Westerbeke 64A FOUR Operator'S Manual Download

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Summary of Contents for 64A FOUR

Page 1: ...NGINES 64 F PUBLICATION NO 49112 FIRST EDITION DECEMBER 2003 member WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A TEL 508 823 7877 FAX 508 884...

Page 2: ...ERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIR IMMEDIATELY Ifsymptoms persist seekmedical attention Shut down the unitanddo notrestart until it has been inspectedandrepaired A WARNING DECAL ispro...

Page 3: ...carburetor 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 fuellme carburetor or fuel filters Do not o...

Page 4: ...er 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 that the exhaust system is adequate t...

Page 5: ...ith other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTALLATIONS Preparations to install an engin...

Page 6: ...low the loaded water line ofthe vessel will result in raw water damage to the engine andpossible flooding ofthe vessel If you have any doubt about the position of the water injected exhaust elbow rela...

Page 7: ...Solenoid 37 Fuel System 15 FuellWater Separator 15 Fuel Filters 15 Oil Pressure 38 Hurth HSW Transmissions 39 Specification 40 Cooling System 16 Changing Coolant 16 Thermostat 17 Raw Water Intake Str...

Page 8: ...BW HURTH TRANSMISSION Q III TRANSMISSION SHIFT LEVER PARTS IDENTIFICATION 20 AMP CIRCUIT FLEXIBLE MOUNT WATER INJECTED _EXlrlAU T ELBOW REAR TRANSMISSION jk ENGINE BLOCK DRAIN PLUG LEFT SIDE FILL MANI...

Page 9: ...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 WARRANTI...

Page 10: ...ts water sediment etc in the fuel system is also essential Another important factor is the consistent use of the same brand of high detergent diesel lubrication oil designed specifically for diesel en...

Page 11: ...ponsible 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 a location where it will b...

Page 12: ...tion ALARM THE ALARM WILL SOUND IF THE ENGINE S OIL PRESSURE FALLS BELOW 5 10 psi 0 4 0 7 kg cm IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATUR...

Page 13: ...35 and 55 psi 2 5 and 3 9 kglcm2 NOTE A newly started cold engine can have an oil pressure reading up to 60 psi 4 2 kglcm2 A warmed engine can have an oil pressure reading as low as 25 psi 1 8 kglcm2...

Page 14: ...onnected to the engine ground stud this location is tagged D Check the coolant level in both the plastic recovery tank and at the manifold NOTE Ifthe engine has not yet beenfilled with coolant refer t...

Page 15: ...op 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 then shut the engine down by turning off...

Page 16: ...is located offthe engine s oil gallery 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 cm2 this switch will activate a pulsating al...

Page 17: ...ecking 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 1...

Page 18: ...e thermostat opens NOTE Never attempt to engage the starter while the engine is running It is important to closely monitor the panelgauges Become aware ofthe normal engine readings and take immediate...

Page 19: ...il and water 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 D D D D D D Clean with...

Page 20: ...ck and adjust injection opening pressure and spray condition see ENGINEADJUSTMENTS Starter Motor 0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor p...

Page 21: ...diesel fuel free from water and dirt To ensure this flow of clean fuel the fuel must pass through at least two fuel filters a fuel filter water separator and the engine s spin on fuel filter Visually...

Page 22: ...coolant expansion and contraction during engine operation without any signifi cant loss of coolant and without introducing air into the cool ing system This tank should be located at or above the eng...

Page 23: ...that there are no leaks at the tbennostat housing mo TEMPERATURE SENDER RAW WATER INTAKE STRAINER NOTE Always install the strainer at or below the waterline so the strainer will always be self primin...

Page 24: ...rts seals and bearings it may be more cost efficient to purchase a new pump and rebuild the original pump as a spare AIR INTAKE FILTERISILENCER The replaceable canister contains a paper element that s...

Page 25: ...there are probably a lot of zinc flakes within the exchanger Remove the end of the heat exchanger and clean the inside of all zinc debris Always have a spare heat exchanger end gasket in case the pres...

Page 26: ...the rubber sealing gasket comes off with the old oil filter If this rubber sealing gasket remains sealed against the filter bracket gently remove it When installing the new oil filter element wipe th...

Page 27: ...formation 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 OUT CONNECTION HOSE MUS...

Page 28: ...on the thermostat housing Open these petcocks whenfilling the engine SO coolant system to allow air to escape Close both tightly after all the air is removed NOTE Ifany portion ofthe heating circuit...

Page 29: ...termi nal and terminal 2 Check for good ground connection between meter ter minal and alternator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurat...

Page 30: ...ertain that everyone is clearofmovingparts Keep away from sheaves andbelts during testprocedures A WARNING When testing with amultimeter DCandAC circuits are often mixed together in marine application...

Page 31: ...clrcultl nevershut offthe engine batteryswitch while the engine Is running Shut off the engine batteryswltchl however to avoid electricalshorts when working on the englnets electrical circuit BATTERY...

