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

15 hp mini-diesel
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TECHNICAL MANUAL AND PARTS LIST
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WESTERBEKE·
- 1-5.
hp.
,.,i.--i-Dies.el
Engine
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:
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M'ODEL
FOUR-60
publication
Numlter 16521
Edition 2
-July
20~O
WESTERBEKECORPORATION
AVON INDUSTRIAL PARK. AVON. MA
02322.
TEL: (61
?j
58fJ..7100

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  • Page 1 TECHNICAL MANUAL AND PARTS LIST WESTERBEKE· ,.,i.--i-Dies.el Engine - 1-5. . . ' . FOUR-60 M'ODEL publication Numlter 16521 Edition 2 20~O -July WESTERBEKECORPORATION AVON INDUSTRIAL PARK. AVON. MA 02322. TEL: (61 58fJ..7100...
  • Page 2 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 3: Table Of Contents

    WESTERBEKE MODEL FOUR- 60 15 h. p. Mini Diesel Engine TABLE OF:' CONTENTS Page No..INTRODUCTION ..' ..PHOTOGRAPHS " INSTALLATION DRAWINGS ......
  • Page 4 LUBRICATION OIL OIL PRESSURE SWITCH ..!!L-~------- FILLER CAP TACH OMETER DRIVE SECONDARY FUEL FILTER BLEED SCREW COLD START SOLENOID FUEL INJECTOR UNION NUT COLD START GLOW PLUG FRESH WATER PUMP SEA WATER PUMP SEA WATER . PUMP DRAIN ADJUSTABLE ~10UNTS FLEX (RemOve after installation) LIFTING...
  • Page 5 ST ARBOARD 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 7: Installation Drawings

    INSTALL}\.TION DRAWINGS 101-- :32.L DIRECT DRiVe: ~ ~ ~.67:1 j o 4 - - - - - 3 7 AND 2:1 RATIO Four-60/SAO Reverse and Reduction Gear ~-------2~'-----~·1 ---' -~3o!-!------' ~-.---' ~'.--~~-.:'::l - .. 1-2;!z.o------ • 3- _ . . _.---- 1--_ _ _ _ _ _ .

  • Page 8: 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 nun.). 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 9 GENERAL DATA-continued Exhaust Inlet Valve mechanism 45° B.B.D.C. Valve opens] with ·020 in. ('508 mm.) valve rocker clear- 5° B.T.D.C. 5° A.T.D.C. Valve closes ance 30° A.B.D.C. 45° Valve seat angle 45° Valve seat face width .. ·075 in. (1·906 mm.) ·075 in.
  • Page 10 Voltage ......12 V. D. C. TRANSMISSIONS Four-60 Gear Options · ..
  • Page 11 INSTALLATION Page No. FOREWORD INSPECTION OF SIllPMENT 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 1.5...

  • Page 12: Installation

    INSTALLATION FOREWORD It 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 precautions to be watched and the relationship of the inst.allation to the operation of the engine.

  • Page 13: Engine Bolts

    ENGINE BOLTS . recQm.meJ}.cj~dJhat Cb.a.ng,~.:.r bolts)~ It is· mch lag bolts preferably of bronze,. be ·1.i~~d ~he enw.!l~· ~uJ).PC?r~~_g ·":L.~g~~crews tM.o:ugh mqunt$;' are less p!-eferred because their hold on the wood is weakene~'every time they are move.d~ whereas the lag bolt stays position and the nuts on top·...

  • Page 14: Engine Cooling System

    1/2 inch for every ten feet of length beyond the first ten. ENGINE COOLING SYSTEM The Westerbeke Four-50 diesel is fresh water cooled, utilizing what is known as a "closed system", wherein the fresh water is circulated by a centrifugal pump...

  • Page 15: Controls

    Throttle Control Fuel Stop Control Idle Stop JI!.' Fig. 2 Fuel Injection Pump Throttle and STOP /RUN Lever Control Positions NOTE: The' fue.l njecti on pump Fuel Stop Control 1 ever shoul d be spr; ng loaded position. to the run CONTROLS used~ If manual SAO transmission is...

  • Page 16: 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. It consists of an audible alarm to indicate either failure, the alarm being part of the key switch panel.
  • Page 17 '"16 START MOTOR & SOLENOID OPTIONAL ENGINE Wiring Diagram with Generator and Skipper Panel Fig. 3 KEY SWITCH PANEL ---;F;--- -------1 . @)WESTERBEKE ALL ELECTRIC PANEL. (WITH ALTERNATOR ONLY) LAMPS ~----~~--~~~ ® START PREHEAT ® L _____________ BATTERY CA8L.E WATER TEMP.

  • Page 18: Starting Aid

    STARTING AID (Fig'. 5) The starting aid on Westerbeke Four- 60 consists of a co'mbustion chamber glow plug preheater 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...

