Страница 1: ...DIESEL ENGINES PUBLICATION NO 037435 REVISION 3 MARCH 2018 J W WESTERBEKE j WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD j MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEB SITE WWW WESTERBEKE COM N...
Страница 2: ...EBIATELY Nsymptomspersist seekmedicalattention Shut down the unitanddo notrestart untilitlulsbeen inspectedandrepaired AWARN NB DECAL isprovidedby WESTERBEKEandshouldbe fixed to a bulkheadnearyour eng...
Страница 3: ...r 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 11 l Do not operate with the air cleaner silencer r...
Страница 4: ...yes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadlygas El Ensure that the exhaust system is adequate to expel gases discharged from the engine...
Страница 5: ...OR INSTALLATIONS Preparations to install an engine should begin with a thor ough examination of the American Boat andYacht Council s ABYC standar ds These standards are a combination of sources includ...
Страница 6: ...the vessel s waterline under the vessel s various operating conditions install a siphon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper operation Failure to proper...
Страница 7: ...ne Troubleshooting 32 Warning Lights Alarms and Circuit Breaker 13 Coolant Temperature Oil Pressure Gauges 34 Maintenance Schedule Chart 14 Adjusting Idle Speed 35 Cooling System 16 Belt Tension and M...
Страница 8: ...cter indicates the decade A 1960s B l970s C 1980s D 1990s the first number represents the year in the decade and the second and third numbers represent the month of manufacture PRODUCT SOFTWARE Produc...
Страница 9: ...time peri ods specified and frequent checking for contaminants water sediment etc in the fuel system is also essential Another important factor is the consistent use of the same brand of high deterge...
Страница 10: ...lever W428 FOUR MARINE DIESEL ENGINE Top Oil Fill Air Intake Silencer Sender Lube Oil Filter DC Charging Alternator Shut off Lever Lube Oil Drain Hose Fresh Water Circulating Pump W388 FOUR MARINE DI...
Страница 11: ...ion Oil and Grade Transmission Sump Capacity Propeller Recommendations Lube Oil Dipstick Oil Pressure Sender Case hardened helical gears with an intermediate reverse gear Reversing is carried out by a...
Страница 12: ...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 kg cm2 These readings fvill vary dependinJ upon the temperature ofthe engine and the load...
Страница 13: ...PLASTIC RECOVERY TANK the negative cable is connected to the engine ground stud this location is ll agged 0 Check the coolant level in both the plastic recovery tank and at the manifold NOTE Ifthe en...
Страница 14: ...lectrical harness The installer is also responsible for installing the buzz er in a location where it will be dry and where it will be audible to the operator should it sound while the engine is runni...
Страница 15: ...0 7 0 4 kg cni INTHIS_ EVENfTHE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILLALSO SOUND IF THE COOLANT TEMPERATUREIN THE FRESHWATER COOLING CIRCUIT RISES TO 210 F 99 G IN THIS EVENT THE ALARM WILL...
Страница 16: ...g intervals without the engine starting can result in the engine exhaust system filling with raw water This may happen because the pump is pumping raw water through the raw water cooling system during...
Страница 17: ...cking 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 13...
Страница 18: ...ull is open STARTING THE ENGINE NOTE See STARTING STOPPING PROCEDURE in this manualfor more detai ed instructions 1 t the transmission in neutral throttle advanced NOTE Hydraulically operated tra zsmi...
Страница 19: ...nuafreset circuit breaker 20 amps DC Excessive current draw or electrical overload anywhere in the instrument panel wiring or engine wiring will cause the breaker to trip In this event most engines wi...
Страница 20: ...rs then change both every 250 hours Initial check at 50 hours then every 250 hours or once ayear Garetully inspect for leaks Check that the exhaust hoses are properly attached and that the securing cl...
Страница 21: ...adjust injection opening pressure and spray conditions Drain flush and re fill the cooling system with appropriate antifreeze mix Torque Bolts and Adjust Valves cold Check solenoid and motor for corr...
