Installation manual
FUEL
SYSTEM
FUEL
LINES
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.
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
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
# 1 0
micron
rating.
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'ยท1j:~l
\f
I
'\
.
FUEL
Fll
TERI
WATER
SEPARATOR
(owner
installed)
FUEL
INJECTION
PUMP
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
injec-
tion
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.
FUEL
INJECTOR
For
information
about
removing
and
checking
the
fuel
injector,
see
TESTING
THE
FUEL
INJECTOR
under
ENGINE
ADJUST-
MENTS.
In
case
of
severe
vibrations
and
detonation
noise,
have
the
injec-
tors
checked
and
overhauled
by
an
authorized
fuel
injection
ser-
vice
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
environ-
ment,
it
is
best
to
carry
at
least
one
extra
injector
as
a
spare
should
a
problem
occur.
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.
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.
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.
Engines & Generators
26