Westerbeke Diesel W 40na Operator's Manual

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failure such electrical systems AdobeUCSCOMMON PARTS BY NUMBER DESCRIPTION PART NUMBER Fuel Hardware Kit including banjo washers injector seat washers 34441 Lift Pump Filter Gasket 30548 Fuel Filter 24363 Lube Oil Filter 35828 Glow Plugs 34380 Sea Water Pump 16423 Sea Water Pump Mounting Gasket 11143 Sea Water Pump Repair Kit 18172 Sea Water Pump Impeller Gasket Kit 33104 Alternator Belt 30475 Thermostat 24688 Thermostat Housing Gasket 33966 Oil Pressure Alarm Switch 34761 Injector 34376 Zinc Plugs 11885 Spare parts Kit A 34444 Spare parts Kit B extended cruising34445 43 NUMBER REQUIRED PER ENGINE 1 1 1 1 4 1 1 1 1 1 1 2 1 4 1 1 1 7 4 7 21 23 44 49 TORQUE SPECIFICATIONS Kgm Ibft Cylinder head bolts Exhaust side 1l5 125 832 905 Intake side 100 110 724 796 Main bearing cap 80 90 579 652 Connecting rod bearing caps 50 60 362 434 Rocker shaft bracket 10 20 72 145 Front plate bolts 7 15 51 108 Timing gear cover 7 15 51 108 Camshaft thrust plate 15 23 108 166 Idle thrust plate 30 40 21 7 289 Crankshaft pulley 395 405 2857 2929 Backplate to block 30 35 21 7 253 Rear oil seal 04 29 Flywheel bolts 80 90 579 652 Oil pan bolts 07 51 Banjo bolt oil drain hose 95 105 687 759 Injector retaining nut 45 55 325 398 Injection pump delivery valve holder 25 35 181 253 41 ENGINE PROBLEM 1 ENGINE DOES NOT START a b c d e f g h i Starting switch is defective Deficient drive torque of the starter motor Improper viscosity of engine oil Engine too cold Seizure of moving parts Air present in fuel system No fuel in fuel tank Fuel filter clogged 20 Amp circuit breaker tripped REMEDY Correct connections and contacts The battery is exhausted trouble with the starter motor or dirty or loose wiring Check the viscosity and renew oil if necessary Use glowplug starting aid Rectify Purge thoroughly wi th electr ic fuel pump Refill Clean or renew Manually reset 2 ENGINE STALLS WHILE IN OPERATION a Fuel tank is empty b Fuel filter clogged c Air present in fuel system 3 IMPROPER OIL PRESSURE a Oil shortage b Oil leak through connections c Oil pressure sender defective d oil filter clogged 4 ENGINE OVERHEATING a Cooling water shortage b Water leaks c Belt loose or smeared with oil d Raw water pump defective e Thermostat defective 5 BATTERY IS UNDERCHARGED a Belt tension improper b Faulty wiring circuit c Alternator not functioning observe voltmeterd Battery faulty e Faulty voltage regulator Refill Clean or renew Retighten fuel line connections and allow electric fuel pump to run long enough to purge air thoroughly Refill Repair Replace Replace Refill Repair Clean or renew Repair or renew Replace Rectify Rectify Replace Replace Repair or renew 40 The plugs can be checked to see if they are magnetic only after removal Touch the inside face with a metallic object such as a screwdriver Clean them and reinstall Usually there are four plugs in the bottom part of the main housing Only two of these are magnetic The other two need not be removed see wi th SAE 30 motor oi I to the proper level see INSTALLATION OIL FILLThe Zerk fitting on the external uni255versal joint should be greased with a light alemite lubricant see ENGINE AL I GNMENT225 2 WATER DRAIN For protection from freezing during winter layup remove the small pipe plugs located diagonally oppositeon the front and back of the housing marked Water Drain see illutrationOn the RVIO only one of the water lines going into the 6 watercooled bottom cover must be disconnected to drain the water 3 FLANGE AND ENGINE REALIGNMENT When the boat is launched after being in drydock the lineup of the Vdrive to the propeller shaft flange and the engine to the V255drive should be rechecked and corrected if necessary Some engines with rubber mounts may sag and must be raised with adjustments or shims for proper alignment see Flange Alignment and Engine Alignment225 39 OPERATION A pressure drop warning light is mounted on the instrument panel on Vdrives equipped with an oil cir255culating pump The warning light will stay on until the boat gets under way and the engine speed increases to suf255ficient RPM for the pump to maintain pressure This normally occurs at approximately 1200 RPM but the actual speed may vary by as much as 400 RPM Extended cruising at low RPM such as when trolling is not harmful to the Vdrive even though the warning light may stay lit Normal operation is between 6 to 12 PSI The light will go on when the oil pressure drops below 2 PSI Loss of oil andor insufficient oil level are the major causes of pressure drop The oil level should immediately be restored 1149 QESSURE J CROP SWITCH and while running the boat the unit should be checked for leaks If the oil level is normal and the light stays lit when the boat reaches normal cruising speed the wiring should be checked for loose andor corroded connections If the wiring is correct and the