Westerbeke FOUR-60 Technical Manual And Parts List
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Westerbeke FOUR-60 Technical Manual And Parts List

Westerbeke FOUR-60 Technical Manual And Parts List

15 hp mini-diesel engine
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TECHNICAL MANUAL AND PARTS LIST
WESTERBEKE
15 hp Mini-Diesel Engine
MODEL FOUR-60
Publication Number 16521
Issue Date June 1, 1972
~r-.v-
'WESTERBEKE
WESTERBEKECORPORATION
j
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319

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  • Page 1 TECHNICAL MANUAL AND PARTS LIST WESTERBEKE 15 hp Mini-Diesel Engine MODEL FOUR-60 Publication Number 16521 Issue Date June 1, 1972 ~r-.v- 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 2 TECHNICAL MANUAL AND PARTS LIST WESTERBEKE 15 hp Mini-Diesel Engine MODEL FOUR-60 Publication Number 16521 Issue Date June 1, 1972 ~r-.v- 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...

  • Page 3: Westerbeke Model Four

    Westerbeke Model Four-60 Marine Diesel Engine, and is designed to be a guide for those concerned with the operation and maintenance of these diesels. The diesel engine closely resembles the gasoline engine inasmuch as the mecha- nism is essentially the same.

  • Page 4: Table Of Contents

    WESTERBEKE MODEL FOUR-60 15 h. p. Mini Diesel Engine TABLE OF CONTENTS Page No. INTRODUCTION PHOTOGRAPHS INSTALLATION DRAWINGS . . • . . . • . . . • . . • . • ..• • . • .
  • Page 5 lIJSRICATICN Cll PRESSURE SWITCH .J:L-~------ FIllER TAQ-!OMETER DRiVE SECONDARY FUEL FILTER BLEED SCRE'w' COLO START SOLENOID FUEL INJECTOR UNION NUT COLO STMT SLOW PLUS FRESH WATER PlJYP ===---- ADJUSTABLE ~tCtItm FLEX (Remove after installation) LIFTING SRACKET HEAT EXCHANGER SURGE TAtiK BLEED SCRE'"...
  • Page 6 STARBOARD AND PORT VIEWS-FOUR 60/SSL Photos above show the SSL Transmission which was designed for the Four-60 Diesel. The gear is available in two Ratios, 1.3:1 and 2:1. Its small size and moderate offset greatly increases installability of Four-60 by de-...

  • Page 8: Installation Drawings

    INSTALLATION DRAWINGS k- - Four-60/SAO Reverse and Reduction Gear 1-------.>1,1-----'1 ",,*.&o-_~-_ -_~~- -.~- I I- -,4,\oJi _____ '_; __ -_ -_-_ _"..LB2IJL._ §=--i~ -----34l- -- ------ 1 - - - - - - - - - 7~=----:. 1-. ___ . .

  • Page 9: General Data

    GENERAL DATA DIESEL ENGINE Number of cylinders Compression ratio 23·6 : 1. Bore 2·477 to 2·4785 in. (62'915 to 62'94i mm.). Stroke 3-0 in. (76'2 mm.). Capacity 57·9 cu. in. (948 c.c.). Idling speed 600 r.p.m. Maximum governed light running speed 2,750 r.p.m.
  • Page 10 GENERAL DATA-continued Exhaust Inlet Valve mechanism B.B.D.C. Valve opens] with mm.) valve rocker clear- 5° B.T.D.C. 45° ·020 ('508 Valve closes ance A.B.D.C. A.T.D.C. 30° 5° Valve seat angle 45° 45° Valve seat face width .. mm.) mm.) ·075 (1'906 ·075 (1'906 Valve stem to guide clearance...
  • Page 11 Alternator (optional) Capacity..• . . 55 amperes Voltage . . . 12 V. D. C. TRANSMISSIONS Four-60 Gear Options ..· ..Direct Drive SAOD .

