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O'PERATORS MANUAL
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MARINE DI"ESEL ENGINES
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!5~58-fOU~ . . •
55C-fQuiji
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,'and 550· OUR -'-
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. PUBLICATION NO.42286
REVISION 4
JULY 2011
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WESTERBEKE
-member .
WESTERBEKECORPORATION.150JOHNHANCOCKROAD
J3tJiJ'
MYLES STANDISH INDUSTRIAL PARK· TAUNTON
MA
02780
WEBSITE: www.WESTERBEKECOM
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Table of Contents
Troubleshooting
Related Manuals for Westerbeke 55B-FOUR
Summary of Contents for Westerbeke 55B-FOUR
- Page 1 "". ' O'PERATORS MANUAL MARINE DI"ESEL ENGINES !5~58-fOU~ . . • 55C-fQuiji I . . ,'and 550· OUR -'- . PUBLICATION NO.42286 REVISION 4 JULY 2011 WESTERBEKE -member . WESTERBEKECORPORATION.150JOHNHANCOCKROAD J3tJiJ' MYLES STANDISH INDUSTRIAL PARK· TAUNTON 02780 WEBSITE: www.WESTERBEKECOM ·'''''i.
- Page 2 GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart until It has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed a bulkhead near your engine generator.
- Page 3 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to fol1ow fundamental rules and precau- WARNING: Fire can cause injury death! tions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, •...
- Page 4 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING WARNING: Accidental starting can cause injury WARNING: Carlion monoxide (CO) is a deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine! discharged from the engine.
- Page 5 Sections of tlte ABYC standards of particular interest are: H-2 Ventilation H-24 Gasoliue Fuel Systems P-l Exhaust Systems P-4 Inboard Engines E-9 DC Electrical Systems All installations must comply witlt tlte Federal Code of Regulations (FCR). " . WESTERBEKE Engines Generators &...
- Page 6 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
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Page 7: Table Of Contents
TABLE OF CONTENTS Parts Identification ..........Remote Oil Filter (Optional) ......Water Heater ............. Introduction ............. 3 Warranty Procedures ......... 3 Tachometer ............Serial Number Location ........4 DC Electrical System .......... Siphon Break ............ 4 Alternator Troubleshooting ......24 Admiral Control Panel ......... -
Page 8: Parts Identification
PARTS IDENTIFICATION INTAKE/AIR FILTER PRESSURE CAP Oil FIll PUUILAW I THERMOSTAT ASSEMBLY WATER INJECTED EXHAUST ELBOW I.D. PLATE ~_'r--lltAI EXCHANGER WATER REAR ANDDE RAW WATER om,," ___ FRONT LEFT SIDE DC AlTERNA1'OR ( "'"'~~ WATER INJECTED EXHAUST ~Ul.<Nl"U, PREHEAT AIR INTAKE/AIR FIll THERMOSTAT . -
Page 9: Introduction
INTRODUCTION This WESTERBEKE Diesel Engine is a product of PRODUCT SOFTWARE WESTERBEKE's long years of experience and advanced Product software, (technical data, parts lists, manuals, technology. We take great pride in the superior durability and brochures and catalogs), provided from sources other than dependable performance of our engines and generators. -
Page 10: Serial Number Location
Take the time to enter this information on the illustration of the nameplate description and part number for each part needed (see the separately furnished Parts List). Insist upon WESTERBEKE shown below, as this will provide a quick reference when packaged parts because fit or generic parts are frequently seeking techuical information and/or ordering repair parts. -
Page 11: Admiral Control Panel
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD FALL TO 5 - 10 psi (0.4 - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND· AT THE SAME TIME. ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING SIGNAL WESTERBEKE Engines. Generators &... -
Page 12: Captain Control Panel
CAPTAIN CONTROL PANEL The panel also includes an alarm buzzer for low OIL DESCRIPTION PRESSURE or high COOLANT 1EMPERATURE. The This manually-operated control panel is equipped with a RPM gauge is illuminated when the KEY switch is turned KEY switch, an RPM gauge, PREHEAT and START but- and remains illuminated while the engine is in operation. - Page 13 ENGINE COOLANT Use a diesel fuel that meets the requirements of No. 2-D WESTERBEKE recommends a mixture of 50% antifreeze SAE J 3 [3 and has a Cetane rating of #45 or higher grade of and 50% distilled water. Distilled water is free from the diesel fuel according to ASTM D975 chemicals that can corrode internal engine surfaces.
