OPERATORS MANUAL 638 and 63C FOUR 71 8 and 71 C FOUR 828 FOUR 1088 and 108C SIX MARINE DIESEL ENGINES PUBLICATION NO. 038922 EDITION FIVE OCTOBER 2006 WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780 WEBSITE: WWW.
A WARNING Exhaust gasses contain carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can include: -Dizziness - Throbbing in Temples -Nausea - Muscular Twitching -Headache - Vomiting - Weakness and Sleepiness -Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention.
SAFETY INSTRUCTIONS INTRODUCTION • Read this safety manual carefully. 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 personne4 and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. PREVENT ELECTRIC SHOCK while engine is running.
SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury A WARNING: Carbon monoxide (CO) Is a deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds/water-injected elbow L" securely attached. • Be sure the unit and its surroundings are well ventilated. Run blowers when running the generator set or engine.
SAFETY INSTRUCTIONS ABye, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. • Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times. • Do not check fluid levels or the drive belts tension while the engine is operating.
INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following infom1ation: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
TABLE OF CONTENTS Remote Oil Filter (Optional) ..............................21 Water Heat Connections ................................... 22 Wiring Diagram .................................................26 Wiring Schematic ..............................................27 Glow Plugs .........................................................28 Starter Motor .....................................................29 Dual Output Alternators ....................................
PARTS IDENTIFICATION (TYPICAL) FILL COOlANT PRESSURE CAP WATER INJECTED EXHAUST ELBOW ASSEMBLY FILTER DC CHARGING ALTERNATOR AIR INTAKE SILENCER WMERHtAltK·-------~ CONNECTION REAR FLEXIBLE MOUNT DRIVE BELT RAWWATERP~ FILTER COOLER CRANKSHAFT PULLEY OIL DRAIN HOSE Oil PRESSURE SENDOR LEFT SIDE Fill THERMOSTAT _",~"o;;l"'DLY FUEL LIFT PUMP ALTERNATOR PREHEAT SOLENOID - - - ZOAMP CIRCUIT BREAKER FRONT HBW HURTH TRANSMISSION MANIFOLD 1.0.
INTRODUCTION This WESTERBEKE Diesel Engine is a product of WESTERBEKE's long 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 WESTERBEKE. In order to get the full use and benefit from your engine, it is important that you operate and maintain it correctly. This manual is designed to help you do this. Please read this manual carefully and observe an the safety precautions throughout.
INTRODUCTION SERIAL NUMBER LOCATION ORDERING PARTS The engine's model number and serial number are located on a nameplate mounted on the side of the engine's manifold. The engine's serial number can also be found stamped into the engine block on the flat sutface of the block just above and inboard of the injection pump.
ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off, the water temperature gauge will continue to register the last temperature reading indicated by the gauge before electrical power was turned off. The oil pressure gauge will fall to zero when the key switch is turned off. The temperature gauge will once again register the engine's true temperature when electrical power is restored to the gauge.
CAPTAIN CONTROL PANEL DESCRIPTION The panel also includes an alarm buzzer for low OIL PRESSURE or high COOLANT 1EMPERATURE. The RPM gauge is illuminated when the KEY switch is turned on and remains illuminated while the engine is in operation. This manually-operated control panel is equipped with a KEY switch, an RPM gauge, PREHEAT and START buttons, an JNSTRL'MEI\TT JEST button and three indicator lamps, one for AL1ERNATOR DISCHARGE, one for low OIL PRESSURE, and one for high ENGINE COOLANT 1EMPERATURE.
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT Use fuel1hat meets 1he requirements or specification of Class 2-D (ASTM), and has a cetane rating of #45 or better. WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the chemicals that can corrode internal engin~ surfaces. The antifreeze performs double duty.