light remains lit the 49 pressure drop switch which is mounted on the side of the Vdrive see be checked for proper operation The switch can easily be removed and an accurate oil pressure gauge installed in its place If the pressure is normal the switch should be replaced If the pressure is below normal the oil lines should be checked for blockage The pump should be inspected and replaced if necessary The pump is standard on the RV48 and an optional feature on other models not available on the RVlOThe oil level should be checked several times during the season especially on Vdrives whitout pumps see OIL FILLA clatter or rattle in the Vdrive at low RPM is due to the over255riding of the propeller during the compression stroke of the engine Although annoying it is not harmful It may be reduced by adjusting the idle speed andor tuning up the engine for smoother operation MAINTENANCE 1 OIL CHANGE AND JOINT LUBE After the first 100 hours of operation and every season andor 500 hours thereafter the oil should be changed Run the boat to warm up the Vdrive to operating temperature Turn off the engine Remove the plug in the 6B bottom cover that is opposite the 43S oil strainer Reinstall after draining Disconnect the oil hose leading from the 43S strainer leave the elbow on the the strainer and clean the outside surface Reinstall the strainer and reconnect the oil hose Unscrew the two 22 magnetic plugs that are located on diagonally opposite corners of the lC main housing 38 a 2 drive train and eliminate many problems that arise due to Final alignment should not be attempted until the boat has been allowed to settle in the water Adjust the Vdrive until the pilot diameters of the gear shaft flange and the propeller shaft flange engage freely Butt the flange faces together Wi thout 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 Vdrive must be readjusted until proper alignment is obtained Turn the pro255peller shaft flange 14 of a turn without moving the gear shaft flange Try inserting the 003 feeler gauge as described above The gap will not change if the propeller shaft is straight If it increases the shaft or flange is bent and must be removed and straightened Rotate the propeller shaft flange in two more 14 turn increments and repeat the procedure The pilot diameters must be rechecked to ensure that they still engage freely Tighten the nuts on the mounting brackets and the locking nuts on the adjusting screws Remove the set screws from the brackets none on RVIO or RV20spot drill and securely tighten Recheck the flange alignment to make sure the Vdrive did not move out of alignment Secure the two flanges together with the heat treated bolts and special high collared lock255washers supplied GEAR SHAFT FLANGE FEELER GAGE HEK255I CLAMPING BOLTS FLANGE ALiGNMEN T SET SCREw WATER AND SWITCH CONNECTIONS cSET SCREW MOUNTING PLATE RV30 RV40 RV48 Hook up the water lines to the two pipe connections on the Vdrive intake and exhaust lines are one line from the seacock to the Vdr i ve and another from the Vdr i ve to the intake of the engine water circulating pump are utilized In some cases scuppers through the hull are connected to and from the Vdrive to provide independent watercooling and are actuated by the movement of the water wi th closed cooling systems the Vdr i ve should be incorporated into the system between the cooler and the suction side of the water pump Proper operating temperatures are from 140 to 36 to the joint end that is on the spool adapter This distance will not with misalignment Since the joint is bolted and cannot movePut the i3lA alignment gauge on the machined diameter of the 24 cover and slide it com255pletely around It will indicate how the engine must be moved to center the spline shaft in the oil seal Remeasure the joints to see if they are still parallel within 18 It is important that both alignments be checked thoroughly It is possible for the spline shaft to be perfectly centered and the flexible joint to be out more than 3 Premature failure of the 26 selfaligning bearing and seals may occur due to misalignment The zerk fitting located on the cross of the universal jointshould be greased with a light alemite lubricant The above procedure should be repeated after the boat has been placed in operation It is possible for the engine to slightly shift and settle espe255cially if it has rubber mounts FLANGE ALIGNMENT INDEPENDENT MODELS Install the propeller shaft flange on to the propeller shaft and tighten the two clamping bolts on the split hub none on RVlOA selflocking set screw is provided for the propeller shaft flange Spot drill the propeller shaft and secure255ly tighten the set screws All Vdrives are supplied with 3way adjustable mounting brackets 2way on the RVlO and RV20as standard equipment The brackets must face down255ward as shown in the illustration to properly absorb propeller thrust The mounting plates can be removed and