Westerbeke FOUR-60 User manual

TECHNICAL

MANUAL

AND

PARTS

LIST

. . . . . . .

WESTERBEKE·

1-5.

hp. ,.,i.--i-Dies.el Engine

..'.

, : .

M'ODEL

FOUR-60

publication

Numlter

16521

Edition 2

-July

20~O

WESTERBEKECORPORATION

AVON

INDUSTRIAL

PARK.

AVON.

02322.

TEL:

(61

58fJ..7100

INTRODUCTION

This

manual

describes

the

operation.

adjustment

and

maintenance

the

Westerbeke

Model

Four-60

Marine

Diesel

Engine.

and

designed

a ,guide

for

those

concerned

with

the

operation

and

maintenance

these

diesels.

The

diesel

engine

closely

resembles

the

gasoline

engine

inasmuch

the

mecha-

nism

essentially

the

same.

Its'

cylinders

are

arranged

above

its

closed

crank-

case,

its

crankshaft

one

the

same

general

type

that

gasoline

engine;

has

the

same

sort

valves~.

camshaft,

pistons,

connecting

rods

and

lubricating

system

and

reverse

and

redqction

gear.

. . .

Therefore,

follows

to. a

great

extent

that

diesel

engine

requires

the

same

preventive

maintenance

that

which

any

intelligent

and

careful

operator

would

give

gasoline

engine.

The

most

important

factors

are

proper

maintenance

the

fuel,

lubricating

and

cooling

systems.

Replacement

fuel

and

lubricating

filter

elements

the

time

periods

specified

must

and

frequent

checking

for

contamination

(i.

e.,

water,

sediment,

etc.)

the

fuel

system

also

essential.

Another

important

factor

the

use

the

same

brand

"High

Detergent"

diesel

lubricating

oil

designed

specifically

for

diesel

engines.

The

diesel

engine

does

differ

from

the

gasoline

engine,

however,

the

method

(

handling

and

firing

its

fuel.

Carburetor

and

ignition

systems

are

done

away

with

and

their

place

single

component

the

Fuel

Injection

Pump

which

per-

forms

the

functions

both.

Unremitting

care

and

attention

the

factory

have

resulted

engine

capable

many

thousands

hours

'of

service.

What

the

manufacturer

cannot

control

how-

ever,

the

treatment

the

product

will

receive

service.

This

part

rests

with

you.

Whenever

service

parts

are

ordered.

always

give

complete

description

and

part

numbers

with

engine

model

and

number.

example:

Please

supply:

For

Four-60

Marine

Diesel

Engine

No. 3870

11951

LUBE

OIL

FILTERS

The

serial

number

stamped

the

name

plate affixed to the exhaust manifold.

(

.,It

(

INTRODUCTION

PHOTOGRAPHS

WESTERBEKE

MODEL

FOUR-

15 h.

Mini

Diesel

Engine

TABLE

OF:'

CONTENTS

...........

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

...

.......

. .

'.'

..........."

,,'

INSTALLATION

DRAWINGS

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

GENERAL

DATA

....

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

•••••

••

INSTALLA

TION

.....

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

......

OPERATION

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

LUBRICATION

SYSTEM

COOLING

SYSTEM

.....

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

FUEL

SYS

TEM

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

SAO

TRANSMISSION

SSL

TRANSMISSION

Page

No.

SECTION

SURGE

TANK

FILLER

CAP

ALTERNATOR

OPTIONAL

AIR

CLEANER

OIL

SUMP

DRAIN

PIPE

'RIMARY

FUEL

FILTER

OIL

PRESSURE

SWITCH

TACH

OMETER

DRIVE

COLD

START

SOLENOID

FUEL

PUMP

PRIMING

LEVER

(RemOve

after

installation)

LIFTING

BRACKET

LUBRICATION

OIL

..!!L-~-------

FILLER

CAP

HEAT

EXCHANGER

BLEED

SCREW

SECONDARY

FUEL

FILTER

BLEED

SCREW

FUEL

INJECTOR

UNION

NUT

COLD

START

GLOW

PLUG

FRESH

WATER

PUMP

SEA

WATER

PUMP

SEA

WATER

PUMP

DRAIN

ADJUSTABLE

~--

FLEX

~10UNTS

STARTER

MOTOR

PROPELLER

SHAFT

COUPLING

STARBOARD

AND

PORT

VIEWS

-FOUR

60/SAO

(

r .

