Westerbeke 44 A FOUR-35C THREE, Operator'S Manual

Page 1: ...EE 448 FOUR 350 THREE 44C FOUR 35E THREE MARINE Dl SEL ENGINES PUBLICATION N0 044180 THIRD REVISION MAY 2012 WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE WWW WESTERBEKE COM A f A j Member National Marine Manufacturers Association ...

Page 2: ...s Carbon Monoxide is poisonous and can cause unconsciousness and death Symptoms of Carbon Monoxide exposure can include Dizziness Nausea Headache Weakness andSleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GET OUTINTO THE FRESH AIR IMMEDIATELY Ifsymptoms persist seek medical attention Shut down the unit a...

Page 3: ...cur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death Do not operate with the air cleaner silencer removed Backfire can cause severe injury...

Page 4: ...r Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is a deadlygas 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 manifol...

Page 5: ...anual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTALLATIONS Preparations to install an engine should begin with a thor ough examination of the American Boat and Yacht Council s ABYC standards These standards are a combination of sources including the USCG and the NFPA Sections o...

Page 6: ...ll result in raw water damage to the engine and possible flooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under the vessel s various operating conditions install a siphon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphon break can res...

Page 7: ... Guide 12 Fuel Injectors 33 Valve Adjustments 34 J S and B W Transmission 35 Borg Warner Velvet Drive Transmission 37 ZF Transmissions 40 PRM Newage Transmissions 43 Maintenance Schedule 13 Transmission Troubleshooting 45 Cooling System 15 Thermostat 16 Propeller Recommendation Chart 46 Lay Up and Recommissioning 47 Raw WaterPump 16 Heat Exchanger 17 Air Intake Silencer 18 Fuel System 19 Fuel Lift...

Page 8: ...LTERNATOR RAW WATER PUMP UNIT I D PLATE OIL PARTS IDENTIFICATION COOLANT PRESSURE CAP BLOCK COOLANT DRAIN HOSE ZINC ANODE OIL DRAIN HOSE OIL COOLER RIGHT SIDE INTAKE AIR FILTER 2 THERMOSTAT ASSEMBLY WATER HEATER CONNECTION FRONT SIDE OIL FILL LIFT PUMP REAR TFORAIN ...

Page 9: ...e char acter indicates the decade A 1960s B 1970s C 1980s D 1990s the first number represents the year in the decade and the second and third numbers represent the month of manufacture PRODUCT SOFTWARE Product software technical data parts lists manuals brochures and catalogs provided from sources other than WESTERBEKE are not within WESTERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CO...

Page 10: ...eplaced at the time peri ods specified and frequent checking for contaminants water sediment etc in the fuel system is also essential Another important factor is the consistent use of the same brand of high detergent diesel lubrication oil designed specifically for diesel engines The diesel engine does differ from the gasoline engine however in its method of handling and firing of fuel The carbure...

Page 11: ...e engine s electrical harness The installer is also responsible for installing the buzzer in a location where it will be dry and where it will be audible to the operator should it sound while the engine is running The buzzer will sound when the ignition key is turned on and should silence when the engine has started and the engine s oil pressure rises above 15 psi 1 1 kg cm2 OIL PRESSURE GAUGE THI...

Page 12: ...LOW 10 5 psi 0 7 0 4 kg em IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 21 o F 99 C IN THIS EVENT THE ALARM WILL EMIT ACONTINUOUS SIGNAL NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINE S OIL PRESSURE REACHES 15 psi 1 1 kg e...

Page 13: ...ne s oil pressure during operation is indicated by the oil pressure gauge on the instrument panel During normal operation the oil pressure will range between 35 and 55 psi 2 5 and 3 9 kg cm2 NOTE A newly started cold engine can have an oil pressure reading up to 60 psi 4 2 kglcm2 A warmed engine can have an oil pressure reading as low as 25 psi 1 8 kglcm2 These readings will vary depending upon th...

Page 14: ... to the starter solenoid and the negative cable is connected to the engine ground stud this location is tagged D Check the coolant level in both the plastic recovery tank and at the manifold NOTE Ifthe engine has not yet been filled with coolant refer to the COOLING SYSTEM section ofthis manual D Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Ch...

Page 15: ...ON 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 exhaustsystem fills Prevent this from happening by closing the raw water supply th...

