Westerbeke W35B User manual

OPERATORS MANUAL
358 Three, 388 Four, 428 Four
MARINE DIESEL ENGINES
PUBLICATION NO. 037435
REVISION. 3
MARCH 2018
J'W 'WESTERBEKE
j WESTERBEKE CORPORATION• 150 JOHN HANCOCK ROAD
j MYLES STANDISH INDUSTRIAL PARK• TAUNTON MA 02780
WEB SITE: WWW.WESTERBEKE.COM
----
NMM4 Member National Marine Manufacturers Association
~--

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
•Muscular Twitching
•Vomiting
•Nausea
·•Headache
,.t
• Weakness and Sleepiness
•Inability to Think Coherently
IF YOU DR ANYONE ELSE EXPERIENCE ANY OF niEsE SYMPTOMS,
BET OUT INTO THE FRESH AIR l•EBIATELY. N symptoms persist,
seek medical attention. Shut down the unit and do not restart
untilit luls been inspected and repaired.
A WARN/NB 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/s/eepiilg quarters ofyoui vessel.
Tiiey are inexpensive and easily
obtainable at your local marine store. ·
... I .
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accUlents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your .
personnel, and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage Is present at these connections!
II Do not operate this machinery without electrical
enclosures and covers in place.
II Shut offelectrical power before accessing electrical
equipment.
II Use insulated mats whenever working on electrical
equipment.
II Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
II Remove wristwatch and alljewelry when working on
electrical equipment.
PREVENT BURNS - HOT ENGINE
A WARNING: Oa not touch hat engine parts or
exhaust system components. A running engine gets very
hat!
Ill Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodically at the filler cap
location on the waterjacketed exhaust manifold, but only
when the engine is COLD.
A WARNING: Steam can cause injury or death!
1111 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!
Ii Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
11\l Do not operate with the aircleaner/silencer removed.
Backfire can cause severe injury or death.
Ill Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
I' Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
l!J 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
running the blower. Run the blower for four minutes
before starting your engine.
!kl Allfuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-
ventilated area away from spark-producing equipment
and out of the reach ofchildren.
Ell Do not fill the fuel tank(s) while the engine is runni.Qg.
E?J Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking; open flames, or other
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
iJ Do not alter or modify the fuel system.
fJ Be sure all fuel supplies have a positive shutoff valve.
11~ Be certain fuel line fittings are adequately tightened and
free ofleaks.
a 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 starting can cause injury
or death/
11 Turn OFF the DC breaker on the control panel or tum the
unit's battery selector switch to OFF before servicing the.
engine.
• Make certain all personnel are clear ofthe 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 nearthe battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by elec~cal
arcing or by lit tobacco products. Shut o~ all ele~lrical
equipment in the vicinity to prevent electrical arcmg
during servicing.
• Never connect the negative(-) battery cable to the
positive (
+) connection terminal of the starter solenoi?.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel
vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive gases.
To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause
!111 explosion. Remo~e
wristwatch, rings, and any otherJewelry before handling
the
battery.
• Always tum the battery charger offbefore disconnecting
the battery connections
.. Remove the negative lead first
and reconnect it last when servicing
the battery.
BATTERY ACID
A WARNING: SUifuric acid in batteries can cause
severe Injury or death!
• When servicing the battery orchecking 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} is a deadly gas!
El 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.
Iii Be sure the unit and its surroundings are well ventilated.
Run blowers when running the geµerator set or engine.
a Do not run the generator setorengine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder ordealer for installation ofapproved
detectors.
Iii For additional information, refer to ABYC TH-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO} Is an Invisible
odorless gas. Inhalation produces Ru-like symptoms,
nausea or death!
ID Do not use copper tubing in diesel exhaust systems.
Diesel
fumes can rapidly destroy coppertubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
11 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
aµd close or restrict the
flow ofexhaust. Avoid overloading the craft.
l!I 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 orsigns ofcarbon monoxide inhalation or
poisoning
are:
Vomiting
Dizziness
Headache
Inability
to think coherently
Throbbing
in temples
Muscular twitching
Nausea Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause Injury
or death!
lill 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
Ill Do not wear loose clothing orjewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in
. moving parts ..
111 Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
111 Do not check fluid levels or the drive belt's tension while
. the engine is operating.
11 Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise l~vels can cause hearing
loss!
11 Never operate an engine without its·muffler installed.
111 Do not run an engine with the air intake (silencer)
removed.
A WARNING: Oo not work an machinery when you are
mentally 01 physically incapacitatedby fatigue!
OPERATORS MANUAL
·Many of the preceding safety tips and warnings are'fepeated
in your Operators Manual along with other cautions and
