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Westerbeke 50 Technical Manual

Westerbeke 50 Technical Manual

Marine diesel engine
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TECHNICAL MANUAL
WESTERBEKE 50
Marine Diesel Engine
Publication #23156
Edition Two
January 1981
~r-.v-
'WESTERBEKE
WESTERBEKECORPORATION
~
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319

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  • Page 1 TECHNICAL MANUAL WESTERBEKE 50 Marine Diesel Engine Publication #23156 Edition Two January 1981 ~r-.v- 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 2 TECHNICAL MANUAL WESTERBEKE 50 Marine Diesel Engine Publication #23156 Edition Two January 1981 ~r-.v- 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 4 "will fit" parts are frequently not made to the same specifications as original equipment. GENERATOR SETS Westerbeke diesels are used for both the propulsion of boats and for generating electrical power. For generator set applications, all...
  • Page 5 YOUR NOTES...
  • Page 6 This is your protection against loss or damage. Claims for loss or damage must be made to the-carrier, not to H. Westerbeke Corporation. RIGGING AND LIFTING The engine is fitted with lifting rings. Rope chain...
  • Page 7 When possible, follow bed design "A" and avoid bed design liB". PROPELLER COUPLING Each Westerbeke Diesel engine is regularly fitted with a suitable coupling connecting the propeller shaft to the engine.
  • Page 8 The coupling must not only transmit the power of the engine to turn the shaft, but must also transmit the thrust either ahead or astern from the shaft to the thrust bear ing which is built into the reduction gear housing of the engine. This coupling is very carefully machined for accurate fit.
  • Page 9 accomplished. Take pLenty time making this alignment satisfied with anything less than perfect results. The alignment is correct when the shaft can be slipped backward and forward into the counter bore very easily when feeler gauge indicates that the flanges come exactly together at all points.
  • Page 10 10 feet. Most exhaust systems today use a water lift type muffler such as the Westerbeke "Hydro-Hush". In most installations there is a dry, insulated high loop after the engine manifold and before the muffler to prevent water flowing backwards into the engine during cranking.
  • Page 11 Checking The Back Pressure Exhaust pipe flange Exhaust line Transparent plastic hose, partly filled with water. Measurement "A" may not exceed 39" for normally asperated engines and 19.5" for turbo-charged engines. WATER CONNECTIONS Seacocks and strainers should be of the full flow type at least one size greater than the inlet thread of the sea water pump.
  • Page 12 ELECTRIC PANEL The Westerbeke all-electric panel utilizes an electronic tacho- meter wi th a built-in hourmeter. Tachometer cables are no longer required, except for the Skipper mechanical panel.
  • Page 13 at engine and transmission must be securely mounted. After linkages are completed, check the installation for full travel, making sure that, when the transmission control lever at the pilot station is in forward, neutral and reverse, the control lever on the transmission on the respective detent.
  • Page 14 If the engine is equipped with a V-drive, fill to the full mark on the dipstick with the recommended lubricant specified on the data tag on the V-drive housing. Fill fresh water cooling system with a 50-50 antifreeze solu- tion only after opening all petcocks and plugs until all entrapped air is expelled.
  • Page 15 The above procedures are basic for all initial engine start-ups or for restarting engines stopping due to lack of fuel. WESTERBEKE W7 AND WPD4 GENERATOR (3600 RPM) (Figure 1) with the use of a 5/16 box wrench or common screw driver, open the...
  • Page 16 Stop cranking and tighten the nut and proceed with normal starting procedures. WESTERBEKE W13, 4.4KW, W21, 7.7KW, W27, 11.lKW, W33, 12.5KW (Figure 6) These units are self-bleeding. Turn the ignition to the ON position and wait 15--20 seconds.
  • Page 17 Figure Figure 3 Figure 7 Figure 4 Typical Mechanical Fuel Figure 5 Lift pump...
  • Page 18 Check the seacock and ensure that it is open. STARTING THE ENGINE (COLD) Most Westerbeke marine diesel engines equipped with cold starting aid to ease in the starting of your engine when cold.