  • Page 19: 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 ~NTENANCESCHEDULE END OF SEASON SERVICE...
  • Page 20 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 SpecificationMIL-L~2104B (API Service CC).

  • Page 21: 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 lubricatin~ oil to the highest mark.

  • Page 22: 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 bl~ed fuel flows from the bleed screw free of air bubbles, tighten the 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 23: To Stop Engine

    Recheck Expansion Tank Water (This applies after'cooling system Level" has been drained or filled for the first 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 24: Cold Weather Precautions

    Do not be alarmed if temperature gauges show a high reading following a sudden stop q.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 25: Ntenanceschedule

    MAINTENANCE SCHEDULE DAILY i~stalled. Check sea water strainer, if one has been 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.
  • Page 26 Drain fresh water cooling system by removing the surge tank pressure petco~k cap and opening the (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 27 SECTION A DIESEL ENGINE Section Camshaft 1\.9 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.IO Lubrication system Oil filter-external .• Oil pressure relief valve Oil pump Oil pump drive Oil strainer...
  • Page 28 >- f+++++++++ •••••• ".IIII.IIIIIII.,II •••• ' •• "1,""'1'1, "'1'" III" 1'11111 ..........,11111.11." ........, •• ,1,.,1 ••••••• ,1,. "'111.1' "'11' ."111.' .,1,"11'.1 •• , •• ,'."."1 •••••••••• ,1 "., ••• ,.11,.'. J " " . THE DmSEL ENGINE EXTERNAL COl\.fPONENTS 3.'(g.
  • Page 29 ..,..-~"''' ' 1 ' 11111111111111111111111 II 111111111111111111111111.11111111111111111.1 II 11111. " " 1 1 . 1 ' " " " •• 11 I " " ' 1 I .1 , , ' " ' • II • II I I' ••• • ••• , ' " ' " I.
  • Page 30 > t'"''''''''''''''''''''''''''''''''''''''''''''''''''''"""""''''''''''''''''''''''''''''''--''''''''''''"""'''''''''''''''''''''''''''''''''''''''''''''-''''"""""""""""""""'"''''''''''''''''''''''"""1 THE ENGINE INTERNAL COMPONENTS 12J\'1~~ \~~m2'~ "8~I.O 22--~ .\~~rIO?~~'~~ ..120. 10.4 .. 21-. ~(!)f~~1i'lf 1J~1:5 .~~'~ I!.O_A~' 1 I 0 i .. 112 .'03 1 / 3 . 117:\IO:~",~ TJ".~:~;i.~~o~~,-,':l.: '~'1'70 IS"-1l.lI[ 102 90 . / ", . 92 l,,;g: ~/ 9.4~~~ ~ ,,~.
  • Page 31 r""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""'" """""""""""""""""""""""""""""""""""""""""""', •.••. u u u • • • • • • u ..THE ENGINE INTERNAL COMPONENTS Description Description Descriptioll Split pin for rocker shaft. 41. Bolt for housing. 81. Camshaft bearing tiner-rear. Plain washer for rocker shaft. 42.
  • Page 32 1111'11 11111 . 1 1 1 1 1 1 1 . 1 1 1 1 1 1 1 1 1 1 ....THE ENGINE (Longitudinal Section) f'"...
  • Page 33 •• 1111111 ..111 ..11111 ..111111.1111 1111111111111""111111 ..11111111111""'111" 1111"11 1'1111111 . f I " I •...
  • Page 34 .1'11 1111'111 , •• 11111 1"11,1 1111111 I I I I I I I I 1 " 1 t I I I 11111 I II I I I I II I 111111', I I I .. I -< : •• , 1111 ••••...