PREPARATIONS FOR INITIAL START-UP PRESTARTINSPECTION Before starting your engine for the first time or after a prolonged layoff, check the following items: o Check the engine oil level. Add oil to maintain the level at the high mark on the dipstick. o Turn on the fuel supply, then check the fuel supply and examine the fuel filter/water separator bowl for contaminants. Check the transmission fluid level. Check the DC electrical system. Inspect wire connections and battery cable connections.
STARTING - STOPPING PROCEDURE CHECKLIST FAILURE TO START Follow this check list each day before starting your engine. D Visually inspect the engine for fuel, oil, or water leaks. D Check the engine oil level (dipstick). D Check the coolant level in coolant recovery tank. Periodically check the manifold coolant leveL. D Check the transmission fluid level. D Check your fuel supply.
ENGINE BREAK-IN PROCEDURE DESCRIPTION Although your engine has experienced a minimum of one hour of test operations at the factory to make sure accurate assembly procedures were followed and that the engine operated properly, a break-in time is required. The service life of your engine is dependent upon how the engine is operated and serviced during its initial 50 hours of use. Breaking-in a new engine basically involves seating the piston rings to the cylinder walls.
WARNING LIGHTS, ALARMS &CIRCUIT BREAKER ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH The Captain Control Panel indicates alternator low discharge with a red warning light The Admiral Control Panel uses a voltmeter to monitor the performance of the alternator. A low oil pressure alarm switch is located off the engine's oil gallery. This switch's sensor monitors the engine's oil pressure. Should the engine's oil pressure fall to 5 -10 psi (0.4 - 0.
MAINTENANCE SCHEDULE A WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. NOTE: Many of the following maintenance jobs are simple but others are more difficult and may require the expert knowledge of a service mechanic.
MAINTENANCE SCHEDULE NOTE: Use the engine hour meter gauge to log your engine hours or record your engine hours by running time. SCHEDULED MAINTENANCE CHECK EACH DAY HOURS OF OPERATION 50 Raw Water Pump 100 250 0 Coolant System Electric Fuel lift Pump SOD EXPLANATION OF SCHEDULED MAINTENANCE 750 1000 1250 0 0 Remove the pump cover and inspect impeller, gasket, cam and cover for wear. Check the bearings and seals (the shaft can turn, but not wobble). Lubricate when reassembling. Drain.
FUEL SYSTEM DIESEL FUEL Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not use kerosene or home heating fueL FUEL FILTER/WATER SEPARATOR Aprimary fuel filter of the water separating type must be installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system on the engine.
COOLING SYSTEM FRESH WATER COOLING CIRCUIT CHANGING COOLANT NOTE: Refer to the ENGINE COOLANT page for the recommended antifreeze and water mixture to be used as the fresh water coolant. The engine's coolant must be changed according to the MAINTENANCE SCHEDULE. If the coolant is allowed to become contaminated, it can lead to ovetbeating problems. Fresh water coolant is pumped through the engine by a circulating pump, absorbing heat from the engine.
COOLING SYSTEM THERMOSTAT RAW WATER INTAKE STRAINER A thennostat, located near the manifold at the front of the engine, controls the coolant temperature as the coolant continuously flows through the closed cooling circuit. When the engine is first started, the closed thennostat prevents coolant from flowing (some coolant is by-passed through a hole in the thennostat to prevent the exhaust manifold from overheating). As the engine wanns up, the thennostat gradually opens.
COOLING SYSTEM RAW WATER PUMP Changing the Raw Water Pump Impeller The raw water pump is a self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller has flexible blades which wipe against a curved cam plate within the impeller housing, producing the pumping action. On no account should this pump be run dry. There should always be a spare impeller and impeller cover gasket aboard (an impeller kit).
COOLING SYSTEM Zinc Anode If the zinc anodes need replacement, hold the hex boss into which the zinc anode is threaded with a wrench while loosening the anode with another wrench. This prevents the hex boss from possibly tearing off the exchanger shell. After removing the Zinc, note the condition Qf it If the zinc is in poor condition, there are probably a lot of zinc flakes within the exchanger. Remove the end of the heat exchanger and clean the inside of all zinc debris.
