Страница 1: ...OPERATORS MANUAL MARINE DIESEL ENGINES 65A FOUR PUBLICATION NO 054218 FIRST EDITION OCTOBER 2008 r rWESTERBEKE...
Страница 2: ...persist seek medicalattention Shut down the unit and do notrestart until it has been inspectedandrepaired A WARNING DECAL is providedby WESTERBEKE andshould be fixed to a bulkheadnearyour engine orge...
Страница 3: ...he 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 fuel line carburetor or fuel filters Do...
Страница 4: ...or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO s adeadly gas Ensure that the exhaust system is adequate to expel gases discharged from t...
Страница 5: ...anual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTALLATIONS Preparations to ins...
Страница 6: ...oad waterline will result in raw water damage to the engine andpossibleflooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterli...
Страница 7: ...Checking Servicing Battery 33 Battery Care 33 Dual Output Alternators 34 Troubleshooting 35 High Output Alternators 36 Starter Motor 37 Troubleshooting 37 ZF Transmissions 39 Change the Fluid 39 Spec...
Страница 8: ...URE CAP OIL DIPSTICK OPTIONAL LEFT SIDE WATER INJ EXHAUST ELBOW PARTS IDENTIFICATION CRANK CASE VALVE NC ANODE THERMOSTAT ASSEMBLY WATER HEATER CONNECTIONS DC ALTERNATOR FRONT OIL DRAIN HOSE INTAKE MA...
Страница 9: ...manuals In summation product software provided with WESTERBEKE products whether from WESTERBEKE or other suppliers must not and cannot be relied upon exclusively as the definitive authority on the res...
Страница 10: ...periods specified and frequent checking for contaminations water sediment etc in the fuel system is also essential Another important factor is the use of the same brand of high detergent diesel lubric...
Страница 11: ...ble 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 be dry...
Страница 12: ...ion ALARM THE ALARM WILL SOUND IF THE ENGINE S OIL PRESSURE FALLS BELOW 5 10 psi 0 4 0 7 kg em IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE...
Страница 13: ...2000 2400 rpm MAXIMUM 2750 2800 rpm ENGINE COOLANT WESTERBEKE recommends a mixture of 50 antifreeze and 50 distilled water Distilled water is free from the chemicals that can corrode internal engine...
Страница 14: ...ound stud this location is tagged D Check the coolant level in both the plastic recovery tank and at the manifold 1 OIL FILL I II 1 COOLANT PASSAGE KEEP CLEAN NOTE Ifthe engine has not yet been filled...
Страница 15: ...he charging system allow about 50 secondsfor the RPM gauge to activate NOTE The START switch will not energize unless the PRE HEAT switch is depressed Depressing the PREHEATswitch activates the glow p...
Страница 16: ...CIRCUIT BREAKER 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 instmment panel wir...
Страница 17: ...water leaks Inspect wiring and oil will inhibit the engine s ability to and electrical connections Keep bolts nuts tight remain cool Check for loose belt tension Fuel Filter 0 0 0 0 0 0 Initial chang...
Страница 18: ...d spray condition see ENGINEADJUSTMENTS 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 opera...
Страница 19: ...4 Replace the washer if necessary 5 Reassemble and install the strainer 6 Open the seacock 7 Run the engine and check for leaks NOTE Alsofollow the above procedure after having run hard aground If the...
Страница 20: ...Loosen the hose clamp as shown and remove the three allen screws that hold down the thermostat housing cover the assembly can now be twisted enough to access the gasket and thermostat 3 Remove replac...
Страница 21: ...ssible NOTE This tank with its shO t run ofplastic wse is best located at or above the level ofthe engine s manifold CHANGING COOlANT The engine s coolant must be changed according to the MAINTENANCE...
Страница 22: ...ow indicates the pump has not primed itself properly NOTE Never allow the pump to run dry Even a short period ofdry running may destroy the impeller RAW WATER PUMP PN52650 INSPECTION CHECK THE BASE OF...
Страница 23: ...e other back to the enginesreturn 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 systemfi...
Страница 24: ...tion pump leave on engine BLEED SCREW The bleed screw on the injection pump should be left in the open position This will then allow for ease in priming the engine s fuel system and during engine oper...
Страница 25: ...ound the filter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Keep your engine clean Inspect the old oil filter as it...
Страница 26: ...ECTION AT THE REMOTE OIL FILTER To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filter kit as shown Always install this kit with the oil filter facing down as illu...
Страница 27: ...ous rating of 175 amps at 12 VDC will normally serve this function but aswitch must never be used to make the startercircuit I I PI o 110 Ito WIRING DIAGRAM 1 01 0 R 8 4 PNII PZtW P ALAIN C SUllER ADM...
Страница 28: ...ALTERNATOR ON THE 638 J lZ 63C J lZ IB ll 826 J lZ IOB6 lZl 10BC lZl OPTIONAL AL TERNATORS O 135A OA I lOA LUlU ALTERNATORS AVAIU8l ON 1H 638 rx UC IX 11B Dl t 8 IX 1088 JJ 08e xr ONLY WIRING SCHEMATI...