Страница 22: ...rough the engine by a circu lating pump absorbing heat from the engine The coolant then passes through the thermostat into the manifold to the heatexchahger where it is cooled and returned to the engi...
Страница 23: ...ngine warms up the thermostat gradually opens The thermostat is acces ible and can be checked cleaned or replaced easily Carry a spare thermostat and gasket Replacing the Thermostat Remove the cap scr...
Страница 24: ...t exchanger Raw Water Intake Strainer STRAINER FILTER TYPICAL RAW WATER INTAKE STRAINER owner lnstalle HEAT EXCHANGER The heat exchanger is a copper cylinder which encloses a number of small copper tu...
Страница 25: ...eplace the gasket refer to your engine model s heat exchanger end gasket part num ber 0 ring and cover and install a new zinc anode NOTE The threads ofthe zinc anodes are pipe threads and do not requi...
Страница 26: ...Periodically check the fuel connections and the bowl for leakage Replace the filter element after the first 50 hours then follow the MAINTENANCE SCHEDULE FUEL LIFT PUMP 039275 Periodically check the...
Страница 27: ...icing mechanic should make to the fuel inje ction pump is the adjustment for engine idle speed see IDLE SPEED ADJUSTMENTunder ENGINE ADJUSTMENTS GLOW PLUGS DESCRIPTION The glow plugs are wired through...
Страница 28: ...ilter to make certain 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...
Страница 29: ...monitor the engine oil pressure and to sound the panel alarm buzzer should a low oil pressure issue occur 10 5 psi The engine alarm buzzer is such cases will sound continuously YOPEN LIFT PUMP OIL PRE...
Страница 30: ...oillines car iectly IfPie allflawsJn the reverse direction the by pass valveIn thB Riterassembly willprevent the ail from reaching the engine Gaoslngan lntemalengine failure Nthere Isno allpressaro r...
Страница 31: ...p 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 Inaccura...
Страница 32: ...remote expansion tank in a conve nient location so the coolant level can easily be checked The remote expansion tank will now s erve as a check and system fill point The plastic coolant recovery tank...
Страница 33: ...TING SOLENOID Prior to testing make certain the ships batteries are at full charge ru1d that the struiing system wiring co1mections terminals are clean and tight Pay particular attention to the ground...
Страница 34: ...motor without engaging theflywheel Turn the starter switch on to provide thepower to the solenoid Hopefully it will create enough magneticfieldfor the arm to move even though the contacts inside the...
Страница 35: ...The alternator charging circuit charges the starting battery and the service battery An isolator with a diode a solenoid or a battery selector switch is usually mounted in the circuit to isolate the...
Страница 36: ...he engine batteryswitch while the engine Is running Shutoff the engine batteryswitch however to avoid electricalshorts when working on the engine s electrical circuit BAnERY The recommended dedicated...
Страница 37: ...lO SUJff R TO OISCQMN Cl THC SAlltRT lit AN M RG NC r AHD WH N LEAVING lH 80 L A SWITCH WITH A CONTINUOUS RATING Of llS AMPS n 11 voe Will S RV nus ruNCTION nus SWfTCU SUOULD HOT 8 UStO ro MAK OR 8R A...
Страница 38: ...Electric grease at the connection After connecting fasten the harness plugs tightly with a Tywrap I i I I I I I I WIRING DIAGRAM 39144 sz ptt p ALARM C Ull R I __ j I I I I I I I I I I I I I I I I I r...
Страница 39: ...Check battery charge state Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open start 1a Check for air in fuel system Bleed air from fuel system 1b Fuel filters clogge...
Страница 40: ...nkcase 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 3 Black smoke 3 Improper grade of fue...
Страница 41: ...d frayed edges 3 Pivot the alternator on the base mouhting bolt to the left or right as required to loosen or tighten 4 Tighten the base mounting bolt and the adjusting strap bolt 5 Run the engine for...