ARBOARD

AND

PORT VIEWS-FOUR 60/SSL

Photos above show the SSL

Transmission

which was designed

for

the Four-60

Diesel.

The gear

available in two

Ratios,

1.3:1 and 2:1.

Its small

size

and moderate offset greatly

increases

installability

Four-60

de-

creasing length

30 inches and reducing depth belowpropeller shaft line

t04

3/4

inches.

INSTALL}\.TION

DRAWINGS

101--

:32.L DIRECT

DRiVe:

jo4-----37

~.67:1

AND

2:1

RATIO

Four-60/SAO

Reverse

and

Reduction

Gear

~-------2~'-----~·1

.---'

-~3o!-!------'

~-.---'

~'.--~~-.:'::l

1-2;!z.o------

•

1--

______

.'.--

_.----

..I

Four-no/SSLReverse

Gear

GENERAL

DATA

DIESEL

ENGINE

Number

cylinders

Compression ratio

Bore

Stroke

Capacity

Idling speed

Maximum governed light running speed

Maximum speed

under

load

Torque

Pistons and rings

Piston ring groove clearance:

No.

1-compression

Nos. 2 and

3-compression

Nos. 4 and

5-oil

scraper

Piston ring fitted gap:

No.

1-compression

Nos. 2

and

3-compression

Nos. 4 and

5-oil

scraper

Piston

bore clearance

(at

bottom

skirt)

Gudgeon pins

Fit

in piston

Clearance in small-end bush

CODDecting

rods

Length between centres

Side clearance

crankshaft

Crankshaft and bearings

Journal diameter

Crankpin diameter

Main bearing clearance·

Big-end bearing cleara;nce .

Crankshaft end-float

Camshaft and bearings

Bearing clearance

Camshaft end-float

Timing chains and wheels

Camshaft drive

Injection pump drive

Injection pump

chain

wheel bearing liner:

Inside diameter (finished

position)

Clearance

hub

23·6:

2'477

2·4785 in. (62'915

62'94i nun.).

3·0 in. (76'2 mm.).

57·9 cu. in. (948 c.c.).

600 r.p.m.

. . 2,750 r.p.m.

_. 2,500 r.p.m.

. . 38 lb. ft. (5'32

kg.m.)

1,750 r.p.m•.

·0025

to·0045

in. ('062

·113 mm.).

·0015

·0035 in. ('038

·097 mm.).

. . ·0015

·0035 in. (-038

'097 mm.).

. . ·010

·015 in.

('2S4lo

·381

mm..).

·007

·012 in. (-178

·305 mm.).

·007

-012 in. (·178

·305 mm.).

·0031

·0037 in. ('787

'940 mm.).

·00025 in. (·0063 mm.) slack,

·00015 in.(-0038 mm.).

tight.

·0001

·0005 in.

(00025

·0127 mm.).

5·75 in. (146'05 mm.).

·006

-010 in. ('152

·254 mm.).

2-0005

2·001 in.

(50·81-3

50·825 mm.).

1·7505

1·7510 in. (44·462

to.

44·475 mm.).

·001

·0027in. ('025

·068mm.).

·001

·0027 in. ('025

·068mm.).

·002

·003 in. ('051

'076 mm.).

·001

·002 in. (·025 to

·051

mm.).

·003

'007 in. ('076

·178

mm..).

Duplex roller chain.

Simplex roller chain.

1·75025

1·7507S·in.

(44·456

44·469 mm.).

·001

·002 in. ('025 to

·051

mm.).

GENERAL

DATA-continued

Valve mechanism

Valve

opens]

with ·020 in. ('508 mm.) valve

rocker

clear-

Valve closes ance . .

. . . . . . . .

Valve

seat

angle

Valve

seat

face width

Valve

stem

guide clearance

Valve

rocker

clearance-cold

Valve lift

Valve

stand-down

Valve springs:

Free

length

Fitted

length-valve

closed

Fitted

length-valve

open

Load

compre!;s

fitted

length-valve

open

Inlet

5°

B.T.D.C.

30° A.B.D.C.

45°

·075 in. (1·906 mm.)

·00

·0025

in.

('038

·062

mm.)

·012 in. (,305

mm.)

·276 in. (7'01

mm.)

·018

·038 in.

