Westerbeke WPDS-20 Operator's Manual

OPERATOR'S MANUAL WESTERBEKE 40NA MARINE DIESEL ENGINE Publication # 37169 Edition One February 1988 ~ WESTERBEKE WESTERBEKE CORPORATION AVON IN

Exhaust Back-Pressure The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust back-pressure. Exhaust back-pr

4 18 17 f: '~, PI (J> ... 1 PI 50 I ::0 2 to PI " PI 22 ~~ ~ ... 0 » 23 .~~II /I 1'\,\/ -----'~U-<> I \ \ \ \§J I,&apos

REF 1 2 3 4 5 6 7 8 9 1 0 1 1 12 13-1 13-2 14-1 14-2 15-1 15-2 lEi-l 16-2 17 18 19-1 19-2 20-1 20-2 21 22-1 22-2 23-1 23-2 23-3 24 25 26 27-1 27-2 27-

N 0> 14 25 50 23 22 41 42 31 4 1 48 49 ~\~ "~ 7 ~~44 ';/'" ~ ~-C £11 (f) -i £11 ::0 <D £11 '" £11 '"&apo

REF 29 30 31-1 31-2 31-3 31-4 31-5 31-6 31-7 32-1 32-2 32-3 33-1 33-2 34 35 36 37 38 39 40 41 42-1 42-2 43 44 45 46 47 48-1 48-2 49 50-1 50-2 51-1 51-

WESTERBEKE 40A -HBW TRANSMISSION SHIFTING BRACKET ~ .~ 4 3 130 13 " ~6 ·5 7

WESTERBEKE 40A -HBW TRANSMISSION SHIFTING BRACKET REF PN NAME REMARKS QUAN 1 030756 NUT PILLAR - M 8 2 2 030181 BRACKET SHIFT CABLE -TOP ENTRY 1 3

WESTERBEKE 40A -STANDARD ALTERNATOR - OIL MANIFOLD 12 --4 ~-7 20 21 132

REF 1 2 3 4-1 4-2 4-3 6 7 8 9 1 0 1 1 12 13 14 15 16 17 18 19 20 21-1 21-2 22-1 22-2 23 WESTERBEKE 40A -STANDARD ALTERNATOR - OIL MANIFOLD PN 031709 0

WESTERBEKE 40A - ELECTRICAL HARNESS 6 7 134

WESTERBEKE 40A -ELECTRICAL HARNESS REF PN NAME REMARKS QUAN 1 024639 SOLENOID PREHEAT 1 3 031678 CAPSCREW 7/16NF X 3/4 2 4 031770 LOCKWASHER 7/16 2 5

Exhaust System Failures When the engine's sea water is fed into an exhaust system so that the full stream of this water strikes a sur-face, erosi

WESTERBEKE 40A - INSTRUMENT PANEL 4 5 3 ~L 8 7 6~7 10 11 14 ( 12 • I 0.1 fi -~ 13 00 , ~ 19 / ,,-16 136

REF 1 2 3 4 5 6 7 8 9 1 0 1 1 12 13 1 4 15 1 6 17 18-1 18-2 1 9 20 PN 033866 030913 030119 035118 035114 035108 03511 0 033865 033693 030003 033684 03

WESTERBEKE W40NA -ALTERNATORS AND COMPRESSOR MOUNTING SYSTEM \ i§Y ~ <0 '" ~:>e ... '" '" '" 138

REF 1 2 3 4 5 6 7 8 9 1 0 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WESTERBEKE W40NA -ALTERNATO

REF 3 4 5 6 7 8 9 1 0 1 1 12 13-1 13-2 13-3 13-4 13-5 13-6 14 PN 019934 020719 020720 032974 013758 015010 020654 011988 020502 012169 034936 033340 0

Connecting Pressure Sensing Devices to Oil Galleries Oil pressure sensing devices, such as senders and switches, must not be connected to an engine&ap

CAUTION DO NOT use a scoop-type through-hull fitting as a means of supplying sea water to the en-gine. Water pressure against this type of fitting, w

Sea Water Intake System Make sure the intake system (sea water cooling system) is in proper order. Check that the through-hull inlet, sea cock and st

Electrical System The electrical system should be checked to ensure that all wiring harnesses are tied down properly with clamps or plastic ties, sp

PREPARATION FOR STARTING This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and

Starting System The W 40NA diesel engine uses an electric starter for both normal and cold weather starting. A cold start aid system is furnished on

STOPPING PROCEDURES In the cockpit of the boat, there Is a tee handle or a knob-type shut-of control. When this control is pulled OUTWARD, the contro

As indicated above, operate the engine in moderation during the 50-hour break-in period. (On one hand don't baby the engine, but on the oth

SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operato

Starting Under Cold Conditions Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below when opera

FUEL SYSTEM Diesel Fuel Use No.2 diesel fuel with a cetane rating of 45 or higher. Never use kerosene or home heating oil since these fuels do not ha

Priming and Bleeding the Fuel System The W 40NA engine has only one replaceable fuel filter located on the engine-mounted fuel system. This fuel fi

NOTE: As a safety precaution, place a small plastic trash bag containing a few cloth rags around and under the secondary filterto catch any fue