Page 16: ...g gauges can be added as accessories to either engine at any time and are easily installed to the prewired engine 10 LOW OIL PRESSURE ALARM SWITCH A low oil pressure alarm switch is located off the engine s oil gallery This switch s sensor monitors the engine s oil pressure Should the engine s oil pressure fall to 10 5 psi 0 7 0 4 kg cm2 this switch will activate a pulsating alarm OIL PRESSURE SWI...

Page 17: ...e while checking that all systems raw water pump oil pressure battery charging are functioning 2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves into the 130 140 F 55 60 C range 11 3 While using the vessel run the engine at various engine speeds for the first 25 hours Avoid prolonged periods of idling 4 Avoid rapid acceleration especially with...

Page 18: ...INE NOTE See STARTING STOPPING PROCEDURE in this manualfor more detailed instructions 1 Put the transmission in neutral throttle advanced NOTE Hydraulically operated transmissions have a neutral safety switch through which the starter solenoid energizing circuit passes This switch is open when the transmission is in gear so the starter solenoid will not energize 2 Turn the KEY to the ON position 2...

Page 19: ...ng oil will inhibit the engine s ability to remain and electrical connections Keep bolts nuts tight cool Check for loose belt tension Fuel Filters on engine 0 0 0 0 0 0 Change at 50 hours then every 250 hours Starting Batteries 0 Check electrolyte levels every 50 operating hours and House Batteries weekly and make sure connections are very tight Clean off excessive corrosion Engine Oil and Filter ...

Page 20: ...D Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pinion drive Preheat Circuit D D Check operation of preheat solenoid Remove and clean glow plugs Reinstall with anti seize compound on threads Engine Cylinder D D Check compression pressure and timing see Engine Compression Adjustments Adjust the Valve Clearances D D D Adjust Valve Clearances see EN...

Page 21: ... pump absorbing heat from the engine The coolant then passes through the thermostat into the manifold to the heat exchanger where it is cooled and returned to the engine block via the suction side of the circulating pump ENGINE BLOCK RELEASE THE COOLANT LINE FROM THE OIL COOLER TO DRAIN THE COOLANT FROM THE ENGINE BLOCK 15 When the engine is started cold external coolant flow is pre vented by the ...

Page 22: ...he thermostat gradually opens The thermostat is accessible and can be checked cleaned or replaced easily Carry a spare thermostat and gasket Replacing the Thermostat Remove the cap screws and disassemble the thermostat hous ing as shown When installing the new thermostat and gas ket apply a thin coat of sealant on both sides of the gasket before pressing it into place Do not over tighten the cap s...

Page 23: ...your periodic engine check The water in the glass should be clear Perform the following maintenance after every 100 hours of operation 1 Close the raw water seacock 2 Remove and clean the strainer filter 3 Clean the glass 4 Replace the washer if necessary 5 Reassemble and install the strainer 6 Open the seacock 7 Run the engine and check for leaks NOTE Also follow the above procedure after having ...

Page 24: ...hould not be used as it may insulate the zinc from the metal ofthe heat exchanger hous ing preventing electrolysis action on the zinc Heat Exchanger Service After approximately 1000 hours of operation remove clean and pressure test the engine s heat exchanger A local auto motive radiator shop should be able to clean and test the heat exchanger NOTE Operating in silty and or tropical waters may req...

Page 25: ...UMP Periodically check the fuel connections to and out of the pump and make sure that no leakage is present and that the fittings are tight and secure The DC ground connection at one of the pump s mounting bolts should be clean and well secured by the mounting bolt to ensure proper pump opera tions When energized thru the preheat circuit the fuel lift pump will purge air from the fuel system and p...

Page 26: ...plug s wire connection and the other to the body of the glow plug as shown A good glow plug will have a 0 4 0 6 ohm resistance This method can be used with the plug in or out of the engine You can also use an ammeter to test the power drain 5 6 amps per plug A WARNING These glowplugs will become very hot to the touch Be careful not to burn your fingers when testing the plugs 20 Re install the plug...

Page 27: ... it can be removed Place some paper towels and a plastic bag around the fil ter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Keep your engine clean 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 rub ber sealing gasket remains sealed ...