reversed to fit wider engine bed centers Before installing the Vdrive loosen all the nuts on the mounting brackets and check to see that the studs are in the center of the slots RelERK nTTN 5tpIT INW Al1SCREW 10 on i AN NCLFlAT MAEMENI lClQ IISlALLAllttl RVIQ RV26720 tighten the nuts place the Vdrive on the engine bed lining it up by eye to the propeller shaft flange as closely as possible Firmly bolt it down through the holes provided in the mounting plates Loosen the locking nuts on the adjusting screws Slightly loosen the nuts on the mounting br ackets just enough to be able to move the V255drive Many good installations are ruined by improper propeller shaft flange alignment Accurate alignment will ensure a smooth operating 35 AdobeUCSWALTER VDRIVES 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 RV10DA selflocking set screw is pro255vided for the propeller shaft 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 allowed to settle in the water After the engine has been installed adjust the mounts per manufacturers instructions until the pilot diameters of the gear shaft flange and the propeller shaft flange engage freely Butt the flange CHECK I rSET SCREW GEAK SHAFT y FLANGE FEELE 267e GAGE 703 11 o 0 II IA LHECK i PROP SHAFT I Jy FLANGE CLAMPING BOLTS FLANGE ALIGNMENT 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 14 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 it increases the shaft or flange is bent and must be removed and straightened Rotate the propeller shaft flange in two more 14 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 spe255cial 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 18 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 RV10Dsthe 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 14 of a turn and measure to the same joint The four distances must be equal within 18 Do not measure 34 AdobeUCSshift 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 pro255peller 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 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 acci255dent 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 ATFType 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 freezing in collecting GENERAL CHECKS from transmission oil cooler This will prevent cooler climates and prevent harmful deposits from 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 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 detec255tion 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 par255ticles 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 and any WARNER HYDRAULIC TRANSMISSIONS SHIFT LEVER FROM COOLER 10131014 1 CONTROL LEVER POSITION FROM COOLER 2101 ONLYDIPSTICK ASSEMBLY SHIFT LEVER FROM COOLER 10171018 EXCEPT 2101The 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 andor ball is permanently removed or if 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 ATFType 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 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 2 The gear box is su i table for single lever remote control using 33C cable The cable should attach at right angles to the actuating lever using the cable bracket supplied o I 3 Both gear box lever and remote lever must be in neutral position when cable is attached so that travel of gearbox lever will be equal forward or reverse 4 5 6 Check that actuating lever hub does not touch cover plate hub Maintain at least 05 mm 0002clearance Over travel of the actuating lever does no harm However if the travel is too short to give full engagement premature wear excessive heat generation and gear failure may result A o o B 7i ro o OSmm The position of the cover plate underneath the actuating lever is factory adjusted to ensure equal lever travel from neutral TO CHECK OIL LEVEL TRANSMISSION IN OPERATION 7 8 to A and B DO NOT LOOSEN THE CAPSCREWS HOLDING THIS ASSEMBLY Y Doing this voids transmission if K 267 I III rr 1f warranty I 1 U Fill gearbox with i transmission fluid to the levelrt indicated by the dipstick mark 1 Study illustrations adjacentIi Note that to check oil level the dipstick drops on the II DI t1 housing It does not screw in I I I Iii I I I I DRAIN PLUG 28 FLUID LEVEL AdobeUCSD 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 12 cu in6 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 in255cluding after dripping 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 30kgcm 2 427 psibetween cylinders or if the cylinder pressure is less than 30kgcm 2 4270 psiat TOO RPM correct it C Fuel injection adjustment GOOD 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 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 CLEANREPLACE 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 type5 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 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 tem255perature and voltage readings E Check for loose parts fan belt