Westerbeke 55B-FOUR Operator'S Manual Download

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Summary of Contents for 55B-FOUR

Page 1: ...ARINE DI ESEL ENGINES 5 58 fOU 55C fQuiji I and 550 OUR PUBLICATION NO 42286 REVISION 4 JULY 2011 WESTERBEKE member WESTERBEKECORPORATION 150JOHNHANCOCKROAD J3tJiJ MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE www WESTERBEKECOM i 0 ...

Page 2: ...obbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU ORANYONEELSE EXPERIENCEANYOF THESESYMPTOMS GETOUTINTO THEFRESHAIR IMMEDIATELY Ifsymptomspersist seek medicalattention Shut down the unit and do notrestart until It has been inspectedandrepaired A WARNING DECAL is provided by WESTERBEKEand shouldbe fixed to abulkheadnearyour engine or generator WESTERBEKEalso recomme...

Page 3: ...rburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death Do not operate with the air cleaner silencer removed Backfire can cause severe injury or death Do no...

Page 4: ... Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carlion monoxide CO is adeadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Pay close attention to the manifold...

Page 5: ...s to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasoline engine or generator should begin witlt a tltorough exantiuation of tlte American Boat and Yacht Council s ABYC standards These standards are from a combination of sources including 1he USCG and tlte NF...

Page 6: ...ine will result in raw 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 the vessel s valious operating conditions install a siphon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphon break ca...

Page 7: ...aily Operation 12 Engine Troubleshooting 33 Maintenance Schedule 13 Engine Adjustments 35 Fuel System 15 FuellWater Separator 15 Fuel Filters 15 Belt Adjustments 35 Fuel Injectors 35 Testing Engine Compression 36 COOling System 16 Changing Coolant 16 Thermostat 17 Oil Pressure 36 Valve Clearance Adjustment 37 Hurth HSW Transmissions 38 Raw Water Intake Strainer 17 Transmission Coolers 40 Raw Water...

Page 8: ...R FUEL LIFT PUMP 20A CIRCUIT BREAKER FUEL FILTER HEAT EXCHANGER SHIFT LEVER OIL COOLER RIGHT SIDE OIL PRESSUIRE SENDOR PUUILAW I PRESSURE CAP INTAKE AIR FILTER WATER INJECTED EXHAUST ELBOW I D PLATE _ r lltAI EXCHANGER REAR ANDDE LEFT SIDE MOUNT Engines Generators 2 FIll THERMOSTAT ___ n HEATER CONNECTION U ALTERNATOR CRANKSHAFT PULLEY Oil FIll FRONT ...

Page 9: ...cal data parts lists manuals brochures and catalogs provided from sources other than WESTERBEKE are not within WESTERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WAR RANTIES OR REPRESENTATIONS WITH RESPECT THERETO INCLUDING ACCURACY TIMEUNESS OR COMPLETENESS THEREOF AND WILL IN NO EVENT BE UABLE FOR ANYTYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WIT...

Page 10: ...th this information so we may properly identify your engine In addition include a complete part description and part number for each part needed see the separately furnished Parts List Insist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment SPARES AND ACCESSORIES Certain spares will be needed to support and ma...

Page 11: ...l Panel The installer is responsible for electrically con necting the buzzer to the four pin connection on the engine s electrical harness The installer is also responsible for installing the buzzer in alocation 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 wh...

Page 12: ...ile the engine is in operation ALARM THE ALARM WILL SOUND IFTHE ENGINE S DIL PRESSURE FALLS BELOW 5 10 psi 0 4 0 7 kglcm IN THIS EVENT 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 9goC IN THIS EVENT THE ALARM WILL EMIT ACONTINUOUS SIGNAL NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SO...

Page 13: ...ll previous statements regarding synthetic oil SAE OIL VISCOSITY GRADE For all temperature ranges SAB l5W 40 or SAB IOW 40 RECOMMENDED RPM RANGES Cruise RPM Models 55BIFour and 55CIFour Model 55DIFour 2000 2500 rpm 2000 2400 rpm Maximum RPM propeller loaded Models 55BIFour and 55CIFour 2950 3000 rpm Model 55DIFour 2550 2600 rpm ENGINE COOLANT WESTERBEKE recommends a mixture of 50 antifreeze and 50...