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Page 14: Preparations For Initial Start-Up
Make sure the mounting installation is secure. TO THERMOSTAT Ensure the propeller shaft securely attached to the HOUSING transmission. Open the thru-hull and make certain raw water is primed TOP Oil Fill to the raw water strainer. DIPSTICK WESTERBEKE ..v' Engines' Generators &... -
Page 15: Starting/Stopping Procedure
Never run the starter for more then 30 seconds. the engine fails to start, refer to the TROUBLESHOOTING CHART in this WESTERBEKE "tOY' Engines & Generators... -
Page 16: Warning Lights, Alarms And Circuit Breaker
WARNING LIGHTS, ALARMS & CIRCUIT BREAKER ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH The Captain Control Panel indicates alternator low discharge A low oil pressure alarm switch is located on the engine with a red warning light. block. This switch's sensor monitors the engine's oil pressure. -
Page 17: Engine Break-In Procedure
ENGINE BREAK-IN PROCEDURE 3. While using the vessel, run the engine at various engine DESCRIPTION speeds for the first 25 hours. Avoid prolonged periods of Although your engine has experienced a minimum of one idling. hour of test operations at the factory to make sure accurate 4. -
Page 18: The Daily Operation
THE DAILY OPERATION CHECKLIST FAILURE TO START Follow this check list each day before starting your engine. If the engine fails to start when the start button is pressed for Visually inspect the engine for fuel, oil, or water leaks. 5 seconds, wait for at least 30 seconds and repeat the starting procadure. -
Page 19: Maintenance Schedule
MAINTENANCE SCHEDULE order to use this Maintenance Schedule, it will be neces- WARNING: Never attempt to perform any service sary to log your engine hours. Use your engine hounneter or record your engine hours by running time. while the engine is running_ Wear the proper safety NOTE: Many of the following maintenance procedures are equipment such as goggles and gloves, and use the... - Page 20 Lubricate Panel Key Switch At first 100 hours, then each year at winterizing. with "Lockeze" Transmission Fluid Initial fluid change at 25 hours, then every 300 hours or at winterizing. 'WESTERBEKE recommends this service be performed by an authorized mechanic. Engines Generators &...
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Page 21: Fuel System
A small fuel filter has been added to the incoming fuel hand. line to ensnre that filtered fuel enters the fuel Iiftpnmp. 7. The key-on preheat sequence will allow the lift pump to .fill the fuel filter. S. Run the engines and inspect for leaks. WESTERBEKE ,.yo Engines & Generators... -
Page 22: Cooling System
Ensure that the upper and lower rubber seals spilled coolant. are in good condition and check that the vacuum valve opens and closes tightly. Carry a spare cap. CHECKING THE PRESSURE CAP COOLANT DRAIN WESTERBEKE & Generators Engines 16- . -
Page 23: Thermostat
COOLANT TEMPERATURE SENDER WASHER HI-TACK SEALANT THERMOSTAT PART NO. 47571 FILTER THERMOSTAT INSPECTAND ASSEMBLY CLEAN EVERY 100 HOURS BY·PASS HOLE WATE:;Riiii~; TYPICAL RAW (OWNER INSTALLED) INCOMING RAW WATER SEACOCK -r'li(l" ...v WESTERBEKE Engines· & Generators... -
Page 24: Raw Water Cooling Circuit
COOLING SYSTEM RAW WATER CODLING CIRCUIT RAW WATER PUMP The raw water flow is created by a positive displacement The raw water pump is a self-priming, rotary pump with a This impeller pump. pump draws water directly from the non-ferrous housing and a Neoprene iropeller. The iropeller ocean, lake, or river from a thru-hull opening through a hose has fle«ible blades which wipe against a curved earn plate to the water strainer. -
Page 25: Zinc Anode