  • Page 35: 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. Oil is passed· through the filter from the pump at a pressure controlled at 50 lb./sq.
  • Page 36 DIESEL ENGINE Inspection (4) Check the relief valve spring against the specifi- cation given in 'GENERAL DATA'. Check the valve seating by appJying engineer;s blue to the conical valve face and testing for continuous marking. If necessary, lap the valve onto the seat, using tool 18G 69.
  • Page 37 DIESEL ENGINE Section A.7 VALVE ROCKER SHAFT AND TAPPETS RemoviDg Valve rocker shaft (1) 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 38 nmSEL ENGINE Dismaniling (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. Remove the spill pipe and clamps from the in- (22) jectors, and .
  • Page 39 DIESEL ENGINE (31) Check the valve stem to guide clearance against the figures given in 'GENERAL DATA'. If new valve guides are fitted, the top face of each guide should in. (15 mm.) above the valve spring seat surface of the cylinder head. (32) Check the valve head stand-down against the figure in 'GENERAL DATA'.
  • Page 40 nmSEL ENGINE the chain tensioner packing block and the injection pump chain wheel hub. (30) Remove the injection pump (Section C.6,.. (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 41 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 42 DIESEL ENGINE Inspection Crankshaft and main bearings (S) Examine the crankshaft oil seal, and renew it if Carry out the procedure in (1) to (8). there is the slightest sign of damage. (10) Remove the engine front plate (Section A.9., (2) to (S), (7) to (19), and (2S) to (28».
  • Page 43 DIESEL ENGINE (9) Remove the rocker shaft and push-rods (Section A.7, (1) to (5) ). (10) Remove the cylinder head (Section A.S, (6) to (9), (11) and (12), (14) and (15), and (17) to (19) ). (11) Unscrew the connecting rod cap bolts, remove the halves~ caps with their bearing and withdraw the...
  • Page 44 DIESEL ENGINE (26) Refit the front axle and radiator by reversing the procedure in Section 0.1, (2) to (7) and Section B.3, (1) to (10). (27) Bleed the fuel system (Section C.S). (28) Refill the hydraulic system (Section M.6). (29) Refill the cooling system (Section B.1, (9) to (11) or Section B.6, (6) to (9) ).
  • Page 45 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, wi:th its plunger contacting the valve spring collar, will facilitate this operation.
  • Page 46 DIESEL ENGINE Fig. A.20 Removing a camshaft liner using tool 18G 124 A and adaptor 18G 124 K. The inset shows the liner being replaced 1. Slotted washer. 2. Slotted washer. 3. 'D' washer. 4. Adaptor 18G 124 K. Fitting new bearing liners Centre bearing liner (15) Insert pilot adaptor 18G 214 K into the front The bearing liners should...
  • Page 47 DIESEL ENGINE Feed the reamer very slowly. Keep the cutters dry and flutes the cutter free of swarf, preferably with air-blast equipment. When half-way through each bearing, withdraw the cutter and remove all swarf from both cutter and bearing liner. When reaming is completed, thoroughly clean all the oil-ways.

  • Page 49: Cooling System

    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 50 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 51 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. Sl~cken the by-pass hose clips Unscrew the four water pump body bolts and withdraw the water pump from the water pump adaptor.
  • Page 52 INSPECTION Check the interference fit of both the pulley hub and the vane on the pump spindle (see GENERAL DATA). If the fit has been destroyed, renew the components. 10. Ensure that the bearing grease retainers are good ·condition. REASSEMBLING 11.
  • Page 53 SECTION C FUEL SYSTEM (DIESEL MODELS) C.IO Altitude settings Filter-main .• CoS' Injection pump Injectors Lift pump •• Maximum and idling speed adjustment ••...
  • Page 54 ~"""II""I'I"'III""I'I""""'II"'I'II'+++++"""""""'++""II ,,"1 I I , I • , I •• I •• , I • I I I I I I •• I I I I • 1+++++++++++++++++++++ " , I , I , , , " , II , , • 11$ ••...
  • Page 55 ..=<---..r.' ....111111111'11, 'I" "111'1'11111"'111'" I •• " " " ' 1 ' , 1"'11'111' ••• ,. " 1 1 " " " " " , •• , .............. ++++++ •••• ,., ••••••• , "...
  • Page 56 OWNERS NOTES...
  • Page 57 FUEL SYSTEM (Diesel Models) Section C.3 FUEL TAP Removing (1) . Turn the fuel tap off. Fig. C.4 (2) Disc9nnect 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 58 FUEL SYSTEM (Diesel Models) Section C.S MAIN FUEL FILTER Removing, (1) Disconnect the fuel pipes from the filter head. (2) 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 59 FUEL SYSTEM (Diesel Models) (S) Press the throttle shaft downwards and withdraw (see Fig. C.7). Remove the drive plate and top adjusting plate, and withdraw the rollers and shoes the control cover complete with shut-off shaft. from the pumping and distributing rotor. Discard theco'ntrol cover gasket.
  • Page 60 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 61 FUEL SYSTEM (Diesel Models) Fig. C.10 Assemble the top adjusting plate and the drive plate periph~ries with the slots in their aligned with the Fig. C.ll scribed mark on the pumping end of rotor Tightening the transfer pump rotor, using torque wrench 180536 and tools 180659' and 18G 634 housing.
  • Page 62 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 18G 634, tighten the transfer pump rotor to the torque figure given in 'GENERAL DATA' (see Fig.
  • Page 63 FUEL SYSTEM (Diesel Models) Testing and adjusting (75) The following precautions must be observed 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 64: Fuel System

