Westerbeke 55A FOUR Operator's Manual

OPERATORS

MANUAL

WESTERBEKE

MARINE

DIESEL

55A

PUBLICATION 041562

2nd Edition

ENGINE

FOUR

I February 1997

l~

----

'WESTERBEKE

WESTERBEKE CORPORATION

~

MYLES STANDISH INDUSTRIAL

WEBSITE:

AlMMA

""'''''''''''-

www.WESTERBEKE.COM

Member

National

Marine

·150

JOHN

PARK·

Manufacturers

HANCOCK ROAD

TAUNTON, MA 02780

Association

CALIFORNIA

Proposition

65

Warning

Diesel engine exhaust and some of

its

constituents are known

the State

of

California

to

cause cancer, birth defects, and other reproductive harm.

I~I

I

WESJ"ERBEKE

Engines & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual carefully. Most accidents are caused by

failure Know when dangerous conditions exist necessary precautions to protect yourself, and

The foUowing safety instructions are the American

PREVENT

A

while

power.

• Do not operate this machinery without electrical

• Shut off electrical power before accessing electrical

• Use insulated mats whenever working on electrical

• Make sure your clothing and skin are dry, not damp

• Remove wristwatch and all jewelry when working on

• Do not connect utility shore power to vessel's

• Electrical shock results from handling a charged capacitor.

PREVENT

A

exhaust very

• Always check the engine coolant level at the coolant

A

• In case

to

foUow fundamental rules

your

machinery.

Boat

and

Yacht Council (ABYC) standards.

ELECTRIC

WARNING:

engine

is

Lethal

voltage

enclosures and covers in place.

equipment.

(particularly shoes) when handling electrical equipment.

electrical equipment.

circuits, except through a ship-to-shore double throw

transfer switch. Damage to vessel's result

if

this procedure is not followed.

Discharge capacitor by shorting terminals together.

BURNS -HOT

WARNING:

system

SHOCK

Do

not

touch

running,

or

is

present

when

ENGINE

Do

not

touch

components. A running

and

in

AC

electrical

connected

at

these

AC

hot

engine

precautions.

and

take the

your

personne~

compliance with

connections to

shore

connections!

AC

generator may

parts

or

engine

gets

hot!

recovery tank.

WARNING:

of

before touching the engine or checking the coolant.

Steam

can

cause

injury

or

death!

an engine overheat, allow the engine to cool

PREVENT

A

• Prevent flash fires. Do not smoke sparks to occur near the carburetor, fuel line, filter, fuel pump, vapors. removing the fuel line, carburetor,

• Do not operate with a Coast Guard Approved flame arrester removed. Backfire can cause severe injury death.

• Do not operate with the air cleaner/silencer removed. Backfire can cause severe injury

• Do not smoke fuel system. Keep the compartment and the engine/gener-

ator clean and free fire. Wipe up all spilled fuel and engine oil.

• Be aware - diesel fuel will bum.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling.

after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before start-

ing your engine.

• All fuel vapors are highly explosive. Use extreme care when handling and storing fuels.

area away from spark-producing equipment and out

reach

• 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. sources Ensure proper ventilation exists when servicing the fuel system.

• Do not alter

• Be sure all fuel supplies have a positive shutoff valve.

• Be certain fuel line fittings are adequately tightened and free

• Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its proper use. Extinguishers rated for all applications encountered in this environment.

BURNS -FIRE

WARNING:

or

Use a suitable container to catch all fuel when

Fire

can

cause

other potential sources

or

permit flames

of

debris to minimize the chances

injury or

or

of

or

death!

permit flames

spilled fuel

or

fuel filters.

death.

sparks to occur near the

BURNS -EXPLOSION

WARNING:

or

death!

of

children.

DO

of

leaks.

Explosions

NOT

allow any smoking, open flames,

fire near the fuel system or engine when servicing.

or

modify the fuel system.

ABC

from

fuel

vapors

Open and ventilate cabin

Store fuel in a well-ventilated

by the NFPA are appropriate

or

can

or

fuel

or

of

cause

of

or

other

the

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect

it

last.

• Make certain all personnel are clear starting.

• Make certain all covers, guards, and hatches are re-

installed before starting the engine.

BATTERY

A

WARNING:

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

tive

(+) connection terminal

test the battery condition by shorting the terminals together. Sparks could ignite battery gases Ventilate any compartment containing batteries to prevent accumulation disturb the battery charger connections while the battery being charged.

• Avoid contacting the terminals with tools, etc., to prevent

bums or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery.

• Always tum the battery charger

the battery connections. Remove the negative lead first and reconnect

BATTERY

A

WARNING:

severe

STARTING

Accidental

EXPLOSION

Battery

of

explosive gases. To avoid sparks, do not

it

last when servicing the battery.

ACID

Sulphuric

injury

or

death!

starting

explosion

(-)

of

acid

can

cause

of

the engine before

can

cause

battery cable to the posithe starter solenoid. Do not

or

off

before disconnecting

in

batteries

injury

fuel vapors.

can

cause

TOXIC

• Ensure that the exhaust system

• Be sure the unit and its surroundings are well ventilated.

• In addition to routine inspection

• For additional information refer to ABYC T-22 (educa-

• Do not use copper tubing in diesel exhaust systems. Diesel

• Do not install exhaust outlet where exhaust can be drawn

is

• Although diesel engine exhaust gases are not as toxic as

AVOID

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. attention to the manifold, water injection elbow, and exhaust pipe nipple. .

install a carbon monoxide detector. Consult your boat

or

builder

tional information on Carbon Monoxide).

A

WARNING:

odorless

nausea

gas.

or

death!

fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration tubing resulting in exhaust/water leakage.

through portholes, vents, exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close or restrict the

of

flow

exhaust fumes from gasoline engines, carbon monoxide gas is present toms or signs are:

exhaust. Avoid overloading the craft.

Vomiting Dizziness

Throbbing

Muscular twitching Intense headache Weakness and sleepiness

MOVING

GASES

Carbon

dealer for installation

Carbon

Inhalation

in

diesel exhaust fumes. Some

of

carbon monoxide inhalation

in

produces

temples

monoxide

or

air conditioners. If the engine

PARTS

(CO)

is a deadly

is

adequate to expel gases

Pay close

of

the exhaust system,

of

approved detectors.

(CO)

is

an

invisible

flu-like

symptoms,

of

copper

of

the symp-

or

poisoning

gas!

• 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. it comes in contact with your skin, wash it off at once with water. Acid may splash on the skin inadvertently when removing electrolyte caps.

or

into the eyes

A

WARNING:

If

Engines & Generators

or

death!

• Do not service the engine/generator while situation arises

ii

Rotating

in

which it is absolutely necessary to make

parts

can

cause

it

injury

is running.

If

a

SAFETY

INSTRUCTIONS

operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components.

• Do not wear loose clothing equipment; avoid wearing loose jackets, shirts, sleeves,

or

rings, necklaces 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/generator is operating.

• Stay clear when the engine is running; hair and clothing can easily be caught in these rotating parts.

of

HAZARDOUS

A

WARNING:

bracelets that could be caught

the drive shaft and the transmission coupling

NOISE

High

or

jewelry when servicing

noise

levels

can

cause

in

hearing

loss!

• Never operate a generator without its muffler installed.

• Do not run an engine with the air intake (silencer) removed.

• Do not run engines their enclosures open.

or

generators for long periods with

ABYC, INSTALLING

NFPA

AND

GASOLINE

USCG

PUBLICATIONS

AND

DIESEL

FOR

ENGINES

AND

GENERATORS

Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their recommendations when installing your WESTERBEKE engine/generator.

ABYC "Safety Standards for Small Craft"

Order

(American Boat and Yacht Council)

From: ABYC 15 East 26th New York, NY 10010

NFPA

(National Fire Protection Association)

"Fire Protection Standard for Motor Craft" Order

From: NFPA

1 Batterymarch Park P.O. Box 9101 Quincy,

USCG

(United States Coast Guard)

"USCG 33CFR183"

From:

Order

U.S. Government Printing Office

Washington, D.C. 20404

~treet

MA

02269-9101

A

WARNING:

are

mentally

OPERATORS

Many

of

the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

GASOLINE

00

or

physically

MANUAL

ENGINE

AND

not

work

on

machinery

incapaCitated

GENERATOR

by

fatigue!

when

you

INSTALLATIONS

Preparations to install a gasoline engine or generator should begin with a thorough examination Yacht Council's (ABYC) standards. These standards are from a combination

Sections H-2 Ventilation

H-24 Gasoline fuel systems P-l

Exhaust systems P-4 Inboard engines E-9

DC

All installations must comply with the Federal Code Regulations (FCR).

of

sources including the USCG and the NFPA.

of

the ABYC standards

Electrical systems

of

the American Boat and

of

particular interest are:

of

Engines & Generators

iii

INSTALLATION

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

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow or below the vessel's waterline, provisions must be made to install a siphon-break the raw water supply hose to the exhaust elbow. This hose must be looped a minimum of

18"

above the vessel's waterline. Failure to use a siphon-break when the exhaust

manifold injection port is damage to the engine

EXHAUST

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 vessels hull.

SYSTEM

A

detailed diesel, dealer.

40

engines

at

or below the load waterline will result in raw water

and

possible flooding

page

Marine

and

generators,

Installation

of

is

available

the boat.

Manual

from

covering

your

WESTERBEKE

gasoline

is

close to

and

in

Engines & Generators

iv

TABLE

OF

CONTENTS

Introduction Warranty

Product Software ................................................... 2 Fuel Filters ........................................................... 16

Notes, Cautions and Wamings .............................. 2 Fuel Water Separator ........................................... 16

Serial Number Location ........................................ 3 Fuel Injection Pump Control ............................... 16

Understanding the Diesel Engine .......................... 3 Priming (Bleeding) the Fuel

Ordering Parts ........................................................ 3 Air Cleaner ..........................................................

Control

Admirals Panel ...................................................... 4 Charging Voltage .................................................

Captains Panel ....................................................... 5 Alternator Drive Belt Adjustment .......................

Diesel Fuel,

Diesel FueL ............................................................ 6 DC Wiring Diagrams ........................................... 20

Engine

Engine Coolant ...................................................... 6

Preparations

Prestart Inspection ................................................. 7 Adjusting Valve Clearances ................................ 23

Starting/Stopping Break-In The

Daily

Check List. ...........................................................

Start Your Engine ................................................

Maintenance Engine

Changing the Coolant ..........................................

Thermostat ...........................................................

Raw

Water

Raw Water Cooling Circuit.. ............................... 14

Raw Water Pump ................................................. 1 4

Zinc Anode ........................................................... 14

Raw Water Pump Belt Adjustment ..................... 14

.............................................................. 2

Procedures

Panels

Coolant

.......................................................... 4

Engine

Oil .............................................................. 6

For

Procedure

Routine

Schedule ...........................................

System .................................................

.............................................. 2

Oil

and

Engine

Initial

Start-Up

Procedure

................................................. 9 Compression Test ................................................ 26

..........................................

.......................................................

Coolant.. ........ 6 Battery Care .........................................................

........................... 7

.................................. 8 Timing Belt Inspection and Replacement... ......... 24

'"

Engine Fuel

DC

Water

Engine

..... 10 Fuel Injection Nozzle Test... ................................ 26

10 10 11 13 13 13 14

HBW Borg Engine

Lay-up WESTERBEKE Standard WESTERBEKE WESTERBEKE

Oil

Change

System ............................................................. 16

Electrical System .............................................

Heater

Water Heater Installations ................................... 22

Adjustments

Transmission

Warner

Troubleshooting .........................................

Troubleshooting Water Temperature and

Oil Pressure Gauges ............................................ 32

and

Recommissioning ............................... 33

Hardware

.................................................

System ....................

.......................................................... 22

.............. , ................................ 23

................................................ 27

Velvet Drive

55A

55A 55A

Transmission

Torque

Torques

FOUR FOUR

............ 29

Specifications ........ 35

................................ 36

Specifications ......... 37

Parts

Identification38

15

17 17 18 18 19 19

31

WESTERBEKE

WESTERBEKE CORPORATION' AVON INDUSTRIAL PARK

AVON, MA

02322'

TEL: (508)'588-7700·' FAX: (508) 559-9323

1

INTRODUCTION

This WESTERBEKE Marine Diesel Engine is a product of

WESTERBEKE' S long years vanced technology. We take great pride in the superior durability and dependable performance

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 all the

safety precautions throughout. quire servicing, contact your nearest WESTERBEKE dealer for assistance.

This is your operators manual. A

also provided and a Technical Manual is available from

your WESTERBEKE dealer. Also,

to

install this equipment, contact your WESTERBEKE

dealer for

WARRANTY

Your WESTERBEKE Warranty is included in a

separate folder.

identification card registering your warranty

submitting the warranty registration form, please contact

the factory in writing with model information, including

the unit's serial number and commission date.

WESTERBEKE'S installation manual.

PROCEDURES

If

you have not received a customer

of

experience and ad-

of

our engines

Should your engine re-

Parts Catalog is

if

you are planning

60 days after

PRODUCT

Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE are not within CONTROL.