ENGINE LUBRICATING OIL - DESCRIPTION ENGINE Oil CHANGE 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 oil filter, oil cooler and various lubricating points in the engine. 'The oil then returns to the oil sump to repeat the continuous cycle.
ENGINE LUBRICATING OIL 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 on the oil filter bracket, and then tighten the filter firmly by hand.. NOTE: The engine oil is cooled by engine coolant flowing through passages in the oil jilter bracket housing assembly.
REMOTE OIL FILTER (OPTIONAL) JNSTALLATION NOTE: Westerbeke is lWt responsible for engine failure due to incorrect installation of the Remote Oil Filter. !fhls popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as an ~ngine room bulkhead. . NOTE: Refer to ENGINE OIL CHANGE in this rna:rw.alfor instructions on removing the oil filter. 'lro install, 'simply remove the engine oil filter and thread on WBSTERBEKB's remote oil filter kit as shown.
WATER HEATER CONNECTION KIT (71B & C, 82B FOUR, & 107 B & C) The models refered to in this manual are equipped with connections for the plumbing of engine freshwater coolant to a domestic hot water heater. One connection (to) is located on the lower side ofthe exhaust manifold. The other connection (return) is located on the center outer surface of the heat exchanger. Both of these connections have square head 1/2 N.P.T. plugs in them to plumb a domestic hot water heater into the engine's freshwater system.
The pressure cap on the engine's manifold should be installed once the engine's cooling system is filled with coolant. Finish filling the cooling system from the remote tank once the system is filled and is free of air and exhibits good coolant circulation. During engine operation, checking the engine's coolant should be done at the remote tank and not at the engine manifold cap.
WATER HEATER CONNECTIONS (71 C & 828 FOUR) FOR PRODUCTION MODELS FROM MARCH 2004 ON NOTE: An air bleed petcock is located on the engine:V heat exchanger and on the thermostat housing. Open these petcocks when filling the engine s coolant system to allow air to escape. Close both tightly after all the air is removed. WESTERBEKE provides easy access for connecting to an on-board hot water system.
WATER HEATER CONNECTION KIT (638 AND 63C ONLY) HOSE CONNECTION TO THE TANK RETURN HOSE CONNECTION FROM THE TANK Remove the hex head plug at the thermostat assembly and install the WATER HEATER CONNECTION KIT. Attach the heater hose to the water heater connection kit and check that all connections are tight. Locate the hose and piping that comes off the engines fresh water pump and cut into the smaller hose that leads to the oil cooler.
WIRING DIAGRAM Btu r~11 I - 'A~'~ I~ - UI MOon.S) E I~1 1 $EE HOT[ 2, I .J ,, I LIFT PUMP IIOTE: An on-off switch should be installed In this circuit to disconnect the starter from the battery in 811 emergency and when leaving the .boat Twelve volt engine staffers typically draw 200 to 300 amps when cranking, A switch with a continuous rating of 175 amps at 12 VDC will normally serve this function, but a switch must never be used to . I "make» the starter circuit. I = ;.. - ::: :.- '2m'" ..
WIRING SCHEMATIC + SS~Rr 12 VDe 0 S'tdHR ~-------7;~~rl171------~'H~ I ~.. ~_.....,. " ~ ------------1-----. I I I, ___---:r~- , Pft(ItUT T IS PROTECTED SY A XCU$IYE CURRENT WILL TItE eUILOER/OWNtR SOL IIISU"ED TO PREVEII --;I'll I -r 1. I A,N Q/Ij,.orr RESET CIRCuIT SR"'rR THE SRU.
GLOW PLUGS Re--install the plugs in the engine 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. DESCRIPTION The glow plugs 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.
STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight and is called a high-speed internal-reduction starter. The pinion shaft is separate from the motor shaft; the pinion slides only on the pinion shaft. A reduction gear is installed between the motor shaft and a pinion shaft. The pinion sliding part is not exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease. The motor shaft is supported at both ends on ball bearings.
