Westerbeke 7A-1 User manual

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OPERATORS MANUAL
. -
7A·1 and 11A·1
MARINE DIESEL ENGINES
PUBLICATION NO. 45145
1st Edition! April 2001
J
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
TEL: [phone]. FAX: [phone]. WEBSITE: www.WESTERBEKECOM
~~~~
NMMA Member National Marine Manufacturers Association ,
~"'~

OPERATORS MANUAL
7A·1 and 11A·1
MARINE DIESEL ENGINES
PUBLICATION NO. 45145
15t Edition! April 2001
~r~ 'WESTERBEKE
~
W£ST£RB£K£ CORPORATION· MYL£S STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
TEL: [phone]· FAX: [phone]· WEBSITE www.WESTERBEKECOM
~~~~
NHHA Member National Marine Manufacturers Association
~,.,~

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
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
-Nausea
-Headache
- Throbbing in Temples
- Muscular Twitching
• Vomiting
- Wea/cness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. «symptoms persist,
seek medical attention. Shut down the unit and do not restart
until
it has been inspected and repaired.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE a/so recommends installing
CARBON MONOXIDE DETECTORS in the
Iiving/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthese safety instructions carefuUy. Most accidents are
caused by failure to follow fundamental rules andprecau-
tions. Know when dangerous conditions exist andtake the
necessary precautions to protectyourself, yourpersonnel,
andyour
machinery.
The foUowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: lID nDt touch AC electrical CfJIInectiDIIS
while engine is running, Of wlren connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut off electrical 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-ta-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
capacitor. Discharge capacitor by shorting terminals
together with an insulated tool.
PREVENT BURNS - HOT ENGINE
A WARNING: lID not touch hot engine parts Of
exhaust system components. A running engine gets
very hot!
A WARNING: Steam can cause injury Of 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 permit flames or
sparks to occur near the 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 or fuel filters.
• Keep the compartment and the engine 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 rapors can cause
injury Of 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 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 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
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starling can cause injury
or death!
• Disconnect the battery cables before servicing the engine.
Remove the negative lead first and reconnect it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries
emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off
all electrical
equipment in the vicinity
to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal
of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
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
burns or sparks that could cause an explosion. Remove
wristwatch, rings,
and any otherjewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
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) isa 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 exhaust 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 boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder or dealer
for installation ofapproved detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Dizziness Throbbing in temples
Headache Muscular twitching
Nausea
Weakness and sleepiness
Vomiting Inability
to think coherently
AVOID MOVING PARTS
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 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 orjewelty 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 while the engine is operating.
HAZARDOUS NOISE
A WARNING: High noise levels can cause
hearing loss!
• Never operate an engine without its mufiler installed.
• Do not run engines for long periods with their
enclosures
open.
A WARNING: 011 not WllrIc lin machinery when Yllu are
mentally IIr physically incapaCitated by fatigue!
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:
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 Solomons Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
Fire Protection StandardforMotor 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 information:
CODES AND REGULATIONS
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 mini-
mum
of 20 in. (51 cm) above the vessel's waterline. Failure to use a siphon-break
when the exhaust manifoldinjection port is at orbelow the load waterline will result
in raw water damage to the engine and possibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative to
the vessel's waterline under any
of the vessel's various operating conditions or when
the vessel is not underway, installa siphon-break. This precaution is necessary to pro-
tect your engine.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper oper-
ation. Failure to properly maintain a siphon-break can result in catastrophic engine
damage. Consult the siphon-break manufacturer
for a proper maintenance schedule.
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 vessel's hull.
A detailed 40-page Marine Installation Manual covering gasoline and diesel,
engines and generators, is available from your WESTERBEKE dealer.