    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 3! 41°. Test6-Back-kakage 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 65 FUEL SYSTEM (Diesel Models) adjustment replace the cover-plate and prime the pump as described in (S2). Re-check the fuel delivery and, if necessary, re-adjust the pump output. Test 8-Maximum fuel 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 66 FUEL SYSTEM (Diesel Models) Fig. C.20 Clearing the pintle orifice Fig. C.21 Cleaning the annular chamber Fig. C.19 Checking the position of the injection timing pump Clean all carbon from the nozzle valve and the pointer, using timing gauge 18G 1052 outside of the body with the brass ..
  • Page 67 FUEL SYSTEM (Diesel Models) Fig. C.23 Cleaning the nozzle seat ~C!-=----2 ·4 Fig. C.24 - - 5 _ _ _ _ 1'11111 Clearing the auxi- [iary spray hole ~----6 ~ses. (14) In where the ca.rbon deposit is particularly hard, it can besoftened by boiling the nozzle bodies in a caustic solution: Dissolve 2 oz.
  • Page 68 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 Reversellushing an injector lzozz1e with testing hole and the nozzle will· be useless. machine 18G 109 A and adaptor 18G 109 E.
  • Page 69 FUEL SYSTEM (Diesel Models) (29) After refacjng, 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 lapping the guide surface of the valve.
  • Page 70 FUEL SYSTEM (Diesel Models) (1) Ensure that the stop control is fully home in the Refitting run position and remove the sealing cap from the (44) Reverse the procedure in (1) to (3), noting the maximum speed stop screw. following: (a) Renew both sealing washers on each injector.
  • Page 71 SAO TRANSMISSION Page No. DESCRIPTION OPERATION TROUBLE SHOOTING DISASSEMBLY OF SAO TRANSMISSION REMOVAL OF REDUCTION GEAR ASSEMBLY FROM REVERSE GEAR HOUSING IF INSTALLED " " REMOVAL OF REVERS.E GEAR·HOUSING ASSEMBLY FROM ENGINE. 51 . REMOVAL OF GEAR CASE ASSEMBLY FROM REV'ERSE GEAR HOUSING DISASSEMBLY OF GEAR CASE INSPECTION...

  • Page 72: 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 On the forward drive.. the reverse gear case and multiple disc clutch are loc.ked together as a solid coupling.
  • Page 73 TROUBLE SHOOTING CH,ARTS Ch art GEAR D~AGGING DRIVE SHAFT ROTATES EITHER FORWARD OR REVERSE WITH SHIFT LEVER IN NEUTRAL Check For DEFECTIVE FORWARD CLUTCH PLATES 3 .. BINDING IN PLANET ASSEMBLY 4. OVER ADJUSTMENT ON 2. REVERSE BAND ENGAGING GEAR CASE FORWARD AND REVERSE ------------------------------REMEDy------------------------------- b.

  • Page 74: Removal Of Reduction Gear Assembly From Reverse Gear Housing If Installed

    TROUBLE SHOOTING CHART hart GEAR riVE INOPERA DRIVE SHAFT OOES NOT ROT ATE WITH SHIFT LEVER IN FORWARD OR REVERSE Cht:ck For 1. FAILURE OF PLANETARY ASSEMBLY 4. REVERSE SAND NOr ENGAGING GEAR CASE 2. FAILURE OF REDUCTION GEAR 5. SROK EN OUTPUT SHAFT 3 ..
  • Page 75 / ..-J ..o· --~'fl' \I 1581 t::::i A IJ.:lJ 1V::&Ul4V'lln"~. fl'--.. '-- ___ :;:0 ..::::s .."'ZM~~"qy .. "V \1 'If"~W 42---- t)it ""1 ::::s r.-sT~ "" • ..• • • :z> ;.JU •...
  • Page 76 CI'I .."~ l2~ta/19 0) FW(6-i w",rr,l2.'s DI~«r L)II21;-£ ".~ "Y" D"'~ECr O~/V£ /:WIll''' SAOD /"=-..., , ....-.-,...

  • Page 77: Removal Of Reverse Gear Housing Assembly From Engine

    REMOVAL OF REVERSE GEAR HOUSING ASSEMBLY FROM ENGINE Remove capscrews and lockwashers that secure reverse gear housing (3) to front end plate (5). Slide entire revers e gear 'housing ( straight back approximately inches until housing is clear of front plate engine gear and lift reverse gear (1 ) housing assembly clear of front plate...

  • Page 78: Disassembly Of Gear Case

    11. Remoye caps crews and lockwashers that secure reduction ada :>ter plate (85) to reverse gear housing (3). Remove reduction adapter plate with attached bearing (88) and reduc- tion drive gear (87). Press bearing with drive gear from adapter plate. Press bearing from drive gear.

  • Page 79: Inspection

    INSPECTION All parts should be thoroughly cleaned before inspection. Parts showing excessive wear should be replaced. Ball and roller bearings should be examined for indication of. corrosion and pitting on balls or ro.!.lers and races. Long and short pinion bushings should be examined for wear. Pinion shafts should be examined for wear o;r "brinelling".
  • Page 80 Insert plnlon shaft (42) plain end first, into unthreaded end of gear case and push through pinion as far as rear wall of gear case, forcing out the dummy shaft. Remove dummy shaft, and start pinion shaft into rear wall of case. ~haft Do not drive pinion all the way into gear case until all shafts...

