Westerbeke 65A-FOUR User manual

OPERATORS MANUAL
MARINE DIESEL ENGINES
65A-FOUR
PUBLICATION NO. 054218
FIRST EDITION
OCTOBER 2008
~r~ rWESTERBEKE

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
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
f'WIwrisrmsEKE i
__ ~----=_En'_i,!,,;--' __ t_o~ __ J 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 tofollow fundamental rules
and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personnel,
and your machinery.
Thefollowing safety instructions are in compliance with
theAmerican Boat
and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 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 elecllical
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 vessels AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessels 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: 00 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 injury or death!
• Prevent flash fires. Do not smoke or pennit 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 fuel line, 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 pelwit flames or sparks to occur near
the fuel system. Keep the compartrnent and the
engine/generator clean and free
of debris to minimize the
chances of fire. 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 vessels
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running 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-
ventilated area away from spark-producing equipment
and out
of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut offthe 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 shutoffvalve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
• 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 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: BaUeryexplosion 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 elect:ical
arcing or by lit tobacco products. Shut o~ all ele~tncal
equipment in the vicinity to prevent electncal arcmg dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection tenninal 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 tenninals with tools, etc., to prevent
burns or sparks
that could cause an explosion. Remove
wristwatch, rings,
and any other jewelry before handling
the
battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last whenservicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in baUeries 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.
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) ;s 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 manifold!
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Don't run the generator set or engine unless the bo?t is
equipped with a functioning marine carbon monOXIde
detector that complies with ABYCA-24. Consult your boat
builder
or dealer for installation of approved detectoi·s.
• 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 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 ofexhaust. 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 ofcarbon monoxide inhalation or
poisoning
are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
Throbbing
in temples
Muscular twitching
Weakness
and sleepiness
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situation
arises
in which it is absolutely necessary to make operat-
ing adjustments, use extreme care
to avoid touching mov-
ing 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 of the 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 of the 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 of the 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
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. 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 infonnation:
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-breakwhen
the exhaust manifold injection port
is at or below the load waterline will result in
raw water damage to the engine andpossibleflooding 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 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
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 (Illustrations) ................................. 2
Tachometer ...................................................................... 27
Introduction ...................................................................... .3
Engine Troubleshooting ................................................. 28
Serial Number Location ...............................................4
Control Panel Troubleshooting ................................... .30
Ordering Parts ..............................................................4
Control Panel (Admiral) ................................................... 5
Control Panel (Captain) ................................................... 6
Alternator Troubleshooting .......................................... .31
Troubleshooting..........................................................
31
Testing ........................................................................32
Diesel Fuel, Engine Oil and Engine Coolant ............... 7
Coolant Recovery Tank................................................7
Preparations for Initial Start .......................................... 8
Pre-start Inspection.......................................................8
Starting/Stopping Procedure .......................................... 9
Warning Lights, Alarms & Circuit Breaker ................ 10
Maintenance Schedule .................................................. 11
Cooling Circuit ................................................................ 13
Raw Water Intake Strainer.........................................13
Draining the Raw Water System................................
13
Thermostat..................................................................14
Fresh Water Circuit ....................................................15
Changing Coolant.......................................................
15
Raw Water Pump ........................................................16
Heat Exchanger..........................................................16
Water Heater...............................................................17
Checking/Servicing Battery.......................................33
Battery Care ...............................................................33
Dual Output Alternators ................................................ 34
Troubleshooting..........................................................35
High Output Alternators ................................................ 36
Starter Motor ................................................................... 37
Troubleshooting.........................................................
.3 7
ZF Transmissions ............................................................ 39
Change the Fluid........................................................39
Specifications ...............................................
,............. 39
Control Cables............................................................40
Transmission Cooler ...................................................41
Maintenance ...............................................................41
ZF Transmissions (HSW Models) ................................ .42
Change the
Fluid ........................................................43
Maintenance ...............................................................43
Fuel System ..................................................................... 18
Velvet Drive Transmissions ......................................... .44
Fuel Filter...................................................................
18
Change the Fluid........................................................45
Fuel Water Separator..................................................
18
Engine Ll.lbricating Oil .................................................. 19
Oil Change ................................................................. 19
Remote Oil Filter ............................................................ 20
Wiring Diagram ............................................................... 21
Wiring Schematic ........................................................... 22
Engine Adjustments ....................................................... 23
Fuel Injectors.........................................................:....23
Troubleshooting..........................................................46
Oil Coolers .................................................................46
Transmission TroubleshootinglF .............................. .47
Control Cables............................................................48
Specifications ................................................................. 49
Lay-Up and Recommissioning ...................................... 51
Metric Conversion Data ................................................ 53
Suggested Spare Parts .................................................. 54
Glow Plugs................................................................. 24
Valve ClearanceAdjustment......................................25
Drive Belt Adjustment ............................................... 26
Testing Oil Pressure ................................................... 26
Engine Compression ..................................................26
Engines & Generators
1