Engines & Generators
iv

TABLE OF CONTENTS
Introduction ................................................................................. 2 Cooling System (continued)
Warranty Procedures............................................................2 Raw Water Pump................................................................. 22
Product Software................................................................. 2 Inspecting/Changing the Raw Water Pump Impeller
... 22
Notes, Caution and Warnings..............................................2 Raw Water Intake.................................................................22
Model No.lSerial No. Location........................................... 2 Raw Water Intake Strainer................................................... 22
Component Locations..........................................................3 Siphon-Break....................................................................... 23
Understanding the Diesel Engine........................................ 3 Draining the Cooling System...............................................23
Ordering Parts......................................................................3 Air Intake Filter ............................................................................ 24
Spares and Accessories........................................................3 Description........................................................................... 24
Protecting Your Investment................................................. 3 Air Filter.......................................................................24
7A-1 Diesel Engine Specifications ............................................. 4 Maintenance................................................................. 24
7A-1 Diesel Engine Parts Identification ..................................... 5 Water Heater ................................................................................ 24
11A-1 Diesel Engine Specifications ............................................ 6 Water Heater Installations....................................................24
11A-1 Diesel Engine Parts Identlfication ................................... .7 Fuel System ................................................................................. 25
Preparations for Initial Start-Up ................................................. 8 Diesel FueL.......................................................................... 25
Diesel FueL..........................................................................8 Fuel Additives...................................................................... 25
Care
of the Fuel Supply...............................................8 Care
of the Fuel Supply........................................................ 25
Fuel Additives............................................................. 8 Fuel Lift Pump..................................................................... 25
Engine OiL ..........................................................................8 Fuel Filter............................................................................. 25
Transmission Fluid.............................................................. 8 Replacing the Fuel Filter..............................................25
Pre-Start Inspection............................................................. 8 Fuel Lines.............................................................................26
Starting/Stopping Procedure ....................................................... 9 Fuel FilterlWater Separator.................................................. 26
Electric Starting................................................................... 9 Fuel Injection Pump.............................................................26
Electric Starting Procedure..........................................9 Fuel Injector......................................................................... 26
Low Battery Electric Starting Procedure.....................9 Bleeding the Fuel System.................................................... 26
Manual Starting (Hand Cranking).......................................9 Spare Parts............................................................................26
Automatic Decompression Device............................
IO DC Electrical System ................................................................... 27
Cold Starting Device..................................................
10 12 Volt DC Control Circuit..................................................27
Manual Starting Procedure........................................
11 Control Panel........................................................................27
Starting Under Cold Conditions................................
12 Engine Circuit Breaker.........................................................27
Operating the Engine......................................................... 12 Battery.................................................................................. 27
Initial Start-Up Check List........................................
.12 Battery Care................................................................. 27
Stopping the Engine...........................................................
12
Checking the Service Battery.......................................27
Engine Break-In Procedure ....................................................... 13
Alternator Troubleshooting..................................................28
Engine Break-In Procedure................................................
13
Testing the Alternator...................................................28
Break-In Check List...........................................................
13
Checking the Service Battery.......................................29
Transmission Break-In.......................................................
13 7A-I Marine Diesel Engine Wiring Diagram #45593.........30
Daily Operation .......................................................................... 13
7A-I Marine Diesel Engine Wiring Schematic #45593...... 31
Daily Operation Check-List....................................... 13
11A-1 Marine Diesel Engine Wiring Diagram #44542.......32
Transmission..............................................................
13 11A-l Marine Diesel Engine Wiring Schematic #44542.... 33
Maintenance Schedule .............................................................. 14
Glow Plugs (ModeI7A-1 only)...................................................34
Exhaust System ......................................................................... 16
Engine Adjustments ..................................................................... 35
Description.........................................................................
16
Tightening the Cylinder Head..............................................35
Siphon-Break.............................................................
16
Valve Clearance Adjustment................................................35
Exhaust System Precautions..............................................
16
Engine Compression Test.....................................................35
Carbon Monoxide......................................................
16
Testing the Fuel Injector.......................................................36
Carbon Monoxide Warning Decal.............................
16
Removing the Fuel Injector..........................................36
Carbon Monoxide Detectors......................................
17
Fuel Injector Components............................................36
Insulation...................................................................
.17
Checking the Injection Starting Pressure.....................36
Overcranking.............................................................. 17
Tightness of the Valve Seat..........................................37
Lubrication System .................................................................... 18
Inspecting the Spray Pattern........................................ 37
Description.........................................................................
18
Checking the Nozzle Body and Needle Valve.............37
Oil Pressure ReliefValve........................................... 18
Reassembly...................................................................37
Low Oil Pressure Alarm Switch................................
18
Injector Installation...................................................... 37
Engine
OiL ......................................................................... 18
Drive BeltAdjustment......................................................... 38
Checking the Oil................................................................
18
Checking Belt Tension.................................................38
Changing the
OiL .............................................................. 19
Adjusting Belt Tension.................................................38
Removing the Old Oil...............................................
.19
Engine Troubleshooting ............................................................... 39
Changing the Oil Filter (Model
llA-l only)............ 19
Hurth HBW Transmission ............................................................. 42
Adding the New Oil.................................................. 20
Hurth HBW Transmission Troubleshooting .................................. 45
Testing the Oil Pressure.....................................................20
Lay-Up and Recommissioning ..................................................... 46
Cooling System ......................................................................... 21
7A-1 & 11A-1 Torque Specifications ........................................... 48
Raw Water Cooling System..............................................
21
Standard Hardware/Sealants & Lubricants ................................ 49
Thermostat.........................................................................
