Westerbeke 35B THREE Operator's Manual
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Westerbeke 35B THREE Operator's Manual

Westerbeke 35B THREE Operator's Manual

Marine diesel engines
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OPERATOR'S MANUAL
WESTER8EKE
358 THREE, 388 FOUR, 428 FOUR
MARINE DIESEL
ENGINES
Publication # 37435
Edition One
March 1988
~
WESI'ERBEKE
WESTERBEKE CORPORATION
AVON INDUSTRIAL PARK, AVON. MA
02322.
TEL: (617) 588-7700

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  • Page 1 OPERATOR'S MANUAL WESTER8EKE 358 THREE, 388 FOUR, 428 FOUR MARINE DIESEL ENGINES Publication # 37435 Edition One March 1988 WESI'ERBEKE WESTERBEKE CORPORATION AVON INDUSTRIAL PARK, AVON. MA 02322. TEL: (617) 588-7700...
  • Page 2 SAFETY PRECAUTIONS The following symbols appear in this manual to call attention • Use Extreme Care When Handling Engine Filel to and emphasize conditions potentially dangerous to the (A constant danger of explosion or fire exists) operator, Do not fill fuel tank{s) while the engine is running. Do not smoke or use an open flame near the engine or the IIWARNINGII fuel tank.
  • Page 3 It not only makes good sense, but is imperative that appropriate representatives of Westerbeke or the sup- plier in question be consulted to determine the accuracy and currency of the product software being con- sulted by the customer.
  • Page 4 FOREWORD Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have you as a customer. Read this manual carefully and observe ali safety precautions included throughout. Operating procedures, periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust- ment procedures are included herein so you can operate your equipment safely and properly, maintain the equipment at a high level of efficiency, and expect dependable performance and long service life in return.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section ................Page W 358 THREE MARINE DIESEL ENGINE GENERAL SPECIFICATIONS .......... 12 W 35B THREE SYSTEM SPECiFiCATIONS ....13 W 38B FOUR MARINE DIESEL ENGINE GENERAL SPECIFICATIONS .......... 15 W 38B FOUR SYSTEM SPECiFiCATIONS ...... 16 W 42B FOUR MARINE DIESEL ENGINE GENERAL SPECIFICATIONS ..........
  • Page 6 TABLE OF CONTENTS (CONTINUED) LAY-UP & RECOMMISSIONING ........89 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ..........93 TORQUE SPECiFiCATIONS ..........94 SPARE PARTS ..............95 INDEX ................96 Westerbeke Diesel Engines...
  • Page 7 "Westerbeke" plate Which is mounted on the engine's exhaust manHold. When ordering parts for your Westerbeke engine, be sure to insist upon Westerbeke factory packaged parts, because "will fit" or generic parts are frequently not made to the same specHications as original equipment.
  • Page 8 Fresh Water Fill Fresh Water Unit Data Plate Air Bleed 20 Amp DC Circuit Breaker 90· Exhaust Elbow Fresh Water Circulating Heat Exchanger Pump Transmission Shift Lever Sea Water Pump Engine Isolator DC Battery Ground Connection Starter with Solenoid Westerbeke Diesel Engines...
  • Page 9 W 35B THREE Marine Diesel Engine Top Lube Oil Fill 20 Amp DC Circuit Breaker Fresh Water Air Bleed Preheat Solenoid DC Charging Fuel. Lift Pl,!mp Instrument Connections Side Lube Secondary Oil Fill Fuel Filter ---..;::..Shut-off Zinc Anode Lever...
  • Page 10 W 38B FOUR Marine Diesel Engine Top Engine Oil Fill Starter Westerbeke Diesel Engines...
  • Page 11 W 388 FOUR Marine Diesel Engine Top Engine Oil Fill Air Intake SilElnCler Fuel Lift pump Connections Secondary Fuel Filter'---- Zinc Anode - - _" ___ '_ Oil Throttle lever lube Oil Dipstick Oil Pressure Oil Pressure Switch Sender lube Oil Filter Westerbeke Diesel Engines...
  • Page 12 W 4213 FOUR Marine Diesel Engine Top Engine Oil Fill 90° Exhaust Elbow Lever Starter Westerbeke Diesel Eng ines...
  • Page 13 W 428 FOUR Marine Diesel Engine Oil Fill Fuel Lift pump Fuel Filler Zinc Anode Throttle lever Lube Oil Dipstick Oil Pressure Oil Pressure Switch Sender Lube Oil Filler Westerbeke Diesel Engines...

