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Westerbeke Diesel W 40na Operator's Manual



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OPERATOR'S MANUAL



      WESTERBEKE 46

   Marine Diesel Engine




                    Publication # 34468
                       Edition Two
                         May 1986




    AVON INDUSTRIAL PARK, AVON, MA 02322 · TEL: (617) 588-7700
    TELEX: 92-4444. FAX: (617) 559-9323· CABLE: WESTCORP
                                   FOREWORD


    Thank you for having                    selected                         a      Westerbeke
Diesel Engine for your use.

    This manual describes the procedures for proper
handling and routine maintenance of:

                                     W-46

             Marine Diesel Propulsion Engines

    To obtain best operating condition and longest
service life, it is important to use it sensibly
and carry  out operation and maintenance according
to this manual.

    If you have questions about your equipment or
in the event of a failure, please contact your
nearest distributor or dealer.

     If, within 60 days of submitting your warranty
registration card, you have not received a Customer
Identification Card (see below) registering your
warranty, please contact the factory in writing.

     We look forward to your continued patronage.



 from:   J.H. Weslerbeke Corp.
         Avon Industrial Park
         Avon, MA 02322




                          r/~1              J. H. WESTERBEKE                             COR~
                                      ·     AVON '''ov.r~'A< p",,~,   AVON, .. AU. oun



                           CUSTOMER IDENTIFICATION
                            W-46     1234C408 Pleasure Craft
                                     expi res 9/15/85
         Mail To:
                                 Adam Smith
                                 85 Maple Street
                                 Alden, IN       12234
                          ~                                                                ~


                                       1
                    TABLE OF CONTENTS
                                                                                PAGE

GENERAL SPECIFICATIONS ·....·········· 3

INSTALLATION, PREPARATION AND SUPPLY
      CAUTIONS. .. · .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ....   5

1.    BREAKING IN.......................................... 7

2..   STARTING SySTEM................................. 8

3.    INSTRUMENT PANEL USE ········.·.· 9

4.    STARTING PROCEDURES ············· IO

5.    STOPPING PROCEDURES ········.···. ll

6.    CAUTIONS ON STARTING
      AND OPERATION ..................................... 11

7.    REQUIREMENTS FOR PROPER
      OPERATION
      7-1 Lubrication System ········· 13
      7-2 Fuel System .··.··....··.·.. 14
      7-3 Wiring Diagram .···· Centerfold
      7-3 Cooling System ·····....···· lS
      7-4 Belt Tension . . . . . . . . . . . . . . . 20
      7-6 Domestic Hot Water ..······· 20
      7-7 Cylinder Head & Valves .····· 24

S.    RECOMMENDED MAINTENANCE SERVICE.25

9..   TRANSMISSIONS .... ................................ .. 28

10.   TROUBLESHOOTING ················· 40

11.   TABLE OF TIGHTENING TORQUES ·.··· 41

12.   COMMON PARTS BY NUMBER ·········· 43

13.   LIMITED WARRANTy ············...· 44




                                          2
                          GENERAL SPECIFICATIONS


Model                          Westerbeke 46

Type                            4-cycle, fresh water cooled diesel engine
                                with raw water exchanger system

*   & Arrangement of Cylinders 4 cylinder-vertical-in line

Bore & Stroke                   84 X 90mm (3.30 X 3.70 in.)

Dry Weight                      535 Ibs.   (242kg)

Total Piston Displacement       2084cc (127 cu. in.)

Compression Ratio               21 : 1.

Firing Order                    1 - 3 - 4 - 2

Rotational Direction            Clockwise as viewed from front of engine

Fuel                            *2   fuel oil (cetane rating 45 or better)

Lubricating Oil                 Mineral oil, heavy duty, A.P.I. CC or CD

Oil Pressure                    Idle 20 - 30 P.S.I. (1.75 - 2.46 kg/cm 2 )
                                Under power 30 - 60 P.S.I.
                                (2.46 - 4.21 kg/cm 2 )

Intermittent Power              47.5 horsepower at 3000 RPM

Westerbeke Rating               46 horsepower at 3000 RPM

Continuous Power                43 horsepower at 3000 RPM

Idle Speed                      700-850 RPM

Cruise R.P.M.                   2000-2500 RPM

Lubrication                     Forced lubrication
   Oil Pump                     Trochoid pump
   Oil Filter                   Full-flow type with paper element
   Oil Sump Capacity            7 quarts & filter

Cooling System                  Forced circulation by centrifugal pump
                                with thermostatically controled temperature
       Operating Temperature    170 - 190· F

Fuel System
    Fuel Injection Pump         NIHON-CAV distributor type
    Fuel Injection Nozzle       Bosch type, DNOSD
    Governor                    Flyweight type, built in pump
    Fuel Filter                 with paper element

Starting System                 Electric starter with glow plugs in head


                                      3
starter                     12V, 1.6KW pinion shift type

Alternator                  12V - 50 ampere

Battery                     12V - 100 ampere hour

Raw Water Flow Rate         9.5-10.0 gallons/minute at 3000 R.P.M.
                            measured at discharge into exhaust elbow

