Table of Contents
Advertisement
Quick Links
OPERATORS MANUAL·
- , .
---.
~
-.
--;
-_.-
...... .
MARINE DIESEL ENGINES
-
. --. -
---• .
"-~-~~--
-
-----..--=---::..-:-::.--
-
~
._-_.------------
-.
~-
.. - -.. - -
-
. 65A-
FOUR~!AND
658 -F·OUR
REVISION 2
JUNE 2011
<
WESTERBEKE'
WESTERBEKE CORPORATION' MYLES STANDISH INDUSmlAL PARK
150 JOHN HANCOCK ROAD, TAUNTON,
MA
02780-7319' TEL. 1-508·823-7677
FAX 1-508 884-9688' WEBSITE: www.WESTERBEKECOM
.
' .
'..,;,.,~
..
-
_ .
.
NMMA Member National Marine Manufacturers Association
---
Advertisement
Table of Contents
Troubleshooting
Subscribe to Our Youtube Channel
Related Manuals for Westerbeke 65A-FOUR
Summary of Contents for Westerbeke 65A-FOUR
- Page 1 .. - -.. - - FOUR~!AND . 65A- 658 -F·OUR REVISION 2 JUNE 2011 < WESTERBEKE' WESTERBEKE CORPORATION' MYLES STANDISH INDUSmlAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, 02780-7319' TEL. 1-508·823-7677 FAX 1-508 884-9688' WEBSITE: www.WESTERBEKECOM '..,;,.,~ NMMA Member National Marine Manufacturers Association...
- Page 2 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 to bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel.
- Page 3 • Make sure a fire extinguisher is installed nearby and is before touching the engine or checking the coolant. properiy maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment. WESTERBEKE Engines Generators &...
- Page 4 Acid may splash on the skin or into the eyes ing parts and hot exhaust system components. inadvertently when removing electrolyte caps. WESTERBEKE Engines & Generators...
- Page 5 USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-I Exhaust systems P-4 Inboard engines E-9 DC Electrical systems All installations must comply with the 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.
-
Page 7: Table Of Contents
Engine Adjustments ............Fuel Injectors ............~ ..23 Suggested Spare Parts ..........Glow Plugs ..............24 Valve Clearance Adjustment ........25 Drive Belt Adjustment ..........26 Testing Oil Pressure ........... 26 Engine Compression ..........26 WESTERBEKE Engines & Generators... -
Page 8: Parts Identification (Illustrations)
PARTS IDENTIFICATION CRANK CASE VALVE ANODE INTAKE '''",lItULU, THERMOSTAT ASSEMBLY PRE-HEAT ELECTRIC SHU'T-OFIB;;;;:JJ:::~:J~:Qj FUEL WATER HEATER CONNECTIONS AND SHUT-OFF BRACKETS SPIN-ON ALTERNATOR FRONT INJECTION JI::;;;Y--"""""''''<D PUMP RIGHT SIDE OIL DRAIN HOSE THERMOSTAT HOUSING COVER INTAKE MANIFOLD COOLANT PRESSURE CAP HEAT EXCHANGER~. -
Page 9: Introduction
PROTECTING YOUR INVESTMENT Care at the factory during assembly and thorough testing have WARRANTY PROCEDURES resulted in a WESTERBEKE engine capable of many thousands Your WES1ERBEKE Warranty is included in a separate of hours of dependable service. However, the manufacturer can- folder. -
Page 10: Serial Number Location
SPARES AND ACCESSORIES Certain spares will be needed to support and maintain your WESTERBEKE engine. Your local WES1ERBEKE dealer Fill in the information for your referanee. will assist you in preparing an inventory of spare parts. See the SPARE PARTS page in this manual. For engine accessories, see WESTERBEKE'S ACCESSORIES brochure. -
Page 11: Control Panel (Admiral)
ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off, the water temperature gauge will continue to register the last This manually-operated control panel is equipped with a temperature reading indicated by the gauge before elecmcal KEY switch and RPM gauge with an ELAPSED TIME power was turned off. -
Page 12: Control Panel (Captain)