or bolt etcdamage 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 hoursB Replacement of fuel filters 1 Secondary spinon 2 Electric fuel pump filter C Tightening of bolts and nuts D Adjustment of valve clearance Intake Exhaust 02 03mm 009 012 inchesE Check security of all electrical connections F Adjust belt tensions G Check secur i ty of propeller shaft coupling transmission flange and shaft to couplings H Adjust engine idle speed if needed 25 both to CYLINDER HEAD AND VALVES 1 Tighten cylinder head bolts in the sequence shown The engine should be cold Loosen each bolt oneeighth to onequarter 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 Q 0 0 0 0 Exhaust Side 0 0 J 0 0 120 kgm 86 Ibft8 1 9 Intake side 0 105 kgm 76 Ibft6 2 7 2 Tighten rocker shaft bracket bolts to 15 kgm 11 Ibft3 Adjust valve clearance with the engine cold following retorquing of cylinder head bolts according to the following procedure The valve clearance is 02 03 mm 0009 0012 inchA Rotate the crankshaft slowly in the normal direction of rotation to bring the piston of the number 1 cylinder front of engineto TDC of its 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 valveB 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 360and 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 T U Inlet valves 24 AdobeUCSP S AdobeUCSVH I WI PI NG DIAGRAM 0L PRESSURE SWICH c SEE NOTEB W srNDER c I I o ACARM I I e FUEL SOL 118 Nj2 70lV100 f oce un ro wl3 N2127 W 3 J 152W81I70WOO CCQoecco NOTEB OP SENDER I NOT USEO r24 EL 4 BI 0 OR i EoPN B I F T i la10 SERlE 15 ALTERNATOR eeN I 22 ALTERNATOR C SI AMP Jl 7 rt o GRN J 0 0 225 I I A 21 1r OPTIONA SPLlTT L R AMMER PREHEAT SOL PuR 2672 WT cs SEE SEE NOTE 2 VDC RED 10 V 0 I1ATTERY WT STARTER 0 SAFETY SWITCH PUR N rSI m b IS ee IC b NHT AdobeUCSModel W 46 comes complete wi th a Flow Control which when proper ly connected to a heater tank produces domestic hot water from waste engine heat Principle With the bypass hose 130962 removed there remain 2 con255necting points A and B for hose to and from the water heater These connections assure a flow of hot water through the heater at all times and yet preclude excessive restriction of engine cooling water flow caused by the heater all simply and automatically Installation The heater should be mounted conveniently either in high or low position so that connecting hoses from heater to engine can run in reasonably direct line without loops which might entrap air Connection Point A on the Flow Control housing should connect to the lower of the two connections on the water heater while the upper connection on the heater returns to B nearest the heat exchanger Hoses should rise continuously from their low point at the heater to the engine so that trapped air will rise naturally from the heater to the engine If trapped air can rise to the heater then an air bleed petcock must be installed at the higher fitting on the heater for bleeding air while filling the system Avoid loops in hose runs which will trap air If any portion of the engine cooling water circuit to or from the heater rises above the engines own pressure cap then the pressurized remote expansion tank must be installed in the circuit to become the highest point The tank kit part number is 24177 Install the remote expansion tank in a convenient location such as a sail locker for ease of checking fresh water coolant level The cap on the engine mounted expansion tankmanifold should not be opened once the remote system is installed and filled The hose should be heater to connection from the heater routed and supported so as the tank enabling any air in to to the the remote expansion tank rise continuously from the system to rise Illustration manifolds below are of Flow Control adapted to our single pass REMOVE RETURN BEND FROM PRESSURE CAP IS RATED LOWER THAN MANIFOLD CAP HEATER COILS BELOW PRESSURE CAP HEATER BELOW ENGINE 21 REMOTE EXPANSION TANK HEATER COILS ABOVE PRESSURE CAP HEATER ABOVE ENGINE AdobeUCSBELT TENSION The belts are properly ten255sioned when they deflect 10 to 12 mm 039 to 047 inas they are depressed with a finger between the alternator pulley and fresh water pump pulley Excessive tension can cause quick wear of the belt and bearings of the water pump and the alternator Excessive slackness or presence of oil on the belt on the other hand can lead to engine overheating insufficient charging due to a slipping alternator belt and rapid wear of the belt CAUTION Never attempt to adjust tension of any drive belt while the engine is in operation WIRING DIAGRAM Your engine has a 12 volt DC startrun circuit A pictoral schematic of this is illustrated on Page 22 Study it and learn to understand how the system functions For installing electrical parts connect them correctly by referring to the diagram and at the same time check for damaged wire sheathing and confirm that grounding is provided properly Care must always be