Westerbeke 46 Operator's Manual
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Westerbeke 46 Operator's Manual

Westerbeke 46 Operator's Manual

Marine diesel engine
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OPERATOR'S MANUAL
WESTERBEKE 46
Marine Diesel Engine
Publication # 34468
Edition Two
May 1986
AVON INDUSTRIAL PARK, AVON, MA 02322 • TEL:
(617)
588-7700
TELEX: 92-4444. FAX: (617) 559-9323· CABLE: WESTCORP

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  • Page 1 OPERATOR'S MANUAL WESTERBEKE 46 Marine Diesel Engine Publication # 34468 Edition Two May 1986 AVON INDUSTRIAL PARK, AVON, MA 02322 • TEL: (617) 588-7700 TELEX: 92-4444. FAX: (617) 559-9323· CABLE: WESTCORP...
  • Page 3 We look forward to your continued patronage. from: J.H. Weslerbeke Corp. Avon Industrial Park Avon, MA 02322 COR~ r/~1 J. H. WESTERBEKE • AVON, .. AVON '''ov.r~'A< p",,~, CUSTOMER IDENTIFICATION 1234C408 Pleasure Craft W-46...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PAGE GENERAL SPECIFICATIONS •..•••••••••• 3 INSTALLATION, PREPARATION AND SUPPLY CAUTIONS. .. • .......... 5 BREAKING IN.......... 7 STARTING SySTEM......... 8 INSTRUMENT PANEL USE ••••••••.•.•...

  • Page 5: General Specifications

    Fuel 2 fuel oil (cetane rating 45 or better) Mineral oil, heavy duty, A.P.I. CC or CD Lubricating Oil (1.75 - 2.46 kg/cm 2 ) Oil Pressure Idle 20 - 30 P.S.I. Under power 30 - 60 P.S.I. (2.46 - 4.21 kg/cm 2 ) Intermittent Power 47.5 horsepower at 3000 RPM...
  • Page 6 starter 12V, 1.6KW pinion shift type Alternator 12V - 50 ampere Battery 12V - 100 ampere hour Raw Water Flow Rate 9.5-10.0 gallons/minute at 3000 R.P.M. measured at discharge into exhaust elbow Propeller Recommendations lSD x 10P-2 blade or lSD x SP - 3 blade (using HBW-150 1.8S:1 propeller should allow engine to reach reduction)

  • Page 7: Cautions

    INSTALLATION, PREPARATION AND SUPPLY CAUTIONS Check important aspects of installation before operating engine. ~EELER GAGE Alignment (Error to be no more than one thousandth of an inch per inch of coupling diameter) Provide sufficient ventilation Provide adequate service room STRAIGHT EDGE around engine (See...
  • Page 8 PREPARATIONS Take steps as shown below in starting your engine for the first time or after a prolonged shut-down. F ill your eng ine wi th oil oil filler port up to or near the upper limi t on the dipstick. Use a good grade of oil with API specifi- cation of CC or...

  • Page 9: Breaking In

    BREAKING IN YOUR NEW ENGINE While your engine has had at least one hour of test operations to demonstrate accurate assembly and correct operation of all systems, it still requires break in time. Service life of your engine is dependent on how your engine is operated and serviced during initial break-in hours of operation.

  • Page 10: Starting System

    DESCRIPTION OF STARTING SYSTEM Model W-46 uses an electr ic starter assisted glow plugs for both normal and cold weather Glow Plug starting. The figure a cross section through cylinder. glow plug enters com- bustion chamber so that the end...

  • Page 11: Instrument Panel Use

    Therefore, when priming the W-46 for the first time or when the system has been wor ked on or has been run out of fuel, allow the electr lc fuel pump to oper te for 2 to 3 minutes before the first cranking effort.

  • Page 12: Starting Procedures

    STARTING PROCEDURES Advance throttle to full, press Preheat button and hold for number of seconds indicated on Page 8 in "Glow Plug Use Data". While still engaging Preheat button, press Start button. Note: Failure to engage the Preheat button will not allow the Starter button to energize the starter.