notes to highlight critical infonnation. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standar.ds. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion ofExhaust Systems for Propulsion
and Auxilliary Engines
P-4 Marine Inboard Engines and Transmissions
E-11 AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NF PA AND USCG PUBLICATIONS FOR
. ~NSTAR.LING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your UNIVERSAL engine
ABYC (American Boat and Yacht Council)
"Safety Standari:ls for Small Craft" ·
Order
From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
( 410) 990-4460
·
www.abycinc.~rg
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1 Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"CFR 33 AND CFR46"
Code ofFederal Regulations
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid
to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON·BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the
raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above
the vessel's waterline. Failure to use asiphon-break when
the exhaust manifold injection portis at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
SIPHON~BR'EAK WITH STAINLESS
wop·
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose
is recommended. The use of this type ofhose allows for extreme bends
and turns without the need of additional fitting and clamps to accomplish these bends
and turns. In this regard, a single length ofcorrugated exhaust hose can be used. The
system MUST be designed to prevent the entry of water into the exhaust system
under
any sea conditions and at any angle ofvessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Introduction ......................................................... 2
Engine Lubricating ............................................ 22
Warranty Procedures......................................2 Changing the Oil Filter................................22
Serial Number Locations...............................3 Changing the Oil .........................................22
Ordering Parts................................................3
Oil Pressure ........................................................ 23
Parts Identification ............................................ .4
Testing Oil Pressure..................................... 23
Transmission Data ............................................... 5
Remote Oil Filter (Optional) .............................. 24
Propeller Recommendations......................... .5
Torque Specifications ....................................... 24
Fuel, Engine Oil and Coolant .............................. 6
Tachometer ........................................................ 25
Oil Pressure ...................................................6
Water Heater ..................................................... 26
· Coolant Recovery Tank.................................6
Starter Motor ..................................................... 27
Preparations for Initial Start-Up ......................... 7
DC Electrical System ......................................... 29
Admiral Control Panel ......................................... 8 Alternator Troubleshooting .........................29
Captain Control Panel ......................................... 9 Battery Care........................ .......................30
Starting/Stopping Procedure ............................. 1o Wiring Schematic .............................................. 31
Engine Break-In Procedure ............................... 11 Wiring Diagram .................................................. 31
The Daily Operation ........................................... 12
Engine Troubleshooting .................................... .32
Warning Lights, Alarms and Circuit Breaker .... 13
Coolant Temperature/Oil Pressure Gauges .34
Maintenance Schedule (Chart) ......................... 14 Adjusting Idle Speed..............;................... .35 ·
Cooling System ........................... : .......... ~ ........... 16 Belt Tension and Maintenance....................35
Changing Coolant................. ~ ......................16 Torquing Cylinder Head Bolts (358) ... : ..... .36
Thermostat................................................... 17 Valve Clearance (358) ......................... J......36
Raw Water Intake Strainer.......................... 18 Torquing Cylinder Head Bolts (388/428) .. .37
Raw Water Cooling Circuit.........................
18
Valve Clearance (388/428) .......................... 37
Heat Exchanger ...........................................
18
HBW·ZF Transmissions ...................................... 38
Raw Water Pump.........................................
18
HBW·ZF Transmission (Chart) ...... ~ .................... .41
Zinc Anode .................................................. 19
JS and BW Transmissions .................................. 42
Air Intake/Silencer.......................................
19 Borg Warner Transmission ................................ 44
Fuel System ....................................................... 20 Oil Coolers...................................................46
Fuel/Water Separator...................................20
Metric Conversion/Hardware (Chart) ............... .47
Fuel Filters...................................................20
Specifications .................................................... 48
Fuel Lift Pumps...........................................
20 W35B Three ................................................48
Fuel Injectors ...............................................
21
W38B Four..................................................50
Fuel Injection Pump .................................... 21
W42B Four ..................................................52
Glow Plugs ..................................................
21
Lay-Up and Recommissioning ........................... 54
Suggested Spare Parts ..................................... .56
Engines & Generators
1

