Westerbeke 108B SIX, Operators Manual And Installation Manual

Page 1: ...OPERATOR S MANUAL AND INSTALLATION GUIDE WESTERBEKE 63 B C FOUR 71B FOUR 82B FOUR 108 B C SIX MARINE DIESEL ENGINES Publication 038922 Edition Three November 1994...

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Page 3: ...OPERATOR S MANUAL AND INSTALLATION GUIDE WESTERBEKE 63 B C FOUR 71B FOUR 82B FOUR 108 B C SIX MARINE DIESEL ENGINES Publication 038922 Edition Three November 1994...

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Page 5: ...eaks and make sure the ex haust manifolds are securely attached and no warp ing exists Be sure the unit and its surroundings are well ven tilated Use Extreme Care When Handling Engine Fuel A constant...

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Page 7: ...software For example components and subassemblies incorporated in Westerbeke s prodUcts and supplied by others such as engine blocks fuel systems and components transmissions electrical components pum...

Page 8: ...Card shown below registering your warranty please contact the factory in writing with model information including the unit s serial number and commission date Unit 1 0 Plates IRBE COR ORllI0 I O 1 1M1...

Page 9: ...RAW WATER INTAKE SYSTEM OPERATIONS CAPTAIN S PANEL ADMIRAL S PANEL PREPARATIONS FOR STARTING STARTING PROCEDURE STOPPING PROCEDURE ENGINE BREAK IN PROCEDURES FUEL SYSTEM DC CONTROL CIRCUIT WIRING DIA...

Page 10: ...icating oil designed specifically for diesel engines Be careful not to put gasoline in the diesel fuel tank s Gasoline does not have the same lubricating qualities as diesel fuel consequently gasoline...

Page 11: ...re thoroughly checked and given a final run under various load conditions before leaving the factory Test running the generator ensures dependable operation long service Iite and a satisfied owner Car...

Page 12: ...Anode Domestic Water Heater Return __ Instrument Panel Connection ___ Transmission Shift Lever Fresh Water Coolant Fill Optional DC Charging Alternator Domestic Water Heater Connection To 63 B FOUR Lu...

Page 13: ...n Pump Alarm Oil Pressure Sender Oil Fill Preheat Solenoid Lube Oil Dipstick Starter with Solenoid inc Anode Domestic Water Heater Return Instrument Panel Connection Battery Ground Connection Transmis...

Page 14: ...r Heater Connection Fuel Manual Primer Preheat Solenoid ________ Zinc Anode Domestic Water Heater Return Heat Exchanger Marine Transmission To Fresh Water Fill Cap 71 B FOUR Optional Refrigeration Com...

Page 15: ...essor Fuel Lift Pump Lube Oil Drain Hose Oil Pressu re Switch Lube Oil Cooler Air Intake Silencer Fuel Manual Primer Lube Oil Dipstick Fuel Filter inc Anode Domestic Water Heater Return Starter with S...

Page 16: ...ust Elb Domestic Water Heater Return Instrument Panel Connection Transmission Shift Lever Domestic Water Fresh Water Unit I D Plate DC Charging Alternator Raw Water Pump Lube Oil Drain Hose To Adjusta...

Page 17: ...ction Pump Top Engine Oil Fill Adjustable Engine Isolator f Oil Pressure Sender Preheat Solenoid Lube Oil Filter Secondary Fuel Filter Zinc Anode Domestic Water Heater Return Fresh Water Block Drain P...

Page 18: ...Exhaust Elbow Exchanger Air Bleed Petcock Transmission Cooler Transmission Dipstick Transmission Vent Transmission Drain Plug Fresh Water Fill Cap Starter with Solenoid 108 B SIX Top Engine Oil Fill...

Page 19: ...Water Temperature Sender Fresh Water Circulating Pump Adjustable Engine Isolator Lube Oil r Secondary Fuel Filter Oil Pressure Sender Fuel Lift Pump 20 A DC Circuit Breaker Zinc Anode Domestic Water...

Page 20: ...gral of the injection pump mechanical flyweight type Overhead Swirl chamber type 3 50 x 3 51 inches 88 9 x 89 9 mm 134 8 cubic inches 2 21 liters 1 3 4 2 Clockwise when viewed from the front 93 Ib ft...

Page 21: ...0 cmm Fresh water cooled block thermostatically controlled with sea water exchanger system 170 1900 F 77 880 C Centrifugal type metal impeller belt driven Positive displacement rubber impeller gear dr...

