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.
FOREWORD Thank you for having Diesel Engine for your use. selected a Westerbeke This manual describes the procedures for proper handling and routine maintenance of: W-46 Marine Diesel Propulsion Engines To obtain best operating condition and longest service life, it is important to use it sensibly and carry out operation and maintenance according to this manual. If you have questions about your equipment or in the event of a failure, please contact your nearest distributor or dealer.
TABLE OF CONTENTS PAGE GENERAL SPECIFICATIONS •....•••••••••• 3 INSTALLATION, PREPARATION AND SUPPLY CAUTIONS. .. • .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... 5 1. BREAKING IN.......................................... 7 2.. STARTING SySTEM................................. 8 3. INSTRUMENT PANEL USE ••••••••.•.• 9 4. STARTING PROCEDURES ••••••••••••• IO 5. STOPPING PROCEDURES ••••••••.•••. ll 6. CAUTIONS ON STARTING AND OPERATION ..................................... 11 7.
GENERAL SPECIFICATIONS Model Westerbeke 46 Type 4-cycle, fresh water cooled diesel engine with raw water exchanger system * & Arrangement of Cylinders 4 cylinder-vertical-in line Bore & Stroke 84 X 90mm (3.30 X 3.70 in.) Dry Weight 535 Ibs. Total Piston Displacement 2084cc (127 cu. in.) Compression Ratio 21 : 1. Firing Order 1 - 3 - 4 - 2 Rotational Direction Clockwise as viewed from front of engine Fuel *2 Lubricating Oil Mineral oil, heavy duty, A.P.I.
starter 12V, 1.6KW pinion shift type Alternator 12V - 50 ampere Battery 12V - 100 ampere hour Raw Water Flow Rate 9.5-10.0 gallons/minute at 3000 R.P.M. measured at discharge into exhaust elbow Propeller Recommendations (using HBW-150 1.
INSTALLATION, PREPARATION AND SUPPLY CAUTIONS * Check important aspects of installation before operating engine. (1) Alignment (Error to be no more than one thousandth of an inch per inch of 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 *2 diesel from a reputable manufacturer.
PREPARATIONS Take steps as shown below in starting your engine for the first time or after a prolonged shut-down. 1. a) F ill your eng ine wi th oil up to or near the upper limi t on the dipstick. Use a good grade of oil with API specification of CC or better. For quantity of oil, you may refer to the General Specifications page. oil filler port the transmission b) Fill with the proper lubricant. NOTE: Some V-Drives are filled separately. 2.
BREAKING IN YOUR NEW ENGINE While your engine has had at least one hour of test operations to demonstrate accurate assembly and correct operation of all systems, it still requires break in time. Service life of your engine is dependent on how your engine is operated and serviced during initial break-in hours of operation. Your new engine needs approximately fifty hours of initial conditioning operation for breaking in each moving part, thus helping maximizing performance and service life of engine.
DESCRIPTION OF STARTING SYSTEM Model W-46 uses an electr ic starter assisted by glow plugs for both normal and cold weather starting. The figure is a cross section through one cylinder. The glow plug enters the combustion chamber so that the end is in the spray path of the injector nozzle. When the glow plugs are energized by the preheat button, they glow red at the tips and assist rapid ignition of the fuel. The result is rapid starts with less wear on the starter.
INSTRUMENT PANEL Description and use of: Note 1: When engine is stopped after use, the water temperature and oil pressure gauges may stay at their running readings. Note 2: When engine is next to be used, turn keyswitch ON. The temperature and pressure gauges will "ZERO" and the voltmeter will register battery voltage. The elecric fuel pump, mounted on the engine, will also begin to operate, purging any air accumulated in the system. Note 3: The engine is now prepared for starting.
STARTING PROCEDURES 1. Advance throttle to full, press Preheat button and hold for the number of seconds indicated on Page 8 in "Glow Plug Use Data". 2. While still engaging Preheat button, press Start button. Note: Failure to engage the Preheat button will not Starter button to energize the starter. allow the 3. The starter will crank the engine which should start in 10 seconds or less. 4. As soon as the engine starts, release buttons and throttle back to a moderate idle warm up of 80 - 1000 RPM.
STOPPING PROCEDURES 1. Model W-46, early models were supplied with a manual shut-off. A 'T' handle or knob is pulled to shut off fuel, stopping the engine. Later Models June 1985 (C506) on, were supplied with an electric shut-off operated by the key switch and having the manual shutoff as an installer's option. 2. With the engine stopped, it is necessary to turn off the keyswitch. If you fail to do this, the panel remains energized and the electric fuel pump continues to run.