  • Page 19 If your engine will not start, then have a qualified Westerbeke'marine mechanic check your engine. WHEN ENGINE STARTS Check for normal oil presure immediately upon engine starting. not continue to run engine if oil pressure is not present within IS seconds of starting the engine.
  • Page 20 engine idle speed when Reverse Operation. Always reduce engaged, shifting gears. However, when the transmission is will carry full engine load. NOTE: The SAO transmission requires that when backing down, the shift lever must be held in the reverse position, since it has no positive overcenter locking mechanism.
  • Page 21 alarmed temperature gauges show high reading following a sudden stop after 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 High temperature reading after a stop does not necessar ily signal alarm against restarting.
  • Page 22 TEN MUST RULES IMPORTANT IMPORTANT IMPORTANT ••• for your safety and your engine's dependability. ALWAYS - Keep this Manual handy and read it whenever in doubt. Use only filtered fuel oil and check lube oil level daily. Check cooling water temperature frequently to make sure it is 190·...
  • Page 23 MAINTENANCE PERIODIC ATTENTION: After you have taken delivery of your engine, it is important that you make the following checks right after the first fifty hours of its operation. Note: Transmissions generally require fluid change after first 25 to 30 hours of operation. Refer to the Transmission section of this manual for details.
  • Page 24 CAUTION: The use of different brands of lubricating oils during oil changes has been known to cause extensive oil sludging and may in many instances cause complete oil starvation. Start engine and run for 3 or 4 minutes. Stop engine and check oil filter gasket for leaks.
  • Page 25 storing the battery, the battery terminals and cable connectors should be treated to prevent corrosion. Recharge battery every 30 days. 15. Check alignment.
  • Page 26 LUBRICATING OILS Lubricating oils 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 tem- peratures. These oils meet requirements Ordnance Specifications MIL-L-2l04B (API Service CC).
  • Page 27 YOUR NOTES...
  • Page 28 Additional operating characteristics are included in the Operation Section of this manual. Any replacements should be made only with genuine Westerbeke parts.
  • Page 29 GENERAL SPECIFICATION DATA ENGINE - Diesel 1.8 litre 18V----D Type . . • • ....Number of cylinders .•..•..Bore ..• ' ....3.16 in (80.26 mm) 3.5 in (88.9 mm) Stroke .
  • Page 30 Camshaft Journal diameteIS: Front ..1.78875 to 1.78925 in (45.43 to 45.44 mm) Centre ..•..1.72875 to 1.72925 in (43.91 to 43.93 mm) Rear •..1.62275 to 1.62325 in (41.22 to 41.23 mm) Bearing liner inside diameter (reamed after fitting): Front.·...
  • Page 31 Alternator pulley nut ....Thermal transmitter ....TRANSMISSIONS Type SAO Westerbeke/Paragon Manual Type SAOV with RVIOS Vee Drive Short Profile Sailing Gear...
  • Page 32 FUEL INJECTION PUMP HUB OIL PUMP DRIVE SHAFT Remove and refit 12.10.26 Remove and refit 12.10.30 Oil pump 12.60.26 Fuel injection pump gear I to 5 and 12 to 18 12.10.25 Removing "'A' Removing Drain the sump. Remove timing chain, Disconnect the oil cooler pipe from 12.65.14.
  • Page 33 17 Lift off the front mounting plate, IBGI24F I 2 Lay the engine on its side with the complete with injection pump, front cylinder head slightly downwards. mounting brackets, chain tensioner 13 Withdraw the dipstick. stop-pin, and chain tensioner shoe. 14 Remove the sump.
  • Page 34 Fit the camshaft gear, timing chain, 49 Fit the camshaft. and timing gear cover, see 12.65.12. 50 Fit the connecting rod and piston Tighten the main bearing bolts to NOTE: Do not leave the crankshaft Tighten the rocker bracket nuts...
  • Page 35 Run the engine for a minimum of Refitting Tighten the oil seal retainer bolts I 5 mins and on return Reverse the procedure in 8 to 12, to 20 Ibf ft (2.8 kgf m, 27 Nm). Tighten the flywheel bolts to 40 slacken cylinder head...
  • Page 36 ~r1I'· CONNECTING RODS AND CRANKSHAFT REAR SEAL PISTONS Remove and refit 12.21.20 Gearbox adaptor plate 12.53.03 Overhaul 12.17.10 Flywheel I to 8 and IS 12.53.07 Connecting rods 1 to 5 and 10 to 12 Pistons 1 to 9 and 12 O;=II~~ Service tools: ISG 134, ISG 134 CQ, ISG IIOS...
