Westerbeke 11A-1 Operator'S Manual Download Page 44 | Manualshive

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Summary of Contents for 11A-1

Page 1: ...S PUBLICATION NO 45145 1st Edition April 2001 J WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A TEL 508 823 7677 FAX 508 884 9688 WEBSITE www WE...

Page 2: ...N NO 45145 15t Edition April 2001 r WESTERBEKE W ST RB K CORPORATION MYL S STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A TEL 508 823 7677 FAX 508 884 9688 WEBSITE www WEST...

Page 3: ...Throbbing in Temples Muscular Twitching Vomiting Wea cness andSleepiness Inability to Think Coherently IF YOU OR ANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GET OUTINTO THE FRESH AIR IMMEDIATELY sympto...

Page 4: ...REVENT BURNS FIRE A WARNING Fire can causeinjury ordeath Prevent flash fires Do not smoke or permit flames or sparks to occur near the fuel line filter fuel pump or other potential sources ofspilled f...

Page 5: ...the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engi...

Page 6: ...thor ough examination ofthe American Boat and Yacht Council s ABYC standards These standards are a combination of sources including the USCG and the NFPA Sections ofthe ABYC standards ofparticular in...

Page 7: ...water damage to the engine and possibleflooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under any of the vessel s var...

Page 8: ...cedure 13 Alternator Troubleshooting 28 Engine Break In Procedure 13 Testing the Alternator 28 Break In Check List 13 Checking the Service Battery 29 Transmission Break In 13 7A I Marine Diesel Engine...

Page 9: ...e decade and the second and third numbers after the character represent the month of manufacture PRODUCT SOFTWARE Product software tech data parts lists manuals brochures and catalogs provided from so...

Page 10: ...r replacement parts are needed always provide the engine model number and serial number You must provide us with this information so we may properly iden tify your engine In addition include a complet...

Page 11: ...or higher Mechanical 1 6 ft 0 5 m lift max Bosch type Direct injection 39 mm BTDC static 2900 psi 203 9 kg cm 0 46 U S gal hr 1 76Iiterlhr Primary replaceable filter 1 4 in 6 35 mm 1 0 minimum 5116 i...

Page 12: ...EVICE HAN CRANK HANDLE GUIDE RAW WATER PUMP RAW WATER flEXIBLE MOUNTS INTAKE CONNECTION TRANSMISSION TRANSMISSION OUTPUT FLANGE FUEL INJECTOR t Hl f H 4 t i M 5 Engines Generators 5 CYLINDER HEAD WATE...

Page 13: ...her Mechanical 1 6 ft 0 5 m lift max Bosch type Direct Injection 60 mm BTDC static 2537 5 psi 178 4 kg cm 0 46 U S gaL hr 1 76Iiterlhr Primary replaceable filter 1 4 in 6 35 mm 1 0 minimum 5 16 in 7 9...

Page 14: ...TIlANS SSION OIPSTIClCIFlll TRANSMISSION 11A 1 DIESEL ENGINE PARTS IDENnFICATION CYLINDER HEAD TlfROTrtE CONTROL STARTER FUEL INJECTOR COOlANT TE PERATURE SWITCH FUEL FILTER fOAArpoc CIRCUIT BREAKER...

Page 15: ...e Oil Viscosity Above 68 F 20 C SAE 30 10W 30 or 15W 40 41 68 F 5 20 C SAE 20 or 10W 30 Below 41 F 5 C SAE10W 30 A CAUTION Do not allow two ormore brands of engine oil to mix Each brand contains its o...

Page 16: ...discharged and too low for a normal electric start but not completely dead an attempt at an electric start can be made by using the Automatic Decompression Device This device works by holding the exh...

Page 17: ...sing the Automatic Decompression Device see Low Battery Electric Starting under ELECfRlC SfAR1 the electrical power required for the start would then be considerably less so that a discharged battery...

Page 18: ...CRANK HANDLE GUIDE 4 Crank the engine counterclockwise approximately 10 to 20 times until the engine turns freely Then remove the crank handle S Set the Automatic Decompression Device pointer to the m...

