Westerbeke 11A-1 Installation 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: (508)823-7677. FAX: (508)884-9688. 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: (508)823-7677· FAX: (508)884-9688· WEBSITE www.WESTERBEKECOM
~~~~
NHHA
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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
- Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
• 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
PREVENT BURNS - FIRE
Read these safety instructions carefuUy. Most accidents 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 foUowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
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 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!
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel rapors can cause
•
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.
injury Of death!
•
•
•
•
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!
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.
All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ventilated area away from spark-producing equipment and
out of the reach of children.
Do not fill the fuel tank(s) while the engine is running.
Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when servicing. Ensure proper ventilation exists when servicing the
fuel system.
Do not alter or modifY the fuel system.
Be sure all fuel supplies have a positive shutoff valve.
Be certain fuel line fittings are adequately tightened and
free of leaks.
Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
Engines & Generators
i
SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
TOXIC EXHAUST GASES
A WARNING: Accidental starling can cause injury
A WARNING: Carbon monoxide (CO) is a deadly gas!
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.
•
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 of approved detectors.
•
For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
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 other jewelry 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.
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
•
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
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
AVOID MOVING PARTS
severe injury or death!
•
Do not use copper tubing in diesel exhaust systems. Diesel
A WARNING: Rotating parts can cause injury
When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash it
off at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing
electrolyte caps.
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
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTAlliNG DIESEL ENGINES
•
Do not wear loose clothing or jewelty 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.
Read the following ABYC, NFPA and USCG pUblications
for safety codes and standards. Follow their recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
Safety Standards for Small Craft
Order from:
ABYC
3069 Solomons Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
HAZARDOUS NOISE
A WARNING: High noise levels can cause
hearing loss!
Fire Protection Standardfor Motor Craft
•
•
Never operate an engine without its mufiler installed.
Do not run engines for long periods with their
enclosures open.
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
A WARNING: 011 not WllrIc lin machinery when Yllu are
mentally IIr physically incapaCitated by fatigue!
USCG 33CFR183
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thorough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
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 minimum of 20 in. (51 cm) above the vessel's waterline. Failure to use a siphon-break
when the exhaust manifold injection port is 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 any of the vessel's various operating conditions or when
the vessel is not underway, install a siphon-break. This precaution is necessary to protect your engine.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper operation. Failure to properly maintain a siphon-break can result in catastrophic engine
damage. Consult the siphon-break manufacturer for 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
Product Software................................................................. 2
Notes, Caution and Warnings .............................................. 2
Model No.lSerial No. Location ........................................... 2
Component Locations .......................................................... 3
Understanding the Diesel Engine ........................................ 3
Ordering Parts ...................................................................... 3
Spares and Accessories ........................................................ 3
Protecting Your Investment................................................. 3
Raw Water Pump................................................................. 22
Inspecting/Changing the Raw Water Pump Impeller... 22
Raw Water Intake ................................................................. 22
Raw Water Intake Strainer................................................... 22
Siphon-Break....................................................................... 23
Draining the Cooling System ............................................... 23
Air Intake Filter............................................................................24
Description........................................................................... 24
Air Filter....................................................................... 24
Maintenance ................................................................. 24
Water Heater................................................................................24
Water Heater Installations .................................................... 24
Fuel System ................................................................................. 25
Diesel FueL .......................................................................... 25
Fuel Additives ...................................................................... 25
Care of the Fuel Supply........................................................25
Fuel Lift Pump..................................................................... 25
Fuel Filter............................................................................. 25
Replacing the Fuel Filter.............................................. 25
Fuel Lines ............................................................................. 26
Fuel FilterlWater Separator.................................................. 26
Fuel Injection Pump............................................................. 26
Fuel Injector......................................................................... 26
Bleeding the Fuel System .................................................... 26
Spare Parts ............................................................................ 26
DC Electrical System ................................................................... 27
12 Volt DC Control Circuit... ............................................... 27
Control Panel. ....................................................................... 27
Engine Circuit Breaker......................................................... 27
Battery.................................................................................. 27
Battery Care ................................................................. 27
Checking the Service Battery....................................... 27
Alternator Troubleshooting .................................................. 28
Testing the Alternator................................................... 28
Checking the Service Battery....................................... 29
7A-I Marine Diesel Engine Wiring Diagram #45593 ......... 30
7A-I Marine Diesel Engine Wiring Schematic #45593 ...... 31
11A-1 Marine Diesel Engine Wiring Diagram #44542 ....... 32
11A-l Marine Diesel Engine Wiring Schematic #44542 .... 33
Glow Plugs (ModeI7A-1 only) ................................................... 34
Engine Adjustments ..................................................................... 35
Tightening the Cylinder Head.............................................. 35
Valve Clearance Adjustment. ............................................... 35
Engine Compression Test. .................................................... 35
Testing the Fuel Injector...................................................... .36
Removing the Fuel Injector.......................................... 36
Fuel Injector Components ............................................ 36
Checking the Injection Starting Pressure ..................... 36
Tightness of the Valve Seat. ......................................... 37
Inspecting the Spray Pattern........................................ 37
Checking the Nozzle Body and Needle Valve............. 37
Reassembly................................................................... 37
Injector Installation ...................................................... 37
Drive Belt Adjustment. ........................................................ 38
Checking Belt Tension ................................................. 38
Adjusting Belt Tension ................................................. 38
Engine Troubleshooting ............................................................... 39
Hurth HBW Transmission .............................................................42
Hurth HBW Transmission Troubleshooting ..................................45
Lay-Up and Recommissioning .....................................................46
7A-1 &11A-1 Torque Specifications ........................................... 48
Standard Hardware/Sealants &Lubricants ................................ 49
Metric Conversions ......................................................................50
Standard and Metric Conversion Oata ........................................ 51
Suggested Spare Parts Kits ......................................................... 52
7A-1 Diesel Engine Specifications ............................................. 4
7A-1 Diesel Engine Parts Identification ..................................... 5
11A-1 Diesel Engine Specifications ............................................6
11A-1 Diesel Engine Parts Identlfication ....................................7
Preparations for Initial Start-Up ................................................. 8
Diesel FueL .......................................................................... 8
Care of the Fuel Supply............................................... 8
Fuel Additives ............................................................. 8
Engine OiL .......................................................................... 8
Transmission Fluid.............................................................. 8
Pre-Start Inspection............................................................. 8
Starting/Stopping Procedure .......................................................9
Electric Starting ................................................................... 9
Electric Starting Procedure .......................................... 9
Low Battery Electric Starting Procedure.....................9
Manual Starting (Hand Cranking) ....................................... 9
Automatic Decompression Device ............................ IO
Cold Starting Device .................................................. 10
Manual Starting Procedure........................................ 11
Starting Under Cold Conditions ................................ 12
Operating the Engine ......................................................... 12
Initial Start-Up Check List... ..................................... .12
Stopping the Engine ........................................................... 12
Engine Break-In Procedure ....................................................... 13
Engine Break-In Procedure................................................ 13
Break-In Check List. .......................................................... 13
Transmission Break-In....................................................... 13
Daily Operation ..........................................................................13
Daily Operation Check-List. ...................................... 13
Transmission .............................................................. 13
Maintenance Schedule .............................................................. 14
Exhaust System ......................................................................... 16
Description ......................................................................... 16
Siphon-Break............................................................. 16
Exhaust System Precautions .............................................. 16
Carbon Monoxide ...................................................... 16
Carbon Monoxide Warning Decal ............................. 16
Carbon Monoxide Detectors ...................................... 17
Insulation ................................................................... .17
Overcranking.............................................................. 17
Lubrication System ....................................................................18
Description......................................................................... 18
Oil Pressure ReliefValve........................................... 18
Low Oil Pressure Alarm Switch ................................ 18
Engine OiL ......................................................................... 18
Checking the Oil ................................................................ 18
Changing the OiL .............................................................. 19
Removing the Old Oil ............................................... .19
Changing the Oil Filter (Model llA-l only) ............ 19
Adding the New Oil... ............................................... 20
Testing the Oil Pressure ..................................................... 20
Cooling System ......................................................................... 21
Raw Water Cooling System.............................................. 21
Thermostat. ........................................................................ 21
CheckinglReplacing the Thermostat... ...................... 21
Coolant Temperature Switch............................................. 21
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 7A-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.
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 CANNOT BE 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.
Customer Identification Card
I~'WESIERBEKE
I Engines & Generators
A
CAUTION: Procedures which. if not strictly
observed. can result in the damage Dr destruction of
your engine.
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
A
WARNING: Procedures which. if not properly
followed. can result in pelSDnai injury or loss of life.
Mode17A-1
Expires 3116102
Ser. #74860/197-E003
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 provide a quick reference when seeking technical information and/or
ordering repair parts.
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 of a
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.
ENGINE mEITIFICATION PlATE
Engines & Generators
2
INTRODUCTION
COMPONENT LOCATIONS
SPARES AND ACCESSORIES
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.
Certain spare parts will be needed to support and maintain 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.
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 preventive 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.
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 serviced in the field. This is up to the buyer/owner-operator.
NOTE: Six important steps to ensure long engine life:
•
•
•
•
•
•
ORDERING PARTS
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.
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 identify 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.
Engines & Generators
3
7A-1 DIESEL ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Type
LUBRICATION SYSTEM
Diesel, four-cycle, one cylinder, raw water cooled,
vertical, in-line overhead valve mechanism
Lubrication System
Forced lubrication by gear-driven pump
Sump capacity
1.3 qts. (1.25 liters)
Aspiration
Naturally aspirated
Govemor
Mechanical, centrifugal type
Operating Oil Pressu re
(engine hot)
25.6-56.9 psi (1.8-4.0 kg/cm')
Combustion System
Direct injected
Oil Grade
Bore and Stroke
3.23 in. x 2.17 in. (82.0 mm x 55.0 mm)
API specification CF or CG-4
SAE 30, 10W-30, 15W-40
Piston Displacement
17.7 cu. in. (290 cm')
Lube oil Strainer
Full-flow, intemal
Crankshaft
Direction of Rotation
Clockwise, when viewed from the front
(raw water pump end)
Compression Ratio
20:1
Maximum Torque
(at 2500 rpm)
11.0 ftIIbs (1.5 kg-m)
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)
COOLING SYSTEM
Height: 17.1 in (433.7 mm)
Width: 14.9 in (379.2 mm)
Length: 22.5 in (571.3 mm)
Cooling System
Raw water-cooled block,
thermostatically controlled
Operating Temperature
13D-150°F(55-66°C)
Raw Water Pump
Positive displacement, neoprene impeller,
gear-driven, sen-priming
Raw Water Row,
at 3600 rpm
7.3w-8.456 gpm
Raw Water Connection
112 in. (12.7 mm) 1.0.
(7~
Ipm)
EXHAUST SYSTEM
Dry Weight
151 Ibs (68.5 kg)
Emission Control Systems
Meets U.S.C.G. Regulation 33 CFR 183
Max. Angle of Installation
Not to exceed 10°
Exhaust ManifoldlElbow
cast aluminum, raw water cooled
Max. Angle of Operation
Not to exceed 15° in all directions
Exhaust Elbow Connection 1-112 in. (38.1 mm) 1.0.
TUNE-UP SPECIFICATIONS
Compression Pressure
478.5 psi (33.6 kg/cm') standard
435.0 psi (30.6 kg/cm') minimum
Valve Seat Angle
Intake 45°; Exhaust 45°
Valve Clearance
(engine cold)
Intake 0.008 in. (0.2 mm)
Exhaust 0.008 in. (0.2 mm)
Engine Timing
39.0 mm BTDC static
Injector Pressure
2900 psi (203.9 kg/cm')
Engine Speed
Idle: 1000 - 1200 rpm
Cruise: 2000 - 2500 rpm
Maximum: 2900 - 3000 rpm
ELECTRICAL SYSTEM
Electrical System
12 volts DC, negative ground,
circuit breaker protected
Battery Charging
Altemator
30 amp, 12 volts, belt-driven, with
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, casehardened helical gears, with a servo-operated
multiple disc clutch
Gear Ratio (optional)
2.05:1
Propeller
Propeller used must allow
the engine to reach its rated
rpm at full open throttle in
forward gear, underway
120 x 8 P two blade RH
12 0 x 6 P three blade RH
Lubricating Ruid
ATF- type A or DEXTRON -/I or 11/
Transmission Sump
capacity
0.37 qts (0.35 liters)
Propeller Shaft
Direction of Rotation
Right hand-standard transmission
FUEL SYSTEM
Fuel System
Open flow, sen-priming, sen-bleeding
Fuel
No.2 diesel oil, cetane rating of 45 or higher
Fuel Lift Pump
Mechanical 1.6 ft. (0.5 m) lift max.