taken while working on the electrical system NEVER SHUT THE ENGINE BATTERY SWITCH OFF WHILE THE ENGINE IS RUNNING DAMAGE TO THE BATTERY CHARGING ALTERNATOR WILL RESULT SHOULD THIS BE DONE DOMESTIC HOT WATER Sketch at right shows Model W46 complete wi th Flow Control mecha255nism and its bypass connection for normal use If it is desired to connect a hot water heater remove the bypass hose altogether and con255nect the heater as instructed on the following page Study the instructions carefully 20 REMOVE ReTURN BEND FROM The total system is very reliable and requires only a daily check of the water level in the system plus routine checks of hose clamps and fittings 225 It is likely that zinc electrodes will waste away from elecroly255sis action in the sea water circuit They should be checked monthly It is also possible for the raw water pump impeller to fail due to lack of sea water or deterioration An early sign of impeller failure is less water and more stearn at the exhaust through hull fitting and higher engine operating temperature It is recommended therefore that zinc electrodes water pump belt alternator belt sea water pump assembly and sea water impeller kit be carried onboard at all times These parts should be ordered from your nearest stocking dealer and used as inpection dictates The part numbers for these mnay be taken from the parts list on page 43 WTENJIECTED ELBOW FRESH WATER THERMOSTAT DRAIN TO HOT WATER TANK INCOMING RAW WATER 19 COOLING SYSTEM 1 Cooling water As cooling water use soft water with least impurity content such as tap water potable wateror rainwater and never use hard water or foul water Use of hard water or water containing much impurity will lead to collection of scale in the engine and heat exchanger with resultant decline in cooling effects 2 Antifreeze In cold districts care should be taken to prevent cooling water from freezing Cooling water when frozen expands to break the heat exchanger and the cylinder block and it is essential that antifreeze be added to cooling water in a quantity proportional to the lowest temperature of the district It is recommended that the antifreeze mixture be used throughout the year Antifreeze of poor will cause corrosion antifreeze prepared by quality or without rust inhibitor of the cooling system Always use a reliable maker Make sure that the cooling system of the engine is cleaned well before adding antifreeze Recommended antifreeze for year round use is ZEREX or PRESTONE with rust inhibitor Thoroughly mix the antifreeze and water before adding to the cooling system ANTIFREEZE ADDITION DATA Antifreeze Concentration 13 23 30 35 45 50 60 Freezing temperature 267C 225 F5 23 10 1415 520 430 2240 40 50 58 Note It is advisable that selected on the basis of 5267C lO267Flower than perature expected 3 Fresh water cooling system antifreeze concentration be a temperature which is about the actual atmospheric temThe system consists of a sea water pump which pumps raw sea water through a heat exchanger to remove heat from the coolant The raw water is discharged overboard through the exhaust line The engine coolant fresh water with or without antifreezeis circulated by the fresh water pump in continuous circuit pumped through the cylinder block cylinder head heat exchanger and back to the fresh water pump 18 On the forward control housing of the injection pump is a buffer screw This buffer screw has all the visual of a bleed screw but it is not The adjustment of this screw should not be tampered with or disturbed Disturbing the adjustment of this buffer screw can shut off the delivery of fuel from the injection pump to the injectors and pre255vent the engine from starting DO NOT TAMPER WITH THIS BUFFER SCREW ADJUSTMENT INJECTOR PUMP BUFFER SCREW 17 3 Notes on fuel system See on prior page a typical exploded view of a fuel system for this engine It is also illustrative of the selfbleeding and priming system used by Westerbeke The Westerbeke selfbleeding fuel system is semiautomatic in operation While it is unlikely that the operator will be forced to service the system at sea the possibility does exist Therefore it is recommended that banjo washers injector seat washers lift pump filter and gasket fuel filter and gasket be carried on board at all timnes Select the parts for your engine on page 43 and purchase spares from your local Westerbeke Dealer or Distributor For example hardware kit 34441 will supply fuel system washers for the Model 46 If a leak should develop at a banjo or washer that cannot be remedied by a simple tightening of the screw renew the washers The engine can be started by taking steps described on pages 9 and 10 In cases where the engine cannot be started easily loosen two injection nuts on the nozzle side turn the speed control lever to full open position turn the starter motor and then tighten the nuts firmly 4 Replacing filter elements After the first 50 hours of