Westerbeke WPDS-20 User manual

TECHNICAL

MANUAL

WESTERBEKE 60

Marine Diesel Engine

WESTERBEKE WPDS-20

Marine Diesel Generator

Publication #15204

Edition

Four

September

1979

j'-.v-

'WESTERBEKE

WESTERBEKECORPORATION

MYLES

STANDISH

INDUSTRIAL

PARK

150

JOHN HANCOCK

ROAD,

TAUNTON,

02780-7319

TECHNICAL

MANUAL

WESTERBEKE 60

Marine Diesel Engine

WESTERBEKE WPDS-20

Marine Diesel Generator

Publication #15204

Edition

Four

September

1979

j'-.v-

'WESTERBEKE

WESTERBEKECORPORATION

MYLES

STANDISH

INDUSTRIAL

PARK

150

JOHN HANCOCK

ROAD,

TAUNTON,

02780-7319

SECTION INDEX

GENERAL

Introduction Operation

Installation Maintenance

ENGINE OVERHAUL

OTHER OVERHAUL

Marine Engine Electrical System

Cooling System (External)

Transmissions

GENERATOR SETS

HYDRAULIC CRANKING SYSTEM

SERVICE BULLETINS

4 YOUR NOTES

INTRODUCTION 5

IMPORTANT

THIS

MANUAL

DETAILED

GUIDE

THE

INSTALLATION,

START-UP,

OPERATION

AND

MAINTENANCE

YOUR

WESTERBEKE

MARINE

DIESEL

ENGINE.

THE

INFORMA-

TION

CONTAINS

VITAL

THE

ENGINE'S

DEPENDABLE,

LONG

TERM

OPERA-

TION.

READ

KEEP

SAFE

PLACE

KEEP

HANDY

FOR

REFERENCE

ALL

TIMES

FAILURE

WILL

INVITE

SERIOUS

RISK,

NOT

ONLY

YOUR

INVESTMENT,

BUT

YOUR

SAFETY

WELL.

UNDERSTANDING

THE

DIESEL

....

The

diesel

engine

closely

resembles

the

gasoline

engine

inasmuch

the

mechanism

essentially

the

same.

Its

cylinders

are

arranged

above

its

closed

crankcase;

its

crankshaft

the

same

general

type

that

gasoline

engine;

has

the

same

sort

valves,

camshaft,

pistons,

connecting

rods,

lubricating

system

and

reverse

and

reduction

gear.

Therefore,

it.follows

great

extent

that

diesel

engine

requires

the

same

preventative

maintenance

that

which

any

intelligent

operator

would

give

gas-

oline

engine.

The

most

important

factors

are

proper

maintenance

the

fuel,

lub-

ricating

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.

The

carbu-

retor

and

ignition

systems

are

done

away

with

and

their

place

single

com-

ponent

the

Fuel

Injection

Pump

which

performs

the

function

both.

Unremitting

care

and

attention

the

factory

have

resulted

Westerbeke

engine

capable

many

thousands

hours

dependable

service.

What

the

manufact-

urer

cannot

control,

however,

the

treatment

receives

service.

This

part

rests

with

you!

ORDERING

PARTS

Whenever

replacement

parts

are

needed,

always

include

the

complete

part

descrip-

tion

and

part

number

(see

separate

Parts

List

furnished,

not

part

this

pub-

lication).

sure

include

the

engine's

model

and

serial

number.

Also

sure

insist

upon

Westerbeke

factory

packaged

parts,

because

"will

fit"

parts

are

frequently

not

made

the

same

specifications

original

equipment.

GENERATOR

SETS

Westerbeke

diesels

are

used

for

both

the

propulsion

boats

and

for

generating

electrical

power.

For

generator

set

app-

lications,

all

details

this

Manual

apply,

except

regard

certain

por-

tions

the

Installation,

Operation

and

Maintenance

sections.