Fuel Injection Pump
Bosch type
Fuel Injector
Direct injection
Fuel Injection Timing
39 mm BTDC static
Injector Pressure
2900 psi (203.9 kg/cm')
Fuel Consumption
(full load)
0.46 U.S. gal./hr. (1.76Iiterlhr.)
Fuel Filter
Primary, replaceable filter
Fuel Supply
and Return Lines
1/4 in. (6.35 mm) 1.0. minimum
5116 in. (7.94 mm) 1.0. maximum
Air Row
(engine combustion)
15.3 cfm (0.43 cmm)
Engines & Generators
4
7A-1 DIESEL ENGINE PARTS IDENTIFICATION
AUTOMATIC
DECOMPRESSION
DEVICE
HAN~-CRANK
HANDLE GUIDE
RAW
WATER
PUMP
flEXIBLE
MOUNTS
RAW WATER
INTAKE CONNECTION
CYLINDER
HEAD
FUEL INJECTOR ---t--Hl'f-H,-#'4:;;;t,i~M"-:;5~~~~
WATER INJECTED EXHAUST
MANIFOLDJELBOW
FUEL INJECTION
PUMP
TRANSMISSION
FUEL FILTER
TRANSMISSION
OUTPUT FLANGE
Engines & Generators
5
11 A·1 DIESEL ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Type
LUBRICATION SYSTEM
Diesel, four-cycle, one cylinder, raw water cooled,
vertical, in-line overhead valve mechanism
Aspiration
Lubrication System
Naturally aspirated
Forced lubrication by gear-driven pump
Sump Capacity
1.7 qts. (1.6 liter)
25.&-56.9 psi (1.8-4.0 kg/cm')
Governor
Mechanical, centrifugal type
Operating Oil Pressure
(engine hot)
Combustion System
Direct injected
Oil Grade
Bore and Stroke
3.74 in. x 2.91 in. (95.0 mm x 74.0 mm)
API specification CF or CG-4
SAE 30, 10W-30, 15W-40
Piston Displacement
31.95 cu. in. (524.0 cm')
Oil Riter
Full-flow, paper element, spin-on type
Crankshaft
Direction of Rotation
Clockwise, when viewed from the front
(raw water pump end)
Compression Ratio
20:1
Maximum Torque
at (2400 rpm)
21.3 ftIIbs (2.9 kg-m)
Manual Starting System
Hand-crank, with automatic
decompression device
Engine Stop
Manual type
COOLING SYSTEM
Dimensions
NOTE: An inserted standard
crank handle increases the
width by 4.5 in. (115 mm)
Height: 21.0 in (532 mm)
Width: 21.3 in (540 mm)
Length: 23.8 in (603 mm)
Cooling System
Raw water-cooled block,
thermostatically controlled
Operating Temperature
13D-150°F (55-66°C)
Raw Water Pump
Positive displacement, neoprene impeller,
gear-driven, seH-priming
Raw Water Row,
at 3600 rpm
7.399-8.456 gpm (7-8lpm)
Raw Water Connection
112 in. (12.7 mm) 1.0.
EXHAUST SYSTEM
Dry Weight
238 Ibs (108 kg)
Emission Control Systems Meets U.S.C.G. Regulation 33 CFR 183
Max. Angle of Installation
Not to exceed 10°
Exhaust ManifoldlElbow
Max. Angle of Operation
Not to exceed 15° in all directions
Exhaust Elbow Connection 1-112 in. (38.1 mm) 1.0.
TUNE-UP SPECIFICATIONS
Compression Pressure
478.5 psi (33.6 kg/cm') standard
435.0 psi (30.6 kg/cm') minimum
Valve Seat Angle
Intake 45°; Exhaust 45°
Valve Clearance
(engine cold)
Cast aluminum, raw water cooled
ELECTRICAL SYSTEM
Electrical System
12 volts DC, negative ground,
circuit breaker protected
Intake 0.008 in. (0.2 mm)
Exhaust O.OOS in. (0.2 mm)
Battery Charging
Alternator
30 amp, 12 volts, belt-driven,
with solid state intemal regulator
Engine liming
60.0 mm BlDC static
Starting Motor
12 volt solenoid, actuated shift
Injector Pressure
2537 psi (178.3 kg/cm')
Cold Cranking Amps
60 amps@66°F (19°C)
Engine Speed
Idle:
1000 -1200 rpm
Cruise:
2000 - 2500 rpm
Maximum: 2900 - 3000 rpm
TRANSMISSION
General
HURTH HBW 40 Standard Transmission, casehardened helical gears, with a servo-operated
multiple disc clutch
FUEL SYSTEM
Fuel System
Open flow, self-priming, seH-bleeding
Gear Ratio (optional)
2.05:1
Fuel
No.2 diesel oil, cetane rating of 45 or higher
Propeller
Fuel Uft Pump
Mechanical 1.6 ft. (0.5 m) lift max.
14 Dx8 Ptwoblade-RH
140 x 6 Pthree blade - RH
Fuel Injection Pump
Bosch type
Propeller used must allow
the engine to reach its rated
rpm at full open throttle in
forward gear, underway
Fuel Injector
Direct Injection
lubricating Ruid
ATF- type A or DEXTRON - /I or 11/
Fuel Injection liming
60 mm BTDC static
2537.5 psi (178.4 kg/cm')
Transmission Sump
Capacity
0.37 qts (0.35 liters)
Injector Pressure
Fuel Consumption
(full load)
0.46 U.S. gaL/hr. (1.76Iiterlhr.)
Propeller Shaft
Direction of Rotation
Right hand-standard transmission
Fuel Riter
Primary replaceable filter
Fuel Supply
and Retum Lines
1/4 in. (6.35 mm) 1.0. minimum
5/16 in. (7.94 mm) 1.0. maximum
Air Row
(engine combustion)
27.7 cfm (0.78 cmm)
Engines & Generators
6
11A·1
DIESEL ENGINE PARTS IDENnFICATION
CYLINDER
HEAD
fOAArpoc
CIRCUIT BREAKER
TlfROTrtE
CONTROL
STARTER
FUEL INJECTOR
COOlANT
TE"'PERATURE
SWITCH
TIlANS""SSION
OIPSTIClCIFlll
FUEL FILTER
'TRANSMISSION
PREPARATIONS FOR INITIAL START-UP
DIESEL FUEL
PRE-START INSPECTION
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not
use kerosene or home heating fuel.
Before starting your engine for the first time, or after a prolonged
lay-up, check the following items:
Care of the Fuel Supply
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 examine the fuel filter/water separator bowl for contaminants.
D Check the transmission fluid level.
D Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the positive (+)
battery cable is connected to the starter solenoid and the
negative (-) cable is connected to the engine ground stud
(this location is tagged).
D Open the raw water intake and make sure the raw water supply 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.
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 operation, 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).
Engines & Generators
8
STARTING/STOPPING PROCEDURE
ELECTRIC STARTING
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.
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.
1. Place the transmission in neutral and advance the throttle control 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).
NOTE: Periodically lubricate the keyswitch mechanism with
LOCKEZE to ensure proper keyswitch functioning.
\\ \-.......-I+-
HOUR METER
POINTER IN ,-T-t----,L.~..,.::,
THE MANUAL
STARTING
PosmON
OIL/WATER
ALARM
-;-t---;i-H-_
ALARM
~~~~E~T
HEX-HEAD BOLT
AUTOMATIC
OECOMPRESSION
DEVICE
KEYSWITCH
W[g~lf'[grtl&&c:.r[g
CONTROL PANEL
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 9 o'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.
Electric Starting Procedure
1. Place the transmission in neutral and advance the throttle control to slightly open.
A
CAUTION: Make certain the transmission is in neutral. 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 1020 seconds. Wait for approx. 30 seconds before repeating the
start. Never operate the starter motor while the engine is still
running.
POINTER IN
THE OPERATING
posmON
j
~
~'lIJ=======
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 a few minutes for the
wann-up at a comfortable rpm (approximately 1,000 rpm), then
reduce the rpm and get underway.
If this attempt at an electric start does not start the engine, then a
manual start by hand-cranking will be necessary.
Low Battery Electric Starting Procedure
MANUAL STARTING (HAND CRANKING)
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.
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.
HEX-HEAD BOLT
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.
POINTER
BULKHEAD
AUTOMATIC
OECOMPRESSION
DEVICE
Cold Starting 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.
~"L~
l=::;:::::~
~~~.I
HANDLE
MODEL 7A-1 SHOWN
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.
Engines & Generators
10
COLD STARTING
DEVICE KNOB
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.
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-cranking in this position, automatic decompression will occur.
A WARNING: Always keep hands and feet clear of
moving parts. Put the transmission in neutral. Do not
use starting aids.
POINTER IN
THE MANUAl
STARTING
PDsmDN
1. Place the transmission in neutral and advance the throttle control 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.
6. Pull down the Cold Starting Device knob. Note: Do not pull
down this knob when restarting a hot engine.
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.
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 automatically disengage. Then remove the crank handle.
CRANK HANDLE GUIDE
HAND-CRANKING
Model7A-1 shown
Engines & Generators
11
STARTING/STOPPING PROCEDURE
Initial Start-Up Check List
o
o
POINTER IN
THE OPERATING
POSITION
o
o
Check for possible leaks from all the connections.
Make sure the cooling water is discharging properly, outboard
from the exhaust outlet.
Make certain that the engine is mounted securely.
Listen for unusual sounds and vibrations.
STOPPING THE ENGINE
9. If the engine has not started, repeat Steps 5-9 above, and consider cranking at a higher speed.
A CAUTION: Prolonged cranking intervals without
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 condition (key switch ON). The best method ofpreventing the battery
from discharging is to remove the key from the keyswitch after
stopping the engine.
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 cranking. 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.
A CAUTION: Neller stop the engine with the
OPERATING THE ENGINE
automatic decompression dellice, or when the engine is
under a full load.
Allow a few minutes for the engine to wann up at a comfortable
rpm (approximately 1500 rpm), then reduce the rpm, and get
underway.
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.
A CAUTION: Never pull the cold starting dellice knob
down when the engine Is operating.
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 procedures 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.
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.
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.
Break-In Check List
Monitor the following during the 50 hour break-in period:
o Check for fuel, engine oil and water leaks.
o
Your new engine requires approximately 50 hours of initial conditioning operation to break-in each moving part in order to maximize the performance and service life of the engine. Perform this
conditioning carefully, keeping in mind the following:
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.
1. Start and stop the engine according to the STARTINGISTOPPING 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.
Transmission Break-In
See the HURTH HBW TRANSMISSION section of this manual for
break-in information on your transmission.
DAILY OPERATION
DAILY OPERATION
o
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 section during the first 50 hours of operation. Make sure all periodic
maintenance is performed according to the MAINTENANCE
SCHEDULE.
o Check drive belt for wear and proper tension (weekly).
Check the starting batteries (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.
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.
o
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.
Transmission
See DAILY OPERATION in the HURTH HBW TRANSMISSION
section.
Engines & Generators
13
MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be necessary
A WARNING: Never attempt to perfonn any service
log your engine hours. Use your engine hounneter or
record your engine hours by running time.
NOTE: Many of the following maintenance procedures are
simple but others are more difficult and may require the expert
/awwledge of a service mechanic.
to
while the engine is running. Wear the proper safety
equipment such as goggles and gloves, and use the
COrtect tools for each job. Disconnect the battery
tenninals when servicing any of the engine's DC
electrical equipment.
MAINTENANCE FREQUENCY
COMPONENT
AFTER
ARST
50
HOURS
WEEKLY
EVERY
100
HOURS
EVERY
3IJO
HOURS
EVERY
600
HOURS
EVERY
1000
HOURS
•
•
Change the oil: see CHANGING THE OIL
under LUBRICATION SYSTEM
Fuel filter/Water
separator
Check the fuel supply. Top up if necessary.
•
Check for water and dirt in the fuel. Drain
and replace the filter if necessary.
•
Fuel lift pump
•
Fuel filter
Raw water pump
•
Check and adjust the injection opening pressure and spray condition (see TESTING THE
FUEL INJECTOR under ENGINE
ADJUSTMENTS).
•
Remove the pump cover and inspect the
impeller, gaSket, cam and cover for wear. Check
the bearings and seals (the shaft can tum, but
not wobble). lubricate when reassembling.
•
Raw water
intake strainer
See RAW WATER INTAKE STRAINER under
COOLING SYSTEM.
•
Thermostat
•
Air intake filter
Starting batteries
and house
batteries
DC Alternator
•
•
Clean or replace the two filters. See FUEL
LIFT PUMP under FUEL SYSTEM.
Change the filter.
Fuel injector·
Engine hosas
Remove the oil strainer and clean it with
diesel fuel. Flush the crankcase with the
proper lube oil.
•
•
•
Fuel supply
MAINTENANCE DESCRIPTION
HOURS
Oil level should be between the full and low
indicating marks on the dipstick. Top up if
necessary.
Crankcase oil
and strainer
Exhaust system·
EVERY
2000
•
Engine oil level
Engine oil change
DAILY
OR
EVERY
8 HOURS
•
Check the functioning of the thermostat; see
THERMOSTATunder COOLING SYSTEM.
Hoses should be hard and tight. Replace if soft
and spongy. Check and tighten all hose clamps.
Clean.
Inspect for leaks. Check the anti-siphon valve
operation. Check that all connections are tight.
Check the exhaust manifold/exhaust elbow for
carbon and/or corrosion buildup on inside passages; clean and replace as necessary. Warning:
A defective exhaust manifold/exhaust elbow can
cause carbon monoxide leakage!
•
Check electrolyte levels and make sure connections are very tight. Clean off excessive corrosian.
•
•
Check the DC charge from the alternator. Check
mounting bracket; tighten electrical connections.
·Westerbeke recommends thai this service be performed by an authorized mechanic.
Engines & Generators
14
(continued)
MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
COMPONENT
AFTER
FIRST
50
HOURS
DAILY
DR
EVERY
8 HOURS
WEEKLY
EVERY
100
HOURS
EVERY
300
HOURS
EVERY
600
HOURS
•
•
Adjust to 1000 - 1200 rpm.
•
•
•
Visual inspection
Cleaning the
engine
Lubricate
control panel
keyswitch
Retorque the nuts (see TIGHTENING THE
CYLINDER HEAD under ENGINE ADJUSTMENTS).
Initial fluid change at 25 hours, then every
300 hours or at winterizing.
Engine
transmission
damper plate
Hardware fastenings and electrical
connections
Check the compression pressure - see
ENGINE COMPRESSION TEST under
ENGINE ADJUSTMENTS.
•
Transmission
fluid level
Throttle and
transmission
control cable
Adjust the valve clearances - see VALVE
CLEARANCE ADJUSTMENT under
ENGINE ADJUSTMENTS.
•
•
•
Cylinder
compression"
Cylinder
head nuts
•
MAINTENANCE DESCRIPTION
Check the solenoid and motor for corrosian. Remove and lubricate. Clean and
lubricate the starter motor pinion drive.
•
Starter motor"
Valve clearances"
EVERY
2000
HOURS
Inspect for proper tension: 3/8 -1/2 in.
(10 -12 mm) deflection, and adjust if necessary. Check belt edges for wear (see
DRIVE BELT ADJUSTMENT under ENGINE
ADJUSTMENTS).
•
Drive belt
Adjust engine
idle speed
EVERY
1000
HOURS
•
•
Chattering at idle and low rpms is an indication of damper plate wear. Remove and
replace.
Check for loose fittings, cotter pins, etc .
Lubricate with WD-40 or equivalent.
Check for oil, fuel and water leaks .