21
Metric Conversions ...................................................................... 50
CheckinglReplacing the Thermostat......................... 21
Standard and Metric Conversion Oata ........................................ 51
CoolantTemperature Switch............................................. 21
Suggested Spare Parts Kits ......................................................... 52
Engines & Generators
1

INTRODUCTION
This WESlERBEKE Diesel Engine is a product of
WESlERBEKE'S many years of experience and advanced
technology. We take great pride in the superior durability and
dependable performance of our engines and generators. Thank
you for selecting WESlERBEKE.
This is the Operators Manual for the 7 A-I and IIA-I Marine
Diesel Engines. Most of the information in this manual applies to
both models; where information applies to only one of the two
models, the applicable model name will be indicated. A Parts
Catalog is also provided for your engine, and a Service Manual is
available from your WESlERBEKE dealer. If you are planning
to install this equipment, contact your WESlERBEKE dealer for
WESlERBEKE'S Installation Manual.
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
WESlERBEKE dealer for assistance.
WARRANTY PROCEDURES
Your WESlERBEKE Warranty is included in the documentation
package. If you have not received a customer identification card
registering your warranty 60 days after submitting the warranty
registration form, please contact the factory in writing with model
information, including the unit's serial number and
commission date.
Customer Identification Card
I~'WESIERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Mode17A-1
Expires 3116102
Ser. #74860/197-E003
Your WESlERBEKE 7A-I/IIA-I Engine serial number is an
alphanumeric number that indicates the date of manufacture. The
date code is at the end of the serial number, and consists ofa
character followed by three numbers. The character indicates the
decade (D= 1990s, E=2000s), the fITSt number after the character
represents the year in the decade, and the second and third
numbers after the character represent the month of manufacture.
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 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 UABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESlERBEKE customers should keep in mind the time span
between printings of WESlERBEKE product software and the
unavoidable existence of earlier WESlERBEKE product
software. The product software provided with WESlERBEKE
products, whether from WESlERBEKE 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
WESlERBEKE or the supplier in question be consulted to
determine the accuracy and currentness of the product software
being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical information will be highlighted by NOlES,
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 Dr destruction of
your engine.
A WARNING: Procedures which. if not properly
followed. can result in pelSDnai injury or loss of life.
MODEL NO./SERIAL NO. LOCATION
The engine's model number and serial number are located on an
identification plate mounted on the engine block, below the
exhaust manifold/elbow. Take the time to enter this information
on the illustration of the nameplate shown below, as his will pro-
vide a quick reference when seeking technical information and/or
ordering repair parts.
ENGINE mEITIFICATION PlATE
Engines & Generators
2

INTRODUCTION
COMPONENT LOCATIONS
Component locations in this manual are referenced from the front
of the engine which is the end at which the raw water pump is
located. Left and right sides are detennined as follows: imagine
straddling the engine, facing the front of the engine: the left side
is at your left, the right side is at your right.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine, since the
mechanism is essentially the same. The cylinder is arranged
above a closed crankcase. The crankshaft is of the same general
type as on a gasoline engine, and the diesel engine has the same
types of valves, camshaft, piston, connecting rod and lubricating
system.
Therefore, to a great extent, a diesel engine requires the same pre-
ventive maintenance as a gasoline engine. The most important
factors are proper ventilation and proper maintenance of the fuel,
lubricating and cooling systems. Fuel 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 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
Whenever replacement parts are needed, always provide
the engine model number and serial number.
You must
provide
us with this information so we may properly iden-
tify your engine.
In addition, include a complete part
description and part number for each part needed (see the
Parts List). Insist upon Westerbeke packaged parts
because will
fit or generic parts are frequently not made to
the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and main-
tain your WESTERBEKE engine when cruising (see
SUGGESTED SPARE PARTS KITS). Often even a
simple item such
as a proper fuel filter can be difficult
to obtain along the way. WESTERBEKE can provide
you with a suggested spares and accessories brochure
to
assist you in preparing an on-board inventory of the
proper WESTERBEKE parts.
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 cannot control how or where the engine is installed
in the vessel or the manner in which the unit is operated and ser-
viced in the field. This is up to the buyer/owner-operator.
NOTE: Six important steps to ensure long engine life:
• Proper engine installation.
• An efficient well-designed exhaust system that includes an
anti-siphon break to prevent water from entering the engine.
• Changing the engine oil every 100 operating hours.
• Proper maintenance of all engine components according to the
maintenance schedule in this manual.
• Use clean, filtered diesel fuel.
• Wmterize your engine according to the LAY-UP AND
RECOMMISSIONING section in this manual.