Propeller Recommendations   lSD x 10P-2 blade or lSD x SP - 3 blade
(using HBW-150 1.8S:1       propeller should allow engine to reach
reduction)                  its rated RPM (3000 + 100) at full
                            throttle underway




                                 4
INSTALLATION, PREPARATION AND SUPPLY CAUTIONS

*   Check important aspects of installation before operating engine.
                                                       003   ~EELER   GAGE
     (1)   Alignment (Error to be no more
           than one thousandth of an inch
           per inch of coupling diameter)

     (2)   Provide sufficient ventilation

     (3)   Provide adequate service room                 STRAIGHT EDGE
           around   engine (See  warranty
           clauses)                                CHECKING COUPLING ALIGNMENT


*    Fill fuel tank with CLEAN *2 diesel from a reputable manufacturer.

*    Fill engine sump with lubricating oil   to full mar k on dipstick
     (Select readily available lubricating   oil of grade CC or CD)
     (Sump capacity 7 quarts).

*    Fill freshwater cooling system with suitable mixture of water and
     antifreeze  to suit your     temperature zone.     Thoroughly mix
     antifreeze and freshwater BEFORE adding to cooling system.

*   Plug-in Panel Harness Connection. After assembly, joint should be
    taped to prevent corrosion or, preferably, assembled using a sili-
    con grease which can be obtained at an electronic store such as
    Radio Shack.

SAFETY PRECAUTIONS

*   Never operate engine with inadequate ventilation.     Confirm that
    there are no exhaust leaks inside engine compartment.

*   Do not touch moving parts during operation.

*    Do not touch hot parts such as exhaust pipe, and do not place com-
     bustible materialS near the engine.

*    Inspect and adjust parts of the engine only after it is stopped.

*   Check and refill engine oil, cooling water and transmission lubri
    cant only after the engine is brought to a stop.

*   A coolant recovery bottle was supplied with the engine together
    with instructions for installation.  Be sure that it is in place.
    Attempting to operate with only the manifold as an expansion tank
    exposes the operator to a severe steam burn if the manifold pres-
    sure cap is removed while the engine is hot.  Follow instructions
    on page 6.

*   Always use tools
    vicing.
                        that fit correctly and use caution during ser-


*   Be sure that current carrying wires are protected from abrasion
    and that all connections are tight.


                                    5
PREPARATIONS
Take steps as shown below in starting your engine for the first time
or after a prolonged shut-down.

1.   a)    F ill your eng ine wi th oil
                                                         oil filler port
     up to or near the upper limi t
     on the dipstick.       Use a good
     grade of oil with API specifi-
     cation of CC or better.        For
     quantity of oil, you may refer
     to    the General Specifications
     page.

     b)   Fill    the   transmission
     with   the  proper   lubricant.
                                                                        oil
     NOTE: Some V-Drives are filled
     separately.

2.   Your engine is supplied with a                       orllevelgauqB_~,J
     coolant   recovery system   to                      and ftller port
     which the following instruc-
     tions apply:
                                                           lower/lm;t      7---- -- _   oil   ~---~-_
     a)   Fill engine completely to
     the neck of the manifold cap.

     b)   Then  fill   the recovery
     tank to the bottom add line.
     Need for    adding coolant  is       COOLANT RECOVERY TANK
     indicated when a cold engine
     has coolant level below the
     bottom add line.
     c)   In winter add antifreeze
     as described on page 18.      A
     mixture of antifreeze should be
     used year round and changed as
     needed.

3.   Fill the fuel tank with *2
     Diesel fuel with *45 Cetane
     rating or better. The interior
     of the fuel tank must be main-
     tained clean.   Be careful not
     to allow introduction of dir t
     when filling fuel.

4.   Engine    oil,   coolant  and
     transmission levels should be
     checked at least once a day
     prior to engine use.




                                      6
BREAKING IN YOUR NEW ENGINE


    While your engine has had at least one hour of test operations to
demonstrate accurate assembly and correct operation of all systems, it
still requires break in time.

    Service life of your engine is dependent on how your engine is
operated and serviced during initial break-in hours of operation.

    Your new engine needs approximately fifty hours of initial con-
ditioning operation for breaking in each moving part, thus helping
maximizing performance and service life of engine.   Perform this con-
ditioning carefully, keeping the following points in mind.

    1.   Start engine, run at idle while checking that all systems are
         functioning - sea water pump, oil pressure, battery charge.

    2.   Warm engine, prefer ably by running propeller at fast idle
         while tied down, until water temperature gauge moves into the
         130 - 140 degree range.

    3.   Then use engine at moderate load (RPM) until normal engine
         operating temperature of 170 - 190'F (77 - BS'C) is reached.

    4.   Avoid rapid acceleration especially with a cold engine.

    5.   Use caution not to overload engine. Grey or black smoke is a
         sign of overload.     Select the correct propeller for the
         engine and transmission reduction.