DI
INTAKE MANIFOLD.
PRE-HEAT
SHIFT AND
THROTTLE
BRACKET
SPIN-ON
OIL FILTER
INJECTION PUMP
RIGHT SIDE
THERMOSTAT
HOUSING COVER
COOLANT PRESSURE CAP
OIL DIPSTICK
(OPTIONAL)
LEFT SIDE
WATER INJ
EXHAUST ELBOW
PARTS IDENTIFICATION
CRANK CASE
VALVE
NC ANODE
THERMOSTAT ASSEMBLY
WATER HEATER CONNECTIONS
DC ALTERNATOR
FRONT
OIL DRAIN HOSE
INTAKE
MANIFOLD
IN-LINE
~~~~lL.l:»~---- FUEL FILTER
TRANSMISSION
OIL COOLER
~~~:;::~;- ____ OIL PRESSURE
~ SENDOR
TRANSMISSION
TRANSMISSION
DRAIN
REAR
Engines & Generators
2

INTRODUCTION
This WESTERBEKE Engine is a product of
WESTERBEKE'S long years of experience and advanced
technology. We take great pride in the superior durability and
dependable perfonnance
of our 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. A Service Manual will also
be available from your WESTERBEKE dealer. If you are
planning to install this equipment contact yourself, contact
your WESTERBEKE dealer for WESTERBEKE'S
Installation Manual.
Customer Identification Card
,...,.",WESTERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model Ser. #
Expires
WARRANTY PROCEDURES
Your WESTERBEKE WatTanty is included in a separate
folder. If, you have not received a customer identification
card registering your warranty 60 days after submitting the
Warranty Registry fonn , please contact the factory in
writing with model infonnation, including the unit's serial
number and commission date.
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE customers should also keep in mind the time
span between printings ofWESTERBEKE product
software and the unavoidable existence
of earlier
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
be relied upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but
is imperative that appropriate representatives of
WESTERBEKE or the supplier in question be consulted
to detennine 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
of your marine
engine, critical infonnation 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 oflife.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing have
resulted in a WESTERBEKE engine capable
of many thousands
of hours of dependable service. However, the manufacturer can-
not control how or where the engine is installed in the vessel or
the manner in which the unit
is operated and serviced in the field.
This is up to the buyer/owner-operator.
NOTE: Six important steps to ensure a long engine/generator life.
• Proper engine installation.
• An efficient, well-designed exhaust system that includes an
anti-syphon break to prevent water from entering the engine.
• Changing the engine oil every 250 operating hours.
• Proper maintenance of all engine components according to the
maintenance schedule in this manual.
• Use clean, filtered diesel fuel.
• Winterize your engine according to the LAY-UP AND
RECOMMISSIONING section in this manual.
Engines &Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
the nameplate mounted
on the side of the engine's manifold.
The engine's serial number is stamped into the engine block
on a fiat surface directly above the injection pump. Take the
time to enter this information
on the illustration of the name-
plate shown below, as this will provide a quick reference
when seeking technical information and/or ordering parts.
Fill in the informationfor your referance.
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 that
of a gasoline engine, and the diesel
engine has the same types
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 important 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
contaminations (water, sediment, etc.) in the fuel system is
also essential. Another important factor is the use
of the 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.
ORDERING PARTS
Wheneverreplacement parts are needed, always provide the
engine model number and engine serial number as they
appear
on the silver and black name plate located on the
manifold.
You must provide us with this infoffilation 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 Pruts List). Insist upon
WESTERBEKE packaged parts because will fit or generic
parts are frequently not
ll1ade to the same specifications as
original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE engine. Your local WESTERBEKE 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 ACCESSORIESbrochure.
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 III0 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 OFTHE
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
0 F(n°-
SSOC).
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.
A separate 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 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.
I
~
, DC VOLTMETER:
INDICATES THE AMOUNT THE
BATIERY 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.
/h : SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
_..I 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 (004 - 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 OF THE PANEL.
OIL PRESSURE ALTERNATOR
ALARM ALARM LIGHT
WATER TEMPERATURE
ALARM LIGHT
START BunON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BunON IS PRESSED AND HELD AT THE SAME
TIME.
The panel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT TEMPERATURE. The
RPM gauge is illuminated when the KEY switch is turned on
and remains illwninated 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/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°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/em'), THE ALARM WILL SILENCE.
TEST BunON: 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
INSTRUMENT PANEL
CLUSTER.
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 BUTTON ENER-
GIZES THE START BUTTON.
Engines & Generators
6