  • Page 81: Assembly Of Reverse Gear Case In Reverse Gear Housing

    CAUTION: The forward clutch is not properly adjusted at the end of this assembly. Proper adjustment is made after installation in boat is complete. Follow instruc- tions as outlined under section on adjustments. ASSEMBL Y OF REVERSE GEAR CASE IN REVERSE GEAR HOUSING REDUCTION MODEL Place new gaskets (8), (7), .and (4) on front, rear, and top of reverse gear housing (3).

  • Page 82: Assemble Transl\Llssion To Engine

    washer and install Woodruff key (27) in keyway in tailshaft. replacement~ 23. If removed for press new oil seal (21) into direct drive plate (15). Press ball bearing (25) into direct drive plate. 24. Place direct drive plate. oil seal and ball bearing assembly on suitable support and press gear half coupling (14) into oil seal (21) and ball bear- ing (25) until gear half coupling is seated against ball bearing.

  • Page 83: Adjustments

    ADJUSTMENTS secu~ed lin~s" With the transmission to the engrne, replace all water etc. Howev~r, "db not connect the shifting :linkage until all' of the adjustrhents· have been made and are satisfactorily tested.' After securing the propellerhaIf coupling to the gear half coupling, c:heck the alignment.
  • Page 84 the forward drive, a full step of adjustment is as outlined above or is z.nade by loosening the locks crew (55) and rotating the screw collar to the right until (53) next hole in the pressure plate (49) can be lined up under the lockscrew. A half a step is made by taking the locks crew out of the hole that it .is in .and placing it in the hole adjoining it in the screw collar.

  • Page 85: Reduction Unit

    REDUCTION' GEARS DESCRIPTION The Westerbeke / Paragon reduction gears consist of an internal ring gear and a drive gear that offers a variety of reduction ratios. ADJUSTMENTS There are no adjustments necessary to maintain the reduction gears in proper rurming condition.
  • Page 86 If removed for replacementJ press new oil seal (79) into reduction gear housing. Place flanged shaft over ring gear (71) and line' up holes in flange with those in ring gear. Place lockwasher over caps crew and insert capscrew into hole in flanged shaft and secure flanged shaft to ring gear.
  • Page 87 Model SS Transmissions are made for both'i"ightand left handed engines. As fitted to model Four-60 Diesel Model SSL is used. It is suited to a left hand engine and turns a right hand propeller. It is available in two ratios.: ModelSSL - 13 (1.3 : I Ratio)
  • Page 88 Drain oil from reverse gear housing. DISASSEMBLY PROCEDURES Remove waterpump (54). - Not applicable on Iv\odel Four-60 Remove Woodruff key from reverse gear engine shaft. ' \ \ Remove four capscrews securing front end plate (1) to housing"...
  • Page 89 •• t.{) «...
  • Page 91 PARTS LIST...
  • Page 92 (not feet or yards). 2. Start looking in the contents ... - if you cannot find any item, check miscellan- eous page. 3. Please -- Report errors and omissions to us via speed letter. (Attention: John H. Westerbeke, Jr.)
  • Page 93 MODEL FOUR-60 CONTENTS Block (Internal) Block (External) Crankshaft ... Camshaft- Rod Injection Pump Drive System Cylinder Head Rocker Shaft - Valve Cover . 210 Lube Oil Pump - Strainer - Filter Lube Oil Sump Fresh Water Pump Cooling System Fuel System El ectri;ta 1 Sys tern...

  • Page 94: Block (Internal)

    BLOCK (INTERNAL) FOUR 60: \ : . .

  • Page 95: Block (External)

    FOUR OCK .( NTt::RNAL.) NAME Rt.MARKS ENGINE 12991 LlSS FLYWHEEl/BACKPLATE/SUMP/MANIFOLUS 15452 BLOCK A SSE.t-1Bl Y 15J92 8UL T BEARING tvtAIN 15489 LOCKWASHER 15J36 DOWEL. MAIN BEARING CAP LIN[R 15451 CAMSHAF'T BEARING ~'4~5J CORE-PLUG PLUG 8· 14~~;' CHANKCASE OIL GAL~tRY PLUG 15481 OIL.
  • Page 96 FOUR 60: BLOC/( ( EXTERNAL)
  • Page 97 (EXTE..RNAL> FOUR 601 BL.OCK NAME. Rt.MARKS 15J9(O COVER 14~43 S~AL. [) I L, 15.s49 OAHPER INJECTION PUMP QRIVl CHAIN STUD 15196 DAMPER 15.s50 LOC~WASHER INDICATOR 15J51 TiMING DAMPER 15410 CAMSHAFT DRIVE CHAIN LOCKWASHER 154"'l GASKET 15.s91 TIMING COVEH TO fRONT Pl..A1E 13~26 CoOVER...
  • Page 98 FOUR 60: CRANKSHAFT - CAMSHAFT - .... Ilmlil 4S 43 46--11 ..(j~)