    6.   Operate the engine in moderation, varying    the   running   RPM
         under load during the break in period.




Explanation:

"Breaking in" a new engine is basically a seating of the piston rings
to the cylinder walls.   This is not accomplished by long periods of
running idle, nor by early running under full load.

Idle running may glaze the cylinder walls causing oil consumption and
smoky operation.  Excessive speeds and loads may score cylinder walls
with similar results, especially with the engine cold.

As indicated above, operate the engine in moderation during the ini-
tial 50 hours of break in. Don't baby it, yet do not abuse it.




                                  7
DESCRIPTION OF STARTING SYSTEM

    Model W-46 uses an electr ic
starter assisted by glow plugs
for both normal and cold weather                  Glow Plug
starting. The figure is a cross
section   through  one   cylinder.
The glow plug enters the com-
bustion chamber so that the end
is in the spray path of the                                      Injector
injector nozzle.    When the glow
plugs are energized by the pre-
heat button, they glow red at the
tips and assist rapid ignition of
the fuel.    The result is rapid
starts with less wear on the
starter.

    This  system   is  common  to
Westerbeke Diesels.     The star t
circuitry is designed so that,
first, the preheat button must be
depressed for the time specified
in the glow plug use char t shown
below.

After which, and while keeping the preheat button engaged,      the start
button is depressed to crank the engine.

                         Glow Plug Use Data



           Atmospheric temperature            Preheating time


         +S'C (+41"F) or higher               Approx" 10 sec.

         +S"C   (+4l'F) to -S'C (+23'F)       Approx, 20 sec"

         -SoC (+23"F) or lower                Approx. 30 sec,

         Limit of continuous use                 1 minute



For complete starting and stopping procedures, see pages 10 and 11.




                                     8
INSTRUMENT PANEL   Description and use of:




Note 1:   When engine is stopped after use, the water temperature and
          oil pressure gauges may stay at their running readings.

Note 2:   When engine is next to be used, turn keyswitch ON.        The
          temperature and pressure gauges will "ZERO" and the voltmeter
          will register battery voltage.      The elecric fuel pump,
          mounted on the engine, will also begin to operate, purging
          any air accumulated in the system.

Note 3:   The engine is now prepared for starting.
Note 4:   For INITIAL STARTS:
          The self-priming feature of the W-46 is different from other
          models in that it requires longer time.      Two circuits are
          required to bleed both fuel filter and injecion pump.
          Therefore, when priming the W-46 for the first time or when
          the system has been wor ked on or has been run out of fuel,
          allow the electr lc fuel pump to oper te for 2 to 3 minutes
          before the first cranking effort.    simply turn the ignition
          key ON to activte the electric fuel pump.




                                   9
STARTING PROCEDURES

1.   Advance throttle to full, press Preheat button and hold for the
     number of seconds indicated on Page 8 in "Glow Plug Use Data".

2.   While still engaging Preheat button, press Start button.

     Note:   Failure to engage the Preheat button will not      allow   the
     Starter button to energize the starter.

3.   The starter will crank the engine which should start in 10 seconds
     or less.

4.   As soon as the engine starts, release buttons and throttle back to
     a moderate idle warm up of 80 - 1000 RPM.

5.   Should the eng ine NOT star t even though cr anking for 10 seconds,
     release the buttons for 30 seconds and repeat the sequence by pre-
     heating the glow plugs sufficiently.     The starter motor should
     never be run more than 30 seconds at a time.


6.   Proper glow plug function is
     indicated   by   voltmeter   drop
     when   the  Preheat   button   1S
     depressed.    This drop will be
     slight but discernible.    If no
     vol tage drop is noted, it may
     indicate defective glow plugs
     or a faulty preheat circuit.
     (Check for loose connection).



7.   As soon as the engine has started, release both Start and Preheat
     buttons. Check that with engine running, oil pressure and battery
     charge voltage are registering and that raw water is discharging
     with the exhaust.

     Note:    An alarm buzzer is supplied with every unit.   It is the
     responsibility of the installer to electrically connect the alarm
     buzzer to the two marked terminal connections on the engine
     electr ical harness and install the buzzer in a dry location so
     that it will be audible to the operator should it sound during
     engine operation. This buzzer will sound when the ignition key is
     turned on and should silence when the engine is started and oil
     pressure rises above 15 Ibs.

8.   To warm up engine, run a few minutes at idle to make checks in '7'
     above.   Then operate under reduced RPM until water temperature
     rises into the 140· range.     Then operate under moderate power
     until normal operating temperature is reached.




                                     10
STOPPING PROCEDURES
1.   Model W-46, early models were supplied with a manual shut-off. A
     'T' handle or knob is pulled to shut off fuel, stopping the
     engine.

     Later Models June 1985 (C506) on, were supplied with an electric
     shut-off operated by the key switch and having the manual shutoff
     as an installer's option.

2.   With the engine stopped, it is necessary to turn off the key-
     switch.   If you fail to do this, the panel remains energized and
     the electric fuel pump continues to run.    This oversight results
     in a dead battery.        with the alarm buzzer     installed and
     functioning, it will sound when the engine is shut down manually
     and the keyswitch left ON signaling to turn the key off.