  • Page 14: W 358 Three Marine Diesel Engine

    Continuous 14° Temporary 25° (not to exceed 30 min.) Dry Weight 3681bs (166.9 kgs) Fuel Consumption 0.42 U.S. gph (1.59 Iph) running at 2500 rpm (approximate) Idle Speed 800 - 1000 rpm Cruise RPM 2500 - 3000 rpm Westerbeke Diesel Engines...

  • Page 15: W 35B Three System Specifications

    W 35B THREE SYSTEM SPECIFICATIONS Open flow, totally self-bleeding FUEL SYSTEM No.2 diesel oil (cetane rating of 45 or higher) Fuel Injection Pump Nippondenso (Bosch M type) 23" ± OS BTDC (Static) Injection Timing Nozzle Throttle type 2275 psi (160 kg/cm 2 )
  • Page 16 API specification of CC, CD, SC, SD, or SE SAE Grade SAE 20W/20 or SAE 30 exclusively (DO NOT mix grades of oil !) (DO NOT use multigrade oils !) Transmission Sump Capacity 1 qt (1 liter) Westerbeke Diesel Engines...

  • Page 17: W 38B Four Marine Diesel Engine General Specifications

    Continuous 14' Temporary 25' (not to exceed 30 min.) Dry Weight 4191bs (190 kgs) Fuel Consumption 0.42 U.S. gph (1.59 Iph) running at 2500 rpm (approximate) Idle Speed 750 - 950 rpm Cruise RPM 2500 - 3000 rpm Westerbeke Diesel Engines...

  • Page 18: W 38B Four System Specifications

    (measured before discharging into exhaust elbow) System Capacity (fresh water) 7 U.S. qts (6.6 liters) LUBRICATION SYSTEM Forced lubrication by gear pump General Oil Filter Paper element, spin-on type Sump Capacity (includes filter) 4.75 U.S. qts (4.5 liters) Westerbeke Diesel Engines...
  • Page 19 Lubricating Oil Grade API specification of CC, CD, SC, SO, or SE SAE Grade SAE 20W/20 SAE 30 exclusively (DO NOT mix grades of oil (DO NOT use multigrade oils Transmission Sump 1 qt (1 liter) Capacity Westerbeke Diesel Engines...

  • Page 20: W 42B Four Marine Diesel Engine

    Continuous 14' Temporary 25' (not to exceed 30 min.) Dry Weight 4191bs (190 kgs) Fuel Consumption 0.42 U.S. gph (1.59 Iph) running at 2500 rpm (approximate) Idle Speed 750 - 950 rpm Cruise RPM 2500 - 3000 rpm Westerbeke Diesel Engines...

  • Page 21: W 428 Four System Specifications

    (measured before discharging into exhaust elbow) 7 U.S. qts (6.6 liters) System Capacity (fresh water) LUBRICATION SYSTEM General F.orced lubrication by gear pump Paper element, spin-on type Oil Filter 4.75 U.S. qts (4.5 liters) Sump Capacity (includes filter) Diesel Westerbeke Engines...
  • Page 22 W 42B FOUR SYSTEM SPECIFICATIONS 35 - 55 3.86 Operating Oil Pressure psi (2.46 - kg/cm API specification CC or CD Oil Grade ELECTRICAL SYSTEM Starting Battery 12-Volt, 35 A-H, (-) negative ground (recommended) (45 A-H cold areas) 90 - 125 (Ampere-Hours) Battery Capacity Starting Aid 12-Volt sheathed type glow plug...