INTRODUCTION
This WESTERBEKE Diesel Engine is a product of
WESTERBEKE's long ye~ ofexperience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your engine, it is
important that you operate and main~n it correctly. i::rus
manual is designed to help you do this. Please read this man-
ual carefully and observe ,illl the safety precautions through-
out. Should your engine require servicing, contact your
nearest WESTERBEKE dealer for assistance.
This is your operators manual. Aparts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment, contact your WESTERBEKE dealer for ·
WESTERBEKE' S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is iftcluded in a separate
folder. If, after 60 days of submitting the Warranty Registry
form you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the engine's
serial number and commission date.
Customer Identification Card
Customer Identification
MR. ENGINE OWNER
MAIN STREET
HOMETOWN, USA
Model 358 Three. Serial # _____ 0402
Expires 10/15/02
The WESTERBEKE engine serial number is an alphanu-
meric number that can assist in determining the date of man-
ufacture of your WESTERBEKE engine. The manufacturer's
date code is placed at the end ofthe engine serial number and
consists ofa character followed by three numbers. The char-
acter indicates the decade (A=1960s, B=l970s, C=1980s,
D= 1990s ), the first number represents the year in. the decade,
and the second and third numbers represent the month of
manufacture.
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBI.E FOR THE
CONTENT OFSUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEUNESS OR
COMPLETENESS THEREOF AND WIU 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.
WESTERBEKE customers should keep in mind the time
span between printings ofWESTERBEKE product software
and the unavoidable existence ofearlier WESTERBEKE
product software. The proguct software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense but is imperative that appropriate
representatives ofWESTERBEKE or the supplier in question
be consulted to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, if not
1
strictly
obsllmnl, can result in the damage or destruction of
your engine.
A WARNING: ProcedufllS which, if not properly fol·
lowed, can result in personal injury or loss of life.
Engines & Generators
2

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model designation and serial number are
located on a nameplate that is mounted on the side of the
water jacketed exhaust manifold. The engine's serial number
can also be found stamped into the fiat block surface located
just
above the manual shut-off lever. Take the time to enter
this information on the illustration ofthe name plate shown
below, as this will provide a quick reference when seeking
technical information and/or ordering parts.
~VE1llt*t=Tl:I)
• MODEL SPEC W04 MA"'" SER.NO. 0
'J
UNDER&TMBING THE DIESEL ENGINE ,
The diesel engine closely resembles the gasoline engine,
since the.mechanism is essentially the same. The ~ylinders
are arranged above a closed crankcase. The crankshaft is the
same general type as a gasoline engine, and the diesel engine
has the same type of valves, camshaft, pistons, connecting
rods and lubricating system. ·
Therefore, to a great extent, a diesel engine requires the same
preventive maintenance as a gasoline engine. The most
important
factors are proper ventilation and proper mainte-
nance of the fuel, lubricating and cooling systems. Fuel and
lubricating filter elements must be replaced at the time peri-
ods specified, and frequent checking for contaminants (water,
sediment, etc.) in the fuel system is also essential. Another
important factor
is the consistent use ofthe same brand of
high detergent diesel lubrication oil designed specifiCally for
diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its metl1od ofhandling 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 as they appear on
the silver and black nameplate located on the manifold. You
must provide us with this information so we may properly
identify your engine. In addition, include a complete part
descriptiqn and part number for each part needed (see the
separately furriished Parts List). Insist upon WESTERBEKE
packaged parts because willfit or generic parts are frequently
not made to the same specifications as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
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 acces-
sories; see WESTERBEKE's ACCESSORIES brochure.
1-W-IWESTERBEKE
IEngines & Generators
3

Connections
Secondary
Fuel Filter
Fuel Lift pump
PARTS IDENTIFICATION
Top Engine Oil Fill
Air Intake Silencer
Lube Oil Dipstick
Lube Oil Filter
DC Charging
Alternator
Shut-of!
Lever
Lube Oil
Drain Hose-
,Throttle lever
W 428 FOUR MARINE DIESEL ENGINE
Top
Oil Fill
Air Intake Silencer
Sender
Lube Oil Filter
DC Charging
Alternator
Shut-off
Lever
Lube Oil
Drain Hose
Fresh Water
Circulating
Pump·
W 388 FOUR MARINE DIESEL ENGINE
RIGHT SIDE
Top Engine Oil Fill Fresh Water Fill
Starter with Solenoid
RIGHT SIDE
Top Engine Oil Fill Fresh Water Fill
Starter with Solenoid
Engines & Generators
4
LEFT SIDE.
LEFT SIDE
90" Exhaust Elbow