WESTERBEKE THE CONTENT WARRANTIES OR REPRESENTATIONS WITH RESPECT TIMELINESS WILL

IN DAMAGE WITH

USE

OF

WESTERBEKE customers should also keep in mind the time span between printings product software and the unavoidable existence WESTERBEKE manuals. In summation, product software provided with WESTERBEKE products, whether from WESTERBEKE or other suppliers, must not and cannot be relied upon exclusively authority on the respective product. good sense but is imperative that appropriate representatives of WESTERBEKE or the supplier in question be consulted to determine the accuracy and currentness the product software being consulted by the customer.

SOFTWARE

WESTERBEKE'S

CANNOT

OF

THERETO, INCLUDING ACCURACY,

OR COMPLETENESS THEREOF

NO

EVENT

OR

INJURY

OR ARISING

SUCH SOFTWARE.

BE

SUCH

OUT

SOFTWARE,

BE

LIABLE FOR

INCURRED

OF

RESPONSIBLE FOR

ANY

IN

CONNECTION

THE FURNISHING OR

of

WESTERBEKE

as

the definitive

It

not only makes

MAKES

TYPE

of

NO

AND

OF

earlier

of

TYPICAL

Customer Identification

WESTERBEKE OWNER MAIN

STREET

HOMETOWN, USA

Model 55A Four Ser. #U53890-48

Expires

CUSTOMER

WESTERBEKE AVON,

7/20/97

MA

02322·

IDENTIFICATION

CORPORATION·

TEL:

(508)

AVON

558·7700·

INDUSTRIAL

FAX:

CARD

(508)

559-9323

PARK

NOTES,

As this manual takes you through the operating procedures, maintenance schedules, and troubleshooting your marine engine, critical information will be highlighted by explanation follows:

NOTE:

A

observed,

your

A

followed,

CAUTIONS

NOTES, CAUTIONS, and WARNINGS. An

An

operating procedure essential to note.

CAUTION:

Procedures,

can

result

AND

in

the

WARNINGS

which

if

not

strictly

damage

or

destruction

engine.

WARNING:

Procedures,

can

result in

which

personal

if

injury

not

or

properly

loss

of

life.

of

I"VVI

I

WESTERBEKE

Engines & Generators

2

INTRODUCTION

(Continued)

SERIAL

An identification nameplate that displays the engine model number and engine serial number is mounted the side this information on the blank decal provided below. This will provide a quick reference when seeking technical information and/or ordering parts.

UNDERSTANDING

The diesel engine closely resembles the gasoline engine, since the mechanism is essentially the same. The cylinders are arranged above a closed crankcase; the crankshaft is gasoline engine, and the diesel engine has the same types lubricating system.

To a great extent, a diesel engine requires the same preventive maintenance as a gasoline engine. Most important are proper ventilation and proper maintenance of

the fuel, lubricating and cooling systems. Replacement

of

fuel and lubricating filter elements at the time periods specified and frequent checking for contamination (water, sediment, etc.) in the fuel system are essential. Also important is the consistant use detergent diesel lubrication oil designed specifically for diesel engines.

The diesel engine does differ from the gasoline engine, however, in its method carburetor and ignition systems are done away with and in their place is a single component - the fuel injection pump - which performs the function

NUMBER

of

the engine manifold. Take the time to enter

of

valves, camshaft, pistons, connecting rods and

LOCATION

THE

DIESEL

of

the same general type as that

of

handling and firing

ENGINE

of

a brand

of

on

of

a

high

fuel. The

both.

ORDERING

Whenever replacement parts are needed, always pro-

vide the engine model number and engine serial number as they appear on the silver and black identification nameplate located with this information so we can identify your engine. In addition, include a complete part description and part number for each part needed (see the separately furnished

Parts Catalog). Also insist upon WESTERBEKE pack-

aged parts because will not made to the same specifications as original equipment.

NOTE:

Component locations in this manual are refer-

enced from the front

drive belt end. Left and right sides are determined as

follows: imagine straddling the engine, facing in the

same direction as the front is at your left, the right side is

PROTECTING

Care at the factory during assembly and thorough testing have resulted in a WESTERBEKE diesel engine capable of

many thousands ever the manufacturer cannot control how 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:

o Proper engine installation o

An cludes an anti-siphon break to prevent water from

entering the engine.

o Changing the engine oil

erating hours.

o Proper maintenance

according to the maintenance schedule in this manual.

PARTS

on

the manifold. You must provide us

fit

or

generic parts are frequently

of

the engine which is the pulley/

of

the engine: the left side

at

your right.

YOUR

efficient well-designed exhaust system that in-

INVESTMENT

of

hours

of

dependable service. How-

and

of

all engine components

or

where the

alignment.

oil filters every 200 op-

I~I

I

o

Use

clean, filtered diesel fueL

o Winterize

Recommissioning" section in this manual.

WSJERBEKE

Engines

& Generators

3

your

engine according to the "Lay-up

and

CONTROL

PANELS

WESTERBEKE offers two optional

the instruction page that applies to the panel you

panels-

select

pur-

chased.

ADMIRALS

This manually-operated control panel is equipped with a KEY

SWITCH and

TIME

meter which measures the

in

hours and in

WATER temperature in degrees Fahrenheit, an OIL gauge which measures the engine's oil pressure in pounds per square inch, and a AGE

gauge which measures the system's voltage. All gauges are illuminated when the key switch is turned and remain illuminated while the engine is in operation. The

panel also contains two rubber-booted push buttons,

one for

PREHEAT

PANEL

RPM

gauge with an ELAPSED

1110

hours. The panel also includes a

TEMPERATURE

and one for START.

WATER GRADUATED ILLUMINATED TURNED TEMPERATURE

engine's

running time

gauge which indicates water

PRESSURE

DC

control circuit VOLT-

ON

TEMPERATURE

IN

ON.

THE

DEGREES

WHILE

THE

ENGINE'S

IS

170°·190°

GAUGE:

THIS FAHRENHEIT KEY

SWITCH

NORMAL

F

GAUGE

AND

IS

OPERATING

You will notice that 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 also hold its reading. The temperature gauge will once again register the engine's

true temperature when electrical power is restored

to the gauge A separate alarm buzzer with harness is supplied with

every Admiral

Panel.

The

installer is responsible for electrically connecting the buzzer to the four-pin connection on the

engine's

electrical harness.

The

installer is also responsible for installing the buzzer in a location where it will be dry and where it will be audible to the operator should it sound while the engine is running.

The

buzzer will sound when the ignition key is turned

ON

and should silence when the engine has started and

the

IS

engine's

IS

oil pressure rises above

OIL

PRESSURE

ATED

ILLUMINATED

TURNED

OIL

PRESSURE

IN

POUNDS

ON.

GAUGE:

WHILE

THE

RANGES

15

psi.

THIS

PER

SQUARE

THE

KEY

ENGINE'S

BETWEEN

GAUGE

SWITCH

NORMAL

IS

INCH

(PSI) OPERATING

30-60

GRADU-

AND

IS

PSI.

IS

RPM

GAUGE: TERS PER ENGINE RECALIBRATED ACCURACY THE PANEL.

HOUR TERS AND AS A GUIDE MAINTENANCE SCHEDULE.

PREHEAT

THE

PUMP, PUMP, PASSES

SURE

BUTTON

START

THE

ENGINE. ELECTRICALLY IS

PRESSED

REGIS-

REVOLUTIONS

MINUTE

OF

THE

AND

CAN

FOR

FROM

REAR

OF

THE

METER:

REGIS-

ELAPSED

BE

FOR

BUTTON:

THE

FUEL

AND

THE

ENGINE'S

ALARM

SWITCH.

ENERGIZES

BUTTON:

THIS

BUTTON

AND

TIME,

SOLENOID

UNLESS

SHOULD

ALTERNATOR'S

STARTER'S

BE

USED

THE

WHEN

PRESSED,

EXCITER,

SOLENOID

ENGINE'S

PROTECTIVE

IN

THE

START

WHEN

PRESSED, WILL

THE

HELD

AT

ENERGIZES

THE

FUEL

ON

THE

INJECTION

GLOW

PLUGS.

OIL

ADDITION,

BUTTON.

ENERGIZES

WHICH

CRANKS

NOT

OPERATE

PREHEAT

THE

SAME

LIFT

IT

BY-

PRES-

THIS

THE

BUTTON

TIME.

/

AUTOMATIC

/

HIGH

WATER

BEEN

SUPPLIED

FRESH

WATER

WILL

CLOSE

TINUOUS

LOW

OIL SWITCH SWITCH ENGINE'S CLOSE

SOUNDING

EMIT A PULSATING

ALARM

TEMPERATURE

WITH

COOLANT

SOUNDING

SIGNAL.

PRESSURE

IS

LOCATED

MONITORS

OIL

PRESSURE

THE

SIGNAL.

SYSTEM

ALARM:

THE

INSTRUMENT

REACHES

THE

ALARM

ALARM: A LOW

OFF

THE

ENGINE'S

THE

ENGINE'S

FALL

TO 5 -10

ALARM.

IN

AN

ALARM PANEL.

210° F (98°C),

WHICH

WILL

OIL

PRESSURE

OIL

GALLERY.

OIL

PRESSURE.

PSI,

THIS

THE

EVENT,

KEY POWER INSTRUMENT CLUSTER. SWITCH ENGINE THE

DC INDICATES THE CHARGED. SHOW

BUZZER

IF

THE

THIS

SWITCH

EMIT A CON-

ALARM

THIS

SHOULD

SWITCH

THE

ALARM

SWITCH:

PROVIDES

ONLY

TO PANEL

THE

KEY

SHUTS

THE

DOWN

WHEN

KEY

IS

TURNED

VOLTMETER:

THE

13V

THE

WILL

AMOUNT

IS

SHOULD

TO

14V.

BATTERY

HAS

ENGINE'S

THE

OFF.

BEING

l-vvl

WESJERBEKE

I

Engines & Generators

4

CONTROL

PANELS

(Continued)

CAPTAINS

PANEL

This manually-operated control panel is equipped with a KEY SWITCH; an RPM gauge;

PREHEAT and START buttons; an INSTRUMENT TEST button; three indicator lamps, one for one for low OIL

RPM

GAUGE:

OF FOR

PANEL.

REGISTERS

THE

ACCURACY

'MINUTE

BRATED THE

PRESSURE, and one for high ENGINE

ENGINE

AND

FROM

ALTERNATOR DISCHARGE,

REVOLUTIONS

CAN

THE

BE

RECALI-

REAR

PER

OF

COOLANT TEMPERATURE; and an alarm buzzer for low OIL

PRESSURE or high WATER TEMPERA-

TURE. The RPM gauge is illuminated when the key

switch is turned

ON and remains illuminated while the

engine is in operation.

ALARM:

THE

ALARM

WILL

SOUND

IF

THE

ENGINE'S

OIL

FALLS

BELOW

IN

THIS

THE

THIS

SOUNDING

OIL

15

SIGNAL.

IN

EVENT,

ALARM

PRESSURE

PULSATING

TEMPERATURE 205°F.

NOTE: ON. ENGINE'S

PSI.

IN

THIS

THE

ALARM

THE

FRESHWATER

THE

ALARM

WILL

SOUND

IS

NORMAL.

REACHES

EVENT,

THE

ALARM

WILL

ALSO

COOLING

WILL

EMIT A CONTINUOUS

WHEN

THE

ONCE

THE

15

PSI,

KEY

ENGINE

THE

WILL

SOUND

CIRCUIT

SWITCH

ALARM

/

PRESSURE

EMIT

A

IF

THE

WATER

RISES

TO SIGNAL.

IS

TURNED

STARTS

AND

WILL

SILENCE.

TEST

BUTTON:

PRESSED,

ALTERNATOR, WATER WHEN

ALTERNATOR, WATER

TO ALARM

TESTS

PRESSURE,

TEMPERATURE

CONTROL

CIRCUITS.

PRESSED,

PRESSURE,

TEMPERATURE INDICATOR LUMINATE

SOUNDING

BUZZER.

THE

WHEN

THE

AND

THE

AND

THE

LIGHTS

IN

ADDITION

THE

OIL

IL-

START

BUTTON:

THE

STARTER'S ENGINE. UNLESS HELD

AT

IT

WILL

THE

PREHEAT

THE

WHEN SOLENOID

NOT

SAME

TIME,

PRESSED,

WHICH

OPERATE

BUTTON

,....,.,

ENERGIZES

CRANKS

ELECTRICALLY

IS

THE

PRESSED

AND

WESJERBEKE

I

Engines & Generators

PREHEAT

BUTTON:

THE

ALTERNATOR'S

PUMP,

THE

AND

THE

IN

START

FUEL

ADDITION, BUTTON.

PUMP, PASSES SWITCH, THE

WHEN

REGULATOR,

SOLENOID

THE

ENGINE'S

PRESSED,

ON

GLOW

OIL

PRESSURE

THIS

BUTTON

KEY POWER STRUMENT

,

THE ENGINE KEY

ENERGIZES

THE

FUEL

THE

INJECTION

PLUGS.

ALARM

ENERGIZES

SWITCH:

ONLY

PANEL

KEY

SWITCH

DOWN

IS

TURNED

LIFT

IT

BY-

PROVIDES TO

THE

IN-

CLUSTER.

