Westerbeke 46 User manual

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

FOREWORD

Thank

you

for

having

selected

Westerbeke

Diesel

Engine

for

your

use.

This

manual

describes

the

procedures

for

proper

handling

and

routine

maintenance

of:

W-46

Marine

Diesel

Propulsion

Engines

obtain

best

operating

condition

and

longest

service

life,

important

use

sensibly

and

carry

out

operation

and

maintenance

according

this

manual.

you

have

questions

about

your

equipment

the

event

failure,

please

contact

your

nearest

distributor

dealer.

If,

within

days

submitting

your

warranty

registration

card,

you

have

not

received

Customer

Identification

Card

(see

below)

registering

your

warranty,

please

contact

the

factory

writing.

look

forward

your

continued

patronage.

from:

J.H. Weslerbeke Corp.

Avon

Industrial

Park

Avon, MA 02322

r/~1

WESTERBEKE

COR~

•

AVON

'''ov.r~'A<

p",,~,

AVON,

AU.

oun

CUSTOMER IDENTIFICATION

W-46

1234C408

Pleasure Craft

Mail To: expi res 9/15/85

Adam

Smith

Maple

Street

Alden,

12234

TABLE

CONTENTS

PAGE

GENERAL

SPECIFICATIONS

•....••••••••••

INSTALLATION, PREPARATION

AND

SUPPLY

CAUTIONS.

•

.. .. .. .. .. .. .. .. ..

.. .. ..

.. .. .. .. ..

.... 5

BREAKING

IN..........................................

2.. STARTING

SySTEM.................................

INSTRUMENT

PANEL

USE

••••••••.•.•

STARTING

PROCEDURES

•••••••••••••

STOPPING

PROCEDURES

••••••••.•••.

CAUTIONS

STARTING

AND

OPERATION

.....................................

REQUIREMENTS

FOR

PROPER

OPERATION

7-1

Lubrication

System

•••••••••

7-2

Fuel

System

.••.••....••.•..

7-3

Wiring

Diagram

.••••

Centerfold

7-3

Cooling

System

•••••....••••

7-4

Belt

Tension

...............

7-6

Domestic

Hot

Water

..•••••••

7-7

Cylinder

Head

Valves

.•••••

RECOMMENDED

MAINTENANCE

SERVICE.25

9..

TRANSMISSIONS

....

................................

10.

TROUBLESHOOTING

•••••••••••••••••

11.

TABLE

TIGHTENING

TORQUES

•.•••

12.

COMMON

PARTS

NUMBER

••••••••••

13.

LIMITED

WARRANTy

••••••••••••...•

GENERAL

SPECIFICATIONS

Model

Type

Westerbeke

4-cycle,

fresh

water

cooled

diesel

engine

with

raw

water

exchanger

system

Arrangement

Cylinders

cylinder-vertical-in

line

Bore

Stroke

Dry

Weight

Total

Piston

Displacement

Compression

Ratio

Firing

Order

Rotational

Direction

Fuel

Lubricating

Oil

Pressure

Intermittent

Power

Westerbeke

Rating

Continuous

Power

Idle

Speed

Cruise

R.P.M.

Lubrication

Oil

Pump

Oil

Filter

Oil

Sump

Capacity

Cooling

System

Operating

Temperature

Fuel

System

Fuel

Injection

Pump

Fuel

Injection

Nozzle

Governor

Fuel

Filter

Starting

System

90mm

(3.30

3.70

in.)

535

Ibs.

(242kg)

2084cc

(127

cu.

in.)

1 - 3 - 4 - 2

Clockwise

viewed

from

front

engine

fuel

oil

(cetane

rating

better)

Mineral

oil,

heavy

duty,

A.P.I.

Idle

P.S.I.

(1.75

2.46

kg/cm

Under

power

P.S.I.