Engines & Generators
3

7 A-1 DIESEL ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Type
Aspiration
Govemor
Combustion System
Bore and Stroke
Piston Displacement
Crankshaft
Direction of Rotation
Compression Ratio
Maximum Torque
(at 2500 rpm)
Manual Starting System
Engine Stop
Dimensions
NOTE: An inserted standard
crank handle increases the
width by 4.5 in (115 mm)
Dry Weight
Max. Angle of Installation
Max. Angle of Operation
Diesel, four-cycle, one cylinder, raw water cooled,
vertical, in-line overhead valve mechanism
Naturally aspirated
Mechanical, centrifugal type
Direct injected
3.23 in. x 2.17 in. (82.0 mm x 55.0 mm)
17.7 cu. in. (290 cm')
Clockwise, when viewed from the front
(raw water pump end)
20:1
11.0 ftIIbs (1.5 kg-m)
Hand-crank, with automatic
decompression device
Manual type
Height: 17.1 in (433.7 mm)
Width: 14.9 in (379.2 mm)
Length: 22.5 in (571.3 mm)
151 Ibs (68.5 kg)
Not to exceed 1 0°
Not to exceed 15° in all directions
TUNE-UP SPECIFICATIONS
Compression Pressure
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Timing
Injector Pressure
Engine Speed
Fuel System
Fuel
Fuel Lift Pump
Fuel Injection Pump
Fuel Injector
Fuel Injection Timing
Injector Pressure
Fuel Consumption
(full load)
Fuel Filter
Fuel Supply
and Return Lines
Air Row
(engine combustion)
478.5 psi (33.6 kg/cm') standard
435.0 psi (30.6 kg/cm') minimum
Intake 45°; Exhaust 45°
Intake 0.008 in. (0.2 mm)
Exhaust 0.008 in. (0.2 mm)
39.0 mm BTDC static
2900 psi (203.9 kg/cm')
Idle: 1000 - 1200 rpm
Cruise: 2000 - 2500 rpm
Maximum: 2900 - 3000 rpm
FUEL SYSTEM
Open flow, sen-priming, sen-bleeding
No.2 diesel oil, cetane rating of 45 or higher
Mechanical 1.6 ft. (0.5 m) lift max.
Bosch type
Direct injection
39 mm BTDC static
2900 psi (203.9 kg/cm')
0.46 U.S. gal./hr. (1.76Iiterlhr.)
Primary, replaceable filter
1/4 in. (6.35 mm) 1.0. minimum
5116 in. (7.94 mm) 1.0. maximum
15.3 cfm (0.43 cmm)
LUBRICATION SYSTEM
Lubrication System
Sump capacity
Operating Oil Pressu re
(engine hot)
Oil Grade
Lube oil Strainer
Cooling System
Operating Temperature
Raw Water Pump
Raw Water Row,
at 3600 rpm
Raw Water Connection
Forced lubrication by gear-driven pump
1.3 qts. (1.25 liters)
25.6-56.9 psi (1.8-4.0 kg/cm')
API specification CF or CG-4
SAE 30, 10W-30, 15W-40
Full-flow, intemal
COOLING SYSTEM
Raw water-cooled block,
thermostatically controlled
13D-150°F(55-66°C)
Positive displacement, neoprene impeller,
gear-driven, sen-priming
7.3w-8.456 gpm (7~ Ipm)
112 in. (12.7 mm) 1.0.
EXHAUST SYSTEM
Emission Control Systems Meets U.S.C.G. Regulation 33 CFR 183
Exhaust ManifoldlElbow cast aluminum, raw water cooled
Exhaust Elbow Connection 1-112 in. (38.1 mm) 1.0.
ELECTRICAL SYSTEM
Electrical System 12 volts DC, negative ground,
circuit breaker protected
Battery Charging 30 amp, 12 volts, belt-driven, with
Altemator solid state internal regulator
Starting Motor 12 volt solenoid, actuated shift
Cold Cranking Amps 70 amps@71°F (22°C)
TRANSMISSION
General HURTH HBW 40 Standard Transmission, case-
hardened helical gears, with a servo-operated
multiple disc clutch
Gear Ratio (optional) 2.05:1
Propeller 120x8P two blade RH
Propeller used must allow 12 0 x6P three blade RH
the engine to reach its rated
rpm at full open throttle in
forward gear, underway
Lubricating Ruid ATF- type A or DEXTRON -/I or 11/
Transmission Sump 0.37 qts (0.35 liters)
capacity
Propeller Shaft Right hand-standard transmission
Direction of Rotation
Engines & Generators
4

7 A-1 DIESEL ENGINE PARTS IDENTIFICATION
AUTOMATIC
DECOMPRESSION
DEVICE
HAN~-CRANK
HANDLE GUIDE
RAW
WATER
PUMP
RAW WATER
flEXIBLE
MOUNTS
INTAKE CONNECTION
TRANSMISSION
TRANSMISSION
OUTPUT FLANGE
FUEL INJECTOR ---t--Hl'f-H,-#'4:;;;t,i~M"-:;5~~~~
Engines & Generators
5
CYLINDER
HEAD
WATER INJECTED EXHAUST
MANIFOLDJELBOW
FUEL INJECTION
PUMP