Page 19: ...operating Initial Start Up Check List o Check for possible leaks from all the connections o Make sure the cooling water is discharging properly outboard from the exhaust outlet o Make certain that the...

Page 20: ...reak in period o Check for fuel engine oil and water leaks o Check for abnormal noise such as knocking friction vibration and blow back sounds o Confmn the exhaust smoke When the engine is cold white...

Page 21: ...e the filter if necessary Fuel lift pump Clean or replace the two filters See FUEL LIFT PUMP under FUEL SYSTEM Fuel filter Change the filter Check and adjust the injection opening pres Fuel injector s...

Page 22: ...ING THE CYLINDER HEAD under ENGINE ADJUST head nuts MENTS Transmission Initial fluid change at 25 hours then every fluid level 300 hours or at winterizing Engine Chattering at idle and low rpms is an...

Page 23: ...water supply hose to the exhaust elbow The siphon break provides an air vent in the raw water cooling system to prevent raw water from filling the exhaust sys tem and the engine s cylinder when the e...

Page 24: ...A CAUTION Prolonged cranking intervals without the engine starting can result in the engine exhaust sys tem filling with raw water This may happen because the pump ispumping raw water through the raw...

Page 25: ...ated on the engine block This switch s sensor monitors the engine s oil pressure Should the engine s oil pressure fall below the specified value this switch will activate a pulsating aIarm on the cont...

Page 26: ...Be sure to change the spin on oil filter at every oil change see Changing the Spin On Oil Filter below NOTE With an inclined engine installation the lube oil must bepumped out otherwise too much oil w...

Page 27: ...ck Fill to but not over the MAX mark on the dipstick should the engine require additional oil TESTING THE OIL PRESSURE Before testing make sure the oil level is at the MAX mark on the dipstick 1 Remov...

Page 28: ...e cylinder head controls the raw water coolant temperature as the coolant flows through the cool ing system The thermostat is set to the maximum temperature of 140 F 60 C When the engine is first star...

Page 29: ...rline during all angles of the boat s operation See Westerbeke s INSTAlL4 TIONMANUALfor MARINE ENGINES and GENERATORS for complete installation guidelines A WARNING Do not use ascoop type through hull...

Page 30: ...t be installed in the high point of a hose that is looped a minimum of 20 inches 51 cm above the vessel s waterline This siphon break must always be above the waterline during all angles of vessel ope...

Page 31: ...oily replace it WATER HEATER WATER HEATER INSTALLATIONS This engine is equipped with connections for plumbing the engine coolant to transfer heat to an on board water heater The water heater should b...

Page 32: ...p should not be more than 1ft 300 mm above the bottom of the fuel tank pickup FUEL FILTER The frequency of a fuel filter change depends on the degree of contamination of the fuel however it should be...

Page 33: ...in handling The fuel injection pump has been thoroughly bench tested and the owner operator is cautioned not to attempt to service it The only adjustment the servicing mechanic should make to the fue...

Page 34: ...erload anywhere in the instrument panel wiring or engine wiring will cause the breaker to trip In this event the engine will shut down because the opened breaker disconnects the fuel supply Ifthis sho...

Page 35: ...re power cord isolate DCandAC converters andshut down the engine before performing DC testing No AC tests shouldbe made without a proper knowledge ofAC circuits 1 Start the engine 2 After the engine h...

Page 36: ...iable service facility NOTE Before removing the alternatorfor repair use a voltmeter to ensure that 12 volts DC excitation is present at the EXC terminal ifthe previous test showed only bat tery volta...

Page 37: ...IlEl AY RELAY 4 RED I 2 WHT 12 RED T 7 1 MODEL IS OUIPPED WITH A TIME DELAY RELAY THAT PREVENTS THE EXCITATION or THE AlTERNATOR DURING PREHEAT AND CRANKING THE ALTERNATOR EXCITATION Will OCCUR APPROX...

Page 38: ...ED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE STARTER EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL KEY SWITCH SHUT DOWN THE BUILDER OWNER MUST BE SURE THAT THE INSTRUME...

Page 39: ...r STARTER DC ELECTRICAL SYSTEM 11A 1 MARINE DIESEL ENGINE WIRING DIAGRAM 44542 I 4 BL K WATER TEJoP SlilTCH 114 VIO 114 RED WHT 112 WHT 1I2RED 14 y l 51 II PI KEY SWITCH L Engines Generators 32 IlL P...

Page 40: ...CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL SHUT DOWN THE BUILDER OWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEV...

Page 41: ...re connection and the other to the body of the glow plug as shown A good glow plug will have a 0 55 ohm resistance This method can be used with the plug in or out of the engine You can also use an amm...

Page 42: ...TION JJ 3 Set the piston at the TDC of the compression stroke 4 Loosen the locknuts on the valve setting screws see illustration 5 For each valve insert a 0 2 mm 0 008 in feeler gauge between the valv...

Page 43: ...washer should be removed with the injector and replaced with a new washer when the injector is reinstalled 5 Remove the gaskets 6 Remove the O rings Fuel Injector Components The fuel injector consists...

Page 44: ...Pattern The number offuel sprays and fineness ofthe injected fuel is substandard Ifthe condition ofthe injected fuel is substandard disassemble wash and recheck the injection nozzle or replace it Chec...

Page 45: ...hile the engine Is in operation Checking Belt Tension 1 To check the belt tension press the belt at the approxi mate midpoint Gust above the bellhousing between the alternator pulley and the flywheel...

Page 46: ...stops Faulty fuel supply 1 Fuel filter clogged 2 Water in fuel 3 Faulty injector nozzle 4 Faulty injection pump 5 Fuel line clogged 6 Fuel lines or connections leak Faulty air intake and or 1 Restrict...

Page 47: ...3 Faulty thermostat 3 Check replace thermostat 4 Clogged raw water intake strainer 4 Clean the strainer 5 Lube oil level too high 5 Drain to proper level 6 Faulty injector nozzle 6 Check replace nozz...

Page 48: ...late 1 Adjust timing 2 Injector nozzle is worn out 2 Replace nozzle 3 Low engine operating temperature 3 Clean thermostat Oil in exhaust discharge 1 Rings not seated 1 Initial 50 hours of operation re...

Page 49: ...nge and the stem gland is less than about 32 in 812 mm Shift Control and Actuating Lever The transmission is suitable for single lever remote control Upon loosening the retaining screw the actuating l...

Page 50: ...PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direction of travel for this purpose Never put the gear shift in the pos...

Page 51: ...more o Loosen attaching hardware from the transmission output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges and spray with lubricant o Inspec...

Page 52: ...needs professional attention gear but fails to propel 2 Propeller shaft is not turning Output 2 The coupling bolts are sheared or the coupling is slipping the boat coupling is tuming on the propeller...

Page 53: ...nd bleed the fuel system as needed Start the engine and allow it to run for 5 10 minutes to make sure there is no air left in the fuel system Check for any leaks that may have been created in the fuel...

Page 54: ...used during the lay up such as filters See SUGGESTED SPARE PARTS KEYSWITCH MAINTENANCE Lubricate the keyswitch with WCKEZE to ensure that the switch mechanism functions freely with no binding STORAGE...

Page 55: ...der injection pump 14 34 39 14 34 39 High pressure fuelline injection pump 17 18 22 17 18 22 High pressure fuel line fuel injector 17 25 30 17 25 30 Injector clamp 10 8 12 13 20 23 Governor on cranksh...

Page 56: ...5 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 M36 55mm 700 950 992 1345 1925 2610 2744 3720 SEALANTS LUBRICANTS GASmSJSE...

Page 57: ...6 56168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHE...

Page 58: ...s g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kil...

Page 59: ...s Drive Belt Raw Water Pump Impeller and Gasket Fuel Filter Fuel Lift Pump Screens 2 and Gasket Oil Filter Model lOA I only Fuel Hardware Kit to fix a leak Air Intake Filter Kit B Includes Drive Belt...

Page 60: ......

Page 61: ...Engines Generators 1045 5C 4JD1...

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