(2.46

4.21

kg/cm

47.5

horsepower

3000

RPM

horsepower

3000

RPM

horsepower

3000

RPM

700-850

RPM

2000-2500

RPM

Forced

lubrication

Trochoid

pump

Full-flow

type

with

paper

element

quarts

filter

Forced

circulation

centrifugal

pump

with

thermostatically

controled

temperature

170

190·

NIHON-CAV

distributor

type

Bosch

type,

DNOSD

Flyweight

type,

built

pump

with

paper

element

Electric

starter

with

glow

plugs

head

starter

Alternator

Battery

Raw

Water

Flow

Rate

Propeller

Recommendations

(using

HBW-150

1.8S:1

reduction)

12V,

1.6KW

pinion

shift

type

12V

ampere

12V

100

ampere

hour

9.5-10.0

gallons/minute

3000

R.P.M.

measured

discharge

into

exhaust

elbow

lSD

10P-2

blade

lSD

x SP - 3

blade

propeller

should

allow

engine

reach

its

rated

RPM

(3000

100)

full

throttle

underway

INSTALLATION, PREPARATION

AND

SUPPLY CAUTIONS

Check

important

aspects

installation

before

operating

engine.

(1)

Alignment

(Error

than

one

thousandth

inch

per

inch

coupling

diameter)

(2)

Provide

sufficient

ventilation

(3)

Provide

adequate

service

room

around

engine

(See

warranty

clauses)

003

~EELER

GAGE

STRAIGHT

EDGE

CHECKING

COUPLING

ALIGNMENT

Fill

fuel

tank

with

CLEAN

diesel

from

reputable

manufacturer.

Fill

engine

sump

with

lubricating

oil

(Select

readily

available

lubricating

(Sump

capacity

quarts).

full

mar

dipstick

oil

grade

CD)

Fill

freshwater

cooling

system

with

suitable

mixture

water

and

antifreeze

suit

your

temperature

zone.

Thoroughly

mix

antifreeze

and

freshwater

BEFORE

adding

cooling

system.

Plug-in

Panel

Harness

Connection.

After

assembly,

joint

should

taped

prevent

corrosion

or,

preferably,

assembled

using

sili-

con

grease

which

can

obtained

electronic

store

such

Radio

Shack.

SAFETY PRECAUTIONS

Never

operate

engine

with

inadequate

ventilation.

Confirm

that

there

are

exhaust

leaks

inside

engine

compartment.

not

touch

moving

parts

during

operation.

not

touch

hot

parts

such

exhaust

pipe,

and

not

place

com-

bustible

materialS

near

the

engine.

Inspect

and

adjust

parts

the

engine

only

after

stopped.

Check

and

refill

engine

oil,

cooling

water

and

transmission

lubri

cant

only

after

the

engine

brought

stop.

coolant

recovery

bottle

was

supplied

with

the

engine

together

with

instructions

for

installation.

sure

that

place.

Attempting

operate

with

only

the

manifold

expansion

tank

exposes

the

operator

severe

steam

burn

the

manifold

pres-

sure

cap

removed

while

the

engine

hot.

instructions

page

Always

use

tools

that

fit

correctly

and

use

caution

during

ser-

vicing.

sure

that

current

carrying

wires

are

protected

from

abrasion

and

that

all

connections

are

tight.

PREPARATIONS

Take

steps

shown

below

starting

your

engine

for

the

first

time

after

prolonged

shut-down.

ill

your

eng

ine

oil

near

the

upper

limi

the

dipstick.

Use

good

grade

oil

with

API

specifi-

cation

better.

For

quantity

oil,

you

may

refer

the

General

Specifications

page.

Fill

with

the

NOTE: Some

separately.

the

transmission

proper

lubricant.

V-Drives

are

filled

Your

engine

supplied

with

coolant

recovery

system

which

the

following

instruc-

tions

apply:

Fill

engine

completely

the

neck

the

manifold

cap.

Then

fill

the

recovery

tank

the

bottom

add

line.