Inspect and tighten all fastenings and accessible screws, bolts and nuts. Inspect all wiring
and electrical connections.
•
Keep the engine's surface clean. Surface dirt
and oil will inhibit the engine's ability to remain
cool.
•
Lubricate with LOCKEZE or equivalent every
100 hours or at winterizing. After lubricating,
check for smooth operating of the switch.
•
"Westerbeke recommends that this service be performed by an authorized mechanic.
Engines & Generators
15
EXHAUST SYSTEM
DESCRIPTION
EXHAUST SYSTEM PRECAUTIONS
It is important to install a proper exhaust system to avoid engine
flooding. The system must be designed to prevent water from
Carbon Monoxide
entering the exhaust line under any sea conditions and at any
angle of the vessel's hull. Exhaust system failures are not covered
by Westerbeke's warranty. The installer should have a basic
knowledge of marine installation requirements.
Westerbeke recommends installing an exhaust system having an
in-line muffler. The in-line muffler should be located below the
engine's exhaust elbow. It must accumulate any water that runs
back down the exhaust line after the engine is shut down. Design
the system so there is an adequate drop in the line between the
exhaust elbow and the through-hull discharge end of the line. The
exhaust hose must be certified for marine use.
The best protection against carbon monoxide poisoning is a daily
inspection of the complete exhaust system. Check for leaks
around the exhaust manifold/elbow, exhaust hose, gaskets, and
welds. Make sure there are no fumes entering your boat from a
nearby vessel. Make sure the exhaust lines are not heating the
surrounding areas excessively. If excessive heat is present, correct
the situation immediately. If you notice a change in the sound or
appearance of the exhaust system, shut down the engine immediately and have the exhaust system inspected and repaired at once
by a qualified mechanic.
A WARNING:
Exhaust gasses contain carbon
Monoxide, an odorless and colorless gas. carbon
Monoxide is pOi5Onous and can cause unconsciousness
and death. Symptoms of carbon Monoxide exposure
can include:
- Dizziness
- Throbbing In Temples
-Nausea
- Muscular Twitching
- Headache
- Weakness and Sleepiness
- Vomiting
-Inability to Think Coherently
A CAUTION: An exhaust line that is too long and/or
has a poor gradient can cause water to retum back to
the engine when it is shut off.
A WARNING:
The exhaust system must be tight
and free of leaks. Exhaust gasses are deadly. Display
the carbon Monoxide waming decal near your engine,
on your cabin bulkhead, or in 50me other prominent
location.
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE
SYMPTOMS, BET OUT lITO FRESH AIR IMMEDIATELY.
If the symptoms persist, seek medical attention. Shut
down the engine and rentilate the area with clean air.
Do not restart the engine until it has been inspected
and repaired.
For more information about exhaust system design, see
Westerbeke's INSTALLATION MANUAL for MARINE ENGINES
and GENERATORS, Publication # 43268.
Westerbeke presumes that the installer of this marine diesel engine
is familiar with the safeguards a water-cooled marine exhaust system will provide for the engine. Failure to design and layout a
proper exhaust system can result in catastrophic damage to the
diesel engine, and possibly result in the sinking of the vessel in
which the unit is installed.
Carbon Monoxide Warning Decal
A carbon monoxide warning decal has been provided by
Westerbeke. Display this decal near your engine, on your cabin
bulkhead, or in some other prominent location.
Siphon-Break
For installations where the water-injected exhaust elbow is close
to or below the vessel's waterline, provisions must be made to
install a siphon-break in the raw water supply hose to the exhaust
elbow. The siphon-break provides an air vent in the raw water
cooling system to prevent raw water from filling the exhaust system and the engine's cylinder when the engine is shut down. See
SIPHON-BREAK in the COOUNG SYSTEM section for more
information.
WARNING
A CAUTION: Fal/ure to use a siphon-break when the
t:5i!EJWI!STE1IBEICE
En,.-..GMemcn
Engines Produce CARBON MONOXIDE
Regular Maintenance Required
exhaust elbow is located at or below the load waterline
will result in raw water damage to the engine and possible flooding of the boat.
CARBON MONOXIDE
WARNINO DECAL
Engines & Generators
16
EXHAUST SYSTEM
Carbon Monoxide Detectors
It is extremely important that a carbon monoxide detector(s) be
installed in your boat's living and/or sleeping quarters. Make sure it is
manufactured for the marine industry. They are inexpensive and available at your marine supplier.
Insulation
Inspect insulated portions of the exhaust system to ensure there is no
deterioration of the insulation.
Overcranking
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 cranking. Remember that engine damage
resulting from raw water entry is not covered by
Westerbeke's warranty.
Engines & Generators
17
LUBRICATION SYSTEM
DESCRIPTION
The lubricating system is a pressure feeding system using an oil
pump. The engine oil is drawn from the oil sump by the oil
pump, which drives the oil, under pressure, through the various
lubricating points in the engine. The oil then returns to the oil
sump to repeat the continuous cycle.
The gear-driven oil pump is built into the oil sump. The
oil is pumped through a spin-on type oil filter (Model IIA-I
only) to the main bearing and connecting rod bearing.
The piston, cylinder liner and rocker arms are splashlubricated. There is an oil strainer in the crankcase (see
Crankcase/Oil Strainer in the MAlNIENANCE SCHEDULE
for maintenance information. A crankcase breather valve is
integrated into the cylinder head's inlet channel and is
maintenance-free.
OIL PRESSURE SWITCH
Model 11A-1 silo. .
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. The SAE grade depends on the ambient
temperature. For the recommended oil viscosity, see the
following chart:
Operating Temperature
Above 68° F (20" C)
41° - 68° F (5° - 20° C)
Below 41° F (5° C)
Oil Viscosity
SAE 30, 10W-30 or 15W-40
SAE 20 or 10W-30
SAE10W-30
A CAUTION: Do not allow two or more brands of
SPIN-ON OIL FILTER -H--t-Model 11A-1 only
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
CHECKING THE OIL
Check the lube oil level (see illustration) prior to starting. With
continuous operation, check the oil level daily or every 8 hOUTS.
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, overheating and
engine runaway.
BREATHER
VAlVE
If a top-up is necessary, clean the area around the oil filler to
prevent dirt from entering the engine.
Oil Pressure Relief Valve
There is an oil pressure relief valve in the sump. If the oil pressure
exceeds the maximum specified value, the valve opens and some
of the oil returns to the sump, keeping the oil pressure below its
maximum specified value.
Low Oil Pressure Alarm Switch
A low oil pressure alarm switch is located on the engine block. This
WBE OIL DIPSTICK
Model7A-1 $lion
switch's sensor monitors the engine's oil pressure. Should the engine's
oil pressure fall below the specified value, this switch will activate a
pulsating aIarm on the control panel.
Engines & Generators
18
LUBRICATION SYSTEM
CHANGING THE OIL
Change the oil after an initial 50 hours of break-in operation and
every 100 hours of operation thereafter. Change the oil only when
the engine is warm.
~,l«<ll--\lrll
Always observe the used oil as it is removed. A yellow/gray
emulsion indicates the presence of water in the oil. Although this
condition is rare, it does require prompt attention to prevent serious damage. Call a qualified mechanic should water be present in
the oil. Raw water present in the oil can be the result of a fault in
the exhaust system attached to the engine and/or a siphoning of
raw water through the raw water cooling circuit into the exhaust,
filling the engine. This problem is often caused by the absence of
an anti-siphon valve, its poor location or lack of maintenance.
Modal7A-1
Model 11A·1
REMOVING THE OLD OIL
A
Changing the Oil Filter (Model 11A-1 only)
CAUTION: Used engine oil contains harmful
contaminants. Avoid prolonged skin contact. Clean skin
and nails thoroughly using soap and water. Launder Dr
discard clothing Dr rags containing used oil. Discard
used oil properly.
When removing the used oil filter, you may fmd it helpful, and
cleaner, to punch a hole in the upper and lower portion of the old
filter to drain the oil from it into a container before removing it.
This helps to lessen spillage. A small automotive filter wrench
should be helpful in removing the old oil filter.
NOTE: Do not punch this hole without first loosening the filter to
make certain it can be removed.
Removing the Old Oil
1. Remove the oil filler cap (see illustration) using a 13 mm
open end spanner.
Place some paper towels and a plastic bag around the filter when
unscrewing it to catch any oil left in the filter. (Oil or any other
fluid on the engine reduces the engine's cooling ability. Keep
your engine clean.) Inspect the old oil filter as it is removed to
make sure that the rubber sealing gasket comes off with the old oil
filter. If this rubber sealing gasket remains sealed against the filter
bracket, gently rem~ve
it
OIL
FILLER
CAP
_
JW
2. Model7A-I: Place a suitable container below the oil drain
plug (see illustration), then remove the oil drain plug and completely drain the used oil into the container. Then remove and
clean the lube oil strainer. Always clean this strainer at every
oil change. After cleaning, replace the strainer and the oil
drain plug.
ModelIM-I: Place a suitable container below the oil drain
cover plate (see illustration), then remove the cover plate and
completely drain the used oil into the container. Then replace
the cover plate. NOTE: Be sure to change the spin-on oil filter
at every oil change (see Changing the Spin-On Oil Filter,
below).
NOTE: With an inclined engine installation, the lube oil must
be pumped out, otherwise too much oil would remain in the
crankcase.
0
SPIN-ON OIL FILTER
Model 11A·1 only
When installing the new oil filter element, wipe the filter gasket's
sealing surface on the bracket free of oil and apply a thin coat of
clean engine oil to the rubber gasket on the new oil filter. Screw
the filter onto the threaded oil filter nipple and then tighten the
filter fmnly by hand.
NOTE: Generic filters are not recommended, as the material
standards or diameters of important items on generic parts might
be entirely different from genuine parts. Immediately after an oil
filter change and oil fill, run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil
filter.
Engines & Generators
19
--==-
~l"~
LUBRICATION SYSTEM
Adding the New 011
1. Add the new oil through the oil fill.
2. Replace the oil filler cap. When tightening it, do not use too
much force otherwise the plastic plug may break.
3. After refilling with new oil, run the engine for a few moments.
Make sure there is no leakage around the oil filler cap or the
new oil filter (ModelllA-l only), then stop the engine. Then
check the quantity of oil with the lube oil dipstick. Fill to, but
not over the MAX mark on the dipstick, should the engine
require additional oil.
TESTING THE OIL PRESSURE
Before testing, make sure the oil level is at the MAX mark on the
dipstick.
1. Remove the oil pressure switch (see illustration).
2. Install a mechanical oil pressure gauge in the oil pressure
switch hole.
3. Warm up the engine, then set the engine speed at 3000 rpm,
and read the gauge.
Operating oil pressure (engine hot):
25.6 - 56.9 psi (1.8 - 4.0 kglcml)
If the oil pressure is too low, see Low Oil Pressure under
ENGINE TROUBLESHOOTING.
NOTE: The oil pressure switch closes at 4.3 - 8.7 psi
(0.3 - 0.6 Bar).
Engines & Generators
20
COOLING SYSTEM
RAW WATER COOLING SYSTEM
The engine is designed for direct raw water cooling. The engine
operates with a raw water coolant temperature up to 90" F (32° C).
The raw water flow is created by a positive displacement impeller
pump that is gear-driven by the camshaft. This pump draws
cooling water directly from the raw water source (ocean. lake or
river) through a hose.
The raw water is pumped through a tee which splits the flow. The
tee directs some of the flow to passages in the engine block and
the remainder to a bypass. The flow to the engine block circulates
around the cylinder and through the cylinder head, cooling the
engine. The flow through the bypass goes directly to the exhaust
manifold/elbow, and is at its greatest when the engine is warming
up and the thermostat is not yet open. Flow though the bypass
also occurs after the thermostat is open. The raw water that is
flowing through the engine block then flows through the thermostat to the exhaust manifold/elbow where it mixes with and cools
the exhaust gases. This mixture of exhaust gas and raw water is
discharged overboard by the engine's exhaust gas discharge pres-
MODEL lA·1
sure.
The coolant temperature switch is located on the cylinder head for
Model 7A-I, and on the thermostat housing for ModelllA-1.
THERMOSTAT
A thermostat, located on top of the cylinder head, controls the raw
water coolant temperature as the coolant flows through the cooling system. The thermostat is set to the maximum temperature of
140° F (60° C). When the engine is first started, the closed thermostat prevents coolant from flowing (some coolant is by-passed
through a bypass tube to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually
opens. The thermostat is accessible and can be checked, cleaned,
or replaced easily. Carry a spare thermostat and gasket.
THERMOSTAT
HOUSING
MODEL 11A·1
Checking/Replacing the Thermostat
Remove the two cap screws and the thermostat housing, then
remove the thermostat from the cylinder head (see illustration).
To check the thermostat, immerse it in water that is approximately
140° F (60° C). The thermostat's cone must then be fully openthis indicates the thermostat is in good condition.
Use a new gasket when reinstalling the thermostat or replacing it.
Apply a thin coat of sealant on both sides of the gasket before
pressing it into place. Do not over-tighten the cap screws.
Run the engine and check for normal temperatures and that there
are no leaks at the thermostat housing.
COOLANT TEMPERATURE SWITCH
BLEED
HOLE
The coolant temperature switch is located near the thermostat
housing (see illustration). If the coolant's operating temperature
reaches approximately 175° F (80° C) this switch will activate
the alarm on the control panel.
CYliNDER
HEAD
THERMOSTAT
ASSEMBLY
Model 7A·1 sIIown
Engines & Generators
21
COOLING SYSTEM
RAW WATER PUMP
RAW WATER INTAKE
The raw water pump is a self-priming, rotary pump with a
non-ferrous housing and a neoprene impeller. The impeller has
flexible vanes which wipe against a curved cam plate within the
impeller housing, producing the pumping action. On no account
should this pump be run dry as water acts as a lubricant for the
impeller. There should always be a spare impeller and impeller
cover gasket (an impeller kit) onboard. Raw water pump impeller
failures occur when lubricant (raw water) is not present during
engine operation. Such failures are not warrantable and operators
are cautioned to make sure raw water flow is present at start-up.
The neoprene impeller has a limited lifetime and must be
inspected regularly.