4. Using the 5/16" box wrench or the 1/4" drive 5/16" socket wrench, open the #3 bleed screw and bleed this portion of the fuel Injecti

While the likelihood of having to service the fuel system at sea is small, the possibility does exist. Therefore, we recommend that a replacement fue

Fuel Injection Pump The fuel injection pump is one of the most important components of the diesel engine and, therefore, calls for the utmost caution

ELECTRICAL SYSTEM Engine 12-Volt DC Control Circuit The Westerbeke 40NA propulsion engine has a 12-Volt DC electrical control circuit, as shown on the

Alternator CAUTION When testing the alternator circuit (charging circuit), do not use a high-voltage tester such as a megger; damaged diodes could res

The charging system consists of two alternators with external voltage regulators, an engine-mounted circuit breaker, a battery and connecting wires. B

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals

W 40NA DC Control Circuit Wiring Diagram #37248 page 1 of 2 WIPING DIAGP.AM @s .. "" .. +~ W~ Westerbeke Diesel Engines 40 ." y "

W 40NA DC Control Circuit Wiring Diagram #37248 page 2 of 2 SCHEMATIC OIAGRA\I1 A @ ~-. ~ ~",. '§l.,,, ... 0L--!-__ -j ® "401'1.

COOLING SYSTEM Description Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combust

Electrical System The electrical system should be checked to ensure that all wiring harnesses are tied down properly with clamps or plastic ties, s

PREPARATION FOR STARTING This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and s

Starting System The W 40NA diesel engine uses an electric starter for both normal and cold weather starting. A cold start aid system is furnished on

DESCRIPTION OF INSTRUMENT PANEL Westerbeke 40NA engines are supplied with instrument panels. Read the following instruction carefully before operat

4. Ammeter Gauge: An Ammeter gauge is provided by the Dealer and is located in the lower right hand corner of the instrument panel. (The Ammeter is no

STARTING PROCEDURE 1. Place the transmission in the NEUTRAL position and advance the throttle to its full open position for a cold engine, and partial

Once the engine starts. move the throttle into a fast idle position (1000 - 1200 rpm). Check your instrumen-tation for proper engine operation. Make

INSTALLATION CHECKS General Because the crafts In which Westerbeke engines are installed vary in design, installation procedures will vary according t

STOPPING PROCEDURES In the cockpit of the boat, there is a tee handle or a knob-type shut-of control. When this control is pulled OUTWARD, the contro

As indicated above, operate the engine in moderation during the 50-hour break-in period. (On one hand don't baby the engine, but on the other

Starting Under Cold Conditions Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below when opera

Fresh water is pumped through the engine by a belt-driven fresh water circulating pump, absorbing heat from the engine. The fresh water coolant circ

COO~ANT RECOVERY TANK ,.. P~IISS'URE CAP Coolant Recovery Tank, Recommended Installation Coolant from the engine, when heated during engine opera

Thermostat Generally, thermostats are of two types. One is simply a choking device which opens and closes as the engine's temperature rises and

Alternator and Water Pump Drive 8elt Tension iWARNINGI Never attempt to adjust the drive belt's tension while the engine is in operation. CAUTION

LUBRICATION SYSTEM Engine Oil For engine lubrication, use lubricating oil designated for diesel service. These oils are classified according to the A

Engine Oil Change (to include filter) 1. Draining the Oil Sump Remove the oil drain hose from ~s attachment bracket and lower the end of the hose into

3. Filling the Oil Sump Add fresh oil through the oil filler cap on the valve cover (refer to the photographs on pages 5 and 6 for the location of the

Rigging and Lifting The engine is fitted with lifting eyes. Rope or chain slings capable of supporting the engine's weight should be attached to

THE HBW 150 TRANSMISSION General The HBW 150 transmission Is equipped with a positively-driven. mechanically-operated helical gearing sys-tem. The se

NOTE: To check the transmission fluid level, remove the dipstick and wipe off all transmission fluid on the dipstick, and place the dipstick back in

Controls The only controls required to operate the transmission is a single lever remote control cable using a 33C cable. The cable should be attache

Service If any seal on the transmission shows signs of leaking, have the transmission looked at by a qualified Hurth Servicing Dealer. This problem, e

ENGINE TROUBLESHOOTING Introduction The tables which follow Indicate troubleshooting procedures based upon certain problem indicators, the probable ca

Problem START switch Is de-pressed: no starter engagement. (continued) No ignition; engine cranks but does not start. Failure to stop. Engine stops. P

Problem Engine stops. (continued) Battery is not charging. Battery runs down. Westerbeke Diesel Engines Probable Cause Transmission failure. Alternato

MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/

Servicing After Initial 50 Hours of Operation 1. Change the engine's lubrication oil and oil filter. 2. Replace the fuel filter element as descri

6. Check the condition of all hoses and drive belts. Replace those that are badly worn. NOTE: Items highlighted by an asterisk (*) should be performe

Engine Bolts Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the engine's flexible mounts. Less pref

VALVE CLEARANCE ADJUSTMENT CAUTION The cylinder head nuts must be retightened after the first 50-hours of break-in operation, and before adjusting the