  • Page 12: Installation

    INSTALLATION Page No. FOREWORD INSPECTION OF SHIPMENT FOUNDATION FOR ENGINE ENGINE BOLTS PROPELLOR COUPLING ALIGNMENT EXHAUST LINE INSTALLATION ENGINE COOLING SYSTEM FUEL PIPING FUEL SUPPLY CONTROLS ELECTRICAL SYSTEM PREWIRING AND OPTIONS STARTING AID...

  • Page 13: Foreword

    INSTALLATION FOREWORD is not the purpose of this section to advise boatyards and engine installers on the generally well understood and well developed procedures for installation of engines. However, the following outline of general procedure is included because it is valuable in explaining the functions of each component, the reasons why, the precautions to be watched and the relationship of the installation to the operation of the engine.

  • Page 14: Engine Bolts

    PROPELLER COUPLING Each Westerbeke Diesel engine is fitted with a suitable coupling for connecting the propeller shaft to the engine. The coupling is very carefully machined for accu- rate fit.

  • Page 15: Engine Cooling System

    In the Westerbeke Diesel fuel system, an excess of fuel oil is supplied to the injec- tion pump by a fuel lift pump and the oversupply which is not required for injection to the engine is returned to the fuel tank.

  • Page 16: Controls

    Throttle Control Fuel Stop Control Idle Stop ..Fig. 2 Fuel Injection Pump Throttle and STOP/RUN Lever Control Positions NOTE: The fue.l injection pump Fuel Stop Control lever should be spring loaded to the run position. CONTROLS manual SAO transmission is used, clutch control may be either Morse type MJ or conventional rod and lever assembly.

  • Page 17: Electrical System

    Factory Installed Engine Alarm System (Optional) This alarm system, to indicate the existence of high water temperature or low oil pressure, is designed and installed on your Westerbeke diesel at the factory. consists of an audible alarm to indicate either failure, the alarm being part of the key switch panel.
  • Page 18 "6 "6 PRESS. START ... OTOR! & SOLENO'D ENGINE OPTIONAL Wiring Diagram with Generator and Skipper Panel KEY SWITCH PANEL ---;;----------1 @)WESTERBEKE ALL ELECTRIC PANEL. (WITH ALTERNATOR ONLY) ® r-____ .,~O ~~~-o-_O~R~U~N_; LA"PS • ® START PREHEAT ® "6 L _ _ _ - - - - - ____ J...

  • Page 19: Starting Aid Ul

    STARTING AID (Fig. 5) The starting aid on Westerbeke Four-60 consists of a combustion chamber glow plug pre heater which operates by heating the air coming into the combustion chamber. Due to the drop in battery voltage from 12 volts to 9 volts· during an engine cranking.

  • Page 20: Operation

    OPERATION Page No. PREPARATION FOR STARTING ENGINE AFTER INSTALLATION BLEEDING THE FUEL SYSTEM TO START ENGINE WHEN ENGINE STARTS TO STOP ENGINE OPERATING PRECAUTIONS COLD WEATHER PRECAUTIONS POST DELIVERY CHECKOUT MAINTENANCE SCHEDULE END OF SEASON SERVICE...
  • Page 21 LUBRICATING OILS Lubricating oils are available for Westerbeke Diesel engines which offer an improved standard of performance to meet the requirements of modern operating conditions such as sustained high speeds and temperatures. These oils meet the requirements of the U. S. Ordnance Specification MIL-L-2104B (API Service CC).

  • Page 22: Preparation For Starting Engine After Installation

    OPERATION PREPARATION FOR STARTING ENGINE AFTER INSTALLATION The engine is shipped "dry", that is, with lubricating oil drained from the crank- case and transmission. The following procedure should be checked methodically before starting the engine for the first time. Remove oil filler cap and fill oil sump with approximately 4.5 U. S. quarts of diesel lubricating oil to the highest mark on the dipstick., Refer to page 18 for an approved lubricating oil.

  • Page 23: To Start Engine

    Slacken the air bleed screw on the fuel injection pump, situated directly above the pump nameplate. Operate the lift pump priming lever, and when fuel flows from the bleed screw free of air bubbles, tighten the bleed screw. Slacken the union nuts at injector end of each of the high pressure pipes (pipes going from the injection pump to each of the four injectors).