SHUTS

WHEN

THE

OFF,

THE

5

DIESEL

FUEL,

ENGINE

OIL

AND

DIESEL

Use fuel that meets the requirements of

Class 2-D (ASTM), and has a cetane rating

or

better. .

Care

Use only clean diesel fuel! The clearance

nents in your fuel injection pump is very critical; invisible dirt particles which might pass through the filter can damage these finely finished parts. clean fuel, and keep it clean. The best fuel can dered unsatisfactory by careless handling storage facilities. tank for your engine's daily use is clean and pure, the following practice is advisable:

Purchase a well-known brand Install and regularly service a good, visual-type filterl

water separator between the fuel tank and the engine. Raycor 500 a filter.

ENGINE

Use a heavy duty engine oil with an API classification CF or CG4 or better. Change the engine oil after an initial 50 hours of

operation thereafter. For recommended oil viscosity,

see the following chart:

Of

The

FUEL

Fuel

FG

or

OIL

of

or

Supply

It

is important to buy

To

assure that the fuel going into the

of

fuel.

900 FG is a good example

break-in operation, and every 200 hours

ENGINE

specification

of

#45

of

the compo-

be

ren-

or

improper

of

such

COOLANT

ENGINE

The use mended for year-round use. Use antifreeze that is compatible with aluminium components, and never mix different brands this can nents.

NOTE:

lasting antifreeze that is now available.

Antifreeze mixtures will protect against an unexpected freeze and they are beneficial to the engine's cooling system. They retard rust and add to the life lating pump seal.

Antifreeze Freezing

COOLANT

A coolant recovery tank kit is supplied with each WESTERBEKE diesel engine. The purpose covery tank is to allow for engine coolant expansion

of

and contraction during engine operation, without the loss of

coolant and without introducing air into the cooling

system.

COOLANT

of

an antifreeze mixture

of

antifreeze. Do not use straight water,

be

detrimental to the cooling system compo-

Lookfor

Temperature

the new environmentally-friendly long

ANTIFREEZE

concentration

23%

14°F

(-5°C)

RECOVERY

of

50/50 is recom-

PROTECTION

35%

-4°F

(-20°C)

TANK

-40°F

(-40°C)

50%

of

the circu-

of

this re-

60%

-58°F

(-50°C)

Operating

Above

41°-68°F

Below

A

CAUTION:

of

engine

oil additives; in

the

mixture

your

engine.

Temperature

68°F

(20°C)

5-20°C)

41°F

(5°C)

00

not

to

mix.

additives

of

to

produce

allow

Each

brand

different

properties

two

or contains

brands

Oil

Viscosity

SAE

30

SAE

20

SAE

more

could

harmful

or

10W-30

or

10W-30

brands

its

own

react

to

COOLANT

RECOVERY

TANK

6

PREPARATIONS

FOR

INITIAL

START-UP

PREST

Before starting your engine for the first time prolonged layoff - check the following items.

ART

INSPECTION

or

after a

o Check the engine oil level; add oil to maintain the

level at the high mark on the dipstick.

o Check the fuel supply and examine the fuel

filter/separator bowls for contaminants.

o Check the transmission fluid level.

NOTE:

Refer to the specifications pages in this manual

fuel, oil, and transmission types and quantities.

OIL

DIPSTICK

FULL

LDW----~1l!J

for

o Check the DC electrical system. Inspect wire

connections and battery cable connections.

o Visually examine the unit. Look for loose or missing

parts, disconnected wires, unattached hoses, and check threaded connections.

o Check the coolant level in the plastic recovery tank

and at the manifold.

NOTE:

If

the engine has not yet been filled with coolant,

refer to the

"Engine Coolant" section

COOLANT RECOVERY

TANK

of

this manual.

MANIFOLD PRESSURE

CAP

l-vvl

WESJERBEKE

I Engines & Generators

7

STARTING/STOPPING

PROCEDURE

STARTING

Place the transmission in neutral and advance the throttle control to slightly open.

A

CAUTION:

in

neutral. damage vessels

Tum

the

PREHEAT:

panel lights, gauges and meters, and fuel solenoid will be activated. The accordance with the following chart:

PROCEDURE

Make

certain

Starting

to

your

in

transmission,

nearby.

KEY

SWITCH to the

Depress the PREHEAT switch.

PREHEAT

the

transmission

gear

could

result

your

ON

position (2

switch should be depressed in

in

boat,

The

is

serious

and

0'

clock)

voltmeter,

Temperature/Preheat

Atmospheric

+41

°F(

+23°F(-5°C)

Limit

START:

press the noid. Upon engine firing, release the not release the PREHEAT switch until the oil pressure reaches ture and low oil pressure protective circuits do not vate, the engine will remain energized and continue to run.

While still depressing the PREHEAT switch, de-

Temperature

°F(

+5°C)

or

higher

+5°C)

to

23°F

(-5°C)

or

lower

of

continuous

START

15

psi. Then as long as the high water tempera-

use

switch. This will engage the start sole-

Preheating

Approx. Approx. Approx.

30

seconds

START

10

seconds

15

seconds

20

seconds

before

switch.

Time

cranking

Do

acti-

A

CAUTION:

the

engine system cause raw water

filling

the

water

can exhaust vent

this

supply

through-hull muffler, engine water

cranking.

entry

owner/operator

Once the engine starts, check instruments for proper oil pressure and battery charging voltage.

NOTE:

Never attempt to engage the starter while the

engine is running.

NOTE:

Some unstable running may occur in a cold engine. Depressing the Preheat switch will help stabilize the engine perature reaches 170°-190°F (77°-88°C) and a propeller

load is applied

and

the

preheat

the

DC

alternator will be discernible.

STARTING

Make certain the lubricating oil conforms with the ratings for the prevailing temperature. Check the table oil section

The

battery should be fully charged to minimize voltage

drop. Use a sufficient amount

See TemperaturelPreheat chart on this page.

Prolonged

starting

with

pump

is

pumping

cooling

enter

manifold

from

and

system

the

once

happening

correcting

Engine

is

not a warrantable

should

to

the engine. When the engine is running

switch is depressed, a charging load on

UNDER

of

this manual.

cranking

can

result

raw

water.

during

engine's

the

by

shut-off,

the

damage

exhaust

cause

intervals

in

the

This

may

raw

water

cranking.

cylinders

system

closing

draining

of

resulting

issue;

keep

this

in

mind.

for

10-15 second intervals

RPM

until the operating tem-

COLD

of

CONDITIONS

preheat to aid in starting.

engine

happen

through

by

the

raw

the

excessive

the

without

exhaust

be-

the

This

raw

way

of

fills.

Pre-

water

exhaust

from

raw

on

the engine

the

NOTE:

When starting:

A voltage drop will occur

when the preheat switch is depressed.

Should the engine not start when the depressed for wait

30 seconds; repeat the procedure above and preheat

longer.

30

seconds.

10 to 20 seconds, release both switches and

Never

run

the

starter

for

more

START

than

switch is

/"VVI

I Engines & GeneratDrs

STOPPING

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.

the key to the the instrument panel and engine, de-energizing the fuel solenoid

it and stopping the engine. Made certain the key switch is in the

(12 o'clock). will discharge. warn the operator

The

is to remove the key from the Key the engine.

on

best method

WESJERBEKE

8

PROCEDURE

Tum

OFF

position. This opens the DC circuit to

the injection pump, stopping fuel flow from

OFF

position

If

the Key Switch is left ON, the battery

An

engine alarm buzzer is provided to

of

this condition (Key Switch ON).

of

preventing the battery from discharge

Switch after stopping

BREAK-IN

PROCEDURE

THE

FIRST

Although your engine has experienced a minimum hour

of proper operation The service life the engine is operated and serviced during its initial hours

of

Your new engine requires approximately tial conditioning operation to break in each moving part in order to maximize the performance and service life the engine. Perform this conditioning carefully, keeping in mind the following:

1. Start the engine according to the Starting Procedure

section in this manual; run the engine at fast idle while checking that all systems (raw water pump, oil pressure, battery charging) are functioning.

2. Allow the engine to warm up (preferably by running

at fast idle) until the water temperature gauge moves into the

3. While using the vessel, run the engine at varying en-

gine speeds for the first

50

HOURS

of

one

test operations to ensure accurate assembly and

of

all systems, break-in time is required.

of

your engine is dependent upon how

50

use.

130° -140°F range.

25

50 hours

hours.

of

ini-

of

4. A void rapid acceleration, especially with a cold engine.

S.

Use caution not to overload the engine. The presence of

a gray or black exhaust, and the inability engine to reach its full rated speed, are signs overload.

6. During the next 25 hours, the engine may be operated at varying engine speeds, with short runs at full rated

rpm. A void prolonged idling during this break-in period.

Breaking-in a new engine basically involves seating

the piston rings to the cylinder walls. This cannot be accomplished by long periods early running at full rpm. Idle running may glaze the cylinder walls, resulting in excessive oil consumption and smoky operation. Excessive speed loading, especially with a cold engine, may cause scoring of

the cylinder walls, producing similar results. Operate the engine in moderation during the riod. (Don't baby the engine, but do not abuse it.)

NOTE:

See the Transmission section

break-in information on your transmission.

of

running at idle, nor by

or

50-hour break-in pe-

of

this manual

of

the

of

an

heavy over-

for

rVtTl

I

WESJERBEKE

Engi_s

& Generators

9

THE

DAILY

ROUTINE

CHECK

Each day before starting your engine, take a few moments to run this check list:

LIST

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 for loose wires at the alternator.

o Check the starting batteries level (weekly) o Check drive belts for wear and proper tension

(weekly).

o Log your engine running time. These hours relate to

scheduled maintenance.

o Check fuel supply; always keep fuel tank(s)

possible.

as

full

o Look for clean fuel in the fuel/water separator bowl. o Check the coolant level in the plastic recovery tank.

START

NOTE:

more detailed instructions.

1.

2. Tum KEY to the

3. Depress

4. While pressing PREHEAT, push START. As engine

5. Hold

NOTE:

the above procedure, and PREHEAT longer.

6. Allow a few minutes for the engine to warm at a

as

YOUR

See Starting/Stopping Procedure in this manual

Put transmission in neutral, throttle advanced.

fires - release START.

PREHEAT until oil pressure reaches

and/or alarm shuts off.

Should engine fail to start, wait 30 seconds, repeat

comfortable rpm (approx. rpm, shift into gear, and get underway.

ENGINE

ON position

PREHEAT (10

(2

o'clock)

to

15

seconds).

1200 rpm), then reduce the

15

for

psi

NOTE:

Excessive loss

tem leak. Check the entire system.

cooling system pressure tester to pressurize the cooling system to locate the area coolant loss, refill the system as outlined

for Initial

Start-Up in this manual.

of

coolant indicates a cooling sys-

If

necessary, use a

of

leakage. In cases

of

excessive

in

Preparations

l-vvl

WESTERBEKE

r

Engines & Generators

10

MAINTENANCE

A

WARNING:

Wear

the

tools

for

engine's

NOTE:

Many

and

may require the expert knowledge

Never

attempt

proper each DC

safety

equipment

job.

Disconnect

electrical

of

the following maintenance jobs are simple but others are more difficult

equipment.

to

perform

such

the

battery

any

as

of

a service mechanic. A complete service

SCHEDULE

service

goggles

terminals

manual is availablefrom your WESTERBEKE dealer.

while and

gloves,

when

the

engine

and

servicing

is

running.

use

the

any

of

correct

the

SCHEDULED

Fuel Fuel/Water

Engine

Transmission

Coolant

Drive

Visual

Throttle

Control Adjust Fuel

Starting (and

Engine

•

Adjust

Lubricate with"

MAINTENANCE

Supply

Separator

Oil

Level

Belts

Inspection

and

Transmission

Cable

Engine

Filter

Batteries

House

Batteries)

Oil

the

Valve

Panel

Lockeze"

Fluid

Level

of

Engine

Idle

Speed

Clearances

Key

Switch

CHECK

EACH

DAY

0 0

0 0 0 0 0

HOURS

OF

OPERATION

100

50

NOTE:

oil will inhibit the engine's ability to remain cool.

0

250

Please keep engine surface clean. Dirt and

0 0

500

750

1000

1250

0

0 0 0 0

Every

50

0 0

Clean Initial

operating

off

excessive

engine

hours

corrosion.

oil & filter

check

change

electrolyte

at

50

hrs.,

0 0 0

0 0 0 0 0 0

Diesel Check

necessary). Oil

level

on

dipstick.

Fluid LOW

Check manifold.

Inspect and

adjust

Check wiring nuts

Check

Lubricate

Adjust

Initial 250

levels

and

then

change

Initial (Do

At 1 st

EXPLANATION

MAINTENANCE

No.2

octane

rating

for

water

and

dirt

should

indicate

level

should

dipstick

recovery

Add

coolant

proper

tension

if

needed.

fuel,

oil

electrical

loose

fittings,

with

WD-40

(750-1000

at

50

sure

both

every

the

hrs.

then

indicate

tank;

and

connections.

rpm).

hrs,

connections

100

at

50

each

on

at

for

for and

tight.

for

to

change

hrs.

make

adjustment

not

retorque

100

OF

SCHEDULED

of

45

in

fuel

between

if

empty,

if

needed.