  • Page 37 » CRANKSHAFT END-FWAT Check and adjust 12.21.26 Check the crankshaft end-float using a dial gauge against the crankshaft pulley bolt. If end-float is outside the limits given in DATA, change the thrust washers as described in the following paragraphs. Drain the sump. Release thtl.
  • Page 38 OIL PUMP 20 Remove the oil pump and its drive 32 Fit the oil pump and its drive shaft, shaft. tightening the retaining nuts to 161bf Overhaul 12.60.32 ft (2.2 kgf m, 22 Nm). Remove the big-end bearing caps and bearing halves.
  • Page 39 -0'005 :"g:r: connected, ensure that the stop (80.19 control has sufficient travel 1.75 in (44.45 mm) Bleed the fuel system, see 19.50.07. D. 0.75 in (19 mm) 34 in B.S. W. thread Pressing-in F. 3.625 in (92.07 mm) pilot: G.3.312in(84.14mm) , 0'000 3.133...
  • Page 40 12.29.48. Remove the cylinder head nuts. Bleed fuel system, Lift off the cylinder head. 19.50.05. NOTE: The combustion chamber Apply Loctite to the bottom of inserts may drop out of the cylinder the dipstick tube: I;g) head as it is lifted;...
  • Page 41 ..18G 167 A Glaze breaker for CYLINDER HEAD exhaust seats. \'J{) Overhaul 12.29.19 18G 167 Cutter for exhaust seats. 18G 167 B Top narrowing cutter Service tools: 18G 27, 18G 29, 18G 45, for exhaust seats. 18G 167, 18G 167 A, 18G 167 B, 18G 167 18G 167 C Bottom narrowing C, 18G 174, 18G 1741\, 18G 174 B, 18G cutter for exhaust...
  • Page 42 Refitting VALVE CLEARANCE Reverse the procedure in I to 6, Check and adjust 12.29.48 noting: Checking Tighten the cylinder head nuts to Remove the rocker cover ana gasket. 75 Ibfft (10.4 kgf m, 102 Nm) in . the sequence shown, using tool Check, and if necessary adjust, the be...j clearance between the rocker arms and...
  • Page 43 15.5 to 16.51bf (7.0 to 7.4 kgf, 69 to 73 N) 22,29 to 41, and 43 to 47 12.65.14 in x I % in (44.5 mm) long 1\ in x 2 in (50 mm) long Service tools: 18G 98 A, 18G 134, 18G l'lOTE: An '0' ring fitted on this 134 BD 'bolt.
  • Page 44 Bolt size idler gear (without its hub) in position ·rw in x I in (44.5 mm) long -A. in x 2 in (50 mm) long on the chain. 25 Adjust the position of the chain, NOTE: An '0' ring fitted on this...
  • Page 45 35 Progressively tighten the three nuts to from the rear. " pull the injection pump fully into position, ensuring that the timing marks on the pump and drive flange are aligned. Reverse the procedure in I to 10 37 Bleed the fuel system, see 19.50.07.
  • Page 46 Remove the lift pump and gasket. Refitting Reverse the proced ure in I to 5. Bleed the fuel system, se.e 19.50.07. LIFT PUMP Overhaul 19.45.16 DismantlinR Remove the lift pump, see 19.45.09. Scribe a reassembly mark across the body joint flanges.
  • Page 47 FUEL SYSTEM Bleeding 19.50.07 NOTE: After renewing the fuel filter element it will only be necessary to bl~ed the fuel filter as described in 1 and 2, provided that the engine has not been cranked while the filter is dismantled.
  • Page 48 14 Check the needle lift against the figure in DATA. I 5 Reverse the procedure in 2 to 7, tightening the nozzle nut to 50 Ibf ft (6.9 kgf m, 68 Nm). 16 Test and set the injectors to the specification given in DATA, using tools 18G 109 A and 18G 109 B.
  • Page 49 l> SERVICE TOOLS All Service Tools mentioned in this Manual must be obtained direct from the tool manufacturers : Messrs V L Churchill Co. Ltd. & PO Box No.3 18G 123 B Cal1L'lhaft Liner Reamer London Road Cutter Daventry Northants NNll 4NF England ~."...
  • Page 50 Gl)"" /JM\,," 18G 124B 18G 123 T Camshaft Liner Reamer 18G 124 B Camshaft Lin e r Pilot Remover /Replacer Adaptor 18G 167 C Valve Seat Narrowing Cutter - Bottom 18G 134 BD Timing Case Seal @ . . , , " ~."...
  • Page 51 .Jio 6, . . . laG 284A 18G 284 A Main Bearing Cap Remover 18G 636 Transfer Pressure - Adaptor - Adaptor 18G 174 D Valve Seat Cutter Pilot 18G 487 Injector Nozzle Cleaning Kit 18G 284 P I nj ector Remover 18G 637 Assembly Rod...
  • Page 52 t::=ID L;;J Clutch Plate Centralizer 18G 1195 18G 691 A Pilot Guide 18G 651 Drive Shaft Holding Tool 18G 641 Assembly Drive Plate Spanner ~." ~" AKM 9990 Timing Pin 18G 643 A Metering Valve Pinion 18G 653 A Relief Valve Timing Protection Cap...