Additional

infor-

mation

provided

the

section

titled

Generator

Sets,

Section

INSTALLATION 7

FOREWORD

Since

the

boats

which

these

engines

are

used

are

many and

varied,

details

engine

installation

are

equally

so.

not

the

purpose

this

section

advise

boatyards

and

engine

installers

the

generally

well

understood

and

well

developed

procedures

for

installation

en-

gines.

However,

the

following

outline

general

procedure

included

because

valuable

explaining

the

functions

each

component,

the

reasons

why,

the

precautions

watched

and

the

relationship

the

installation

the

operation

the

engine.

There

are

details

the

installation

which

should

have

periodic

check

and

which

the

operator

should

have

thorough

understanding

insure

good

operating

conditions

for

the

engine

and

correct

procedure

for

its

servicing.

INSPECTION

EQUIPMENT

The

engine

shipped

from

the

factory

mounted

securely

and

properly

crated.

Ac-

cessory

equipment

shipped

separate

small

box,

usually

packed

with

the

engine

crate.

Before

accepting

shipment

from

the

transportation

company,

the

crate

should

opened

and

inspection

made

for

con-

cealed

damage.

either

visible

con-

cealed

damage

noted,

you

should

require

the

delivering

agent

sign

"Received

damaged

condition".

Also

check

contents

the

shipment

against

the

packing

list

and

make

sure

note

made

any

discrep-

ancies.

This

your

protection

against

loss

damage.

Claims

for

loss

damage

must

made

the

carrier,

not

Westerbeke

Corporation.

RIGGING

AND

LIFTING

The

engine

fitted

with

lifting

rings.

Rope

chain

slings

should

at-

tached

the

rings

and

the

engine

lifted

means

tackle

attached

this

sling.

The

lifting

rings

have

been

designed

carry

the

full

weight

the

engine,

therefore

auxiliary

slings

are

not

re-

quired

desired.

CAUTION:

Slings

must

not

short

place

the

engine

lifting

eyes

sig-

nificant

sheer

stress.

Strain

the

engine

lifting

eyes

must

not

excess

100

from

the

vertical.

spacer

bar

must

placed

between

the

two

lifting

eyes,

supported

valve

cover

studs.

The

general

rule

moving

engines

see

that

all

equipment

used

amply

strong

and

firmly

fixed

place.

Move

the

engine

little

time

and

see

that

firmly

supported.

Eliminate

possibil-

ity

accidents

avoiding

haste.

not

lift

from

the

propeller

coupling,

pry

against

this

with

crowbar,

you

may

distort

the

coupling.

some

cases

may

necessary

lift

the

engine

other

than

the

regular

horizontal

position.

may

that

the

engine

must

lowered

endwise

through

small

hatchway

which

cannot

made

larger.

the

opening

extremely

restricted

possible

reduce,

some

extent,

the

outside

clearances

such

generator,

cooling

piping,

water

tank,

filters,

mounting

lugs,

etc.

This

accessory

equip-

ment

should

removed

competent

mechanic

and

special

care

should

taken

avoid

damage

any

exposed

parts

and

avoid

dirt

entering

openings.

The

parts

which

have

been

removed

should

returned

position

soon

the

restriction

has

been

passed.

case

necessary

hoist

the

engine

either

front

end

upwards

reverse

gear

end

upwards,

the

attachment

slings

must

done

very

carefully

avoid

the

possibility

damage

the

parts

which

the

weight

may

bear.

best

special

rigging

work

done

someone

experienced

and

competent

the

handling

heavy

machinery.

ENGINE

BOLTS

recommended

that

bronze

hanger

bolts

appropriate

size

used

through

the

engine

flexible

mounts.

Lag

screws

are

less

preferred

because

their

hold

the

wood

weakened

every

time

they

are

moved,

whereas

the

lag

bolt

stays

pos-

ition

and

the

nut

top

used

tight-

the

engine

down

removed

permit

the

engine

lifted.