(,457

·965

mm.)

Inner

1·672 in. (42·471

mm.)

1·165 in. (29·6

mm.)

·889 in. (22·576 mm.)

28·71b. (13 kg.)

Exhaust

45°

B.B.D.C.

5°

A.T.D.C.

45°

·075 in. (1·906 mm.)

·002

·003 in.

(·051

·076 mm.)

·012

in.

(·305 Inm.)

·276 in. (7·01 mm.)

·018

·038

.jn.

(·457

·965 mm.)

Outer

2·047 in. (52 mm.)

1·328 in. (33·746 mm.)

1·052 in. (26,746 mm.)

43 lb. (19'5 kg.)

Rocker

shaft

diameter

Rocker

shaft

bush

clearance

Tappet

diameter

. . ·5615 to ,5625

in.

(14'263

14·288 mm.).

·0005

·002 in. ('013

·051 mm.).

Flywheel

and

starter

ring

Number

teeth

starter ring

Starter

ring

fitting

temperature

Oil

pump

Rotor

end-float

Rotor

lobe

clearance

Oil

pressure relief valve

Spring free length

Spring fitted length

Load

compress spring

fitted length

Oil

pressure

Idling

speed

Normal

running

speed

COOLING

SYSTEM

Fan

belt

Depth

Width

(outside)

Angle

~V'

Lateral

movement

(measured

the vertical

run)

Thermostat

Opening

temperature

Fully

open

temperature

Water

puomp

spindle

Interference fit

hub

Tnterference

fit

vane

·81125

to·81175

in. (20·606

20·618 mm.).

94.

200

230°

(392

446° F.).

·003 in. (·076

mm.)

maximum.

·004

in~

(·102

mm.)

maximum.

2·86 in. (72-64

mm.).

2·156 in. (54,77

mn1~).

13·5 lb. (6'127 kg.).

lb./sq. in. (1,05 kg.jcm.2

50 Ib./sq. in. (3'52 kg./em.2

H in. (10·72

mm.)

tin.

(12,7

mm.).

40°.

1in. (25

mm.).

84°

(175

183° F.).

96°

(201

205° F.).

·0015

·0028 in. ('038

·071

mm.).

·001

·0023 in. (·025

·058 mm.). 7

GENERAL

DATA-continued

VEL

SYSTEM

Diesel models

Lift pump ••

Main filter

Injection order

Static injection timing

Injection pump

Type'

••

A.C.-YE

type.

C.A.

bowl-less.

1.3,4,2.

16°

B.T.D.C.

DPA

3248530.

Roller to roller dimension

Governor link length

••

.. 1'962 in.

(49'84

mm.).

2·087±·039 in.

(S3±1

mm.).

Injectors

Nozzle

Nozzle holder

Opening pressure

Needle lift

BDN.O.SPC.6389.

BKB.35S.S237.

135

atmospheres.

·6

·75

mm.

rorque

Wrench

Settings

Cylinder

head

nuts

• . . • • • • • . . • • • . • • . . . •

Inj

ector

clamp

nuts

•••••••••••••...••••.

Rocker

bracket

nuts

..••••.•.•.••••.•......

Flywheel

bolts

••••••••••..•.••••••.••.

Main

bearing

bolts

•.....•...•••.••...•..

Connecting

rod

bolts

•.•.••..••...••••••..

Injector

nozzle

nuts

...•.....•..•.•..•••.

B::lectrical

~ystem

Nominal

voltage

.••...

••

'.'

..••.••.••.•..

Battery

(NOT

supplied

with

engine)

Terminal

voltage

.••••.•••••...•..•..

Recommended

capacity

•....•.....••.

•..

Generator

....•......••..•.....•••...

Capacity

........•.....•••.....•...

Voltage

...•••..••..•.••.•...•••..

Alternator

(optional)

Capacity.

. . . . . . • • . . • . .

•.

• . • . . • . . • . .

Voltage

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

TRANSMISSIONS

Four-60

Gear

Options

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

ft.

lbs.

volts

(ne

gati

ground)

volts

130

ampere

hours

negative

ground

amperes

12V.D.C.

amperes

V. D. C.

SAOD

SA002

SAOV

·.............................

Direct

Drive

2:1

SSL-13

SSL-20

·...........................

·.............................

·...........................

·..........

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

29:1

67:1

2:1

3:1

2:1

(

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