  • Page 54: Table Of Contents

    OTHER OVERHAUL CONTENTS SECTION PAGE MARINE ENGINE ELECTRICAL SySTEM..... Activation by Keyswitch (1980 onwards) ...•....• Q.2 Activation by Fuel Pressure .•••.•.....•..Q.4 Acti vati on by Lube Oi 1 Pressure......Q. 6 COOLING SYSTEM (EXTERNAL)....TRANSMI SS IONS. • ..• ..... . . Type SAO Manual..........

  • Page 55: Marine Engine Electrical System

    SECTION Q MARINE ENGINE ELECTRICAL SYSTEM ACTIVATION BY KEY SWITCH Thjs system is supplied on most Wester- beke engines beginning May. 1980. Essen- tially activation of the circuit is accomplished by the ignition position of the key switch. No oil pressure switch is required.

  • Page 56: Activation By Keyswitch (1980 Onwards)

    SECTION Q ACTIVATION BY KEYSWITCH SCHEMATIC DIAGRAM. Z VDC BATTERY &AT'TERY M'TU,," PRE-ICAT " WI RI NG DIAGRAM. NOT USED OC" •• ®.5U NOT!- D W.T.5ENDER WATtR TtMPT. ~IT'H Olt. PR!S!.URe ALTERNATOR @SWITCH '¥----~ ..L..L.. tt"\. Of=lTIONAL ALARM ALARM ---;@--- '@---- @) •.

  • Page 57: Activation By Fuel Pressure

    MARINE ENGINE ELECTRICAL SYSTEM ACTIVATION BY FUEL PRESSURE (Push Button Start) This system is supplied on all four and six cylinder Westerbeke engines beginning January 1975. Basically, the system is very simple and eliminates the need for a separate switch position to activate the engine alarm system, when supplied.
  • Page 58 ACTIVATION BY FUEL PRESSURE (PUSH BUTTON STARn C---------, START 5w PANEL. ASSEMBLY ~ I"+~--I-~il'-::::,( I:)TA.RT 5W PREH["" :)W'I L. _ _ _ _ . · . < · " • ° ® OPfiONA ~=====:::;LJI2~ ; ALARM • « r------------l p"j:i "$ L--...:~--_>,A~--;:,i'!":/;CO;:', - ..

  • Page 59: Acti Vati On By Lube Oi 1 Pressure

    Marine Engine Electrical System ACTIVATION BY LUBE OIL PRESSURE (Keyswitch Start) This system is supplied on all 4 and 6 cylinder Westerbeke diesels produced prior to January 1975. Operation is very simple. Putting the start switch in the Run posi- tion energizes an alarm system (when sup- plied).
  • Page 60 ACTIVATION BY LUBE OIL PRESSURE (KEYSWITCH START) t---t---r----I_~_ ~W'TCH C,t,toLE --+-- - ===t:-= --+- - --====--________ t---- -r- '- --;===-:..:- --f-- - '" " " J.B2 > i - - r----- ® f..---f- f----;-- EN~r'-le ..RN!~~ ® ® C P SENDER T SENDER @ '------' £I..ECTllIIC )fOJi...
  • Page 61 YOUR NOTES...