  • Page 24: To Stop Engine

    Recheck Expansion Tank Water Level. (This applies after'cooling system has been drained or filled for the !"irst time.) Stop engine after engine has reached operating temperature of 175 F and add water to within one inch of top of tank. WARNING: The system is pressurized when overheated and the pressure must be released gradually if the filler cap is to be removed.

  • Page 25: Cold Weather Precautions

    Do not be alarmed if temperature gauges show a high reading following a sudden stop ~fter engine has been operating at full load. This is caused by the release of residual heat from the heavy metal masses near the combustion chamber. Prevention for this is to run engine at idle for a short period before stopping it.

  • Page 26: Maintenance Schedule

    MAINTENANCE SCHEDULE DAILY Check sea water strainer, if one has been installed. Check water level in cooling system. Check lubricating oil level in sump, fill to highest mark on dipstick. Turn down grease cup on water pump one firm turn. Check lubricating oil level in transmission, fill to high mark on dipstick.
  • Page 27 Drain fresh water cooling system by removing the surge tank pressure cap and opening the petcock (turn counter-clockwise) near the flywheel housing on the fuel hand pump side of cylinder block. Remove the hex screw plug on port under side of heat exchange and deter- mine if zinc rod in plug needs replacing.
  • Page 28 SECTION A DIESEL ENGINE Section Camshaft Camshaft bearing liners A.16 Connecting rods A.12 Crankshaft A.ll Cylinder head Cylinder liners A.17 Engine back plate A.IO Engine front plate Flywheel A.10 Lubrication system Oil filter--external .. Oil pressure relief valve Oil pump Oil pump drive Oil strainer A.ll...
  • Page 29 • ~"""""""I .-++++++ ..1111.1 ••• 11 ••••••• 111111.1 •• 11 •• 1 ............ 1.,11.1 • • • • • • • • 11 ••• 1 ....THE DIESEL ENGINE EXTERNAL COMPONENTS ff. ' GP"-- 4 ", '"...
  • Page 30 KEY TO THE ENGINE EXTERNAL COMPONENTS Description Description Description 37. Oil seal for crankshaft-rear. Main bearing cap-front. 1. Clamp for injector. 38. Housing for oil seal. 74. Oil seal for front main bearing cap. 2. Stud for clamp. 39. Setscrew for housing. 75.
  • Page 31 > THE ENGINE INTERNAL COMPONENTS 1 2 3 ' " \\1 \ " lti' ; ' M o ~=i ~p ~ \ : ~ : + ~ r : ; " . t . , . ~ . " , , \ : - 22~1 V"...
  • Page 32 KEY TO THE ENGINE INTERNAL COMPONENTS Description Description Description 1. Split pin for rocker shaft. 41. Bolt for housing. 81. Camshaft bearing liner-rear. 2. Plain washer for rocker shaft. 42. Spring washer for bolt. 82. Locating plate for camshaft. 3. Spring washer for rocker shaft. 43.
  • Page 33 ~'~'+'~I'~'.'+I'~'+I'~'~'+'~'I~'+'+IIH'+'+IIH'~'+'~"H'+'~"~+H~'+HII~'~I'H'_~~~~H'+'+fIH'.'+'HII~'~IIH'+'+"H'++II~~~+H~'I~"+HIIH'~II~'+IIH'~'+'HI'~~++H'+H~+'I~'~H'++'~'~'+'~IIH'+I~~~ THE ENGINE (Longitudinal Section)
  • Page 34 11111 ..1111111 . . 111 . . " ..11111111111 11111111' . . 1111111 111111111.11.111"1111,,11 ... " 1 . . . '"1111111 1111111 THE ENGINE (l'ransverse Section)
  • Page 35 .., .., ..'_.,_,ll ..,I ..1111111 111111 11111 II~II~' II""I_~ ,..,..e,:, 1111111111111...