  • Page 13: Stopping Procedures

    STOPPING PROCEDURES Model W-46, early models were supplied with a manual shut-off. handle knob pulled shut off fuel, stopping engine. Later Models June 1985 (C506) on, were supplied with an electric shut-off operated by the key switch and having the manual shutoff as an installer's option.
  • Page 14 Cautions during operation Confirm that the oil pressure is normal during operation. Confirm that exhaust gas is as follows: While engine is cold •••••••••..••...••••• White smoke When the engine grows warm •••...••••••••• Almost smokeless When the engine is overloaded .•••••••... ~Some black smoke Check...

  • Page 15: Requirements For Proper Operation

    REQUIREMENTS FOR PROPER OPERATION LUBRICATION SYSTEM Engine oil For engine lubrication, use diesel engine oil. Diesel engine oils are classified according to the API Specifications into grades CA, CB, CC and CD. Anyone of them is usable, but use of CC or higher grades prepared by well-known makers...

  • Page 16: Fuel System

    SLlre th" lUbing I',-o)ects #32974 from your local inch th"-'Llg~ the [",r"le b€fo,~ tiqhteninq t,no nut. Westerbeke representative pip~d with 11D5~. LJS~ two I>r,,05 narl>eo your: boat builder. This f U- [itL,lr.g~ dm) ,"""hprs suppiied, cert.Hn...
  • Page 17 IT IS WELL TO REMEMBER THAT WATER DAMAGE TO THE FUEL SYSTEM IS NOT COVERED BY WARRANTYl While many boat builders do supply a water trap filter, there are some who do not. It is to prevent such omission that Westerbeke offers sedimenter/water trap...
  • Page 18 Select the parts for your engine on page 43 and purchase spares from your local Westerbeke Dealer or Distributor. For example, hardware kit *34441 will supply fuel system washers for the Model 46.
  • Page 19 On the forward control housing of the injection pump is a buffer screw. This buffer screw has all the visual characteristeics of a bleed screw, but it is not. The adjustment of this screw should not be tampered with, or disturbed. Disturbing the adjustment of this buffer screw can shut off the delivery of fuel from the injection pump to the injectors and pre-...
  • Page 20 COOLING SYSTEM Cooling water As cooling water, use soft water with least impurity content such tap water (potable water) rainwater, never use hard water or foul water. Use of hard water or water containing much impurity will lead to collection of scale in the engine and heat exchanger with resultant decline in cooling effects.
  • Page 21 The total system is very reliable and requires only a daily check water level system plus routine checks of hose clamps and fittings • It is likely that zinc electrodes will waste away from elecroly- action sea water circuit. They should be checked monthly.

  • Page 22: Wiring Diagram

    DAMAGE TO THE BATTERY CHARGING ALTERNATOR WILL RESULT SHOULD THIS BE DONE. REMOVE ReTURN BEND FROM DOMESTIC HOT WATER Sketch right shows Model W-46 complete wi th Flow Control mecha- nism and its bypass connection for normal use. If it is desired to...
  • Page 23 Model W 46 comes complete wi th a Flow Control which, when proper ly connected to a heater tank, produces domestic hot water from waste engine heat. Principle: With the bypass hose 130962 removed, there remain 2 con- necting points A and for hose to and from the water heater.
  • Page 24 WI PI NG DIAGRAM @SEE NOTE- B srNDER '" T[MP~. 'V.H 0'L PRESSURE ALTERNATOR @SWI-:- CH '" ?> C"-::"" "c "' '" '" SI AMP ~,\j'ACH ACARM O"~ R£~' r--t-, 1--r <f 2 1 @ FUEL 1'1';:,8, 'N'j2. ".\' 70,\lV100 BU\"I~ SPLlTT( OPTIONA...
  • Page 25 SCHEMATIC DIAGRAM r2VDC BATTERY BATTERY RETURN ~?TEY NOTES 0"-1 BU!/J'..£i?/O'NNER5 R£SPONSIBIf-ITV. AlTERNATOR '" 120AMP O!.HER rygTES: PRE-HEA1" SOL PANEl -~-~- WARNING ;!ENC>£R CONIYECITot-l: KEYSW CONTACT WlrH MAY DAMAGE SENPER. ~Rw[-HEAT © ,ALL_J?.£IUI?NS ARe THRQUGH ENGINE 8LOC;::. SOl. \.::) START ,----~,4-j(i~JYY';" WIRING OF AUX/(LAI?Y AlTE~NATO,eS Sec THE FOLLOWING DIAGRAHS.