FUEL FILTER

11 A·1 DIESEL ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Type Diesel, four-cycle, one cylinder, raw water cooled,
vertical, in-line overhead valve mechanism
Aspiration Naturally aspirated
Governor Mechanical, centrifugal type
Combustion System Direct injected
Bore and Stroke 3.74 in. x 2.91 in. (95.0 mm x 74.0 mm)
Piston Displacement 31.95 cu. in. (524.0 cm')
Crankshaft Clockwise, when viewed from the front
Direction of Rotation (raw water pump end)
Compression Ratio 20:1
Maximum Torque 21.3 ftIIbs (2.9 kg-m)
at (2400 rpm)
Manual Starting System Hand-crank, with automatic
decompression device
Engine Stop Manual type
Dimensions
NOTE: An inserted standard
crank handle increases the
width by 4.5 in. (115 mm)
Dry Weight
Height: 21.0 in (532 mm)
Width: 21.3 in (540 mm)
Length: 23.8 in (603 mm)
238 Ibs (108 kg)
Max. Angle of I nstallation Not to exceed 1 0°
Max. Angle of Operation Not to exceed 15° in all directions
TUNE-UP SPECIFICATIONS
Compression Pressure
Valve Seat Angle
Valve Clearance
(engine cold)
Engine liming
Injector Pressure
Engine Speed
Fuel System
Fuel
Fuel
Uft Pump
Fuel Injection Pump
Fuel I njector
Fuel Injection liming
Injector Pressure
Fuel Consumption
(full load)
Fuel Riter
Fuel Supply
and Retum Lines
Air Row
(engine combustion)
478.5 psi (33.6 kg/cm') standard
435.0 psi (30.6 kg/cm') minimum
Intake 45°; Exhaust 45°
Intake 0.008 in. (0.2 mm)
Exhaust O.OOS in. (0.2 mm)
60.0 mm BlDC static
2537 psi (178.3 kg/cm')
Idle: 1000 -1200 rpm
Cruise: 2000 - 2500 rpm
Maximum: 2900 - 3000 rpm
FUEL SYSTEM
Open flow, self-priming, seH-bleeding
No.2 diesel oil, cetane rating of 45 or higher
Mechanical 1.6 ft. (0.5 m) lift max.
Bosch type
Direct Injection
60 mm BTDC static
2537.5 psi (178.4 kg/cm')
0.46 U.S. gaL/hr. (1.76Iiterlhr.)
Primary replaceable filter
1/4 in. (6.35 mm) 1.0. minimum
5/16 in. (7.94 mm) 1.0. maximum
27.7 cfm (0.78 cmm)
LUBRICATION SYSTEM
Lubrication System
Sump Capacity
Operating Oil Pressure
(engine hot)
Oil Grade
Oil Riter
Forced lubrication by gear-driven pump
1.7 qts. (1.6 liter)
25.&-56.9 psi (1.8-4.0 kg/cm')
API specification CF or CG-4
SAE 30, 10W-30, 15W-40
Full-flow, paper element, spin-on type
COOLING SYSTEM
Cooling System
Operating Temperature
Raw Water Pump
Raw Water Row,
at 3600 rpm
Raw Water Connection
Raw water-cooled block,
thermostatically controlled
13D-150°F (55-66°C)
Positive displacement, neoprene impeller,
gear-driven, seH-priming
7.399-8.456 gpm (7-8lpm)
112 in. (12.7 mm) 1.0.
EXHAUST SYSTEM
Emission Control Systems Meets U.S.C.G. Regulation 33 CFR 183
Exhaust ManifoldlElbow Cast aluminum, raw water cooled
Exhaust Elbow Connection 1-112 in. (38.1 mm) 1.0.
ELECTRICAL SYSTEM
Electrical System
Battery Charging
Alternator
Starting Motor
Cold Cranking Amps
General
Gear Ratio (optional)
Propeller
Propeller used must allow
the engine to reach its rated
rpm at full open throttle in
forward gear, underway
lubricating Ruid
Transmission Sump
Capacity
Propeller Shaft
Direction of Rotation
12 volts DC, negative ground,
circuit breaker protected
30 amp, 12 volts, belt-driven,
with solid state intemal regulator
12 volt solenoid, actuated shift
60 amps@66°F (19°C)
TRANSMISSION
HURTH HBW 40 Standard Transmission, case-
hardened helical gears, with a servo-operated
multiple disc clutch
2.05:1
14 Dx8 Ptwoblade-RH
140x6P three blade - RH
ATF- type A or DEXTRON - /I or 11/
0.37 qts (0.35 liters)
Right hand-standard transmission
Engines & Generators
6

TIlANS""SSION
OIPSTIClCIFlll
'TRANSMISSION
11A·1 DIESEL ENGINE PARTS IDENnFICATION
CYLINDER
HEAD
TlfROTrtE
CONTROL
STARTER
FUEL INJECTOR
COOlANT
TE"'PERATURE
SWITCH
FUEL FILTER
fOAArpoc
CIRCUIT BREAKER

PREPARATIONS FOR INITIAL START-UP
DIESEL FUEL
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not
use kerosene or home heating fuel.