  • Page 99: Crankshaft

    FOUR CRANKSHAfT .. CAMSHAFT 61/1' P!'.! Rf.MARKS NAME: 15,j CYLINUEHS 2 & 15J45 CYl..INDERS & 3 15.543 BUSHING 15Jl1 BOLT 15J44 WASHER 15447 BEARING 6"1 CONNECTING ROD STANDARD 15448 BEARING CONNECTING ROO '~10" CRANKSHAF'T 15J32 PLUG 1544"" 9"'1 1544~ Ri:,;ARING MAIN ST'ANUARD 15446...
  • Page 100 FOUR 60: INJECTION PUMP DRIVE SYSTEM "-- .,..
  • Page 101 tOUR 60: JNJECTION PUMP URIVE SYSTEM NAME Rt.MARKS 15J6'" BOLT 15J61 15J62 HUB TO fROMT PLATE GASKET GEAR 1536J INJECTION PUMP ORIV~ BUSHING 15436 PLATE 15364 TWO HALVES 1536!'J F"LANGE RING 15429 RETAINING 15366 CHAIN INJECTION PUMP DRIVE 15J98 L.1NE OIL - TENSrONER BOLT BANJO...
  • Page 102 FOUR 60: CYLINDER HEAD • ____ 20 <s>---- 17"i 16"1 eY'4 ~-~- -~--~---~--~---~--~~~~-- 361/...

  • Page 103: Cylinder Head

    F"OOk 00: CYLINOE.H HEAD 1'">J1t" Hi:.AU ASS~MBLY I~CLUOING VALVl GUIDES GUlDr l';Jltj INLlT VALVE - STANDARD GUIDE l"'j?!l1 I~LET VALVE - ,010" DIS .. 1 rXHAtlST VALVE .,. srA~DAHD 1?j11 GUIOE:: lC)..sl~ GUIlJF ~ .~10" EXHAUST VALVE 1443j PLUG 14~QI PLlft;...
  • Page 104 ROC~ER ~HAFT FOUR 60: - VALVE COVER .._- -._---- --- ....13-~ • I~~~ ·210...
  • Page 105 FOUR ROCKER SHAFT VALVE COYER NAME R~MARKS 15.s04 SHAFT ROCKER 14~5~ PLAIN PL.UG 14()46 PLUG THREADED BRACKET 1 PlR ENGIN:; 15461 TAPPt;O 15459 BRACKET 2 PER ENGIN~ - PLAIN 5 ... 2 BRACKET WITH ENGIN~ 15461d 011. H.OLE 1 PER SPRING 15487 154(11...

  • Page 106: Lube Oil Pump - Strainer - Filter

    FOUR 60: LUBE OIL PUMP - STRAINER - FILTER . 27 ----_. 15----...
  • Page 107 rOUR 60: FILTER l.UBE OIL. PUMP • STRAINER • NAME RlMARKS 15J39 PUMP GASKET 15J40 PUMP TO CRANKCASE SHAFT 15404 1540~ HOUSING TACHOMETER DRIVE SHAFT GASKET 15J41 15406 SE.AL 14~5(Q VALVE OIl.. REL.IEF SPRING 14'49 14008 14!)2e WASHER COPPER 15.s12 STRAINER 15J56 TU8E...

  • Page 108: Lube Oil Sump

    FOUR 60: LUBE OIL SUMP (t---s...
  • Page 109 LUBE rOUR 011. SUMP NAME RlMARKS 151D84 SUMP 15462 PLUG DRAIN WASHER 14453 15JS7 DIPSTICK 15421 BUSHING GASKET 1545~ SUMP TO BLOCK RING 15499 TUSE 15435 DIPSTICK 15386 SI:.AL OIL • SUMP TO F"RONT MAIN BEARING STUD 15433...
  • Page 110 FOUR 60: FRESH WATER PUMP L _ _ _ _ _ _ _ _ _...

