OPERATORS MANUAL WESTERBEKE MARINE DIESEL ENGINE 55A FOUR PUBLICATION 041562 2nd Edition I February 1997 l~ 'WESTERBEKE ~ WESTERBEKE CORPORATION ·150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK· TAUNTON, MA 02780 WEBSITE: www.WESTERBEKE.
CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to foUow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne~ and your machinery. The foUowing safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. PREVENT ELECTRIC SHOCK A WARNING: Fire can cause injury or death! • Prevent flash fires.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING A TOXIC EXHAUST GASES A WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) is a deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Pay close attention to the manifold, water injection elbow, and exhaust pipe nipple. .
SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING GASOLINE AND DIESEL ENGINES AND GENERATORS operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system components. • Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. Read the following ABYC, NFPA and USCG publications for safety codes and standards.
INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
TABLE OF CONTENTS Introduction .............................................................. 2 Warranty Procedures .............................................. 2 Product Software ................................................... 2 Notes, Cautions and Wamings .............................. 2 Serial Number Location ........................................ 3 Understanding the Diesel Engine .......................... 3 Ordering Parts ........................................................
INTRODUCTION PRODUCT SOFTWARE This WESTERBEKE Marine Diesel Engine is a product of WESTERBEKE' S long years of experience and advanced technology. We take great pride in the superior durability and dependable performance of our engines and generators. Thank you for selecting WESTERBEKE. Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE are not within WESTERBEKE'S CONTROL.
INTRODUCTION (Continued) SERIAL NUMBER LOCATION ORDERING PARTS An identification nameplate that displays the engine model number and engine serial number is mounted on the side of the engine manifold. Take the time to enter this information on the blank decal provided below. This will provide a quick reference when seeking technical information and/or ordering parts.
CONTROL PANELS WESTERBEKE offers two optional panels- select the instruction page that applies to the panel you purchased. You will notice that when the engine is shut down with the Key Switch turned OFF, the water temperature gauge will continue to register the last temperature reading indicated by the gauge before electrical power was turned OFF. The oil pressure gauge will also hold its reading.
CONTROL PANELS (Continued) CAPTAINS PANEL COOLANT TEMPERATURE; and an alarm buzzer for low OIL PRESSURE or high WATER TEMPERATURE. The RPM gauge is illuminated when the key switch is turned ON and remains illuminated while the engine is in operation.
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT Use fuel that meets the requirements or specification of Class 2-D (ASTM), and has a cetane rating of #45 or better. . The use of an antifreeze mixture of 50/50 is recommended for year-round use. Use antifreeze that is compatible with aluminium components, and never mix different brands of antifreeze. Do not use straight water, this can be detrimental to the cooling system components.
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION o Before starting your engine for the first time or after a prolonged layoff - check the following items. Check the DC electrical system. Inspect wire connections and battery cable connections. o Visually examine the unit. Look for loose or missing parts, disconnected wires, unattached hoses, and check threaded connections. o Check the coolant level in the plastic recovery tank and at the manifold.
STARTING/STOPPING PROCEDURE STARTING PROCEDURE A CAUTION: Prolonged cranking intervals without the engine starting can result in the engine exhaust system filling with raw water. This may happen because the pump is pumping raw water through the raw water cooling system during cranking. This raw water can enter the engine's cylinders by way of the exhaust manifold once the exhaust system fills.
BREAK-IN PROCEDURE THE FIRST 50 HOURS 4. Avoid rapid acceleration, especially with a cold engine. Although your engine has experienced a minimum of one hour of test operations to ensure accurate assembly and proper operation of all systems, break-in time is required. The service life of your engine is dependent upon how the engine is operated and serviced during its initial 50 hours of use. S. Use caution not to overload the engine.