  • Page 23: Installation Checks

    INSTALLATION CHECKS General Because the crafts in which Westerbeke engines are installed vary in design, installation procedures will vary according to your craft's specific design. The intent of this section is not to advise boatyards or installers on procedures alreadywell-developed and well-understood. However, the owner/operator must realize there are details of the installation which require periodic checks to ensure the best operating conditions for the equipment and safe operating conditions for the personnel on board.
  • Page 24 In case it becomes necessary to hoist the engine either front-end upwards or transmission-end upwards, the attachment of slings must be done carefully to avoid the possibility of damaging the parts on which the weight may bear. Special rigging work is best done by someone experienced and competent in handling heavy machinery. Engines Westerbeke Diesel...
  • Page 25 Supports between the bed stringers, and extending from the stringers to the hull, may be required for proper support and to aid in the absorption of vibra- tions. Note: Avoid excessive height, use solid stringer construction (A). Westerbeke Diesel Engines...
  • Page 26 The best lime to perform the propeller shaft/transmission coupling alignment is with the fuel and water tanks about half full and all the usual equipment on board, and after the main mast has been stepped and the final rigging has been accomplished. Westerbeke Diesel Engines...
  • Page 27 It may even be necessary to realign the coupling hal- again at later time. Westerbeke Diesel Engines...
  • Page 28 Exhaust System The exhaust system provides an outlet line to vent engine exhaust gases out 01 and away from the vessel. The system also discharges sea water which has passed through the engine's sea water circuit by mixing it with hot exhaust gases. This mixing helps cool the exhaust gases and exhaust elbow and plumbing. The must exhaust system and the sea water supply to the exhaust be configured to prevent the siphoning of sea...
  • Page 29 The engine's exhaust system must be separate from any other engine's exhaust system. Dry portions of the exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be insu- lated to hold in the heat. Westerbeke Diesel Engines...
  • Page 30 Make sure there are no unnecessary objects suspended from any portion of the exhaust lines. Excessive weight could cause deflection or distortion of the lines, resulting in damage or leaks. Inspect insulated por- tions of the exhaust system to make sure there is no deterioration of the insulation. Westerbeke Diesel Engines...
  • Page 31 Exhaust Elbow Installation The Westerbeke Corporation offers a 45°and 90 exhaust elbow as well as an exhaust riser you can install on your propulsion engine. Refer to the instructions below when installing the exhaust elbow purchased for your engine. 1. Coat only one side of the exhaust gasket with '''High Tack"...
  • Page 32 The use of common-type street elbows is not recommended for plumbing the sea water cir- cuit. These generally have very restrictive inside diameters. Machine fittings are preferred. Engines Westerbeke Diesel...
  • Page 33 Fuel tanks that are located below the engine's fuel system level must have its fuel return at the tank extend- ing down into the tank in the same manner as the pickup tube, otherwise fuel siphoning out of the engine's fuel system through the return will take place. Westerbeke Diesel Engines...
  • Page 34 Make sure the fuel tank filler is properly sealed to prevent water entry should it become awash. The fuel tank's vent should be routed so as to prevent water entry as well. Be sure there is a fire extinguisher installed near the unit and that it is properly maintained. Be familiar with its use.

  • Page 35: Preparation For Starting

    Follow the procedures as presented, for the conditions indicated, and your Westerbeke engine set will give you reliable performance and long service life. Fill your engine with oil up to or near the upper limn on the dipstick (the installation angle may have an effect on the dipstick reading).
  • Page 36 This system is common to Westerbeke Diesels. The start cirCUITry is designed so that the PREHEAT button must be depressed for the time specified in the "Preheat" chart shown on page 39. Then, while keeping the PREHEAT button engaged, the START button is depressed to crank the engine.

