Westerbeke 35B THREE Operator'S Manual Download Page 17

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Summary of Contents for 35B THREE

Page 1: ...RATOR S MANUAL WESTER8EKE 358 THREE 388 FOUR 428 FOUR MARINE DIESEL ENGINES Publication 37435 Edition One March 1988 WESI ERBEKE WESTERBEKE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 TEL 617 588 7...

Page 2: ...aks and make sure the exhaust manifolds are securely attached and no warping exists Be sure the unit and its surroundings are well ventilated Use Extreme Care When Handling Engine Filel A constant dan...

Page 3: ...facturers with their own software and Wester beke must depend on such software for the design of Westerbeke s own product software Such software however may be outdated and no longer accurate Routine...

Page 4: ...tact the factory in writing with Model information including the engine s serial number and commission date from WESTERBEKE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 Mail To Inspection of Equipme...

Page 5: ...FOUR SYSTEM SPECiFiCATIONS 19 INSTALLATION CHECKS 21 PREPARATION FOR STARTING 33 DESCRIPTION OF INSTRUMENT PANELS 35 STARTING PROCEDURE 39 STOPPING PROCEDURE 41 FUEL SYSTEM 43 ELECTRICAL SYSTEM 46 CAP...

Page 6: ...TABLE OF CONTENTS CONTINUED LAY UP RECOMMISSIONING 89 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 93 TORQUE SPECiFiCATIONS 94 SPARE PARTS 95 INDEX 96 Westerbeke Diesel Engines 4...

Page 7: ...asoline in the fuel lines will damage components in the fuel lift pump assembly fuel injection pump and injectors The diesel engine does differ from the gasoline engine however in its handling and fir...

Page 8: ...Water Pump Engine Isolator Westerbeke Diesel Engines W 358 THREE Marine Diesel Engine Fresh Water Fill Unit Data Plate Starter with Solenoid 20 Amp DC Circuit Breaker 90 Exhaust Elbow DC Battery Heat...

Page 9: ...t Pl mp Instrument Connections Secondary Fuel Filter Zinc Anode Transmission Dipstick JS Transmission Fresh Water Block Drain Lube Oil Dipstick Oil Pressure Sender 7 Fresh Water Air Bleed Switch DC Ch...

Page 10: ...W 38B FOUR Marine Diesel Engine Top Engine Oil Fill Starter Westerbeke Diesel Engines...

Page 11: ...e Top Engine Oil Fill Air Intake SilElnCler Fuel Lift pump Connections Secondary Fuel Filter Zinc Anode lube Oil Dipstick Oil Pressure Sender lube Oil Filter Oil Pressure Switch _ ___ _ Oil Throttle l...

Page 12: ...W 4213 FOUR Marine Diesel Engine Top Engine Oil Fill 90 Exhaust Elbow Lever Starter Westerbeke Diesel Engines 10...

Page 13: ...el Lift pump Fuel Filler Zinc Anode W 428 FOUR Marine Diesel Engine Lube Oil Dipstick Top Oil Fill Lube Oil Filler 11 Oil Pressure Sender Oil Pressure Switch Oil Throttle lever Westerbeke Diesel Engin...

Page 14: ...cylinder fresh water cooled vertical in line 32 hp at 3600 rpm maximum Mechanical centrifugal weight type Overhead Swirl chamber type 3 07 x 3 07 inches 78 x 78 mm 68 23 cubic inches 1 118 liters 1 3...

Page 15: ...ity includes filter Open flow totally self bleeding No 2 diesel oil cetane rating of 45 or higher Nippondenso Bosch M type 23 OS BTDC Static Throttle type 2275 psi 160 kg cm2 12 Volt DC lift capac y 6...

Page 16: ...egative ground recommended 45 A H cold areas 90 125 Ampere Hours 12 Voit sheathed type glow plug 12 Volt 1 2KW solenoid actuated shift 60 Amps at 11 5 Volts 6500 rpm min 190 Amps at 12 Volts 12 Volt D...

Page 17: ...vertical in line 37 hp at 3600 rpm maximum Mechanical centrifugal weight type Overhead Swirl chamber type 2 87 x 3 07 inches 73 x 78 mm 79 64 cubic inches 1 305 liters 1 3 2 4 Clockwise when viewed fr...

Page 18: ...lter Westerbeke Diesel Engines Open flow totally self bleeding No 2 diesel oil cetane rating of 45 or higher Nippondenso Bosch M type 23 OS BTDC Static Throttle type 2275 psi 160 kg cm2 12 Volt DC lif...

Page 19: ...45 A H cold areas 90 125 Ampere Hours 12 Volt sheathed type glow plug 12 Volt 1 2KW solenoid actuated shift 60 Amps at 11 5 Volts 6500 rpm min 190 Amps at 12 Volts 12 Volt DC 50 Amps Internal regulato...

Page 20: ...cylinder fresh water cooled vertical in line 42 hp at 3600 rpm maximum Mechanical centrifugal weight type Overhead Swirl chamber type 3 07 x 3 07 inches 78 x 78 mm 90 93 cubic inches 1 49 liters 1 3 2...

Page 21: ...ter Open flow totally self bleeding NO 2 diesel oil cetane rating 0145 or higher Nippondenso Bosch M type 23 0 5 BTDC Static Throttle type 2275 psi 160 kg cm2 12 Volt DC lift capacity 6 ft 1 8 m Canis...

Page 22: ...egative ground recommended 45 A H cold areas 90 125 Ampere Hours 12 Volt sheathed type glow plug 12 Volt 1 2KW solenoid actuated shift 60 Amps at 11 5 Volts 6500 rpm min 190 Amps at 12 Volts 12 Volt D...

Page 23: ...mission are NOT filled with lubricating oil for ship ment Before leaving the factory however each engine with transmission is thoroughly tested with oil in it This testing among other things provides...

Page 24: ...situations it may be necessary to lift the engine in positions otherthan the horizontal position Cer tain situations exist by which the engine must be lowered endwise through a small hatchway which c...

Page 25: ...finally pushes against the engine s bolts and bed in fiberglass hulls we recommend that similar wooden stringers as in wooden hulls be formed fitted and then glassed securely to the hull This allows t...

Page 26: ...it the engine to reach its full rated RPM at full throttle while under a normal load and while it is moving the boat forward through the waler Alignment of the Engine The engine must be exactly aligne...

Page 27: ...eller coupling in each of four positions A while rotated 90 be tween each pOSition This test will also check whetherthe propeller s half coupling is in exact alignment on its shaft Then keeping the pr...

Page 28: ...lop of this loop The top of the loop should be placed high enough above the vessel s water line so as to remain above the water line when the vessel is underway no matter what the angle of heel or rol...

Page 29: ...ng the other end of the tube with a 1 4 inch NPT National Pipe Tap pipe fit ting Measure back pressure at the exhaust elbow when the engine is running at 3600 rpm Dimension A cannot exceed 39 inches o...

Page 30: ...fold should not exceed 8 Ibs in total weight when rigidly con nected Excessive weight and vibration can result in a manifold failure and or the fracturing of the riser from the manifold at its attachm...

Page 31: ...e rotated B The exhaust elbow discharge must be directed downward so the mixture of sea water and exhaust gases will flow fall downward into the exhaust muf fler which must be positioned below the exh...

Page 32: ...sea water pump where it cools the fresh water that circulates through the engine block and is then injected into the exhaust discharge car rying with it the heat removed from the engine s fresh water...

Page 33: ...sed sections which would restrict water flow Make sure there are no air leaks at any of the connections Fuel System The fuel system should be installed in such a manner as to allow the engine mounted...

Page 34: ...attery Make sure the positive battery connection is connected to the battery connection of the starting solenoid The negative battery connection should be connected to the system ground the engine blo...

Page 35: ...G SYS TEM section 01 this manual page 53 Operate the engine and observe the coolant level in the manifold Maintain this level to the base 01 the Iiller neck Once the engine reaches its operating tempe...

Page 36: ...he result is a rapid start with less wear on the starter This system is common to Westerbeke Diesels The start cirCUITry is designed so that the PREHEAT button must be depressed for the time specified...

Page 37: ...witch The Key Switch provides power only to the instrument panel cluster Refer to the STOP PING PROCEDURE section of this manual page 41 2 PREHEAT The PREHEAT button energizes the alternator s regulat...

Page 38: ...ure is 170 190 F 77 88 C 7 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and is illuminated while the Key Switch is turned ON The engine s normal operating oil pressure rang...

Page 39: ...key switch is turned ON and remain illuminated while the engine is in operation The panel also contains two rubber booted push buttons one for PREHEAT and one for START 1 Key Switch The Key Switch pro...

Page 40: ...heit and is illuminated while the Key Switch is turned ON The engine s normal operating temperature is 170 190 F 77 88 C 6 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and...

Page 41: ...Check your instrumentation for proper engine operation Make sure sea water discharges with the ex haust discharge Should the engine not start when the START button is depressed for 10 to 12 seconds re...

Page 42: ...for proper oil pressure and battery charging voltage Never attempt to engage the starter while the engine is running NOTE Some unstable running may occur in a cold engine but this condition should smo...

Page 43: ...chaser Engine Break In Procedures Although your engine has experienced a minimum of one hour of test operations to make sure accurate as sembly procedures were followed and that the engine operated pr...

Page 44: ...ses of excessive coolant loss the system must be refilled as outlined under the PREPARATION FOR STARTING section of this manual page 33 4 Check for oil and fuel leaks particularly Hsigns of such leaks...

Page 45: ...ge to the fuel sys tem is not covered under the Westerbeke warranty In addttion any gasoline in the fuel system HOSE FITTING XNSTRLLRTION INSTRUCTIONS L BOLT SEDI EHT fA1ER TRAP SHURELl TO RII ACCESSI...

Page 46: ...mage resulting from this type of sea water entry is nol II warrantable issue the owner operator should keep this in mind Replacing the Fuel Filler Elements While it is unlikely that the operator will...

Page 47: ...tampered with Idle speed and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump Other types of adjustments or repairs must be performed by a qualified i...

Page 48: ...125 Ampere hours minimum CAUTION When quick charging the battery with an external charger be sure to disconnect the battery cables from the battery Leaving the charging circuit connected while quick...

Page 49: ...age Test I I I 1 Using a voltmeter connect the voltmeter s red wire clip to the B output terminal on the alternator Refer to the schematic shown above 2 Connect the other wire clip to a ground on the...

Page 50: ...R TEMP SENDER lo TIONAL T ST PA tU DIAGRAM ATER TEMP SWITCH l r PflEHEh 1 1 SOLENOtO G j i l IJ i i f l Q Q i I I o 1 rio ll Q 0 Q J1 0 I SO 8 OP fT ti r cuE 0 STIlRT I L Se Ifl i TEST SwiTCH r L I r...

Page 51: ...THE KEY TO THE OFF POSITION I THIS PRODUCT IS PROTECTED a A MANUAL RESET CIRCUIT BREAKER LOCATED EAR THE STARTER EXCESSIVE CURRENT DRAIN WILL CAUSE THE BREAKER TO 7RIf AND THE ENGINE WILL SHUT OO iN...

Page 52: ...rl i RE I I I I CIRCUIT J 20 A 1m i GROUND 1 C I BREAKER TO ENGINE STARTER I BLOCK I I GRO NO TO NEUTRAL I PUMP 1 ENGINE BLOCK illSAFETY SWITCH I t USED ON SOME r L M D D E I__ i r t1 BA IT Y I 12VDC...

Page 53: ...UT DOWN THE BUILDER OWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SALT WATER 2 AN ON OFF SWITCH SHOULD BE INSTALLED BET...

Page 54: ...sses through the thermostat into the exhaust manifold to the heat exchanger where it is cooled and then is returned to the engine block through the suction side of the fresh water circulating pump Whe...

Page 55: ...ow A stainless steel mounting bracket is supplied with each kit along with a 30 inch length of clear plastic hose and clamps to connect the hose between the engine s manifold fitting to the hose spud...

Page 56: ...nd observe the coolant s expansion flow into the plastic recovery tank 6 Check for leaks between the pressure cap filler neck and then plastic recovery tank Stop the engine and allow it to cool Coolan...

Page 57: ...nc anode should be checked monthly and the anode cleaned or replaced as required Spare anodes should be car ried on board Sea Water Pump The sea water pump is a self priming gear driven rotary pump wi...

Page 58: ...ss than 3 8 inch and no more than 1 2 inch 10 mm 12 mm as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span of the belt See the figure below A spare driv...

Page 59: ...need to order cooling system parts for your engine NOTE When the remote expansion tank 24177 is used the plastic coolant recovery tank should be removed and discarded and its connection point on the e...

Page 60: ...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 Connection point A on the Flow Control housing shou...

Page 61: ...aluminum remote expansion tank must be installed in the circuit to become the highest point The remote expansion tank s part number is 24177 Install the remote expan sion tank in a convenient locatio...

Page 62: ...F 5 C 68 F 20 C 41 F 5 C or lower Viscosity SAE 30 or 10W 30 SAE 20 or 10W 30 SAE 10W 30 NOTE Do not use an engine lubricating oil with an SAE number greater than 30 in the en gine Oil Pressure The e...

Page 63: ...This helps to lessen spillage A small style automotive filter wrench should be helpful in removing the old oil filter Place some paper towels and a plastic bag around the fil ter when unscrewing it to...

Page 64: ...ling 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 The...

Page 65: ...ipstick with SAE 20 W 20 or SAE 30 weight engine oil exclusively Multigrade oils are not to be used in this transmission DO NOT mix grades of oil Lubricating oils may have an API specification of CC C...

Page 66: ...to shift the gear box into FORWARD or into REVERSE from the NEUTRAL position without running out of cable Allow ap proximately 1 1 2 inches of cable throw from the NEUTRAL position on the transmissio...

Page 67: ...eviates unnecessary drag on the vessel because the propeller is able to freewheel spin However to lock the propeller shaft and to prevent it from rotating place the transmission into FORWARD gear Serv...

Page 68: ...able should attach at right angles to the actuating lever using the cable bracket supplied 33G CABLE 3 Both gear box lever and remote lever must be in neutral position when cable is attached so that t...

Page 69: ...ipstick drops on the housing It does not screw in FLUID LEVEL 9 The HBW gear box can be free wheeled in Neutral To stop 11 h f t t h l DRAIN PLUG prope er sat ro a 10n w 1 e under sail place the gear...

Page 70: ...e control lever is changed in any manner or repositioned or if linkage between remote control and transmission shift lever does not have sufficient travel in both directions This does not apply to tra...

Page 71: ...from the cooler and cooler lines The external plumbing should be changed to prevent any drain back Starling the Engine Move the shift lever to the center position where the spring loaded ball enters...

Page 72: ...s Hoses should be routed so there is no possibility for engine shifting to cause hoses to pull loose or become pinched A visual inspection of hoses while under way will sometimes allow detec tion of f...

Page 73: ...commended in pleasure boats Work boats require more frequent changes Change oil any time the oil becomes contaminated changes color or becomes rancid smelling Automatic transmission fluids ATF Type A...

Page 74: ...ensure proper cooling 5 Check engine rotation and transmission pump setting and the pro peller rotation prior to assembling the transmission to engine 6 Check oil pressue and temperature when transmis...

Page 75: ...usted until proper alignment is obtained Turn the propeller shaft flange 1 4 of a turn without moving the gear shaft change Try inserting the 003 feeler gauge as descr ibed above The gap will not chan...

Page 76: ...two clamping bolts on the split hub none on RV IO A self locking set screw is provided for the propeller shaft flange spot drill the propeller shaft and secure ly tighten the set screws All V drives...

Page 77: ...king nuts on the adjusting screws Remove the set screws from the brackets none on RV IO or RV 20 spot drill and securely tighten Recheck the flange alignment to make sure the V drive did not move out...

Page 78: ...r moving parts 12 BREATHER CAP UNSCREW FOR Oil Filll WATER LINE 12A BREATHER ELBOW ATER mAIN L LEVEL c GA I PULL UP TO J REM lVE Additional Molykote after break in is not required Reinstall the breath...

Page 79: ...curate oil pressure gauge installed in its place If the pressure is normal the switch should be replaced If the pressure is below normal the oil lines should be checked for blockage The pump should be...

Page 80: ...2 WATER DRAIN For protection from freezing during winter lay up remove the small pipe plugs located diagonally opposite on the front and back of the housing marked Water Drain see illutration On the...

Page 81: ...or alternator excitation Probable Cause 1 Battery OFF 2 20 Amp circuit breaker is tripped 3 Loose battery cable connection 1 Faulty solenoid connections or switch 2 Faulty connection or tripped 10 Amp...

Page 82: ...ication Remedy 1 Check connection S at the starter solenoid for 12 volts with the SWITch depressed 2 Check switch with an ohmmeter 3 Twelve volts is present at the S terminal of the starter solenoid 4...

Page 83: ...tank is ON 2 Inspect the fuel pump for 12 volt and to see if it is pumping 3 Pump water out of the bottom of the fuel tank s change the fuel filters and bleed the fuel system 4 Check exhaust system f...

Page 84: ...level and add additional lubricant as needed 4 Visually inspect the unit check for loose belts chafed or broken wires loose brackets and fittings damaged hoses loose clamps and other equipment not pr...

Page 85: ...ller shaft is securely connected to the transmission coupling Servicing Alter Every 100 Hours of Operation 1 Change the engine s lubrication oil and oil filter 2 Adjust the alternator and water pump d...

Page 86: ...move each glow plug and check each cylinder s compression pressure The engine s cranking speed is at 280 rpm Standard Minimum POOR i f i r 410104i dI GOOD 455 psi 32 kg cm2 369 7 psi 26 kglcm2 Maximum...

Page 87: ...Ib ft 7 to 8 kg m FRONT OF ENGINE 0 7 4 0 02 Torquing Cylinder Head Bolts W 38B FOUR and W 42B FOUR Engine Tighten the cylinder head bolts according to the sequence shown in the illustration shown to...

Page 88: ...nter on ks compression stroke Check both intake and exhaust valve clearances for this cylinder If the valves have no specified clearance adjust by means of the ad justing screws Remember to align the...

Page 89: ...al direction of rotation placing the NO 1 cylinder at the top of its compres sion stroke The TDC mark on the crankshaft pulley should be in line with the pointer on the front of the gear case cover an...

Page 90: ...s normal direction of rotation to posi tion piston No 1 at the beginning of its compression stroke Move the throttle leverto Hs full open position and operate the electric lift pump Slowly rotate the...

Page 91: ...not in use unless they have been dry for a considerable period of time Fresh Water Cooling System A 50 50 solution 01 antifreeze and fresh water is recommended for use in the fresh water cooling syst...

Page 92: ...l system during this servicing correcting them as needed Sea Water Circuit Close the through hull sea cock Remove the sea water intake hose from the sea cock Place the end of this hose into a 5 gallon...

Page 93: ...and return line sealing washers Spares Lay up time provides a good opportunity to inspect your Westerbeke engine to see ff external items such as drive belts or coolant hoses need replacement Check yo...

Page 94: ...electrical ar cing during servicing 3 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 tigh...

Page 95: ...25 21 7 32 5 3 0 4 5 10mm bolt head nut 1 5 19 5 30 4 2 7 4 2 12mm bolt head nut 1 25 ISO 36 2 57 9 5 0 8 0 12mm bolt head nut 1 5 36 2 50 6 5 0 7 0 12mm bolt head nut 1 75 34 7 49 2 4 8 6 8 Grade 7T...

Page 96: ...23 1 25 3 3 2 3 5 Flywheel bolt WITh separate washers 83 2 90 4 11 5 12 5 Flywheel bolt washer attached 95 0 100 0 13 0 14 0 Oil pan drain plug 36 2 43 4 5 0 6 0 Oil filter 8 0 9 4 1 1 1 3 or tighten...

Page 97: ...on to those listed above especially if the vessel is to be taken on long ocean voyages These parts are listed below 1 Fuel Injectors 2 Glow Plugs 3 Cooling System Hoses 4 An Alternator 5 A Starter 6 A...

Page 98: ...uing Cylinder Head 0N 35B THREE Engine 85 Bolts Torquing Cylinder Head 0N 38B FOUR and W 42B FOUR Engines 85 Break in Procedures Engine 41 C CAUTIONS SHIPPING ENGINE WITHOUT ENGINE OIL 21 LIFTING SUNG...

Page 99: ...7 Captains Panel Control Circuit 48 and 49 DESCRIPTION OF INSTRUMENT PANELS 35 Description of Starting System 34 Diesel Engine Understanding the 5 Diesel Fuel 43 DISCLAIMER IMPORTANT PRODUCT SOFTWARE...

Page 100: ...CATIONS W 42B 18 H HARDWARE TIGHTENING TORQUES TABLE OF STANDARD 93 Head Bolts Torquing Cylinder W 35B THREE Engine 85 Head Bolts Torquing Cylinder W 38B FOUR and W 42B FOUR Engines 85 Hose Oil Drain...

Page 101: ...30 Oil Pressure 60 OPTIONAL TRANSMISSIONS 66 Ordering Parts 5 Panel Admirals 37 Panel Captains 35 PANELS DESCRIPTION OF INSTRUMENT 35 Parts Ordering 5 PARTS SPARE 95 PREPARATION FOR STARTING 33 Pressu...

Page 102: ...Lay up and Recommissioning 91 STARTING PREPARATION FOR 33 STARTING PROCEDURE 39 Starting System Description 01 34 Starting Under Cold Conditions 42 Starting Under Normal Conditions 42 STOPPING PROCEDU...

Page 103: ...ARNINGsl DIESEL FUMES 28 FLAMES NEAR BATTERIES 32 SERVICING BATTERIES 32 ADJUSTING DRIVE BELT TENSION 55 SERVICING BATTERIES 92 Walter V Drives 73 Warner Hydraulic Transmissions 68 Water Domestic Hot...

Page 104: ...YOUR NOTES Westerbeke Diesel Engines 102...

Page 105: ...YOUR NOTES 103 Weslerbeke Diesel Engines...

Page 106: ...YOUR NOTES Westerbeke Diesel Engines 104...

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Summary of Contents for 35B THREE

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Westerbeke 35B THREE, Operator'S Manual, Page: 17 / 108

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Summary of Contents for 35B THREE

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