THE DAILY ROUTINE CHECK LIST START YOUR ENGINE Each day before starting your engine, take a few moments to run this check list: NOTE: See Starting/Stopping Procedure in this manual for more detailed instructions. o 1. Put transmission in neutral, throttle advanced. o o o o o o Visually inspect the engine for fuel, oil, or water leaks. 2. Tum KEY to the ON position (2 o'clock) Check the oil level (dipstick). 3. Depress PREHEAT (10 to 15 seconds). Check the transmission fluid level. 4.
MAINTENANCE SCHEDULE A WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. NOTE: Many of the following maintenance jobs are simple but others are more difficult and may require the expert knowledge of a service mechanic. A complete service manual is availablefrom your WESTERBEKE dealer.
MAINTENANCE SCHEDULE (Continued) NOTE: Use engine hour meter gauge to log your engine hours or record your engine hours by running time. SCHEDULED MAINTENANCE CHECK EACH DAY HOURS OF OPERATION 50 100 250 500 750 1000 1250 EXPLANATION OF SCHEDULED MAINTENANCE D D D D D D Hose should be hard & tight. Replace if soft or spongy. Check & tighten all hose clamps. Heat Exchanger Zinc Anode D D D D D D D Clean or replace. Open heat exchanger end cap and clean out debris.
ENGINE COOLANT CHANGING THE COOLANT Start the engine and bring it to operating temperature. Monitor the coolant in the manifold and add as needed. Fill the manifold to the filler neck and install the pressure cap. The engine's coolant must be changed every eight to twelve months depending on the engine's use. If the coolant is allowed to become contaminated, it can lead to overheating problems.
ENGINE OIL CHANGE DRAIN THE SUMP filter when unscrewing it to catch any oil left in the filter. Inspect the old oil filter as it is removed to make sure that the rubber sealing gasket comes off with the old oil filter. If this rubber sealing gasket remains sealed against the engine block, gently remove it. When installing the new oil filter element, wipe the filter gasket's sealing surface on the engine block free of oil and apply a thin coat of clean engine oil to the rubber gasket on the new oil filter.
FUEL SYSTEM A WARNING: Shut off the fuel valve at the tank when servicing the fuel system. Take care in catching any fuel that may spill. DO NOT allow any smoking, open flames or other sources of fire near the fuel system when servicing. Ensure proper ventilation exists when servicing the fuel system.
FUEL(Continued) SYSTEM FUEL ADDITIVES If fungus or bacteria is causing fuel problems, you should have an authorized dealer correct these problems. Then use a diesel fuel biocide to sterilize the fuel (follow the manufacturer's instructions). SPARES While the likelihood of having to service the fuel system at sea is slim, the possibility does exist. Therefore, we recommend that banjo washers, injector seat washers, and a fuel filter be carried on board at all times.
DC ELECTRICAL SYSTEM DESCRIPTION A. WARNING: Before starting the engine make certain The charging system consists of an alternator with a mounted voltage regulator, an engine DC wiring harness, a mounted DC circuit breaker, and a battery and connection wires. Because of the use of integrated circuits (IC's) the electronic voltage regulator is very compact and is mounted internally or on the back of the alternator.
DC ELECTRICAL SYSTEM (Continued) DRIVE BELT ADJUSTMENT BATTERY CARE Review the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine starting batteries and house batteries. A CAUTION: Drive belts must be properly tensioned. Loose drive belts will not provide proper alternator charging and will eventually damage the alternator. Drive belts that are too tight will pull the alternator out of alignment and/or cause the alternator to wear out prematurely.
DC ELECTRICAL SYSTEM WIRING DIAGRAM #39144 " " 110 R. R IU PHI( r~11 I Il!ll. I(~E MOOnS. i6i SEE NOTE 11 '~ -9' I I +~ ~~ BAnERY ® $I NOTE: AN ON-OFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATIERY AND STARTER TO DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH WITH A CONTINUOUS RATING OF 175 AMPS AT 12 VDC WILL SERVE THIS FUNCTION. THIS SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT. ADMIRAL PANEL -, " CAPTAIN PANEL oz ;; ~~~~~--, o ALT.