Page 28: ...alve in the oil pump and returns to the oil sump keeping the oil pressure within its specified range To test the oil pressure remove the oil pressure sender then install a mechanical oil pressure gauge in it s place After warming up the engine set the engine speed at 3000 rpm and read the oil pressure gauge Oil Pressure 35 0 lb in 3 8 kg em or more at 3000 rpm Sender and Switch Torgue 9 13 ft lb 1...

Page 29: ...l the oillines cor rectly II the oil flows in the reverse direction the by pass valve In the fllter assembly w 11prevent the oil from reaching the engine causing an intemal engine failure II there is no o 1pressure reading shutdown Immediately and check the hose connections 23 To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filter kit as shown Always install th...

Page 30: ... return Tee at the heater and plumb a single line up to the tank s location and the other back to the engine s return Install the remote expansion tank in a conve nient location so the coolant level can easily be checked The remote expansion tank will now s erve as a check and system fill point The plastic coolant recovery tank is not used when the remote expansion tank kit is installed since this...

Page 31: ...ear ofmoving parts Keep away from sheaves and belts during test procedures A WARNING When testing with a multimeter DC Qnd AC circuits are often mixed together in marine applications Always disconnect a shore power cord isolate DC and AC converters and shut down the engine before performing DC testing No AC tests shouldbe made without a proper knowledge ofAC circuits 1 Start the engine 2 After the...

Page 32: ... circuit never shut off the engine batteryswitch while the engine Is running Shut off the engine batteryswitch however to avoid electrical shorts when working on the engine s electrical circuit BATTERY The minimum recommended capacity of the battery used in the engine s 12 volt DC control circuit is 600 900 Cold Cranking Amps CCA 26 Checking the Service Battery Check the voltage of the service bat...

Page 33: ...MAKE OR RREAK TH CIRCUIT J THE PINK WIRE AT PLUG 2 IS UNUSED AND SHOULD 0 INSULATED CAPTAIN PANEL ONLY 4 THE GRAY WIRE AT PLUG 2 IS UNUSED AND SHOULD BE INSULAT 0 ADMIRAL PANEL ONLY I 4 l T BtU I I PINK BALMAR 100 AMP_ ALT U R D I STARTING IIA TT R II I If USING liiATT IIl Sl tit GIU NOT USEOl MALE CONNECTOR ON THIS 51 DE 11 BAN il CH10 114 BRN 1 IORul UILNA 0cROOt lOCATION I 114 BlK liS R D NOT W...

Page 34: ..._L _Dlll 118 Blll 28 z c z c J L 51 PIL p ALUM C UZIER ADMIRAL PANEL l l TERNATOR r L rro Aiil i 0 lloi PNK 11 0 5C7S lOPT ro c o 0foEM O O L CONF IGUIU TIDN SHOWN IS FOR i5A OLDER MODELS MAY HOT HAVE CONNECTOR FOR RUN SOLENOl D AND BLACI WIRE IS CONN CT 0 TO TERM IHAL ON SOlENOID CAPTAIN PANEL ...

Page 35: ...1 Check connection 2 Gear shift must be in neutral see NEUTRAL SWITCH under HURTH HSW TRANSMISSIONS 3 Check switch with ohmmeter 4 Check that 12 volts are present at the solenoid connection 5 Check battery connections 6 Check battery charge state 1 Check connections 2 Check that 12 volts are present at the connection on the fuel pump 1 Check that fuel valves are open 1a Check for air in fuel syste...

Page 36: ...1 Incorrect grade of engine oil 1a Crankcase is overfilled with engine oil oil is blowing out through the exhaust 2 White smoke 2 Engine is running cold 2a Faulty injector or incorrect injector timing 3 Black smoke 3 Improper grade of fuel 3a Fuel burn incomplete due to high back pressure in exhaust or insufficient air for proper combustion check for restrictions in exhaust system check air intake...

Page 37: ...Check for good ground connection between meter ter minal and alternator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurate a Using a hand held strobe tachometer reading front crank pulley speed Adjust the speed to 112 rated engine rpm b Using the coars adjustment select A B 4 6 or 8 that puts the panel tachometer rpm reading the closest to the s...

Page 38: ...harging and will eventu ally damage the alternator Drive belts that are too tight will pull the alternator out of alignment and or cause the alterna tor to wear out prematurely Excessive drive belt tension can also cause rapid wear of the belt and reduce the service life of the coolant pump s bearing A slack belt or the presence of oil on the belt can cause belt slipping resulting in high oper ati...