Page 22: ...d recommended 300 400 cold cranking amp CCA 12 volt 1 6KW solenoid actuated shift reduction geared Glow plugs 100 Amps at U S volts 3000 rpm min 280 300 Amps at 10 volts 250 rpm min 12 volt DC 50 Amps...

Page 23: ...Intergral of the injection pump mechanical flyweight type Overhead Swirl chamber type 3 50 x 4 0 inches 88 9 x 101 6 mm 154 0 cubic inches 2 5 liters 1 3 4 2 Clockwise when viewed from the front 118 I...

Page 24: ...iKi mechanical governed 0 TOC Throttle type 1920 psi 135 kg cm2 12 volt plunger type Spin on type replaceable Metal screen type cleanable 160 4 cfm 4 5 cmm at 3600 rpm Fresh water cooled block thermos...

Page 25: ...Volt 125 AH negative ground recommended 150 A H cold areas 125 155 Ampere Hours 12 Volt 1 6KW solenoid actuated shift reduction gear Glow plug 100 Amps at 11 5 Volts 3000 rpm min 250 300 Amps at 10 V...

Page 26: ...wirl chamber type 3 74 X 4 13 inches 95 X 105 mm 18 2 cubic inches 2 977 liters 1 3 4 2 Clockwise when viewed from the front 147 Ib ft 20 4 kg m 21 1 427 psi 30 0 kglcm2 at 200 rpm Intake 45 Exhaust 3...

Page 27: ...ity Westerbeke Diesel Engines No 2 diesel oil cetane rating of 45 or higher Diesel Kiki 0 TDC Static Timing Throttle 1920 psi 135 kg cm2 12 Volt plunger tyupe Spin on replaceable Metal screen type cle...

Page 28: ...re API Specification CC or CD 12 Volt 125 A H negative ground recommended 150 A H cold areas 125 155 Ampere Hours Glow plugs 12 Volt 3 0KW solenoid actuated shift reduction gear 100 Amps at 11 5 volts...

Page 29: ...p mechanical flyweight type Overhead S rlchambertype 3 62 x 3 40 inches 91 9 x 101 6 mm 247 2 cubic inches 4 05 liters 1 5 3 6 2 4 C1oc se when viewed from the front 1881b ft 26 0 kg m 21 1 427 psi 30...

Page 30: ...cmm Fresh water cooled block thermostatically controlled with sea water exchanger system 170 190 F 77 88 C Centrifugal type metal impeller belt driven Positive displacement rubber impeller gear drive...

Page 31: ...negative ground recommended 400 500 cold cranking amp CCA 12 volt 1 6KW solenoid actuated shift reduction geared Glow plugs 100 Amps at 11 5 volts 3000 rpm min 250 300 Amps at 10 volts 250 rpm min 12...

Page 32: ...NOTES 26 Westerbeke Diesel Engines...

Page 33: ...ith a coating of oil This oil acts as a preservative providing reliable protection against corrosion for at least one year if the engine and transmission is properly stored Inspection of Equipment The...

Page 34: ...special care should be taken to avoid damage to any exposed parts In addition be careful not to allow dirt to enter any opening created by the removal of equipment Removed parts should be returned to...

Page 35: ...o properly support the engine and should be well glassed to the hull when installed GOOD A BAD B Avoid excessive height use solid The temptation to install the engine on a pair stringer construction A...

Page 36: ...the boat s hull will change its shape to a greater extent than is usually realized when the boat is launched and operated in the water Therefore it becomes extremely important to check the engine s al...

Page 37: ...hile in each go position until the half coupling has been rotated full circle The engine s alignment should be rechecked after the boat has been in service for one to three weeks and if necessary perf...

Page 38: ...the vessel is not underway NOTE DO NOT use spring loaded check valves in the fuel supply line in lieu of mechani cal shut off valves This type valve can create fuel starvation problems for the engine...

Page 39: ...ittings used to connect the hose to the gallery be of steel or malleable iron composition Brass must not be used for this application Electrical System The electrical system should be checked to make...

Page 40: ...or a vent in the raw water supply hose to the water injected exhaust elbow This stops the flow of raw water that runs through the raw water cooling system from filling the exhaust and engine cylinders...

Page 41: ...asured by a manometer a pressure gauge or water column should not be over the specifications listed below To measure for back pressure use a mercury manometer a pressure gauge or a water column A boat...

Page 42: ...anufactured by Per matex Company Brooklyn N Y adhesive sealant Place this coated surface against the exhaust manifold s exhaust port flange the gasket should stick to the flange without falling off 2...