Page 14: ...gine ground stud this location is tagged D Check the coolant level in both the plastic recovery tank A P 19 ti and at the manifold j j 1N NOTE Ifthe engine luls not yet beenfilled with coolant refer to the COOUNG SYSTEM section ofthis manual D Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Check the threaded connections and engine attachments D ...

Page 15: ...rt blltton is pressed for 5 seconds wait for at least 30 seconds and repe t the starting procedure Make certain the transmission confrQ is in the neutral position as some engines have a neutral safety switch to prevent starting in gear Never run the starterfor more then 30 seconds Ifthe engine fails to start refer to the TROUBLESHOOTING CHARTin this A CAUTION Prolonged cranking intervals without t...

Page 16: ...block This switch s sensor monitors the engine s oil pressure Should the engine s oil pressure fall to 5 10 psi 0 4 0 7 kg cm this switch will activate a pulsating alarm TO r nri rrlnl ENGINE CIRCUIT BREAKER OIL PRESSURE ALARM SWITCH The DC harness on the engine is protected by an engine mounted manual reset circuit breaker 20 amps DC Excessive current draw or electrical overload anywhere in the i...

Page 17: ...hecking 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 130 140 P 55 60 C range 3 While using the vessel run the engine at various engine speeds for the first 25 hours Avoid prolonged periods of idling 4 Avoid rapid acceleration especially with a cold engi...

Page 18: ...he thermostat opens NOTE Never attempt to engage the starter while the engine is running Itisimporttint to closely m onitor the panel gauges Become aware ofthe normal engine readings and take immedWie action ifthese readings start to vary 12 FAILURE TO START If the engine fails to start when the start button is pressed for 5 seconds wait for at least 30 seconds and repeat the starting procadure Ma...

Page 19: ...ter leaks Inspect wiring oil will inhibit the engine s ability to remain and electrical connections Keep bolts nuts tight cool Check for loose belt tension Fuel Filter 0 0 0 0 0 0 Change at 50 hours then every 250 hours Starting Batteries 0 Check electrolyte levels every 50 operating hours and House Balteries weekly and make sure connections are very tight Clean off excessive corrOSion Engine Oil ...

Page 20: ...replace Fuel Injectors 0 Check and adjust injection opening pressure and spray condition Starter Motor 0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pinion drive Preheat Circuit 0 0 Check operation of preheat solenoid Remove and clean glow plugs Reinstall with anti seize compound on threads Engine Cylinder 0 0 Check compression pressure and t...

Page 21: ...are tight and secure The DC ground connection at one of the pumps mounting bolts should be clean and well secured by the mounting bolt to ensure proper pump operations When energized thru the preheat circuit the fuel lift pump will purge air from the fuel system and provide a continuous flow of fuel as the engine is running Asmall fuel filter has been added to the incoming fuel line to ensnre that...

Page 22: ...a spare cap CHECKING THE PRESSURE CAP CHANGING COOLANT The engine s coolant must be changed according to the MAINTENANCE SCHEDULE Ifthe coolant is allowed to become contaminated it can lead to overheating problems A CAUTION Proper cooling system maintenance is critical asubstantialnumberofengine failures can be traced back to cooling system corrosion Drain the engine coolant by removing the drain ...

Page 23: ...TEM COOLANT TEMPERATURE SENDER RAW WATER INTAKE STRAINER NOTE Always install the strainer at or below the waterline so the strainer will always be self priming A clean raw water i ntake strainer is a vital component of the engine s cooling system Include a visual inspection ofthis strainer when making your periodic engine check The water in the glass shoufd be clear Perform the following maintenan...

Page 24: ...OUSING RAW WATER PUMP The raw water pump is a self priming rotary pump with a non ferrous housing and a Neoprene iropeller The iropeller has fle ible blades which wipe against a curved earn plate within the iropeller housing producing the pumping action On no account should this pump be run dry There should always be a spare iropeller and impeller cover gasket aboard an iropeller kit Raw water pum...

Page 25: ...ode NOTE The threads ofthe zinc anodes are pipe threads and do not require sealant Sealant should not be used as it may insulate the zincfrom the metal ofthe heat exchanger housing preventing electrolysis action on the zinc NOTE Operating in silty and or tropical waters may require thot a heat exchanger cleaning be peiformed more often than every 1000 hours AIR INTAKE I SILENCER INSTALL THE FILTER...