Страница 42: ...is rotated 3 Align the timing mark on the gear case with the timing mark pulley indicated for cylinder 1 the one nest to the three injection timing marks In this position the No I cylinder is at its t...
Страница 43: ...their compression stroke Remember the engines firing order is 1 3 4 2 The engine s valves must be adjusted in this order while the valves are closed You may find that tuning the engine s crankshaft i...
Страница 44: ...shifting is not 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 c...
Страница 45: ...running Hot fluid will splash from the dipstick hole This could cause severe burns OPERATING TEMPERATURE The maximum permissible ATF temperature should not exceed 230 110 This temperature can only be...
Страница 46: ...dically 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...
Страница 47: ...ning 1 Transmission needs professional attention fails to propel the boat 2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping Output coupling is turning on th...
Страница 48: ...il 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 controled cable The cable should...
Страница 49: ...ok for signs of water contamination fluid will appear as strawberry cream Lay up Winterize Storage requires special care Fol low these procedures NOTE This operation will usually occur when the engine...
Страница 50: ...mage 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 Neutra...
Страница 51: ...drain into a container 0 Reconnect the oil cooler return line 0 Use a suction pump to remove the transmission oil through the filler cap dipstick hole 0 Clean off the transmission and properly disp6s...
Страница 52: ...d 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 fluid This contam...
Страница 53: ...eight strongest The marl s correspond to two marks less than the actual grade i e agrade seven bolt will displayfive embossed marks Metric boll class f umbers identify bolts by their strength with 10...
Страница 54: ...ht type Overhead Swirl chamber type 3 07 x 3 07 inches 78 x 78 mm 68 23 cubic inches l 118 liters 1 3 2 Clockwise when viewed from tl le front 41 lbs ft 5 67 kgs m 23 1 455 psi 32 kg cm2 at 320 rpm In...
Страница 55: ...regulator built into alternator 14 1 Volts DC 3 Volts Open flow totally self bleeding No 20 SAE J313 45 Cetane or higher grade of diesel according to ASTM 0975 Nippondenso Bosch M type 23 0 5 BTDC Sta...
Страница 56: ...ximum Mechanical centrifugal weight type Overhead Swirl chamber type 2 87 x 3 v1 inches 73 x 78 mm 79 64 cubic inches 1 305 liters 1 J 4 2 Clockwise when viewed from the front 53 lbs ft 7 33 kgs m 23...
Страница 57: ...ntrolled with sea water exchanger system Operating Temperature 150 1701 F 66 77 0 C Fresh Water Pump Centrifugal type metal impeller belt driven Sea Water Pump Positive displacement rubber impeller ge...
Страница 58: ...ifugal weight type Overhead Swirl chamber type 3 07 x 3 07 inches 78 x 78 mm 90 93 cubic inches l 49 liters t 5 4 2 Clockwise when viewed from the front 56 lb ft 7 74 kg m 23 l 455 psi 32 kg cm2 at 32...
Страница 59: ...sea water exchanger system Operating Temperature 150 170i 66 77 c Fresh Water Pun ip Centrifugal type metal impeller belt driven Sea Water Pump Positive displacement rubber impeller gear driven SeaWat...
Страница 60: ...ine of 89 octane or higher A fuel 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 certa...
Страница 61: ...sed tluring the lay up such as filters and zinc anodes Refer to the SPARE PARTS section of this manual Transmission Propulsion Engine Check or change the fluid in the transmission as required Wipe off...
Страница 62: ...or more extensive off shore cruising AKit Impeller t Heat Exch nger Gasket Fuel Filter with Gasket Oil Filter Drive Belt Zinc Anodes FUEL FILTER WATER SE ERATOR FILTER HARDWARE KIT WESTERBEKERECOMMENO...
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Страница 64: ...412018 1245 WESTERBEKE WESTERBEKECORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE WWW WESTERBEKE COM...