CAPTAIN CONTROL PANEL DESCRIPTION The panel also includes an alarm buzzer. for low OIL PRESSURE or high COOLANT TEMPERATURE. The This manually-operated control panel is equipped with a RPM gauge is illuminated when the KEY switch is turned oil KEY switch, an RPM gauge, PREHEAT and START but- and remains illuminated while the engine is in operation. -
Page 13: Diesel Fuel, Engine Oil And Engine Coolant
ENGINE COOLANT Use a diesel fuel that meets the requirements of No. 2-D WESTERBEKE recommends a mixture of 50% antifreeze 313 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. -
Page 14: Preparations For I.nitial Start
Open the thru-hull and make certain raw water is primed stud (this location is tagged). to the raw water strainer. Check the coolant level in both the plastic recovery tank and at the manifold. COOLANT RECOVERYTANK ..WESTERBEKE Engines Generators &... -
Page 15: Starting/Stopping Procedure
NOTE: The START switch will no! energize unless the PRE- HEATswitch is depressed Depressing the PREHEATswitch PRE~ activates the glow plugs in the cylinder head so use the HEAT inter1l/.ittently to avoid overheating the glow plugs. WESTERBEKE Engines & 4,enerators... -
Page 16: Warning Lights, Alarms & Circuit Breaker
WARNING L1GIITS, ALARMS & CIRCUIT BREAKER ALTERNATOR WARNINGS COOLANT TEMPERATURE SWITCH The Captain Control Panel indicates alternator low discharge A coolant temperature switch is located on the thermostat with a red warning light. housing. This switch will activate a continnous alarm coolant's operatiog temperature reaches approxiroately 21O'F The Admiral Control Panel uses a voltmeter to monitor the (99'C). -
Page 17: Maintenance Schedule
Raw Water Pump Remove Ihe pump cover and inspect Ihe impeller, gasket, cam and cover for wear. Check the bearings and seals (the shaft can turn, but not wobble). Lubricate when reassembling. Inlel Fuel Filler Replace. ""'" WESTERBEKE Engines & Generators... - Page 18 At first 100 hours, Ihen each year at winterizing. with "Lockeze" Initial fluid change at 25 hours, then every Transmission Fluid 300 hours or at winterizing. *WESTERBEKE recommends this service be performed by an authorized mechanic. WESTERBEKE "'SoY" Engines'& (ilenerators...
-
Page 19: Cooling Circuit
COOLING SYSTEM DESCRIPTION Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by com- bustion and friction is transferred to fresh water coolant which circulates throughout the engine. This circulating fresh water coolant cools the engine block; its internal moving parts, and the engine oil. -
Page 20: Thennostat
COOLING SYSTEM THERMOSTAT REPLACING THE THERMOSTAT A thermostat, located near the manifold at the front of the 1. Drain off some coolant: Release the coolant pressure cap engine, controls the coolant temperature as the coolant and drain coolant to the approximate level off the continuously flows through the closed cooling circuit. -
Page 21: Fresh Water Circuit
Beware of the hot engine coolant. NOTE: TI.;s tank, with its shOlt run of plastic hose, is best Wear protective gloves. located at or above the level of the engine manifold. '~/WESTERBEKE "" _ , __ ::1 ..Enaines & Generators... -
Page 22: Raw Water Pump
, motive radiator shop should be able to clean and test the heat , . ':: exchanger.) NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours. WESTERBEKE Englnes'& Generators... -
Page 23: Water Heater
WATER HEATER any portion of the heating circuit rises abov~ the WATER HEATER INSTALLATIONS NOTE: engine's own pressure cap, then a pressurized (aluminum) These engines are equipped with connections for the plnrnbing remote expansion tank (Kit #024177) must be installed in the of engine coolant to transfer heat to an on-board water heater. -
Page 24: Fuel System