('h "

to

Check

belt

water

leaks.

cotter

or

equivalent.

then

change

hours.

hrs.,

then

cylinder

head)

year

cetane

or

better.

(drain/replace

MAX.

and

MAX.

and

check

at

'Is"

depression)

edges

for

wear.

Inspect

Keep

bolts

pins,

etc.

every

are

very

tight.

every

50Q

at

winterizing.

if

LOW

&

hrs.

TransmiSSion

Air

Cleaner

Exhaust

·WESTERBEKE

Fluid

System

recommends

this

service

be

0 0 0 0 0

0 0

0 0 0 0

performed

by

an

authorized

/"VVI

I Engines & GeneratDrs

mechanic.

WESJERBEKE

11

Initial

fluid

hrs.

or

at

winterizing.

Replace

element

Initial

check

Inspect

for

siphon

brake

elbow

for inside necessary.

carbon

passages;

change

filter.

at

50

leaks.

operation.

and/or

clean

at

50

Clean

hrs.,

then

Tight

connections

and

hrs.,

then

or

replace

every

Check

the

corrosion

replace

every

250

elements.

250

hrs.

check,

exhaust

buildup as

on

MAINTENANCE

SCHEDULE

(Continued)

SCHEDULED

Engine

Heat Zinc

Electric (if

applicable)

Raw

Coolant

*Fuellnjectors

*Starter

*Preheat

MAINTENANCE

Hoses

Exchanger

Anode

Fuel

Lift

Water

Pump

System

Motor

Circuit

Pump

Filter

NOTE:

CHECK

EACH

DAY

Use engine

hour

meter

gauge to log

your

or record your engine hours by running time.

HOURS

OF

OPERATION

50

100

250

D

D D D D D

500

750

1000

1250

D D D D D D D D D D D D D

D

D D

D

D D

engine hours

EXPLANATION

Hose

should

spongy.

Check & tighten

Clean

or

replace.

and

clean

out

Initial

filter

every

pump

replace

both

flush,

and

condition

solenoid

and

operation

clean

glow

ohms).

change 250

adjust

lubricate.

filter Remove

wear; Lubricate

Drain, appropriate

Check spray

Check Remove Clean

Check and

(4-6

OF

MAINTENANCE

be

hard & tight.

all

Open

heat

debris.

at

50

hours,

hours.

cover

and

if

needed.

when

and

anti-freeze

and

lubricate.

plugs;

Also

reassembling.

refill

cooling

mix.

injection

(see

Engine

motor

Start.

of

preheat

check

inspect

SCHEDULED

Replace

if

clamps.

then

impeller

pressure

pinion

soft

end

change

gasket.

with

Remove

hose exchanger

replace

system

opening

Adjustments).

for

corrosion.

motor

solenoid.

resistance

or

cap

for

and

drive.

*Engine

Cylinder

and

Valve

Clearance

DC

Alternator

Heat

Exchanger

Transmission

Engine

Transmission

Damper

Plate

Engine

Timing

'WESTERBEKE

recommends

Compression

Oil

Cooler

Belt

this

service

be

performed

by

an

D D

D D D

D D D D

authorized

mechanic.

Incorrect engine pressure

Check ing

Remove; press u re

Remove; pressure

Chattering of

Remove NOTE:

recommended interval could result belt failure resulting in major damage to the engine.

valve

clearance

performance;

and

timing,

DC

charge

bracket;

tighten

have

professionally

tested. have

professionally

tested.

at

damper

idle

plate

and

replace.

Failure to replace the timing belt

and

from

electrical

and

wear.

will

check

compression

adjust

alternator.

low

rpms

Remove

result

valve

connections.

cleaned

in clearances.

Check

is

an

indication

and

replace.

in

poor

mount-

and

at

timing

the

I~l

I

WSJERBEKE

Engines & Gene",tors

12

ENGINE

COOLANT

CHANGING

The engine's coolant must be changed every eight to

twelve months depending on the engine's use. coolant is allowed to become contaminated, it can lead to overheating problems.

A coolant recovery tank allows for engine coolant expansion

and nificant loss cooling system. This tank should be located at or engine manifold level, and be easily accessible.

Drain the engine coolant by loosening the drain plug on the engine block and opening the manifold pressure cap. Flush the system with fresh water, then start the refill process. ual for locations.

NOTE:

The petcock on the heat exchanger can also be

used to drain engine coolant.

THE

COOLANT

If

the

contraction during engine operation, without

of

coolant and without introducing air into the

.\:>?i~:":';';~---

~---

COOLANT

See the Parts Identification photos in this man-

any

sig-

above

COOLANT RECOVERY

TANK

CAP

COOLANT RECOVERY TANK

EXPANSION

the

Start the engine and bring it to operating temperature. Monitor the coolant in the manifold and add as needed. Fill the manifold to the filler neck and install the pressure

cap. Remove the cap on the coolant recovery tank, fill with

coolant to halfway between

the cap.

Run the engine and observe the coolant expansion flow into the recovery tank.

After checking for leaks, stop the engine and allow

it to cool. Coolant should draw back into the cooling

system as the engine cools down. Add coolant to the recovery tank

NOTE:

Periodically check the condition Ensure that the upper and lower rubber seals are in good condition and check that the vacuum valve opens and closes tightly. Carry a spare cap.

if

needed. Clean up any spilled coolant.

LOW

and MAX, and replace

of

the pressure cap.

THERMOSTAT

A thermostat, located near the manifold at the front engine, controls the coolant temperature as it continuously flows through the closed cooling circuit. When the engine is first started the closed thermostat prevents coolant from flowing (some coolant is by-passed through

a hole in the thermostat to prevent the exhaust manifold

from overheating). As the engine warms up the thermo-

stat gradually opens. The thermostat is accessible and can

be checked, cleaned, or replaced easily. Carry a spare thermostat and gasket.

of

the

WATER TEMPERATURE ALARM

A

WARNING:

Wear

protective

TO

REFILL

With the enginge running in idle, slowly pour clean premixed coolant into the manifold.

NOTE:

Open the air bleed petcock on the heat exchanger to help remove air from the system. When a steady flow of

coolant appears water drain plug and continue to fill the system until the manifold remains full. Close the petcock on the heat exchanger when antifreeze flows from

Beware

gloves.

WITH

at

of

the

hot

COOLANT

the drain plug opening, close the

engine

it.

coolant.

I~l

I Engines & GeneratDrs

WSJ&lBEKE

13

THERMOSTAT

WATER TEMPERATURE SENDER

ENGINE

OIL

CHANGE

DRAIN

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil to drain, or attach a pump to the end the oil drain hose is capped and properly secured in its holder after all the old oil has been drained.

NOTE:

is

Always observe the old oil as it is removed. A yellow/ gray emulsion indicates the presence Although this condition is rare, it does require prompt attention to prevent serious damage. Call a competent mechanic in the oil can be the result attached to the engine and/or a siphoning through the raw water cooling circuit into the exhaust, filling the engine. This problem is often caused by the poor location

Installation Manual.

THE

SUMP

of

the drain hose and pump out the old oil. Make sure

Thread size

1/4

NPT.

if

for

the lube oil drain hose capped end

of

water in the oil.

water is present in the oil. Raw water present

of

a fault in the exhaust system

of

raw water

of

the syphon brake. See WESTERBEKE'S

filter when unscrewing it to catch any oil left in the filter. Inspect the old oil filter as it is removed to make sure that the rubber sealing gasket comes

If

this rubber sealing gasket remains sealed against the engine block, gently remove it. When installing the new oil filter element, wipe the filter gasket's sealing surface on the engine block free

clean engine oil to the rubber gasket on the new oil filter. Screw the filter onto the threaded oil filter stub, and tighten the filter firmly by hand.

of

off

with the old oil filter.

oil and apply a thin coat

SPIN-ON OIL

q

__

-OIL COOLER

of

FILTER

~

A

WARNING:

contaminants. skin

and

nails Launder oil.

or

Discard

REPLACE

When removing the used oil filter, you may find it helpful and cleaner the old filter to drain the oil from it into a container before removing ter wrench should be helpful in removing the old oil filter. Place some paper towels and a plastic bag around the

to

it.

This helps to lessen spillage. An automotive fil-

OIL

Used

Avoid

thoroughly

discard

used

oil

THE

OIL

punch a hole in the upper and lower portion

OIL

CONTAINER

engine

prolonged

using

clothing

properly.

FILTER

DRAIN

HOSE

oil

contains

skin soap

or

rags

harmful

contact.

and

Clean

water.

containing

used

NOTE:

Use genuine WESTERBEKE oil filters - generic

filters are not recommended.

REFILL

Add fresh oil through the filler cap. After refilling the oil, run the engine for a few moments while checking the engine's oil pressure. Make sure there is no leakage around the new oil filter or from the oil drain system, and then stop the engine. Then check the quantity the lube oil dipstick. fill to, but not over, the high mark on the dipstick.

of

LOW-

THE

FULL-+--ra

__

OIL

~1frI

SUMP

of

oil with

If

the engine requires additional oil,

!-VVI

r

WESTERBEKE

Engines & Generators

15

FUEL

SYSTEM

A

WARNING:

when

servicing

catching

smoking,

the

fuel

lation

exists

FUEL

The fuel injection pump and the fuel injectors are

precisely manufactured and they must receive clean diesel fuel, free from water and dirt. To ensure this flow of filters, a fuel/water separator and the engines spin-on fuel filter. Visually inspect, clean, and change these filters according to the maintenance schedule in this manual.

FILTERS

clean fuel, the fuel must pass through at least two fuel

Shut

any

fuel

open

flames

system

when

O-RING----

off

the

fuel

that

when

servicing

the

fuel

system.

may

spill.

or

other

sources

servicing.

the

valve

at

Take

care

DO

NOT

Ensure fuel

system.

the

tank

in

allow

of

fire

proper

any

near

venti-

FUEL

A primary fuel filter 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.

Most installers include a type with the installation package problems that contaminants in the fuel can cause.

A typical fuel filter/water separator is illustrated in this

diagram. This is the Raycor Model mind that

between the fuel supply tank and engine-mounted fuel

system, any water in the fuel will affect the fuel pump,

engine filter, and injection equipment. The ownerl

operator is responsible for making certain the fuel

reaching the engine's injection equipment is free

impurities. This process is accomplished by installing and maintaining a proper filtration/separation system.

WATER

if

SEPARATOR

of

the water separating type must be

of

filter/water separator

as

they are aware

500 MA. Keep in

a water separator type filter is not installed

of

the

of

SPIN-ON FUEL

FILTER-_---JI~~~

1.

Shut fuel supply off.

2.

Loosen the fuel filter, turning counterclockwise with a filter wrench.

3.

Using a rag, wipe clean the sealing face on the housing bracket so the new filter can be seated properly.

4. Lightly oil the sealing O-ring on the To reinstall, turn the filter assembly counterclockwise carefully until the O-ring contacts the sealing surface of

the housing bracket. Turn 2/3 further with the filter

wrench.

5. Turn on the fuel and manually prime the fuel filter using the priming pump on top a slow steady pumping action until resistance is felt. The filter is now primed and the engine is ready to start.

NOTE:

The cartridge contains fuel. Take care

it

during disassembly. Peiform the "fuel system

bleeding" after replacing the spin-on filter.

new filter.

ofthe

housing. Use

not

to spill

air

FILTER/WATER

L

/SEPARATOR

FUEL

The fuel injection pump is precisely adjusted; most of them. When an adjustment is necessary, contact your WESTERBEKE dealer.

NOTE:

rpm governor adjustment seals.

NOTE:

vide for a satisfactory idle speed with each specific installation.

INJECTION

the adjustments are sealed, so be careful not to break

There is no warranty on engines with broken high

The idle adjustment screw can be readjusted

PUMP

CONTROL

to

pro-

f"VtTf

(Engines

WESJERBEKE

& Generators

16

FUEL

SYSTEM

(Continued)

FUEL

If have an authorized dealer correct these problems. Then use a diesel fuel biocide to sterilize the fuel (follow the manufacturer's instructions).

ADDITIVES

fungus or bacteria is causing fuel problems, you should

SPARES

While the likelihood at sea is slim, the possibility does exist. Therefore, we recommend that banjo washers, injector seat washers, and a fuel filter be carried on board at all times. (See the

Spares

spares from your local WESTERBEKE dealer or distributor. that cannot be corrected by a simple tightening fitting, replace the sealing washer with a replacement found in the engine fuel hardware kit for your model.

PRIMING

The on-engine fuel system is virtually self priming. Under ordinary circumstances the engine's electric fuel lift pump, which is energized by the key switch/preheat button, will supply a continuous flow tank. This fuel is drawn through the fuel/water separator to the engine lift pump, the primary spin-on fuel filter, and the injection pump.

And

Accessories brochure"). Purchase needed

If

a leak should develop at a banjo washer

(BLEEDING)

of

having to service the fuel system

of

the

THE

FUEL

SYSTEM

of

fuel from the

A

CAUTION:

keep

in

mind

are

also

Once the fuel filter assembly is free

screw tightened, use the preheat button the primer pump for between the filter housing and injection pump out system to the tank via the return line.