operation unscrew and discard fuel filter element Install a new filter This same treatment is required of the filter element in the fuel lift pump Similarly replace with a new filter element using a new gasket After the first 50 hours change the change period may be increased at 200 hours or once per season 5 Fuel injection pump The fuel injection pump is one of the most important components of the diesel engine and thus it calls for the utmost caution in handling Furthermore the fuel injection pump has been thoroughly shopadjusted and should never be readjusted carelessly Such adjustments whenever necessary should be performed at an authorized service station as a precision pump tester skill are required To obtain long and satisfactory use of your injection pump Always use fuel which is free from impurities Clean and renew the fuel filters periodically Inspect water entrapment filter regularly 16 If a water trap type filter is not interposed between the fuel tank and engine lift pump any entrained water will tend to lay in the bottom of the electric lift pump Internal metal parts of the lift pump will rust Particles will pass on to filters and eventually to injection pump and injectors with damaging and expensive results IT IS WELL TO REMEMBER THAT WATER DAMAGE TO THE FUEL SYSTEM IS NOT COVERED BY WARRANTYl While many boat builders do supply a water trap filter there are some who do not It is to prevent such omission that Westerbeke offers a trap filter as a desirable optional extra at moderate cost It is supplied with fittings for either hose piping or metal tube piping Priming and self bleeding All engines covered by this manual have a fuel filter with hand priming pump in the head casting for emergency use The main priming source is the electric lift pump mounted on the cylinder head front The Westerbeke selfbleeding fuel system on Model W46 is If you run out of fuel perform a filter change or any disassembly of the fuel system the system will then contain air which may prevent the engine from starting In such event turn the keyswitch on allow electric pump to run for two minutes and crank engine for approximately seven seconds If the engine has not started wait for approximately thirty seconds more of electric pump action and crank engine again These time periods may vary from engine to engine Note The self bleeding feature on the W46 relates to the enginess fuel system only INJECTORS ELECTRIC LIFT PUMP FUEL FILTER THROTTLE CONNECTION INCOMING FUel INJECTOR PUMP BUFFER SCREW 15 AdobeUCSf i TRAP Bolt no to an aCPcslole tl1eurf positioned tht B to 0 Lcll cnage r 2 If up I is to be piel with cq01 hundy utdng use anj tcrules jlrovllel Be SLlre th lUbing Io14 inch the rle tiqhteninq tno nut It ud to with hp two Ir05 narleo dmhprs suppiied certHn lhat the hose oeiectell hao diagonal braid In to on the barthat j js neoprene lined and that it USCG 4 It s 1 ihc fuel it will collect dowly in bottom of the Seiente hen tlw red float r1ng line on the plastic bowl loown the bottom drain plug 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 wellknown makers is recommended The oil selected should be used thereafter 2 Engine oil viscosity Use oil having viscosity best suited to the atmospheric tem255perature Use of an allseason oil SAE10W30 with minimum visco255sity change under different temperatures is suggested Atmospheric temperature Viscosity 20C 6SFor higher SAE 30 or 10W30 SC 41F20C 6SFSAE 20 or 10W30 SC 41For lower SAE 10W30 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 Power30 and 60 PSI 210 421 kgcm2At idle speed 225225225225 e 20 30 PSI 17S 210 kgcm2At the time of cranking Pressure will rise 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 Oring and then tighten it by hand firmly When removing the used filter cover over wi th a plastic bag This will allow both filter element and spilled oil to be collected cleanly without spilling oil in the bilge 13 OIL DRAIN SYSTEM 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 black smoke Check for abnormal noise such as knocking friction or leaking sounds and vibration and blowback 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 21 reverse and reduction gear 12 PROCEDURES 1 Model W46 T handle engine early models were supplied with a manual shutoff A or knob is pulled to shut off fuel stopping the Later Models June 1985 C506on were supplied with an electric shutoff operated by the key switch and having the manual shutoff as an installers option 2 With the engine stopped it is necessary to turn off the key255switch 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 1Check the engine and transmission oil levels and refill if necessary 2Insure that you have sufficient fuel Keep tank as full as possible 3Check 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 4Start the engine in accordance with the procedures given on the preceding pages 5Allow the engine to warm up to 140150 