NOTE: S.hould a failure occur with the pump's internal parts
(seals and bearings), it may be more cost effective to purchase a
new pump and rebuild the original pump as a spare.
A flush-type though-hull fitting is recommended for the raw water
intake. It should be located on the boat's hull where it will be
below the waterline during all angles of the boat's operation. See
Westerbeke's INSTAlL4.TION MANUALfor MARINE ENGINES
and GENERATORS for complete installation guidelines.
A WARNING: Do not use a scoop-type through-hull
fitting for supplying raw water to this engine. Ascooptype raw water inlet can develop substantial pressure
and force water past the raw water pump. flooding the
exhaust system and allowing the water to enter the
engine's cylinder. Damage caused by raw water entry
into the engine's cylinder ria the exhaust system is not
covered by Westerbeke's wananty.
Inspecting/Changlng the Raw Water Pump Impeller
Flooding of the exhaust system due to water pressure can also
occur with a flush-type raw water intake on a powerboat that has
its bow up. This pressure can be caused by the boat's decreased
waterline before the boat reaches its final trim, or by the angle of
the boat to the sea surface when its is underway.
Close the raw water intake valve. Remove the pump cover and,
with the aid of two small screwdrivers, carefully pry the impeller
out of the pump. Install the new impeller and gasket. Move the
blades to conform to the curved cam plate and push the impeller
into the pump's housing. When assembling, apply a thin coating
of lubricant to the impeller and gasket. Open the raw water intake
valve.
NOTE: Never allow the pump to run dry. Even a short period
of dry running may destroy the impeller.
RAW WATER INTAKE STRAINER
NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.
A clean raw water intake strainer is a vital component of the
engine's cooling system. Include a visual inspection of this
strainer when making your periodic engine check. The water in
the glass should be clear.
Perform the following maintenance after every 100 hours
of operation:
1. Close the raw water seacock.
2. Remove and clean the strainer filter.
3. Clean the glass.
4. Replace the sealing washer if necessary.
5. Reassemble and install the strainer.
6. Open the seacock.
7. Run the engine and check for leaks.
NOTE: Also follow the above procedure after having run
hard aground.
If the engine is indicating higher than normal operating temperatures (i.e the alarm is sounding), the cause may be that silt, leaves
or grass may have been caught up in the strainer, slowing the flow
of raw water through the cooling system.
RAW WATER PUMP
Engines & Generators
22
COOLING SYSTEM
HOSE FROM THE
SIPHON-BREAK
RAW WATER INTAKE STRAINER
OWNER INSTALLED (TYPICAL)
HOSE TO THE
SIPHON-BREAK
THERMOSTAT
HOUSING
SIPHON-BREAK
For installations where the water-injected exhaust elbow is close
to or below the vessel's waterline, provisions must be made to
install a siphon-break in the raw water supply hose to the exhaust
elbow. The siphon-break provides an air vent in the raw water
cooling system to prevent raw water from filling the exhaust system and the engine's cylinder when the engine is shut down.
A CAUTION: Failure to use a siphon-break when the
exhaust elbow Is located 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 any of the
vessel's various operating conditions or when the vessel is not
under way, install a siphon-break. This precaution is necessary
to protect your engine.
The siphon-break must be installed in the high point of a hose that
is looped a minimum of 20 inches (51 cm) above the vessel's
waterline. This siphon-break must always be above the waterline
during all angles of vessel operation to prevent siphoning from
occurring. WESTERBEKE has provided two siphon-break hoses
(these are tagged). The hose to the siphon-break connects to the
raw water line at the thermostat housing. The hose from the
siphon-break attaches to the water-injected exhaust elbow (see
illustration). The owner must furnish the siphon-break, and any
additional lengths of hose that may be required.
SIPHON-BREAK
Model 11A-1 shown
NOTE: A siphon-break requires periodic inspection and cleaning
to ensure proper operation. Failure to properly maintain a
siphon-break can result in severe engine damage. Consult the
siphon-break manufacturer for a proper maintenance schedule.
DRAINING THE COOLING SYSTEM
When freezing temperatures are expected, the cooling system can
be drained by unscrewing the pump cover. The raw water coolant
will then flush back down the inlet line.
Engines & Generators
23
AIR INTAKE FILTER
DESCRIPTION
The 7A-I and llA-l marine diesel engines, when operating in the
cruise rpm range, will typically consume in excess of 1000 cubic
feet of air per hour. The engine compartment must be well ventilated, and the air flow into the engine must be unrestricted.
Air Filter
The air fliter cartridge prevents dust and dirt from entering the
engine; it also improves oil consumption, extends engine life, and
quiets the engine.
Maintenance
The fliter should be cleaned every 100 operating hours. Tap the
cartridge on a flat surface to dislodge loose dirt or clean it off with
compressed air. If the cartridge is badly contaminated or oily,
replace it.
WATER HEATER
FROM
WATER
HEATER
~
WATER HEATER INSTALLATIONS
TO
WATER
HEATER
This engine is equipped with connections for plumbing the engine
coolant to transfer heat to an on-board water heater. The water
heater should be mounted in a convenient location either in a low
or high position in relation to the engine.
Plumb the heater hoses into the raw water line that connects the
thermostat housing to the exhaust manifold/elbow (see illustration).
NOTE: If the exhaust manifold/elbow on your engine is close to or
below the vessel s waterline, you must also install a siphon-break
on the same hose (see Siphon-Break under RAW WATER COOLING SYSTEM for more information). The water heater connections may be located either before or after the siphon-break.
THERMOSTAT
HOUSING
WATER HEATER CONNECTIONS
Model llA-l shown
Engines & Generators
24
FUEL SYSTEM
DIESEL FUEL
FUEL FILTER
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not
use kerosene or home heating fuel.
The frequency of a fuel filter change depends on the degree of
contamination of the fuel, however it should be performed at least
after every 100 hours of engine operation.
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).
Also use, on a regular basis, a fuel conditioner such as STA-BIL.
Follow the manufacturer's instructions for the quantity to add.
Replacing the fuel filter
1. Clean the fuel line with a rag and clamp it off between
the fuel lift pump and the fuel filter.
2. Pull off the inlet and outlet lines from the filter. Make
sure dirt does not enter the fuel lines. Discard the
used filter.
3. Install the new filter, making sure the flow arrow on the
filter housing is pointed in the proper direction. Push the
fuel lines as far as possible onto the connection nipples
of the new filter.
After installing the new filter, bleed the air from the fuel lines
using the manual fuel primer (see BLEEDING mE FUEL
SYSTEM).
CARE OF THE FUEL SUPPLY
Use only clean diesel fuel! Purchase a well-known brand of 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 fmely fmished 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 to your engine is clean and pure, be sure to filter
it properly. Install and regularly service a good Coast-Guard
approved fuel filter/water separator having a filter element with a
micron rating of #2 or # 1O. Install it between the fuel tank and the
engine.
FUEL LIFT PUMP
To assure proper suction, the engine's fuel lift pump should not be
more than 1 ft (300 mm) above the bottom of the fuel tank pickup
tube.
OUTLET
Periodically check the fuel connections to and from the fuel lift
pump and make sure that no leakage is preSent and that the fittings
are tight and secure.
A WARNING: Fuel leakage at the fuel litt pump or its
connections is a fire hazard and should be corrected.
Make sure proper "entilation exists whene"er sellficing
fuel system components.
The fuel lift pump has two filter inserts in the pump's cap. To clean
or replace them, unscrew the cap and retaining plate, and remove
the two filter inserts. Note the disassembly sequence to ensure
proper reassembly.
FUEL LIFT PUMP
Engines & Generators
25
FUEL SYSTEM
FUEL LINES
FUEL INJECTION PUMP
The fuel return line at the fuel tank should extend down to the
bottom of the tank in the same manner as the fuel pickup tube.
This must be done in an installation where the fuel tank is located
below the engine's fuel system. This precaution insures against
hard starting due to air displacing fuel siphoning out of the
engine's fuel system through the return line when the engine is
shutdown.
The fuel injection pump is a very important component of the
diesel engine, requiring the utmost care in handling. The fuel
injection pump has been thoroughly bench-tested and the
owner-operator is cautioned not to attempt to service it. The only
adjustment the servicing mechanic should make to the fuel injection pump is the adjustment for engine idle speed (see IDLE
SPEED ADJUSTMENT under ENGINE ADJUSTMENTS). Ifit
requires servicing, remove it and take it to an authorized fuel
injection pump service facility. Do not attempt to disassemble
and repair it.
A WARNING: Shut off the fuel valve at the tank when
servicing the fuel system. Take care in catching any fuel
that may spill. DD NOT allow any smoking, open flames
Dr other sources of fire near the fuel system when
servicing. Ensure proper ventilation exists when
servicing the fuel system.
FUEL INJECTOR
For information about removing and checking the fuel injector,
see TESTING THE FUEL INJECTOR under ENGINE ADJUSTMENTS.
In case of severe vibrations and detonation noise, have the injectors checked and overhauled by an authorized fuel injection service center. Poor fuel quality, contaminants and loss of positive
fuel pressure to the injection pump can result in injector faults.
Since fuel injectors must be serviced in a clean room environment, it is best to carry at least one extra injector as a spare should
a problem occur.
FUEL FILTER/WATER SEPARATOR
Westerbeke recommends that you install and regularly service a
good quality Coast Guard approved visual-type primary fuel fIlter
of the water-separating type. This fuel fIlter/water separator must
be installed between the fuel tank and the engine to prevent any
contaminants or water that may be in the fuel from reaching the
fuel lift pump and causing damage to the fuel system components.
It may also prolong the life of the fuel fIlter that comes installed
on the fuel line. It is the responsibility of the owner-operator to
install this fuel filter/water separator. Select a fIlter that has a #2
or # 10 micron rating.
BLEEDING THE FUEL SYSTEM
The fuel injection pump is self-bleeding; any air in the fuel lines
will bleed out through the fuel return line. Bleeding can also be
done by using the manual fuel primer on the fuel lift pump (see
illustration). In case the engine is shut down due to lack of fuel,
use the manual fuel primer to bleed the system after refilling the
fuel tank; it will not be necessary to disconnect the fuel lines to
bleed the air. Also use the manual fuel primer to bleed the
system after changing the fuel filters.
Most installers include a fuel fIlter/water separator with the
installation package as they are aware of the problems
contaminants in the fuel can cause.
A typical fuel fIlter/water separator is illustrated below. This is the
Raycor Model 500 MA. Keep in mind that if a water separator
type fIlter is not installed between the fuel supply tank and the
engine-mounted fuel system, any water in the fuel will affect the
fuel pump, engine filter and injection equipment. The
owner/operator is responsible for making certain the fuel reaching
the engine's injection equipment is free of impurities. This
process is accomplished by installing and maintaining a proper
fuel fUlcr/wMer
sepmmo'·1j:~l
Bleeding the fuel system will also be necessary before the
engine is layed-up during the off-season or for prolonged periods
of inactivity. See LAY-UP AND RECOMMISSIONING.
To use the manual fuel primer, work the lever back and forth with
slow complete strokes. If pressure isn't felt, rotate the engine 112
turn; this will reposition the fuel pump to improve the pumping
action.
\f I'\ .
SPARE PARTS
While the likelihood of having to service the system at sea is slim,
the possibility does exist. Therefore, we recommend that banjo
washers, injector seat washers and a fuel fIlter be carned on board
at all times. Purchase needed spare parts from your local
WESTERBEKE dealer or distributor. If a leak should develop at
a banjo washer that cannot be corrected by a simple tightening of
the fitting, replace the sealing washer with a replacement found in
the hardware kit for your model.
FUEL FllTERI
WATER SEPARATOR
(owner installed)
Engines & Generators
26
DC ELECTRICAL SYSTEM
12 VOLT DC CONTROL CIRCUIT
ENGINE CIRCUIT BREAKER
The engine has a 12 volt DC electrical control circuit that is
shown on the wiring diagrams. Refer to these diagrams when
troubleshooting or when servicing the DC electrical system.
The DC wiring harness on the engine is protected by an enginemounted manual reset circuit breaker (10 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 the engine will shut down because the opened breaker
disconnects the fuel supply. If this should occur, check and repair
the source of the problem. After repairing the fault, reset the
breaker and restart the engine.
A CAUTION:
To avoid damage to the battery chargIng circuit, never shut off the engine battery switch
while the engine is running. Shut off the engine battery
switch, however. to avoid electrical shorts when working
on the engine's electrical circuit.
BATTERY
The minimum recommended capacity of the battery used in the
engine's 12 volt DC control circuit is 200 Cold Cranking Amps
(CCA).
CONTROL PANEL
The engine is started by using the keyswitch on the control panel.
The keyswitch has three positions: OFF, ON, and START (see
STARTINGISTOPPING PROCEDURE).
NOTE: Push the key in to preheat after turning the key to the
ON position.
NOTE: Periodically lubricate the keyswitch with WCKEZE to
maintain proper operation.
Battery Care
Review the manufacturer's recommendations and then establish a
systematic maintenance schedule for your engine's starting batteries and service batteries.
o
The oil pressure/coolant temperature alarm beeps when either the
oil pressure is too low or the engine is overheated.
The hourmeter registers the elapsed engine running time, and
should be used as a guide for the maintenance schedule.
o
o
o
HOURMmR
o
KEYSWITCH
Monitor your voltmeter for proper charging during
engine operation.
Check the electrolyte level and specific gravity with
a hydrometer.
Use only distilled water to bring electrolytes to a proper level.
Make certain that battery cable connections are clean and
tight to the battery posts and to your engine.
Keep your batteries clean and free of corrosion.
A WARNING: Sulfuric acid in lead batteries can
cause severe burns on skin and damage clothing. Wear
protective gear.
Oil PRESSUREI
COOLANT TEMPERATURE
AlARM
Checking the Service Battery
ALARM
Check the voltage of the service battery. This battery should have
a voltage between 13 and 14 volts when the engine is running. If
not, there is a problem in the service battery charging circuit
Troubleshoot the service battery charging circuit by checking the
wiring and connections, the solenoid, isolator, battery switch, and
the battery itself.