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 it clean.
The best fuel can become 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, purchase a
well-known brand of fuel. Also install and regularly service a
good, Coast Guard approved fuel filter/water separator between
the fuel tank and the engine.
Fuel Additives
If fungus or bacteria is causing fuel problems, you should have
an authorized dealer correct these problems. Then use a diesel
fuel biocide to sterilize the fuel (follow the manufacturer's
instructions). Use a fuel stabilizer on a regular basis as well.
STA-BIL is an example of such a product.
ENGINE OIL
A CAUTION: This engine was shipped from the fac-
to" without lubricant in the engine. Before operating,
fill with the proper engine oil.
Use an engine oil with an API classification of CF or CG-4.
Change the engine oil after an initial 50 hours of break-in opera-
tion, and every 100 hours of operation 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 or 10W-30
Below 41° F (5° C)
SAE10W-30
A CAUTION: Do 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 hannful to your engine.
TRANSMISSION FLUID
Use ATF type A or Dextron II or ill transmission lubricating fluid.
The transmission sump capacity is 0.37 qts. (0.35liters).
PRE-START INSPECTION
Before starting your engine for the first time, or after a prolonged
lay-up, check the following items:
D Check the engine oil level. The oil level must be between the
max. and min. marks on the dipstick.
D Turn on the fuel supply, then check the fuel supply and exam-
ine 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 Open the raw water intake and make sure the raw water sup-
ply reaches the raw water strainer.
D VIsually examine the engine. Look for loose or missing
parts, disconnected wires, and unattached hoses. Check the
threaded connections. Check for fuel leaks.
D Make sure the exhaust system is secure and all the
connections are tight
D
Make sure there is good ventilation and an ample air supply.
These are necessary for proper engine performance.
D Make sure the mounting installation is secure.
D Make sure the propeller shaft is securely attached to the
transmission.
Engines &Generators
8

STARTING/STOPPING PROCEDURE
ELECTRIC STARTING
The 7A-I/llA-1 diesel engine has a 12 VDC electric starter. The
engine is started by using a keyswitch on the control panel. The
switch has three positions: OFF, ON and START.
NOTE: Periodically lubricate the keyswitch mechanism with
LOCKEZE to ensure proper keyswitch functioning.
OIL/WATER
ALARM
ALARM ~~~~E~T
W[g~lf'[grtl&&c:.r[g
CONTROL PANEL
Electric Starting Procedure
\\ \-.......-I+- HOUR METER
KEYSWITCH
1. Place the transmission in neutral and advance the throttle con-
trol to slightly open.
A CAUTION: Make certain the transmission is in neu-
tral. Starting in gear could result in serious damage to
your transmission, your boat, and vessels nearby.
2. Turn the keyswitch to the ON position. The alann buzzer on
the control panel will beep. Push the key in to preheat. Hold
the key in and turn it to the START position. When the
engine starts, let go of the key and it will come out of preheat
and spring back to the ON position (observe that it does this).
NOTE: If the engine doesn ~ start, limit each starting trial to 10-
20 seconds. Wait for approx. 30 seconds before repeating the
start. Never operate the starter motor while the engine is still
running.
NOTE: Some unstable running may occur in a cold engine. This
condition should smooth out as the nOf77Ul1 operating temperature
is reached and a load is applied. Allow afew minutes for the
wann-up at a comfortable rpm (approximately 1,000 rpm), then
reduce the rpm and get underway.
Low Battery Electric Starting Procedure
If the battery is discharged and too low for a normal electric start
but not completely dead, an attempt at an electric start can be
made by using the Automatic Decompression Device. This device
works by holding the exhaust valve open, and is normally used
when manually starting (hand-cranking) the engine.
NOTE: The Automatic Decompression Device is not used for
nOf77Ul1 electric starting. During engine operation, the pointer on
this device is in the operating (9 o'clock) position.
1. Place the transmission in neutral and advance the throttle con-
trol to slightly open.
2. Using a IOmm wrench, turn the hex-head bolt on the
device so the pointer is in the manual starting position
(see illustration).
POINTER IN ,-T-t----,L.~..,.::,
THE MANUAL
STARTING
PosmON
-;-t---;i-H-_ HEX-HEAD BOLT
AUTOMATIC
OECOMPRESSION
DEVICE
3. Turn the keyswitch to the START position. The alann on the
control panel will beep until the engine oil pressure comes up.