IF THE FILTER ELEMENT IS CONTAMINATED WITH DRY DUST OR DIRT, IT CAN BE CLEANED WITH COMPRESSED AIR FROM INSIDE OUT IF THE ELEMNET HAS ACCUMULATED CARBON OR GREASE, IT MUST BE REPLACED. WESTERBEKE . Engines & Generators 19 . -
Page 26: Changing The Oil Filter
ENGINE LUBRICATING OIL ENGINE OIL Use a heavy duty engine oil with an API classification of CF pr CG-4 or better. Change the engine oil after an initial 50 hours of break-in operation, and every 250 hours of operation thereafter. For recommended oil use SAE I;iW-40 SPIN-ON OIL FILTER' (oil viscosity) and stay with the same brand of oil thru-out TURN ON HANO TIGHT... -
Page 27: Remote Oil Filter (Optional)
REMOTE OIL FILTER (OPTIONAL) NOTE: INSTALLATION Westerbeke is not responsible for engine failure due to incorrect installation of the Remote Oil Filter. This popular accessory is used to relocate the engine's oil fil- ter from the engine to a more convenient location such as an engine room bulkhead. -
Page 28: Water Heater
Rel1W1!e and store the plastic. recovery tank it has been already installed. '~""'ml" THIS HOSE AND CONNECT THE 1WO WATER HEATER HOSES TO THESE mT/Ntis HOT WATER CONNECTIONS . WESTERBEKE engines & Generators... -
Page 29: Tachometer
J<..o- c. Using a 5/64 (2mm) allen wrench, adjust the calibration pod on the panel tachometer to read the same as the ":' J ,, strobe tachometers rpm. mSNlTtll YOLT~(lU :J® Iliij[C """ WESTERBEKE EngInes & Generators... -
Page 30: Dc Electrical System
DC ELECTRICAL SYSTEM ALTERNATOR 1. Start the engine. 2. After the engine has run for a few minutes, measure the The charging system consists of a DC belt driven alternator starting battery voltage at the' battery terminals using a with a voltage regulator, an engine DC wiring harness, a multimeter set on DC volts. -
Page 31: Battery Care
The minimum recommended capacity of the battery used in the engine's 12 volt DC control circuit is 600 - 900 Cold. WARNING: Sulfuric acid in lead batteries can Cranking Amps (CCA). cause severe burns on skin and damage clothing. Wear protective gear. WESTERBEKE Engines.& Generators... -
Page 32: Glow Plugs
GLOW PLUGS DESCRIPTION Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7 to 15 The glow plugs are wired through the preheat solenoid. seconds. the plugs don't heat up quickly, check for a short When PREHEAT is pressed at the control panel this solenoid circuit. -
Page 33: Wiring Diagram
WIRING DIAGRAM #39144 0" PRfsSURE SWITCH. :0;£ ~£~ F'il-~-~ i~' , ' · · " \~v~ (» IIillill. ."-=- ADMIRAL PANEL L-_--'<"") ----~---------------------~ I ______ " r':O:O\ " 01" CAPTAIN PANEL >0 " " -~~r t~c?"~ 1',--- " 'f.-./ liB ORN I"... -
Page 34: Wiring Schematic
WIRING SCHEMATIC #39144 SlARHR PRE~EAr r--ISOl. AL lERHAlon ~~~~~--------~:GN---------~ • lrOHT: ~AND~l I. THIS PRODUCl IS PROTECT[D OY A RESn CIRCUIT BREAKER LOCATED NEAR THE ~-~-""-+====-+---""{"P"}-'-' SURTER. EXCESSIVE CURRENT WILL C~US( THE BRUXER TO TRIP AHO THE ENGINE WILL SHUT DOliN. THE BUILDER/OWNER MUst BE SUH[ THAT THE INHRUHENT PANEt, waiNG. -
Page 35: Starter Motor
STARTER MOTOR DESCRIPTION (+) POSITIVE starter 111e starting system includes tlle battery, motor, solenoid, TERMINAL and starter button. When the starter button on the instrument panel is depressed, current flows and energizes tlle starter's solenoid coil. 111e --~IIMI TERMINAL energized coil becomes an electroillllgnet, which pulls tlle plunger into file coil, and closes a set of contacts which allow high cun-ent IGNITION to reach tlle starter motor. - Page 36 (f) POSITIVE TERMINAL replacing the starter motor, meke certain. tile new motor cerlified ror marine use. Automotive starters do not meet USCG standards. If in dO)lb!; contact your WESTERBEKE dealer. R..---(M) TERMINAL TO REMOVE FOR SERVICE IGNITION 1.· Discol1lJect the negative battery cable.