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification of Class
2-D (AS1M), 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
particles
which might pass through the filter can damage
these finely finished parts. It is important to buy clean fuel,
and keep itclean. 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.
TheRayeor500
FG or 900 FG are good examples of such
filters.
ENGINE OIL
Use a heavy duty diesel oil with an API classification of
CF, CG-4, CH-4 or CI-4. Change the engine oil and tilter
after the initial 50 hours
of break-in operation. Then follow
the oil and tilter change intervals
as specified in the
MAINTENANCE SCHEDULE in this manual.
The use
of synthetic oil is permited ONLY after the initial
break-in period
of 50 hours of engine operation has been
achieved.
A CAUTION: Do not allow two 01 more brands of
engille 011 to mix. Each brand contains Its own additives;
additives of different brands could react In the mixture
to produce properties harmful to YOUI engine.
RECOMMENDED RPM RANGES
IDLE: 800 -1000 rpm
CRUISE: 2000 -2400 rpm
MAXIMUM: 2750 -2800 rpm
ENGINE COOLANT
WESTERBEKE recommends 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 thai 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 of antifreeze, 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 053456.
MAINTENANCE
Change the engine coolant every five years regardless of the
number ofoperating 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 10'S ofcoolant and without introducing air into
the cooling system.
Engines & Generators
7 Revised November 2009

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
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 Tum 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.
--1 OIL FILL
. ~I II
,.-1/
COOLANT PASSAGE
(KEEP CLEAN)
NOTE: If the engine has not yet been filled 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,
COOLANT
RECOVERY TANK
MAINTAIN
COOLANT LEVEL
AT 1/2 FULL
Engines & Generators
8

STARTING/STOPPING PROCEDURE
CHECK LIST
Follow this check list each day before starting your engine.
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
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 starter solenoid will not
energize.
2. Tum the KEY SWITCH to the ON position (2 o'clock).
[The panel is energized, gauges are lit}.
3. Depress the PREHEAT BUTION, hold for 5 to 15
seconds depending how cold it is.
[The fuel lift pump is priming the engine and the preheat
is activated}.
4. Continue pressing the PREHEAT BUTION and press
the START BUTION. [The start motor is cranking the
engine}.
5. Release the START BtJrrON as the engine starts.
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 normal.
NOTE: Never attempt to engage the starter while the
engine is running.
It is important to closely monitor the panel gauges.
Become aware of the normal engine readings and take
immediate action if these readings start to vary.
If a "smart" regulator is part of the charging system,
allow about 50 secondsfor the RPM gauge to activate.
NOTE: The START switch will not energize unless the PRE-
HEAT switch is depressed. Depressing the PREHEAT switch
activates the glow plugs in the cylillder head so use the PRE-
HEAT intermittently to avoid overheating the glow plugs.
o
NOTE: When starting:
A voltage drop will occur
when the preheat switch
is depressed.
NOTE: Some unstable running may occur in a cold engine.
Depressing the PREHEATswitchfor 10-15 second intervals
will
help stabilize the engine rpm until the operating
temperature reaches 140 -J50° F and a load is applied to
the engine. .
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 starling 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 shut-off I 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.
Slopping Procedure
To stop the engine, bring the throttle to an idle position and
place the transmission in neutrali Allow the engine to idle for
a few moments to stabilize temperatures. Then shut the
engine down by tuming off the key switch
NOTE: Make certain this key switch is in the OFF
positioll(J2o'clock). If the key switch is left ON, the
energized instrument panel will put a drain on the battery.
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.
OIL GALLERY
LOW OIL PRESSURE ALARM SWITCH
A low oil pressure alarm switch is located on the engine
block. This switch's sensor monitors the engine's oil pres-
sure. Should the engine's oil pressure fall to 5 - 10 psi
(0.4-0.7 kglcm2 ), 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 instmment 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 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 210°F
(99°C).
Engines &Generators
10

MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be necessary
to log your engine hours. Use yor engine hourrneter or record
your engine hours by mnning time.
NOTE: Many of the following maintenance jobs are simple but
others are more difficult and may require the expert knowledge
of a service mechanic.
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.
CHECK
HOURS OF OPERATION
SCHEDULED EACH EXPLANATION OF SCHEDULED
MAINTENANCE DAY
50
100 250
500
750 1000 1250
MAINTENANCE
Fuel Supply
0
Diesel No.2 rating of 45 cetane or higller.
Fuel/Water Separator
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
Engine Oil Level
D
Oil level should indicate between MAX. and LOW on
dipstick.
Coolant Level
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Transmission Fluid Level
0
Fluid level should indicate between MAX and LOW
on the dipstick
Drive Belts
0
Inspect for proper tension (3/8" to 1/2" deflection)
weekly and adjust if needed. Check belt edges for wear.
VisuallnspecUon 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 ~Irs, then change every 250 hrs.
Starting Batteries
0
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)
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 250 hours.
Heat EXChanger Zinc Anode
0 0 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 L 0 0
Change every 200 hours.
Exhaust System
0 0 D 0
Initial check at 50 hrs., then every 250 ~Irs. 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.
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Throttle and Transmission
0 0 0 0
Check for loose fittings, cotter pins, etc
Control Cable
Lubricate with WD-40 or equivalent.
Adjust Engine Idle Speed
0 800-1000
rpm (adjust for transmission used)
Raw Water Pump
0 0 0
Remove the pump cover and inspect the impeller,
gasket, cam and cover for wear. Check the bearings
and seals (the shaft can turn, but not wobble).
Lubricate when reassembling.
Inlet Fuel Filter
0 0 0 0 0
Replace.
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hounneter 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.
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 (0.9 Ohm). Reinstall with anti-seize
compound
on the 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 EXGhanger
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 Fluid
0 0 0 0 0 0
Initial fluid change at 25 hours, then every
300 hours or at winterizing.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines'& ~enerators
12