CAUTIONS ON STARTING AND OPERATION
1.   Normal starting

     Follow the procedures below for routine starting of your engine.

     1)   Check the engine and transmission oil levels and refill i f
          necessary.
     2)   Insure that you have sufficient fuel.    Keep tank as full as
          possible.
     3)   Check cooling water level, and refill if necessary.
          Note: Check for leaks of water or oil, particularly when
          signs of such leak are found on the bottom of the engine or
          in the drip tray when provided.
     4)   Start the engine in accordance with the procedures given on
          the preceding pages.
     5)   Allow the engine to warm up to 140'-150' F before placing the
          engine under heavy load.

2.   Starting under cold conditions

     The following three adverse conditions concur as the atmospheric
     temperature drops exceedingly, and the engine must, under such
     conditions, be started by taking steps described below:
          LUBRICATING OIL TURNS VISCOUS    Make certain that viscosity
          is proper for the prevailing atmospheric temperature.  Check
          the oil also for deterioration. (Study page 13.)

          VOLTAGE ACROSS BATTERY TERMINALS DROPS        Check that the
          battery is fully charged.

          THE TEMPERATURE OF INTAKE AIR IS LOW AND COMPRESSION
          TEMPERATURE DOES NOT RISE ENOUGH      Allow the glow plug to
          operate sufficiently to aid starting. See table on page 8.




                                      11
3.   Cautions during operation

     Confirm that the oil pressure is normal during operation.

     Confirm that exhaust gas is as follows:

     *    While engine is cold ·········..··...····· White smoke
     *    When the engine grows warm ···...········· Almost smokeless
     *    When the engine is overloaded .·······... ~Some black smoke

     Check for abnormal noise such as knocking,     friction   or   leaking
     sounds, and vibration and blow-back sounds.

     Check for leaks of fuel and engine oil.

     A knocking sound is normal while the engine is cold, during quick
     acceleration and at idle. Confirm that no knocking sound is heard
     in other cases.




     Photo above is right hand side of the W46 with Hurth 2:1 reverse
     and reduction gear.




                                    12
                     REQUIREMENTS FOR PROPER OPERATION

LUBRICATION SYSTEM

1.   Engine oil
     For engine lubrication, use diesel engine oil. Diesel engine oils
     are classified according to the API Specifications into grades CA,
     CB, CC and CD. Anyone of them is usable, but use of CC or higher
     grades prepared by well-known makers is recommended.       The oil
     selected should be used thereafter,

2.   Engine oil viscosity
     Use oil having viscosity best suited to the atmospheric tem-
     perature.  Use of an all-season oil SAE10W-30 with minimum visco-
     sity   change   under   different   temperatures  is    suggested"
          Atmospheric temperature                              Viscosity

          20"C (6S"F) or higher                             SAE 30 or 10W-30

          S"C (41"F) - 20"C (6S'F)                          SAE 20 or 10W-30
          S"C (41'F) or lower                               SAE 10W-30

 3" Oil pressure
     The oil pressure during operation of the engine is indicated by
     the oil pressure gauge.

     During normal operation .··········· Oil pressure will range between
     (Under Power)                        30 and 60 PSI.
                                          (2.10 - 4.21 kg/cm 2 )
     At idle speed ...·..···...   e   ·········   20 - 30 P.S.I.
                                         (1.7S - 2.10 kg/cm 2 )
     At the time of cranking ···..····.·· Pressure will rise proportion-
                                         ately with speed.

4.   Replacement of oil filter

     Being a replaceable car tr idge
     type, the oil filter requires
     no cleaning inside.
     In installing the oil filter
     element,   apply    engine  oil
     thinly on to the O-ring, and
     then tighten it by hand firmly.
     When removing the used filter,
     cover over wi th a plastic bag.                                 OIL DRAIN SYSTEM
     This will allow both filter
     element and spilled oil to be
     collected    cleanly    without
     spilling    oil in the bilge,


                                          13
     Note A:   After-market filters are not recommended since the
               material standard or diameters of important items might
               be entirely different from genuine parts.

     Note B:   Immediately after filter change and oil filler, run
               engine to ensure that oil pressure is normal and that
               there are no oil leaks.

5.   Engine oil change:    Initially at 50 hours then every 100 hours of
     (including filter)    operation

     To renew engine oil, discharge old oil through the sump drain hose
     attached at front of engine while engine is still warm.
     Drain old oil completely, replace the hose, plug the end securely
     and add fresh oil through the oil fill cap on the valve cover.
     After refilling oil, idle the engine for several minutes and stop.
     Then check the quantity of oil by the oil level gauge.      Fill to
     but not over the high mark on the dipstick.     Always observe old
     oil as it is removed.   A yellow/grey emulsion indicates presence
     of water in the oil.      While this condition is rare, it does
     require prompt attention to prevent serious damage.     Call a com-
     petent mechanic.



FUEL SYSTEM

1.   Diesel fuel

     USE #2 DIESEL FUEL.    NEVER USE KEROSENE OR HEAVY OIL.