The pointer on the Automatic Decompression Device will
automatically move clockwise with each crank. The pointer
will stop at the 9o'clock position and compression will occur
after 8 cranks. Hold the keyswitch in the START position
until either the engine starts or the pointer stops after the 8th
crank. Then let go of the key and it will spring back to the
ON position.
POINTER IN
THE OPERATING
posmON
j
~
~'lIJ=======
If this attempt at an electric start does not start the engine, then a
manual start by hand-cranking will be necessary.
MANUAL STARTING (HAND CRANKING)
When installing the engine, it is important to provide enough
space at the front end to allow for manual starting (hand cranking)
in case of an emergency or when the starting battery has become
too low to allow an electrical start.
Engines & Generators
9

STARTING/STOPPING PROCEDURE
The upper illustration shows the distance [4.5 in. (115 mm)] that
the standard hand-crank handle protrudes from the crank-handle
guide on the engine. An additional 2.5 in. (64 mm) minimum
must be allowed for room to insert the handle.
If hand cranking must be done from outside the engine
compartment (see lower illustration), then the standard
hand-crank handle must be extended to the required length.
This modification to the handle must be done by the owner.
BULKHEAD
~"L~
l=::;:::::~
~~~.I
HANDLE
The engine may be started by hand-cranking in an emergency or
when the starting battery has become too low to allow an electric
start. A manual start is possible with a completely dead battery.
For easy and safe manual starting, the engine is fitted with an
Automatic Decompression Device and a Cold Starting Device.
Use both of these devices when hand-cranking.
Before using the hand-crank handle, an attempt at a normal
electric start could be made by using the Automatic
Decompression Device (see Low Battery Electric Starting under
ELECfRlC SfAR1); the electrical power required for the start
would then be considerably less, so that a discharged battery, if
not completely dead, might allow the start
NOTE: Oil will be supplied to all the bearing points when
hand-cranking.
Automatic Decompression Device
The Automatic Decompression Device works by holding the
exhaust valve open. The device has three positions, as indicated
by the pointer. When setting the pointer, tum the hex-head bolt
with a 10 mm wrench.
A CAUTION: Neller use the Automatic Decompression
Device to stop the engine.
POINTER
Cold Starting Device
HEX-HEAD BOLT
AUTOMATIC
OECOMPRESSION
DEVICE
This device provides more fuel from the injection pump. There
are two positions for the knob: up (oft) and down (activated).
When activating this device, pull the knob down (see illustration).
To release this device, move the speed control lever down, then
release it (see illustration).
NOTE: Never pull the Cold Starting Device knob down when the
engine is operating or when restarting a hot engine.
MODEL 7A-1 SHOWN
COLD STARTING
DEVICE KNOB
Engines & Generators
10

STARTING/STOPPING PROCEDURE
Manual Starting Procedure
To manually start the engine, follow the procedure described
below. When starting after cold nights or freezing temperatures
when the engine must first be turned over with no compression,
follow all of the steps, beginning with Step 1. If cold weather is
not a factor, bypass Steps 1-3, and begin with Step 4.
A WARNING: Always keep hands and feet clear of
moving parts. Put the transmission in neutral. Do not
use starting aids.
1. Place the transmission in neutral and advance the throttle con-
trol to slightly open.
NOTE: Make sure the stop lever is in the RUN position.
2. Set the Automatic Decompression Device pointer to the
Neutral position (see illustration). Compression is released
when the pointer is in this position.
POINTER IN
THE NEUTRAl
PDSmDN
~
~
~
~'lli=======
3. Insert the crank handle into the crank handle guide (see
illustration). Standing to the right of the crank handle, put your
right hand on top of the air intake filter for support and grip the
crank handle with your left hand, with the thumb on your left
hand in the position shown in the illustration.
HAND-CRANKING
Model7A-1 shown
CRANK HANDLE GUIDE
4. Crank the engine counterclockwise approximately 10 to 20
times until the engine turns freely. Then remove the crank
handle.
S. Set the Automatic Decompression Device pointer to the
manual starting position (see illustration). When hand-crank-
ing in this position, automatic decompression will occur.
POINTER IN
THE MANUAl
STARTING
PDsmDN
6. Pull down the Cold Starting Device knob. Note: Do not pull
down this knob when restarting a hot engine.
COLD STARTING
DEVICE KNOB
7. Insert the crank handle into the crank handle guide (see
illustration). Standing to the right of the crank handle, put
your right hand on top of the air intake silencer for support
and grip the crank handle with your left hand, with the thumb
on your left hand in the position shown in the illustration.
S. Slowly crank the engine counterclockwise 4 times, then crank
the engine as fast as possible. The pointer on the Automatic
Decompression Device will automatically move clockwise
with each crank. Compression will occur after 8 cranks.