  • Page 62: Cooling System (External)

    COOLING SYSTEM (EXTERNAL) DESCRIPTION: charge of the sea water pump to the heat exchanger sea water inlet. After Westerbeke marine diesel engines are passing through the tubes of the heat equipped with fresh water cooling. exchanger, the sea water may enter a...
  • Page 63 A thermostat can be checked for prop- It is preferable to fill your engine er operation by placing it in a pan with a 50% antifreeze-water mixture. of cold water and then raising the This precludes the necessity of drain- temperature of the water to a boil.
  • Page 64 TWO PASS MANIFOLD Note: Drawing is indicative only. Specific models may vary in detail • . - - - TO EXHAUST 5YSTE/v1 FRESH WATt':? PUMP...
  • Page 65 SINGLE PASS MANIFOLD Note: Drawing is indicative only. Specific models may vary in detail. EXHAUST SURGE MANIFOLD TANK i\lER - - BOARD J" EXCHANGER FRESH FROM WATER <J:l c::I PUMP COCK ~~--~M WATt:.R PUMP - ..- ---"""III.."' FILTER • •...

  • Page 66: Transmissions

    SECTION S TRANSMISSIONS...
  • Page 67 YOUR NOTES·...

  • Page 68: Paragon P-21 Series Hydraulic

    S.29 PARAGON P-21 SERIES HYDRAULIC I. SPECIFICATIONS A. Description Chart MODEL REDUCTION RATIO DIRECTION OF ROTATION P21L DIRECT ALL LEFT HAND P22L 1. 5: 1 AS VIEWED FROM P23L THE OUTPUT END P24L 2. 5: 1 OF THE TRANS- P25L MISSION B.
  • Page 69 S.30 II. INTRODUCTION ward drive is through a multiple disc clutch arrangement, while the reverse drive utilizes a reverse clamp band and planetary gear train. The transmission oil is circulated and Transmissions have been designed for smooth cooled through a sep&.rate external oil cooler operation and dependability in marine use.
  • Page 70 adjust the shaft control cable length until or reverse position, and should return the cockpit control station hand lever is exactly to the neutral position when the in the neutral position. Move the cockpit hand lever is in the neutral position. control hand lever to forward and reverse positions several times while observing the G.
  • Page 71 8.32 V. MAINTENANCE are full. necessary, refill to the mark on the dipstick to ensure proper operation A. Lubrication of the transmisSion. The transmission oil level should be checked each time the engine The Models P200, P300 and P400 trans- oil level is checked, before running the missions are self-contained units, indepen- engine.
  • Page 72 S.33 C. Trouble Shooting Chart PROBLEM POSSIBLE CAUSES AND METHODS OF CORRECTION GEAR INOPERATiVE Drive Shaft does not operate with selector valve in forward Low Oll Pressure. Low oil supply. Add oll, refer to or reverse. lubrication. Faulty oil gauge. Replace gauge. Oil gauge slow to register, air or obstruction in oll gauge line.
  • Page 73 S.34 PROBLEM POSSIBLE CAUSES AND METHODS OF CORRECTION GEAR DRAGGING Drive Shaft rotates either forward or reverse with Forward clutch plates warped and Selector Valve in neutral Defective forward sticking. Remove clutch plates and position. Clutch Plates. replace. Defective forward Forward clutch piston release spring Clutch piston Release broken or weak.

  • Page 74: Warner Hydrau1 I C

    S.35 WARNER HYDRAULIC DESCRIPTION be shifted to the point where it covers the letter" F" on the case casting, and VVesterbeke Four-107 is located in its proper position by the Engines are also furnished with VVarner poppet ball. The VVarranty is cancelled hydraulic direct drive and reduction if the shift lever poppet spring and/ or gear assemblies.
  • Page 75 S.36 CHANGING OIL It is recommended that the transmis- sion oil be changed once each season. After draining oil from the unit. the removable screen should thoroughly cleaned before refilling transmission with the recom- mended oil (ATF) Type "A". REDUCTION GEAR BOX The reduction gear box operates in conjunction with the direct drive unit.