FUEL SYSTEM DIESEL FUEL ENGINE FUEL filTER Use No.2-D (SAE J3l3) diesel fuel with a Cetane rating of Periodically check the fuel connections and the filter bowl for #45 or higher. Grade of diesel fuel according to ASTM D975. leakage. Change the filter element after the first 50 hours. See In conjunction with Ultra Low Sulphur Diesel. -
Page 25: Engine L~Bricating Oil
ENGINE LUBRICATING OIL I • •• ENGINE OIL CHANGE Draining the oil sump. Discharge the used oil through the sump drain hose (attached to the front of the engine) while the engine is warm. Drain the used oil completely, APPLY CLEAN replace the hose in its bracket and replace the end cap ENGINE OIL INSTALLING... -
Page 26: Remote Oil Filter
To install, simply remove the engine oil filter and thread on INSTALLATION WESTERBEKE's remote oil filter kit as shown. Always This popular accessory is used to relocate the engine's oil install this kit with the oil filter facing down as illustrated. -
Page 27: W' Io" N Ng Lagram
WIRING DIAGRAM #39144 ". R~8RED 114 L tl4 IT. BLU '''RE. Oil PRESSURE lliID· "'~~&HM-~' 1 - - - - - - '14 OR 15[[ NOTE Z GROUND " BLOCK +lufl ® illL.fQM< ~-==- lliI..E..B.1 > " OME MODElS) liN IS FOR 6SA Af NOT HAVE "... -
Page 28: Wiring Schematic
WIRING SCHEMATIC #39144 START I< SOL _ STARTER r-----+i--<- -: _ .. _ .. _ .. _ .. +-. M)---c----+ f"7o ~~l~ . _ . ' - PREHEAT !'R~TER~'I= r--,SDL ~J~;~ GLOWPlUGS 1 ,I mOE" ~""" AL HRNHOH __ .. TIMER •... -
Page 29: Engine Adjustments
2. Raise the fuel pressure and keep it at 12.75 MPa (130kgf/cm', 1849 psi) for 10 seconds. a fuel leak is found, replace .the nozzle piece . . "·FACTORY SPECIFICATIONS fuel leak at: 12:75MPA . '""'" WESTERBEKE kgf/cm" . _ .E'lglnes Qt __ QEmerator~ .1849 psi... -
Page 30: Glow Plugs
When reinstalling the glow plugs, use anti-seize compound on the threads. ke~pgi~ CAUTION: Do not plug on for more than 30 seconds. GLOW PLUGS REFER TO THE WIRING DIAGRAM IN THIS MANUAL FOR ALL WIRING CONNECTIONS -...v- WESTERBEKE Engines & Generators... -
Page 31: Valve Clearance Adjustment
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust· ments be peifonned a competent engine mechanic. The infonnation below is provided to assist the mechanic. CHECKING VALVE CLEARANCE Valve clearance must be checked and adjusted when engine is cold Remove the head cover. -
Page 32: Drive Belt Adjustment
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be pe/formed by a competent engine mechanic. The information below is provided to assist the mechanic. COMPRESSION TESTER TESTING OIL PRESSURE To test the oil pressure, remove the oil pressure sender, then install a mechanical oil pressure gauge in it's place. -
Page 33: Tachometer
TACHOMETER TACHOMETER/HOUR METER The tachometerlhour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and the other the tachometer. The hour meter circuit operates on 12 volts alternator charging voltage supplied to the (+) tenninal on the back of the instrument. -
Page 34: Engine Troubleshooting
ENGINE TROUBLESHOOTING The following troubleshooting table describes certain problems NOTE: The engine's electrical system is protected by a 20 relating to engine service, the probable causes of these prob- ampere manual reset circuit breaker located on a bracket at lems, and the recommendations to overcome these problems. the back of the engine. - Page 35 ENGINE TROUBLESHOOTING Problem Probable Cause .Verilication/Remedy Engine slows and stops. Fuel 11ft pump failure. Fuel lift pump should make a distinct ticking sound. Replace pump with spare. 2. Switches and/or wiring loose 2. Inspect wiring for short circuits and loose connections. or disconnected.