Page 43: ...m requires that the raw water inlet be positioned so that the entering stream of raw water does not directly strike a surface In addttion the velocity of the entering raw water stream should be as low...

Page 44: ...Sea cocks and strainers should be at least one size greater than the inlet thread of the sea water pump The strainer should be of the type that may be withdrawn for cleaning while the vessel is at se...

Page 45: ...are preferred Coolant Recovery Tank Recommended Installation A coolant recovery tank kit is supplied with each Westerbeke diesel engine The purpose of this recovery tank is to allow for engine coolant...

Page 46: ...ne 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 o...

Page 47: ...dicator lights illuminate in addition to sounding the alarm buzzer 5 Alarm The alarm is located above the test button and will sound if the engine s oil pressure falls below 15 psi In this event the a...

Page 48: ...1 Key Switch The Key Switch provides power only to the instrument cluster The key switch does shutdown the engine when the key is turned OFF 2 PREHEAT The PREHEAT button energizes the alternator s exc...

Page 49: ...ture once electrical power is restored to the gauge NOTE A separate alarm buzzer with harness is supplied with every Admiral Panel The installer is responsible for electrically connecting the buzzer t...

Page 50: ...igniting the fuel The result is a rapid start with less wear on the starter This system is common to Westerbeke Diesels The start circuitry is designed so that the PREHEAT button ll UW be depressed fo...

Page 51: ...ill the engine s cooling system with a mixture of water and antHreeze suitable for your temperature zone Close the petcock on the exchanger once coolant flows from it Operate the engine and observe th...

Page 52: ...ir found in the fuel system prior to each start would be the result of a leak in the system or improper fuel system plumbing ie supply to the engine or return NOTE Fuel tanks that are positioned below...

Page 53: ...e If no voltage drop is noted it may indicate defective glow plugs or a faulty preheat circuit check for loose connections or faulty preheat solenoid I CAUTION I Prolonged cranking can damage the engi...

Page 54: ...below the engine Start the engine in accordance with the Starting Procedure instructions found on page 46 and allow the engine s operating temperature to reach 140 150 F before operating the engine u...

Page 55: ...el has a mechanical shut off arrn on the outboard side of the injection purnp that can be used to stop the engine by mechanical means When this rnode is used the fuel solenoid on the injection pump is...

Page 56: ...the 130 140 F range 3 While using the vessel run the engine at varying engine speeds for the first 25 hours 4 Avoid rapid acceleration especially with a cold engine 5 Use caution not to overload the e...

Page 57: ...oint is an 11mm hex slotted head screw that should be opened 1 2 turns to remove air from the upper housing area of the fuel filter Energizing the preheat switch for 10 20 seconds or by using the palm...

Page 58: ...ystem on the engine Most installers included with the generator installation package a type of filter water separator for they are aware of the problems contaminants in the fuel can cause all of which...

Page 59: ...peration While the likelihood of having to service the system at sea is slim the possibility does exist Therefore we recommend that fuel system banjo washers injector seat washers a lift pump filter a...

Page 60: ...lift pump as the fuel passes through this filter element before it reaches the secondary filter After the first 50 hour filter change the change period may be increased to 200 hours or once per seaso...

Page 61: ...h adjustment whenever necessary should be performed at an authorized service station as a precision pump tester and skills are required to obtain long and satisfactory service from engine s your injec...

Page 62: ...NOID r fi4l 4LT e u 1 0 0 _ PRESSURE fD ill in G S TCH ill 9 5 r t _ I nLI ED 1D IUsE Ot SCJ o t Ooc S o il C l CIRCUIT STARTER SREAKER mo TO G NE LCn DNEUT I L SAFETY Io IT H USED ON 5 t r O L 6ATTE...

Page 63: ...OR LAMP GOES OUT I tELEASE THE PREHEAT SWITCH STOP TURN THE KEY m THE OFF POSITION I THIS PRODuCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE STARTER EXCESSIVE Cu RENT D AIN WILL C...

Page 64: ...r r 6 OOELS NOTE 2 _ PRESSURE s J 1 7 f Tl SENDER CIRCUIT J C I BREAKER 12 A I GROUND STARTER I TO ENGINE BLOCK GRO NO TO NEUTRAL ENGINE BLOCK SAFEn SWITCH t I IUSEDON SOME S __M O O E LS c ___ __ h...

Page 65: ...ER TO TRIP AND THE ENGINE WILL SHUT DOWN THE BUILDER OWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETIVEEN ELECTRICAL DEVICES AND SALTWATER 2 AN ON O...