  • Page 76: Short Profile Sailing Gear

    S.41 SHORT PROFILE SAILING GEAR Description Brief description The Short Profile Sailing Gears are equipped with a positively driven, mechanically operated helical gearing system. servo-operated multiple-disc clutch requires only minimum effort for gear changing, making the transmission suitable for single-lever remote control via a rod linkage, Morse or Bowden cable.
  • Page 77 5.42 Gear casing The rotating parts of the HBW transmission are accomodated in an oil-tight casing divided into two halves in the plane of the vertical axis. Amply dimensioned cool- ing ribs ensure good heat dissipation and mechanical rigidity. An oil filler screw with dipstick and an oil drain plug are screwed into the gear casing.
  • Page 78 S.43 Multiple-disc clutch including operation - power train The engine torque is applied to the input shaft (36) in the specified direction of rotation and, in shifting position A (see item 1.2), via gear (44), the frictionally engaged clutch discs (51 and 52) to the external disc carrier (57) and from there via the guide sleeve (59) to the output shaft (66).
  • Page 79 5.44 Shaft beari ngs Both the input and the output shafts are carried in amply dimensioned taper roller bearings. The intermediate gear and the movable gears are carried in sturdy needle roller bearings. Shaft seals External sealing of the input and output shafts is provided by radial sealing rings. The running surfaces on the shafts are casehardened.
  • Page 80 S.45 Installation Delivery condition For safety reasons, gearbox is NOT filled with oil for shipment. The actuating lever is mounted on the actuating shaft. Before leaving the factory, each transmission is subjected to a test run with the prescribed ATF oil. The residual oil remaining in the transmission after draining acts as a preservative and provides reliable protection against corrosion for at least 1 year if the units are properly stored.
  • Page 81 S.46 Operation of gearbox Gear changing requires only minimum effort. The gearbox is suitable for single lever remote control. Upon loosening the retaining screw, the actuating lever (see illustration) can be moved to any position required for the control elements (cable or rod linkage).
  • Page 82 S.47 Oil dipstick and oil filler screw 17 mm width across flats Min. distance of actuating lever 0.5 mm The position of the cover plate underneath the actuating lever is factory-adjusted to ensure equal lever travel from neutral position to A and B. When installing the gearbox, make certain that shifting is not impeded e.g.
  • Page 83 S.48 Operating temperature The max. permissible temperature of the transmission oil is 130 Operation of gearbox Shifting is initiated by a cable or rod linkage via the actuating lever and an actuat- ing cam. The completion of the gear changing operation is automatic and cannot be influenced by external control.
  • Page 84 (see item 2.9). OVERHAUL Disassembly of the transmission in the field is not recom- mended. If an overhaul or repair is needed, the work should be done by Westerbeke or an authorized Westerbeke service center.
  • Page 86 SECTION V SERVICE BULLETINS The following Bulletins contain supplementary and updated information about various components service procedures which important proper functioning of your eng ine and its support systems. You should familiarize yourself with the subjects make sure that consult appropriate Bulletin (s) whenever your eng ine requires service...
  • Page 87 Any fittings used to connect the hose to the gallery must be of steel or malleable iron. Brass must not be used fo"r this purpose . '..~j H. WESTERBEKE CORP. •. AVO" ",O«Ie.",'A' NIt«, AIIOII, MAee. ·'.17/ . . . -7700 CA.'.: "...
  • Page 88 The goal is to prevent excessive exhaust temperatures with the least amount of sea water. H. WESTERBEKE CORP. AVON 'NDU.TR'AI. ,.AR", AVON, iliA ••• 02322· '8f71 588-7700 Mi ••...