  • Page 37: Description Of Instrument Panels

    DESCRIPTION OF INSTRUMENT PANELS Westerbeke offers two types of control panels as optional equipment for the W 35B, the W 38B, and the W 42B engines, Read the following instructions that apply to the panel you purchased with your engine.
  • Page 38 OFF. The temperature gauge will once again register the engine's true temperature once electrical power is restored to the gauge. The oil pressure gauge will fall to zero when the engine is manually shut down. Westerbeke Diesel Engines...
  • Page 39 In addition, this button is energizes the START button. 3. SIABI: The START button, when pressed, energizes the starter's solenoid which cranks the engine. This button will not operate electrically unless the PREHEAT button is pressed and held at the same time. Westerbeke Diesel Engines...
  • Page 40 OFF. The temperature gauge will once again register the engine's true temperature once electrical power is restored to the gauge. The oil pressure gauge will fall to zero when the engine is manually shut down. Westerbeke Diesel Engines...

  • Page 41: Starting Procedure

    10 obtain a start. Engine damage resulting from this type of sea water entry is not a warrantable issue; Ihe owner/operator should keep this in mind. Westerbeke Diesel Engines...
  • Page 42 Never attempt to engage the starter while the engine is running. NOTE: Some unstable running may occur in a cold engine, but this condition should smooth out as the operating temperature of 130 - 150 F (55 - 66 is reached. Engines Westerbeke Diesel...

  • Page 43: Stopping Procedure

    (that is, operating the engine with a propeller that is too large). 6. During the next 25 hours, the engine may be operated at varying engine speeds, with short runs at full rated speed. Avoid idling the engine for prolonged periods of time. Westerbeke Diesel Engines...
  • Page 44 RISE ENOUGH - Allow the glow plugs to operate sufficiently to aid in starting during the preheat period when- ever the temperature of the intake air is low and when the compression temperature does not rise enough. Refer to the preheat chart found in the "STARTING PROCEDURE" section, page 39. Westerbeke Diesel Engines...

  • Page 45: Fuel System

    Although most boatbuilders supply a water trap/filter, some do not. Westerbeke offers a sedimentary/water trap/filter as an optional extra at moderate cost. The filter is supplied with fittings for either hose or metal tubing fuel lines.
  • Page 46 Priming the Fuel System The Westerbeke self-bleeding fuel system is semiautomatic in operation. The self-bleeding feature of the fuel system allows for easy servicing the fuel filters. Simply remove the and replace the filter elements (take care in catching any fuel that may drain out the fuel filtering assemblies) as described In the "Replacing...
  • Page 47 To obtain long and satisfactory service from the injection pump, always use fuel which is free from impurities and maintain a good filtration and water separation system between the fuel tank and engine. Service this system regularly: the injection pump it saves will be your own. Westerbeke Diesel Engines...

  • Page 48: Electrical System

    Engine 12-Volt DC Control Circuit The Westerbeke 35B, 38B and 42B propulsion engines have a 12-Volt DC electrical control circuit, as shown on the wiring diagrams which follow on pages 48 to 51. Refer to these diagrams when troubleshooting or servicing electrical components on the engine.
  • Page 49 Note: Before removing the alternator for repair, make sure 12-Volts excitation is present at the R terminal should the above test show only battery voltage at the B output terminal. Westerbeke Diesel Engines...

  • Page 50: Captains Panel Dc Control Circuit Wiring Diagram #36467

    STIlRT Ifl~i I'L.Se> TEST SwiTCH ' " , , , 15- I['r---, ,- - I) '-""'L ~A~pl ~. ~';~I " LA~tPt W T. ~E" TACHOMETER £!, PREHEAT ',4s,Ur """'" I S"ITCH "18 Bl< "BBL" "oSL' ~------------------------------~ Westerbeke Diesel Engines...

  • Page 51: Wiring Diagram # 36467

    DISCONNECT THE BATTER'!' IN AN EMERGENCY AND WHEN LEAVING THE EOAT. A SWITCH WITH A CONTI"lUOUS RATING OF 17';AMPS AT 12VDC WILL,SERVE THIS FUNCTION THIS SWITCH SHOULD NOT 8E USED TO MAKE 0R BREAK TH£ CIRCUIT. .:. PINK WIRE AT PLUG 2. IS UNUSEf' AND SHOULD BE ItISULATEiJ. Westerbeke Diesel Engines...

