are on.)
3. Press the PREHEAT BUTION, and hold for 5 seconds.
(The fuel lift pump is priming the engine.)
4. Release the PRESTART BUTION and press the START
BUTION. (The starter motor is cranking the engine).
5. Release
the START BUTION as the engine starts.
6. With the engine running, check the instruments for
proper oil pressure and battery charging voltage. The
water temperature will rise slowly and then stabilize
when the thermostat opens.
NOTE: Never attempt to engage the starter while the
engine is running.
It is important to closely monitorthe panel gauges.
Become aware of the normal engine readings andtake
immediate action if these readings start to vary.
Temperature/Preheat
Atmospheric Temperature Preheating Time
41°F(5°C) or higher
Approx. 10 seconds
41°F(5°C) to 23°F (-5°C) Approx. 15 seconds
23°F(-5°C) or lower Approx. 20 seconds
Limit of continuous use 30 seconds before cranking
NOTE: The STARTbutton will not energize unless the
PREHEATbutton is depressed. Depressing the PREHEAT
button activates
the glow plugs in the cylinder head so use
the PREHEATintermittently to avoid overheating the glow
plugs.
NOTE: When starting:
A voltage
drop will occur
when the preheat button
is depressed.
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: Make certain this key switch is in the OFF position
(12 o'clock). If the key switch is left ON, the energized
instrument panel will put a
drain on the battery.
Starting Under Cold Conditions
Make certain the lubricating oil is appropriate for the
prevailing temperature. Use oil with an API Specification
of CF or CG-4, SAE 30, lOW-30, or 15W-40.
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 the
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 fills. 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.
Engines & Generators
9

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER
ALTERNATOR WARNINGS
The Captain Control Panel indicates alternator low discharge
with a red warning light.
The Admiral Control Panel uses a voltmeter to monitor the
performance of the alternator.
COOLANT TEMPERATURE SWITCH
Acoolant temperature switch is located on the thermostat
housing. This switch will activate a continuous alarm if the
coolant's operating temperature reaches approximately
2100P (99°C).
COOLANT
SENOOR
THERMOSTAT
ASSEMBLY
LOW OIL PRESSURE ALARM SWITCH
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.
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
OIL GALLERY
2DACIRCUIT
BREAKER
Engines & Generators
10

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.
Perform 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 warm up (preferably by running at
fast
idle) until the water temperature gauge moves into
the
130 - 140
0P
(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.
CHECKLIST
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 Confirm 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 manualfor
break-in information on your transmission.
Engines. & Generators
11

THE DAILY OPERATION
CHECK LIST
Follow this check list each day before starting your en~ine.
D VIsually inspect the engine for fuel, oil, or water leaks.
D Check the oil level (dipstick).
D Check the coolant level in the 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.
D 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
NOTE: See STARTINGISTOPPING PROCEDURE in thi,;,'
manual for more detailed instructions.
1. Put 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 starler solenoid will not
energize.
2. Tum the KEY SWITCH to the ON position (2 0' clock).
[The panel is energized, gauges are lite}.
3. Depress the PRESTART BUITON, hold for 5 seconds.
[Thefuel lift pump is priming the engine}.
4. Release the PRESTARr BUITON and press the START
BUITON. [The startmotor is cranking the engine}.
5. Release the START BUITON as the engine starts.
6. With the engine running, check the instruments for
proper
oil pressure and battery charging voltage. The
water temperaturewill rise slowly until the thermostat
opens.
NOTE: Never attempt to engage the starter while the
engine is running.
It is important to closely monitor the panelgauges. Become
aware of the normalengine readings and take immediate
action if these readings start to vary.
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 the
neutral position as some engines have a neutral safety switch
to prevent starting in gear.
Never run the starter for more than 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 sytem fills. 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 offthe key switch.
NOTE: Make certain this key switch is in the OFF
position( 120' clock}. If the key switch is left ON, the
energized instrumentpanel will put a drain on the battery.
Engines. & Generators
12

MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hounneter or
record
your engine hours by running time.
NOTE: M0J7.Y of the following maintenance procedures are
simple but others are more difficult 0J7.d may require the
expert knowledge of a service mech0J7.ic.
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
co"ect tools for each job. Disconnect the battery
terminals when servicing any of the engine's DC
elecuicalequipment
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE DESCRIPTION
MAINTENANCE
EACH
DAY
50 100 250 500
750 1000 1250
Fuel Supply
D
Diesel No.2 rating of 45 cetane or higher.
Fuel/Water Separator
D
Check for water and dirt in fuel (drainlreplace filter if
necessary).
Engine Oil Level
D
Oil level should indicate between MAX. and lOW on
dipstick.
Coolant Level
D
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Transmission Fluid Level
D
Fluid level should indicate between MAX and LOW
on dipstick.
Drive Belts
D
Inspect for proper tension (3/8" to 1/2' deflection)
weekly
and adjust if needed. Check belt edges for wear.
Visuallnspeclion of Engine
D
NOTE: Keep engine surface clean. Dirt and
Check for fuel, oil and water leaks. Inspect wiring
oil will inhibit the engine's ability to remain and electrical connections. Keep bolts & nuts tight.
cool.
Check for loose belt tension.
Fuel Filter
D D D D D D
Clean with kerosene at 50 hours then clean every
100 hours. Change at 500 hours.
Starting Batteries
D
Check electrolyte levels every 50 operating hours
(and House Batteries)
weekly
and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil and Filter
D D D D D D D
Initial engine oil & filter change at 50 hours, then
change both every 100 hours.
Heat Exchanger Zinc Anode
D D D D D D D
Inspect zinc anode, replace if needed. Clear the heat
exchanger end of zinc anode debris.
Fuel/Water Separator
D D D D D D
Change filter every 200 hours.
Exhaust System
D D D D
Initial check at 50 hours, then every 250 hours.
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 tight. Check casting integrity.
Engine Hoses
D D D D D D
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Throttle and Transmission
D D D D
Check for loose fittings, cotter pins, etc.
Control Cable Lubricate with WD-40 or equivalent.
Adjust Engine Idle Speed
D
Adjust to 750 -1000 rpm
Raw Water Pump
D D D
Remove the pump cover and inspect the impeller,
gasket, cam and cover for wear. Check the bearings,
seals and shaft drive tang.
(continued)
Engines & Generators
13

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE
EACH
MAINTENANCE DESCRIPTION
DAY 50
100 250 500 750 1000 1250
Coolant System
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
Air Cleaner/Silencer
0 0 0 0 0 0 0
Every 100 hours, inspect, clean, replace as needed.
DC Alternator
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
Transmission Oil Cooler
0
Remove; have professionally cleaned and pressure
tested.
Engine Transmission
0
Chattering at idle and low rpms is an indication
Damper Plate
of damper plate wear. Remove and replace.
*Fuellnjectors
0
Check and adjust injection opening pressure and
spray condition (see ENGINE ADJUSTMENTS).
*Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
*Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs, check resistance value of heater
element (X-X ohms). Reinstall with anti-seize
compound on threads.
*Engine Cylinder
0 0
Check compression pressure and timing (see Engine
Compression
Adjustments).
*Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances (see ENGINE
ADJUSTMENTS).
*Heat Exchanger
0
Remove, have professionally cleaned and pressure
tested.
Lubricate Panel Key Switch
0 0 0 0 0 0
At first 100 hours, then each year at winterizing.
with "Lockeze"
Transmission
0 0 0 0 0 0
Initial fluid change at 25 hours, then every
Fluid
300 hours or at winterizing.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
14