     In cold weather particularly, water vapor is produced by conden-
     sation when air is present in the fuel tank. The tank, therefore,
     should be kept full as much as possible.

     The fuel tank, furthermore,     needs     to be kept completely free of
     dirt and water.

2.   It is required that a primary                                              5EDJHi:t1T,·:nj'.;AT[H TRAP ;)2974


     fuel    filter    of   the   water                                                        :';,'(];m~"tel!~'atcr

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                                                                                  ,-"" "r !,l<,c~(l LJ~d~r.

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                                                                                                                  ITEM




                                                                                    23
CYLINDER HEAD AND VALVES

1.   Tighten cylinder head bolts in the sequence shown.     The engine
     should be cold.   Loosen each bolt one-eighth to one-quarter turn
     when tightening in the sequence shown.   Note that bolt 14 and 5
     are located under the intake manifold where it is attached to the
     head.



     0        16   14   12       10       11       15   1            Head Bolt Tightening Torque:
              0    0    0        0        0    0   0    Q
      0                                                              Exhaust Side
          0
              0
              8    @J                 0
                                      1        @)
                                                            0
                                                                9
                                                                         12.0 kg/m (86 Ib/ft)
                                                                     Intake side
              0                                                          10.5 kg/m (76 Ib/ft)
              6              2                              7



2.   Tighten rocker shaft bracket bolts to 1.5 kg/m (11 Ib/ft).

3.   Adjust valve clearance with the engine cold following retorquing
     of cylinder head bolts according to the following procedure. The
     valve clearance is 0.2 - 0.3 mm (0.009 - 0.012 inch).

     A.       Rotate the crankshaft slowly in the normal direction of
              rotation to bring the piston of the number 1 cylinder (front
              of engine) to T.D.C. of it's compression stroke.     (Observe
              when this is done that the valves of the number 4 cylinder
              are in a position of valve overlap, ie., the period between
              the opening of the inlet valve and the closing of the exhaust
              valve.)

     B.       In   this  position  adjust   the  valve  clearance   in the
              conventional manner of the intake and exhaust valve of the
              number 1 cylinder,    the intake valve of the number       2
              cylinder and the exhaust valve of the number 3 cylinder.

     C.       Rotate the crankshaft in the normal direction of rotation one
              full turn (360") and stop.

     D.       In this position adjust the valve clearance of the intake
              and exhaust valve of the number 4 cylinder, the exhaust valve
              of the number 2 cylinder and the intake valve of the number 3
              cylinder.

                                                                                        Exhaust valves



                                                                       l               \f            \    l            \1
                                                                                        I :          :    ~            I:
                                                                       \                         ~  ,./ U ~
                                                                           ...   -- "---;---\... --       .,.... -- "T"\
                                                                                                                   ~   ... _.... "

                                                                                      -~--




                                                                                              Inlet valves
                                                                24
                       RECOMMENDED MAINTENANCE SERVICE


Check and service your engine at specified intervals to maintain it in
its best conditions and permit it to perform as it should. As for
those asterisked items, it is suggested that you have them performed
by an authorized distributor or dealer.

1.    Daily inspection before use.

     A.    Check up of engine oil lever and refilling.

           No refill is required if the level is near      the upper     limit
           line of the gauge.
      B.   Checkup of cooling water and refilling.

           Refill up to the ADD line on coolant recovery tank.

      C.   Check your fuel supply.

      D.   Checkup of gauges and meters.

           After starting your engine, check oil pressure,       water    tem-
           perature and voltage readings.

      E.   Check for   loose parts   (fan belt or bolt, etc.),   damage and
           leaks.

      F.   Check for abnormality with exhaust gas, noise and vibration.

2.    Servicing following initial 50 hours of operation.

      A.   1.    Renewal of engine lube oil and filter
           2.    Renewal of transmission lubricant
                (HBW units 25 hours).
      B.   Replacement of fuel filters.

           1.   Secondary spin-on.
           2.   Electric fuel pump filter.

     *C.   Tightening of bolts and nuts.

     *D.   Adjustment of valve clearance Intake & Exhaust - 0.2 - 0.3mm
                                                  (.009 - .012 inches).

      E.   Check security of all electrical connections.

      F.   Adjust belt tensions.

      G.   Check  secur i ty of  propeller   shaft  coupling,      both     to
           transmission flange and shaft to couplings.

      H.   Adjust engine idle speed, if needed.



                                      25
      I.   Check condition of zinc anode in heat exchanger.

           Should material be flaking off the zinc, it should be scraped
           clean, or be replaced by a good solid zinc pencil.

           If it appears that a lot of material has been flaking off the
           zinc, then it is advised that the end cap of the exchanger be
           removed, and the flaked material be cleaned from that area of
           the exchanger. A new end cap gasket should be on hand in case
           it is needed when replacing the end cap.




              ZINC #11885              REPLACE         CLEAN/REPLACE


     *J.   Check for proper movement and security of throttle and shift
           linkage.