  • Page 52: Wiring Diagram #36844

    RTi! I ALARM BUZZER -+------;--, , - ' T -- --il-I- -WATERTE~ OIL PRESS GAUGE GAUGE >'21~E,> I"'~YEL ,'''"", I~"GRN! ·cJ~G>t'._. I " 'V_~ W::: :0 ",' "14GRN. ~-,---,-".--c/,:.,c,o:~ <i>~ lJiTART PREHEAT KEY SWITCH S,WITCH SWITCH VOLTMETER ~oel'. Westerbeke Diesel Engines...

  • Page 53: Admirals Panel Dc Control Circuit Wiring Diagram #36844

    A CONTINUOUS RATING OF 175 AMPS AT 12 VOLTS DC WILL SERVE THIS FUNCTION, THIS SWITCH SHOULD NOT BE useD TO MAKE OR BREAK THE CIRCUIT. 3. THE GRAY WIRE AT PLUG #21S UNUSED AND SHOULD BE INSULATED. Westerbeke Diesel Engines...

  • Page 54: Cooling System

    COOLING SYSTEM Description Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water which circulates throughout the engine. This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred ex- ternally from the fresh water to sea water by means of a heat exchanger, similar in function to an automo- tive radiator.
  • Page 55 B. Filling the Fresh Water System A coolant recovery tank kit is supplied wtth each Westerbeke diesel engine. The purpose of this recovery tank is to allow lor engine coolant expansion and contraction, during engine operation, without the loss of coolant and without introducing air into the cooling system.
  • Page 56 Since 1980, each type of thermostat has a hole punched through it. The hole is a bypass to prevent the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have this design characteristic. Westerbeke Diesel Engines...
  • Page 57 Sea Waler Circuit The sea water flow is created by a bel!- driven, positive displacement, neoprene impeller pump, The pump draws sea water directly from the ocean through the '" sea cock and sea water strainer and pas- ~ ::~ ses the water to the heat exchanger's sea water inlet.
  • Page 58 3/8 inch and no more than 1/2 inch (10 mm, 12 mm) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span of the belt. (See the figure below.) A spare drive belt should be carried on board. Alternator and Water Pump Selt Tension Westerbeke Diesel Engines...
  • Page 59 Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow through their independent cooling circutts. Refer to your engine's Parts List for part numbers and part descriptions if you need to order cooling system parts for your engine.
  • Page 60 HEATER ABOVE ENGINE HEATER BELOW ENGINE The illustrations shown above are Flow Control designs that have been adapted to operate with the single pass manifolds installed on the W 358, the W 388, and the W 428 engines. Westerbeke Diesel Engines...
  • Page 61 The hose connection from the heater to the remote expansion tank should be routed and supported so as to rise continuously from the heater to the lank, enabling any air in the system to rise. Refer to the illustrations on the previous page. Westerbeke Diesel Engines...

  • Page 62: Lubrication System

    NOTE: A newly started, cold engine can have an oil pressure reading upwards of 60 psi. A warmed engine can have an oil pressure reading as low as 35 psi. These readings will vary depending upon the speed at which the engine is running. Westerbeke Diesel Engines...
  • Page 63 Immediately after an oil filter change and oil fill, run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil filter. Westerbeke Diesel Engines...
  • Page 64 Oil Dipstick Fill to, but not over, the high mark on the dipstick, should the engine require additional oil. Upper Li.it Leve~l~fl~ l~~~~==~~~ INor •• l ----.. -- - 0 i l ===== --. t."r Li.i Crankcase Westerbeke Diesel Engines...