PUSH 10
PREHEAT
CONTROL PANEL
Engines & Generators
27
DC ELECTRICAL SYSTEM
ALTERNATOR TROUBLESHOOTING
MULTIMETER
A WARNING: A failed alternator can become very
hot. Do not touch until the alternator has cooled down.
Use this troubleshooting section to determine if a problem
exists with the charging circuit or with the'alternator. If it is
determined that the alternator or voltage regulator is faulty,
have a qualified technician check it.
The alternator charging circuit charges the starting battery
and the service battery. An isolator with a diode, a solenoid
or a battery selector switch is usually mounted in the circuit
to isolate the batteries so the starting battery is not discharged
along with the service battery. If the alternator is charging the
starting battery but not the service battery, the problem is in
the service battery's charging circuit and not with the alternator.
TESTING THE STARTING
BATTERYIALTERNATOR
(ENGINE RUNNING)
3. Tum off the engine. Inspect all wiring and connections.
Ensure that the battery terminals and the engine ground
connections are tight and clean.
Testing the Alternator
A
CAUTION: Before starting the engine make certain
that everyone is clear of moving parts! Keep away from
sheaves and belts during test procedures.
A CAUTION: To avoid damage to the battery
charging circuit, never shut off the engine battery
switch when the engine is running!
A WARNING: When testing with a multimeter:
4. If a battery selector switch is in the charging circuit,
ensure that it is on the correct setting.
5. Tum on the ignition switch, but do not start the engine.
DC and AC circuits are often mixed together in marine
applications. Always disconnect a shore power cord,
isolate DC and AC converters, and shut down the engine
before performing DC testing. No AC tests should be
made without a proper knowledge of AC circuits.
6. Check the battery voltage. If the battery is in good condition, the reading should be 12 to 13 volts.
~--MULTIMmR
1. Start the engine.
2. After the engine has run for a few minutes, measure the
starting battery voltage at the battery terminals using a
multimeter set on DC volts.
a. If the voltage is increasing toward 14 volts, the alternator is working; omit Steps 3 through 8 and go directly
to "Checking the Service Battery" on the next page.
b. If the voltage remains around 12 volts, a problem
exists with either the alternator or the charging circuit;
continue with Steps 3 through 8.
TESTING THE
ALTERNATOR VOLTAGE
e~=~3i
(IGNITION ON • ENGINE OFF)
-= GROUND
Engines & Generators
28
DC ELECTRICAL SYSTEM
Checking the Service Battery
7. Now check the voltage between the alternator output terminal (B+) and ground. If the circuit is good, the voltage at
the alternator will be the same as the battery, or if an isolator is in the circuit the alternator voltage will be zero. If
neither of the above is true, a problem exists in the circuit
between the alternator and the battery. Check all the
connections - look for an opening in the charging circuit.
Check the voltage of the service battery. This battery should
have a voltage between 13 and 14 volts when the engine is
running. If not, there is a problem in the service battery
charging circuit. Troubleshoot the service battery charging.
circuit by checking the wiring and connections, the solenOId,
isolator, battery switch, and the battery itself.
MULTIMETER
MUlTIMETE.
i
COM
TESTING THE STARTING
BATTERY/ALTERNATOR
(ENGINE RUNNING)
-c==>-'
ENGINE
GROUND
8. Start the engine again. Check the voltage between the
alternator output and ground.
SERVICE BATTERY
The voltage reading for a properly operating alternator
should be between 13.5 and 14.5 volts. If your alternator
is over- or under-charging, have it repaired at a reliable
service facility.
GROUND
NOTE: Before removing the alternator for repair; use a
voltmeter to ensure that 12 volts DC excitation is present
at the EXC terminal if the previous test showed only battery voltage at the B output terminal.
TESTING THE SERVICE
BATTERY (ENGINE RUNNING)
A CAUTION: To avoid damaging the alternator diodes,
do not use a high voltage tester (i.e. a megger) wilen
performing tests on the alternator charging circuit.
If 12 volts is not present at the EXC terminal, trace the
wiring and lookfor breaks and poor connections.
Engines & Generators
29
DC ELECTRICAL SYSTEM'
7A-1 MARINE DIESEL ENGINE
WIRING DIAGRAM #45593
I' 4 Bl K
RD
tI4R[O
r-------------,
I
WATER TEIF.
SWITCH
:r~
l§j
SEE NOTE 2
I
I
I
+ I
IlL PRESSUIE SWITCH
o
r_- - - - - - - -,
~
w
~
:
I
I
I
5
CfICUT
IIIIEAKER
4
'!WE
IlEl..AY
RELAY
3
110 RED
.,4 RED
GLOW
PLUOS
STARlBI
I'IEt£AT
SOI..ENOIl
I' 4 V 10
• I 2 WHT
'12 RED
11.4
VEL
i:14 ORANGE
51
• I 4 Bl II.
PI
® ~~T~~[
THE
7"-1 MODEL IS [OUIPPED WITH A TIME DELAY RELAY THAT PREVENTS
EXCITATION or THE AlTERNATOR DURING PREHEAT AND CRANKING. THE
ALTERNATOR EXCITATION Will OCCUR APPROX
31041NS AFTER THE
IGNITION
KE Y HAS BEEN TURNED ON
~~_r--t-----------_+_,
.. ,
0c
KEY SWITCH
! REMlTE PAf.E...
WESTERBEKE
Engines & Generators
30
DC ELECTRICAL SYSTEM
7A-1 MARINE DIESEL ENGINE
WIRING SCHEMATIC #45593
G) <
)
12 VDC
G
STARTER
r----'
STARTER
SOLENOIO
_____
J
GlOWPLUGS
r----'
I PREt£AT I
I SOLENOID I
I
I
- - - - _ ..
30
~8~7
AlTERNATOR
______~________~____________________________~__/
86
(
ClRCUT
BREAKER
NO
5
T1r.tE
DEl..AY
RELAY
WATER TEMP.
SWITCH
3
NC
OIl PRESSURE SWITCH
SI
6
7
5
3
PI
AlARM
HOl.fl
METER
+
START
PREJ-EAT0
IGN
OFF
KEY SWITCH
NOTES
THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
STARTER
EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL
SHUT DOWN. THE BUILDER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL, WIRING. AND
ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER
AN ON·orr SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO
DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT.
A SWITCH
WITH A CONTINUOUS RATING or 175 AMPS. AT 12 VDC WILL SERVE THIS rUNCTION
THIS
SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT
Engines & Generators
31
DC ELECTRICAL SYSTEM
11A-1 MARINE DIESEL ENGINE
WIRING DIAGRAM # 44542
• I 4 BL K
r------------...,
I
I
I
1"0""
SEENlTE2:~
I~ .J
I
I
I
+ I
WATER TEJoP.
SlilTCH
:
IlL PIESSUAE SWITCH
r.- - - - - - - ...,
~
®
STARTER
®
114 VIO
114 RED/WHT
®112 WHT
®1I2RED
.14 y[ l
51
II. BLK
PI
.:;:
;;
.'".-
KEY SWITCH
L
REMOTE PAt£l.
Engines & Generators
32
DC ELECTRICAL SYSTEM
11A-1 MARINE DIESEL ENGINE
WIRING SCHEMATIC # 44542
+
~(-----------12
vee
----------~)
STARTER
STARTER SOLENOID
ALTERNATOR
(
CIRCUT
BREAKER
WATER TEMP.
SWITCH
NC
DI.. PRE5SUE SWITCH
SI
B
5
7
3
P1
ALARM
HOUR
METER
+
START
KEY SWITCH
NOTES:
I. THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
STARTER. EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL
SHUT DOWN. THE BUILDER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL. WIRING. AND
ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER.
2. AN ON-orF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO
DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT.
A SWITCH
WITH A CONTINUOUS RATING or 175 AMPS
AT 12 VDC WILL SERVE THIS rUNCTION
THIS
SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT
Engines & Generators
33
GLOW PLUGS
MODEL 7A-1 ONLY
DESCRIPTION
The glow plugs (2) are wired through the preheat solenoid. When
PREHEAT is pressed at the control panel this solenoid should
"click" on and the glow plug should begin to get hot.
Re-install the plugs in the air intake adapter and test them again. __
The plugs should get very hot (at the terminal end) within 7 to 15
seconds. If the plugs don't heat up quickly, check for a short circuit. When reinstalling the glow plugs, use anti-seize compound
on the threads.
INSPECTION
To inspect the plug, remove the electrical terminal connections,
then unscrew each plug from the air intake adapter. Thoroughly
clean each plug's tip and threads with a soft brush and cleaning
solution to remove all the carbon and oil deposits. While cleaning, examine the tip for wear and burn erosion; if it has eroded too
much, replace the plug.
A WARNING: Do not keep a glow plug on for more
than 30 seconds.
Glow plug tightening torque: 7 - 11 ft-Ib (1.0 - 1.5 m-kg)
TESTING
~==-======"""",::e.. TERMINAL
END
An accurate way to test glow plugs is with an ohmmeter. Touch
one prod to the glow plug's wire connection, and the other to the
body of the glow plug, as shown. A good glow plug will have a
0.55 ohm resistance. This method can be used with the plug in or
out of the engine. You can also use an ammeter to test the power
drain (5 - 6 amps per plug).
TESTING AGLOW PLUG
WITH AN OHMMETER
A
WARNING: These glow plugs will become very hot
to the touch. Be careful not to bum your fingers when
TIP
testing the plugs.
TESTING A GLOW PLUG
USING A TEST UGHT
+
Engines & Generators
34
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine adjustments
be performed by a competent engine mechanic. The information below
is provided to assist the mechanic.
TIGHTENING THE CYLINDER HEAD
After the initial break-in period (approximately 50 hours),
retorque the cylinder head nuts. Do this when the engine is cold.
1. Remove the cylinder head cover and gasket.
2. Retighten the four cylinder head nuts in an X-pattern
sequence as shown in the illustration. Start with any nut.
Before applying the torque to a nut, loosen it 114 to 112 a
tum, then apply the torque. See TORQUE
SPECIFICATIONS for the proper torque.
3. Reinstall the cylinder head cover and gasket. Insert new
plastic washers under the two nuts and tighten to the
specified torque.
5. For each valve, insert a 0.2 mm (0.008 in.) feeler gauge
between the valve stem and the rocker arm, and adjust the
clearance until a slight drag is felt on the gauge when it is
pulled out.
6. Tighten the locknut while holding the setting screw with
a screwdriver.
7. Recheck the clearance.
ENGINE COMPRESSION TEST
VALVE CLEARANCE ADJUSTMENT
Check the valve clearances after the first 50 hours of operation and
every 600 hours thereafter.
NOTE: Tighten the cylinder head bolts to their specified torque
before adjusting the valve clearances (see TIGlffENING THE
CYUNDER HEAD).
Adjust the valve clearances when the engine is cold. The
clearance is 0.2 mm (0.008 in.) for both intake and exhaust valves.
1. Remove the cylinder head.
2. Check to make sure the automatic decompression
device is in its normal operating position, i.e. not activated
(see illustration).
To check the engine's compression pressure, warm up the engine,
shut off the raw water through-hull, remove the fuel injector, and
install a compression adapter in the injector hole. Connect a compression tester on the adapter and crank the engine with the starter
motor until the pressure reaches a maximum value.
Compression pressure at 350 rpm:
Minimum: 435.0 psi (30.6 kg/cm 2)
Standard: 478.5 psi (33.6 kg/cm2)
ADAPTER
~INJECTOR
HOLE
If the pressure is weak, the problem is either valve- or piston-
POINTER
'---l-'H--
related. Check the valve clearance, adjust as needed, and test
again. If the compression is still low, apply a small amount of oil
into the cylinder to seal the rings, and repeat the test. If the
compression comes up, the rings are faulty.
An abnormally high reading indicates heavy carbon accumulation,
a condition that might be accompanied by high pressure and noise.
AUTOMATIC DECOMPRESSION
DEVICE IN THE NORMAL
OPERATING POSITION
~
~
="~JJ=======
NOTE: In case of severe vibrations and detonation noise, have the
injector checked and overlw.uled by an authorized fuel injection
service center. Poor fuel quality, contaminants and loss ofpositive
fuel pressure to the injection pump will result in injector faults.
3. Set the piston at the TDC of the compression stroke.
4. Loosen the locknuts on the valve setting screws
(see illustration).
Engines & Generators
35
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine adjustments
be performed by a competent engine mechanic. The information below is
provided to assist the mechanic.
TESTING THE FUEL INJECTOR
Checking The Injection Starting Pressure
NOTE: The fuel injector must be serviced in a clean room
environment.
1. Set the nozzle tester in a clean place where there is
no dust or dirt.
Removing the Fuel Injector
2. Mount the nozzle and the nozzle holder on the
nozzle tester.
1. Disconnect the high pressure fuel line from the injector,
then loosen the line at its attachment to the injection
pump and move it out of the way of the injector. Avoid
bending the line.
2. Remove the fuel return line in its entirety from the top of
the injector. Take care not to lose the two sealing
washers and banjo bolt that attaches the fuel return line
to the injector.
3. Remove the fuel injector holder bracket mounting nuts,
then remove the holder bracket.
4. Remove the fuel injector.
3. Use new fuel that has an approximate temperature of
68°F (20°C).
4. Bleed the air in the nozzle line by pumping the nozzle
tester handle several times.
5. Slowly lower the nozzle tester handle and check the
reading on the pressure gauge when the injection starts.
Injection starting pressure:
2850 - 2900 Ib/in2 (200 - 203 kglcm2)
A CAUTION: Keep hands away from the nozzle spray.
The spray nozzle velocity Is such that It may psnettate
dBfl/J/y into tllB fingBIS and hands, destroying tissue. If
it enters the bloodstream, It may CBIISB blood pOisoning.
NOTE: Clean the area around the base ofthe injector prior to
lifting it out ofthe cylinder head to help prevent any rust or
debris from falling down into the injector hole. ifthe injector
will not lift out easily and is held in by carbon build-up or the
like, worlc the injector side-ta-side with the aid ofa socket
wrench to free it, and then lift it out.
The injector seats in the cylinder head on a copper sealing
washer. This washer should be removed with the injector and
replaced with a new washer when the injector is reinstalled.