STARTER MOTOR EMERGENCY START A WARNING: When performing these procedures, Corrosion to the starter brushes and/or the solenoid contacts can cause the sporadic problem of the engine starting one time but not another. If corrosion is the problem, the starter will need to be rebuilt. It is however, sometimes possible to get started by taping the starter lightly with a small hammer. With the battery switch off and no ignition,.
DUAL OUTPUT ALTERNATORS SPACER TO MOUNTING BRACKET DESCRIPTION Dual output and high output alternators are available as optional equipment on most WESTERBEKE engines. These altemators can be installed during factory assembly or as add-on equipment at anytime. Dual alternators can be configured to charge two banks of batteries at the same time or, using a battery selector switch, charge each set of batteries separately.
DUAL OUTPUT ALTERNATORS TROUBLESHOOTING Alternator Testing NOTE: Before troubleshooting, make certain that the drive The regulator is functioning properly and the batteries are in good condition. 1. Test the voltage at the alternator plug with the engine off-key on. The voltage at the alternator terminal F and the voltage in the plug [blue wire F] from the regulator should read the same. 2. Hold a screw driver close [112") to the alternator pulley.
DUAL OUTPUT ALTERNATORS DESCRIPTION 5. Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable. 6. Mount the regulator to a flat surface in a cool dry location. a. Connect the black wires to the mounting bolt on the alternator (ground) Dual output and high output alternators are available as optional equipment on most WESTERBEKE engines. These alternators can be installed during factory assembly or as add-on equipment at anytime.
ALTERNATORS TESTING/TROUBLESHOOTING SEE WIRING DIAGRAM FOR WIRE CONNECTIONS TO OPTIONAL ALTERNATORS 50AMP ALTERNATOR EXCITER TERMINAL l!. NOTE: FOR CORRECT WIRING HARNESS CONNECTIONS TO THE ALTERNATOR, REFER TO THE WIRING DIAGRAMS IN THIS MANUAL. DESCRIPTION VOLTAGE REGULATOR The following infonnation applies to the standard alternators that are supplied with WESTERBEKE'S Marine Engines and Marine Generators.
ALTERNATORS TESTING/TROUBLESHOOTING PRELIMINARY INSPECTION 3. Thrn off the engine. Inspect all wiring and connections. Ensure that the battery terminals and the engine ground connections are tight and clean. 4. If a battery selector switch is in the charging circuit, ensure that it is on the correct setting. S. 'furn on the ignition switch, but do not start the engine. 6. Check the battery voltage. If the battery is in good condition, the reading should be 12 to 13 volts.
ALTERNATORS TESTING/TROUBLESHOOTING TESTING THE OUTPUT CIRCUIT ENGINE RUNNING 5. If no reading is obtained, an open exists in the alternator-excitation lead or in the excitation circuit of the regulator. Disconnect the lead from exe. terminal R. Connect the positive multimeter probe to the excitation lead and the negative multimeter probe to ground terminal E. If the multimeter now indicates an approximate battery voltage, the voltage regulator is defective and must be replaced.
ENGINE TROUBLESHOOTING The following troubleshooting table describes certain problems relating to engine service, the probable causes of these problems, and the recommendations to overcome these problems. Problem No panel indications; fuel solenoid or fuel pump is no! working (key switch is on and PREHEAT button is depressed). NOTE: The engine '8 electrical system is protected by a 20 ampere manual reset circuit breaker located on a bracket at the back of the engine.
ENGINE TROUBLESHOOTING Problem Probable Cause Engine slows and stops. Verification/Remedy 1. Fuel lift pump failure. 1. Fuel lift pump should make a distinct ticking sound. Replace pump with spare. 2. Switches and/or wiring loose 2. Inspect wiring for short circuits and loose connections. or disconnected. Engine overheats/shuts down. Inspect switches for proper operation. 3. Fuel starvation. S. Check fuel supply, fuel valves, fuel lift pump. 4. 20 Amp circuit breaker tripping. 4.