Page 39: ...W COMPRESSION When low compression is found determine the cause by applying a small amount of oil in the cylinder thru the glow plug hole Allow the oil to settle Install the pressure gauge and repeat the above test If the compression reading rises dramatically the fault is with the rings If the compression valve does not rise the problem is with the valves A slight rise in compression would indica...

Page 40: ...er arms move No l piston is at top dead center on the intake or exhaust stroke In such a case tum the crankshaft 360 in the direction of engine rotation again No 1 piston is now at top dead center on the compression stroke 4 Loosen the lock nut for the adjusting screw With a feeler gauge inserted between the rocker arm and valve cap adjust the valve clearance by turning the adjusting screw Make ce...

Page 41: ... the oil may be sucked out The operating oil temperature must not exceed 250 F l20 C CONTROLS The only controls required to operate the transmission is a single level remote controlled cable The cable should be attached to the gear box lever using the cable bracket supplied with the unit Both the gear box lever and the remote control lever must be in the NEUTRAL position when the cablds attached t...

Page 42: ... vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawberry cream Lay up Winterize Storage requires special care Follow these procedures NOTE This operation will usually occur when the engine raw water water cooling system is properly winterized DIPSTICK Clean up the transmission and touch up any unpainted AWWATER COOLING areas use heat re...

Page 43: ...t mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi tion may be made at any time below 1000 rpm and in any order Shifts should be made at ...

Page 44: ...low the oil to drain into a container D Reconnect the oil cooler return line D Use a suction pump to remove the transmission oil through the filler cap dipstick hole 38 D Clean off the transmission and properly dispose of the used fluid 0 Refill the transmission with DEXTRON III ATF The quantity will vary depending on the transmission model and the installation angle Fill through the dipstick hole...

Page 45: ...d through the engine exhaust A loss oftransmission fluid will cause the transmission to fail 2 The raw water will leak into the transmission fluid causing an increase in transmission fluid This contaminated fluid will appear as strawberry cream The transmission will eventuallyfail Either case requires an immediate response 1 Install a new oil cooler 2 Refill the transmission with DEXTRON III ATF W...

Page 46: ...ed by restricted movability ofthe Bowden cable or rod linkage by unsuitably positioned guide sheaves too small a bending radius etc In order to mount a supportfor shift control cable connections use the two threaded holes located above the shift cover on top ofthe gear housing Refer to the WESTERBEKE parts list CONTROL CABLES The transmission is suitable for single lever remote control Upon loosen...

Page 47: ... dip stick hole This could cause severe burns 41 OPERATING TEMPERATURE The maximum permissible ATF temperature should not exceed 230 110 This temperature can only be reached for a short time A CAUTION cIf the transmissio11 fluid temperature is too high stop the engine immediately and check the transmission fluid LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not req...

Page 48: ...dically inspect the transmission and the cooler for leaks and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawberry cream Lay up Wi nterize Storage requires special care Follow these procedures D Drain water from the transmission oil cooler and replace with a proper mixture of antifreeze coolant NOTE Thi...

Page 49: ...ear box with automatic transmission fluid ATF Dextran III Fill the transmission with the recommended capacity of fluid Model PRM80 l O U S pint 0 6L Model PRM 120 1 4 U S pints 0 8L NOTE Always clean the area around the dipstick plug before filling with fluid Replace the dipstick by screwing it down Run the engine to warm up the fluid and after shutting down the engine re check the fluid level CHA...

Page 50: ...nited States Atlantis Marine Gear Supply Inc 418 Boston Street Topsfield MA 01933 Tel 978 887 0001 Fax 978 887 5599 Harbor Marine Transmission 1402 West Marine View Drive Everett WA 98021 Tel 425 259 3285 Transmission Marine 223 Southwest 33 Court P O Box 21086 Ft Lauderdale FL 33335 1086 Tel 954 467 1540 Fax 954 467 1525 Or contact your Westerbeke deale1 NEUTRAl 8 REVERSE A greater amount of shif...