5. Remove the gaskets.
6. Remove the O-rings.
FUEL
INJECTOR
Fuel Injector Components
The fuel injector consists of the following parts:
INJECTION PRESSURE TEST
NOZZLE HOLOER
6. If the injection starting pressure is not within the specified
range, adjust it by replacing the shim with one of a more
appropriate thickness.
ADJUSTING SHIMS ~
~@
If the thickness of a shim is increased 0.004 in (0.1 mm),
the injection pressure increases approximately 145lblin2
(10.1 kglcm2).
PRESSURE SPRING--I.
VALVE CONE--!
PRESSURE PIECE-e
ADJUSTING SHIM
"
FUEL INJECTOR ADJUSTING SHIM
FUEL INJECTOR
COMPONENTS
Engines & Generators
36
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine adjustments
be peiformed by a competent engine mechanic. The information below is
provided to assist the mechanic.
Tightness of the Valve Seat
Checking the Nozzle Body and Needle Valve
Apply a pressure of 2600 Iblin2(182 kglcm2) and check if fuel
leaks from the injection nozzle holes. If fuel leaks, disassemble,
wash and recheck the injector nozzle or replace it
1. Check for damage to the valve seat of the needle valve
and check for damage to other parts.
2. Check for damage to the nozzle body. Hold the nozzle
body upright and insert four-fifths of the needle valve.
Then release the needle valve and check that it drops into
the valve seat under its own weight.
Reassembly
Be sure to do the following when reassembling the-fuel injector:
1. Tighten the nozzle body onto the nozzle holder to the
specified torque.
Nozzle torque:
29 - 36 ft-Ib (4.0 - 5.0 kg-m)
CHECKING THE TIGHTNESS OF THE VALVE SEAT
Inspecting the Spray Pattern.
1. Mount the nozzle and nozzle holder on the nozzle tester.
2. Bleed the air in the nozzle line by pumping the nozzle
tester handle several times.
3. Keep the reading on the pressure gauge of the nozzle
TIGHTENING THE
NomE BODY ONTO
THE NomE HOLDER
tester just below the injection starting pressure while
pumping the handle of the nozzle tester as quickly as
possible so that a pulsating whistling sound is heard.
Check the atorni~tion of the fuel injected from the
nozzle (see illustration).
2. After assembling the fuel injector, check the injection
starting pressure and the spray pattern.
Injector Installation
NORMAl
PAmAN
FAUlTY
PAmAN
The fuel injector installation sequence is the reverse of the
removal sequence. Make sure to include the following:
1. Use new gaskets - do not reuse the old gaskets.
2. Replace the copper sealing washer for each injector.
3. Tighten the fuel injector holder bracket mounting nuts to
the specified torque.
Bracket mounting nuts torque:
6 - 9 ft-Ib (0.8 - 1.2 kg-m)
FAUlTY
PAmRN
FUELIIUECTOR SPRAY PAnERNS
Normal Pattern: The fuel is sprayed uniformly and finely from
all five injection nozzle holes.
Faulty Pattern: The number of fuel sprays and fineness of the
injected fuel is substandard. If the condition of the injected fuel is
substandard, disassemble, wash and recheck the injection nozzle
or replace it.
Engines & Generators
37
ENGINE ADJUSTMENTS
NOTE: WESfERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The infonnation
below is provided to assist the mechanic.
DRIVE BELT ADJUSTMENT
The drive belt must be properly tensioned. A loose drive belt will
not provide proper alternator charging and will eventually damage
the a1temator. A drive belt that is too tight will pull the alternator
out of alignment and/or cause the alternator to wear out prematurely. Excessive drive belt tension can also cause rapid wear of
the belt A slack belt or the presence of oil on the belt can cause
belt slipping, resulting in high operating temperatures and rpm
variations.
A WARNING: Never attempt to check or adjust the
drive belt's tension while the engine Is in operation.
Checking Belt Tension
GOOD
BAD
3. Pivot the alternator on the base mounting bolt to the left
or right as required, to loosen or tighten.
4. Tighten the base mounting bolt and the adjusting strap
bolt securely.
5. Run the engine for about 5 minutes, then shut down and
recheck the belt tension.
1. To check the belt tension, press the belt at the approximate midpoint Gust above the bellhousing) between the
alternator pulley and the flywheel pulley with a force of
221bs (10 kg!) (98 N). The belt deflection should be 3/8"
- 112" (10 - 12 rnm) deep.
ALTERNATOR
PUUEY
BELLHOUSING
flYWHEEL
. PULLEY
FLYWHEEL
Adjusting Belt Tension
1. To adjust the belt tension, loosen the alternator adjusting
strap bolt and the base mounting bolt.
2. With the belt loose, inspect the belt for damage, wear,
cracks and frayed edges. If the belt is damaged, replace
it. If it is nearly worn out and deeply sunk in the pulley
groove, replace it.
Engines & Generators
38
ENGINE TROUBLESHOOTING
The following troubleshooting chart provides information based
upon certain problem indicators, the probable causes of these
problems, and the recommendations to overcome them.
1. Engine will not start
Problem
Fuel supply failure
(check by cranking engine
and listening for the
characteristic squirting in
the fuel injector).
Poor compression
Difficult to crank the engine
Probable Cause
Remedy
If squirting cannot be heard:
No fuel in tank.
Vent hole in tank cap plugged.
Fuel filter clogged.
Faulty injector nozzle.
Faulty injection pump.
Fuel line blocked.
Broken fuel line or leaking connection.
If squirting can be heard:
1. Starting fuel button not pulled.
2. Gasoline instead of diesel in tank.
3. Air intake blocked.
1.
2.
3.
4.
5.
6.
7.
1. Automatic decompression
device malfunction.
2. Incorrect valve clearance.
3. Valves not seating properly.
4. Cylinder head loose.
5. Piston rings stuck in grooves.
6. Worn cylinder and piston.
7. Rusty exhaust valve.
1.
2.
3.
4.
5.
6.
7.
Fill tank.
Replace cap.
Replace filter.
Check/replace nozzle.
Check/repair/replace pump.
Check fuel lines and remove blockage.
Replace fuellineltighten connections.
1. Pull button.
2. Drain gasoline, flush system, fill with diesel.
3. Check system for blockage.
1. CheCk/replace automatic decompression device.
2.
3.
4.
5.
6.
7.
8. Valves sticking.
Adjust valve clearance.
CheCk/repair/replace valves.
lighten cylinder head nuts.
Check rings and clean the piston.
Overhaul the engine.
Spray lubricating oil into the cylinder, activate the
automatic decompression device, then start.
8. Free valves.
1. Lube oil too thick.
2. Bearings seized.
3. Piston seized.
1. Change to correct viscosity.
2. Overhaul the engine.
3. Overhaul the engine.
2. Engine starts but fires intermittently or soon stops
Faulty fuel supply
1.
2.
3.
4.
5.
6.
Faulty air intake and/or
exhaust system.
1. Restrictedlblocked exhaust system.
2. Restrictedlblocked air intake.
Poor Compression
Fuel filter clogged.
Water in fuel.
Faulty injector nozzle.
Faulty injection pump.
Fuel line clogged.
Fuel lines or connections leak.
1.
2.
3.
4.
5.
6.
Replace filter.
Drain fuel; fill with clean fuel.
CheCk/replace nozzle.
CheCk/repair/replace pump.
Check the fuel lines and remove the blockage.
Replace fuellineltighten connections.
1. Check/clean exhaust system.
2. Check/clean air intake system.
See Poor Compression under
Engine will not Start.
(continued)
Engines & Generators
39
ENGINE TROUBLESHOOTING
3. Engine lacks power and/or makes black smoke
Problem
Remedy
Probable Cause
1. Engine overloaded.
2. Power reduction due to altitude and/or
ambient temperature has not
been considered.
3. Clogged air filter.
1. Reduce the load.
1. Gasket under injector missing or
too many gaskets are installed.
2. Fuel filter clogged.
3. Faulty injection nozzle.
4. Faulty injection pump.
1. Correct the number of gaskets.
1. Excessive carbon on piston and
cylinder head.
2. Faulty piston rings.
3. Worn piston and cylinder.
4. Worn bearings.
1. Decarbonize.
Engine overheats
1.
2.
3.
4.
5.
6.
Engine ove~oaded.
Faulty raw water pump impeller.
Faulty thermostat.
Clogged raw water intake strainer.
Lube oil level too high.
Faulty injector nozzle.
1.
2.
3.
4.
5.
6.
Reduce load.
Replace impeller.
Check/replace thermostat.
Clean the strainer.
Drain to proper level.
Check/replace nozzle.
Knocking
1.
2.
3.
4.
5.
6.
Injector needle sticking.
Fuel timing too far advanced.
Broken piston ring.
Worn piston.
Worn bearings.
Loose flywheel.
1.
2.
3.
4.
4.
6.
Replace nozzle.
Adjust timing.
Replace piston ring set.
Replace piston and liner.
Replace bearings.
Tighten flywheel nut.
Engine is hunting
1.
2.
3.
4.
Engine is overheating.
Air in fuel lines.
Governor sticking or defective.
Fuel filter clogged.
1.
2.
3.
4.
See Engine Overheats, above.
Check fuel system for leaking connections.
Free the governor or replace.
Replace filter.
Engine stops suddenly
1.
2.
3.
4.
5.
6.
7.
Fuel tank is empty.
Vent hole in fuel tank cap is plugged.
Vapor lock (fuel is too hot).
Clogged injector.
Fuel line is broken.
Seized piston.
Seized crankshaft.
1.
2.
3.
4.
5.
6.
7.
Fill tank.
Replace tank cap.
Cool the fuel.
Replace nozzle.
Replace.
Replace piston and liner.
Repair/replace crankshaft and bearings.
Operating conditions
Faulty fuel supply
Engine condition
3. Clean/replace.
2. Replace filter.
3. Check/replace nozzle.
4. Check/repair/replace pump
2. Check/replace piston ring set.
3. Overhaul engine.
4. Overhaul engine.
4. Faulty running
(continued)
Engines & Generators
40
ENGINE TROUBLESHOOTING
Problem
Probable Cause
Remedy
Blue smoke
1.
2.
3.
4.
Breather valve is clogged.
Oil seal at intake valve is defective.
Worn valves/valve guides.
Worn piston/cylinder.
White smoke
1. Fuel timing is too late.
2. Injector nozzle is worn out.
3. Low engine operating temperature.
1. Adjust timing.
2. Replace nozzle.
3. Clean thermostat.
Oil in exhaust discharge
1. Rings not seated.
2. Low compression - bad valve.
1. Initial 50 hours of operation required to seat rings.
2. Check/repair/replace valves.
1. Incorrect oil viscocity.
2. Faulty pressure relief valve.
3. Incorrect oil filter.
1. Change oil to correct viscocity.
2. Replace pressure relief valve.
3. Install correct oil filter.
1.
2.
3.
4.
Replace breather.
Replace oil seal.
Replace valves and guides.
Replace piston and cylinder.
5. Low Oil Pressure
Low oil pressure
Engines & Generators
41
HURTH HBW TRANSMISSION
WESTERBEKE'S 7A-l and llA-l diesel engines each use a
HURTH Model HBW 40 transmission. Installation, operation,
maintenance and troubleshooting infonnation for this transmission
is included in the following instructions.
The control cable, or rod, should be arranged at a right angle to _
the actuating lever when in the neutral position. The neutral position of the shift lever on the control console should coincide with
the neutral position of the actuating lever.
INSTALLATION
The shifting travel, as measured at the pivot points of the actuating lever between the neutral position and end positions A and B,
should be at least 35 mm for the outer pivot point and 30 mm for
the inner pivot point
NOTE: When installing the transmission. make certain that shifting is not impeded by restricted movability of the cable or rod
linkLlge, by unsuitably positioned guide sheaves, too small a bending radius or other restrictions. In order to mount a support for
shift control cable connections, use the two threaded holes located
above the cable bracket mounted on the gear housing. Refer to
the WESfERBEKE Parts list.
A greater amount of shift lever travel is in no way detrimental and
is recommended. However, if the lever travel is shorter, proper
clutch engagement might be impeded which, in tum, would mean
premature wear, excessive heat generation and clutch plate failure.
This would be indicated by slow clutch engagement or no engagement at all.
Shaft Couplings
NOTE: Check for proper actuating lever travel at least each
season.
WESTERBEKE recommends a flexible connection between the
transmission and the propeller shaft if the engine is flexibly
mounted, in order to compensate for angular deflections. The
installation of a special propeller thrust bearing is not required,
since the propeller thrust will be absorbed by the transmission
bearing, provided the value specified under SPECIFICATIONS is
not exceeded. However, the output shaft should be protected
from additional loads. Special care should be taken to prevent torsional vibration. When using a universal joint shaft, make certain
to observe the manufacturers instructions.
Even with the engine solidly mounted, the use of a flexible coupling or DRNESAVER* will reduce stress in the gearbox bearings
caused by hull distortions, especially in wooden boats or where
the distance between the transmission output flange and the stem
gland is less than about 32 in. (812 mm).
Shift Control and Actuating Lever
The transmission is suitable for single lever remote control. Upon
loosening the retaining screw, the actuating lever can be moved to
any position required for the shift control (cable or rod linkage).
Make certain that the actuating lever does not contact the actuating lever cover plate: the minimum distance between lever and
cover should be 0.02 in. (0.5 mm), (see illustration).
ACTUATING
LEVER
COVER
A Caution:
The position of the mechanism behind
the actuating lever is factory-adjusted to ensure equal
actuating lever travel from Neutral position N to Reverse
position A and Forward position B. «this mechanism is
in any way tampered with, the transmission warranty will
be mid.
mm)~~
0.02 in. (0.5
MINIMUM DISTANCE
*DRIVESAVER is a product o/Globe Marine. Rocldand MA.
Engines & Generators
42
HURTH HBW TRANSMISSION
INITIAL OPERATION
LOCKING THE PROPELLER
All HBW maine transmissions are test-run on a test stand with the
engine at the factory prior to delivery. For safety reasons the fluid
is drained before shipment.