  • Page 26: Cylinder Head & Valves

    CYLINDER HEAD AND VALVES Tighten cylinder head bolts in the sequence shown. The engine should be cold. Loosen each bolt one-eighth to one-quarter turn when tightening in the sequence shown. Note that bolt 14 and 5 are located under the intake manifold where it is attached to the head.

  • Page 27: Recommended Maintenance Service.25

    RECOMMENDED MAINTENANCE SERVICE Check and service your engine at specified intervals to maintain it in its best conditions and permit it to perform as it should. those asterisked items, it is suggested that you have them performed by an authorized distributor or dealer. Daily inspection before use.
  • Page 28 Check condition of zinc anode in heat exchanger. Should material be flaking off the zinc, it should be scraped clean, or be replaced by a good solid zinc pencil. If it appears that a lot of material has been flaking off the zinc, then it is advised that the end cap of the exchanger be removed, and the flaked material be cleaned from that area of the exchanger.
  • Page 29 Checkup of glow plugs. Check glow plugs for blowout. Do resistance check. Removal of cooling water and flushing is suggested. Lubricate fresh water pump (Grease fitting - refill capacity 1.2 cu. in.) Servicing at ever 800 hours of operation. Checkup of nozzles. set the injection starting +142 pressure to 1706...

  • Page 30: Transmissions

    HBW TRANSMISSIONS All HBW models turn right hand propellers. All HBW models have their own oil sumps and dipsticks. All HBW models use ATF lubricant. HBW models should shifted into gear swift motion - not allowed to slip in slowly. Control of gearbox - gear box su i table...
  • Page 31 WARNER HYDRAULIC TRANSMISSIONS FROM COOLER (2.10:1 ONLY) DIPSTICK ASSEMBLY SHIFT LEVER SHIFT LEVER FROM 10-13/10-14 FROM COOLER 10-17/10-18 COOLER (EXCEPT 2.10:1) CONTROL LEVER POSITION The position of the control lever on transmission when forward should be shifted to the point where it covers the letter "F" on the case casting, located in its proper position by the poppet...
  • Page 32 FILLING AND CHECKING THE HYDRAULIC SYSTEM The oil level should be maintained at the full mark on the dipstick. Check oil level prior to starting engine. Check daily before starting engine. The hydraulic circuit includes the transmission, oil cooler, cooler lines gauge lines...
  • Page 33 7. COOLING PROBLEMS Water passages inside of the cooler will sometimes become clogged, and this will reduce cooling capacity cause overpressuring. Back flushing cooler will sometimes help flush foreign mater ial from cooler passages. The cooler and hose should be thoroughly flushed or replaced in the event a failure has occurred.
  • Page 34 ROUTINE CHECKS AND MAINTENANCE ANNUAL CHECKS PROPELLER AND OUTPUT SHAFT ALIGNMENT: This check should also be made any time the propeller strikes a heavy object and after any acci- dent where the boat is stopped suddenly. Shaft alignment should also be checked after the boat has been lifted by a hoist or moved on a tr ailer .
  • Page 35 shift lever is positioned so that the spring loaded ball enters the chamfered hole in the side of the shift lever. Connect an oil cooler into the cooler circuit before cranking or starting the engine. various cooler circuits have been used and correct cooler connections...