Page 26: ...aust filling it up into theengine OIL SEALING GASKET APPLI CLEAN ENGINE OIL CHANGING THE OIL FilTER SPIN ON OIL FILTER TURN ON HANO TIGHT When removing the used oil filter you may find it helpful tu punch a hole in the upper and lower portion ofthe old filter t Qrain the oil into a container before removing it This helps to lessen spillage An automotive filterwrench should be helpful in removing t...

Page 27: ...more information THE OUT CONNECTION MUST ATTACH TO THE IN CONNECTION ATTHE REMOTE OIL FILTER APPLY ATHIN COAT OF CLEAN OIL TO THE O RING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN ADDITIONAL 3 4 TURN AFTER THE O RING CONTACTS THE BASE THE IN CONNECTION HOSE MUST ATTACH TO THE OUT __iC O NMN iETC TION ATTHE OIL FILTER A CAUTION it is vital to instal the 011 lines cor rectly If ...

Page 28: ...nginesreturn Install the remote expansion tank in a convenient location so the coolant level can easily be checked The remote expansion tank will now serve as a check and systemfill point The plastic cooklnt recovery tank is not used when the remote expansion tank kit is installed since this tank serves the samefunction Rel1W1 e and store the plastic recovery tank ifit has been already installed T...

Page 29: ... between meter tenninal 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 reading front crank shaft pulley speed Adjust the engine speed to 112 rated engine rpm b Using the coal S adjustment select A B 4 6 or 8 that puts tile panel tachometer rpm reading the closest to the strobes tachometers...

Page 30: ...ne is clear ofmovingparts Keep awayfrom sheaves andbelts during testprocedures A WARNING When testing with a multimeter DC andAC circuits are often mixed togetherin marine applications Always disconnect a shore powercord isolate DC andAC converters andshut down the engine before performing DC testing No AC tests should be made without aproperknow edge ofAC circuits 1 Start the engine 2 After the e...

Page 31: ...cuit nevershut offthe engine batteryswitch while the engine is running Shut offthe engine batteryswitch however to avoIdelectricalsholfs when working on the engine selectrical circuit BATTERY The minimum recommended capacity of the battery used in the engine s 12 volt DC control circuit is 600 900 Cold Cranking Amps CCA Checking the Service Battery Check the voltage of the service battery This bat...

Page 32: ...to the glow plug s wire connection and the other to the body of the glow plug as shown A good glow plug will have a 1 0 1 5 ohm resistance This method can be used with the plug in or out of the engine You can also use an multimeter to test the power drain 8 9 amps per plug A WARNING These glowplugs willbecome veryhot to the touch Be carefulnot to burn your fingers when testing the plugs PLUG INJEC...

Page 33: ...9144 0 PRfsSURE SWITCH ADMIRAL PANEL i L _ r I ______ r O O 01 0 r t c J 0 f liB ORN 1 I TEST SWITCH 3 cs XTO 4 SWITCH OP L PREt T SWITctI 6 _ liD HE K 1 L l KETSWITCH liB BLK II SLU 118 BLK 118 BLK 118 BlK r 27 CAPTAIN PANEL g 11 BR 1 W o a ...

Page 34: ...NEL ONLY 4 THE GRAY WIRE AT PLUG Z 15 UNUSEO AND SHOULD 8 INSULAT O AO IRAL PANEL ONLY 14 11 BtU 14 PINK 14 RED 114 O H BAI MAR 100 AMP 114 BlK ALT INOT U5 01 iii lAtE CONNECTOR ON THIS SIDE 7 6 RED tJ IU Q elnt l 18 RU PRESTOLIH lffCE NEVILLf JO AMP ALT GROUND lAP rl4 8RN 4 L1 BLU 114 PN IS RED PI PH PI PI IIII PH PHi 1 1 At 1 LANP SlUT D P LA P I W T L P PREHEAT ALARM SWITCH 04 Dl t ANP TEST CAP...

Page 35: ...in the ships batteries are at full charge and11mttlle startiIlg system wiring COlmections terminals are clean and tight Pay particularattention to the ground wire connectious on the engine block To check111e wiring try cranking 111e starter for a few seconds nevermore 11la1l 10 seconda at a time then run your hand along 111ewires and temrinals looking for warm spots tlJa iIldicate resistance Repai...