Fill the gearbox with Automatic Transmission fluid (DEXTRON
111). The fluid level should be up to the index mark on the dipstick. To check the fluid level, just insert the dipstick, do not
screw it in. Screw the dipstick into the case after the fluid level is
checked, and tighten. Do not forget the sealing ring under the
hexhead of the dipstick. Check for leaks and make a visual
inspection of the coupling, oil cooler and hoses, and shift cables.
Locking of the propeller shaft by an additional brake is not
required: use the gear shift lever position opposite your direction
of travel for this purpose. Never put the gear shift in the position
corresponding to the direction of travel of the boat.
CHECKING
FLUID
TRANSMISSION
OPERATING
I
FLUID
Rotation of the propeller without a load, such as when the boat is
being sailed, being towed, or anchored in a river, as well as operation of the engine with the propeller stopped (for charging the battery), will have no detrimental effects on the transmission.
DAILY OPERATION
DIPSTICK
f!l[h
WHEN UNDER SAIL OR BEING TOWED
o
o
o
Check the transmission fluid level.
Visually check the gear shift linkage and transmission.
Start the engine in neutral, allowing a few minutes at idle to
warm the fluid.
o Shift into gear.
NOTE: Too Iowan idle speed will produce a chattering noise
from the transmission gear and damper plate. In such cases the
idle speed should be increased.
For additional information refer to the following text in this
Transmission section: SHAFT COUPliNGS, MAINTENANCE,
and TRANSMISSION TROUBI.£SHOOTING.
FLUID LEVEL
DRAI~Ql.
Operating Temperature
I
A WARNING: if the transmission fluid temperature is
FLUID CHANGE
too high, stop the engine immediately and check the
transmission fluid.
Change the fluid for the first time after about 25 hours of operation, then every 300 operating hours or at winterizing.
Normal operating temperature of the transmission fluid should be
in the range of 1220 F (500 C) to 2120 F (100° C). A maximum
temperature of 266° F (1300 C) may be only reached for a short
time.
Make certain there is enough space around the transmission to
provide good ventilation and cooling.
Removing the Fluid
Push a suction pump hose down through the dipstick hole to the
bottom of the housing and suck out the fluid. If space allows, use
the transmission drain. Remove the drain plug from the bottom
of the transmission and allow the fluid to drain into a container,
then reinstall the plug with its sealing washer. Wipe down the
transmission and properly dispose of the used fluid. After running
the engine, shut down and recheck the fluid level.
SPECIFICATIONS
TRANSMISSION
Drain plug torque: 20 - 2S Mb (27.7 - 34.6 Nm)
NOTE: When changing the fluid, take care not to lose the drain
plug sealing washer. The drain plug will leak without this sealing
washer.
A WARNING: Never pullout the dipstick while the
engine is running. Hot fluid will splash from the dipstick
hole. This could cause sever bums.
General
HURTH HBW 40 Standard Transmission,
case hardened helical gears, with a servooperated multiple disc clutch.
Gear Ratio (optional)
2.05:1
Lubricating Fluid
ATF- type A or DEXTRON - /I or /1/
Transmission Sump
Capacity
0.37 qts (0.35 liters)
Propeller Shaft
Direction of Rotation
Right hand-standard transmission
Engines & Generators
43
HURTH HBW TRANSMISSION
MAINTENANCE
Transmission maintenance is minimal. Keep the exterior housing
clean, check the fluid level as part of your regular routine, and
change the fluid every 300 operating hOUTS.
Periodically inspect the transmission for leaks and corrosion.
Lubricate the cable connections.
Lay-up/Winterize
Storage requires special care. Follow these procedures.
o Clean up the transmission and touch up unpainted areas (use
heat resistant paint).
o Fill the transmission with Dextron III ATF fluid to prevent
internal corrosion (extended storage only, twelve months or
more).
o Loosen attaching hardware from the transmission output
flange and propeller shaft coupling flange before removing the
boat from the water. Separate the flanges and spray with
lubricant.
o Inspect the gear shift cable, linkage, and attachments. Look
for corrosion of the end fittings, cracks or cuts in the conduit,
and bending of the cable rods. Lubricate all moving parts.
NOTE: If the transmission is to be stored for a long time
(twelve months or more), it sJwuld be topped off with fluid to
prevent internal corrosion. Reduce the fluid level before
putting the engine back into service.
For additional information contact:
HURTH MARINE GEAR
ZF Industries
Marine US Headquarters
3131 SW 42nd Street
Fort Lauderdale, FL 33312
Tel.: (954)581-4040
Fax.: (954)581-4077
Engines & Generators
44
HURTH HBW TRANSMISSION TROUBLESHOOTING
CONTROL CABLES
A new cable and perhaps a new linkage mechanism may be
needed. While the cable is loose, shift the transmission in and out
of gear using the actuating lever on the side of the transmission to
make sure there's no binding inside the case.
The majority of transmission difficulties arise as a result of problems with control cables rather than from problems with the transmission itself.
If the transmission passes these tests, crank the engine and have a
helper put it in forward and reverse while you observe the propeller shaft; if the shaft isn't turning, the transmission needs professional attention. If it does tum but there's no thrust, check to
see if you still have a propeller on the end of the shaft or, if you
have a folding or feathering propeller, that it isn't stuck in the "no
pitch" position.
If you experience operating problems with the transmission, shut
the engine down. First check the transmission fluid level, then
have a helper move the cockpit shift lever through the full range
- from neutral to full forward, back to neutral, into full reverse,
and back to neutral - while you observe the actuating lever on
the transmission. If the remote is stiff to operate, break the cable
loose at the transmission and try again. If it is still stiff, check the
cable for kinks or excessively tight bends, and check any linkage
for binding.
Problem
Transmission gears cannot
be shifted. Fails to move
into gear.
Transmission shifts into
gear, but fails to propel
the boat.
NOTE: If you suspect a major problem in your transmission,
immediately contact your WESTERBEKE dealer or an authorized
marine transmission facility.
Probable Cause
Remedy
1. Actuating lever is loose.
2. Shifting cable is broken, bent or unattached.
Cable radius is too severe.
3. Actuating lever is binding against cover
plate.
1. Tighten damping bolt on actuating lever.
2. Check the cable, reattach or replace.
1. Output coupling is not turning.
2. Propeller shaft is not turning. Output
coupling is tuming.
1. Transmission needs professional attention.
2. The coupling bolts are sheared or the coupling is slipping
on the propeller shaft. Tighten or replace set screws, keys,
pins and coupling bolts as necessary.
3. Inspect the propeller; it may be missing or damaged. A
folding propeller may be jammed. Avariable pitch propeller
may be in "no pitch" position.
3. Output coupling and propeller shaft are
both turning.
3. Detach the shift cable and operate the actuating lever by
hand. Clearance should be 0.02 in. (0.5 mm).
Delay of gear engagement
or engages only after an
increase in speed.
1. Actuating lever travel Nto B not equal to
Nto A. Refer to diagram.
2. Actuating lever travel is insufficient.
3. Actuating lever is binding against cover plate.
1. Adjust cover plate until the lever is exact mid position.
Refer to actuating lever text and diagram.
2. Check actuating lever cable length. Refer to lever diagram.
3. Check clearance, adjust if necessary.
Chattering transmission
noise, mainly at low engine
speed.
1. The engine or propeller generates torsional
vibrations in the drive unit which produces
a "chattering" noise in the transmission.
1. Mount a flexible coupling with another stiffness factor
between the transmission coupling and the driveshaft. A
higher stiffness factor might be sufficient.
2. Inspect the damper plate between the engine and the
transmission. Replace if necessary.
Transmission noise becomes
louder.
1. Damage starting on flexible coupling due to
wear or fatigue, possibly due to misalignment between engine and the drive shaft.
2. Beginning damage of bearings in transmission due to torsional vibrations, running
without fluid, overload, wrong alignment
of transmission, or excessive engine output.
1. Check alignment, inspect flexible coupling. If noise
persists, inspect the damper plate between the transmission and the engine. Replace if necessary.
2. Transmission needs professional attention.
Boat tails to attain specified
max. speed.
1. Operating temperature is high.
1. Wrong type of fluid; use ATF type A or DEXTRON /I or III.
Check fluid level.
Oil leakage.
1. Corrosion at radial sealing ring and shaft.
Damaged sealing ring.
2. Misalignment of output flanges.
1. Transmission needs professional attention.
2. Check alignment. Must be within 0.003 in. (0.08 mm).
Engines & Generators
45
LAY-UP AND RECOMMISSIONING
GENERAL
Many owners rely on their boatyards to prepare their craft,
including engines and generators, for lay-up during the off season
or for long periods of inactivity. Others prefer to accomplish
lay-up preparation themselves.
The procedures which follow will allow you to perfonn your own
lay-up and recommissioning, or you may use them as a check list
if others do the procedures.
Change the fuel ftlter elements on the engine (see FUEL
SYSTEM) and bleed the fuel system, as needed. Start the engine
and allow it to run for 5-10 minutes to make sure there is no air
left in the fuel system. Check for any leaks that may have been
created in the fuel system during this servicing, correcting them as
needed. Operate the engine for 5-10 minutes. This will allow
movement of the treated fuel through the injection equipment of
the engine.
Long-Term Lay-Up Procedure (over 12 months)
These procedures should afford your engine protection during
lay-up and also help familiarize you with the maintenance needs
of your engine.
If you have any questions regarding lay-up procedures, call your
local servicing dealer; he will be more than willing to provide
assistance.
For a long-tenn lay-up, follow the fuel system lay-up procedures
described above, then do the following:
Disconnect the fuel supply line from the fuel tank at the fuel lift
pump. Fill a suitable container with a 0.132 U.S. gallon (0.5 litre)
mixture of 9/10 diesel fuel and 1110 anti-corrosion oil. Connect a
short suction pipe between the container and the fuel lift pump.
Set the speed control lever to full load, set the automatic
decompression device to its neutral position, then hand-crank the
engine approximately 20 times. Put the speed control lever back
to the idle position.
PROPELLER SHAFT COUPLING
The transmission and propeller half couplings should always be
opened up and the bolts removed when the boat is hauled out of
the water or moved from land to water, and during storage in the
cradle. The flexibility of the boat often puts a severe strain on the
propeller shaft or coupling or both, while the boat is taken out or
put in the water. In some cases, the shaft has actually been bent
by these strains. This does not apply to small boats that are
hauled out of the water when not in use, unless they have been
dry for a considerable period of time.
RAW WATER COOLING CIRCUIT
Remove the impeller from your raw water pump and allow the
raw water in the cylinder head coolant chamber to drain out.
Allow it to drain completely. Examine the impeller. Acquire a
replacement, if needed, and a cover gasket. Do not replace the
impeller (into the pump) until recommissioning, but replace the
cover and gasket. Drain the water lift muffler.
LUBRICATING SYSTEM
With the engine warm, drain all the engine oil from the oil sump.
Fill the sump with the correct amount of oil for your engine (refer
to the SPECIFICATIONS section of this manual). Use an oil with
an API specification of CF or CG-4. Run the engine and check
for proper oil pressure and make sure there are no leaks.
AIR INTAKE & THROUGH-HULL EXHAUST
Remove the air intake silencer and place a clean cloth, lightly
soaked in lubricating oil, in the air intake opening to block the
opening. Do not shove the cloth out of sight (if it is not visible at
recommissioning, and an attempt is made to start the engine, you
may need the assistance of a servicing dealer). Make a note to
remove the cloth prior to start-up. The through-hull exhaust port
can be blocked in the same manner.
A Caution: Do not leave the engine's old engine
oil in the sump over the lay-up period. Engine oil and
combustion deposits combine to produce harmful
chemicals which can reduce the life of your engine's
intemal parts.
CYLINDER AND VALVES
To protect the cylinder and valves, remove the air intake silencer.
Then spray fogging oil into the cylinder head air intake opening.
Rotate the engine two revolutions using the hand crank. Spray
fogging oil into the air intake again. Replace the air intake
silencer.
If you anticipate a long lay-up period (12 months or more)
WESTERBEKE recommends removing the fuel injector for
access to the cylinder, then squirting light lubricating oil into the
cylinder to prevent the piston rings from sticking to the cylinder
walls. After squirting the oil, move the piston by a quick electric
start or the hand crank to distribute the oil. Make sure you have
replacements for the injector and return line sealing washers.
FUEL SYSTEM
Top off your fuel tanks with No.2 diesel fuel. Fuel additives such
as BlOBOR AND STA-BIL should be added at this time to control
algae and condition the fuel. Care should be taken that the additives used are compatible with the primary fuel filter/water separator used in the system. Change the ftlter element in your primary
fuel ftlter/water separator, if the fuel system has one, and clean the
separator sediment bowl. Reinstall and make certain there are no
leaks. Clean up any spilled fuel.
Engines & Generators
46
LAY-UP AND RECOMMISSIONING
STARTER MOTOR
STORAGE
Lubrication and cleaning of the starter drive pinion is advisable.
Make sure the battery connections are shut off before attempting
to remove the starter. Take care in properly replacing any
electrical connections removed from the starter.
Thoroughly clean the outside of the engine, then store the
engine in a dry place, protected against the weather.
BATTERIES
The recommissioning of your WESTERBEKE engine after a seasonallay-up generally follows the same procedures as those
described in the PREPARATIONS FOR INITIAL START-UP
section regarding preparation for starting and normal starts.
However, some of the lay-up procedures will need to be
counteracted before starting the engine.
1. Remove the oil-soaked cloths from the air intake opening
and the through-hull exhaust port.
2. Remove the raw water pump cover and gasket and
discard the old gasket.
Install the raw water pump impeller that was removed
during lay-up (or a replacement, if required). Install the
raw water pump cover with a new cover gasket.
3. Reinstall the batteries that were removed during the
lay-up, and reconnect the battery cables, making sure the
terminals are clean and that the connections are tight.
Check to make sure that the batteries are fully charged.
RECOMMISSIONING
If batteries are to be left on board during the lay-up period, make
sure they are fully charged, and will remain that way, to prevent
them from freezing. If there is any doubt the batteries will not
remain full charged, or that they will be subjected to severe
environmental conditions, remove the batteries and store them in a
warmer, more compatible environment
A WARNING: Lead acid batteries emit hydrogen, a
highly-explosive gas, which can be ignited by electrical
arcing or a lighted cigarette, cigar, or pipe. Do not
smoke or allow an open flame near the battery being
serviced. Shut off all electrical equipment in the vicinity to prevent electrical arCing during servicing.