  • Page 36 WALTER V-DRIVES FLANGE ALIGNMENT - DIRECT COUPLED MODELS Install the propeller shaft flange on to the propeller shaft and tighten the two clamping bolts on the spli t hub (none on CHECK--, RV-10D). A self-locking set screw is pro- rSET SCREW vided propeller shaft...
  • Page 37 to the joint end that is spool adapter. This distance will v~ry with misalignment lERK nTTN:> Since joint bolted and cannot move.) i3lA alignment gauge machined diameter cover and slide it com- 5tpIT INW:!! Al(1)l pletely around. It will ,~<;,["lN£ SCREW 10 AN N.:CLFlAT( M(A"'-"'EMENI indicate how the engine...
  • Page 38 drive train and eliminate many problems that arise due to misalign- ment. Final alignment should not be attempted until the boat has been allowed to "settle" in the water. Adjust the V-drive until the pilot diameters of the gear shaft flange the propeller shaft flange...
  • Page 39 IBO'F, although safe operating temperatures may be as high as 210·F. models equipped with oil circulating pump, the *49 oil pressure drop switch 12 volt *49A warning light should be hooked up per the wir ing diagr am. The swi tch may be grounded to any part of the V-drive or engine (either terminal may be used for...
  • Page 40 OPERATION A pressure drop warning light is mounted instrument panel V-drives equipped with cir- culating pump. The warning light will stay on until the boat gets under way and the engine speed increases to suf- ficient RPM for the pump to maintain pressure.
  • Page 41 The plugs can be checked to see if they are magnetic only after removal. Touch the inside face with a metallic object, such as a screwdriver. Clean them reinstall. Usually, there are four plugs in the bottom part of the main housing. Only two of these are magnetic.

  • Page 42: Troubleshooting

    ENGINE TROUBLESHOOTING REMEDY PROBLEM ENGINE DOES NOT START Starting switch is defective Correct connections and contacts Deficient drive torque of The battery is exhausted, trouble the starter motor with the starter motor, or dirty or loose wiring Improper viscosity of engine Check the viscosity and renew oil if necessary Engine too cold...

  • Page 43: Table Of Tightening Torques

    TORQUE SPECIFICATIONS Kg-m Ib-ft Cylinder head bolts 83.2 90.5 Exhaust side 1l.5 12.5 Intake side 10.0 11.0 72.4 79.6 Main bearing cap 57.9 65.2 Connecting rod bearing caps 36.2 43.4 14.5 Rocker shaft bracket Front plate bolts 5.1 - 10.8 Timing gear cover 5.1 - 10.8 10.8...
  • Page 44 UNLESS OTHERWISE INDICATED pitch kg-m Ib-ft. Grade 4T 6mm bolt/nut 0.4 - 2.9 - 8mm bolt/nut 1. 25 1.0 - 7.2 - 11. 6 10mm bolt/nut 1. 25 1.9 - 22.4 13.7 - 10mm bolt/nut 1.8 - 13.0 - 21. 7 12mm bolt/nut 1.

  • Page 45: Common Parts By Number

    COMMON PARTS BY NUMBER NUMBER REQUIRED DESCRIPTION PART NUMBER PER ENGINE Fuel Hardware Kit, including banjo washers, injector seat washers 34441 Lift Pump Filter & Gasket 30548 Fuel Filter 24363 Lube Oil Filter 35828 Glow Plugs 34380 Sea Water Pump 16423 Sea Water Pump Mounting Gasket 11143...

  • Page 46: Limited Warranty

    Generators, only (whichever occurs first). Remedy Westerbeke will elect to repair or replace free of charge to you any product or part returned to our factory transportation costs prepaid which we adjudge defective in materials or workmanship, Alternatively, we may reimburse at our discretion a portion of labor costs incurred to repair defective parts or products on site.

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