  • Page 36: Lubrication System

    DIESEL ENGINE EXTERNAL OIL FILTER The external filter is of the full-flow type, thus ensuring that all oil in the lubrication circuit passes through the filter before reaching the bearings. pump at a Oil is passed through the filter from the pressure controlled at SO lb./sq.
  • Page 37 DIESEL ENGINE Inspection (4) Check the relief valve spring against the specifi- cation given in 'GENERAL DATA'. (5) Check the valve seating by applying engineeris blue to the conical valve face and testing for continuous marking. If necessary, lap the valve onto the seat, using tool 18G 69.
  • Page 38 DIESEL ENGINE Section A.7 VALVE ROCKER SHAFT AND TAPPETS RemcnriDg Valve rocker shaft (I) Disconnect the breather pipe from the rocker cover. (2) Unscrew the two rocker cover retaining nuts and remove the two engine sling brackets. (3) Remove the rocker cover, cup washers, and rubber bushes.
  • Page 39 DIESEL ENGINE Dismantling (20) Unscrew the heater plugs from the cylinder head. (21) Remove the two nuts and washers securing the exhaust manifold, and the six nuts and washers securing both air and exhaust manifolds, and lift both manifolds away. (22) Remove the spill pipe and clamps from the in- jectors, and withdraw the injectors from the cylinder head, using tool 18G 284 and adaptor...
  • Page 40 DIESEL ENGINE Check the valve stem to guide clearance against the (31) figures given in 'GENERAL DATA'. If new valve guides are fitted, the top face of each guide should in. (IS mm.) above the valve spring seat surface of the cylinder head. Check the valve head stand-down against the (32) figure in 'GENERAL DATA'.
  • Page 41 DIESEL ENGINE the chain tensioner packing block and the injection pump chain wheel hub. C.6~ (30) Remove the injection pump (Section (1) to (3) ). (31) Remove the chain wheel hub from the front plate. Inspection (32) Examine the crankshaft front oil seal, and renew it if there is the slightest sign of wear or damage.
  • Page 42 DIESEL ENGINE Camshaft (38) Reverse the procedure in (20) to (23), noting the following points: Fit the camshaft retaining plate with its white- metal face towards the camshaft. Bleed the fuel system as described in Section C.8, after the lift pump has been connected into the system.
  • Page 43 DIESEL ENGINE Inspection Crankshaft and main bearings (5) Examine the crankshaft oil seal, and renew it if Carry out the procedure in (I) to (8). A.~, there is the slightest sign of damage. (10) Remove the engine front plate (Section (2) to (5), to (19), and (25) to (28».
  • Page 44 DIESEL ENGINE (9) Remove the rocker shaft and push-rods (Section A.7, (1) to (5) ). (10) Remove the cylinder head (Section A.8, (6) to (9), (11) and (12), (14) and (15), and (17) to (19) ). (11) Unscrew the connecting rod cap boIts, remove the caps with their bearing halves, and withdraw the connecting rods and pistons from the top of the cylinder bores.
  • Page 45 DIESEL ENGINE (26) Refit the front axle and radiator by reversing the procedure in Section G.I, (2) to (7) and Section B.3, (10). (27) Bleed the fuel system (Section C.S). (28) Refill the hydraulic system (Section M.6). (29) Refill the cooling system (Section B.l, (9) to (11) Section B.6, to (9) ).
  • Page 46 DIESEL ENGINE Section A.14 VALVE TIMING CHECK Set the valve rocker clearance of No.1 cylinder inlet valve to ·020 in. ('51 mm.). Crank the engine until the exact point at which No. 1 inlet valve is about to open. A clock gauge, with its will facilitate plunger contacting the valve spring collar, this operation.
  • Page 47 DIESEL ENGINE Fig. A.20 Removing a camshaft liner using tool 18G A and adaptor I8G 124 K. The inset shows the liner being replaced Slotted washer. 2. Slotted washer. 3. 'D' washer. 4. Adaptor 18G 124 K. Fitting new bearing liners Centre bearing liner The bearing liners should be so positioned that their oil (15) Insert pilot adaptor ISG 214 K into the front...
  • Page 48 DIESEL ENGINE Feed the reamer very slowly. Keep the cutters dry and cotter flutes free of swarf, preferably with air-blast equipment. When half-way through each bearing, withdraw the "'----H :!r-- cutter and remove all swarf from both cutter and bearing G-I;...