  • Page 89 2 3/8" dia panel S8 #44 S8 #44 cut-out LAMP'" SND~B'" LAMP+ Wiring diagram SND~B+ SN .._·,... (;ND Also see S8 #36 (;ND H. WESTERBEKE CORP. AIION INDUSTRIAL PARK, AIION, MAS.S. 02322· (517} 588-7700 CABLE: WESTCORP, AIION· TELEX: .2-4444 PIN: 19190...
  • Page 90 SERVICE· BULLETIN DATE: August 27, 1975 BULLETIN NUMBER: 76 Four-9l, W-30 ; W-50 (If fitted with thi s type pump) MODEL: Proper bleeding procedure for hydraulically governed fuel injection SUBJECT: pumps incorporating an engine anti-stall device An anti-stall device is incorporated on fuel injection pumps fitted to the Four-91 engines.
  • Page 91 SERVICE BULLETIN #76 conlt. has not been screwed in far enough. In either case, re-adjustment should be made accordingly. CAUTION: Use extreme caution when tighteniny the locknut or the bleed screw because the "threaded boss" that the assembly is screwed into is pressed into the governor housing.
  • Page 92 12 V.D.C. 170-200 W-120 & 45 KW 12 V.D.C. 200 minimum The ampere hour range shown is minimum. There is no real maximum. H. WESTERBEKE CORP. (ts.71 AIION INDUSTRIA&. PARK, AIION, IIfASS. 02322 . 588-7700 CAS&.E: WESTCORP, AIION·TE&.E/(: 112- ••••...
  • Page 93 In any cases of engine overheating where such a rubber end cap is used, it should be checked for proper positioning along with other routine troubleshooting. H. WESTERBEKE CORP. '.,71 -7700 AVON 'NDUsrR'AL "AR", AVON, MASS.
  • Page 94 The center splitter terminal should read .82 volts higher than the readings of the side terminals. Continued ... H. WESTERBEKE CORP. AI/ON INDueTRIAL ,.AR/(, AI/ON, MAee. 02322·,ef7} 5 • • -7700 CA.L~; WtEeTCOR,., AI/ON·...
  • Page 95 70 I NOTE: On Alternators which have an isolation diode between their output and regulator terminals, such as the Motorola units used with most WESTERBEKE engines, the regulator wire should be removed from the REG terminal and reconnected to the OUTPUT terminal as shown. The diode in the splitter will...
  • Page 96 If the sender to gauge conductor is O.K. and the engine block is grounded, the sender is probably defective and should be replaced. H. WESTERBEKE CORP. AVON INDIJSTRIAL PARI<, AVON, MASS. 02322· (fS'7} 588-7700 CABLE: WESTCORP, AVON· TELEX: 92 - ..
  • Page 97 Under its head are 1 to 3 washers. Remove one washer. This should stop forward boat movement. But under NO circumstances use fewer than one washer nor more than three. H. WESTERBEKE CORP. AI/ON 'NDuaTR'AL PARIC, AI/ON, "A.a. 02322 - (8171 588-7700 CABLE: WE.TCORP, AI/ON-TELEX: .2-4444...
  • Page 98 Overleaf is a parts list and an illustration showing the proper installation of the fuel pressure switch used on most of our engine products. H. WESTERBEKE CORP. AVON INDUSTRIAL PARK, AVON, If ASS. 01131111· (8171 588-7700 CABLE: WESTCO"P, AVDN· TELEX: .11- ••••...
  • Page 99 '0" RINt; /9185" ADAPTER 1f}261 Wt4SHee COPPeR 19204 SCReW ASs')" (Bl.eCD) ITEU PART NO. DESCRiPTION aT)" IJ· ,!?~".~~~, H. WESTERBEKE CORP. AVON. 02322 OKelMAL P"",CTIO"AL o;:!:, 21 7 4 3 AHGULA" rUW'NG NUMm MAD. IN U_ •. A. :~::::.".·.~.~~~~!"D K·E...
  • Page 100 "by-pass" nipples in these situations: HEATER ALLCRAFT RARITAN MODEL SENDURE 3/8" NPT ' - - - - 3/8" NPT 1/2" NPT W 50 3/4" NPT 1/2" NPT 1/2" NPT \0158 ___ HaQ l{p'L_ 1/2" NPT 1/2" 3f~NPT 1/2" NPT 3/4"...
  • Page 101 V.16 EN(;I NE THERMOSTAT HOUSING ..DUAL PASS MANIF'OLD ~LTERNATE INTERRUPT CES TO ~ONNECT~IRU'T HEATER ENGINE N SERIES. THERMOSTAT HOUSING BYPASS NIPPLE ..E~URE SINGLE CAP (MUST MANIFOLD ESSURE T/;AN 8E HIGHER REMOn ENGINE' CAP). TANK . FILL WATER ALrERNATf EATER H -- INST...
  • Page 102 Sea Water Pump Pulley Set Screw P.N. 11357 SUBJECT: The sea water pump pulley on the Westerbeke 30 and 50 engines is keyed to the sea water pump shaft and locked in position with a heat treated 5/32" Allen head set screw, Westerbeke P.N.
  • Page 103 We strongly recommend that only genuine WESTERBEKE thermostats be used in WESTERBEKE products to assure proper design in this regard. H. WESTERBEKE CORP. AVON INDUSTRIAL PARK, AVON, IIIASS. 0:1322· (fl171 .88-7700 CA8LE: WESTCORP, AVON·...