Fresh Water
Air Bleed
Fresh Water
Circulating
Pump
Starter with Solenoid
W35BTHREE
PARTS IDENTIFICATION
Unit Data Plate
20AmpDC
Circuit Breaker
90' Exhaust Elbow .
Heat Exchanger
LEFT SIDE
20 Amp DC Circuit Breaker
Fuel Lift Pump
Instrument
Connections
RIGHT SIDE
DC Charging
Alternator
MARINE DIESEL ENGINE
Side Lube
Oil Fill
TRANSMISSION DATA
(standard JS Transmission )
ALL MODELS.
General:
Zinc Anode
Transmission
Dipstick
JS Transmission
Standard Gear Ratio:
Propeller Shaft Rotation:
TransmiSsion Oil.
and Grade.
·. Transmission Sump Capacity:
Propeller Recommendations:
Lube Oil Dipstick Oil Pressure
Sender
Case-hardened helical gears with an intermediate reverse
gear. Reversing is carried out by a servo double disc system.
2. 47: 1.
Right Hand.
API Spec. CG-4, CH4, Cl-4, SJ, SL, SM, dr better.
SAE 20W or SAE 30 exclusively.
Do not rnlx:9f8des of oil and do not use multigrades oils
1 Quart ( 1 LitPr ).
428 FOUR ... 180.x 12P, two blade or 180 x10Pthree blade
388THREE ... 1611.x 12P; two blade or t60ll1PPthree blade.
358THREE ... 16:0x10P. two blade or 160 x 8P, three blade.
Shut-off
Lever
Propeller should allow the engine to reach its full rated RPM ( 3600 +I - 100)
at full open throttle while underway.
{;nginps &. Generators
' 5

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
USE A DIESEL FUEL WITH CETANE RATING OF #45 OR HIGHER.
(No. 2-D (SAE J313) diesel fuel according to ASTM D975).
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance ofthe 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 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 ofdiesel fuel. The use of
additives
to combat BACTERIAL growth in the fuel tank
is recommended such as Bio-Bor and e such as Diesel
Kleen +cetane Boost
to help restore lubricity back into the
diesel fuel when an Ultra Low Sulfur diesel is being used.
DO NOT use any additives containing ALCOHOL.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor 500
MA or 230 RMAM are good examples of
such filters.A
10 micron filter element is recommended.
ENGINE OIL
Use a heavy duiy engine oil with an API classification and
SAE as specified in the Specifications section ofthis manual
for the engine model you have. The engine oil and filter must
be changed after the initial 50 hours
of break-in operation.
Then follow the oil and filter change intervals
as specified in
the
MAINTENANCE SCHEDULE in this manual.
Westerbeke Corporation does not approve or disapprove of
the use ofsynthetic oils. If synthetic oils are used, engine
break-in must.be performed using conventional oil. Oil
change intervals must be as in the MAINTENANCE
SCHEDULE, not extended because synthetic oils are used.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure may range from
25 psi (l.75 kg/cm2) at idle upwards of80 psi (5.6 kg/cm2)
at rated rpm.
NOTE: A newly started, cold engine can have an oil pressure
reading up to 60 psi (4.2 kglcm2 ). A warmed engine can have
an oil pressure reading as low as 25 psi (1.8 kg!cm
2
). These
readings fvill vary dependinJ upon the temperature of the
engine and the load placed on the engine.
TRANSMISSION FLUID
Refer to the TRANSMISSJON SECTJON of this manual for
type of
fluid and quantity for each transmission model.
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.
PURCHASING ANTIFREEZE
Select a brand ofantifreeze specified for diesel engines.
Antifreeze specified for diesel engines contain aspecial
additive
to protect against cavitation erosion of the engine's
cylinder walls. Prestone and Zerex are two nationally known
brands that offer antifreeze specifically for the use in diesel
engines. Select the pre-mix variety so that the correct mixture
will always be added to the cooling system when needed.
Change the antifreeze mixture according to the
MAJNTENANCE SCHEDULE in this manual.
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
engine. or generator. The purpose of
this recovery tank is to
allow for engine coolant expansion and contraction during
engine operation, without the loss ofcoolant and without
introducing air into the cooling system. This kit is provided
and must be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, is best
located at or above the level of the engine's manifold, but it
can be located below the level of the engine's manifold if the
particular installation makes this necessary.
lwlWESTERBEKB
f Eng/"9S & Generators
6,

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff, check the following items:
0 Check the engine oil level. Add oil to maintain the level
at the high mark on the dipstick.
0 Tum on the fuel supply, then check the fuel supply and
examine the fuel filter/water separator bowl for contami-
nants.
0 Check the transmission fluid level.
NOTE: Refer to the previous page for fuel, oil and
transmission fluid.
O Check the DC electrical system. Inspect wire connections ·
and battery cable connections. Make certain the positive
(+) battery cable is connected to the starter solenoid and
PLASTIC RECOVERY TANK
the negative(-) cable is connected to the engine ground ~--~ ~...,.
stud (this location is.ll:agged).
0 Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: If the engine has not yet been filled with coolant,
refer to the COO UNG SYSTEM section of this manual.
0 Visually examine the engine. Look for loose or missing
parts, disconnected wires, and unattached hoses. Check
the threaded connections and engine attachments.
0 Make certain there is proper ventilation around the
engine. An ample supply is necessary for proper engine
performance.
0 Make sure the mounting installation is secure.
0 Ensure the propeller shaft is securely attached to the
transmission.
0 Open the through-hull and prime the raw water intake
strainer. Inspect the raw water supply.
GLOW PLUG
CONNECTION
DIPSTICK~
Engines & ~nerstors
7
Oil.FILL CAP