TRANSMISSION
Check or change the fluid in the transmission as required. Wipe
off grime and grease and touch up any unpainted areas. Protect
the coupling and the output flange with an anti-corrosion coating.
Check that the transmission vent is open.
A CAUTION:
Wear rubber gloves, a rubber apron
and eye protection when servicing batteries. Lead
acid batteries emit hydrogen, a highly explosive gas,
which can be ignited by electrical arcing or a lighted
cigarette, cigar or pipe. Do not smoke or allow an
open flame near the battery being serviced. Shut off
all electrical equipment in the vicinity to prevent
electrical arcing during servicing.
For additional information, see Lay-uplWinterize in the HURTH
HBW TRANSMISSION section.
SPARE PARTS
Lay-up time provides a good opportunity to inspect your
WESTERBEKE engine to see if external items such as the drive
belt or coolant hoses need replacement. Check your basic spares
kit and order items not on hand, or replace those items used
during the lay-up, such as filters. See SUGGESTED SPARE
PARTS.
4. Start the engine in accordance with the PREPARATIONS
FOR INITIAL START-UP and STARTING/STOPPING
PROCEDURE sections of this manual.
KEYSWITCH MAINTENANCE
Lubricate the keyswitch with WCKEZE to ensure that the switch
mechanism functions freely with no binding.
Engines & Generators
47
7A·1 & 11 A·1 TORQUE SPECIFICATIONS
Component
MOOEl7A-1
SPANNER
SIZE
(mm)
-
MODEL 11A-1
MIN.
MAX.
SPANNER
SIZE
(mm)
TIGHTENING TORQUE (Nm)
TIGHTENING TORQUE (Nm)
MIN.
MAX.
Cylinder head
13
30
33
17
52
56
Connecting rod
13
30
33
14
52
56
Cylinder head cover
13
8
12
13
8
12
Main bearing plate
13
30
33
13
30
33
Fuel lift pump
13
30
33
13
30
33
Fuel injection pump
13
30
33
13
30
33
Delivery valve holder-injection pump
14
34
39
14
34
39
High pressure fuelline-injection pump
17
18
22
17
18
22
High pressure fuel line-fuel injector
17
25
30
17
25
30
Injector clamp
10
8
12
13
20
23
Governor on crankshaft
14
55
60
14
55
60
Aywheel
36
216
226
46
390
410
Gear end cover
6
34
38
6
34
38
Push rod guide
4
8
10
4
8
10
Crank handle guide
10
8
12
10
8
12
Oil pump
5
16
20
5
16
20
cross-slotted
9
11
cross-slotted
9
11
Banjo bolt on fuel lift pump
17
25
35
17
25
35
Banjo bolt on tank
12
8
10
12
8
10
Rocker bracket
13
30
33
17
52
56
Oil filter
-
-
-
-
Sump plate
Engines & Generators
48
Hand-tighten
STANDARD HARDWARE
BOLT HEAD MARKINGS
Metric bolt class numbers identify bolts by their strength with 10.9 the
strongest
1. Use the torque values listed below when specific torque values are not available.
2. These torques are based on clean, dry threads. Reduce torque by 10% when engine oil is used.
3. Reduce torques by 30% or more, when threading capscrews into aluminum.
STANDARD BOLT & NUT TORQUE SPECIFICATIONS
C8psrew Body SIze
(Inches) - (TIIread)
SAE Glade 5
TDIqIII
FHb (Nm)
1/4-20
-28
8 (11)
10 (14)
SAE Glade 6-7
Torque
Ft-lb(Nm)
10 (14)
METRIC BOLT & NUT TORQUE SPECIFICATIONS
SAEGrada8
Torque
R-Lb(Nm)
Bon
12 (16)
14 (19)
5/16 -18
-24
17 (23)
19 (26)
19(26)
24 (33)
27 (31)
3/8 -16
-24
31 (42)
35 (41)
34(46)
44 (60).
7116-14
-20
49(66)
55 (75)
55 (75)
70 (95)
78 (106)
1!2 -13
-20
75 (102)
85 (115)
85 (115)
105 (142)
120 (163)
9/16 -12
-18
110 (149)
120(163)
120 (163)
155 (210)
·170 (231)
5t8 -11
-18
150 (203)
170 (231)
167 (226)
210 (285)
240 (325)
314 -10
-16
270 (366)
295(400)
280 (380)
375 (508)
42!"(569)
7/8- 9
-14
395 (536)
435 (590)
440 (591)
605 (820)
675 (915)
1- 8
-14
590(800)
660(895)
660 (895)
910 (1234)
990 (1342)
Ola.
Wrench Size
Grada4.6
A-Lb(Nm)
Grade 4.B
A-Lb(Nm)
M3
M5
5.5mm
7mm
8mm
0.3 (0.5)
0.8 (1.1)
1.5 (2.5
0.5 (0.1)
1 (1.5)
2(3)
1 (1.3)
2 (3)
4.5 (6)
1.5 (2)
3(4.5)
6.5 (9)
M8
M9
Ml0
10mm
13mm
16mm
3 (4)
7 (9.5)
14 (19)
4 (5.5)
10 (13)
18 (25)
7.5 (10)
18 (25)
37 (50)
11 (15)
35(26)
55 (75)
M12
M14
M16
18mm
21 mm
24mm
26 (35)
37 (50)
59 (80)
33 (45)
55 (75)
85 (115)
63(85)
103 (140)
159 (215)
'fl (130)
151 (205)
232 (315)
M18
M20
M22
27mm
30mm
33mm
81 (110)
118 (160)
159 (215)
118 (160)
166 (225)
225 (305)
225 (305)
321 (435)
435 (590)
321 (435)
457 (620)
620 (840)
M24
M27
M30
36mm
41 mm
46mm
203 (275)
295 (400)
402 (545)
288 (390)
417 (565)
568 (770)
553 (750)
811 (1100)
1103 (1495)
789 (1070)
1154 (1565)
1571 (2130)
M33
51 mm
55mm
546 (740)
700 (950)
774 (1050)
992 (1345)
1500 (2035)
1925 (2610)
2139 (2900)
2744 (3720)
M4
49(66)
M36
Grade B.B - 9.8 Grade 10.9
FI-Lb(Nm)
R-Lb(Nm)
SEALANTS &LUBRICANTS
GASmSJSEALANTS
Oil based PERMATEX 12 and it's HIGH TACK equivalent are excellent all
purpose sealers. They are effective in just about any jOint in contact with
coolant, raw water, oil or fuel.
A light coating of OIL or LlaUID TEFLON can be used on rubber gaskets
and O-rings.
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil
filter assembly.
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer.
When installing gaskets that seal around water (coolant) passages, coat both
sides with WHITE SILICONE grease.
High-copper ADHESIVE SPRAYS are useful for holding gaskets in position during assembly.
Specialized gasket sealers such as HYLOMAR work well in applications requiring non-hardening properties. HYLOMAR is particlarly effective on
copper cylinder-head gaskets as it resists fuel, oil and water.
Use LlaUID TEFLON for sealing pipe plugs and fillings that connect coolant
passages. Do nat use tape sealants!
BOIis & FASTENERS/ASSEMBUES
Ughtly oil head bolts and other fasteners as you assemble them. Bolts and
plugs that penetrate the water jacket should be sealed with PERMATEX #2 or
HIGH TACK.
When assembling the flywheel, coat the bolt threads with LOCTITE blue.
Anti-seize compounds and thread locking adhesives such as LOCTITE protect
threaded components yet allows them to came apart when necessary.
LOCTITE offers levels of locking according to the job.
LITHIUM based grease is waterproof, ideal for water pump bearings and stuffing boxes.
Heavily oil all sliding and reCiprocating components when assembling. Always
use clean engine all!
Engines & Generators
49
METRIC CONVERSIONS
INCHES TO MILUMETERS
mm
Inches
1
2
3
4
5
10
25.40
50.80
76.20
101.60
127.00
254.00
15
20
25
30
35
40
MILUMETERS TO INCHES
mm
Inches
381.00
508.00
635.00
762.00
889.00
1016.00
mm
Inches
mm
Inches
1
2
3
4
5
10
0.0394
0.0787
0.1181
0.1575
0.1969
0.3937
15
20
25
30
35
40
0.5906
0.7874
0.9843
1.1811
1.3780
1.5748
=
=
10 MILLIMETERS 1 CENTIMETER, 100 CENTIMETERS 1 METER
INCHES TO METERS
Inches
Meters
1
2
3
4
5
6
0.0254
0.0508
0.0762
0.1016
0.1270
0.1524
Inches
METERS TO INCHES
Meters
7
8
9
10
11
12
=39.37 INCHES (3.3 FEET)
Meters
0.1778
0.2032
0.2286
0.2540
0.2794
0.3048
Inches
0.1
0.2
0.3
0.4
0.5
0.6
3.937
7.874
11.811
15.748
19.685
23.622
Inches
Meters
0.7
0.8
0.9
1.0
1.1
1.2
27.559
31.496
35.433
39.370
43.307
47.244
TO CONVERT METERS TO CENTIMETERS, MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS
METERS TO YARDS
Yards
Meters
Yards
Meters
Meters
Yards
Meters
1
2
3
4
5
0.91440
1.82880
2.74320
3.65760
4.57200
6
7
8
9
10
5.48640
6.40080
7.31520
8.22960
9.14400
1
2
3
4
5
1.09361
2.18723
3.28084
4.37445
5.46807
6
7
8
9
10
MOVE DECIMAL POINT FOR HIGHER VALUES - e.g. 6,000 METERS
POUNDS TO KILOGRAMS
kg
kg
Ib
Ib
1
2
3
4
5
0.454
0.907
1.361
1.814
2.268
Gallons
Uters
6
7
8
9
10
kg
2.722
3.175
3.629
4.082
4.536
3.79
7.57
11.36
15.14
18.93
Uters
1
2
3
4
5
0.47
0.95
1.42
1.89
2.37
Uters
Uters
Gallons
10
20
30
40
50
37.86
75.71
113.57
151.42
189.28
1
2
5
10
20
0.26
0.53
1.32
2.64
5.28
Uters
6
7
8
9
10
2.84
3.31
3.79
4.26
4.73
50
I
I
I
I
5
I
I
10
15
60
I
70
I
I
20
Gallons
Liters
15.66
23.77
31.32
39.62
47.54
60
90
120
150
180
UTERS TO PINTS
Pints
40
Ib
13.228
15.432
17.637
19.842
22.046
6
7
8
9
10
LITERS TO GALLONS
Gallons
32
I
0
=6,561.68 YARDS
2.205
4.409
6.614
8.818
11.023
1
2
3
4
5
PINTS TO UTERS
Pints
6.56168
7.65529
8.74891
9.84252
10.93614
KILOGRAMS TO POUNDS
Ib
kg
GALLONS TO LITERS
1
2
3
4
5
Yards
Uters
1
2
3
4
5
TEMPERATURE
75
85
95
I
I
25
I
I
I
I
30
35
Liters
2.11
4.23
6.34
8.45
10.57
6
7
8
9
10
Pints
12.68
14.79
16.91
19.02
21.13
105 140
I
I
I
I
175 212
I
I
40
80 100
Engines & Generators
50
Pints
60
I
OF
I
°C
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
Feet (ft) x .305 = Meters (m) x 3.281 = Feet
Miles x 1.609 = Kilometers (km) x .0621 =Miles
VOLUME
Cubic Inches (in3) x 16.387 = Cubic Centim~ters x .061 =in3
Imperial Pints (IMP pt) x .568 = liters (L) x 1.76 = IMP pt
Imperial Quarts (IMP qt) x 1.137 =liters (L) x.88 = IMP qt
Imperial Gallons (IMP gal) x 4.546 = liters (L) x .22 = IMP gal
Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 =IMP gal
Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
US Pints (US pt) x .473 = Liters(L) x 2.113 =Pints
US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons
MASS-WEIGHT
Ounces (oz) x 28.35 = Grams (g) x .035 =Ounces
Pounds (I b) x .454 = Kilograms (kg) x 2.205 =Pounds
PRESSURE
Pounds Per Sq In (psi) x 6.895 = Kilopascals (kPa) x .145 = psi
Inches of Mercury (Hg) x .4912 = psi x 2.036 =Hg
Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
Inches of Water (H20) x .07355 = Inches of Mercury x 13.783 = H20
Inches of Water (H20) x .03613 = psi x 27.684 = H20
Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20
TORQUE
Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 =in-Ib
Pounds-Force Feet (ft-Ib) x 1.356 = Newton Meters (Nm) x .738 = ft-Ib
VELOCITY
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
POWER
Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH
FUEL CONSUMPTION
Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
Kilometers Per liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/L)
Kilometers Per Liter (Km/L) x 2.352 = US MPG
TEMPERATURE
Degree Fahrenheit (OF) = (DC X 1.8) + 32
Degree Celsius (DC) = (OF - 32) x .56
Engines & Generators
51
SUGGESTED SPARE PARTS KITS
Carry only Genuine WESTERBEKE Spare Parts
SPARE PARTS KITS
WESTERBEKE offers two Spare Parts Kits,
each packaged in a rugged hinged toolbox.
Kit "A" includes the basic spares.
Kit "B" is for more extensive off-shore cruising.
Kit "A" includes:
Drive Belt
Raw Water Pump Impeller and Gasket
Fuel Filter
Fuel Lift Pump Screens (2) and Gasket
Oil Filter (Model lOA-I only)
Fuel Hardware Kit (to fix a leak)
Air Intake Filter
Kit "B" Includes:
Drive Belt
Raw Water Pump Impeller and Gasket
Raw Water Pump Repair Kit
Fuel Filter
Fuel Lift Pump Screens (2) and Gasket
Oil Filter (Model lOA-I only)
Fuel Hardware Kit (to fix a leak)
Thermostat Kit
Complete Gasket Kit
Fuel Injector
Air Intake Filter
Engines & Generators
52
Engines & Generators
1045-.5C-4JD1