Westerbeke 108C SIX Installation Manual

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

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

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 but-tons, an JNS

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL Use fuel1hat meets 1he requirements or specification of Class 2-D (ASTM), and has a cetane rati

PREPARATIONS FOR INITIAL START-UP PRESTARTINSPECTION Before starting your engine for the first time or after a prolonged layoff, check the following i

STARTING -STOPPING PROCEDURE CHECKLIST Follow this check list each day before starting your engine. D Visually inspect the engine for fuel, oil, or wa

ENGINE BREAK-IN PROCEDURE DESCRIPTION Although your engine has experienced a minimum of one hour of test operations at the factory to make sure accura

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH The Captain Control Panel indicates alternator low disc

SCHEDULED MAINTENANCE Fuel Supply Fuel/Water Separator Engine Oil Level Coolant Level Drive Belts MAINTENANCE SCHEDULE A WARNING: Never attempt to per

SCHEDULED MAINTENANCE Raw Water Pump Coolant System Electric Fuel lift Pump Inlet Fuel Filter DC Alternator *Fuellniectors *Starter Motor *Preheat Cir

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

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 SEPARATO

COOLING SYSTEM FRESH WATER COOLING CIRCUIT NOTE: Refer to the ENGINE COOLANT page for the recommended antifreeze and water mixture to be used as the f

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

COOLING SYSTEM RAW WATER PUMP The raw water pump is a self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller has f

COOLING SYSTEM Zinc Anode A zinc anode, or pencil, is located in the raw water cooling .circuit within the heat exchanger. The purpose of having the z

ENGINE LUBRICATING OIL DESCRIPTION The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by

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

REMOTE OIL FILTER (OPTIONAL) JNSTALLATION !fhls popular accessory is used to relocate the engine's oil fil-ter from the engine to a more convenie

WATER HEATER CONNECTION KIT (71B & C, 82B FOUR, & 107 B & C) The models refered to in this manual are equipped with connections for the pl

The pressure cap on the engine's manifold should be installed once the engine's cooling system is filled with coolant. Finish filli

SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precau-tions.

WATER HEATER CONNECTIONS (71 C & 828 FOUR) FOR PRODUCTION MODELS FROM MARCH 2004 ON WESTERBEKE provides easy access for connecting to an on-board

WATER HEATER CONNECTION KIT (638 AND 63C ONLY) HOSE CONNECTION TO THE TANK Remove the hex head plug at the thermostat assembly and install the WATER H

I~ 1 1 $EE HOT[ 2, I .J I , , IIOTE: An on-off switch should be installed In this circuit to disconnect the starter from the battery in 811 emergenc

WIRING SCHEMATIC + 12 VDe SS~Rr S'tdHR 0 ~-------7;~~rl 171------~'H~ ~ I I ------------1-----. ~.. I, I Pft(ItUT ~_...,. ___ ---:r~-, S

GLOW PLUGS DESCRIPTION The glow plugs are wired through the preheat solenoid. When PREHEAT is pressed at the control panel this solenoid should "

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

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

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

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

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

ALTERNATORS TESTING/TROUBLESHOOTING SEE WIRING DIAGRAM FOR WIRE CONNECTIONS TO OPTIONAL ALTERNATORS 50AMP ALTERNATOR EXCITER TERMINAL l!. NOTE: FOR CO

ALTERNATORS TESTING/TROUBLESHOOTING PRELIMINARY INSPECTION Before starting the actual alternator and voltage regulator, testing the following checks a

ALTERNATORS TESTING/TROUBLESHOOTING BATTERY TESTING THE OUTPUT CIRCUIT ENGINE RUNNING TO STARTER SOLENOIO TESTING THE EXCITATION CIRCUIT '. 1. C

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

SERVICE SCHEDULE Servicing After Every 100 Hours of Operation 1. Change the engine's lubrication oil and oil filter. 2. Adjust the alternator and

SERVICE SCHEDULE This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/operator can petform wit

18 SERVICE SCHEDULE CYLINDER HEAD BOLT TORQUING Servicing After Every 1000 Hours of Operation 1. Remove, clean, and pressure test the primary heat e