3. Cautions during operation Confirm that the oil pressure is normal during operation. Confirm that exhaust gas is as follows: * * * While engine is cold •••••••••..••...••••• White smoke When the engine grows warm •••...••••••••• Almost smokeless When the engine is overloaded .•••••••... ~Some black smoke Check for abnormal noise such as knocking, sounds, and vibration and blow-back sounds. friction or leaking Check for leaks of fuel and engine oil.
REQUIREMENTS FOR PROPER OPERATION LUBRICATION SYSTEM 1. Engine oil For engine lubrication, use diesel engine oil. Diesel engine oils are classified according to the API Specifications into grades CA, CB, CC and CD. Anyone of them is usable, but use of CC or higher grades prepared by well-known makers is recommended. The oil selected should be used thereafter, 2. Engine oil viscosity Use oil having viscosity best suited to the atmospheric temperature.
5. Note A: After-market filters are not recommended since the material standard or diameters of important items might be entirely different from genuine parts. Note B: Immediately after filter change and oil filler, run engine to ensure that oil pressure is normal and that there are no oil leaks.
If a water trap type filter is not interposed between the fuel tank and engine lift pump, any entrained water will tend to lay in the bottom of the electric lift pump. Internal metal parts of the lift pump will rust. Particles will pass on to filters and eventually to injection pump and injectors with damaging and expensive results. IT IS WELL TO REMEMBER THAT WATER DAMAGE TO THE FUEL SYSTEM IS NOT COVERED BY WARRANTYl While many boat builders do supply a water trap filter, there are some who do not.
3. Notes on fuel system See on prior page a typical exploded view of a fuel system for this engine. It is also illustrative of the self-bleeding and priming system used by Westerbeke. The Westerbeke self-bleeding fuel system is semi-automatic in operation. While it is unlikely that the operator will be forced to service the system at sea, the possibility does exist.
On the forward control housing of the injection pump is a buffer screw. This buffer screw has all the visual characteristeics of a bleed screw, but it is not. The adjustment of this screw should not be tampered with, or disturbed. Disturbing the adjustment of this buffer screw can shut off the delivery of fuel from the injection pump to the injectors and prevent the engine from starting.
COOLING SYSTEM 1. Cooling water As cooling water, use soft water with least impurity content as tap water (potable water) or rainwater, and never use water or foul water. Use of hard water or water containing impurity will lead to collection of scale in the engine and exchanger with resultant decline in cooling effects. 2. such hard much heat Antifreeze In cold districts, care should be taken to prevent cooling water from freezing.
The total system is very reliable and requires only a daily check of the water level in the system plus routine checks of hose clamps and fittings • It is likely that zinc electrodes will waste away from elecrolysis action in the sea water circuit. They should be checked monthly. It is also possible for the raw water pump impeller to fail due to lack of sea water or deterioration.
BELT TENSION The belts are properly tensioned when they deflect 10 to 12 mm (0.39 to 0.47 in) as they are depressed with a finger between the alternator pulley and fresh water pump pulley. Excessive tension can cause quick wear of the belt and bearings of the water pump and the alternator. Excessive slackness or presence of oil on the belt, on the other hand, can lead to engine overheating, insufficient charging due to a slipping alternator belt and rapid wear of the belt.
Model W 46 comes complete wi th a Flow Control which, when proper ly connected to a heater tank, produces domestic hot water from waste engine heat. Principle: With the bypass hose 130962 removed, there remain 2 connecting points A and B for hose to and from the water heater. These connections assure a flow of hot water through the heater at all times and yet preclude excessive restriction of engine cooling water flow caused by the heater - all simply and automatically.
WI PI NG DIAGRAM @SEE NOTE- B W ~ srNDER c ~[R '" eeN T[MP~. 'V.H I 0'L PRESSURE , @ I @SWI-:- CH "' '" ,I @ o "c @ I '" C"-::"" ?> SI AMP J;l ACARM I I e
SCHEMATIC DIAGRAM + r2VDC BATTERY BATTERY RETURN ~?TEY NOTES 0"-1 BU!/J'..£i?/O'NNER5 R£SPONSIBIf-ITV. AlTERNATOR @ '" ,o ~ KEYSW I : iCB ~ iI ' G) \.::) 120AMP @ ~ -~-~-I ~Rw[-HEAT -' 01 SOl. START ,----~,4-j(i~JYY';" S.TART O!.HER rygTES: PRE-HEA1" SOL PANEl WARNING © ,ALL_J?.£IUI?NS ARe THRQUGH ENGINE 8LOC;::. @ SW'@I I@ , i @ ;!ENC>£R CONIYECITot-l: CONTACT WlrH 8+- MAY DAMAGE SENPER. FOR WIRING OF AUX/(LAI?Y AlTE~NATO,eS Sec MOTOROt.A 8.5 AMP'.