  • Page 65: Js Transmission

    JS TRANSMISSION (Standard) General The transmission's gear ratio is 2.47 to 1. The JS transmission is made of a lightweight, high-strength, cor- rosion-resistant aluminum alloy suitable for the marine environment. This manual transmission rotates op- posite to the engine when in forward gear. The JS transmits its power with case-hardened helical gears and, in reverse, an intermediate gear.
  • Page 66 Alignment Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious problems. Make sure the alignment procedures outlined in the "Propeller Shaft Coupling," the" Propeller, " and the" Alignment of the Engine" sections of this manual are followed, pages 24 and 25. Controls The only controls required to operate the transmission is a single lever remote control...
  • Page 67 Disassembly olthe transmission in the field is not recommended. If an overhaul or repair is needed, the work should be done by Westerbeke or an authorized Westerbeke service center. Cooling The JS transmission is sea water-cooled. Sea water enters the transmission through a stainless steel inlet pipe located at the base of the bell housing.

  • Page 68: Optional Transmissions

    (0.002") clearance. :r-- Over travel of the actuating lever does no harm. O.Smm However, if the travel is too short to give full Control of engagement, premature wear, excessive heat Gearbox generation and gear failure may result. Westerbeke Diesel Engines...
  • Page 69 Gear Ratios 1.5:1 2.5:1 HBW 100 HBW 150 1.5:1 2.5:1 HBW 150V 1.5:1 2.5:1 These transmissions each have their own oil sumps and dipsticks. The HBW transmis- sion uses Automatic Transmission Fluid (ATF) type A or Dextron II. Westerbeke Diesel Engines...
  • Page 70 Therefore, extremely important that recommended oil, automatic transmission fluid (ATF), Type A or Dexron II be used. NOTE: Be sure cooler properly installed when required and the transmission contains oil before cranking or starting the engine. Westerbeke Diesel Engines...
  • Page 71 Attempting to place the gear into forward or reverse while under sail to stop propeller shaft rotation will have effect. TO stop propeller shaft rotation while under sail, mechanical shaft brake would be needed. Westerbeke Diesel Engines...
  • Page 72 It is possible for cross leaks to occur inside the cooler, permitting flow into the water water flow into the oil. Checking transmission fluid levels at each days use will help spot such a hap- pening, undetectable loss of fluid and/or emulsified fluid. Westerbeke Diesel Engines...
  • Page 73 Low engine idle speed can produce drive damper chatter. Winter Checks Drain water from transmission cooler. This will prevent freezing cooler climates, and prevent harmful deposits from collecting. General Checks Check coupling alignment each time a transmission is replaced in the boat. Westerbeke Diesel Engines...
  • Page 74 Check oil level immediately after the engine has been shut off. 10. Use a clean container for handling transmission fluid. 11. Replace cooler and lines after a transmission failure, prior to installing a new or rebuilt transmission. 12. Check fluid level at operating temperature. Westerbeke Diesel Engines...
  • Page 75 Rotate the shaft exactly 1/4 of a turn and measure to the same joint. The four distances must be equal within 1/8". (DO not measure Westerbeke Diesel Engines...
  • Page 76 to the joint end that is spool adapter. This distance will vary wi th misalignment "~H',,,,,",,,,,,, .- ?'! ~ RI":,~ Slnce joint bolted and cannot move.) #31A alignment gauge machined diameter Z' Y.'NCO -lJ'ft[ClIN(' "'''''. cover and slide it com- pletely around.
  • Page 77 Proper operating temperatures are from 140· ISO'F, although safe operating temperatures may be as high as 210"F. the models equipped with an oil circulating pump, the #49 oil Westerbeke Diesel Engines...
  • Page 78 pressure drop switch and 12 volt H9A warning light should be hooked up per the wiring diagram. The switch may be grounded to any part of the V-drive or engine (either terminal may be used for ground). Oil Fill Pullout level gauge.
  • Page 79 #438 strainer (leave the elbow on the strainer). Unscrew 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. Westerbeke Diesel Engines...
  • Page 80 V- drive should be rechecked and corrected necessary. Some engines with rubber mounts may sag and must be raised with adjustments or shims proper alignment (see "Flange Alignment" "Engine Alignment n) • Westerbeke Diesel Engines...