ADMIRAL CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch and RPM gauge with an ELAPSED TIME
meter
which measures the engine's running time in hours and
in 1/10 hours. The panel also includes a WATER TEMPER-
ATURE gauge which indicates water temperature in degrees
Fahrenheit, an
OIL PRESSURE gauge which measures the
engine's
oil pressure in pounds per square inch, and a DC
control circuit VOLTAGE gauge which measures the sys-
tem's voltage. All gauges are illuminated when the key
switch is turned on and remain illuminated while the engine
is in operation. The panel also contains two rubber-booted
pushbuttons, one for PREHEAT and one for START.
RPM GAUGE: REGIS-
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATED FOR
ACCURACY FROM THE
REAR OFTHE PANEL.
HOURMETER: ~
REGISTERS ELAPSED
TIME, AND SHOULD BE
USED AS A GUIDE FOR
THE MAINTENANCE
SCHEDULE.
WATER TEMPERATURE GAUGE: THIS GAUGE IS
GRADUATED IN DEGREES FAHRENHEIT AND IS
ILLUMINATED WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
TEMPERATURE IS 170° -190° F (77° - 88°C).
When the engine is shut down with the key switch turned off,
the water temperature gauge will continue to register the last
temperature reading indicated by the gauge before electrical
power
was turned off. The oil pressure gauge will fall to z.ero
when the key switch is turned off. The temperature gauge
will once again register the engine's true temperature when
electrical po"'.er 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 buzz.er in a location where it will be dry and where it will
be audible to the operator should it sound while the engine is
running. The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engine's oil pressure rises above 15 psi (1.1 kg/cm
2
).
,
Oil PRESSllRE MUGE: THIS GAUGE IS GRAOU·
ATED If\! POUNgS PER SQUARE INCH (PSI) AND IS
ILLUMINATEDWl-ULE THE KEY SWITCH IS TURNED
ON. THE ENGINE'S NQl)fl.:'IAL OPERATING OIL
PRESSURE RANGES BElWEEN 30 - 60 psi
(2.1-4.2 kg/cm').
KEY SWITCH: THE KEY
SWITCH WHEN TURNED
ON SUPPLIES DC POWER
TO THE INSTRUMENT
PANEL CLUSTER, PREHEAT
SWITCH, EXCITATION
TERMINAL OF THE DC
CHARGING ALTERNATOR
AND TO THE ALARM
BUZZER ENERGIZING IT IN
A PULSING MODE.
~ DC VOLTMETER:
INDICATES THE AMOUNT THE
.BATIERY IS BEING CHARGED.
SHOULb SHOW 13V TO 14V.
PREHEAT BUTION: WHEN DEPRESSED, IT CLOSES ·
THE CONTACTS IN THE PREHEAT SOLENOID SENDING
POWER TO THE GLOW PLUGS. THE "I" TERMINAL ON
THE PREHEAT SOLENOID ALSO RECEIVES POWER AND
THIS IS TRANSMITTED TO THE ELECTRIC FUEL PUMP.
DC POWER IS ALSO TRANSMITIEO TO THE START
BUTION.
AUTOMATIC ALARM SYSTEM
'.---,,,r
' COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
SUPPLIED WITH THE INSTRUMENT PANEL IFTHE ENGINE'S COOLANT
REACHES 210° F (99"C), THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
START BUTION: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.
THIS BUTION WILL NOT OPERATE ELECTRICALLY
UNLESS THE PREHEAT BUTION IS PRESSED AND HELD
AT THE SAME TIME.
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 10 - 5 psi (0.7 - 0.4 kg/cm'), THE SWITCH WILL CLOSE SOUND·
ING THE ALARM. IN THIS EVENT. THE ALARM WILL EMIT A PULSATING
SIGNAL.
Engines & Generators
8