SERVICE SCHEDULE Servicing After Every 100 Hours of Operation 1. Change the engine's lubrication oil and oil filter. 2. Adjust the alternator and water pump drive belt tension, if required. 3. Lubricate panel keyswitch (use "Lockeze" only). 4. Inspect the syphon-break assembly for proper operation. (When installed) Servicing After Every 250 Hours of Operation Replace the fuel filter elements in the on-engine fuel filter and in the optional water/sediment separator.
SERVICE SCHEDULE This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/operator can petform without the bene.fit of sophisticated and eXlJensive tools and instruments. Preventive Maintenance Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs. Adherence to these schedules will ensure the equipment is maintained in the best possible condition and that it will petform to expectations.
SERVICE SCHEDULE CYLINDER HEAD BOLT TORQUING Servicing After Every 1000 Hours of Operation 1. Remove, clean, and pressure test the primary heat exchanger. (A local automotive radiator shop should be able to clean and test the heat exchanger.) NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours. *2. Check the injection pump's timing.
SERVICE SCHEDULE CYLINDER HEAD BOLT TORQUING Tighten the cylinder head bolts to the specified torque before making valve adjustments. When No.1 cylinder J. 1 TINC!.'EX IS at top dead enler When No.1 cylinder is at top dead center liN I i (l~EX fEX \11 EX i'~31IN When NoA cylinder J (rEX T (fiN IS a t top dead center 63(BXC)FOUR, 71(B)(C)FOUR & 82BFOUR 108(BXC) SIX Valve Clearance: Intake & Exhaust 0.012 inch (0.30 rom) Procedure to adjust 1.
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. ENGINE IDLING SPEED INJECTION PUMP SERVICE The engine idling speed is pre-set at the factory but once the boat is operating in the water other variables such as propeller size, shaft length, and the transmission can affect the idle speed.
TACHOMETER TACHOMETER/HOUR METER The tachometerlhour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and the other the taehometer. The hour meter circuit operates on 12 volts alternator charging voltage supplied to the (+) terminal on the baek of the instrument. NOTE: Current model tachometers use a coarse adjustment dial to set the tachometer to the crankshaft pulley rpms.
OIL PRESSURE NOTE: WESTERBEKE recommends that the following engine adjustments he peifomled by a competent engine mechanic. The infomtation below is provided to assist the mechanic. DESCRIPTION OIL PRESSURE 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 oil filter and various lubricating points in the engine.
SPECIFICATIONS 638 AND 63C FOUR MARINE DIESEL ENGINES ENGINE SPECIFICATIONS Engine Type Governor Valve mechanism Combustion Ghamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Maximum Torque (at 2900 rpm) Compression Ratio Compression Pressure Valve Seat Angle Valve Clearance (engine cold) Dimensions Inclination Dry Weight Engine Speed Fuel Consumption COOLING SYSTEM Diesel, four-cycle, fresh water-cooled, vertical in-line (63 hp at 3600 rpm maximum) Integral ofthe injection pump
SPECIFICATIONS 71 BAND 71 CFOUR MARINE DIESEL ENGINES COOLING SYSTEM ENGINE SPECIFICATIONS Engine Type Govemor Valve mechanism Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Maximum Torque (at 2200 rpm) Compression Ratio Compression Pressure Valve Seat Angle Valve Clearance (engine cold) DimenSions Inclination Dry Weight Engine Speed Fuel Consumption Diesel, four-cycle, four cylinder, fresh water-cooled, vertical in-line (71 hp at 3600 rpm maximum) Integral of th
SPECIFICATIONS 828 FOUR MARINE DIESEL ENGINE FUEL SYSTEM ENGINE SPECIFICATIONS Engine Type Aspiration Combustion Chamber Bore &Stroke Piston Displacement Firing Order Direction of Rotation Compression Ratio Dimensions Weight Inclination Generator Power Take Off General Operating Temperature Fresh Water Pump Raw Water Pump TUNE-UP SPECIFICATIONS Valve Clearance Injector Pressure Engine Timing Raw Water Flow, at 2600 rpm System capacity (coolant) Fresh water-cooled block, thermostaticallycontrolled wi