Page 66: ...BATTERY Marine Diesel Propulsion Engines Diagram 39144 page 1 of 2 TEST SWITCH 10 8 0 1 Ol 8 i PI II I I 8 0 q I U ill I 60 ADMiRAL PANEL CAPTA Ar LL Westerbeke Generators...

Page 67: ...ROP iON PRESTOL I t 51 AMP AL lLjIMP ALTERN TOR STANDARD AL T RNA COR ON THE 638 lJL 63C J 8 DC 82B IT cea lJ t l08e JlI rMAL CON ECTQR J ON THIS O10E lOR CAPiAiN PANEL H ED Y i O t r i 19 NOES Or T 3...

Page 68: ...gine block through the suction side of the fresh water circulating pump When the engine is starred cold external fresh water flow is prevented by lbe closed lbermostat allbough some fresh water flow i...

Page 69: ...y check that the passage Al between the 900 fitting on the manifold and the filler neck in the manifold is clear so coolant can flow in etther direction Fill the fresh water system as follows 1 Remove...

Page 70: ...E REPLACE REPLACE Zinc Anode Conditions CLEAN OR REPLACE tity The purpose of the zinc anode is to sacrrrice itself to electrolysis action taking place in the sea water cooling circuit thereby reducing...

Page 71: ...of the fresh water pump and alternator shaft bearings Excessive slack or the presence of oil on the belt can cause belt slipping resulting in high operat ing temperature as well as insufficient altern...

Page 72: ...the heater to the engine so that trapped air will rise naturally from the heater to the engine If trapped air is able rise to the heater then an air bleed petcock must be installed at the higher fitt...

Page 73: ...connection from the heater to the remote expansion tank should be routed and supported so as to rise continuously from the heater to the tank enabling any air in the system to rise NOTE An air bleed...

Page 74: ...00F 50 C 600F 200C 400F 5 C or lower Viscosity SAE 30 or 10W 30 SAE 20 or 10W 30 SAE 10W 30 NOTE Do not use an engine lubricating oil with an SAE number greater than 30 in the engine Oil Pressure The...

Page 75: ...as it is removed to make sure that the rubber sealing gasket came off with the old oil filter If this rubber sealing gasket remains sealed against the engine block gently remove it The replaceable ca...

Page 76: ...ia the actuating lever and an actuating cam The completion of the gear changing operation is servo automatically controlled within the gear Gear changing should be smooth not too slow and continuous w...

Page 77: ...actuating lever between the neutral position and end positions A and B should be at least 35mm for the outer and 30mm for the inner pivot point A greater amount of shift lever travel is in no way detr...

Page 78: ...ing lever on the control console and to the acutating lever on the gearbox on this occasion The minimum lever travel from the neutral pOSITion to operating pOSITions O A O B should be 35mm for the out...

Page 79: ...e Visual checks for leakage should be made from time to time IWARNING I Work on the transmission must only be peIiormed with the engine and propeller at standstill II CAUTION II Before the first stali...

Page 80: ...g the shifting lever figure IV I item I at the control block figure IV I item 2 Shifting positions A Propeller rotation Right Hand N Neutral position B Propeller rotation Left Hand IWARNING I Stali en...

Page 81: ...evant IWARNING I Do not work on the transmission when being towed or anchoring in a river because the propeller may rotate Do not work on the transmission in a twin engine boat when one unit is under...

Page 82: ...turning the handle clockwise II CAUTION II Depending on the type and arrangement of the cooler and hoses a cCliain amount of fluid will remain in these after stopping the engine and may flow back into...

Page 83: ...filter element Always carry a spare 2 1 Remove Fluid Filter 2 1 1 Turn the filter cover figure V 3 item 1 counterclockwise and gently pull out of the housing 2 1 2 Pull filter element figure V 4 item...

Page 84: ...sition N Start the engine and let it run idle for a short time to fill the cooler and hoses with transmission fluid 3 3 Stop the engine and check fluid level again If necessary add additional fluid to...

Page 85: ...urn b Fonvard Move selector lever to the fonvard position You should feel the detent The shift lever on the transmission is in the fomard position The output shaft and the propeller should move the bo...

Page 86: ...efore checking oil shut off engine Hot oil could cause burns d Shut off engine and check transmission oil level and add oil if required to the full mark on the dipstick e Restart engine Westerbeke Die...