DC ELECTRICAL SYSTEM WIRING DIAGRAM #39144 r---~~--------------------_+ -----1 I I I I I I I I I AL TERIfATOR rT;,;-;.~-----1 LIFT PUMP I ~-+~-r------r.-~P -R- TERM. I I I fUn U .jDac~l: ~ .--+-+-+____---<'-'5run 0.=.: &II~I_ .WM(I SOL. I O.P. I SENDER =1 I 12080 &. 308ITI ONLY L __ ~~~~ __ I NOTES: I. THIS PRODUCT IS PROTECTED BT A MANUAL RESET CIRCUIT BR[AKER LOCATEO NEAR THE STARTER. EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE [NGINE WILL SHUT DOWIf.
WATER HEATER WATER HEATER INSTALLATIONS This engine is equipped with connections for the plumbing of engine coolant to heat an on-board water heater. The water heater should be mounted in a convenient location either in a high or low position in relation to the engine, so that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap air.
-ENGINE ADJUSTMENTS ADJUSTING VALVE CLEARANCES 7. Using a small screwdriver or magnet, remove the adjusting disc. 1. Remove the cylinder head rocker cover. 8. Select an appropriate disc thickness depending on the 2. Manually rotate the engine crankshaft and bring #1 piston up on TDC of its compression stroke. clearance measured. Install it and verify proper clearance. NOTE: When this occurs, the intake and exhaust cam lobes will face upwards.
ENGINE ADJUSTMENTS (Continued) Timing Belt Tensioner TIMING BELT INSPECTION AND REPLACEMENT' 1. Check the rotation of the timing belt tensioner pulley. Check for play or abnormal noise. 1. Before removing the timing belt and timing belt tensioner, rotate the engine crankshaft by hand and align the three timing marks as shown in the illustration. NOTE: Do not clean the timing belt tensioner with cleaning solvents. If dirty, use a clean rag to wipe it clean.
ENGINE ADJUSTMENTS (Continued) 3. Install the timing belt. NOTE: If reinstalling the original belt, be sure to install with the arrow in the correct direction of belt rotation. 7. Re-check the timing mark positions between the three gears and the gear case. Check the timing belt deflection at the point on the belt shown in the illustration with a pushing force of 10 kg (22Ib). Standard Deflection (unit cold): 10.8-12.9 mm (0.43-0.51 in) DIRECTION ARROW 4.
ENGINE ADJUSTMENTS (Continued) COMPRESSION TEST FUEL INJECTION NOZZLE TEST 1. Warm the engine up to operating temperature. When the injection starting pressure is too high or too low or the fuel spray pattern is improper, an abnormal fuel combustion takes place in the engine leading to lowered power output, blackish exhaust smoke and unwanted combustion noise. Further, it can cause a piston seizure or piston damage if not corrected.
HBW TRANSMISSION INITIAL OPERATION LOCKING THE PROP All HBW marine transmissions are test-run on a test stand with the engine at the factory prior to delivery. For safety reasons the fluid is drained before shipment. Locking of the propeller shaft by an additional brake is not required: use the gear lever position opposite your direction of travel for this purpose. Never put the gear lever in the position corresponding to the direction of travel of the boat.
HBW TRANSMISSION (Continued) A CAUTION: The position of the cover plate underneath the actuating lever is factory-adjusted to ensure equal shift lever travel from neutral position to A and B. If this side shift cover is removed or in any way tampered with, the transmission warranty will be void. Authorized Hurth personnel only may adjust or remove this cover.
BORG WARNER VELVET DRIVE TRANSMISSION INITIAL OPERATION NOTE: If the boat moves backwards with the selector control in the forward position, shut off the engine! This problem may be the result of incorrect movement of the shift lever by the shift control. Transmission Fluid Check transmission fluid level on the dipstick. If the transmission has not been filled, fill with Dextron III and continue to use this fluid.