Page 36: ...h astarter will run the motor without engaging theflywheel Thrn thestarterswitch on to provide thepowerto the solenoid Hopifi lly it will create enough magneticfieldfor the ann to move even though the confllcts inside the solenoid are bad SERVICE Westerbeke uses aS1 mdard marine starter motor which can be serviced orrebuilt at any starter motor automotive service center Ifreplacing the starter mot...

Page 37: ...e s from the alternator s output terminal s Using the cable sizes indicated 5 Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable 6 Mount the regulator to a flat surface in a cool dry location a Connect the black wire to the ground terminal on the alternator A CAUTION 00 not connect anypowersource without first grounding the ...

Page 38: ...2 volls 14 2volts Alternator Testing The regulator is functioning properly and the batteries are in good condition 1 Test the voltage at the alternator plug with the engine off key on The voltage at the alternator tenninal F and the voltage in the plug blue wire F from the regulator should read the same Z Hold a screw driver close 1 2 to the alternator pulley Ifvoltage is present you should feel t...

Page 39: ...WAYS USE FINE STRAND CABLE IGNITION 8 14 BWE 14 PINK IGNITION Bt c i 14 BROWN 14 RED TO STARnNG BAmRY8 WHEN USING 7WOBATTERIES MALE CONNECTOR THISSIDE 14BROWN TACHOMErER 5 Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable 6 Mount the regulator to aflat suITace in a cool dry location a Connect the black wires to the mounting...

Page 40: ... Alternator Testing The regnlator Is functioning properly and the batteries are in good condition 1 Test the voltage at the alternator plug with the engine off key on The voltage at the alternator terminal F and the voltage in the plug blue wire F from the regnlator should read the same 2 Hold a screw driver close 1 2 to the alternator pulley Ifvoltage is present you should feel the magnetic field...

Page 41: ... OK fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present althe connection on the fuel run solenoid Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open start fuel solenoid energized 1 Check for air in fuel system Bleed air from fuel system lb Fuel filters clogged Replace filters and bleed air from fuel system 2 Preheat solenoid f...

Page 42: ...rade of engine oil la Crankcase is overtilled 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 3 Black smoke 3 Improper gradaof fuel 3a Fuel bum incomplete due to high back pressure in exhaust or insufficient air for proper combustion check for restrictions in exhaust system check air intake 3b lmproperly ...

Page 43: ...Tighten the base mounting bolt and the adjusting strap bolt 5 Run the engine for about 5 minutes then shut down and recheck the belt tensions RAW WATER PUMP The tension of the raw water pump belt is adjusted by releasing the pumps fasteners and Sliding the pump back and forth The water pump belt should be finnly tight and checked often STARTER AND DC ALTERNATOR SERVICE The starter and the DC charg...

Page 44: ...by applying a small amount of oil in the cylinder thru the glow plug hole Allow the oil to settle Install the pressure gauge and repeat the above test If the compression reading rises dramatically the fault is with the rings Ifthe compression valve does not rise the problem is with the valves Aslight rise in compression would indicate a problem with both the rings and the valves MEASURING COMPRESS...

Page 45: ...NDER NO 1 COMPRESSION 7 l J G _ _ 57 CYLINDER NO 1 r EXHAUST 3 In accordance with tlJe ccmditions of cylinder No 1 mea sure and adjust ifrequired the clearance of the valves marked with either or in the table below Cylinder No 1 2 3 4 Valve arra ngemant I E I E I E I E When No 1 cylinder is at TDC in the compression stroke When No 4 cylinder is at TOC in the cotnpression stroke I1il I Inlet E Exha...

Page 46: ...l a bending radius etc In order to mount a supportfor shift control cable connections use the two threaded holes located above the shift cover on top ofthe gear hausing Refer to the WESTERBEKE parts list CONTROL CABLES The transmission is suitable for single lever remote control Upon loosening the retaining screw the actuating lever can be moved to any position required for the shift control eleme...

Page 47: ...evere burns OPERATING TEMPERATURE rhe maximum permissible A f F temperature should not exceed 230 110 This temperature can only be reached for a short time A CAUTION If the transmission fluid temperature is too high stop the engine immediately and check the transmission fluid LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever positi...

Page 48: ...d after initial 25 hour break in and then at 300 hours of operation or at least once a seaSOD Periodically 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 strawberry cream Lay up Winterize Storage requires special care Follow these procedures o Drain water...