Страница 29: ...move the hand lever at intervals of one stroke per second while read ing tlle injection starting pressure A CAUTION The spray injected from the nozzle is ofsuch velocity that it maypenetrate deeply in...
Страница 30: ...s is with an ohmmeter Touch one prod 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 0 9 ohm resistance This method can be used with...
Страница 31: ...in the window on the flywheel housing Turn the flywheel 0 26 radius 15 clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position Now referring t...
Страница 32: ...linder is still low apply a small amount of oil into the cylinder to seal the rings and repeat the test If compression comes up the rings are faulty Abnonnally high readings on all cylinders indicates...
Страница 33: ...lternator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurate a With a hand held tach on the front of the crankshaft pulley retaining nut or with a...
Страница 34: ...K fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present at the connection on the fuel run solenoid Engine cranks but does not 1 Faulty fueling system 1 Check that f...
Страница 35: ...ce thermostat 2b loss of coolant check hoses hose clamps drain plug etc for leaks 2e Broken or loose belts tighten replace 2d Air leak in system run engine and open the pressure cap to bleed air Add c...
Страница 36: ...ce leak to ground 2 Check the wiring Insert sensitive 0 25 amp meter in battery lines Do NOT start engine Remove connections and replace after short is located 3 Low resistance leak to ground 3 Check...
Страница 37: ...by the field diode or diode trio package contained in the alternator These alternators produce a rated output of 50 or 51 amps Rated output is achieved at approximately 6000 alternator rpm at an ambie...
Страница 38: ...king the Service Battery b If the voltage remains around 12 volts a problem exists with either the alternator or the charging circuit continue with Steps 3 through 8 MEASURING BATTERY VOLTAGE ENGINE R...
Страница 39: ...This battery should have a voltage between 13 and 14 volts when the engine is running Ifnot there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit...
Страница 40: ...4 WIRE UP TO 2 WIRE _____ U LP lT O 20 0 WIRE ALWAYS USE FINE STRAND CABLE 5 Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cabl...
Страница 41: ...olts 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 The voltage at the...
Страница 42: ...USE FINE STRAND CABLE 14 BLUEI 14 PINK IGNITIONB 14 BLUEI 14 PINK IGNITION B _ 14 WHITE STATOR 14 RED TO STARTING BATTERYB WHEN USING TWO BATTERIES MALE CONNECTOR THIS SIDE 14 BROWN TACHOMETER 5 Make...
Страница 43: ...ing the starter for a few seconds never more than 10 seconds at a time then run your hand along the wires and terminals looking for wann spots that indicate resistance Repair or replace any trouble sp...
Страница 44: ...ause the sporadic problem of the engine starting one time but not another If corrosion is the problem the starter will need to be rebuilt It is however sometimes possible to get started by taping the...
Страница 45: ...erpullout the dipstick while the engine is running Hot fluid will splash from the dipstick hole This could cause severe burns LOCKING THE PROPELLER Locking of the propeller shaft by an additional brak...
Страница 46: ...shifting is not impeded by restricted movability ofthe Bowden cable or md linkage by unsuitably positioned guide sheaves too small a bending radius etc In order to mount a supportfor shift control cab...
Страница 47: ...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...
Страница 48: ...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 pennissible since the multip...
Страница 49: ...and recheck the fluid level A WARNING Neverpullout the dipstick while the el gine is running Hot fluid will splash from the dipstick oole This could cause severe burns MAINTENANCE Transmission mainten...
Страница 50: ...e throttle control lever will hold the engine at a quiet idle 750 1000 RPM 3 Tighten the locknut 4 Race the engine several times to ensure the idle speed remains as set ENGINE STOP ADJUSTMENT POSITION...
Страница 51: ...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 shift in Neu...
Страница 52: ...ntainer o Reconnect the oil cooler relul11 line D Use a suction pump to remove the transmission oil through the filler cap dipstick hole D Clean off the transmission and properly dispose of the used f...
Страница 53: ...ugh the engine exhaust A loss oftransmission fluid will ca lse the transmission to fail 2 The raw water will leak into the transmission fluid caus ing an increase in transmission fluid This contaminat...
Страница 54: ...damping bolt on shifting 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 c...
Страница 55: ...ropeller may be in no pitch position HSW TROUBLESHOOTING Probable Cause Verification Remedy Fluid level high during operation 1 Pump out fluid to the maximurn and rnark on dipstick Fluid level low 2 A...
Страница 56: ...the range specified where it operates the smoothest Different model transmissions will affect engine idle speeds General Operating Temperature Fresh Water Pump Raw Water Pump Raw Water Flow at 2800 rp...
Страница 57: ...e Top off your fuel tanks with unleaded gasoline of 89 octane or higher Afuel conditioner such as STABIL gasoline stabilizer should be added Change the element in your gasoline water separator and cle...
Страница 58: ...ies 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 fTom freezing If there exists any doubt that the batteries will not remai...
Страница 59: ...ms g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x6 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...
Страница 60: ...5 17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7...
Страница 61: ...Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising KIT A ZINC ANODES DRIVE BELTS OIL FILTER FUEL FILTER HEAT EXCHANGER GASKET...
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Страница 63: ...Engines Generators 1136 DW WM J0 08...