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Page 37: Dual Output Alternators
TO THE Dual Pulleys BUZZER. THE BLUE CONNECTS TO THE A variety of accessory pulleys for high powered and dual SWI~CH. 'OIL PRESSURE charging alternators are available from your WESTERBEKE dealer. DUAL OUTPUT ALTERNATOR [CHARGING TWO BATTERIES] REGULATOR Engines. & Generators... - Page 38 DUAL OUTPUT ALTERNATORS mOUBLESHOOTING Alternator Testing NOTE: Before troubleshooting, make certain that the drive The regulator functioning properly and the batteries belts are tight and the batteries are in good condition. are in good condition. 1. Test the voltage at the alternator plug with the engine Regulator Testing off-key on.
- Page 39 INSTALLATION If an optional dual alternator has already been factory b. Plug the 2-piJf connector into the alternator connection installed, simply follow the WESTERBEKE wiring diagram and make certain it is finnly seated and the engine installation instructions. c. The red "battery sense" wire should be connected to the If the new dual alternator is being added to an existing "in·...
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Page 40: Troubleshooting
When the alternator is producing high amperage, it will become very hot. When replacing the alternator drive belts, always purchase and replace dual belts in matched pairs. NOTE: For additional information on regulators and alternators, contact www.BALMAR.COM. WESTERBEKE Engines & Generators... -
Page 41: Engine Troubleshooting
Tesllng the BatteI)' Charging Circuit. 2. Alternator drive. 2. Check drive belt tension; alternator should turn freely. Check for loose connections. Check output with voltmeter. Ensure 12 volts are present at the Exc. terminal. (continued) WESTERBEKE -.¥ Engines & Generators... - Page 42 2. Remove the wire attached to the sender tenninal at the sender and connect it to ground. See if the gauge reads tenninals), the ground side will not necessarily be connected full scale, which is the normal reading for this situation. to the block. WESTERBEKE 'WIY' Engines & Generators...
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Page 43: Engine Adjustments
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine ad' 'st- ments be peiformed by a competent engine mechanic. The infO! below is provided to assist the mechanic. DRIVE BELT ADJUSTMENT Proper inspection, service and maintenance of drive belts is important for the efficient operation of your engine (see Drive Belts under MAINTENANCE SCHEDULE). -
Page 44: Testing Engine Compression
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. TESTING ENGINE COMPRESSION OIL PRESSURE Make certain the oil level (dipstick) is at the correct level... -
Page 45: Valve Clearance Adjustment
IDC in the compression stroke, and when only the exhaust valve is open, it is at IDC in the exhaust stroke. CYLINDER NO.1 COMPRESSION· 7\ . ~l-J-- G . . . CYLINDER NO.1, .._"'57\ EXHAUST r ---' \ ",,--, WESTERBEKE Engines & Genera/ors... - Page 46 CONNECTION OF GEAR BOX WITH PROPELLER threaded holes located above the shift cover on top of the gear hausing. Refer to the WESTERBEKE parts list. HBW recommend a flexible connection between the trans- mission gearbox and the propener shaft if the engine is...
- Page 47 ZF MARINE TRANSMISSIONS " INITIAL OPERATION OPERATING TEMPERATURE All HBW marine transmissions test-run on a test stand 'rhe ·maximum permissible A'f.F temperature should not exceed This temperature can.only be reached for a short with the engine at the factory prior to delivery. For safety 230' (110').