In cases where excessive amounts fuel system, follow the above procedure but in addition, loosen all the high pressure injector lines (not injectors) and crank the engine starter motor; between the nut and the line, tighten the injector lines in sequence and then tighten the bleed screw.

NOTE:

Do

A

WARNING:

safety

glasses

sure

injector

AIR

CLEANER

Dual air cleaner filters are located on the top engine manifold. These filters should be inspected, cleaned, and/or replaced at maintenance periods. With the engine turned off, remove the single hex bolt, lift the manifold top, and the dual air cleaner filters become accessible. When reassembling, make certain the filters are positioned properly, and do not overtighten when refastening the bolt.

When

using

the

preheat

that

the

preheat

energized;

not

attempt this procedure on a hot engine.

take

10 to 20 seconds to force any air

Always and

wear

gloves

elements

care

not

protective

when

of

function,

(glow

to

overheat

of

air and the bleed

or

slowly pump

air exist in the

as

fuel spurts from

clothing,

bleeding

lines.

them!

high

of

the

plugs)

of

the

pres-

FUEL

LIFT

A

WARNING:

near

the

proper

If

the following procedure: Open the bleed screw by turning the thumbscrew on

the fuel filter 1 or 2 turns. Energize the preheat button (key the palm top from the bleed screw, tighten, but do not overtighten, the screw.

ventilation.

it becomes necessary to bleed air from the system, use

ON) for 10 to 20 seconds or do it manually using

of

the fuel filter housing. When fuel flows freely

00

not

allow

smoking

fuel

system

your hand to pump the primer pump on the

when

servicing.

PUMP

or

Also

open

provide

flames

17

AIR

CLEANER

DC

ELECTRICAL

DESCRIPTION

The

charging system consists voltage regulator, an engine DC

circuit breaker, and a battery and connection wires. Because voltage regulator is very compact and is mounted internally or

Alternator

If

voltage to charge the engine's battery, check the following:

of

the use

of

integrated circuits (IC's) the electronic

on the back

of

the alternator.

Troubleshooting

you suspect that the alternator is not producing enough

A

WARNING:

hot.

00

not

touch

A

failed

until

of

an alternator with a mounted

DC

wiring harness, a mounted

alternator

the

alternator

can

has

become

cooled

very down.

SYSTEM

A.

WARNING:

that

everyone

sheaves

5. Start the engine.

6. The voltage reading for a properly operating alternator

NOTE:

voltmeter to ensure that the R terminal

age at the B output terminal.

and

should be between 13.5 and 14.5 volts. is overservice shop.

or

Before removing the alternator for repair, use your

Before

starting

is

clear

of

moving

belts

during

undercharging, have it repaired at a reliable

i 2 volts

if

the previous test showed only battery volt-

the parts!

test

procedures.

DC

engine

make

certain

Keep

away

from

If

your alternator

excitation is present

at

o Make certain your alternator is securely mounted. o Check the drive belts for proper tension.

o Inspect for loose

NOTE:

An

isolator with a diode, a solenoid,

selector switch is usually mounted in the circuit to isolate the

batteries the house batteries. battery but the problem is

A

disconnect electrical

Checking

If

tests with the engine off:

1. Using a voltmeter, connect the voltmeter red wire clip to

2. Connect the voltmeter negative wire to any ground on the

so

the starting battery is

not

WARNING:

system.

for

you suspect the alternator has failed perform the following

the output terminal B+.

engine .

or

disconnected wires at the alternator.

not

discharged along with

If

the isolator is charging the starting

the house battery, the alternator

in the battery charging circuit.

Shut

off

the

engine

battery

from

the

Proper

battery

Voltage

when

working

or

a battery '14

is

OK

and

switch

or

on

the

engine

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51

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CONNECTIONS

. 3. Check the battery voltage. It should read

4. Check the voltage between the alternator

minal B and any engine ground. voltage at the alternator should (unless there's an isolator in the circuit, then the reading would

be

zero).

A

CAUTION:

circuit, the

never

engine

To

shut

is

running!

avoid

off

the

damage

engine

If

the circuit is good, the

be

the same as the battery

to

the

battery

12

to 12 volts.

(+) positive ter-

battery

switch

charging

when

rvvl

WESIERBEKE

I Engines & Generators

18

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DC

ELECTRICAL

SYSTEM

(Continued)

DRIVE

Belt tension adjustment is made by pivoting the

1.

2.

3. Tighten the base mounting bolt and the adjusting

4.

BELT

A

CAUTION:

tensioned. alternator alternator.

Drive

belts

out

of

alignment

out

prematurely.

alternator on its base mounting bolt.

Loosen the alternator adjusting strap bolt and the base mounting bolt.

Pivot the alternator on the base mounting bolt to the left or right as required.

strap bolt.

Operate the engine for about 5 minutes at idle, then shut down and recheck belt tension.

ADJUSTMENT

Drive

belts

must

Loose

drive

belts

charging

that

and

are

too

and/or

will

tight

cause

be

properly

will

not

provide

eventually

will

pull

the

alternator

proper

damage

alternator

to

wear

the

BATTERY

Review the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine starting batteries and house batteries.

CARE

o Monitor your voltmeter for proper charging during

engine operation.

o Check the electrolyte level and specific gravity with a

hydrometer.

o Use only distilled water to bring electrolytes to a

proper level.

o Make certain that battery cable connections are clean

and tight to the battery posts (and to your engine).

o Keep your batteries clean and free

A

WARNING:

cause

severe

Wear

protective

Sulfuric

burns

on

gear.

acid

skin

in

and

of

corrosion.

lead

batteries

damage

can

clothing.

A

CAUTION:

Belts;

poor

and

belt

Use

only

quality

elongation

belts

resulting

BELT

genuine

will

lead

in

alternator

TENSION

WESTERBEKE

to

premature

Drive

wear

damage.

I~I

I Engines & Generators

WESJERBEKE

19

DC

ELECTRICAL

SYSTEM

i6i

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NOTE

'~

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+~

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NOTE:

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ON-OFF

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BATIERY

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Engines & Generators

21

PROPUlSION

TE

51

AMP

AL

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Revised

October 2000

WATER

HEATER

WATER

This engine is equipped with connections for the plumbing The water heater should be mounted in a convenient location either in a high or low position in relation to the engine, so that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap air.

OIL COOLER

Hoses should rise continuously from their low point at the heater to the engine so that air will rise naturally

from the heater to the engine.

to the heater, then an air bleed petcock must be installed at the higher fitting on the heater for bleeding air while

filling the system.

NOTE:

the engine's own pressure cap, then a pressurized (aluminum) remote expansion tank (Kit #024177)

be installed in the circuit to become the highest point.

Tee the remote expansion tank into the heater circuit,

choosing the higher

Tee location and the other back to the engine's return. Install the remote expansion tank so the fresh water coolant level can easily be checked. The

remote expansion tank will now serve as a check and system fill point. used since this

HEATER

of

engine coolant to heat an on-board water heater.

HEATER

If

any portion

at

the heater,

when

the

tank

INSTALLATIONS

(~-...J'.~~

I

I I

, I

...J,

..........

BELOW

THE

of

the heating circuit rises above

of

the two connections

and

plumb a single line up to the tank's

in

The

plastic coolant recovery

remote expansion

serves

the

same

I

"....J

ENGINE

If

trapped air is able to rise

a convenient location

tank

kit

function.

for

the return.

tank

is installed,

must

is

not

The pressure cap on the engine's manifold should be in-

stalled after the engine's cooling system is filled with coolant. Finish filling the cooling system from the remote tank after the system is filled and is free

its good coolant circulation. During engine operation,

checking the remote tank and not at the engine manifold cap. The hose connection from the heater to the remote expansion tank should be routed and supported so it rises continuously from the heater to the tank, enabling any air in the system to rise up to the tank and out

NOTE:

heat exchanger. Open this petcock when filling the engine's fresh water system to allow air escape. Close tightly after all the air is removed.

the engine's coolant should be done at

REMOTE

EXPANSION

TANK

1124117

I

I '

i !

, I

) I

, J

.

_./.

HEATER

An

air bleed petcock is located on the engine's

" '

ABOVE

THE

ENGINE

of

air and exhib-

of

the system.

in

the exchanger to

I~I

I

WESIERBEKE

Engines & Generators

22

-

ENGINE

ADJUSTMENTS

ADJUSTING

1. Remove the cylinder head rocker cover.

2. Manually rotate the engine crankshaft and bring

piston up on TDC

NOTE:

lobes will face upwards.

3. Measure the valve clearance

thickness gauge.

Standard Valve Clearances (Engine Cold): Intake: Exhaust:

VALVE

When this occurs, the intake

0.20 - 0.30mm (0.008 - 0.012 in)

0.30 - 0.40mm (0.012 - 0.016 in)

CLEARANCES

of

its compression stroke.

of

#1

and

exhaust cam

cylinder by using a

#1

7. Using a small screwdriver or magnet, remove the adjusting disc.

8. Select an appropriate disc thickness depending on the

clearance measured. Install it and verify proper clearance.

EXAMPLE

removed plus the clearance measured minus the standard clearance will give the thickness adjusting disc.

(Intake Valve): The thickness

4.0 mm + (0.30 - 0.25 mm) = 4.05

0.157 in + (0.012 - 0.010 in) = 0.159 in

of

mm

the disc

the new

VALVE CLEARANCE MEASUREMENT.

If

the valves clearances are not within standard

values, continue using the following procedure to

adjust the valves.

4. Rotate the valve cam lobe so that it points straight upward.

of

5. Rotate the tappet so that one

the exhaust manifold. This allows for better access to the adjusting disc.

6. Using the tappet holder WESTERBEKE #41978,

press the tappet down to the position where the adjusting disc becomes accessible.

the notches is facing

NOTE:

The number marked on the disc indicates

its thickness. Example: in). Adjusting discs are available in 25 different thicknesses between

0.1811 in) range, in).

9. Measure and adjust as needed the valves in cylinders #3,

#4

and #2 following the instructions above.

CAM

(INTAKE)'\...

3825 means 3.825mm (0.1056

3.40 and 4.60mm (0.1339-

at

variations

of

0.050 mm (0.002

VALVE CLEARANCE

23

ENGINE

ADJUSTMENTS

(Continued)

TIMING

BELT

INSPECTION

AND

REPLACEMENT'

1. Before removing the timing belt and timing belt

tensioner, rotate the engine crankshaft by hand and

align the three timing marks as shown in the illustration.

A

CAUTION:

DO

NOT

pistons

rotate

will

After

the

crankshaft

damage

removal

the

opened

of

the

timing

or

camshaft;

valves.

belt,

the

~nM"G.AA~

TIMING MARKS

NOTE:

If

the timing belt is

the belt pointing in the direction

in

Replace it

the same direction.

to

be reused, draw an arrow on

of

the belts rotation.

Timing

1.

NOTE:

ing solvents. Avoid scratching the

Timing

1. Check the gear teeth for any indication

Timing

1.

Belt

Tensioner

Check the rotation Check for play or abnormal noise.

Do not clean the timing belt tensioner with clean-

If

dirty, use a clean rag

OAMAGE,/

WEAR

Belt,

Camshaft

wear, deformation, etc. Replace found.

Belt

Installation

Check to ensure that the timing marks on the gears are properly aligned with the marks on the case.

of

the timing belt tensioner pulley.

to

wipe it clean.

suiface the belt travels over.

OAMAGE, WEAR

I

",

.

I:"

.

','

,~

.

. '

...

.

:.,

:.

And

Injection

Pump

of

if

any faults are

Gears

damage,

DIRECTION ARROW

Inspection

1. Replace the timing belt

grease or water.

2. Check for damage, wear, peeling, cracks or hardening. Replace

NOTE:

Never forcefully twist the timing belt; turn it inside

out or bend

it.

if

it is contaminated with oil,

if

suspect.

I~l

2. Loosely install the timing belt tensioner, locking bolt and spring. Push the timing belt tensioner toward the lock bolt the locking bolt to temporarily hold the tensioner in place.

LOCKING BOLT

WESTERBEKE

I

Engines & Generators

to

the left

as

far as it will go and then tighten

TIMING

BELT

TENSIONER

24

ENGINE

ADJUSTMENTS

(Continued)

3. Install the timing belt.

NOTE:

If

reinstalling the original belt, be sure to install with the arrow in the correct direction rotation.

DIRECTION

ARROW

4. Release the timing belt tensioner lock bolt to allow the tensioning spring tensionor to bring pressure on the timing belt.

of

belt

7. Re-check the timing mark positions between the three gears and the gear case. Check the timing belt deflection at the point on the belt shown in the illustration with a pushing force

Standard Deflection (unit cold):

10.8-12.9 mm (0.43-0.51 in)

8. Install the timing belt left cover with its rubber seal.

9. Install the timing belt right cover with its rubber seal. Bolt torque for timing belt cover bolts:

0.7-1.0 m-kg

(5-7

ft-Ib)

of

10

kg (22Ib).