3.    Servicing at every 100 hours of operation.

      A.   Renewal of engine oil.

      B.   Replacement of oil filter.

4.    Servicing at every 200 hours of operation.

      A.   Replacement of engine mounted fuel filter elements.

      B.   Relacement of fuel filter     (cartridge type).

5.    Servicing at every 500 hours of operation.

      A.   Adjustment of engine idle, if necessary.

     *B.   Tightening of bolts and nuts.

     *C.   Adjustment of valve clearance.




                                       26
     *D.   Checkup of glow plugs.

           Check glow plugs for blowout.   Do resistance check.
      E.   Removal of cooling water and flushing is suggested.

      F.   Lubricate fresh water pump
           (Grease fitting - refill capacity 1.2 cu. in.)

6.    Servicing at ever 800 hours of operation.
     *A.   Checkup of nozzles.


           set the injection starting
                             +142
           pressure to 1706    -0 psi
           and eliminate undesirable
           injection conditions in-
           cluding "after dripping".
                                                                  GOOD


     *B.   Check Compression pressure

           Remove each glow plug and
           check cylinders, one by
           one, using a compression
           pressure gauge.     If the
           pressure differs by more
           than 3.0kg/cm 2 (42.7 psi)
           between cylinders or if
           the cylinder pressure is
           less    than   30kg/cm   2
           (427.0 psi) at TOO RPM,
           correct it.



     *C.   Fuel injection adjustment.
           In case of severe vibration during idling, have it repaired
           at an authorized distributor or dealer which is equipped with
           a pump tester.

     *D.   Check tightness of nuts and bolts.

     *E.   Check up of starter motor and alternator.




                                    27
                                HBW TRANSMISSIONS


           All HBW models turn right hand propellers.
           All HBW models have their own oil sumps and dipsticks.
           All HBW models use ATF lubricant.
           All HBW models should be shifted into gear in one                                                    swift
           motion - not allowed to slip in slowly.

Control of gearbox -

1.   The gear box   is   su i table  for                                                           o
     single   lever    remote    control                        o                      A                            B
     using 33C cable.                                           I
                                                                                        \                       /
                                                                                                           7i
2.   The cable should attach at right
                                                                                                          /
                                                                                                            ro
     angles to the actuating lever
     using     the   cable    bracket
     supplied.

3.   Both gear box lever and remote lever must be in                                    o                    o
     neutral position when cable is attached so that
     travel of gearbox lever will be equal forward or
     reverse.

4.   Check that actuating lever hub does not touch
     cover plate hub.    Maintain at least 0.5 mm
     (0.002") clearance.

5.   Over travel of the actuating lever does no harm.                                             O.Smm
     However, if the travel is too short to give full
     engagement,   premature   wear,  excessive  heat
     generation and gear failure may result.

6.   The position of the cover plate
     underneath the actuating lever
     is factory adjusted to ensure                                                                     TRANSMISSION
                                                                           TO CHECK OIL LEVEL
     equal lever travel from neutral                                                                   IN OPERATION
     to A and B.   DO NOT LOOSEN THE ~ ¢f?~
     CAPSCREWS HOLDING THIS ASSEMBLY. ~/.".,
     Doing this voids transmission (';' if ~
     warranty.                         : I" ~ 1
                                               ......;.""'Y.

                                               · . I; .' III rr
                                                                    .K
                                                                     U(
                                                                      1f
7.   Fill   gearbox   with  automatic'~' ~l.1 i ,
     transmission fluid to the l e v e l ' r t , ~
     indicated by the dipstick mark.             1: '
     (Study illustrations adjacent.)             Ii.
                                                 ,      ,
                                                            ,
                                      ~:I
8.   Note that to check oil level,          , "
     the   dipstick   drops   on  the I ' DI /'t,1['                                        FLUID LEVEL
     housing.   It does not screw in.     I
                                               " I, I   Iii I, I~
                                                            , ' I
                                                            ~       i~ I
                                           DRAIN PLUG




                                          28
                         WARNER HYDRAULIC TRANSMISSIONS



                                        FROM COOLER
                                         (2.10:1 ONLY)
        SHIFT LEVER                                                 DIPSTICK ASSEMBLY
                                                         SHIFT LEVER




         FROM         10-13/10-14
        COOLER                                    FROM COOLER       10-17/10-18
                                                  (EXCEPT 2.10:1)



1.   CONTROL LEVER POSITION

The position of the control lever on transmission when in forward
should be shifted to the point where it covers the letter "F" on the
case casting, and is located in its proper position by the poppet
ball.   The Warranty is cancelled if the shift lever poppet spring
and/or ball is permanently removed, or i f the the control lever is
changed in any manner, or repositioned, or if linkage between remote
control and transmission shift lever does not have sufficient travel
in both directions.    This does not apply to transmissions equipped
with Warner Gear electrical shift control.


2.   LUBRICATION
The properties of the oil used in the transmission are extremely
important to the proper function of the hydraulic system. Therefore,
it   is extremely important that the recommended oil,      automatic
transmission fluid (ATF), Type A or Dexron II be used.