SERVICE SCHEDULE CYLINDER HEAD BOLT TORQUING Tighten the cylinder head bolts to the specified torque before making valve adjustments. When No.1 cylind

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

SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sle

TACHOMETER TACHOMETER/HOUR METER The tachometerlhour meter used in propulsion engine instru-ment panels contains two separate electrical circuits with

OIL PRESSURE NOTE: WESTERBEKE recommends that the following engine adjustments he peifomled by a competent engine mechanic. The infomtation below is p

SPECIFICATIONS 638 AND 63C FOUR MARINE DIESEL ENGINES ENGINE SPECIFICATIONS Engine Type Governor Valve mechanism Combustion Ghamber Bore & Stroke

SPECIFICATIONS 71 BAND 71 C FOUR MARINE DIESEL ENGINES ENGINE SPECIFICATIONS Engine Type Govemor Valve mechanism Combustion Chamber Bore & Stroke

SPECIFICATIONS 828 FOUR MARINE DIESEL ENGINE ENGINE SPECIFICATIONS Engine Type Aspiration Combustion Chamber Bore & Stroke Piston Displacement Fir

SPECIFICATIONS 1088 AND 108C FOUR MARINE DIESEL ENGINES ENGINE SPECIFICATIONS Engine Type Governor Valve mechanism Combustion Chamber Bore & Strok

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

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

ZF TRANSMISSIONS SHIPMENT For safety reasons, the transmission is not filled with transmission fluid during shipment and the selector lever is tempora

ZF TRANSMISSIONS CHANGING THE TRANSMISSION FLUID 16MM.(8") SCREW O-RINGS ZF·45 FILTER Filter Element The ZF transmission has a filter element loc

INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following infom1ation: CODES AND R

IF TRANSMISSIONS CABLE CONNECTIONS The transmission is suitable for a single lever gear shift. Upon loosening the retaining screw, the actuating lever

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

TRANSMISSION TROUBLESHOOTING [ZF] CONTROL CABLES The majority of transmission difficulties arise as a result of improper clutch adjustments (manual tr

BORG WARNER VELVET DRIVE TRANSMISSION OPTIONAL TRANSMISSION SHIPMENT BORG WARNER VELVET nRIVE , TRANSlV!ISSION. For safety reasons, the transmission i

BORG WARNER VELVET DRIVE TRANSMISSION FORWARD NEUTRAl. REVERSE TRANSMISSION ACTUATING LEVER POSITIONS DAILY OPERATION o Check the transmission fluid.

BORG WARNER VELVET DRIVE TRANSMISSION MAINTENANCE Transmission maintenance is minimaL Keep the exterior housing clean, check the fluid level as part o

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 Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter permits its eas

TORQUE DATA Lb-ft km Cylinder head bolts ~ 63 (B)(C) Four, 108(B)(C) Six & 7lC Four 80-85 11.0-11.7 -7IB Four & 82B Four 85 -90 11.8 - 12.5 Co

DECIMAL TO METRIC EQUIVALENT CHART Fractions of Decimal (in.) Metric (mm) Fractions of Decimal (in.) Metric (mm) an inch an inch 1164 0.015625 to.39

TABLE OF CONTENTS Parts Identification ... 2 Remote Oil Filter (Optional) ... 21

STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 '" Millimeters (mm) x .0394;; Inches Feet (ft) x .305 ::: Meters (m)

SUGGESTED SPARE PARTS ,MARINE ENGINES CONTACJ YOUR WESTERBEKE DEALER FOR,SUGGESTIONS ANDADDITlONAL INFORMATION GLOW PLUGS WESTERBEKE RECOMMENDS CARRYI

Engines & Generators 11 08WMDW1 0/06

PARTS IDENTIFICATION ASSEMBLY DC CHARGING ALTERNATOR COOlANT PRESSURE CAP WMERHtAltK·-------~ CONNECTION DRIVE BELT RAWWATERP~ CRANKSHAFT PULLEY OIL D

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