  • Page 111: Fresh Water Pump

    fOUR 60' PUMP f'RESH WATER NAME pt\1 RE.MAqKS PUMP 15409 FRESH WATER .. COMPLETE IMPELLER 15379 15463 SEAL. 15415 BEARING WIRE 15J13 BEAHING t,.OCATING SCREW 15<497 LUBRICAT10N POINT 15484 ~IASHER FIBRE 15J80 WATER PUMp.~ULlEY ADAPTER 15383 THEHMQSTAT BYPASS WASHER 15422 ADAPTER 15414 WATER PUMP TO BLOCK...
  • Page 112 '<1 §5 <:> .:!C /'"--~ DWG No.I5714 --'~...
  • Page 113 tOUR SYSTEM CUQl.ING NAME RI;.MARKS EXCHANGER 15rt355 CL.,AMP 11~~5 CLAMP 114@5 HOS£. 11179· ~OSE 11~54 NIPP~E HOSt::: 16434 ELBOW NIPPLE 13554 FL..ANGE 15~57 . EXHAUST 12~72 STUD EXHAUST F"I.,ANGE GASKET 15"'58 EXHAUST FLANGE 16433 PLUG 11928 STUD MANIFO~D PLATE 15(094 PLATE MANIFOLD ENO 15(096...
  • Page 114 "TI -< :s:: DRAWING NO.l57l3 //~..
  • Page 115 tOUR SYSTEM CUQ\..ING NAME RI;.MARKS EXCHANGER 15rtl55 11!)05 CL.AMP CL.AMP 1+.405 HOS~ 11179 HOSE NIPPLE 11254 HOSt: ELBOW 16434 NIPPLE 13554 F'L.;ANGE EXHAUST 15k357 STUD 12~72 EXHAUST F~ANGE 1511J58 GASKET EXHAUST FLANGE 16433 PLUG ~TUD 11926 MANIFOLD ENO PLATE PL.ATE 15"9~ MANIFOLD END GASKET...
  • Page 116 " "T1 -< DRAWING NO.l5713 ,/A'-'-:C.--...,., /~=-...
  • Page 117 of!: FOUR SYSTEM rUE~ NAME RI:.MARKS LINE. 15370 ~JJECTOR LINE . 15S71 INJECTOR 15J72 L 1 f\!E #3 I NJECT.OR 15J73 l~~E INJECTOR 14492 CLAMP 1449~ BUSHING 14548 NO~tLE. INJI=..CTOR INJECTOR 15393 COMPLETE ASHER 14463 HI:.AT SHIELD 15480 RI:.TURN .. PLASTIC 14462 SHIELD HE-AT...
  • Page 118 FOUR 60: ELECTRICAL SYSTEM ~Y_ S!!I!5-!! .!.~-'=- ______ ., WESTERBEKE SKIPPER PANEL "0 ®. START . . --~AMP~----~ GROUND ·'6 "6 'Ie. L _________ ._ ·'6 "' f > O'L. PRESS. SENDER WATER TEMP. SENDER '.It'O'L. ·'6 ·'6 PRE$$. START MOTOR SOL.ENO'D...
  • Page 119 FOUR 60: ELECTRICAL SYSTEM REF' RE.MARKS 11931 AM"1ETER 00 • ELECTRIC PANEL 3/8" AMMETER 16~50 EL~CTRIC 00 - PANEL 1/32" 11917 TACHOMETER ELECTRIC PANEL 2,..2 16~56 TACH CABLE 3/~"-27 T~I TH~EAO 4' - FOR TACH DRIVE 2 .. 3 16457 TACH CABLE TPI TACH DRIVE THREAO 6' - FOR...
  • Page 120 ELECTRICAL SYSTEM FOUR 60: ® ~Y_~I!.f!:!..!:~E.!::... _ _ _ _ _ _ , WESTERBEKE :'1<lPPER PANE:L , START "--~AMP~----~ COROUND "16 ",6 'If> 0'1. PRESS. SENDER 'HATER TEMP. SENDER 111011. ·'6 ~E> PRESS. START "'OTOR 6. SOLENOID ENGINE OPTIONAL 13706...
  • Page 121 E.LECTRICAL SYSTEM FOUR 61t REMARKS NAME RE.F PULLEY 1~789 G£N£RATOR 25-4 15425 WASHER GENERATOR PULLEY 15~75 1~789 25-~ 13789 GEN£A.ATOR TO ADJUSTING 'STRAP 15~77 STl'D 25-6 25-7 15~7·6 1"789 GENERATOR MOU"NTING B'H-ACKET 15472 25-R SELT 13789.·CENERATOR· REGULATOR 1379Z 13789 "GENERATQR VOL"T"...
  • Page 122 FOUR 60: MOUNTS ..

  • Page 123: Mounts

    FOUR MOUNTS RlMARKS NAME MOUNT fRONT LEfT 15~6~ ~IGHT & REAR LEFT RIGHT - SIDE HOUSING PAD 12275 MOUNT MOUNT & 16~4~· REAR LEFT RIGHT FOR TyPE SS TRA~SMISSION USED WITH ALL MOUNTS 11687 ISO~ATQR...
  • Page 124 FOUR 60: BACK END ARRANGEMENTS DRAWING NO.15712...

