Westerbeke 65B-FOUR Installation Manual

OPERATORS MANUAL MARINE DIESEL ENGINES . ~ . - . . . . 65A·FOUR., AND 658 ·FOUR -·• -PUBLICATION N0.054218 REVISION 3 OCTOBER 2014 WESTERS EKE WES

INTRODUCTION SERIAL NUMBER LOCATION The engine's model number and serial number are located on the nameplate mounted on the side of the engine&ap

ADMIRAL CONTROL PANEL DESCRIPTION This manually-operated control panel is equipped with a KEY switch and RPM gauge with an ELAPSED TIME meter which me

CAPTAIN CONTROL PANEL DESCRIPTION This manually-operated control panel is equipped with a KEY switch, an RPM gauge, PREHEAT and START bul-tons, an INS

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL Use a diesel fuel that meets the requirements of No. ~-D SAE J 313 and has a Cetane rating of

PREPARATIONS FOR INITIAL START·UP PRESTART INSPECTION Before starting your engine for the first time or after a prolonged layoff, check the following

STARTING/STOPPING PROCEDURE CHECK LIST Follow this check list each day before starting your engine. lJ Visually inspect the engine for fuel, oil, or w

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER ALTERNATOR WARNINGS The Captain Control Panel indicates alternator low discharge with a red warning light

.•MAINTENANCE.-SCHEDULE A wARNING:· Nererattempt to.pertorm-sny:SIIrrlc~-Whl/1-the englne·ls runnlng •.• Weaithepropersafety,equlpment 5uchtiS goggles

MAINTENANCE SCHEDULE NOTE: Use the engine hourmeter gauge to log your engine hours or record your engune hours running time. SCHEDULED MAINTENANCE I E

COOLING SYSTEM DESCRIPTION Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the ·engine by com-bu

A wARNING Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.

COOLING SYSTEM THERMOSTAT A thermostat, located near the manifold at the front of the engine, controls the coolant temperature as the coolant continuo

COOLING SYSTEM FRESH WATER COOLING CIRCUIT NOTE: Refer to the ENGINE COOLANT section for the rec-ommended antifreeze and water mixture to be used as t

COOLING SYSTEM \ RAW WATER COOLING CIRCUIT The raw water flow is created by a positive displacement impeller pump. This pump draws water directly from

I ! WATER HEATER WATER HEATER INSTALLATIONS These engines are equipped with connections for the plumbing of engine coolant to transfer heat to an on-b

FUEL SYSTEM DIESEL FUEL Use No.2-D (SAE J313) diesel fuel with a Cetane rating of #45 or higher. Grade of diesel fuel according to ASTM D975. In conju

ENGINE LUBRICATING OIL ENGINE OIL CHANGE 1. Draining the oil sump. Discharge the used oil through the sump drain hose (attached to the front of the en

REMOTE OIL FILTER (OPTIONAL) PN. 054372 INSTALLATION This popular accessory is used to relocate the engine's oil filter from the engine to a more

~-----1 SE£ NOTE 2 i~l I I I I _j I I I +ill ~~ lill.Iill NO'IE: ~ Use di-electric grease on the wiring connections when mating the instrument p

WIRING SCHEMATIC 12 voc START SOL STARTER ._---------7'-;-ri-~:--------~~>4CB)r-------·---------. I I I ~''J---PREH-EAT ------. ._-

ENGINE ADJUSTMENTS REMOVING THE INJECTORS NOTE: Injector must be senJiced in a "clean room" environment. 1: Disconnect the high pressure lin

SAFETY.INSTRUCTI'ONS: ·. INTRODUCTION Read this &afety manual carefully. Most accidents ate caused by failure to foUow fundamentalnde& an

ENGINE ADJUSTMENTS GLOW PLUGS A WARNING: These glow plugs will become very hot ·to the touch. Be careful not to burn your fingers when testing plugs.

ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust-ments be performed by a competent engine mechanic. The information be

ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust-ments be performed by a competent engine mechanic. The information bel

TACHOMETER TACHOMETER/HOUR METER The tachometer/hour meter used in propulsion engine instrument panels contains two separate electrical circuits with

ENGINE TROUBLESHOOTING The following troubleshooting table describes certain problems relating to engine service, the probable causes of these prob-le

ENGINE TROUBLESHOOTING Problem Probable Cause Verification/Remedy Engine slows and stops. 1. Fuel lift pump failure. 1. Fuel lift pump should make a d

ALTERNATORS TESTING/TROUBLESHOOTING SEE WIRING DIAGRAM FOR WIRE CONNECTIONS TO OPTIONAL ALTERNATORS 50 AMP ALTERNATOR NOTE: FOR CORRECT WIRING HARNESS