Continue to crank after compression occurs until the engine
starts firing. As decompression ends and compression occurs,
the pointer will automatically stop at the operating (9 o'clock)
position.After the engine starts, the crank handle will automat-
ically disengage. Then remove the crank handle.
Engines &Generators
11

STARTING/STOPPING PROCEDURE
POINTER IN
THE OPERATING
POSITION
9. If the engine has not started, repeat Steps 5-9 above, and con-
sider cranking at a higher speed.
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 cylinder 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 crank-
ing. Remember that engine damage resulting from raw
water entry is not covered by Westerbeke's warranty.
Starting Under Cold Conditions
Make sure 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. The battery should be fully
charged to minimize voltage drop.
OPERATING THE ENGINE
Allow a few minutes for the engine to wann up at a comfortable
rpm (approximately 1500 rpm), then reduce the rpm, and get
underway.
A CAUTION: Never pull the cold starting dellice knob
down when the engine Is operating.
Initial Start-Up Check List
o Check for possible leaks from all the connections.
o Make sure the cooling water is discharging properly, outboard
from the exhaust outlet.
o Make certain that the engine is mounted securely.
o Listen for unusual sounds and vibrations.
STOPPING THE ENGINE
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. Turn the engine off using the
stop control cable, then turn off the keyswitch at the control panel.
NOTE: Make certain this keyswitch is in the OFF position (12
o'clock). if the keyswitch is left ON, the battery will discharge.
An engine alarm is provided to warn the operator of this condi-
tion (key switch ON). The best method of preventing the battery
from discharging is to remove the key from the keyswitch after
stopping the engine.
A CAUTION: Neller stop the engine with the
automatic decompression dellice, or when the engine is
under afull load.
Check the lube oil level a few minutes after stopping the engine,
because lube oil from the bearings etc. continues to drain down
into the oil sump. Disregarding this fact and not maintaining the
proper oil level may lead to overfilling, causing overheating and
the possibility of engine runaway.
After shutdown, carefully inspect the engine. Check for possible
leaks from all the connections.
Engines &Generators
12

ENGINE BREAK-IN PROCEDURE
ENGINE BREAK-IN PROCEDURE
Although your engine has experienced a minimum of one hour of
test operations at the factory to make sure accurate assembly pro-
cedures were followed and that the engine operated 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 piston
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 of initial condi-
tioning operation to break-in each moving part in order to maxi-
mize the performance and service life of the engine. Perform this
conditioning carefully, keeping in mind the following:
1. Start and stop the engine according to the STARTINGISTOP-
PING PROCEDURE section. Run the engine at fast idle
while checking that all systems are functioning.
2. Allow the engine to warm up, preferably by running at fast
idle.
NOTE: Some unstable running may occur in a cold engine. This
condition should abate as normal operating temperature is
reached and the propeller load is applied
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 a cold engine.
S. Use caution not to overload the engine. The presence of a
grey or black exhaust and the inability of the engine to reach
its full rated speed are signs of an overload.
6. During the second 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.
Break-In Check List
Monitor the following during the 50 hour break-in period:
o Check for fuel, engine oil and water leaks.
o Check for abnormal noise such as knocking, friction, vibration
and blow-back sounds.
o Confmn the 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.
Also see the DAILY OPERATION CHECKllSTfor additional
items to check each day.
The MAINTENANCE SCHEDULE section gives the maintenance
procedures to follow after the 50 hour break-in period.
Transmission Break-In
See the HURTH HBW TRANSMISSION section of this manual for
break-in information on your transmission.
DAILY OPERATION
DAILY OPERATION
Start and stop the engine according to the instructions given in the
STARTINGISTOPPING PROCEDURE section. Also follow the
instructions given in the ENGINE BREAK-IN PROCEDURE sec-
tion during the first 50 hours of operation. Make sure all periodic
maintenance is performed according to the MAINTENANCE
SCHEDULE.
Daily Operation Check List
Follow this check list each day before starling your engine.
o Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule).
o Visually inspect the engine for fuel, oil or water leaks.
o Check the oil level (dipstick).
o Check the transmission fluid level.
o Check your diesel fuel supply.
o Look for clean fuel in the fuel filter/water separator transparent
bowl.
o Check for loose wires at the alternator and make sure its
mounting is secure.
o Check the starting batteries (weekly).
o Check drive belt for wear and proper tension (weekly).
o Check the raw water pump to make sure its mounting is
secure.
After starting the engine, check the following:
o Check for abnormal noise such as knocking, vibration and
blowby sounds.
o Confmn 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.
o Make sure the cooling water is discharging properly, outboard
from the exhaust outlet.
Transmission
See DAILY OPERATION in the HURTH HBW TRANSMISSION
section.
Engines & Generators
13