The

bolt

itself

stays

pos~tion

all

times,

stud,

and

the

bond

between

the

bolt

and

the

wood

not

weakened

its

removal.

FOUNDATION

FOR

ENGINE

good

engine

bed

contributes

much

toward

the

satisfactory

operation

the

engine.

The

engine

bed

must

rigid

construction

and

neither

deflect

nor

twist

when

subjected

the

engine

weight

the

position

the

boat

may

have

take

under

the

effects

rough

seas.

The

bed

must

keep

the

engine

within

one

two

thous-

andths

inch

this

position

all

times.

has

withstand

the

forward

push

the

propeller

which

applied

the

propeller

shaft,

the

thrust

washer

bearing

the

engine

and

finally

the

engine

bolts

and

engine

bed.

fiberglas

hulls,

recommend

that

similar

wooden

stringers

wooden

hulls

formed

and

fitted,

then

glassed

the

hull

securely.

This

allows

hanger

bolts

installed

firmly

wood,

thus

reducing

noise

and

transmitted

vibration.

The

temptation

install

the

engine

pair

fiberglas

"angle

irons"

should

resisted.

Such

construction

will

allow

engine

vibrations

pass

through

the

hull.

Flexible

mounts

require

firm

foundation

against

which

react

they

are

their

job.

When

possible,

bed

design

"A"

and

avoid

bed

design

"B".

GOOD

PROPELLER

COUPLING

Each

Westerbeke

Diesel

engine

regu-

larly

fitted

with

suitable

coupling

for

connecting

the

propeller

shaft

the

engine.

The

coupling

must

not

only

transmit

the

power

the

engine

turn

the

shaft,

but

must

also

transmit

the

thrust

either

ahead

astern

from

the

shaft

the

thrust

bearing

which

built

into

the

reduction

gear

housing

the

engine.

This

coupling

very

carefully

machined

for

accurate

fit.

For

all

engine

models,

propeller

half-

coupling,

bored

shaft

size

for

the

specific

order,

supplied.

The

coupling

either

has

a keyway

with

set

screws

the

clamping

type.

The

forward

end

the

propeller

shaft

has

long

straight

keyway.

Any

burrs

should

removed

from

the

shaft

end.

The

coupling

should

light

drive

fit

the

shaft

and

the

shaft

should

not

have

scraped

down

filed

order

get

fit.

important

that

the

key

properly

fitted

both

the

shaft

and

the

coupling.

The

key

should

fit

the

side

the

keyway

very

closely,

but

should

not

touch

the

top

the

keyway

the

hub

the

coupling.

seems

difficult

drive

the

coupling

over

the

shaft,

the

coupling

can

expanded

heating

pail

boil-

ing

water.

The

face

the

propeller

coupling

must

exactly

perpendicular

the

centerline

axis

the

propeller

shaft.

PROPELLER

The

type

and

size

propeller

varies

with

the

gear

ratio

and

must

selected

fit

the

application

based

upon

boat

tests.

utilize

the

full

power

the

engine,

and

achieve

ideal

con-

ditions,

desirable

use

propel-

ler

which

will

permit

the

engine

reach

its

full

rated

speed

full

throttle

under

normal

load.

ALIGNMENT

ENGINE

The

engine

must

properly

and

exactly

aligned

with

the

propeller

shaft.

matter

what

material

used

build

boat

will

found

flexible

some

extent

and

the

boat

hull

will

change

its

shape

greater

extent

than

usually

realized

when

launched

and

operated

the

water.

therefore

very

important

check

the

engine

align-

ment

frequent

intervals

and

correct

any

errors

when

they

may

appear.

Misalignment

between

the

engine

and

the

propeller

shaft

the

cause

troubles

which

are

blamed

often

other

causes.

will

create

excessive

bearing

wear,

rapid

shaft

wear

and

will,

many

cases,

reduce

the

life

the

hull

loosening

the

hull

fastenings.

bent

propeller

shaft

will

have

exactly

the

same

effect

and

therefore

necessary

that

the

propeller

shaft

itself

perfectly

straight.