CYLINDER HEAD AND VALVES 1. Tighten cylinder head bolts in the sequence shown. The engine should be cold. Loosen each bolt one-eighth to one-quarter turn when tightening in the sequence shown. Note that bolt 14 and 5 are located under the intake manifold where it is attached to the head. 0 0 16 0 0 0 8 14 0 11 10 12 0 0 @J 0 0 1 0 15 0 @) Head Bolt Tightening Torque: 1 Q 0 9 0 6 2 Exhaust Side 12.0 kg/m (86 Ib/ft) Intake side 10.5 kg/m (76 Ib/ft) 7 2.
RECOMMENDED MAINTENANCE SERVICE Check and service your engine at specified intervals to maintain it in its best conditions and permit it to perform as it should. As for those asterisked items, it is suggested that you have them performed by an authorized distributor or dealer. 1. Daily inspection before use. A. Check up of engine oil lever and refilling. No refill is required if the level is near line of the gauge. B. the upper limit Checkup of cooling water and refilling.
I. Check condition of zinc anode in heat exchanger. Should material be flaking off the zinc, it should be scraped clean, or be replaced by a good solid zinc pencil. If it appears that a lot of material has been flaking off the zinc, then it is advised that the end cap of the exchanger be removed, and the flaked material be cleaned from that area of the exchanger. A new end cap gasket should be on hand in case it is needed when replacing the end cap. ZINC #11885 *J. 3. 4. 5.
*D. Checkup of glow plugs. Check glow plugs for blowout. 6. Do resistance check. E. Removal of cooling water and flushing is suggested. F. Lubricate fresh water pump (Grease fitting - refill capacity 1.2 cu. in.) Servicing at ever 800 hours of operation. *A. Checkup of nozzles. set the injection starting +142 pressure to 1706 -0 psi and eliminate undesirable injection conditions including "after dripping". GOOD *B.
HBW TRANSMISSIONS All HBW models turn right hand propellers. All HBW models have their own oil sumps and dipsticks. All HBW models use ATF lubricant. All HBW models should be shifted into gear in one motion - not allowed to slip in slowly. swift Control of gearbox 1. The gear box is su i table for single lever remote control using 33C cable. o I 7i ro / The cable should attach at right angles to the actuating lever using the cable bracket supplied. 3.
WARNER HYDRAULIC TRANSMISSIONS FROM COOLER (2.10:1 ONLY) DIPSTICK ASSEMBLY SHIFT LEVER SHIFT LEVER FROM COOLER 1. 10-13/10-14 FROM COOLER (EXCEPT 2.10:1) 10-17/10-18 CONTROL LEVER POSITION The position of the control lever on transmission when in forward should be shifted to the point where it covers the letter "F" on the case casting, and is located in its proper position by the poppet ball.
3. FILLING AND CHECKING THE HYDRAULIC SYSTEM The oil level should be maintained at the full mark on the dipstick. Check oil level prior to starting engine. Check daily before starting engine. The hydraulic circuit includes the transmission, oil cooler, cooler lines and any gauge lines connected to the circuit. The complete hydraulic circuit must be filled when filling the transmission and this requires purging the system of air before the oil level check can be made.
7. COOLING PROBLEMS Water passages inside of the cooler will sometimes become clogged, and this will reduce cooling capacity and cause overpressuring. Back flushing of the cooler will sometimes help to flush the foreign mater ial from the cooler passages. The cooler and hose should be thoroughly flushed or replaced in the event a failure has occurred. Metallic particles from the failure tend to collect in the case of the cooler and gradually flow back into the lube system.
ROUTINE CHECKS AND MAINTENANCE ANNUAL CHECKS 1. PROPELLER AND OUTPUT SHAFT ALIGNMENT: This check should also be made any time the propeller strikes a heavy object and after any accident where the boat is stopped suddenly. Shaft alignment should also be checked after the boat has been lifted by a hoist or moved on a tr ailer . 2.
shift lever is positioned so that the spring loaded ball enters the chamfered hole in the side of the shift lever. 3. Connect an oil cooler into the cooler circuit before cranking or starting the engine. various cooler circuits have been used and the correct cooler connections should be found from service literature prior to makeing the cooler installation. 4. Use a cooler or sufficient size to insure proper cooling. 5.
WALTER V-DRIVES FLANGE ALIGNMENT - DIRECT COUPLED MODELS Install the propeller shaft flange on to the propeller shaft and tighten the two clamping bolts on the spli t hub (none on CHECK--, RV-10D). A self-locking set screw is proI rSET SCREW vided for the propeller shaft flange. GEAK SHAFT -~" ' y - - , / , FLANGE spot drill the propeller shaft and then securely tighten the set screw. Many good installations are ruined by improper shaft flange alignment.
to the joint end that is on the spool adapter. This distance will not v~ry with misalignment Since the joint is bolted and cannot move.) Put the i3lA alignment gauge on the machined diameter of the #24 cover and slide it completely around. It will indicate how the engine must be moved to center the spline shaft in the oil seal. Re-measure the joints to see if they are still parallel within 1/8". It is important that both alignments be checked thoroughly.
drive train and eliminate many problems that arise due to misalignment. Final alignment should not be attempted until the boat has been allowed to "settle" in the water. Adjust the V-drive until the pilot diameters of the gear shaft flange and the propeller shaft flange engage freely. Butt the flange faces together. Wi thout rotating either flange, check with a feeler gauge in at least four places as shown in the illustration.