COOLING SYSTEM
DESCRIPTION
Westerbeke marine diesel engines are designed and equipped
for fresh water cooling. Heat produced in the engine by com-
bustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block, its internal moving
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means
of a heat
exchanger, similar
in function to an automotive radiator. Raw
water flows through the tubes
of the heat exchanger while
fresh water coolant flows around the tubes; engine heat trans-
ferred to the fresh water coolant is conducted through the
tube walls to the raw water which is then pumped into the
exhaust system where finally
it is discharged overboard. In
other words, the engine is cooled by fresh water coolant, this
coolant is cooled by raw water, and the raw water carries the
transferred heat overboard through the exhaust system.
The
fresh water coolant and raw water circuits are independent of
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.
RAW WATER INTAKE STRAINER
A major pmt of the raw water cooling system is a proper
boatyard!builder installed intake strainer.
NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.
A clean raw water intake strainer is a vital component of the
engine's cooling system. Include a visual inspection
of this
strainer when making your periodic engine check. The water
in the glass should
be clear.
Perform the following maintenance after every 100 hours
of
operation:
1. Close
the raw water seacock.
2. Remove and clean the strainer filter.
3. Clean the glass.
4. Replace the washer
if necessary.
5. Reassemble and install the strainer.
6.
Open the seacock.
7. Run the engine and check for leaks.
NOTE: Alsofollow the above procedure after having run hard
aground.
If the engine temperature gauge ever shows a higher than
normal reading, the cause may
be that silt, leaves or grass
may have been caught up in the strainer, slowing the flow
of
raw water through the cooling system.
WASHER
STRAINER ~~ ....
i
FILTER
1..
r .,
~---~
TYPICAL RAW WATER INTAKE STRAINER
INCOMING
RAW WATER
SEACOCK
(Owner Installed)
.;.'
~
DRAINING THE RAW WATER SYSTEM
INSPECT AND
CLEAN EVERY
100 HOURS
When freezing temperatures are expected, it is best to
protect the raw water cooling circuit and engine exhaust
from damage. _
This procedure is bestaccomplished by disconnecting the
water intake hose from the vessels thru-hull fitting. Close
the
intake valve before disconnecting the hose. Inselt the hose
end into a large container
of fresh water.
Before starting the engine, remove the engine thermostat
(replace the gasket and cover). This will ensure a full flow
of water thru the engine. Re-insta1l the thermostat once
flushing is complete.
Run the unit for 10 minutes
or longer to adequately flush the
r cooling syste
Il1
.
Provide an external fresh water supply for the bucket to
maintain the water level in the bucket while the unit is being
operated during the flushing process.
The fresh water will flush out the engines water passages and
exhaustlines.
If the engine is being stored and there is a
probability
of freezing, flush the engine with fresh water and
then prior to shutting the unit down substitute the fresh water
supply with a concentrated antifreeze mixture and run this
through the engine to provide freeze and corrosion protection
for both the engine and exhaust system.
When recommissioning, make certain the valves and
seacocks are open so the engine will
quickly receive fresh
water.
if the engine is stowed where it is warm, the fresh
water can stay in the engine.
Engines & Generators
13

COOLING SYSTEM
THERMOSTAT
A thennostat, located near the manifold at the front of the
engine, controls the coolant temperature as the coolant
continuously flows through the closed cooling circuit.
When the engine
is first started, the closed thermostat'pre-
vents coolant from flowing (some coolant is by-passed
through a hole in the thermostat to prevent the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens.
The thermostat is accessible
and can be checked, cleaned, or replaced easily. Carry a
spare thermostat and gasket.
REPLACING THE THERMOSTAT
1. Drain ofT some coolant: Release the coolant pressure cap
and drain the coolant to the approximate level offthe
thermostat housing. This can
be done using the heat
exchanger drain plug.
2.
Rotate the thermostat assemhly: Loosen the hose clamp
as shown and remove the three allen screws that hold
down the thermostat housing cover, the assembly can now
be twisted enough to access the gasket and thermostat.
3. Remove/replace the gasket and thermostat: When
installing the new parts, apply a thin coat
of sealant on
both side
of the gasket before pressing it into place.
HEAT
EXCHANGER
_ ~ Re-assemble~' Thm the cov ...bock into place and
..... ~ I tighten the three screws. Do not over-tighten! Tighten the
THERMOSTAT
ASSEMBLY
GASKET
SEAL WITH HI-TACK
COOLANT
TEMPERATURE
SWITCH
COOLANT PASSAGE
(KEEP CLEAN)
l~
hose clamp and tighten the drains. Top offthe coolant and
run the engine. Check for normal temperature and for any
leaks around the thermostat assembly.
A CAUTION: The engine I{lust be allowed to cool
down before attempting these procedures. Not only
is the surface of the engine hot but coolant
temperatures can be at 190· 1.
'\It.f(ll(I')...~--AIR BLEED
THERMOSTAT
COOLANT
TEMPERATURE
SEND OR
, PETCOCK
THERMOSTAT
HOUSING COVER
engines & Generators
14