CAPTAIN CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEYswitch, an RPM gauge, PREHEAT and START but-
tons,
an INSTRUMENT 'JEST button and three indicator
lamps, one for ALTERNATOR DISCHARGE, one for low
OILPRESSURE, 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 LIGHT ALARM LIGHT
WATER TEMPERATURE
ALARM LIGHT
START BUTION: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THEENGINE. THIS
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE
PREHEAT BUTTON IS PRESSED AND HELD ATTHE SAME
TIME.
Thepanel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT'IEMPERATURE.
The
RPM gauge is illuminated when the KEYswitch is turned on
and remains illuminated while the engine is in operation.
ALARM: THE ALARM'WILLSdUND'IF THE ENGINE'S'OIL PRESSURE FALLS
BELOW 10.:. 5·psl'(0.7.:. 0.4 kg/cni'). INTHIS_ EVENfTHE 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°G}: IN THIS: EVENT, THE ALARM WILL EMITA CONTINUOUS SIGNAL.
NOTE: THE, ALARM WILL·SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
PRESSURE REACHES 15 psi (1.1 kg/cm'), THE ALARM WILL SILENCE.
TEST BUTTON: WHEN
PRESSED, TESTS THE
ALTERNATOR, THE OIL
PRESSURE, AND THE
COOLANT TEMPERA·
TU.RE CONTROL CIR·
CutTS. 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: THE KEY
SWITCH WHEN TURNED ON
SUPPLIES DC POWER TO THE
INSTRUMENT PANEL
CLUSTER, PREHEAT SWITCH,
EXCITATION TERMINAL OF THE
. DC CHARGING ALTERNATOR
AND TO THE ALARM BUZZER
ENERGIZING IT tN A PULSING
.MODE.
PREHEAT BUTTON: WHEN DEPRESSED, IT CLOSES
THE CONTACTS IN THE PREHEAT SOLENOID SENDING
POWER TO THE GLOW PLUGS. THE "I" TERMINAL ON THE
PREHEAT SOLENOID ALSO RECEIVES POWER AND THIS IS
TRANSMITTED TO THE ELECTRIC FUEL PUMP. DC POWER
IS ALSO TRANSMITTED TO THE START BUTTON.
Engine_s & Generators
9

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
The models in this manual have a 12V DC electric starter
assisted by a
DC air intake heater for both normal and cold
weather starting. The air heater heats the engine intake air,
providing a rapid start with less wear on the starter.
The start circuitiy is designed so that
the PREHEAT button
must be depressed for the time specified
in the preheat chart.
Then, while keeping the PREHEAT button engaged, the
START button is depressed to crank the engine.
Starting Procedure
1. Place the transmission in neutral and advance the throttle
control to slightly open.
CAUTION: Make certain the transmission is
in neutral. $,tarting in gear could result in serious
damage to your transmission, your boat, and
vessels nearby.
2. Tum the KEY SWITCH to the ON position (2 o'clock).
3. Depress the PREHEAT button and hold it.
The .
instrument panel will energize.
The alarm buzzer will
pulse and the electric fuel pump will energize. The
Preheat button should be depressed in accordance with
the following chart:
Temperature/Preheat
Atmospheric Temperature Preheating Time
____ 41°F(5°C) or higher . ---+--- Approx. 10 seconds
41°F(5°C) to 23°F (-5°C) __ 1-- Approx. 15 seconds
23°F(-5°C) or lower Approx. 20 seconds
limit of continuous use 30 seconds before cranking
--
NOTE: The START button will not energize unless the
PREHEAT button is depressed. Depressing the PREHEAT
button activates the glow plugs in the cylinder head so use
the PREHEATintennittently
to avoid overheating the glow
plugs.
4. While still depressing the PREHEAT button, depress the
START button. This will engage the starter solenoid.
When the engine starts, release
the start switch and
preheat button.
The pulsing alarm will silence once the
oil pressure reaches 5-10 psi.
NOTE: When starting:
A voltage drop will occur
when the preheat button
is depressed.
S. Should the engine not start when the START button is
depressed for 10
to 20 seconds, release both buttons and
wait
30 seconds; repeat the procedure above and preheat
longer. Never
run the starter for more than 30 seconds.
CAUTION: Prolonged cranking intervals without the
engine starting can result in the engine exhaust system
filling with raw water. This may happen because the
pump is pumping raw water through the raw water
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this from
happening by closing the raw water supply through-hull
shutoff, draining the exhaust muffler, and correcting the
cause of the excessive engine cranking. Engine damage
resulting from raw water entry is not a warrantable
issue; the owner/operator should keep this in mind.
6. Once the engine starts, check the instruments for proper
oil pressure and battery charging voltage.
NOTE: Never attempt to engage the starter while the
engine is running.
NOTE: Some unstable running may occur in a cold
engine. Depressing the PREHEATbuttonfor
10-15
second intervals will help stabilize the engine rpm until
the engine operating temperature reaches 170 -190°F
(77 -88°C)
and a propeller load is applied to the engine.
When the engine is running
and the PREHEATbutton is
depressed, a charging load on the DCalternator will be
discernible.
Starting Under Cold Conditions
Make sure the lubricating oil is appropriate for the prevailing
temperature.
Use oil with an API an, SAE rating as specified in
the Specifications section
of this manual.
The battery should
be fully charged to minimize voltage drop.
Use a sufficient amount of preheat to aid in starting. See the
Temperature/Preheat chart elsewhere in this section.
Stopping Procedure
To stop the engine, bring the throttle to an idle ~ositio? and
place the transmission
in neutral. Allow the engme to idle for
a few moments to stabilize temperatures.
Tum the key to the
OFF position. This opens the DC circuit to the instrument
panel and engine, de-energizing the fuel
~olenoid on.the
injection pump, stopping fuel flow from
1t and stoppmg the
engine.
Make certain the key switch is in the OFFposition
(12 o'clock).
If the key switch is left ON, the battery will
discharge.
An engine alann buzzer is provided to warn the
operator
of this condition (key switch ON). The best method
of preventing the batteryfrom discharging is to remove the
key from the key switch after stopping the engine.
Engines & Generators
10