Page 32: ...connection and the other to the body of the glow plug as shown A good glow plug wiII have a 1 0 to 1 5 ohm resistance This method can be used with the plug in or out of the engine You can also use an...

Page 33: ...oi D SOl e USEDI Il2c 298 II BAT KEY SW IGN o ALARM PH PI PH PI T P2 UP2 1I PH KEY S j PREHEAT ALARM SWI TCH 1 P2 12 s N iR T XJ SENDER 0 J W T SWITCH TACHOMETER S GNO VOL TMETER GNO w T GAUGE GND NO...

Page 34: ...300 amps when cranking A switch with acontinuous rating of 175amps at 12 VDC will normallyserve this function butaswitch must never be used to make the startercircuit SI PI QI PRESS OAUGII o WIRING D...

Page 35: ...e slups batteries are at full charge and that the starting system wiring connections termiI1als are clean and tight Pay particular attention to the ground wiI e connections on the engine block To chec...

Page 36: ...ill run the motor without engaging theflywheel Tum the starter switch on to provide thepower to the solenoid HopefUlly it will create enough magneticfieldfor the ann to mave even though the contacts i...

Page 37: ...GTH_REQUIRED Up TO 20 0 WIRE ALWAYS USE FINE STRAND CABLE S 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 reg...

Page 38: ...put 12 6 volts 12 volts 14 2 volts 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...

Page 39: ...ck connection 2 Gear shift must be in neutral see NEUTRAL SWITCHunder HURTH HSW TRANSMISSIONS 3 Check switch with ohmmeter 4 Check that 12 volts are present atthe solenoid connection 5 Check battery c...

Page 40: ...1 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 timin...

Page 41: ...osen or tighten 4 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 BELT The tension of the r...

Page 42: ...WHEN NO 4 CYLINDER IS AT TOP DEAD CENTER I 41NTAKE 31NTAKE 4 EXHAUST EXHAUST 2 2 INTAKE NTAKE1 fEXHAUST I EXHfUST WHEN NO 1 CYLINDER IS AT TOP DEAD CENTER I 8 Adjust each valve s clearance by inserti...

Page 43: ...reduce Once the speed is set to your satisfaction tighten the locknut THROTTLE STOP BOLT FACTORY SET FUEL INJECTION PUMP TOP INJECTION PUMP SERVICE For disassembly inspection reassembly and internal...

Page 44: ...e sender then install a mechanical oil pressure gauge in it s place After warming up the engine set the engine speed at approx 2600 rpm and read the oil pressure gauge OIL PRESSURE GAUGE WITH ADAPTER...

Page 45: ...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 use the two threaded holes locat...

Page 46: ...ERATING TEMPERATURE The maximum permissible ATF temperature should not exceed 2300 110 This temperature can only be reached for a short time A CAUTION Ifthe transmission fluid temperature is too high...

Page 47: ...your regular routine and change the fluid every 300 operating hours Periodically inspect the transmission and the cooler for leaks and corrosion Lubricate the cable connections Lay up Winterize Stora...

Page 48: ...enough in idle to fill the cooler and hoses with transmission fluid Shift into gear forward and reverse shifting should be smooth and positive Direct changes from forward to reverse are permissible s...

Page 49: ...e engine shut down and recheck the fluid level A WARNING Neverpullout the dipstick while the engine is running Hot uid willsplash from the dipstick hole This could cause severe bums MAINTENANCE Transm...

Page 50: ...ensure equal shift lever travel from neutralposition to AandB If this mechanism is in any way tampered with the transmission warranty will be void SHAFT COUPLINGS WESTERBEKE recommends a flexible conn...

Page 51: ...lt on actuating lever Shifting cable is broken bent or 2 Check the cable reattach or replace unattached Cable radius is too severe Actuating lever is binding against the 3 Detach the shift cable and o...

Page 52: ...a majorproblem in your transmission immediately contactyour WESTERBEKE dealer or an authorized marine transmissionfacility 1 1 2 3 Engines Generators 46 Verification Remedy Mount aflexible coupling w...

Page 53: ...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 befor...

Page 54: ...to a container 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 u...

Page 55: ...arged overboard through the engine exhaust A loss oftransmissionfluid will cause the transmission to fail 2 The raw water will leak into the transmission fluid caus ing an increase in transmission flu...

Page 56: ...onditioner such as STABIL 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 s...

Page 57: ...es are to be left on board during the lay up period make sure they are fully charged and will remain that way to prevent them from freezing If there exists any doubt that the batteries will not remain...

Page 58: ...s Ib x 454 Kilograms kg x2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg I...

Page 59: ...Emission Control Systems Indirect Fuel Injection General Fuel Fuel Injection Pump Fuel Injection liming Nozzle Fuel Filter on engine Air cleaner Airflow engine combustion General Operating Temperature...

Page 60: ...TALLED WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is more extensive KIT A DRIVE BELTS OIL FILTER FUEL FILTER FUEL SYSTEM...

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Page 62: ...Engines Generators 107412D3WMDW...

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