ALTERNATORS TESTING/TROUBLESHOOTING PRELIMINARY INSPECTION Before staJ.1ing the actual alternator and voltage regulator, testing the following checks

ALTERNATORS TESTING/TROUBLESHOOTING BAITERY TESTING THE OUTPUT CIRCUIT ENGINE RUNNING TO STARTER SOLENOID TESTING THE EXCITATION CIRCUIT 1. Connect t

DUAL OUTPUT ALTERNATORS DESCRIPTION Dual output and high output alternators are available as optional equipment on most WES1ERBEKE engines. These alte

SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury or death! • Disconnect the battery cables before servicing th

DUAL OUTPUT ALTERNATORS TROUBLESHOOTING NOTE: Before troubleshooting, make certain that the drive belts are tight and the batteries are in good condi

HIGH OUTPUT ALTERNATORS DESCRIPTION Dual output and high output alternators are available as optional equipment on most WESTERBEKE engines. These alte

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 se

STARTER MOTOR A WARNING: When performing these procedures, position yourself safely away from the moving parts of the engine in case the engine starts

ZF MARINE TRANSMISSIONS DESCRIPTION The information below is specific to the ZF Transmissions, the TRANSMISSION TROUBLESHOOTING SECfiON applies to all

ZF MARINE TRANSMISSIONS INITIAL OPERATION All ZF marine transmissions are test-run on a test stand with the ·engine at the factory prior to delivery.

ZF MARINE TRANSMISSIONS OPERATING TEMPERATURE A CAUTION: If the transmission fluid temperature is too high, stop the engine immediately and check the

SHIPMENT ZF TRANSMISSIONS (HSW MODELS) INITIAL OPERATION For safety reasons, the transmission is not filled with transmission fluid during shipment an

ZF TRANSMISSIONS (HSW MODELS) CHANGING THE TRANSMISSION FLUID DIPSTICK 16MM (8") SCREW Filter Element PN# 049737 FILTER ASSEMBLY HSW The ZF trans

TRANSMISSIONS CABLE CONNECTIONS (HSW MODELS) The transmission is suitable for a single lever gear shift. Upon loosening the retaining screw, the actua

SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces

TRANSMISSION TROUBLESHOOTING (ZF MODELS) CONTROL CABLES The majority of transmission difficulties arise as a result of improper clutch adjustments (ma

TRANSMISSION TROUBLESHOOTING (ZF MODELS) Problem Chattering transmission noise, mainly at low engine speed. Transmission shifts into gear, but fails t

VELVET DRIVE TRANSMISSIONS OPTIONAL TRANSMISSION SHIPMENT BORG WARNER VELVET DRIVE . TRANSMISSION For safety reasons, the transmission is not filled w

VELVET DRIVE TRANSMISSIONS n n FORWARD NEUTRAL REVERSE TRANSMISSION ACTUATING LEVER POSITIONS DAILY OPERATION 0 Check the transmission fluid. 0 Visua

VELVET DRIVE TRANSMISSION Lay-up/Winterize Storage requires special care. Follow these procedures: 0 Drain the water from the transmission cooler and

65A·FOUR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type Aspiration Compression Ratio Governor Combustion Chamber Bore & Stroke Piston Displaceme

&58-FOUR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type Aspiration Compression Ratio Governor Combustion Chamber Bore & Stroke Piston Displa

LAY-UP & RECOMMISSIONING GENERAL Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during t

LAY-UP & RECOMMISSIONING Starter Motor Lubncation and cleanmg ot the starter dnve pm10n ts advis-able, if access to the starter pennits its easy

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 = Fee

INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: · CODES AND

DECIMAL TO METRIC EQUIVALENT CHART Fractions of Decimal (in.) Metric (mm) Fractions of Decimal (in.) Metric (mm) an inch an inch 1/64 0.015625 0.3

SUGGESTED SPARE PARTS Carry Only Genuine Westerbeke Spare Parts CONTACT YOUR WESTERBEKE DEALER FOR ADDITIONAL SUGGESTIONS AND INFORMATION FUEUWATER .·

Engines & Generators 1198 -11 /2014

TABLE OF CONTENTS Parts Identification (Illustrations) ... .2 Tachometer ...

AIR PLENUM PRE-HEAT SOLENOID ELECTRIC FUEL SHUT-0 INJECTION RIGHT SIDE THERMOSTAT HOUSING COVER COOLANT PRESSURE CAP HEAT EXCHANGER , LEFT SIDE OIL DI

INTRODUCTION This WESTERBEKE Engine is a product of WESTERBEKE'S long years of experience and advanced technology. We take great pride in the sup