IBO'F, although safe operating temperatures may be as high as 210·F. On the models equipped with an oil circulating pump, the *49 oil pressure drop switch and the 12 volt *49A warning light should be hooked up per the wir ing diagr am. The swi tch may be grounded to any part of the V-drive or engine (either terminal may be used for the ground) . OIL FILL Pullout the #21 oil level gauge. Unscrew the #12 breather cap and fill the V-drive with SAE #30 motor oil through the #12A breather elbow.
OPERATION A pressure drop warning light is mounted on the instrument panel on V-drives equipped with an oil circulating pump. The warning light will stay on until the boat gets under way and the engine speed increases to sufficient RPM for the pump to maintain pressure. This normally occurs at approximately 1200 RPM, but the actual speed may vary by as much as 400 RPM. Extended cruising at low RPM, such as when trolling, is not harmful to the V-drive, even though the warning light may stay lit.
The plugs can be checked to see if they are magnetic only after removal. Touch the inside face with a metallic object, such as a screwdriver. Clean them and reinstall. Usually, there are four plugs in the bottom part of the main housing. Only two of these are magnetic. The other two need not be removed (see illustration). Refill wi th SAE 30 motor oi I to the proper level (see INSTALLATION - OIL FILL).
ENGINE TROUBLESHOOTING REMEDY PROBLEM 1. ENGINE DOES NOT START a. b. Starting switch is defective Deficient drive torque of the starter motor c. Improper viscosity of engine oil Engine too cold Seizure of moving parts Air present in fuel system d. e. f.
TORQUE SPECIFICATIONS Kg-m Ib-ft Cylinder head bolts Exhaust side 1l.5 - 12.5 83.2 - 90.5 Intake side 10.0 - 11.0 72.4 - 79.6 Main bearing cap 8.0 9.0 57.9 65.2 Connecting rod bearing caps 5.0 6.0 36.2 Rocker shaft bracket 1.0 2.0 7.2 - 1.5 5.1 - 10.8 1.5 5.1 - 10.8 Camshaft thrust plate 1.5 Idle thrust plate 3.0 Crankshaft pulley 39.5 - Backplate to block 3.0 - Rear oil seal 0.4 Flywheel bolts 8.0 Oil pan bolts 0.7 Front plate bolts .
UNLESS OTHERWISE INDICATED pitch kg-m Ib-ft. Grade 4T 6mm 8mm 10mm 10mm 12mm 12mm 12mm 13mm 14mm 14mm 16mm 16mm bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut 1 1. 25 1. 25 1.5 1. 25 (ISO) 1.5 1. 75 1.5 1.5 2 1.5 2 0.4 1.0 1.9 1.8 3.5 3.5 3.0 4.5 5.0 4.7 7.5 7.1 0.7 1.6 3.1 3.0 5.5 5.5 5.0 7.1 8.0 7.7 - 11. 2 - 10.6 2.9 7.2 13.7 13.0 25.3 25.3 21. 7 32.5 36.2 34.0 54.2 51. 4 - 5.1 11. 6 22.4 21. 7 39.8 39.8 36.2 50.6 57.9 55.7 79.6 76.
COMMON PARTS BY NUMBER PART NUMBER NUMBER REQUIRED PER ENGINE Fuel Hardware Kit, including banjo washers, injector seat washers 34441 1 Lift Pump Filter & Gasket 30548 1 Fuel Filter 24363 1 Lube Oil Filter 35828 1 Glow Plugs 34380 4 Sea Water Pump 16423 1 Sea Water Pump Mounting Gasket 11143 1 Sea Water Pump Repair Kit 18172 1 Sea Water Pump Impeller & Gasket Kit 33104 1 Alternator Belt 30475 1 Thermostat 24688 1 Thermostat Housing Gasket 33966 2 Oil Pressure Alarm Swi
WESTERBEKE LIMITED WARRANTY 1. Warranty Obligation and Duration Westerbeke warrants to the original con~umt:r purchaser that all standard Westerbeke marine engines and generator sets manufactured or supplied by us wii! be free from defects in material and workmanship for a period of one year: from date of commission, or Jate of purchase on rcpower, OR fifteen hundred (1500) hours on Commercial Generators, only (whichever occurs first). 2.