NOTE: Be sure the cooler is properly installed and the transmission
contains oil before cranking or starting the engine.




                                        29
3.   FILLING AND CHECKING THE HYDRAULIC SYSTEM

The oil level should be maintained at the full mark on the dipstick.
Check oil level prior to starting engine. Check daily before starting
engine.   The hydraulic circuit includes the transmission, oil cooler,
cooler lines and any gauge lines connected to the circuit.         The
complete   hydraulic   circuit  must   be  filled  when   filling  the
transmission and this requires purging the system of air before the
oil level check can be made.    The air will be purged from the system
if the oil level is maintained above the pump suction opening while
the engine is running at approximately 1500 RPM.   The presence of air
bubbles on the dipstick indicates that the system has not been purged
of air.

New applications or a problem installation should be checked to insure
that the oil does not drain back into the transmission from the cooler
and cooler lines. Check the oil level for this drain back check only,
immediately after the engine has been shut off and again after the
engine has been stopped for more than one hour           (overnight is
excellent). A noticeable increase in the oil level after this waiting
per iod indicates that the oil is draining from the cooler and cooler
lines.   The external plumbing should be changed to prevent any drain
back.

4.   STARTING ENGINE

Move the shift lever to the center position where the spring-loaded
ball enters the chamfered hole in the side of the shift lever and pro-
perly locates lever in neutral position before starting engine.

5.   SHIFTING

Shifts from any selector position to any other selector position may
be made at any time and in any order if the engine speed is below 1000
RPM; however, it is recommended that all shifts be made at the lowest
feasible engine speed.   Move the shift lever to the extreme forward
position where the spring loaded ball enters the chamfered hole in the
side of the shift lever and properly locates lever in forward
position.

Move transmission shift lever to the extreme rearward position where
the spring-loaded ball enters the chamfered hole in the side of the
shift lever and properly locates it in the reverse position.


6. FREEWHEELING

Under sail with the propeller turning, or at trolling speeds with one
of two engines shut down, the design of the gear maintains adequate
cooling and lubrication.




                                   30
7. COOLING PROBLEMS

Water passages inside of the cooler will sometimes become clogged, and
this will reduce cooling capacity and cause overpressuring.       Back
flushing of the cooler will sometimes help to flush the foreign
mater ial from the cooler passages.    The cooler and hose should be
thoroughly flushed or replaced in the event a failure has occurred.
Metallic particles from the failure tend to collect in the case of the
cooler and gradually flow back into the lube system.       Replace oil
cooler to prevent contamination of the new transmission.

Water hoses may collapse and reduce or completely shut off all flow to
the cooler.  Collapsed hoses are usually caused by aging of the hoses
or improper hose installation.   Hose installation should be made with
no sharp bends. Hoses should be routed so there is no possibility for
engine shifting to cause hoses to pull loose or become pinched.      A
visual inspection of hoses while under way will sometimes allow detec-
tion of faulty hoses.

Reduction or complete loss of water flow can be caused by a faulty
water pump.   A rubber water pump impeller will sometimes fail and
after such a failure the cooler passages may be restricted by the par-
ticles of rubber from the failed impeller.   Water pump cavitation may
be caused by improper or faulty plumbing or an air leak on the inlet
side of the pump. The water pump may not prime itself or may lose its
prime when inlet plumbing is not properly installed.

It is possible for cross leaks to occur inside the cooler, permitting
oil to flow into the water or water flow into the oil.




                                  31
                    ROUTINE CHECKS AND MAINTENANCE


ANNUAL CHECKS
1.   PROPELLER AND OUTPUT SHAFT ALIGNMENT:  This check should also be
made any time the propeller strikes a heavy object and after any acci-
dent where the boat is stopped suddenly.   Shaft alignment should also
be checked after the boat has been lifted by a hoist or moved on a
tr ailer .
2.  SHIFT LEVER POSITIONING: The selector controls must position the
shift lever exactly in F, Nand R selection positions with the ball
poppet centered in the shift lever hole for each position.

3.   BOLT TORQUE:   Check all bolts for tightness.

4.  COOLER CONNECTIONS: Check water lines, oil lines and connections
for leakage.    Make sure lines are securely fastened to prevent
shifting.
5.  CHANGING OIL:   A seasonal oil change is recommended in pleasure
boats. Work boats require more frequent changes. Change oil any time
the oil becomes contaminated,     changes color or becomes rancid
smelling.  Automatic transmission fluids (ATF), Type A is recommended
for use.


DAILY CHECKS
1.   Check transmission oil level.
2.   Check for any signs of oil leakage in the bellhousing, at gasket
     sealing surfaces or at the output shaft oil seal.
3.   A quick visual check of the general condition of the equipment may
     cause faulty equipment to be detected.

4.   Listen for any unusual noises        and   investigate   to determine   the
     cause of any such noises.


WINTER STORAGE

1.   Drain water from transmission oil cooler.   This will prevent
     freezing in cooler climates, and prevent harmful deposits from
     collecting.