Page 51: ...and propeller shaft are turning Delay of gear engagement or engages 1 Levertravel Nto Bnot equal to Nto A only after an increase in speed Refer to diagram 2 Shift level travel in insufficient 3 Shift lever is binding against cover plate Transmission noise becomes louder 1 Damage starting on flexible coupling due to wear or fatigue possibly due to misalignment between engine and driveshaft 2 Beginn...

Page 52: ... 180 x 13P 2 Blade 180 x 11P 3 Blade 2 0 1 170 x 11P 2 Blade 170 x 9P 3 Blade 2 47 1 200 x 13P 2 Blade 200 x 11P 3 Blade 2 72 1 200 x 14P 2 Blade 200 x 12P 3 Blade 2 99 1 220 x 15P 2 Blade 220 x 13P 3 Blade 35C THREE 350 THREE 31 hp 3000 rpm 2 0 1 160 x 10P 2 Blade 35E THREE 28 hp 3000 rpm 160 x BP 3 Blade 2 47 1 180 x 13P 2 Blade 180 x 11P 3 Blade 2 72 1 200 x 12P 2 Blade 200 x 10P 3 Blade 2 99 1...

Page 53: ... chemicals which can reduce the life ofyour engine s internal parts Fuel System Gasoline Top off your fuel tanks with unleaded gasoline of 89 octane or higher A fuel conditioner such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any spilled fuel Fuel System Diesel T...

Page 54: ...ime and grease and touch up any unpainted areas Protect the coupling and the output flange with an anti con osion coating Check that the transmission vent is open For additional information refer to the TRANSMISSION SECTION Spare Parts Lay up time provides a good opportunity to insp ct your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement Check your ...

Page 55: ...Hp at 3000 rpm General Fuel Fuel Injection Pump Nozzle Fuel Filter Air cleaner Air Flow engine combustion Fuel Lift Pump FUEL SYSTEM Open flow self priming No 2 diesel oil cetane rating of 45 or higher In line plunger type BOSCH Throttle type Cartridge Type Replaceable paper filter cartridge 140 ctm 3 9 cmm at 3600 rpm 93 cfm 26 2 cmm at 3000 rpm 12 volt DC lift capacity of 5 1 5 mm solid state EL...

Page 56: ...nd 35E Three 31 Hp at 3000 rpm 50 General Fuel Fuel Injection Pump Noule Fuel Filter Air cleaner Air Flow engine combustion Fuel Lift Pump FUEl SYSTEM Open flow self priming No 2diesel oil cetane rating of 45 or higher In line plunger type BOSCH Throttle type Cartridge type Replaceable paper filter cartridge 83 7 cfm 2 3 cmm at 3600 rpm 69 7 cfm 1 9 cmm at 3000 rpm 12 volt DC lift capacity of 5 1 ...

Page 57: ... 0 5 28 9 36 2 39 18 Glow Plug M10 1 25 12 60 1 75 0 25 12 7 2 17 2 2 5 Glow Plug Connection Plate M4 0 7 8 0 125 0 025 0 9 0 2 1 2 0 2 Intake Manifold 1 6 2 4 12 17 16 2 Main Bearing Cap Bolt M10 1 25 17 81 5 25 0 25 38 2 51 5 2 5 Oil Filter M20 1 5 1 2 0 1 8 7 0 7 12 1 Oil Pan Bolt M8 1 25 12 25 2 8 0 3 20 3 2 2 27 5 3 Oil Pan Drain Plug M14 1 5 22 10 4 0 0 5 29 4 39 5 Oil Pressure Sender 1 2 1 ...

Page 58: ... 288 390 553 750 789 1070 7 8 9 395 536 440 597 605 820 14 435 590 675 915 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 BOO 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 M36 55mm 700 950 992 1345 1925 2610 2744 3720 SEALANTS LUBRICANTS GASKETS SEALANTS Oil based PERMATEX 2 and it s HIGH TACK equivalent are e...

Page 59: ...x 28 35 Grams g x 035 Ounces Pounds lb x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x 13 783 H20 Inches of Water H20 x 03613 psi x 27 684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4 026 H20 TORQUE ...

Page 60: ...OOLANT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising AKit Impeller Kit Heat Exchanger Gasket Fuel Filter with Gasket Oil Filter Drive Belt Zinc Anodes 54 HARDWARE KIT AIR INTAKE FILTER BKit Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc Anodes Complete Gask...

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