BORG WARNER VELVET DRIVE TRANSMISSION (Continued) MAINTENANCE OIL FILLER CAP AND DIPSTICK ASSEMBLY D Visually check for oil leaks at hydraulic connections. Check wear on hydraulic lines and replace if worn. D Lubricate detent ball and shift cable attachments. OIL FILLER CAP AND DIPSTICK --==--M ASSEMBLY HOLE D Inspect shift linkage. D Inspect transmission bolts; retorque if necessary. A CAUTION: Clutch failure will occur if the transmission shift lever does not fully engage the detent ball positions.
ENGINE TROUBLESHOOTING NOTE: The engine's electrical system is protected by a 20-Ampere manual reset circuit breaker located on a bracket on the left front side of the engine. The preheat solenoid is mounted on the same bracket. The following troubleshooting table describes certain problems, the probable causes of the problems, and the recommendations to overcome the problems.
ENGINE TROUBLESHOOTING (Continued) Ensure 12 volts are present at the "R" terminal. Problem Battery runs down. Probable Cause Verification/Remedy 1. Oil pressure switch. 1. Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure switch. 2. High resistance leak to ground. 2. Check wiring. Insert sensitive (0-.25 amp) meter in battery lines. (Do not start engine.) Remove connections and replace after short is located. 3. Low resistance leak. 3.
LAY-UP AND RECOMMISSIONING GENERAL small amount of oil on the rubber sealing gasket at the base of the filter. Fill the sump with the correct amou'nt of oil for your engine model. (Refer to the SPECIFICATIONS section of this manual.) Use an oilwith an API specification of CF or CG4. Run the engine and check for proper oil pressure and make sure there are not leaks. Stop the engine, check oil level and add oil as needed to bring level to dipstick full mark.
LAY-UP AND RECOMMISSIONING (Continued) protect the raw water circuit from freezing during the winter lay-up, as well as providing corrosion protection. Rempve the impeller from your raw water pump (some antifreeze mixture will accompany it, so catch it in a bucket). Examine the impeller. Acquire replacement, if needed, and a cover gasket. Do not replace the impeller (into the pump) until recommissioning, but replace the cover and gasket.
WESTERBEKE 55A FOUR TORQUE SPECIFICATIONS Ib-ft kg-m Cylinder Head Bolts Cylinder head bolts are not retorqued. Bolts are torqued only during engine assembly. Connecting Rod Cap Bolts 51-54 7.0-7.5 Main Bearing Cap Bolts 61-65 8.4-9.0 Injection Pump Drive Gear 43-52 6.0-7.0 5-7 0.7-1.0 Crankshaft Pulley Bolts 17-24 2.3-3.3 Glow Plugs 11-15 1.5-2.0 Intake Manifold Bolts 12-20 1.6-2.7 Exhaust Manifold Bolts 16-20 2.2-2.7 Switches and Senders 9-13 1.2-1.
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Pitch lb-ft kg-m Grade 4 6mm bolt head/nut 8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut 1 1.25 1.25 1.5 1.25 (ISO) 1.5 1.75 1.5 1.5 2 1.5 2 2.9-5.1 7.2-11.6 13.7-22.4 13.0-21.7 25.3-39.8 25.3-39.
WESTERBEKE 55A FOUR SPECIFICATIONS COOLING SYSTEM ENGINE SPECIFICATIONS Engine Type Diesel, four-cycle, four-cylinder, freshwatercooled, vertical, in-line (55 hp at 3600 rpm maximum) Governor Integral of the injection pump, mechanical flyweig ht type Valve Mechanism Overhead Combustion Chamber Swirl chamber type Bore &Stroke 3.38 x 3.70 inches (86.0 x 94.0 mm) Piston Displacement 133.2 cubic inches {2.
WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK AVON, MA 02322· TEL: (508) 588-7700 • FAX: (508) 559-9323 --- ~ Member National Marine ManufacturersAssocUztion