GENERAL CHECKS
1.   Check coupling alignment each time a tr ansmiss ion is replaced in
     the boat.
2.   Check shift linkage adjustment to insure that the transmission


                                     32
     shift lever is positioned so that the spring loaded ball enters
     the chamfered hole in the side of the shift lever.

3.   Connect an oil cooler into the cooler circuit before cranking or
     starting the engine.   various cooler circuits have been used and
     the correct cooler connections should be found from service
     literature prior to makeing the cooler installation.

4.   Use a cooler or sufficient size to insure proper cooling.

5.   Check engine rotation and transmission pump setting and the pro-
     peller rotation prior to assembling the transmission to engine.

6.   Check oil pressue and temperature     when   transmission    function
     indicates that a problem exist.

7.   Use the recommended fluid for filling the transmission.

8.   Fill the transmission prior to starting the engine.

9.   Check oil level immediately after the engine has been shut off.

10. Use a clean container for handling ransmission fluid.

11. Replace cooler line after a transmission        failure,     prior   to
    installing a new or rebuilt transmission.

12. Check fluid level at operating temperature.




                                   33
                                     WALTER V-DRIVES


FLANGE ALIGNMENT - DIRECT COUPLED MODELS

    Install the propeller shaft flange on
to the propeller shaft and tighten the two
clamping bolts on the spli t hub (none on                         CHECK--,
RV-10D). A self-locking set screw is pro-                                  I           rSET SCREW
vided for    the propeller shaft flange.      GEAK SHAFT -~" ' y - - , / ,
                                                FLANGE
spot drill the propeller shaft and then
securely tighten the set screw. Many good
installations are ruined by improper shaft
flange alignment. Accurate alignment will
ensure a smooth operating drive train and
eliminate many problems that arise due to
misalignment.   Final alignment should not
be attempted until the boat has been
                                                FEELE,
                                                 GAGE     .. o
                                                                   ~
                                                               03 !,
                                                                     7  ~···tt
                                                                 ':\0" \I;'{I
                                                                  IA/ --(,.'
                                                                               ~, ~ .~"
                                                                                  '.·e..
                                                                                   / 11,.
                                                                                            '

allowed to "settle" in the water.      After             .              /  L- HECK \ i
the engine has been installed, adjust the            PROP. SHAFT -----.I
                                                       FLANGE
                                                                             -
                                                                          CLAMPING
                                                                                   Jy'
mounts   per   manufacturer's   instructions                                BOLTS
until the pilot diameters of the gear                        FLANGE ALIGNMENT
shaft   flange  and the propeller      shaft
flange engage freely.      Butt the flange
faces together.   without rotating either flange, check with a feeler
gauge in at least four places as shown in the illustration.                            If the
maximum feeler gauge that can slip between the flange faces at any
point is .003", the unit is properly aligned.       If a thicker gauge can
be inserted at any point, the engine must be readjusted until proper
alignment is obtained. Turn the propeller shaft flange 1/4 of a turn
without moving the gear shaft change. Try inserting the .003" feeler
gauge as described above.     The gap will not change if the propeller
shaft is straight.   If i t increases, the shaft or flange is bent and
must be removed and straightened.     Rotate the propeller shaft flange
in two more 1/4 turn increments and repeat the procedure.                       The pilot
diameters must be rechecked to ensure that they still engage freely.
Secure the two flanges together with the heat treated bolts and spe-
cial high collared lockwashers supplied.


ENGINE ALIGNMENT - INDEPENDENT MODELS
    The engine must be adjusted so that the alignment of the flexible
joint is within 3'.    An accurate steel rule should be used for this
purpose as shown in the illustration.   On short installations using a
flexible joint assembly, the faces of the flexible joint must be
parallel within 1/8". Measure this in at least four places around the
diameter without rotating the assembly. With long installations using
the #36 tubular drive shaft (also on all RV-10D's) the distance from
the 133A spool adapter to the bores in the universal joint which is
welded to the tubular shaft must be measured on both sides of the
joint. Rotate the shaft exactly 1/4 of a turn and measure to the same
joint. The four distances must be equal within 1/8".    (Do not measure




                                               34
                         to the joint end that is
                         on the spool adapter.
                         This distance will not
                         v~ry   with misalignment                                        lERK nTTN:>



                         Since    the     joint   is
                         bolted and cannot move.)
                         Put the i3lA alignment
                         gauge on the machined
                         diameter    of    the   #24
                         cover and slide it com-          5tpIT INW:!! Al(1)l

                         pletely around. It will                             ,~<;,["lN£
                                                                             i
                                                                                           SCREW 10   on
                                                                                 AN N.:CLFlAT( M(A"'-"'EMENI

                         indicate how the engine
                         must be moved to center
                         the spline shaft in the
                         oil seal.        Re-measure
                         the joints to see if
they are still parallel within 1/8".           It is
important   that   both  alignments     be   checked   lCl'71 568        7700
                                                               CABlf"   Wf"SrCOflP, AVON   THf"IC    92   .. 4 .. 4

                                                                   44


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