ENGINE BREAK-IN PROCEDURE
DESCRIPTION ·
Although your engine has experienced a minimum ofone
hour oftest operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-
ated properly, a break-in time is required. The service life of
your engine is dependent upon how the engine is operated
and serviced during its initial 50 hours of use.
Breaking-in a new engine basically involves seating the pis-
ton rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
scored, which is cause<! by overloading the engine during the
break-in period.
Your new engine requires approximately 50 hours ofinitial
conditioning operation to break in each moving part in order
to maximize the performance and service life ofthe engine.
Perform this conditioning carefully, keeping in mind the fol-
lowing:
1. Start the engine according to the STARTING PROCE-
DURE section. Run the engine at fast idle while checking
that all systems (raw water pump, oil pressure, battery
charging) are functioning.
2. Allow the engine to warm up (preferably by running at
fast idle) until the water temperature gauge moves into
the 130- 140°F (55 - 60°C) range.
3. While using the vessel, run the engine at various engine
speeds for the first 25 hours. Avoid prolonged periods of
idling.
4. Avoid rapid acceleration, especially with a cold engine.
5. 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 next 25 hours, the engine may be operated at
varying engine speeds, with short runs at full rated rpm.
Avoid prolonged idling during this break-in period.
CHEGKLIST
0 Monitor the control panel gauges.
D Check for leaks of fuel and engine oil.
0 Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
0 Confirm exhaust smoke:
When the engine is cold -white smoke.
When the engine is warm -almost smokeless.
When the engine is overloaded - some black smoke and soot.
NOTE: See the TRANSMISSION section of this manualfor
break-in information
on your transmission.
Engines & Generators
11

THE DAILY OPERATION
CHECKLIST
Follow this check list each day before starting your engine.
D Record the hounneter reading in your log (engine hours
relate to the maintenance schedule).
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 diesel fuel supply and that the fuel valve is
turned
on.
O Look for clean fuel in the fuel filter/water separator
transmission
bowl.
D Check for loose wires at the alternator and make sure its
mounting is s~ure.
D Check the starting batteries (weekly).
D Check drive belts for wear and proper tension (weekly).
D Check the raw water pump to make sure its mounting is
secure.
D Check that the raw water thru hull is open.
STARTING THE ENGINE
.· NOTE: See STARTING/STOPPING PROCEDURE in this
manual for more detai~ed instructions.
1. ~t the transmission in neutral, throttle advanced.
NOTE: Hydraulically operated tra:zsmissions have a .
neutral safety switch through which the staner solenoid
energizing circuit passes. This switch is ope~ wh.en the
transmission is in gear so the starter solenoid will not
energize.
2. Tum the KEY to the ON position (2 o'clock).
3. Depress PREHEAT (10 to 15 seconds).
4. While pressing PREHEAT, push START. As the engine
fires, release START.
5. Hold PREHEAT until the oil pressure reaches 15 psi
and/or the alarm shuts off.
NOTE: Some unstable running may occur in a cold
engine. This condition should abate as non;ial operating
temperature is reached and loads are r;ipplzed.
NOTE: Should the engine fail to start, wait 30 seconds,
then repeat the above prpcedure, and PREHEAT longer.
6. Allow a few minutes for the engine to warm at a ·com-
fortable rpm (approximately 1000 rpm), then teduce the
rpm, and get underway.
Engines &Generators
12