Page 87: ...if the transmission shift lever does not fully engage the detent ball positions The shifting mechanism and transmission shift lever should be free of dirt to ensure proper operation Do not remove det...

Page 88: ...e Connect oil cooler return line and torque to 25 35 ft Ibs 34 47 Nom f Use a suction pump in the oil filler cap hole to remove remaining oil in the tranmsission g Remove suction pump from transmissi...

Page 89: ...he ben housing output shaft and other gasket sealed areas c Visually check the general condition of the transmission and wipe clean During operation be aware of any unusual noises or vibrations and in...

Page 90: ...failure of its gear involving a warranty claim If it is found that the failure was caused by a shock load the warranty claim will be denied Lay up Storage requires special care Before winter storage o...

Page 91: ...lled in its place If the pressure is normal the switch should be replaced If the pressure is below normal the oil lines should be checked for blockage The pump is standard on the RV 48 and an optional...

Page 92: ...ected Damage to the shaft shaft log and V drive can result Flange Alignment Direct Coupled Models Install the propeller shaft flange on to the propeller shaft and tighten the two clamping bolts on the...

Page 93: ...er the spline shaft in the oil seal Re measure the joints to seal if they are still parallel within 1 8 It is important that both alignments be check thoroughly It is possible for the spline shaft to...

Page 94: ...s bent and must be removed and straightened Rotate the propeller shaft flange in two more 114 turn increments and repeat the procedure The pilot diameters must be rechecked to ensure that they still e...

Page 95: ...Add a 2 ounce tube of Molykote molybdenum disulfide which is supplied with each V drive for extra lubrication and break in It provides protection against scoring or galling of gears bearings and other...

Page 96: ...connection or tripped 10 Amp breaker on the terminal on the preheat solenoid 1 Connection to solenoid faulty 2 Faulty START switch 3 Faulty solenoid 4 Loose battery connection 5 Low batteries Low volt...

Page 97: ...run circuit 2 Check EXC terminal from alternator with harness unplugged 1 Check to see that the shut offvalve at the fuel tank is ON 2 Fuel pump is inoperative 2 Inspect the fuel pump to see ifit is...

Page 98: ...chafed or broken wires loose brackets and fittings damaged hoses loose clamps and other equipment not properly secured 5 Check the fuel supply Fill tank s with a good grade of No 2 diesel fuel if requ...

Page 99: ...esh water cooling system For an illustration showing the heat exchanger and block drain locations see engine photos at beginning of this manual 4 Check the condition of the starter motor drive pinion...

Page 100: ...ove each glow plug and check each cylinder s compression pressure The engine s speed is at 280 rpm 3 Check the battery charging alternator for proper operation 4 Check the tightness of bolts nuts and...

Page 101: ...Bolt Torquing Tighten the cylinder head bolts according to the sequence shown in the illustration for your model The engine should be at room temperature Prior to applying torque to each bolt loosen...

Page 102: ...Top Dead Center of its compression stroke Adjust the valve clearance on the values for the cylinders specified 4 Cylinder Model Intake valves No 1 and No 2 cylinders Exhaust valves No 1 and NO 3 cyli...

Page 103: ...ter Cooling System A 50 50 solution of antifreeze and fresh water is recommended for use in the fresh water cooling system at all times This solution may require a higher concentration of antifreeze d...

Page 104: ...should protect the raw water circuit from freezing during the winter lay up as well as providing corrosion protection Remove the impeller from your raw water pump some antifreeze mixture will accompan...

Page 105: ...xhaust port 2 Remove the sea water pump cover and gasket Discard the gasket Install the sea water pump impeller removed during lay up or a replacement if required Install the sea water pump cover with...

Page 106: ...nut 16 111m bolt headfnut Grade 5 eap sere 1 4 UNC 1 4 UNF 5116 UNC 5116 UNF 3 8 UNC 3 8 UNF 7116 UNC 7116 UNF 1 2UNC 1 2 UNF Westerbeke Diesel Engines Pitch 1 25 1 25 1 5 125 ISO 1 5 1 75 1 5 1 5 2 1...

Page 107: ...C Six Oil Pressure Switch Sender All Models Injection HJP Line Nut All Models Fresh Water Pump Mounting Bolts All Models Timing Gear Cover All Models Back Plate All Models Flywheel bolts 63 B C Four...

Page 108: ...hould be carried on board in addition to those listed above especially if the vessel is to be taken on long ocean voyages These parts are listed below L Fuel Injectors or injector nozzles these can be...

Page 109: ...NOTES 103 Westerbeke Diesel Engines...

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