  • Page 81: Engine Troubleshooting

    2. Check for 12 volts at the tripped 10 Amp breaker 10 Amp breaker. Check on the terminal on the for 12 volts at fuellifl pump preheat solenoid. and at the R terminal on the alternator when the preheat button is pushed. Westerbeke Diesel Engines...
  • Page 82 probable Cause Verification/Remedy Problem 1. Connection to starter 1. Check connection S at the START switch is de- solenoid faulty. starter solenoid for 12 volts pressed: no starter engagement. with the SWITch depressed. 2. F aully START switch. 2. Check switch with an ohmmeter.
  • Page 83 B terminal on the alternator. 2. Faulty alternator. 2. Voltage leak through the alternator when not operating. 3. Bad battery 3. Connections are corroded connections. or loose at the battery or/and at the engine. Westerbeke Diesel Engines...

  • Page 84: Maintenance & Adjustments

    9. Check to make sure the propeller shaft is securely connected to the transmission coupling. Monthly Check the condition of the zinc anode in the heat exchanger's sea water circuit. Clean or replace the anode, as required. Keep the area inside the heat exchanger clean of zinc anode debris. Westerbeke Diesel Engines...
  • Page 85 3. Drain, flush, and refill the fresh water cooling system. The illustration on pages 6 to 11 show the heat exchanger and the zinc anode location. The drain plug for the fresh water system is next to the zinc anode. Check the condition of the starter motor drive pinion; lubricate the pinion. Westerbeke Diesel Engines...
  • Page 86 NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours. *2. Check the injection pump's timing. Westerbeke Diesel Engines...
  • Page 87 Torquing Cylinder Head Bolts 35B THREE Engine) Tighten the cylinder head bolts according to the sequence shown in the illustration shown to the right. Make sure the engine is cold when this is FRONT OF ENGINE done. Before applying the specHied torque to the bolt, loosen it 1/4 to 1/2 of a turn and then apply the torque.
  • Page 88 Valve Clearance Adjustment 35B THREE Engine) CAUTION Adjust the valve clearance when the TOC MRRK ( Cylinder Ko.ll engine is cold. Valves are adjusted by cylinder in the firing order of the en- gine. Tighten the cylinder head bolts to the specified torque before adjusting the valves.
  • Page 89 180" and adjust the valve clearances for the intake and exhaust valves for cylinder NO.2. Adjust each valve's clearance by inserting a 0.010 inch (0.25 mm) feeler gauge between the rocker arm and the valve stem. Westerbeke Diesel Engines...
  • Page 90 Injection Pump Timing Adjustment (Spill Timing) If your engine's fuel injection timing is not property adjusted, the engine will not operate property and will be difficult to start. Have the injection pump delivery rate checked by a well-established fuel Injection shop. Ad- just the injection timing as follows: NOTE: The fuel shut-off lever must be In the RUN posHion while making the adjustment or no fuel will flow from the fuel injection pump.

  • Page 91: Lay-Up & Recommissioning

    LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their cralt, including engines and generators, for lay-up during off-season or lor long periods of inactivity. Others prefer to accomplish lay-up preparation them- selves. The procedures which follow will allow you to perform your own lay-up and recommissioning, or to use as a check list il others do the procedures.
  • Page 92 CAUTION Do not leave the engine's old lubricating oil in the sump over the lay-up period. Lubricating oil and combustion deposits combine to produce harmful chemicals which can reduce the life of your engine's internal parts. Transmission lubrication System Fill the transmission completely full of the same oil that was use during its operating season. DO NOT mix grades of oil.
  • Page 93 Spares Lay-up time provides a good opportunity to inspect your Westerbeke engine to see ff external items such as drive belts or coolant hoses need replacement. Check your basic spares kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes.
  • Page 94 3. Drain the transmission of all oil. Fill the transmission to the proper level with the correcttype of oil specified in your engine's "SYSTEM SPECIFICATIONS" section of this manual. IWARNINGI Wear rubber gloves, a rubber apron, and eye protection when servicing batteries. Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical arcing or a lighted cigarette, cigar, or pipe.