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
petfonnance of the alternator.
COOLANT TEMPERATURE SWITCH
Acoolant'temperature switch is located on the thermostat
housing. This switch wilt activate acontinuous alarm if the
coolant's operating temperature reaches approximately 210°F
(99°C).
AIR BLEED PETCOCK
COD LANT
TEMPERATURE
SWITCH
ENGIJIE CIR8UIT IRBAHIR
.;·
The DC harness .on the engine is protected by an engine-
mounted manuafreset circuit breaker (20 amps DC).
Excessive current draw or electrical overload anywhere in
the instrument panel wiring or engine wiring will cause the
breaker to trip. In this event most engines will shut down
because the opened breaker disconnects the fuel supply. If
this should occur, check and repair the source of the problem.
After repairing tlie fault, reset the breaker and restart the
engine.
--.
~
20 AMP CIRCUIT N
BREAKER •+..,.,
l"
i:'.
LOW OIL PRESSURE ALARM SWITCH
A low oil pressure alarm switch is located off the engine's
oil
gallery. This switch's sensor monitors the engine's oil
pres~ure. Should the engine's oil pressure fall to 10- 5 osi
(0.7 -0.4 kg/cm2 ), this s.witch will activate a pUlsatinJ? alann
~~
/'
. ---~(~
~-- ... --~·'
,....,-···.
·~-- - .... ~~ '
-· '•0)
SPIN-ON OIL FILTER
Oil PRESSURE
SEND OR
lwiWEB7ERBEKE
Engines & Generators
- 13

MAINTENANCE SCHEDULE
A WARNING: NeviJI' aftempt to perform any service while the engine Is running. Wear the proper safety equipment Sllth as goggles
and gloves, "'l use the correct tools for each job. When servicing/replacing DC components, tum o" the DC circuit breaker on the
ctJntrol panel, 111 tum 11" the banery switch~
SCHEDULED MAINTENANCE
I OAILYCHECK BEFORE START-UP
Coolant Level
Engine Oil Level
Fuel/Water Separator (owner installed)
Fqel Supply
Visual Inspection of Engine
Drive Belts-
'INITIAL 50 HOURS OF OPERATION
Engine Oil and Riter
*Exhaust System
Engine Throtlle, TransmisSion
and Shutoff Lever Cables
•1Head BoltTorque/Adjust Valves
*Fuel RHer
Engine Idle Speed
Transmission fluid
Heat Exchanger
I EVERY 50 OPERATING HOURS OR MONTHLY
*Drive Belt
(Fresh WaterJRaw Water Pumps)
Starting Batteries
"Electric fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Air Intake Filter
Heat Exchanger
Key Swilt:h (Instrument Panel)
*Drive Belts
(Fresh Water/Raw Water Pumps as applicable)
Starting Batteries
Electric Fuel Pump
Raw Water Pump
Engine Oil and Riter
EXPLANATION OF SCHEDULED MAINTENANCE
Check at recovery tank •. if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dlpstick. Do not overfill!
Check for water ar~d dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
· Use properly filtered 112 diesel with a Cetane rating of #45 or higher. Check that
there is adequate fuel for the vessel's needs.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as neede~.
-------
Inspect for frayed edges. Belts must be properly tensioned
Initial engine oil and filter change at 50 hours then change both every 250 hours.
Initial check at 50 hours, then every 250 hours or once a year. Garetully inspect for leaks.
Check that the exhaust hoses are properly attached and that the securing clamps are tight.
Check the integrity/mounting security of the water injected exhaust elbow.
Check Check all connections are secure, proper travel and lubricate with WD-40.
Torque Bolts and Adjust Valves (cold)
Initial change, thefT every 250 hours or once a year.
Refer to Specifications.
Initial change, then at 300 hours or once a season.
Open end caps and clean out debris. Change zinc anode if necessary. Determine zinc service
interval for your area.
Inspect for proper tension (3/8' to 112" deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect, no leaks. Connections are clean and tight Glean/replace filter element if applicable.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.
Inspect, Clean and replace as needed.
Inspect and clean zinc anode. Note the condition, then determine your own schedule. If zinc
anode needs replacing, you should remove the end cap and clean out the debris.
Replace zinc if necessary.
Lubricate with "lockeze".
Inspect for proper tension (3/8" to 112' deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect, no leaks. Connections are clean and tight. Clean/replace filter element if applicable.
Inspect impeller, check drive shaft security. Inspect there is no shaft water or oil sealle~ks.
Change the engine oil and oil filter (always together)
Engines & Generators
14