Page 49: ...g bolt on actuating lever Shifiing cable is broken bent or 2 Check the cable reattach or replace unattaChed Cable redius Is too severe Actuating lever is binding against the 3 Detach the shift cable and operate the actuating lever by cover plate hand Clearance should beO 02 in 0 5mm Output coupling is not turning 1 Transmission needs professional attention Propeller shafi is not turning 2 The coup...

Page 50: ...ctyour WESTERBEKE dealer or an authorized marine transmission facility Verlilcallon Remedy 1 Mount aflexible coupling with another stiffness factor between the engine and transmission acoupting with ahigher stiffness factor might be sufficient 2 Advance throttle slightly if chatter stops the idle speed should be adjusted 2a If chatter continues inspect the damper plate 1 Transmission needs profess...

Page 51: ...e 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 shift in Neutral before starting the engine Shifting from one selector position to another selector posi tion may be made at any time below 1000 rpm and in any order Shifts should be made at the lowest practical engine...

Page 52: ...n into acontainer o Reconnect the oil cooler return line o Use a suction pump to remove the transmission oil through the filler cap dipstick hole o Clean offthe transmission and properly dispose of the used fluid o Refill the transmission with DEXTRONIIIATF The r quantity will vary depending on the transmission model and the installation angle Pill through the dipstick hole 0 Check the dipstick fo...

Page 53: ...rd through the engine exhaust A loss oftransmission fluid will cause the transmission to fail 2 The raw water will leak into the transmission fluid caus ing an increase in transmission fluid This contaminated fluid will appear as strawberry cream The transmission will eventuallyfail Either case requires an immediate response 1 Install a new oil cooler 2 Refill the transmission with DEXIRON III ATF...

Page 54: ... the life ofyour engine s internalparts Fuel System Gasoline Top off your fuel tanks with unleaded gasoline of 89 octane or higher Afuel conditioner such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any spilled fuel Fuel System Diesel Top off your fuel tanks with N...

Page 55: ...ectrical arCing oralighted cigarette cigar orpipe 00 not smoke orallowan open game near the battery being serviced Shut offall electrical equipment in the vicinity to preventelectrical arcing dur ing servicing Spare Parts Lay up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement Check your basic spares k...

Page 56: ... 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 Kilopascals kPa x 2961 Hg Inches of Water H D x 07355 Inches ofMercury x 13 783 H D Inches of Water H D x 03613 psi x 27 684 H D Inches of Water H D x 248 Kilopascals kPa x 4 026 H D TORQUE Pounds Force Inches in Ib x 113 Newton Me...

Page 57: ... Exhaust Hose Size Exhaust Gas Flow Muffler Size min 50 Amp rated belt driven 12V Glow plugs 12V sheathed 12 Voh 1 8 KW with solenoid 175 200 Amps Internal regulator built into alternator EXHAUST SYSTEM 45 elbow 3 0 1 0 hose 265 cfm at 3000 RPM 14 x t4 General Fuel Fuel Injection Pump Injectors Fuel Filter Air cleaner Fuel Lift Pump General Operating Temperature Fresh Water Pump Raw Water Pump Sys...

Page 58: ...Volt H negative ground 400 600 CCA min 50 Amp rated belt driven 12V Glow plugs 12V sheathed 12 Volt 1 8 IIiN with solenoid 175 200 Amps Internal regulator built into alternator EXHAUST SYSTEM 450 elbow 9 044876 3 0 I D hose 230 cim at 2600 RPM 14 x14 General Fuel Fuel Injection Pump Injectors Fuel Filter Air cleaner Fuel Lift Pump General Operating Temperature Fresh Water Pump Raw Water Pump Syste...

Page 59: ...rs 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 KITA ZINC ANODES DRIVE BELTS OIL FILTER FUel FILTER HEAT EXCHANGER GASKET IMPELLER KIT FUEL SYSTEM HARDWARE I IT FUEL PUMP INLET FILTER Engines Generators 50 KIT B ZINC ANODES DRIVE BELTS OIL FILTER FUEL FILTER BELTS MOLDED HOSE KIT INA CANVAS CARRYING BAG...

Page 60: ... WESTERBEKE Engines Generators 8 14 2011 1162 ...

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