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Page 48: Transmission Coolers
Inspect the gear shift cable, liokage, and attachments. WESTERBEKE recommends having a spare cooler aboard. Look for corrosion of the end fitrings, cracks or cuts in the. conduit, and bending of the actuator rods. Lubricate all moving parts. -
Page 49: Troubleshooting
- while you immediately contact your WESTERBEKE dealer or an observe the actuating lever on the transmission, If the remote authorized marine transmission facility,... - Page 50 A folding propeller may be jammed. Variable pitch propeller may be in "no pitch" position. NOTE: you suspect a major problem in your transmission, immediately contact your WESTERBEKE dealer or an authorized marine transmission facility. WESTERBEKE Engines & Generators...
- Page 51 This centers the actuating lever on the trans- Before leaving the WESTERBEKE plant, each transmission mission. With the control in tltis position, hydraulic power is undergoes a test run, with Dextron III ATF transmission completely interrupted and the output shaft of the transmis- fluid.
- Page 52 BORG WARNER VELVET DRIVE TRANSMISSION Clean off the transmission and properly dispose of the used fluid. Refill the transmission with DEXTRON III ATF. The quantity will vary depending on the transmission model and the installation angle. Pill through the dipstick hole. ,0 Check the dipstick for the proper fluid level.
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Page 53: Maintenance
This contaminated waters, maintenance, etc. it might only last half that time. fluid will appear as strawberry cream. The transmission WESTERBEKE recommends having a spare cooler aboard. will eventually fail. Either case requires an immediate response: 1. -
Page 54: Lay-Up And Recommissioning
LAY-UP RECOMMISSIONING & GENERAL Fuel System [Gasoline] Many Owners rely on their boatyards to prepare their craft, Top off your fuel tanks with gasoline of 89 octane unleaded including engines and generators, for lay-up during the or higher. A fuel conditioner such as Sta-Bil gasoline stabilizer should be added. - Page 55 Cylinder Lubrication [Diesel] Recommissioning If you anticipate a long lay-up period (12 months or more) The recommissioning of your Westerbeke engine after a WESTERBEKE recommends removing the glow plugs from seasonal lay-up generally follows the same procedures as the cylinder head (injectors if engine does not have glow plugs) those described in the PREPARATIONS FOR STARTING sec- and squirt light lubricating oil into each cylinder.
- Page 56 Degree Celsius (OC) = (OF - 32) x .56 LIQUID WEIGHTS Diesel Oil = 1 US gallon = 7.131bs Fresh Water: 1 US gallon: 8.33 Ibs Gasoline = 1 US gallon = 6.11bs Salt Water = 1 US gallon: 8.56 Ibs WESTERBEKE Engines & _Generators...
- Page 57 175 - 200 Amps Internal regulator, built into alternator Alternator Regulator EXHAUST SYSTEM Exhaust Elbow 45' elbow 3.0" 1.0. hose Exhaust Hose Size Exhaust Gas Flow 265 cfm at 3000 RPM 14" x t4" Muffler Size min.) WESTERBEKE Engines Generators &...
- Page 58 SPECIFICATIONS 550 ENGINE SPECIFICATIONS FUEL SYSTEM Engine Type Self bleeding Diesel, water cooled, four cycle, four cylinder, General in-line overhead valve type Fuel Diesel fuel (cetane rating of 45 or higher). Displacement 133 cubic inches (2.179 liter) BOSCH, PFR type Fuel Injection Pump Combustion Type In-direct injection...
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Page 59: Suggested Spare Parts
SUGGESTED SPARE PARTS WESTERBEKE MARINE DIESEL ENGINES . CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION HARDWARE KIT ·ZINCANODE BELTS RAW WATER PUMP IMPELLER AND O-RING WESTERBEKE ALSO RECOMMENDS HAVING ENOUGH OIL ON-BOARD FOR AT LEAST ONE OIL CHANGE... - Page 60 WESTERBEKE -.¥' Engines & Generators .. ··8/14;2011,/1162 .