One

particularly

annoying

result

mis-

alignment

may

leakage

transmission

oil

through

the

rear

oil

seal.

Check

make

sure

that

alignment

within

the

limits

prescribed.

The

engine

should

moved

around

the

bed

and

supported

the

screw-jacks

shims

until

the

two

halves

the

coup-

lings

can

brought

together

without

using

force

and

that

the

flanges

meet

evenly

all

around.

best

not

drill

the

foundation

for

the

foundation

bolts

until

the

approximate

alignment

has

been

accu-

rately

determined.

Never

attempt

final

alignment

with

the

boat

land.

The

boat

should

the

water

and

have

had

opportunity

assume

its

final

water

form.

best

the

alignment

with

the

fuel

and

water

tank

about

half

full

and

all

the

usual

equipment

board

and

after

the

main

mast

has

been

stepped

and

final

rig-

ging

has

been

accomplished.

Take

plenty

time

making

this

alignment

and

not

satisfied

with

anything

less

than

perfect

results.

The

alignment

correct

when

the

shaft

can

slipped

backwards

and

forward

into

the

counterbore

very

easily

and

when a

feeler

gauge

indicates

that

the

flanges

come

exactly

together

all

points.

The

two

halves

the

propeller

coupling

should

parallel

within

0.002

inches

(A).

making

the

final

check

for

alignment,

the

engine

half

coupling

should

held

one

position

and

the

alignment

with

the

propeller

coupling

tested

with

the

propeller

coupling

each

four

positions,

rotated

900

between

each

position.

This

test

will

also

check

whether

the

propeller

half

coup-

ling

exact

alignment

its

shaft.

Then,

keeping

the

propeller

coupling

one

position

the

alignment

should

checked

rotating

the

engine

half

coupling

full

position

each

900

from

the

one.

The

engine

alignment

should

rechecked

after

the

boat

has

been

service

for

one

three

weeks

and,

necessary,

the

alignment

remade.

will

usually

found

that

the

engine

longer

alignment.

This

not

because

the

work

was

improperly

done

first,

but

because

the

boat

has

taken

some

time

take

its

final

shape

and

the

engine

bed

and

engine

stringers

have

probably

absorbed

some

moisture.

may

even

necessary

re-

align

further

period.

The

coupling

should

always

opened

and

the

bolts

removed

whenever

the

boat

hauled

out

moved

from

the

land

the

water,

and

during

storage

cradle.

The

flexibility

the

boat

often

puts

very

severe

strain

the

shaft

the

coupling

both

when

being

moved.

some

cases

the

shaft

has

actually

been

bent

these

strains.

This

does

not

apply

small

boats

that

are

hauled

out

the

water

when

not

use,

unless

they

are

dry

for

considerable

time.

EXHAUST

SYSTEM

Exhaust

line

installations

vary

consid-

erably

and

each

must

designed

for

the

particular

job.

The

general

requirements

are

provide

outlet

line

with

mini-

mum

restrictions

and

arranged

that

sea

water,

rain

water,

condensation

cannot

get

back

into

the

engine.

There

should

be a

considerable

fall

the

line

between

the

exhaust

manifold

flange

and

the

discharge

end.

This

slope

the

pipe

makes

difficult

for

water

driven

very

far

by a wave;

and

steep

drop

followed

by a

long

slope

better

than

straight

gradual

slope.

Avqid

any

depres-

sion

trough

the

line

which

would

fill

with

water

and

obstruct

the

flow

exhaust

gas.

Also

avoid

any

sharp

bends.

Brass

copper

not

acceptable

for

wet

exhaust

systems,

the

combination

salt

water

and

diesel

exhaust

gas

will

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