SPECIFICATIONS 1088 AND 108C FOUR MARINE DIESEL ENGINES ENGINE SPECIFICATIONS Engine Type Governor Valve mechanism Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Maximum Torque (at 2900 rpm) Compression Ratio Compression Pressure Valve Seat Angle Valve Clearance (engine cold) Dimensions Inclination DryWeighl Engine Speed Fuel Consumption COOLING SYSTEM Diesel, four-cycle, four cylinder, fresh water-cooled, vertical in-line (108 hp at 3600 rpm maximum) Integral of
ZF MARINE TRANSMISSIONS DESCRIPTION NOTE: When installing the transmission, make certain that shifting is not impeded by restricted movability of the Bowden cable or rod linkage, by unsuitably positioned guide sheaves, too small a bending radius, etc. In order to mount a support for shift control cable connections, use the two threaded holes located above the shift cover on top of the gear housing. Refer to the WESTERBEKE parts list.
ZF MARINE TRANSMISSIONS INITIAL OPERATION OPERATING TEMPERATURE All HBW marine transmissions are test-run on atest stand with the engine at the factory prior to delivery. For safety reasons the fluid is drained before shipment. FilI the gearbox with Automatic Transmission Fluid (DEXRON n or DEXTRON ill). The fluid lev~l should be up to the index mark on the dipstick. To check the fluid level, just insert the dipstick, do not screw it in.
ZF TRANSMISSIONS SHIPMENT INITIAL OPERATION For safety reasons, the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft. Before leaving the WESTERBEKE plant, each transmission undergoes a test run, with Dextron /II ATF transmission fluid. The residual fluid remaining in the transmission after draining acts as a preservative and provides protection against corrosion for at least one year if properly stored.
ZF TRANSMISSIONS Replacing the Fluid CHANGING THE TRANSMISSION FLUID Pour in new Dextron 1II ATF fluid and check the quantity with the dipstick. Transmission fluid quantities will vary with the use of coolers,length of hoses and'the angle of the transmission. Approximate Quantities ZF 45 - 2.12 quarts (2.0 Liters) ZF 63 - 3.2 quarts (3.0 Liters) ZF 63V -4.2 quarts (4.0 Liters) Reinsert the filter assembly into the housing. Press it in place and tighten the Allen screw.
IF TRANSMISSIONS CABLE CONNECTIONS SHAFT COUPLINGS The transmission is suitable for a single lever gear shift. Upon loosening the retaining screw, the actuating lever (see illustration) can be moved to any position required for the control elements (cable or rod linkage). Make certain that the actuating lever does not contact the lever hub: the minimum distance between the lever and the hub should be O.02in (O.5mm).
ZF MARINE TRANSMISSIONS OPERATING TEMPERATURE MAINTENANCE A CAUTION: If the transmission fluid temperature is too high, stop the engine immediately and check the transmission fluid. Norn1al operating temperature of the transmission fluid should be in the range of 1220 F (500 C) to 2120 F (1000 C) .. A maximum temperature of 2660 F (1300 C) may b~ only reached for a short time. Make certain there is enough space around the transmission to provide good ventilation and cooling.
TRANSMISSION TROUBLESHOOTING [ZF] 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 lever on the side of the transmission to make sure there's no binding inside the case. 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.
BORG WARNER VELVET DRIVE TRANSMISSION OPTIONAL TRANSMISSION SHIFT LEVER POSITION The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward (F), Neutral (N), and Reverse (R) shifting positions. A dete])t ball located behind the transmission lever must work freely to center the lever in each position. The gear shift positions at the helm must be coordinated with those of the Velvet Drive actuating lever through shift mechanism adjustments.