5. Turn the crankshaft twice in the direction engine rotation (clockwise) to equalize tension on the timing belt.

NOTE:

Do

not

turn the engine in reverse

rotation.

6. Tighten the timing belt tensioner lock bolt. Lock bolt torque: 3.2-4.7 m-kg

(23-34

of

its normal

ft-Ib)

normal

10. Install the crankshaft pulley and torsional damper onto the timing belt drive gear with the semicircular (woodruff) key. Tighten the attachment.

Crankshaft pulley bolt torque:

2.3-3.3 m-kg

NOTE:

When installing the torsional damper onto the timing belt drive gear, align the mark on the damper with the knock pin on the gear.

TIMING

COVER

(17-24

BELT

(RIGHT)

ft-Ib)

TIMING COVER

BELT

(LEFT)

I"VVJ WESJERBEKE

r

Engines

& Generators

25

ENGINE

ADJUSTMENTS

(Continued)

COMPRESSION

1.

Warm the engine up to operating temperature.

2.

Stop the engine.

3. Remove all four glow plugs.

4. Disconnect the DC power connection shutoff solenoid on the injection pump.

5. Install the compression tester glow plug adapter in the

glo\y plug opening

compression gauge to the glow plug adapter.

6. Crank the engine with the starter and allow the gauge to reach its maximum reading.

7. Record the reading and proceed to the next cylinder.

8. Compare readings action

as

needed.

Compression

Standard

TEST

to

pressure

to

the fuel

of

#1

cylinder. Connect the

the table below. Take corrective

kg/cm2 (lb/in2)-rpm

30

(426) -200

FUEL

When the injection starting pressure is too high or too low or the fuel spray pattern is improper, an abnormal fuel combustion takes place in the engine leading to lowered power output, blackish exhaust smoke and un-

wanted combustion noise. Further, it can cause a piston seizure or piston damage if not corrected. In such cases, the injection nozzle test should be performed and the faulty nozzle(s) replaced

Use an injection nozzle tester to check the static injection starting pressure and condition 800 operating hours.

Injection nozzle pressure is (135 kg/cm2

INJECTION

A

WARNING:

high

pressure

injury.

Keep

NOZZLE

+ 5 kg/cm2.

When

might blow

away

from

as

required.

of

1920 psi +

testing a

off

the

nozzle

TEST

the spray pattern every

71

psi

nozzle

the

beware

light oil

end!

and

that cause

Limit

NOTE:

Whenpeiforming the compression test, shut

to

raw water supply

is

to

This water while

prevent filling

peiforming the test.

the engine mounted raw water pump.

of

the exhaust system with raw

27

(384) -200

off

the

GOOO

POOR

l-vvl

WESTERBEKE

I

Engines & Generators

26

HBW

TRANSMISSION

INITIAL

All HBW marine 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

(DEXRON

up to the index mark on the dipstick. To check the fluid level, the dipstick into the case after the fluid level is checked, and tighten. Do not forget the sealing ring under the hexhead after the first 25 hours.

OPERATION

II

or

DEXTRON

just

insert the dipstick, do not screw it in. Screw

of

the dipstick. Check for leaks and change the fluid

Ill). The fluid level should be

TRANSMISSION

IN

OPERATION

LOCKING

Locking not required: use the gear lever position opposite your direction in the position corresponding to the direction the boat.

CONTROL

The gearbox is suitable for single lever remote control. Upon loosening the retaining screw, the shift lever can be moved to any position required for the control elements (cable or rod linkage). Make certain that the shift lever does not contact the shift lever cover plate: the minimum distance between lever and cover should be O.5mm.

The control cable or rod should be arranged at a right angle to the shift lever when in the neutral position. The neutral position sole should coincide with the neutral position lever on the gear box.

The shifting travel, shift lever, between the neutral position and end positions A and B should be at least 35mm for the outer and for the inner pivot point.

THE

PROP

of

the propeller shaft by an additional brake is

of

travel for this purpose. Never put the gear lever

of

travel

CABLES

of

the operating lever on the control con-

of

the shift

as

measured at the pivot point

of

the

30mm

The neutral position console must coincide with the neutral position

actuating lever on the transmission. Shifting is initiated

by a cable or rod linkage via the actuating lever and an

actuating cam. The completion eration is servo-automatically controlled within the gear. Gear changing should be smooth, not too slow, and continuous (without interruption). Direct changes from forward to reverse are permissible, since the multiple-disc clutch permits gear changing at high rpm, including sudden reversing at top speeds in the event

WHEN

Rotation boat is sailing, being towed, or anchored in a river, as

well as operation

(for charging the battery), will have no detrimental ef-

fects on the gearbox.

NOTE:

lever must be in neutral position. The propeller is

and can free wheel.

UNDER

of

the propeller without load such as when the

When the boat is sailing (engine stopped), the gear

of

the operating lever on the control

of

the

of

the gear changing op-

of

danger.

SAIL

OR

BEING

of

the engine with the propeller stopped

TOWED

at

idle

of

A greater amount detrimental, and is recommended. However, 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.

NOTE:

Checkfor

season.

shift lever travel is in no way

proper shift lever travel

COVER

PLATE

HUB

if

the shift

at

least each

CLOCKWISE

27

HBW

TRANSMISSION

(Continued)

A

CAUTION:

underneath

ensure

equal to A and any

way

will

be

void. adjust

or

NOTE:

When installing the gearbox, make certain that shifting is not impeded by restricted movability Bowden cable guide sheaves, too small a bending radius, etc. In order to mount a support use the two threaded holes located above the shift cover on top

of

the gear housing. Refer to the WESTERBEKE

parts list.

The

position

the

actuating

shift

lever

B.

If

this

side

tampered

with,

Authorized

remove

this

or

rod linkage, by unsuitably positioned

for

of

the

cover

lever

is

factory-adjusted

travel

from

neutral

shift

cover

is

removed

the

transmission

Hurth

personnel

cover.

shift control cable connections,

plate

position

or

warranty

only

may

of

the

to

in

MAINTENANCE

Transmission

To ensure trouble-free operation

use Automatic Transmission Fluid (ATF), (Dexron II

or

Ill).

Fluid

of

the gearbox, only

Checking

The Bowden cable regular intervals. Check the neutral position ing lever (on the control console) and the actuating lever (on the gearbox). The minimum lever travel from the

neutral position to the operating positions (0 - A = 0 - B)

should be 35mm for the outer and 30mm for the inner pivot point. Make certain that these minimum values are safely reached. Check the cable movability

Connection

HBW recommends a flexible connection between the gearbox and the propeller shaft mounted, in order to compensate for angular deflections. The installation required, since the propeller thrust will be taken 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 manufacturer's instructions.

the

Bowden

or

rod linkage should be checked at

a~d

proper attachment.

of

Gearbox

of

a special propeller thrust bearing is not

Cable

or

with

if

or

Rod

Linkage

of

the operat-

rod linkage for easy

Propeller

the engine is flexibly

Capacity

Add the fluid quantity for the proper model transmission to the gearbox. After filling, check the fluid level with the dipstick. Adjust level as needed. Install the dipstick with the sealing washer, operate unit, check fluid, check

for leaks.

Transmission

HBW

HBW 150V HBW250

Fluid

Change

Change the fluid for the first time after about 50 hours operation, then every 250 operating hours a year

or

when you change engine oil. When changing the fluid, also check the gearbox cooling device and clean or replace it as necessary.

NOTE:

When changing the fluid, take care not to lose the drain plug sealing washer. The drain plug will leak without this sealing washer.

150

Fluid

0.59 Quarts (0.56 Liters)

1.10 Quarts (1.05 Liters)

1.84 Quarts (1.75 Liters)

Quantity

or

at least once

Even with the engine solidly mounted, the use ble coupling reduces stresses in the gearbox bearings caused by hull distortions, especially in wooden boats where the distance between the gearbox output flange and the stem gland is less than about 800mm.

of

Lay-up/Winterize

If

the transmission is not used for periods

one year, it should be completely filled with fluid

same grade to prevent corrosion. Protect the input shaft and the output flange by means ing, as required.

of

an anticorrosive coat-

of

more than

a flexi-

or

of

the

I~l

I Engines & Generators

WESJERBEKE

28

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

INITIAL

Transmission

Check transmission fluid level on the dipstick. transmission has not been filled, fill with continue to use this fluid. During the first operation, keep a lookout for any leakage at the bell housing, output shaft, and transmission cooler. This fluid should be changed after the first approximately every lay-up.

NOTE:

safety switch. Unless the transmission shift lever I per-

fectly aligned

activate.

Shifting

Place the transmission selector control in Neutral before starting the engine. Shifting from one selector position to another selector position may

1000 rpm and in any order. Shifts should be made at the lowest the throttle at idle speed; allow the transmission fluid to warm up for a few minutes.

Neutral

Move selector lever to the middle position. You should feel the detent. Center the shift lever through the linkage to the selector lever. With the control in this position, hydraulic power is completely interupted and the output shaft

Forward

Move selector lever to the forward position. You should feel the detent. The shift lever on the transmission is in the forward position. The output shaft and the propeller shaft move the boat in a forward direction.

OPERATION

Fluid

If

the

Dextron III and

50 hours

50

hours and

1000 operating hours

Some transmissions are equipped with a neutral

in

neutral the engine starter will

Into

Gear

be

made at any time below

practical engine speed. Start the engine and

of

the transmission does not turn.

or

on

the transmission

of

at winter

not

s~t

NOTE:

If

the boat moves backwards with the selector

control in the forward position, shut problem may be the result shift lever by the shift control.

DAILY

OPERATION

of

incorrect movement

off

the engine! This

of

the

o Check transmission fluid.

o Visually check transmission and gear shift linkage.

o Start engine in neutral. Allow a few minutes for fluid

to warm.

NOTE:

Too

Iowan

noise from the gear and damper plate. In such cases the

idle speed should be increased.

idle speed will produce a chattering

o Shift into gear.

A

WARNING:

damage

SHIFT

The selector control mechanism and linkage must position the shift lever on the transmission exactly in Forward (F), Neutral (N), and Reverse (R) shifting positions. A detent ball located behind the transmission shift lever must work freely trol positions at the helm(s) must be coordinated

of justments. An improperly adjusted shift mechanism can

cause damage to the transmission. The shifting mechanism

and transmission shift lever should be free proper operation.

NOTE:

LEVER

to

center the lever in each position. The selector con-

the Velvet Drive shift lever through shift mechanism ad-

Do not remove detent ball!

the

Shifting

engine

and

POSITION

gears

above

1000

transmission.

rpm

can

with those

of

dirt to ensure

Reverse

Move selector lever to the reverse position. You should feel the detent. The shift lever on the transmission is in the reverse position. The output shaft and the propeller should move the boat in a reverse direction (astern).

NOTE:

Moving the transmission shift lever from Neutral Position to Forward is always towards the engine. Reverse is always away from the engine.

NOTE:

Be aware investigate to determine the cause.

of

any unusual noises

or

vibrations and

l-vvl

FORWARD

WESIERBEKE

I Engines & Generators

29

NEUTRAL

REVERSE

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

D Visually check for oil leaks at hydraulic connections.

Check wear on hydraulic lines and replace

D Lubricate detent ball and shift cable attachments. D Inspect shift linkage. D Inspect transmission bolts; retorque

A

CAUTION:

mission ball

positions.

Changing

After the initial

should be changed at haul-out. However, fluid must be changed whenever it becomes contaminated, changes color or smells rancid.

D Remove oil filler cap and dipstick.

D Remove oil cooler return line and allow oil to drain

into a container.

D Reconnect oil cooler return line.

D

Use a suction pump to remove transmission oil through the filler cap/dipstick hole.

D Clean

the used fluid.

D Refill the transmission with

mission fluid. The quantity will vary depending on . the transmission model and installation angle. Fill through the dipstick hole.

D Check dipstick for proper fluid level. D Replace oil filler cap/dipstick. (Dipstick is pressed

into place and turned clockwise until finger-tight.)

D Run engine - then shutdown and recheck fluid level.

A

WARNING:

gine

running.

hole.

This

Clutch

failure

shift

lever

does

Transmission

50

hour change, the transmission fluid

1000 operating hours or at winter

off

the transmission and properly dispose

Never

pull

Hot

fluid will

could

cause

will

not

fully

Fluid

the

splash

severe

occur

engage

Dextron II

dipstick

from

burns.

if

necessary.

if

the

or

III trans-

with

the

dipstick

if

worn.

trans-

detent

en-

of

(Continued)

OIL

FILLER

CAP

DIPSTICK

OIL

FILLER

AND

DIPSTICK

ASSEMBLY

CAP

HOLE

--==--M

AND ASSEMBLY

Lay-up/Winterize

Storage requires special care. Follow these procedures:

D Drain water from the transmission oil cooler and

of

replace with a proper mixture

NOTE:

This operation will occur normally when the

engine raw water cooling system is properly winterized.

D Clean up the transmission and touch up unpainted

areas (use heat resistant paint).

D Fill the transmission with

prevent internal corrosion.

D Loosen attaching hardware from the transmission

output flange and propeller shaft coupling flange before removing the boat from the water. Separate the flanges.

Spray the flanges with an anticorrosive coating.

