Westerbeke FOUR-60 User manual

TECHNICAL MANUAL AND PARTS LIST
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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. MA 02322. TEL: (61 ?j 58fJ..7100

INTRODUCTION
This manual describes the operation. adjustment and maintenance of the
Westerbeke Model Four-60 Marine Diesel Engine. and is designed to be a ,guide
for those concerned with the operation and maintenance of these diesels.
The diesel engine closely resembles the gasoline engine inasmuch as the mecha-
nism is essentially the same. Its' cylinders are arranged above its closed crank-
case, its crankshaft is one of the same general type as that of a gasoline engine;
it has the same sort of valves~. camshaft, pistons, connecting rods and lubricating
system and reverse and redqction gear. . . .
Therefore, it follows to. a great extent that a diesel engine requires the same
preventive maintenance as that which any intelligent and careful operator would
give to a gasoline engine. The most important factors are proper maintenance of
the fuel, lubricating and cooling systems. Replacement of fuel and lubricating
filter elements at the time periods specified is a must and frequent checking for
contamination (i. e., water, sediment, etc.) in the fuel system is also essential.
Another important factor is the use of the same brand of a "High Detergent" diesel
lubricating oil designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine, however, in the method of (
handling and firing its fuel. Carburetor and ignition systems are done away with
and in their place is a single component - the Fuel Injection Pump - which per-
forms the functions of both.
Unremitting care and attention at the factory have resulted in an engine capable of
many thousands of hours 'of service. What the manufacturer cannot control how-
ever, is the treatment the product will receive in service. This part rests with
you.
Whenever service parts are ordered. always give complete description and part
numbers with engine model and number. As an example:
2
Please supply:
For Four-60 Marine Diesel Engine No. 3870
10 of 11951 LUBE OIL FILTERS
The serial number ;s stamped on the name plate affixed to the exhaust manifold.

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INTRODUCTION
PHOTOGRAPHS
WESTERBEKE MODEL FOUR- 60
15 h. p. Mini Diesel Engine
TABLE OF:' CONTENTS
........... .. .....................
...
,. ....... .' . . '.' . '. ..........." ,,' ~ .:
INSTALLATION DRAWINGS ......................... .
GENERAL DATA .' .... " ................... e' ' ••••• ' •• "
INSTALLA TION ..... ~ ..... ' ............... ' ...... .
OPERATION ................................... .
LUBRICATION SYSTEM
COOLING SYSTEM ..... ......................... .
FUEL SYS TEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAO TRANSMISSION
SSL TRANSMISSION
Page No.
2
4
5
6
9
17
SECTION A
SECTION B
SECTION C
45
62
3

SURGE TANK
FILLER CAP
ALTERNATOR
OPTIONAL
AIR CLEANER
OIL SUMP
DRAIN PIPE
'RIMARY FUEL
FILTER
4
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
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ST ARBOARD AND PORT VIEWS-FOUR 60/SSL
Photos above show the SSL
Transmission which was designed for the Four-60 Diesel.
The gear is available in two Ratios, 1.3:1 and 2:1.
Its small
size and moderate offset greatly increases installability of Four-60 by de-
creasing length to 30 inches and reducing depth belowpropeller shaft line t04 3/4 inches.
4A

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INSTALL}\.TION DRAWINGS
101-- I
:32.L DIRECT DRiVe: ~ I
jo4-----37 ~ ~.67:1 AND 2:1 RATIO ~
Four-60/SAO Reverse and Reduction Gear
~-------2~'-----~·1
.---'
-~3o!-!------' - .. ~-.---' ~'.--~~-.:'::l
1-2;!z.o------ 16 •
1-- ______ .'.--
34
3- _ .. _.---- ..I
Four-no/SSLReverse Gear
5