  • Page 50: Coolingsystem

    COOLING SYSTEM FUNCTIONAL DESCRIPTION The indirect system of heat exchange cooling is used and consists of a closed fresh water circuit and an open sea water circuit. The coolant circulation in the closed circuit is from the combination exhaust mani- fold and surge tank, through the heat exchanger and engine water jacket, and then returned to the surge tank.
  • Page 51 THERMOSTAT Removing: Drain the cooling system so that the coolant level is below the mounting surfaces of the thermostat housing. Loosen clamp securing water hose to thermostat housing. Remove the three retaining nuts securing the thermostat housing to the cylinder head. Lift housing from cylinder head;...
  • Page 52 REMOVING FRESH WATER PUMP (Fig. B5) Drain the cooling system. Slacken the dynamo mounting and adjusting link bolts and disengage the drive belt from the water pump pulley. Unscrew the four bolts and remove the water pump pulley. Slacken the by-pass hose clips Unscrew the four water pump body bolts and withdraw the water pump from the water pump adaptor.
  • Page 53 INSPECTION Check the interference fit of both the pulley hub and the vane en the pump spindle (see GENERAL DATA). the fit has been destroyed, renew the components. 10. Ensure that the bearing grease retainers are in good condition. REASSEMBLING 11.
  • Page 54 SECTION C FUEL SYSTEM (DIESEL MODELS) Altitude settings C.IO Filter-main .. Injection pump Injectors Lift pump Maximum and idling speed adjustment •. .•...
  • Page 55 THE INJECTION PUMP COMPONENTS .7tl \}-17 c:r-- 11---'il ~~15 10~g B-fl~16 ~ ~ 13 --------{) 9-~ ~ 6---:! ~~ 20~22 1199 : . I T'.' . . . 9rii\ 104 103 102 B.6855 " " " . , " . 1 ••• , 11'11"'" ••••...
  • Page 56 >++-.._ ... 111111111.111111111111.1111 •• 11.1111111111 111111111III1I I I I ' I I ' I 11111I1 I" I I I I . ' I 1 1111111'1111' I I 1 111'1'11 1111111+++++++ ....++11111 •••• • 1.1111++++++· _ _ .._ .
  • Page 57 OWNERS NOTES...
  • Page 58 FUEL SYSTEM (Diesel Models) Section C.3 FUEL TAP Removing Turn the fuel tap off. Fig. C.4 (2) Disconnect the fuel supply pipe and injector spill return pipe from their connections on the fuel tap. Section through the fuel lift pump (3) Drain the fuel tank.
  • Page 59 FUEL SYSTEM (Diesel Models) Section C.5 MAIN FUEL FILTER Removing , (1) Disconnect the fuel pipes from the filter head. Remove the two bolts from the filter head mount- ing flange and withdraw the filter from the engine. Dismantling (3) Unscrew the centre-bolt in the filter head and detach the base from the filter.
  • Page 60 FUEL SYSTEM (Diesel Models) (see Fig. C.7). Remove the drive plate and top (8) Press the throttle shaft downwards and withdraw the control cover complete with shut-off shaft. adjusting plate, and withdraw the rollers and shoes Discard the control cover gasket. from the pumping and distributing rotor.
  • Page 61 FUEL SYSTEM (Diesel Models) (35) Check that the transfer pump vanes are a sliding fit in their slots when lubricated with fuel oil. (36) Inspect the bore of the regulating valve sleeve for wear and ensure that the valve piston can move freely through it.
  • Page 62 FUEL SYSTEM (Diesel Models) Fig. C.1O Assemble the top adjusting plate and the drive plate with the slots in their peripheries aligned with the Fig. C.ll scribed mark on the pumping end of the rotor Tightening the transfer pump rotor, using torque wrench 18G 536 and tools 659 and 18G 634 housing.
  • Page 63 FUEL SYSTEM (Diesel Models) Fit the two hydraulic head locking screws finger- tight, positioning the screw with the vent valve above the pump nameplate. (51) Hold the drive hub with tool 180 659 and, using spanner 180634, tighten the transfer pump rotor to the torque figure given in 'GENERAL DATA' (see Fig.
  • Page 64 FUEL SYSTEM (Diesel Models) Testing and adjusting (75) The following precautions must oe ooserved when testing the pump: Ensure that the power-driven test bench is set to run in the direction of pump rotation as indicated on the pump nameplate. Ensure that the fuel flow at the-pump inlet is not less than 1,000 c.c./min.
  • Page 65 FUEL SYSTEM (Diesel Models) Test 5-Advance position Increase the pump speed to 1,400 r.p.m. The advance gauge reading should now be 41°. Test fr-Back-leakage Run the pump at 1,000 r.p.m. and measure the \:;..:...--.~- back-leakage in the measuring glass: it should be 5 to 50 c.c.
  • Page 66 FUEL SYSTEM (Diesel Models) adjustment replace the cover-plate and prime the pump as described in (82). Re-check the fuel delivery and, if necessary, re-adjust the pump output. Test 8-Maximumfuel delivery check Decrease the pump speed to 150 r.p.m. The average delivery for 200 shots should now be not less than that obtained in 'Test 7' minus 1·6 c.c.
  • Page 67 FUEL SYSTEM (Diesel Models) Fig. C.20 Clearing the pintl. orifice Fig. C.2I "'1,,11,\\,\\.\\\' Cleaning the ·-7 annular chamber "'6502 Fig. C.19 Checking the position of the injection pump timing Clean all carbon from the nozzle valve and the pointer, using timing gauge 18G 1052 outside of the body with the brass-wire brush.