  • Page 125: Back End Arrangements

    FOUR BACK ENO ARRANGEMENT NAME Rt.MARKS VWHf..EI. RING GEAR 15"8'" EXCl,..UDES LOCKWASHER 1533ij FLYWHEEL BOLT 15494 BOLT FLYWHEEL. TO CR.ANKSHAfT 151064 DAMPER TYPESA0 TRANSMISSION 4 .. 2 DAMPER 16024 FREEWHEELING SAILING TRANSMISSION 15109ra HOUSING TYPESA0TRANSMISSION 5t1!12 HOUSING 16399 SAILl~G FHEEWHEELING TRANSMISSION 5 ..
  • Page 126 -< I /,) /,-1 ):» lYh1tlJ ,--, ill \~I~ ):» ~IYJ ..18-1 ..p-,~,>f' ~'.:I~. O/l~£C roR w,;tTER.'S 11/1'" t')II!lYe DRIVe DIRECT D.Ie/VE S,tfJOD :;:a » ../--.,...
  • Page 127 /r----. G> ..-< ""0 .." » ~I//~' ::s:: 57~~!~ ..
  • Page 128 TRANSMISSION TYPE NAME tiEF REMARKS Gt::AR 14ts94 ENGINE TAILSHAFT 14857 RI:.VE..RSE GEAR TAILSHAFT 14858 REVERSE GEA~ 14ts99 TAILSHAFT 1 4 H91 HOUSING RlVt:,:RSE GEAH GASKET 14868 HANO HOLE COVER PLATE 14ti92 FRONT END RING 14J73 RETAINING REVERSE GEA~ HOUSING GASKET 1489J REVERSE GEAH HOUSING ..
  • Page 129 TYPE SA" TRANSMISSION NAME Rt:,MARKS RING 14674 RETAINING • PINION SHArT GEAR CASE. BEARING 1457"1 GEAR CASE BALL - 14J73 RING RETAINING - GEAR CASE BALL BEARING 14881 BEARING BALL PILOT 14644 WOOORUrr - REYERSE GEAR .., TAILSHAFT BAND B~AKE 85"...
  • Page 130 FREEWHEELING SAILING GEAR - MANUAL - 1.9:1 DRAWING NO .. 13893 '"...
  • Page 131 F'REE WHEELING SAILING GEAR MANUAL - 1,911 II!! NAME REMARKS ADAPTER 14~12 PLUG 14211 14172 PL,UG GASKET 14205 PL.UG 1417[(1 6 .. 1 COUPLING 11645 80Rt:.O 1" COUPL I t,IG OTHt:.R THAN 1" BURl"" SPECIFY 13974 BOLT 14228 COVER 14177 GASKET 14178 BOLT...
  • Page 132 FREEWHEELING SAILING GEAR - MANUAL - 1.9:1. ~---fj,'C 1 1 / 1 - - - - : 0 ;:::----1 DRAWING NO.-13893...
  • Page 133 rRE£ WHEELING SAILING GEAR - MANUAL 1.911 NAME REMARKS 14c20 0 RING COVER 14195 rl..ANGE 1419b . SEAL 1420~ 14191 GASKET BOLT 14222 1419~ HOUSING 14197 GASKET BOLT 14219 14c3~ 1 4 218 BOLT 1423~ 14188 141S9 SLEEVE SPRING 14191 14-1.71 BOLT 14224...
  • Page 134 TYPE SSR AND SSL MANUAL TRANSMISSION <t:...
  • Page 135 TY~E S5R COS ENGINE) & SSL (4~6~ ENGINE) TRANSMISSION NAME. REMARKS 1 ..1 l4Y9~ HOUSING HOUSING & PLATE A~SY ENGIN~ 1 .. 2 16~10 HOUSING HOUSING & PLATE ASSY - FOUR 60 ~NGINE 14993 GASKET 1499k1 ALIGNMENT CAPSCREW l4999 POINT PLUG 13341...
  • Page 136 TYPE SSR AND SSL MANUAL TRANSMISSION ?tln...
  • Page 137 TYPE SSR (OS ENGINE) & SSL (4~60 ENGINE) T~~NSHISSION NAME RlMARKS SPRING INDEX I·NG SEGMENT 14979 GUIDE INDEXING - SEGMENT 14Y9k' SEGMENT INDEXING 14971 NAMEPLATE DRIVE SCREW 16119 IULER SHAFT 14994 CLUTCH 14995 SHOE. NAMEPLATE 16428 REPLACEMENT~_ 16b62 54-1 IMPELLER Not applicable 54.2 16b6J...
  • Page 138 FOUR 60: RAW WATER PUMP DWG NO. 11197...

  • Page 139: Raw Water Pump

    RAW WATER PUMP F0UR NAME REMARKS 80DY 17557 PUMP REBUILD 17561 C0VER 17558 17559 SHAFT IMPELLER 17556 17555 SEAL TW0 REQUIRED 17552 RETAINING RING 17550 GASKET C0VER 17560 SCREW C0VER - FIVE REQUIRED 17551 PLUG 17554 GREASE CUP 17553...

  • Page 140: Miscellaneous

    F'OlJR MISCELLANEOUS NAME Rf.MARKS ALTERNATOR DRIVING Bt:.LT 13859 GASKET UPPER 15457 GASKET 15456 LOWER SPARE PARTS ' A ' 16b51t1 16651 SPARE PARTS ' B ' PAINT 13758 Rf.D - AEROSOL CAN PUMP 11,92 LUBE OIl. SUMP TURING 13ti26 SUMP PUMP TO DIPSTICK TUBE...

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