GENERAL DATA
DIESEL ENGINE
Number of 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 to bore clearance (at bottom of skirt)
Gudgeon pins
Fit in piston
Clearance in small-end bush
..
CODDecting rods
Length between centres
Side clearance on 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:
6
Inside diameter (finished in position)
Clearance
on hub ..
4.
.. 23·6: 1.
2'477 to 2·4785 in. (62'915 to 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.) at 1,750 r.p.m•.
·0025
to·0045 in. ('062 to ·113 mm.).
·0015 to ·0035 in. ('038 to ·097 mm.).
. . ·0015
to ·0035 in. (-038 to '097 mm.).
. . ·010
to ·015 in. ('2S4lo ·381 mm..).
·007 to ·012 in. (-178 to ·305 mm.).
·007 to -012 in. (·178 to ·305 mm.).
·0031 to ·0037 in. ('787 to '940 mm.).
·00025 in. (·0063 mm.) slack, to ·00015 in.(-0038 mm.).
tight.
·0001 to ·0005 in. (00025 to ·0127 mm.).
5·75 in. (146'05 mm.).
·006 to -010 in. ('152 to ·254 mm.).
2-0005 to 2·001 in. (50·81-3 to 50·825 mm.).
1·7505 to 1·7510 in. (44·462 to. 44·475 mm.).
·001 to ·0027in. ('025 to ·068mm.).
·001
to ·0027 in. ('025 to ·068mm.).
·002
to ·003 in. ('051 to '076 mm.).
·001 to ·002 in. (·025 to ·051 mm.).
·003 to '007 in. ('076 to ·178 mm..).
Duplex roller chain.
Simplex roller chain.
1·75025 to 1·7507S·in. (44·456 to 44·469 mm.).
·001 to ·002 in. ('025 to ·051 mm.).
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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 to guide clearance
Valve
rocker clearance-cold
Valve lift
Valve
stand-down
Valve springs:
Free length
Fitted length-valve closed
Fitted length-valve open ..
Load to compre!;s to fitted length-valve open
Inlet
5° B.T.D.C.
30° A.B.D.C.
45°
·075 in. (1·906 mm.)
·00 15 to ·0025 in.
('038 to ·062 mm.)
·012 in. (,305 mm.)
·276 in. (7'01 mm.)
·018 to ·038 in.
(,457 to ·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 to ·003 in.
(·051 to ·076 mm.)
·012 in. (·305 Inm.)
·276 in. (7·01 mm.)
·018 to ·038 .jn.
(·457 to ·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 to bush clearance
Tappet diameter
. . ·5615 to ,5625 in. (14'263 to 14·288 mm.).
·0005 to ·002 in. ('013 to ·051 mm.).
Flywheel and starter ring
Number of teeth on 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 to compress spring to fitted length
Oil pressure
Idling
speed
Normal running speed
COOLING SYSTEM
Fan belt
Depth ..
Width (outside)
Angle
of ~V'
Lateral movement (measured at the vertical run)
Thermostat
Opening temperature
Fully open temperature
Water puomp spindle
Interference fit
in hub ..
Tnterference fit in vane
·81125 to·81175 in. (20·606 to 20·618 mm.).
94.
200 to 230° C. (392 to 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.).
15 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.).
79 to 84° C. (175 to 183° F.).
94
to 96° C. (201 to 205° F.).
·0015
to ·0028 in. ('038 to ·071 mm.).
·001 to ·0023 in. (·025 to ·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. V. 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 to ·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
60 ft. lbs.
15 ft. lbs.
25 ft. lbs.
40 ft. lbs.
70 ft. lbs.
35 ft. lbs.
50 ft. lbs.
12 volts (ne gati ve ground)
12 volts
130 ampere hours
negative ground
14 amperes
12V.D.C.
55 amperes
12 V. D. C.
SAOD
SA002
SAOV
·.............................
Direct Drive
2:1 RG
SSL-13
SSL-20
8
·...........................
·.............................
·...........................
·.......... .. ................
1. 29:1 RG
1. 67:1 RG
2:1 RG
1. 3:1 RG .
2:1
RG
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