  • Page 95: Table Of Standard Hardware Tightening Torques

    3.7 - 4.6 3/8 UNF 30 - 35 4.1 - 4.8 7/16 UNC 44 - 49 6.1 - 6.8 7/16 UNF 50 - 55 6.9 - 7.6 1/2 UNC 68 - 73 9.4-10.1 1/2 UNF 73 - 10.1-11.1 Diesel Westerbeke Engines...

  • Page 96: Torque Specifications

    4.0 - 5.0 Nozzle mounting bolt 10.8 -14.5 1.5 - 2.0 Nozzle holder and retaining nut 43.4 - 57.9 6.0 - 8.0 Glow plug 10.8 -14.5 1.5 - 2.0 NOTE: M8 indicates Metric, 8 mm thread diameter Westerbeke Diesel Engines...

  • Page 97: Spare Parts

    From the list provided directly above and from these inquiries, you can determine what spare parts may be needed. In addition, you are planning a long ocean voyage, consult your local Westerbeke dealer for a listing of the Westerbeke dealers located on your route. Westerbeke Diesel Engines...

  • Page 98: Index

    INDEX Adjustment, Injection Pump Timing ......................88 ADJUSTMENTS, MAINTENANCE AND ...................... 82 Adjustment, Valve Clearance 35B THREE Engine) ................86 Adjustment, Valve Clearance 38B FOUR and W 42B FOUR Engines) ..........87 Admirals Panel ............................. 37 Admirals Panel Control Circutt DC Wiring Diagram 36844 ......
  • Page 99 Engine Oil Viscosity (SAE Number) ......................60 ENGINE TROUBLESHOOTING ........................79 EqUipment, Inspection of ..........................2 Exhaust Back-Pressure (Installation Checks) .................... 27 Exhaust Elbow Installation (Installation Checks) ..................29 Exhaust System (Installation Checks) ......................26 Exhaust System Failures (Installation Checks) ..................28 Westerbeke Diesel Engines...
  • Page 100 GENERAL SPECIFICATIONS W 42B ......................18 HARDWARE TIGHTENING TORQUES, TABLE OF STANDARD ............... 93 Head Bolts, Torquing Cylinder (W 35B THREE Engine) ................85 Head Bolts, Torquing Cylinder (W 38B FOUR and W 42B FOUR Engines) ..........85 Hose, Oil Drain (Installation Checks) ......................30 Hot Water, Domestic ...........................
  • Page 101 PRODUCT SOFTWARE DISCLAIMER, IMPORTANT .................. 1 Propeller (Installation Checks) ........................24 Propeller Shaft Coupling (Installation Checks) ..................24 Propeller Shaft Coupling (Lay-up and Recommissioning) ................ 89 Pump, Fuel Injection ........................... 45 Pump, Sea Water ............................55 Pump Timing Adjustment, Injection ......................88 Westerbeke Diesel Engines...
  • Page 102 Thermostat .., .................. , ............54 TORQUE SPECiFiCATIONS ......, ..................94 Torquing Cylinder Head Bolts 35B THREE Engine) ................85 Torquing Cylinder Head Bolts (W 38B FOUR and W 42B FOUR Engines) ..........85 Transmission Lubrication System (Lay-up and Recommissioning) ............90 TRANSMISSIONS, OPTIONAL.
  • Page 103 Under Cold Conditions, Starting ........................ 42 Under Normal Conditions, Starting ......................42 Understanding the Diesel Engine ......................... 5 Valve Clearance Adjustment 35B THREE Engine) ................86 Valve Clearance Adjustment 38B FOUR and W 42B FOUR Engines) ..........87 V-Drives ............................... 73 Ventilation ..............................
  • Page 104 YOUR NOTES Westerbeke Diesel Engines...
  • Page 105 YOUR NOTES Weslerbeke Diesel Engines...
  • Page 106 YOUR NOTES Westerbeke Diesel Engines...

This manual is also suitable for:

38b four42b four

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