  • Page 68: Fuel System

    SYSTEM FUEL (Diesel Models) Fig. C.23 12----~~~~ Cleaning the nozzle seat " ~~---2 Fig. C.24 Clearing the auxi- liary spray hole ~----6 (14) In cases where the carbon deposit is particularly hard, it can be softened by boiling the nozzle bodies caustic solution: (a) Dissolve 2 oz.
  • Page 69 FUEL SYSTEM (Diesel Models) Fig. C.28 Correct nozzle and valve seat angles Fig. C.27 to seat in a lower position than the auxiliary spray Reverse-flushing an injector nozzle with testing hole and the nozzle will useless. machine 18G 109 A and adaptor 18G 109 E. A sec- tioned adaptor with a nozzle in position is shown inset (26) Reverse-flush the nozzle as described in (13), dry it with compressed air, and make a final inspection...
  • Page 70 FUEL SYSTEM (Diesel Models) (29) After ref acing, inspect the valve under the nozzle microscope. (30) If, due to slight distortion or deposits on its guide surface, the valve is found to be a tight fit in the nozzle body, it can be corrected by tapping the guide surface of the valve.
  • Page 71 FUEL SYSTEM (Diesel Models) Ensure that the stop control is fully home in the Refitting (44) Reverse the procedure in (1) to (3), noting the run position and remove the sealing cap from the following: maximum speed stop screw. Renew both sealing washers on each injector. (2) Run the engine until it has attained its normal One washer passes over the nozzle and seals running temperature.
  • Page 72 SAO TRANSMISSION Page DESCRIPTION OPERATION TROUBLE SHOOTING DISASSEMBLY OF SAO TRANSMISSION REMOVAL OF REDUCTION GEAR ASSEMBLY FROM REVERSE GEAR HOUSING IF INSTALLED REMOVAL OF REVERSE GEAR HOUSING ASSEMBLY FROM ENGINE REMOVAL OF GEAR CASE ASSEMBLY FROM REVERSE GEAR HOUSING DISASSEMBLY OF GEAR CASE INSPECTION ASSEMBL Y OF GEAR CASE ASSEMBLY OF REVERSE GEAR CASE IN REVERSE GEAR...

  • Page 73: Sao Transmission

    SAO TRANSMISSION DESCRIPTION The Westerbeke Paragon manually operated reverse gear units consist of a multiple disc clutch and a planetary reverse gear train. The units are self (:on- tained and are independent of the engine lubrication system. OPERATION the forward drive, the reverse gear case and multiple disc clutch are locked together as a solid coupling.

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