D

WARRANTY

Service manuals are available from your BORG

WARNER dealer.

BORG WARNER is aware placed on its gears as the result

operation or fully reversing

shifting. Therefore torque loads and directional changes should be made at low engine speeds. the failure was caused by a shock load, the warranty claim will be denied.

Oil temperature maximum is 190°F (105°C) during operation. BORG WARNER distributor.

NOTES

of

If

oil temperature runs too high, consult your

antifreeze coolant.

Dextron

the shock loads that can be

propeller blades while

II

or

III fluid to

of

mechanical propeller

If

it is found that

tvv/

A

CAUTION:

can

occur

gear

ranle transmission. total

system-related

WESIERBEKE

(Engines

& Generators

30

System-related

at

low

engine

resulting

BORG

speeds

in

damage

WARNER

torsional

noises

or

which

to

the

engine

is

not

responsible

vibration

vibrations

can

cause

of

this

and/or

for

type.

ENGINE

TROUBLESHOOTING

The following troubleshooting table describes certain problems, the probable causes

of

the problems, and the

recommendations to overcome the problems.

NOTE:

The engine's electrical system is protected by a 20-Ampere manual reset circuit breaker located on a bracket on the left front side

of

the engine. The preheat

solenoid is mounted on the same bracket.

Key

Switch

depressed:

fuel

solenoid,

and

preheat

Key

Switch depressed; depressed;

START

switch indications fuel

solenoid

No

ignition:

start;

fuel

solenoid

No

ignition.

Engine

cranks

Engine

can't

Engine

stops.

Battery

not

Problem

on,

PREHEAT

no

panel

electrical

solenoid

on,

PREHEAT

START

switch

no

starter

is

depressed;

OK;

start

not

functioning.

cranks,

energized.

Fuel

solenoid

slowly,

be

stopped.

charging.

switch

indications;

fuel

pump

not

energized.

switch

engagement.

panel

solenoid

OK;

but

does

not

energized.

then

fails.

1.

Battery 20-Amp

2.

3.

10

4.

Loose

5.

Preheat

1.

Connection

2.

Faulty

3.

Faulty

4.

Neutral

5.

Loose

S.

Low

1.

Poor

2.

Defective

1.

Faulty

2.

Preheat Starting

1.

2.

Water

STOP

1.

2.

Fuel

3.

Check through

Fuel

1.

2.

Switches connected.

3.

Fuel

4.

20-amp.

5.

Exhaust

Water

6.

Alternator

1.

Probable

switch

circuit

Amp

breaker

battery

solenoid

to START solenoid.

safety

battery

batteries.

connections

fuel

fueling

solenoid

battery

in

engine

switch

run

solenoid

DC

alternator

regulator

lift

pump

and/or

Starvation

circuit

system

in

fuel.

drive

Cause

not

on.

breaker

tripped.

connections.

not

operating.

solenoid

faulty.

switch.

switch

open.

connection.

to

fuel

solenoid.

system.

faulty.

failure

failure.

will

not

for

feedback

circuit.

failure.

wiring

loose

breaker

tripping.

is

restricted.

solenoid.

de-energize.

or

dis-

1.

Check Reset

2. noid

3.

Check

4.

Check engine

5.

Check

1.

Check

2.

Check

3.

Check activation

4.

Shift Check

5.

Check

6.

1.

Check

2.

Check

(+)

1.

Check

1a.

Check system.

1b.

Filters

2.

Check

1.

Check

1a.

Switch

1b.

Replace

2.

Exhaust ders. problem

1.

Check shutoff ohmmeter.

2a.

Manually solenoid

2b.

Loosen

ware

3.

Disconnect

1.

Fuel Replace

2.

Inspect Inspect

3.

Check

4.

Check sure cause

5.

Check exhaust

6.

Pump

fuel

1.

Check Check

switch

and/or

breaker;

circuit

and

voltage

at

(+)

connection

ground

stud.

Solenoid.

connection switch

with

that

12

volts

connection.

lever

in

neutral -check

battery

connection.

battery

charge connections. that

12

that

fuel

for

air

clogged. solenoid.

start

to

combine batteries. system

Water

that

switch

lever

disconnect

at

the

high

of

fuel

lift

pump

all

wiring

switches

fuel

supply,

for

high

switch

tripping.

for

blockage,

elbow.

water

drive for

loose

volts

in

batteries.

must

can

will

on

pressure

spray.

the R terminal.

should

is

from

belt

connection

system.

Verification/Remedy

battery

connections.

if

breaker

trips

again,

check

circuit

and

after

on

starter

Check

battery

at

solenoid.

ohmmeter.

are

present

state.

are

present

on

the

fuel

valves

are

fuel

system.

(Replace

filters

house

failure -raw

be

removed

be

corrected.

not

open

the

injection

the

injection

with

DC

not

12

pump.

injector

make a distinct

spare.

for

short

for

proper

fuel

valves,

amperage

overly

sensitive

collapsed

fuel

tank(s);

tension.

connections.

breaker.

run

open.

and

circuits

Alternator

for

shorts

solenoid

cable

at

starter

switch.

at

the

solenoid.

Bleed

air

and

bleed

start

batteries.

water

has

from

engine

run

circuit.

pump

side.

volt

connection

lines

at

and

operation.

fuel

lift

draw

during

to

hose,

change

should

Check

check

and

connections.

from

Manually

each

ticking

loose

pump.

heat

carbon

filters

output

preheat

to

ground.

(-)

connection

solenoid

engine

fuel

system

backed

- a

Test

switch

to

injector.

sound.

connections.

operation. which

buildup

and

turn

with

sole-

fuel

of

into

cylin-

serious

move

with

the

fuel

Be-

En-

would

at

bleed

freely.

voltmeter.

to

air.)

the

run

I~l

I Engines & Generators

WESJERBEKE

31

Battery

runs

Engine

overheat.

NOTE:

Shut

engine

Exhaust

smoking

Transmission of

gear,

or

drive

Problem

down.

down

problems.

will

not

the

vessel.

immediately.

shift

in

or

ENGINE

Probable

1.

Oil

pressure

switch.

2.

High

resistance

3.

Low

resistance

Alternator.

4.

Poor

battery

water

not

smoke.

or

gray

connections.

not

circulating.

smoke.

out

5.

Raw

1. Coolant

2.

1.

Blue

2.

White

Black

3.

1.

Transmission

2.

Transmission

TROUBLESHOOTING

(Continued)

Ensure

12

volts

are

present

at

the

"R"

terminal.

Cause

leak

to

ground.

leak.

Circulating.

failure.

oil

cooler

failure.

1.

Observe gine

2.

Check lines. place

3.

Check

4.

Disconnect charging. test.

5.

Check

1.

Broken

2.

Raw

2a.

Obstruction

2b.

Thermostat

thermostat.

2c.

Loss

etc.

2d.

Broken

2e.

Air

petcocks,

Add

1.

Incorrect

1a.

Crankcase (oil

2.

Engine

2a.

Faulty

3.

Improper

3a.

Fuel or

strictions

3b.

Improperly

1a.

Check mission

1b.

Check

1c.

Check

1d.

Check

2a.

Replace

is

Repair

water

of

for

leak

coolant

is

burn

insufficient

Verification/Remedy

if

gauges

not

wiring. (Do after

all

cable

or

coolant -check

leaks. or

in

blowing

is

injector

cable

lever.

transmission shaft drive

oil

and

running.

Insert

not

start

engine.)

short

is

located.

wires

for

temperature

alternator

If

leakage or

replace.

connections

loose

belt

pump

failure.

at

raw

water

-

remove

loose

belts -tighten/replace.

system;

run

heat

exchanger,

as

needed.

grade

of

engine

overfilled

out

through

running

cold.

or

incorrect

grade

of

fuel.

incomplete

air

for

in

exhaust

timed

injectors

connections

couplings damper

cooler.

panel

Test

the

sensitive

at

output,

stops,

remove

at

raw

water

Check

intake

and

test

hoses,

engine

manifold,

oil.

with

engine

the

injector

due

to

proper

system;

or

at

fluid.

or

engine

lights

are

oil

Remove

battery.

high

combustion.

steering

activated

pressure

switch.

(0-.25

amp)

connections

rise

to

locate

after a good

alternator

pump.

impeller -replace.

or

raw

water

in

hot

water.

hose

clamps,

and

open

cooling

etc.

to

oil

exhaust).

timing.

back

pressure

air

intake.)

or

station

damper

(Check

poor

plate.

check

valves

when

meter

in

battery

and

the

fault.

battery

and

bench

filter.

Replace

drain

plug,

system

bleed

air.

in

exhaust

for

re-

compression.

and

at

trans-

en-

re-

TROUBLESHOOTING

If

the gauge reading is other than what is normally indicated by the gauge when the instrument panel is energized, the first step is to check for between the ignition (B+) and the Negative terminals

Assuming that there is 12 volts as required, leave the instrument panel energized and perform the following steps:

1.

2. Connect the sender terminal at the gauge to ground

of

the gauge.

Disconnect the sender wire at the gauge and see

gauge reads zero, which is the normal reading for this

situation.

and see

if

the gauge reads full scale, which is the

normal reading for this situation.

WATER

TEMPERATURE

If undoubtedly

12

volts DC

(B-)

conductor from the sender to the gauge or with the

sender. If

is probably defective and should be replaced. Assuming the gauge is

sender to the sender terminal at the gauge for continuity.

if

the

Check that the engine block is connected to the ground. Some starters have isolated ground terminals and battery is connected to the starter (both plus and minus terminals), the ground side will not necessarily be connected to the block.

1"VV1 WESJERBEKE

I

Engines & Generators

32

both

either

AND

OIL

PRESSURE

of

the above gauge tests are positive, the gauge is

GAUGES

OK and the problem lies either with the

of

the above gauge tests are negative, the gauge

OK, check the conductor from the

if

the

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 prefer to accomplish lay-up preparation themselves.

The following procedures will allow you to perform your own lay-up and recommissioning, or you may use them as

a check list for others. These procedures should afford your engine protection during a lay-up and also help familiarize you with the maintenance needs gine.

If

you have any questions regarding lay-up procedures, call your local servicing dealer; he will be more than willing to provide assistance.

PROPELLER

The transmission and propeller half couplings should al-

ways be opened up and the bolts removed when the boat is hauled out and during storage in a cradle. The flexibility often puts a severe strain on the propeller shaft or cou-

pling, 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 been dry for a considerable period

FRESH

A 50-50 solution

mended for use in the freshwater cooling system at all

times. This solution may require a higher concentration

of

antifreeze, depending on the area's winter climate.

Check the solution to make sure the antifreeze protection

is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated mixture. Operate the engine to ensure a complete circulation and mixture

throughout the cooling system. Now recheck the anti-

freeze solution's strength.

LUBRICATION

With the engine warm, drain all the engine oil from the oil sump. Remove and replace the oil filter. (Place some paper towels and a plastic bag around the filter to catch the oil during its removal.)

When installing the new oil filter, be sure to apply a

SHAFT

of

the water or moved from land to water,

of

the water when not in use, unless they have

WATER

of

COUPLING

COOLING

antifreeze and fresh water is recom-

of

the antifreeze concentration

SYSTEM

of

inactivity. Others

of

time.

SYSTEM

your en-

of

the boat

small amount base

of

oil for your engine model. (Refer to the SPECIFICA-

TIONS section

specification of CF or CG4. Run the engine and check for proper oil pressure and make sure there are not leaks. Stop the engine, check oil level and add oil as needed to bring level to dipstick full mark.

ACAUTION:

oil

in combustion ful

chemicals

gine's

FUEL

Top off your fuel tanks with tives should be added at this time to control algae, and a fuel conditioner such that the additives used are compatible with the primary filter/water separator used in the system. Change the element in your primary fuel filter/water separator, the fuel system contains one, and clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the system, for

5-10 minutes to make sure no air is 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.

RAW

Close the through-hull fitting. Remove the raw water intake hose from the fitting. Place the end a 5-gallon bucket engine, check the zinc anode found in the heat exchanger on the engine and clean or replace it as required. Clean the raw water strainer, the hull.

Start the engine and allow the raw water pump to draw fresh water through the system. When the bucket is empty, stop the engine and refill the bucket with an antifreeze solution slightly stronger then needed for winter freeze protection in your area.

Start the engine again and allow all drawn through the raw water system. empty, stop the engine. This antifreeze mixture should

of

oil on the rubber sealing gasket at the

the filter. Fill the sump with the correct amou'nt

of

the

sump

internal

this manual.) Use an

Do

not

leave

over

the

lay-up

depOSits

which

combine

can

reduce

parts.

the

oilwith

engine's

period.

to

produce

the

life

an API

old

engine

Engine

harm-

of

the

oil

en-

SYSTEM

No.2

diesel fuel. Fuel addi-

as

ST

ABIL.