BORG WARNER VELVET DRIVE TRANSMISSION o o D o FORWARD NEUTRAl. REVERSE A WARNING: Never pullout the dipstick while the TRANSMISSION ACTUATING LEVER POSITIONS engIne is running. Hot fluId will splash from the dipstick hole. This could cause severe burns. DAILY OPERATION o o o Check the transmission fluid. Visually check the gear shift linkage and transmission. Start the engine in neutral. Allow a few minutes at idle for the fluid to warm. Oil Capacity Approximately 2.5 quarts (2.
BORG WARNER VELVET DRIVE TRANSMISSION MAINTENANCE WARRANTY NOTES 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 and the cooler for leaks and corrosion. Make certain the air vent is clear and when checking the fluid level look for signs of water contamination (fluid will appear as strawberry cream).
LAY-UP &RECOMMISSIONING GENERAL Fuel System [Gasoline] 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 perform your own lay-up and recommissioning, or you may use them as a check list if others do the procedures.
LAY-UP & RECOMMISSIONING Starter Motor Spare Parts Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter permits its easy removal. 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. Lay-up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement.
TORQUE DATA Lb-ft km Cylinder head bolts ~ 63 (B)(C) Four, 108(B)(C) Six & 7lC Four - 7IB Four & 82B Four 80- 85 85 -90 11.0-11.7 11.8 - 12.5 Connecting rod caps - 63(B)(C) Four & 7lC Four - 71B Four & 82B Four 108 (B)(C) Six - 50 - S4 59 - 65 5S - 60 6.9 -7.5 8.2 - 9.0 7.6 - 8.3 Main Bearing Caps - All Models 80- 85 11.0-11.7 Injection Pump Gear - All Models 29 - 52 4-7 Oil Pan Bolts - 63(B)(C) Four - 7l(B)(C) Four & 82B Four & 108 (B)(C) Six 5-9 12 - 17 0.7 - 1.2 1.6 - 2.
DECIMAL TO METRIC EQUIVALENT CHART Fractions of an inch Decimal (in.) Metric (mm) 39688 33/64 0.515625 13.09687 0.79375 17/32 0.53125 13.49375 0.046875 1.19062 35/64 0.546875 13.89062 1/16 0.0625 1.58750 9116 0.5625 14.28750 5/64 " " .. n"?F; 1.98437 37/64 0.578125 14.68437 3/32 0.09375 2.38125 19/32 0.59375 15.08125 7/64 0.109375 '2.77812 39/64 0.609375 15.47812 1/8 0.125 3.175 5/8 0.625 15.87500 9/64 0.140625 3.57187 41/64 0.640625 16.27187 5/32 0.
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 x1.609:::: Kilometers (km) x .0621 :::: Miles DISTANCE EQUIVALENTS 1 Degree of Latitude:::: 60 Nm :::: 111.120 km 1 Minute of Latitude:::: 1 Nm :::: 1.852 km VOLUME s Cubic Inches (inS) x 16.387:::: Cubic Centimeters x .061 =In Imperia! Pints (IMP pt) x .568 :::: Liters (L) x1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137:= Liters (L) x.
SUGGESTED SPARE PARTS ,MARINE ENGINES CONTACJ YOUR WESTERBEKE DEALER FOR,SUGGESTIONS ANDADDITlONAL INFORMATION GLOW PLUGS WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL (YOUR BRAND) fOR AN OIL CHANGE AND A GAUON Of PREMIXED COOLANT. FUEl LINE FILTERS (OWNER INSTALLED) SPARE PARTS KITS KIT B WESTERBEKE also offers two Spare Parts Kits, each packaged in a rugged hinged toolbox. Kit "A" includes the basic spares.
Engines & Generators 11 08WMDW1 0/06