-
Page 36: Control Panel Troubleshooting
(both plus and minus gauge and connect it to ground. See if the gauge reads full tennhlals), the ground side will not necessalily be connected scale, wInch is the nmmal reading for tlrls situation. to tile block. WESTERBEKE -$i--Generators Engines... -
Page 37: Alternator Troubleshooting
VOLTAGE REGULATOR The following information applies to the standard alternators The integral voltage regulator is an electronic switching that are supplied with WESTERBEKE'S Marine Engines device which senses the system voltage level and switches and Marine Generators. the voltage applied to the field in order to maintain a proper system voltage. -
Page 38: Testing
R, inspect the wiring for breaks and poor connections. Jump 12 volts from a 12 volt source (such as the battery) and operate the alternator. voltage output is 13-14 volts, then Ihe alternator is OK. MEASURING BATTERY VOLTAGE ENGINE RUNNING WESTERBEKE "'IIY'" Eng!ne~ _~_ Gener~t~rs... -
Page 39: Checking/Servicing Battery
2. 'furn the ignition switch to the on position and note shop can do the job. the multimeter The reading should be 1.3 to 2.5 volts (see NOTE: WESTERBEKE'S Service ManuallUlS detailed EXCITER instructions for the disassembly and repair of their TERMINAL standard altem.ators. BATTERY CARE... -
Page 40: Dual Output Alternators
INSTALLATION an optional dual alternator has already been factory installed, . simply follow the WESTERBEKE wiring diagram and the engine installation instructions. the new dual alternator is being added to an existing "in- the-boat" engine, carefully follow the alternator installation instructions below: 1. -
Page 41: Troubleshooting
DUAL OUTPUT ALTERNATORS Alternator Testing TROUBLESHOOTING NOTE: The regulator is functioning properly and the batteries Bejore troubleshooting, make certain that the drive are in good condition. belts are tight and the batteries are in good condition. 1. Test the voltage at the alternator plug with the engine Regulator Testing off-key on. -
Page 42: High Output Alternators
Dual output and high output alternators are available as positive cable. optional equipment on most WESTERBEKE engines. These 6. Mount the regulator to a flat surface in a cool dry location. alternators can be installed during factory assembly or as add-on equipment at anytime. -
Page 43: Starter Motor
STARTER MOTOR [DESCRIPTION irhe starter is a new type, small, light-weight and is called a N.gh-speed intemal-reduction starter. The pinion shaft is separate from the motor shaft; the pinion slides only on the binion shaft. A reduction gear is installed between the motor ~haft and a pinion shaft. - Page 44 If the starter spins, the solenoid is faulty. SERVICE If the starter fails spin, the motor is probably faulty. WESTERBEKE uses a standard starter motor which can be Ifno arching occurred, there no juice reaching the serviced or rebuilt at any starter motor automotive service solenoid.
-
Page 45: Troubleshooting
ZF MARINE TRANSMISSIONS INITIAL OPERATION LOCKING THE PROPELLER All ZF marine transmissions are test-run on a test stand with Locking of the propeller shaft by an additional brake is not the engine at the factory prior to delivery. For safety reasons required: use the gear shift lever position opposite your the fluid is drained before shipment. -
Page 46: Control Cables
CONNECTION OF GEAR BOX WITH PROPELLER threaded holes located above the shift cover on top of the gear housing. Refer to the WESTERBEKE parts list. HBW recommend a flexible connection between the transmission gearbox and the propeller shaft if the engine is... -
Page 47: Transmission Cooler
WESTERBEKE recommends having a spare cooler aboard. Inspect the gear shift cable, linkage, and attachments. Look for corrosion of the end fittings, cracks or cuts in... -
Page 48: Zf Transmissions (H8W Models)
Shift into gear, forward and reverse; shifting should smooth and positive. Direct changes from Before leaving the WESTERBEKE plant, each transmission forward to reverse are permissible since the multiple disc undergoes a test run, with Dextron III ATF transmission fluid. -