  • Page 104 Please see diagram on overleaf. H. WESTERBEKE CORP. AVON INOUSTRIAL PARI(, AVON, MASS. OZ3ZZ· (8f7/ 5B8-7700 CABLE: WESTCORP, AVON· TELEX: '2-4444...
  • Page 105 V.20 SCHEMATIC DIAGRAM. WIRING DIAGRAM.
  • Page 106 1. A remote fill point for the circuit, in which case it should be located slightly higher than the engine's pressure cap. Continued •••.•. H. WESTERBEKE CORP. AVON INDUSTRIAl. "ARIC. AVON. MASS. 02322· (fl17} 588-7700 CABI.E: WESTCOR". AVON·TEI.EX: 82-4444 24721...
  • Page 107 V.22 2. A means of conveniently observing the water level in the circuit. 3. A means of assuring that the circuit is always completely full of cooling water. 4. The coolant recovery system operates without diverting engine cooling water. It is a one-way connection to the system which provides a place for expanding water to go while the engine is warming up and, conversely, a source of water to refill the system as the engine cools down.
  • Page 108 MODEL: SUBJECT: Ammeter Wire Sizes Ammeters may be installed in conjunction with any Westerbeke marine diesel engine or diesel generator set. The range of the ammeter must be appropriate for the maximum output of the alternator. Additionally, the wire size for the alternator output circuit,·inc1uding the ammeter, varies with the total length of that circuit.
  • Page 109 Ensure that the throttle is full open and the engine shut-off lever is in the RUN position when proceeding to Step #4. over ..H. WESTERBEKE CORP. AVON INDUSTRIAL PARK, AVON, MASS. 02322· (617/588-7700 CABLE: WESTCORP, AVON· TELEX: fl2- • • • • PIN:...
  • Page 110 V.25 4. With the aid of a 5/16 box wrench or socket (1/4 Drive), open the bleedscrew #4 located at the base of the high pressure line 1 to 2 turns. NOTE: DO NOT remove this bleedscrew. At the same time with a open-end wrench, loosen all four high pressure injector line nuts #5 at the base of each fuel injector 1 to 2 turns.
  • Page 111 V.26...
  • Page 112 48 inches of lift on the discharge side. The installation information given in this text is to be used as a guide only. Westerbeke cannot be responsible in any way for muffler installations. Wester- beke presumes the installer to have a basic knowledge of marine installation requirements.
  • Page 113 V.28 Hydro-Hush Muffler Installations Page 2 Use as few right angle fittings as possible. The use of wire reinforced hose is recommended and the hose should be routed to produce the bends needed. The use of 90° and 45° fittings contribute to the rise of engine exhaust back pressure.
  • Page 114 V.29 Page 3 ENGINE INSTALLATIONS .-~-.,-.~~~ "{t Insulate ENCINE INSTALLATIONS WITH EXHAUST MANI- FOLD/WATER INJECTED ELBOW AT OR BELOW VESSEL WATER LINE max. 12" min. ENCINE INSTALLATIONS WITH EXHAUST MANI- FOLD/WATER INJECTED ELBOW MINIMUM OF 6 INCHES ABOVE VESSEL WATER LINE.
  • Page 115 V.30 Page 4 GENERATOR INSTALLATIONS "- ~.;,:..-- --:,--- Raw Water Pump Raw Water Generator Installations with Intake - Thru exhaust manifold/water injected Hull Fitting --'- elbow at or below vessel water line. Generator Below Water Line Raw Water Pump Raw Water Generator Installations with Intake - Thru Hull Fitting...
  • Page 116 D.C. output voltage. C. Check for A.C. voltage at tach terminal on alternator to ground. D. Check electrical connectio'ns from "tach Inp." terminal to alternator connection. H. WESTERBEKE CORP. AVON INDUSTRIAL PARK, AVON, MASS. 02322· (6f7} 5BB-7700 CABLE: WESTCORP, AVON· TELEX: 92-4444...
  • Page 117 V.32 2. Sticking 1. Check for proper A.C. voltage between "tach inp." terminal and (-) terminal. 2. Check for good ground connection between meter (-) Terminal and alternator. 3. Check alternator is well grounded to engine block at alternator pivot bolt. Inaccurate 1.
  • Page 118 V.33 Page 3 SERVICE BULLETIN #148 LATE MODEL TACHOMETER Replaces Earlier Model as Shown on Page 2 of this Bulletin Access Hole for Tachometer Calibration ( - ) Ground Terminal 'Tachometer Input (AC Voltage)