Care should be taken

if

as

needed. Start the engine and allow it to run

WATER

CIRCUIT

of

this hose into

of

clean fresh water. Before starting the

if

one is installed in the inside

of

this mixture to be

Once the bucket is

and

of

tvvl

WESTERBEKE

I

Engines

& Generators

33

LAY-UP

AND

RECOMMISSIONING

(Continued)

protect the raw water circuit from freezing during the

winter lay-up, as well as providing corrosion protection. Rempve the impeller from your raw water pump (some anti-

freeze mixture will accompany it, so catch it in a bucket). Examine the impeller. Acquire replacement, and a cover gasket. Do not replace the impeller (into the pump) until recommissioning, but replace the cover and gasket.

INTAKE

Open the intake manifold and inspect the filter elements inside. Clean with low pressure compressed air or replace if

needed. Do not leave filters installed during lay-up period. Filter elements should be stored in a clean dry area. dampness out.

STARTER

Lubrication and cleaning

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.

MANIFOLD

Place an oil rag in the intake opening to keep

MOTOR

of

the starter drive pinion is

if

access to the starter permits its removal.

if

needed,

BATTERIES

If

batteries are to be left on board during the lay-up pe-

riod, make sure they are fully charged and will remain

If

emit

hydrogen,

ignited

the arcing

apron

you have any

a

by

elec-

Do

not

banery

being

during

and

that way, to prevent them from freezing. doubt that the batteries will not remain fully charged, or that they will be subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

AWARNING:

highly

explosive

trical

arcing

smoke

or

serviced. in

the

vicinity servicing. eye

protection

Lead

or

allow

Shut

to

Wear

acid

gas,

which

lighted

an

open

off

all

prevent

rubber

when

servicing

baneries

can

be

tobacco

flame

electrical

products.

near

equipment

electrical

gloves, a rubber

batteries.

RECOMMISSIONING

The recommissioning after a seasonal lay-up generally follows the same procedures as those presented in the

STARTING section regarding preparation for starting and

normal starts. However, some will need to be counteracted before starting the engine.

of

your WESTERBEKE engine

PREPARATION FOR

of

the lay-up procedures

CYLINDER

It is not necessary to remove the glow plugs from the

cylinder head to squirt light engine oil into the cylinders for the few months anticipate a longer lay-up period (12 months or more), we recommend that this procedure be performed. The light oil in the cylinders will prevent the pistons' rings from sticking to the cylinder walls. With oil in the cylinders, tum the engine over by hand two revolutions.

LUBRICATION

of

normal lay-up. However,

if

you

TRANSMISSION

Check or change fluid in the transmission Wipe off grime and grease and touch up unpainted areas. Protect coupling and output flange with anticorrosion coating. Check that transmission vent is open.

as

required.

SPARES

Lay-up time provides a good opportunity to inspect your WESTERBEKE engine to see drive belts 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 and zinc anodes.

if

external items such as

1. Remove the oil-soaked cloths from the intake mani-

fold and from the through-hull exhaust port.

2. Remove the raw water pump cover and gasket. Discard the gasket. Install the raw water pump impeller re-

if

moved during lay-up (or a replacement, Install the raw water pump cover with a new cover gasket.

3. Reconnect the shaft coupling and check for proper alignment.

4. 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 the batteries are fully charged.

of

5. Check the condition ter circuit and clean or replace the anode that it is not necessary to flush the antifreeze/freshwater solution from the raw water coolant system. When

the engine is put into operation, the system will self-flush

of

in a short period

6.

Start the engine in accordance with procedures in the

PREPARATION FOR INITIAL START-UP section

manual.

time with no adverse affects.

the zinc anode in the raw wa-

required).

as

needed. Note

of

this

!-VVI

I Engines & Generatol'S

WSJERBEKE

34

WESTERBEKE

55A

FOUR

TORQUE

Cylinder Head Bolts

Connecting Rod Cap Bolts 51-54 Main Bearing Cap Bolts Injection Pump Drive Gear 43-52 Oil Pan Crankshaft Pulley Bolts 17-24 Glow Intake Manifold Bolts 12-20 Exhaust Manifold Bolts Switches and Injector HIP Line Nuts 13-17 Freshwater Pump Mounting Bolts 23-34

Timing Belt Covers

Flywheel Bolts 130-137 Camshaft Cap Bolts

Block Oil Jets Rocker Cover Bolts Back Plate Bolts 12-17 Rear Oil Timing Belt Drive Gear Bolt 116-123 Thermostat Assembly 12-17

Oil Cooler Assembly Bolts

Bolts

Plugs 11-15

Senders 9-13

Oil Seal Housing

Strainer Pick-Up

SPECIFICATIONS

Ib-ft

Cylinder head bolts are not retorqued. Bolts are torqued only during engine assembly.

61-65

5-7

16-20

5-7

15-20 2.0-2.7

9-13 1.2-1.8 5-7

5-7 5-7

MIO 23-24 3.2-4.7 M6

5-7

kg-m

7.0-7.5

8.4-9.0

6.0-7.0

0.7-1.0

2.3-3.3

1.5-2.0

1.6-2.7

2.2-2.7

1.2-1.8

1.8-2.3

3.2-4.7

0.7-1.0 18-19

0.7-1.0

1.6-2.3

0.7-1.0

0.7-1.0 16-17

1.6-2.3

0.7-1.0

l-vvl

WESJERBEKE

I

Engines & Generators

35

/

STANDARD

NOTE:

Unless stated otherwise

following torque values when tightening standard hardware.

HARDWARE

for

a specific assembly, use the

TORQUES

Grade

Grade6T

4 6mm bolt head/nut 1 8mm bolt head/nut 1.25

10mm bolt head/nut 1.25 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

6mm bolt head/nut 1

8mm bolt head/nut 1.25 10mm bolt head/nut IOmm

bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 1.75

Pitch

1.5

1.25

(ISO) 25.3-39.8

1.5

1.75

1.5

2

1.5

2 51.4-76.7

1.25

1.5

1.25

(ISO) 36.2-57.9

1.5

lb-ft

2.9-5.1

7.2-11.6

13.7-22.4

13.0-21.7

25.3-39.8

21.7-36.2

32.5-50.6

36.2-57.9

34.0-55.7

54.2-79.6

4.3-6.5

10.8-15.9

21.7-32.5

19.5-30.4

36.2-50.6

34.7-49.2

kg-m

0.4--0.7

1.0-1.6

1.9-3.1

1.8-3.0

3.5-5.5

3.0-5.0

4.5-7.0

5.0-8.0

4.7-7.7

7.5-11.0

7.1-10.6

0.6-0.9

1.5-2.2

3.0-4.5

2.7-4.2

5.0-8.0

5.0-7.0

4.8-6.8

Grade

Grade 5 Cap

7T,

8T

and

8.8 6mm bolt head/nut 8mm bolt head/nut 1.25

IOmm bolt head/nut 1.25 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 1.5 14mm bolt head/nut 1.5 14mm bolt head/nut 2 16mm bolt head/nut 16mm bolt head/nut

Screw

114

UNC

114

UNF

5116

UNC

5116

UNF

3/8 UNC 3/8 UNF

7/16

UNC

7/16

UNF 1I2UNC 112

UNF

1 5.8-8.7

14.5-21.7

28.9-39.8

1.5

1.25

(ISO) 54.2-75.9

1.5

1.75 43.4-61.5

1.5 2

26.8-37.6

50.6-65.1

57.9-86.8

72.3-108.5

68.7-101.3

108.5-166.4

101.3-159.1

9-11 11-13 18-20 21-23 28-33

30-35 44-49 50-55 68-73 73-80

0.8-1.2

2.0-3.0

4.0-5.5

3.7-5.2

7.5-10.5

7.0-9.0

6.0-8.5

8.0-12.0

10.0-15.0

9.5-14.0

15.0-23.0

14.0-22.0

1.2-1.5

1.5-1.8

2.5-2.8

2.9-3.2

3.7-4.6

4.1-4.8

6.1-6.8

6.9-7.6

9.4-10.1

10.1-11.1

l-vvl

WESJmBEKE

r

Engines & Gene",tors

36

WESTERBEKE

55A

FOUR

SPECIFICATIONS

Engine

Type

Governor

Valve

Mechanism

Combustion

Bore & Stroke Piston

Displacement

Firing

Drder Direction Maximum

(at Compression Compression Valve Valve

(engine Dimensions

Inclination

Dry Engine

Fuel

Injection Injection Injectors Injection

Lift Fuel Air Air

(engine (engine

Exhaust Exhaust Muffler

of

Torque

1920

rpm)

Seat

Angle

Clearance

cold)

Weight

Speed

Consumption

Pump

Timing

Pressure

Pump

Filter

(on Cleaner Flow

combustion) cooling)

Elbow Hose

Size

Chamber

Rotation

Ratio Pressure

engine)

Size

(min.)

ENGINE

Diesel, cooled, maximum)

Integral flyweig

Overhead Swirl

3.38 x 3.70

133.2 1-3-4-2 Clockwise, 93

22.7 427 Intake Intake

Exhaust Height:

Width: Length:

Continuous (not

470

Idle Cruising No

1.5 (approximate) 3600

un~erway

FUEL

No.2 (cetane

Zexel

OOTDC Th 1920

(135 12 Spin-on

Replaceable

140

250

EXHAUST

45° 2-1/2 14

SPECIFICATIONS

four-cycle,

vertical,

of

ht

chamber

cubic

Ib-ft

(12.9

:1

psi

(3D 45°, .008 -0.012

0.012 -0.016

26.78

50.0

35.0

to

exceed

Ibs

(213.2

speed:

load: U.S.

gph

rpm

four-cylinder,

in-line

the

injection

type

inches

(86.0 x 94.0

inches

{2.18

when

viewed

kg-m)

kg/cm2)

at

Exhaust

45° in.{0.20 -0.30mm)

inches

(546.1

inches

14°,

Temporary

30

min.)

kgs)

750 -1000

speed:

2500 -3000

4200 -4500

(5.6

Iph)

when

at

full

open

in

forward

(55

pump,

200

in.

(680.2

(889.0

rpm

running

the

'propeller

throttle

gear.

SYSTEM

dies'el

oil

rating

of

45

or

higher)

mechanical

rottle

type

psi + 71

kg/cm

volt -plunger

cfm cfm

psi

2

+ 5

type

(replaceable)

paper

(3.9

cmm)

(7.0

cmm)

governed

kg/cm2)

type

filter

element

at

3600

.

SYSTEM

elbow

inch

1.0.

hose

inch x 14

inch

freshwater-

hp

at

3600

mechanical

mm)

liters)

from

the

front

rpm

(0.30 -0.40mm)

mm)

25°

rpm

at

2500

allows

while

rpm

General

Operating Fresh Sea

Sea

(measured

ing System

(fresh

Starting

Battery

Starter

Starting

DC Cold Alternator

Regulator

General

Gear Propeller

of Propeller

(using

2.74:1

Lubricating Transmission

Capacity

General

Oil

Sump

Operating

Oil

Temperature

Water

Pump

Water

Flow,

before

into

exhaust Capacity

water)

Battery

Capacity

Motor

Aid

No-Load

Cranking

(Standard)

ratio

(standard)

Shaft

Rotation

Recommendations

standard

reduction)

Fluid

Filler

Capacity

Oil

Grade

Pump

at

3600

discharg-

elbow)

Current

Direction

transmission

Sump

Pressure

COOLING

rpm

ELECTRICAL

SYSTEM

Freshwater-cooled controlled

170 -190°F Centrifugal

POSitive belt

16.0

9.5

with

displacement,

driven

gpm

(60.5

U.S.

qts

SYSTEM

12-volt,

(-) 300 -400 12-volt,

1.6kw,

reduction

Glow 100 280 -300 12-volt,

Internal

plug

amps

DC,

regulator,

gear

at

TRANSMISSION

(Hurth

Standard

hardened operated

2.74: 1 (HBW250 -3R) Right

20

propeller full open gear.

ATF -type A or

0.79

ENGINE

Pressure

gears

Full

4.5

30 -60

engine temperature

helical

multiple

handed -standard

D x

13

P -2

should

rated

rpm

throttle

U.S.

qts

OIL

SYSTEM

feed,

from

flow,

paper

U.S.

qts

psi

rpm

API

Specification

block,

raw

(77 -88°C)

type,

Ipm)

(10.0

negative

Cold

solenoid,

11.5

amps

50

amps

blade

(3600 + 000 -100)

while

Dextran

(0.75

rotor

camshaft

element, (5.9 (2.1 -4.2

and

thermostatically-

water

exchanger

metal

impeller rubber

approximate

liters)

ground

Cranking

amps

actuated

volts

(3000

at

10

volts

built

into

Transmission)

gears,

with a servo-

disc

clutch.

transmission

or

20

D x

allow

the

engine

underway

-

/I

liters)

approximate

type,

driven

spin-on

liters)

including kg/cm2)

at

normal

operating

CF

or

CG4

belt-driven

impeller,

(CCA)

shift

rpm,

min.)

(250

rpm,

alternator

Case-

11

P -3

to

at

in

forward

OR

11/

by

type filter

at

maximum

system.

(min.)

min.)

blade

reach

full

spiral

its

I"VtTI WESJERBEKE

(Engines

& Generators

37

Revised

October 2000

WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK

AVON, MA

---

~

02322·

TEL:

(508) 588-7700 • FAX: (508) 559-9323

Member

National Marine ManufacturersAssocUztion

Westerbeke 55A FOUR Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual