Westerbeke 44A FOUR - 35C THREE Operator'S Manual Download Page 1

Page: 1 / 62

Summary of Contents for 44A FOUR - 35C THREE

Page 1: ...ON NO 044180 REVISION 4 APRIL 2015 WE STE RBE KE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE WWW WESTERBEKE COM N M mh National MCJJ iM Manufactunm Associ...

Page 2: ...eekmedicalanentio n Shut down the unit and do not restart until it has been inspected andrepaired WARNING Genera1D1s PrtxiJce CAABON MONOXIDE Regular Maintenance AecJ lired A WARNING DECAL is provided...

Page 3: ...rces of spilled fuel or fuel vapors Use a suitable container tQ catch all fuel when _removing the fuel lines or fuel filters Do not operate with the air cleaner silencer removed Backfire can cause sev...

Page 4: ...your slQn wash it off at once with water Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO Is adeadlygas Ensure...

Page 5: ...LLATIONS Preparations to install an f ngine should begin with a thor ough examination of the American Boat and Yacht Council s ABYC standards These standards are a combination of sources including the...

Page 6: ...e vessel s waterline under the vessel s various operating conditions instaU a siphon br alc NOTE A siphon break requ n s periodic inspection and cleaning to ensure proper operation Failure to properly...

Page 7: ...sion 32 RPM Chart 32 Fuel Solenoid optional 32 Valve Clearance Timing 33 44 Four Engine Specifications 34 35 Three Engine Specifications 34A J S and B W Transmission 35 Cooling System 15 Thermostat 16...

Page 8: ...ELBOW 20ACIRCUIT BREAKER REAR FRONT DC ALTERNATOR RAW WATER PUMP RIGHT SIDE OIL FILL UNIT I D PLATE START MOTOR 2 COOLANT PRESSURE CAP OIL FILTER OIL COOLER AIR_ INTAKE AIR FILTER WATER HEATER CONNECT...

Page 9: ...lso keep in mind the time span between printings ofWESTERBEKE product software and the unavoidable existence ofearlier WESTERBEKE manuals In summation product software provided with WESTERBEKE product...

Page 10: ...engines The diesel engine does differ from the gasoline engine however in its method of handling and firing of fuel The carburetor and ignition systems are replaced by a single component the fuel inje...

Page 11: ...trical 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 T...

Page 12: ...NTHIS EVENr THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 210 F 99 C IN THIS EVENT THE ALARM WILL EMIT ACONTINU...

Page 13: ...engine can have an oil pressure reading as low as 25 psi 1 8 kg cm2l T7zese readings will vary depending upon the temperature of the engine the load placed on the engine and the RPM s TRANSMISSION FL...

Page 14: ...enoid and the negative cable is connected to the engine ground iii stud this location is tagged D Check the coolant level in both the plastic recovery tank and at the manifold NOTE Ifthe engine has no...

Page 15: ...rolonged cranking intervals without the engine starting can result in the engine exhaust system filling with raw water This mayhappen because the pump is pumping raw water through the raw water coolin...

Page 16: ...gauges can be added as accessories to either engine at any time and are easily installed to the prewired engine LOW OIL PRESSURE ALARM SWITCH A low oil pressure alarm switch is located off the engine...

Page 17: ...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 i...

Page 18: ...STARTING STOPPING PROCEDURE in this manualfor more detailed instructions 1 Put the transmission in neutral throttle advanced NOTE Hydraulically operated transmissions have a neutral safety switch thro...

Page 19: ...per tension 3 8 to 112 deflection and adjust if needed Initial change then every 250 hours or once ayear Initial change then every 250 hours or once ayear Initial engine oil and filter change at 50 ho...

Page 20: ...No exhaust leaks Hoses and muffler are in good serviceable condition NOTE An exhaust leak will cause exposure to diesel exhaust Check and adjust injection opening pressure and spray conditions Drain f...

Page 21: ...ump absorbing heat from the engine The coolant then passes through the thermostat into the manifold to the heat exchanger where it is cooled and returned to the engine block via the suction side of th...

Page 22: ...gradually opens The thermostat is accesSible and can be checked cleaned or replaced easily Carry a spare thermostat and gasket Replacing the Thermostat Remove the cap screws and disassemble the therm...

Page 23: ...periodic engine check The water in the glass should be clear Perform the following maintenance after every 100 hours of operation 1 Close the raw water seacock 2 Remove and clean the strainer filter 3...

Page 24: ...should not be used as it may insulate the zincfrom the metal ofthe heat exchanger hous ing preventing electrolysis action on the zinc Heat Exchanger Service After approximately 1oOo hours of operation...

Page 25: ...PUMP Periodically check the fuel connections to and out of the pump and make sure that no leakage is present and that the fittings are tight and secure The DC ground connection at one of the pump s mo...

Page 26: ...y an authorized fuel injection service center Poor fuel quality contaminants and loss of positive fuel pressure to the injection pump can result in injector faults Since fuel injectors must be service...

Page 27: ...rtain it can be removed Place some paper towels and a plastic bag around the fil ter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s co...

Page 28: ...lief valve in the oil pump and returns to the oil sump keeping the oil pressure within its specified range To test the oil pressure remove the oil pressure sender then install a mechanical oil pressur...

Page 29: ...ll the oillines cor rectly Nthe oil flows In the reverse diftlctlon the by pass valve In the finer assembly willpnwent the oil from rsachlng the engine causing an Internal engine failure Nth11tt1is no...

Page 30: ...return Tee at the heater and plumb a single line up to the tanks location and the other back to the engines return Install the remote expansion tank in a conve nient location so the coolant level can...

Page 31: ...is clear ofmoving parts Keep away from sheaves and belts during test procedures A WARNING When testing with amultimeter DC lnd AC circuits are often mixed together in marine applications Always disco...

Page 32: ...harging circuit nevershut off the engine batteryswitch while the engine Is running Shut off the engine batteryswitch however to avoid electricalshorts when working on the engine s electrical circuit B...

Page 33: ...VDC WILL S RV THIS FUNCTION THIS SWITCH SHOULD NOT 8 US O TO MAKE OR 8R Ak THE CIRCUIT 3 TH PINK Wilt l PLUG Z IS UNUSED AND SHOULD BE INSULATED CAPTAIN PA N l ONLY 4 THE GRAY WillE AT PLUG Z IS UNUSE...

Page 34: ...iingthe insfnlmentP tnelharness o th e engine harness Then ty wrap the plugs together to ensureatight endserumconnection P 1 I I I I i ___ I I I I I I LU r J L P2m LARM UZZER ADMIRAL PANEL I IIDRED I...

Page 35: ...Check connection 2 Gear shift must be in neutral see NEUTRAL SWITCH under HURTH HSW TRANSMISSIONS 3 Check switch with ohmmeter 4 Check that 12 volts are present at the solenoid connection 5 Check bat...

Page 36: ...Incorrect grade of engine oil 1a Crankcase is overfilled with engine oil oil is blowing out through the exhaust 2 White smoke 2 Engine is running cold 2a Faulty injector or incorrect injector timing...

Page 37: ...und connection between meter ter minal and alternator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurate a Using a hand held strobe tachometer read...

Page 38: ...he drive belt is properly adjusted if the belt can be deflected no less than 3 8 inch 10mm and no more than 1 2 inch 12mm as the belt is depressed with the thumb at the mid point between the two pulle...

Page 39: ...to ease the rota tion of the crankshaft manually to position the various cylinders pistons at TDC Top Dead Center TDC TOP DEAD CENTER I ROTATION EARLY MODELS b Rotate the crankshaft to position 1 cyl...

Page 40: ...eral Fuel Fuel Injection Pump Nozzle Fuel Filter Air cleaner AirFlow engine combustion Fuel Lift Pump FUEL SYSTEM Open flow self priming No 2 D Cetane rating of 45 or higher SAE J313 grade of diesel f...

Page 41: ...000 rpm General Fuel Fuel Injection Pump Nozzle Fuel Filter Air Cleaner AirFlow engine combustion Fuel Lift Pump FUEL SYSTEM Open flow self priming No 2 D Cetane rating of 45 or higher SAE J313 grade...

Page 42: ...opening so the oil may be sucked out The operating oil temperature must not exceed 250 F 120 C CONTROLS The only controls required to operate the transmission is a single level remote controlled cable...

Page 43: ...el look for signs of water contamination fluid will appear as strawberry cream Lay up Winterize Storage requires special care Follow the procedures NOTE This operation will usually occur when the engi...

Page 44: ...an cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shif...

Page 45: ...ow the oil to drain into a container D Reconnect the oil cooler return line D Use a suction pump to remove the transmission oil through the filler cap dipstick hole D Clean off the transmission and pr...

Page 46: ...through the engine exhaust A loss oftransmission fluid will cause the transmission to fail 2 The raw water will leak into the transmission fluid causing an increase in transmission fluid This contamin...

Page 47: ...impeded by restricted movability ofthe Bowden cable or rod linkage by unsuitably positioned guide sheaves too small a bending radius etc In order to mount a supportfor shift control cable connections...

Page 48: ...stick hole This could cause severe burns 41 OPERATING TEMPERATURE The maximum permissible ATF temperature should not exceed 230 110 This temperature can only be reached for a short time A CAUTIO ffth...

Page 49: ...ically inspect the transmission and the cooler for leaks and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as s...

Page 50: ...ith automatic transmission fluid ATF Dexron III Fill the transmission with the recommended capacity of fluid Model PRM80 l O U S pints 0 6L Model PRM 120 1 4 U S pints 0 8L NOTE Always clean the area...

Page 51: ...ates Atlantis Marine Gear Supply Inc 418 Boston Street Topsfield MA 01933 Tel 978 887 0001 Fax 978 887 5599 Harbor Marine Transmission 1402 West Marine View Drive Everen WA 98021 Tel 425 259 3285 Tran...

Page 52: ...propeller shaft are turning Delay of gear engagement or engages 1 Lever travel Nto Bnot equal to Nto A only after an increase in speed Refer to diagram 2 Shift level travel in insufficient 3 Shift lev...

Page 53: ...de 2 63 1 170 x 13P 2 Blade 170 x 11P 3 Blade 2 99 1 180 x 13P 2 Blade 180 x 11P 3 Blade 2 0 1 170 x 11P 2 Blade 170 x 9P 3 Blade 2 47 1 200 x 13P 2 Blade 200 x 11P 3 Blade 2 72 1 200 x 14P 2 Blade 20...

Page 54: ...hemicals which can reduce the life ofyour engine s internal parts Fuel System Gasoline Top off your fuel tanks with unleaded gasoline of 89 octane or higher A fuel conditioner such as Sta Bil gasoline...

Page 55: ...e and grease and touch up any unpainted areas Protect the coupling and the output flange with an anti con osion coating Check that the transmission vent is open For additional information refer to the...

Page 56: ...0 5 28 9 36 2 39 18 Glow Plug M10 1 25 12 60 1 75 0 25 12 7 2 17 2 2 5 Glow Plug Connection Plate M4 0 7 8 0 125 0 025 0 9 0 2 1 2 0 2 Intake Manifold 1 6 2 4 12 17 16 2 Main Bearing Cap Bolt M10 1 2...

Page 57: ...597 605 820 14 435 590 675 915 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 BOO 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 15...

Page 58: ...rams g x 035 Ounces Pounds lb 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...

Page 59: ...COOLANT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising AKit Impel...

Page 60: ......

Page 61: ......

Page 62: ...Engines Generators 5 2015 1204...

Search results

Summary of Contents for 44A FOUR - 35C THREE

Reviews:

Related manuals for 44A FOUR - 35C THREE

Brands by name

Popular brands

Westerbeke 44A FOUR - 35C THREE, Operator'S Manual

Search results

Summary of Contents for 44A FOUR - 35C THREE

Reviews:

Related manuals for 44A FOUR - 35C THREE

Brands by name

Popular brands