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: [phone]
TELEX: 92-4444. FAX: [phone]· CABLE: WESTCORP

FOREWORD
Thank you for having selected a Westerbeke
Diesel Engine for your use.
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.
If, within 60 days of submitting your warranty
registration card, you have not received a Customer
Identification Card (see below) registering your
warranty, please contact the factory in writing.
We look forward to your continued patronage.
from: J.H. Weslerbeke Corp.
Avon Industrial Park
Avon, MA 02322
r/~1
J. H. 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
85 Maple Street
Alden,
IN 12234
~ ~
1

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. REQUIREMENTS FOR PROPER
OPERATION
7-1 Lubrication System ••••••••• 13
7-2 Fuel System .••.••....••.•.. 14
7-3 Wiring Diagram .•••• Centerfold
7-3 Cooling System •••••....•••• lS
7-4 Belt Tension ............... 20
7-6 Domestic Hot Water ..••••••• 20
7-7 Cylinder Head & Valves .••••• 24
S. RECOMMENDED MAINTENANCE SERVICE.25
9.. TRANSMISSIONS .... ................................ .. 28
10. TROUBLESHOOTING ••••••••••••••••• 40
11. TABLE OF TIGHTENING TORQUES •.••• 41
12. COMMON PARTS BY NUMBER •••••••••• 43
13. LIMITED WARRANTy ••••••••••••...• 44
2

GENERAL SPECIFICATIONS
Model
Type
Westerbeke 46
4-cycle, fresh water cooled diesel engine
with raw water exchanger system
*& Arrangement of Cylinders 4 cylinder-vertical-in line
Bore & Stroke
Dry Weight
Total Piston Displacement
Compression Ratio
Firing Order
Rotational Direction
Fuel
Lubricating Oil
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
84 X 90mm (3.30 X 3.70 in.)
535 Ibs. (242kg)
2084cc (127 cu. in.)
21 : 1.
1 - 3 - 4 - 2
Clockwise as viewed from front of engine
*2 fuel oil (cetane rating 45 or better)
Mineral oil, heavy duty, A.P.I. CC or CD
Idle 20 - 30 P.S.I. (1.75 - 2.46 kg/cm
2)
Under power 30 - 60 P.S.I.
(2.46 - 4.21 kg/cm
2)
47.5 horsepower at 3000 RPM
46 horsepower at 3000 RPM
43 horsepower at 3000 RPM
700-850 RPM
2000-2500 RPM
Forced lubrication
Trochoid pump
Full-flow type with paper element
7 quarts & filter
Forced circulation by centrifugal pump
with thermostatically controled temperature
170 - 190· F
NIHON-CAV
distributor type
Bosch type, DNOSD
Flyweight type, built in pump
with paper element
Electric starter with glow plugs in head
3

starter
Alternator
Battery
Raw Water Flow Rate
Propeller Recommendations
(using HBW-150 1.8S:1
reduction)
12V, 1.6KW pinion shift type
12V - 50 ampere
12V - 100 ampere hour
9.5-10.0 gallons/minute at 3000 R.P.M.
measured at discharge into exhaust elbow
lSD x 10P-2 blade or lSD x SP - 3 blade
propeller should allow engine to reach
its rated RPM (3000 + 100) at full
throttle underway
4

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.
*
*
*
Fill engine sump with lubricating oil
(Select readily available lubricating
(Sump capacity 7 quarts).
to full mar k on dipstick
oil of grade CC or CD)
Fill freshwater cooling system with suitable mixture of water and
antifreeze to suit your temperature zone. Thoroughly mix
antifreeze and freshwater BEFORE adding to cooling system.
Plug-in Panel Harness Connection. After assembly, joint should be
taped to prevent corrosion or, preferably, assembled using a sili-
con grease which can be obtained at an electronic store such as
Radio Shack.
SAFETY PRECAUTIONS
*
*
*
*
*
*
*
*
Never operate engine with inadequate ventilation. Confirm that
there are no exhaust leaks inside engine compartment.
Do not touch moving parts during operation.
Do not touch hot parts such as exhaust pipe, and do not place com-
bustible materialS near the engine.
Inspect and adjust parts of the engine only after it is stopped.
Check and refill engine oil, cooling water and transmission lubri
cant only after the engine is brought to a stop.
A coolant recovery bottle was supplied with the engine together
with instructions for installation. Be sure that it is in place.
Attempting to operate with only the manifold as an expansion tank
exposes the operator to a severe steam burn if the manifold pres-
sure cap is removed while the engine is hot. Follow instructions
on page 6.
Always use tools that fit correctly and use caution during ser-
vicing.
Be sure that current carrying wires are protected from abrasion
and that all connections are tight.
5

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 specifi-
cation of CC or better. For
quantity of oil, you may refer
to the General Specifications
page.
b) Fill
with the
NOTE: Some
separately.
the transmission
proper lubricant.
V-Drives are filled
2. Your engine is supplied with a
coolant recovery system to
which the following instruc-
tions apply:
a) Fill engine completely to
the neck of the manifold cap.
b) Then fill the recovery
tank to the bottom add line.
Need for adding coolant is
indicated when a cold engine
has coolant level below the
bottom add line.
c) In winter add antifreeze
as described on page 18. A
mixture of antifreeze should be
used year round and changed as
needed.
3. Fill the fuel tank with *2
Diesel fuel with *45 Cetane
rating or better. The interior
of the fuel tank must be main-
tained clean. Be careful not
to allow introduction of dir t
when filling fuel.
4.
Engine oil, coolant
transmission levels should
checked at least once a
prior to engine use.
and
be
day
6
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 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 con-
ditioning operation for breaking in each moving part, thus helping
maximizing performance and service life of engine. Perform this con-
ditioning carefully, keeping the following points in mind.
1. Start engine, run at idle while checking that all systems are
functioning - sea water pump, oil pressure, battery charge.
2. Warm engine, prefer ably by running propeller at fast idle
while tied down, until water temperature gauge moves into the
130 - 140 degree range.
3. Then use engine at moderate load (RPM) until normal engine
operating temperature of 170 - 190'F (77 - BS'C) is reached.
4. Avoid rapid acceleration especially with a cold engine.
5.
Use caution not to overload engine. Grey
sign of overload. Select the correct
engine and transmission reduction.
or black smoke is a
propeller for the
6. Operate the engine in moderation, varying the running RPM
under load during the break in period.
Explanation:
"Breaking in" a new engine is basically a seating of the piston rings
to the cylinder walls. This is not accomplished by long periods of
running idle, nor by 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.
As indicated above, operate the engine in moderation during the ini-
tial 50 hours of break in. Don't baby it, yet do not abuse it.
7

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 com-
bustion chamber so that the end
is in the spray path of the
injector nozzle. When the glow
plugs are energized by the pre-
heat 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.
This system is common to
Westerbeke Diesels. The star t
circuitry is designed so that,
first, the preheat button must be
depressed for the time specified
in the glow plug use char t shown
below.
Glow Plug
Injector
After which, and while keeping the preheat button engaged, the start
button is depressed to crank the engine.
Glow Plug Use Data
Atmospheric temperature Preheating
time
+S'C (+41"F)
or
higher
Approx" 10
sec.
+S"C (+4l'F)
to -S'C (+23'F)
Approx,
20
sec"
-SoC
(+23"F) or lower Approx.
30
sec,
Limit of
continuous use
1
minute
For complete starting and stopping procedures, see pages 10 and 11.
8