Page 49: Change The Fluid
Replacement filters can be obtained from your Loosen attaching hardware from the transmission output local WESTERBEKE dealer. flange and propeller shaft coupling flange before removing the boat from the water. Separate the flanges Removing the Fluid and spray with lubricant. -
Page 50: Adjusting Idle Speed
Refer to the WESTERBEKE parts list, *DRIVESAYER is a product of Globe Marine, Rockland,MA.·... -
Page 51: Velvet Drive Transmissions
TNs centers the actuating lever on the trans- Before leaving the WESTERBEKE plant, each transmission mission. With the control in this 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: Troubleshooting
VELVET DRIVE TRANSMISSIONS Clean off the transmission and properly dispose of the used fluid. fl4l:'''''l Refill the transmission with DEXTRON III ATF. The quantity will vary depending on the transmission model and the installation angle. Fill through the dipstick hole. D Check the dipstick for the proper fluid level. -
Page 53: Oil Coolers
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: Transmission Troubleshooting ,Zf
If the remote NDTE: If you suspect a major problem in your transmission, is stiff to operate, break the cable loose at the transmission immediately contact your WESTERBEKE dealer or an again. it is still stiff, check the cable for kinks or authorized marine transmission facility. - Page 55 Propeller shaft broken. 5. Contact marine repair. Transmission malfunction. Contact manufacturer. Engine malfunction. ContaCt marine repair. NOTE: you suspect a major prt}Q.!em ·iWYour transmission, immediately contact your WESTERBEKE dealer or an authorized marine transmission facility .. WESTERBEKE Engines Generators &...
-
Page 56: Specifications
SPECIFICATIONS COOLING SYSTEM ENGINE SPECIFICATIONS General Engine Type Fresh water-cooled engine block, Diesel, l!JUr-cycle, four-cylinder, tresh water-cooled, vertical in-line overhead valve thermostatically-controlled with heat exchanger. mechanism Operating Temperature 160 -180° F (71 - 82° C) Aspir~tlon Naturally aspirated Fresh Water Pump Centrifugal type, metal impeller, belt-driven Compression Ratio 22.6: 1... - Page 57 Spray fogging oil into the open air intake, with the flame arrester removed, while the engine is running. The fogging stall out the engine and coat the valves, cylinders and will spark plugs for winter protection. ""'" WESTERBEKE Engines & Generators...
- Page 58 LAY-UP & RECOMMISSIONING Starter Motor SPARE PARTS Lubrication and cleaning of the starter ddve pinion is advis- Lay-up time provides a good opportunity to inspect your able, if access to the starter permits its easy removal. Make WES1ERBEKE engine to see if external items such as drive sure the battery connections are·...
-
Page 59: Metric Conversion Data
STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 Millimeters (mm) x .0394 = Inches Feet (ft) x .305 = Meters (m) x 3.281 = Feet Miles x 1.609 = Kilometers (km) x .0621 = Miles VOLUME Cubic Inches (in') x 16.387 = Cubic Centim~ters x .061 =in' Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal... - Page 60 DECIMAL TO METRIC EQUIVALENT CHART Fractions of Fractions of Metric (mm) Decimal (in.) Metric (mm) Decimal (in.) an inch an inch 13.09687 1/64 0.015625 0.39688 0.515625 33/64 13.49375 1/32 0.03125 0.79375 0.53125 17132 0.046875 0.546875 13.89062 3/64 1.19062 35/64 1/16 0.0625 0.5625 14.28750...
-
Page 61: Suggested Spare Parts
SUGGESTED SPARE PARTS Carry Only Genuine Westerbeke Spare Parts CONTACT YOUR WESTERBEKE DEALER FOR ADDITIONAL SUGGESTIONS AND INFORMATION FUEUWATER. \'l'IIr.\~t.Jll!i.,.~FILTERS FUEL INJECTOR HEAT EXCHANGER END ZINC·ANODE GASKET AND O-RING MATCHING DRIVE BELTS FUEL SYSTEM HARDWARE;KI~T~2~~ THERMOSTAT AND GASKET MOLDED HOSE KIT INA CANVAS CARRYING BAG .. - Page 62 , ' I ~WESTERBEKE Engines & Generators 1161/811...
Need help?
Do you have a question about the 65A-FOUR and is the answer not in the manual?
Questions and answers