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 13VOLTAGE ACROSS BATTERY TERMINALS DROPS battery is fully charged Check that the THE TEMPERATURE OF TEMPERATURE DOES NOT operate sufficiently INTAKE AIR RISE ENOUGH IS LOW AND COMPRESSION Allow the glow plug to See table on page 8 to aid starting 11 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 pre255heating 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 connection7 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 140267 range Then operate under moderate power until normal operating temperature is reached 10 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 selfpriming feature of the W46 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 W46 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 DESCRIPTION OF STARTING SYSTEM Model W46 uses an electr ic starter assisted by glow plugs for both normal and cold weather starting The figure is a cross section through one cylinder The glow plug enters the com255bustion chamber so that the end is in the spray path of the injector nozzle When the glow plugs are energized by the pre255heat 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 Glow Plug Injector 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 SC 41For higher Approx 10 sec SC 4lFto SC 23FApprox 20 sec SoC 23For lower Approx 30 sec Limit of continuous use 1 minute For complete starting and stopping procedures see pages 10 and 11 8 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 breakin hours of operation Your new engine needs approximately fifty hours of initial operation for breaking in each moving part thus helping maximizing performance and service life of engine Perform this 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 RPMuntil normal engine operating temperature of 170 190F 77 BSCis reached 4 Avoid rapid acceleration especially with a cold engine 5 Use caution not to overload engine Grey sign of overload Select the correct engine and transmission reduction or black smoke is a propeller for the 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 ini255tial 50 hours of break in Dont baby it yet do not abuse it 7 PREPARATIONS Take steps as shown below in starting your engine for the first time or after a prolonged shutdown 1 aF ill your eng ine wi th oil up to or near the upper limi t on the dipstick Use a good grade of oil with API of CC or better For quantity of oil you may refer to the General Specifications page bFill with the NOTE Some separately the transmission proper lubricant VDrives are filled 2 Your engine is supplied with a coolant recovery system to which the following apply aFill engine completely to the neck of the manifold cap bThen fill the recovery tank to the bottom add line Need for adding coolant is indicated when a cold engine has coolant level below the bottom add line cIn 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 main255tained clean Be careful not to allow introduction of dir t when filling fuel 4 Engine oil coolant transmission levels should checked at least once a prior to engine use and be day 6 oil filler port oil and ftller port lowerlmt 7 oil COOLANT RECOVERY TANK PREPARATION AND SUPPLY CAUTIONS Check important aspects of installation before operating engine 1Alignment Error to be no more than one thousandth of an inch per inch of coupling sufficient ventilation 3Provide adequate service room around engine See warranty clauses003 GAGE STRAIGHT EDGE CHECKING COUPLING ALIGNMENT Fill fuel tank with CLEAN 2 diesel from a reputable manufacturer Fill engine sump with lubricating oil Select readily available lubricating Sump capacity 7 quartsto full mar k on dipstick oil of grade CC or CDFill 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 Plugin Panel Harness Connection After assembly joint should be taped to prevent corrosion or preferably assembled using a sili255con 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 com255bustible 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 pres255sure cap is removed while the engine is hot Follow instructions on page 6 Always use tools that fit correctly and use caution during ser255vicing Be sure that current carrying wires are protected from abrasion and that all connections are tight 5 AdobeUCS3 1 3 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 W46 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 your warranty please contact the factory in writing We look forward to your continued patronage from JH Weslerbeke Corp Avon Industrial Park Avon MA 02322 J H WESTERBEKE 225 AVON AVON AU oun CUSTOMER IDENTIFICATION W46 1234C408 Pleasure Craft Mail To expi res 91585 Adam Smith 85 Maple Street Alden IN 12234 1 MANUAL WESTERBEKE 46 Marine Diesel Engine Publication 34468 Edition Two May 1986 AVON INDUSTRIAL PARK AVON MA 02322 225 TEL 6175887700 TELEX 924444 FAX 6175599323267 CABLE WESTCORP

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