Need

for

adding

coolant

indicated

when a

cold

engine

has

coolant

level

below

the

bottom

add

line.

winter

add

antifreeze

described

page

18.

mixture

antifreeze

should

used

year

round

and

changed

needed.

Fill

the

fuel

tank

with

Diesel

fuel

with

*45

Cetane

rating

better.

The

interior

the

fuel

tank

must

main-

tained

clean.

careful

not

allow

introduction

dir

when

filling

fuel.

Engine

oil,

coolant

transmission

levels

should

checked

least

once

prior

engine

use.

and

day

oil

filler

port

oil

orllevelgauqB_~,J

and

ftllerport

lower/lm;t

7----

_ oil

~---~-_

COOLANT RECOVERY TANK

BREAKING IN

YOUR

NEW

ENGINE

While

your

engine

has

had

least

one

hour

test

operations

demonstrate

accurate

assembly

and

correct

operation

all

systems,

still

requires

break

time.

Service

life

your

engine

dependent

how

your

engine

operated

and

serviced

during

initial

break-in

hours

operation.

Your

new

engine

needs

approximately

fifty

hours

initial

con-

ditioning

operation

for

breaking

each

moving

part,

thus

helping

maximizing

performance

and

service

life

engine.

Perform

this

con-

ditioning

carefully,

keeping

the

following

points

mind.

Start

engine,

run

idle

while

checking

that

all

systems

are

functioning

sea

water

pump,

oil

pressure,

battery

charge.

Warm

engine,

prefer

ably

running

propeller

fast

idle

while

tied

down,

until

water

temperature

gauge

moves

into

the

130

140

degree

range.

Then

use

engine

moderate

load

(RPM)

until

normal

engine

operating

temperature

170

190'F

(77

BS'C)

reached.

Avoid

rapid

acceleration

especially

with

cold

engine.

Use

caution

not

overload

engine.

Grey

sign

overload.

Select

the

correct

engine

and

transmission

reduction.

black

smoke

propeller

for

the

Operate

the

engine

moderation,

varying

the

running

RPM

under

load

during

the

break

period.

Explanation:

"Breaking

in"

a new

engine

basically

seating

the

piston

rings

the

cylinder

walls.

This

not

accomplished

long

periods

running

idle,

nor

early

running

under

full

load.

Idle

running

may

glaze

the

cylinder

walls

causing

oil

consumption

and

smoky

operation.

Excessive

speeds

and

loads

may

score

cylinder

walls

with

similar

results,

especially

with

the

engine

cold.

indicated

above,

operate

the

engine

moderation

during

the

ini-

tial

hours

break

in.

Don't

baby

it,

yet

not

abuse

it.

DESCRIPTION

STARTING

SYSTEM

Model

W-46

uses

electr

starter

assisted

glow

plugs

for

both

normal

and

cold

weather

starting.

The

figure

cross

section

through

one

cylinder.

The

glow

plug

enters

the

com-

bustion

chamber

that

the

end

the

spray

path

the

injector

nozzle.

When

the

glow

plugs

are

energized

the

pre-

heat

button,

they

glow

red

the

tips

and

assist

rapid

ignition

the

fuel.

The

result

rapid

starts

with

less

wear

the

starter.

This

system

common

Westerbeke

Diesels.

The

star

circuitry

designed

that,

first,

the

preheat

button

must

depressed

for

the

time

specified

the

glow

plug

use

char

shown

below.

Glow

Plug

Injector

After

which,

and

while

keeping

the

preheat

button

engaged,

the

start

button

depressed

crank

the

engine.

Glow

Plug

Use

Data

Atmospheric

temperature

Preheating

time

+S'C

(+41"F)

higher

Approx"

sec.

+S"C

(+4l'F)

-S'C

(+23'F)

Approx,

sec"

-SoC

(+23"F)

lower

Approx.

sec,

Limit

continuous

use

minute

For

complete

starting

and

stopping

procedures,

see

pages

and

11.

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