TORQUE SPECIFICATIONS The following torque tensions apply when the components are lightly oiled before assembly. Lb-ft Kg-m N-m Cylinder Head Nuts 60

GENERAL TORQUE TIGHTENING CHART UNLESS OTHERWISE INDICATED Grade 6T 6mm bolt/nut 8mm bolt/nut 10mm bolt/nut 12mm bolt/nut 14mm bolt/nut Grade 8T and 8

LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the

CAUTION Do not leave the engine's old lubricating oil in the sump over the lay-up period. Lubricating oil and combustion deposits combine to pro

Cylinder Lubrication It is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into the cylinders for t

4. Check the condition of the zinc anode in the sea water circuit and clean or replace the anode as needed. Note that it is not necessary to flush the

INDEX A ADJUSTMENTS, MAINTENANCE AND ... 57 ADJUSTME

Controls (The HBW 150 Transmission) ... 52 Connect

Fuel Injection Pump ...

Propeller Shaft Coupling The propeller shaft coupling fitted to the transmission's output flange must transmit not only the power of the engine t

a Oil Change. Engine (to Include filter) ... .48

Shifting, Transmission ...

v VALVE CLEARANCE ADJUSTMENT ... 60 Ventilation

PARTS LIST Cylinder Block ... 100 Cylinder Head and Valves ...

+---17 4--16 100 15 14

REF 1 -1 1-2 2 4 5 6 7 8 9 1 0 1 1 12 13 14 15 16 17 18 1 9 20 21 22 23 24 25 26 27 28 29 30-1 30-2 31 32 33 34 35 36 37 38 40 41 42 PN 030870 011487

WESTERBEKE 40A -CYLINDER HEAD AND VALVES 24 1 2 ~ ~ 21 ~20 --18 25 ~r-19 11 15 ---'ii!l 28 14 102

\.jESTERBEKE 40A - CYLINDER HEAD AND VALVES REF PN NAME REMARKS QUAN 1 019939 HEAD ASSEMBLY 1 2 019979 PLUG TOP 3 3 023143 PLUG TOP 4 4 012452 PLUG SI

WESTERBEKE 40A -CR ~~~~~______ ANKSHAFT AND PISTONS 21 20 19 1 8 104

WESTERBEKE 40A -CRANKSHAFT AND PISTONS REF PN NAME REMARKS QUAN 1 023105 CRANKSHAFT ASSEMBLY 1 2-1 012343 BEARING SET-CONNECTING ROD STD 1 2-2 012414

Take plenty of time in making this alignment and do not be satisfied wtth anything less than perfect results. The alignment is correct when the shaft

~ESTERBEKE 40A -TIMING SYSTEM AND CAMSHAFT 3 l~ 1 8 ab, :!s---12 7 I 9 10 20 17 16 23 30 31 22 106

WESTERBEKE 40A - TIMING SYSTEM AND CAMSHAFT REF PN NAME REMARKS QUAN 1 012605 CAMSHAFT 1 2 012460 PUSHROD FUEL LI FT PUMP 1 3 012654 PLATE CAMSHAFT T

a <0 <0 ! 21 I ! <0 <2 I , <0

WESTERBEKE 'lOA -ROCKER SHAFT AND COVER REF PN NAME REMARKS QUAN 1 012681 COVER ROCKER 2 012404 GASKET ROCKER COVER 1 3 012429 NUT 2 4 012535 WAS

WESTERBEKE 40A -INTAKE MANIFOLD 12 1 10 11 0

WESTERBEKE 40A -INTAKE MANIFOLD REF PN NAME REMARKS QUAN 1 012683 COVER AIR INTAKE 1 2 012556 FILTER AIR INTAKE 1 3 011411 CLAMP HOSE 32 1 4 020021

~ESTERBEKE 40A -LUBE OIL SUMP AND OIL PUMP 27 26 19 a---18 17 1 112

REF 1 2 3 4 5 6 7 8 9 1 0 1 1 12 13 14 15 1 6 1 7 18 1 9 20 21 22 23 24 25 26 27 28 2':1 30 31 32 33 34 35 36 PN 035304 035305 035306 012473 0317

.j>. 3 2 1 40 28 J. ~~;;;;-""7:> ...;-(W-2:': .·t~Z \ "\ .. '.--' " .,,, 23 26 9j/10 ® • " / 11 13~1O

REF 1 2 3 4 5 6 7 8 9 1 0 1 1 12 13 14 15 1 6 17 18 19 20 21 22 23 24 25 26 27 28-1 28-2 28-3 29-1 29-2 30 31 32-1 32-2 32-3 33 34 35 36 37 38 39 40 P

Exhaust System The exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vessel. The system also discharges sea

'" / 26 9:1r/10 .''\, / Jt11 tIl?} 12 '-13 ~10 "'\ ~--~f,l '_C'i. t,f5p I /14 15 ~b ® /20 1 22 41 34 ~df1

REF 41 42 43 44-1 44-2 44-3 45-1 45-2 46-1 46-2 47 413 49 50 51 52 53 54 55 56 57 PN 036260 0344134 0351131 031506 031752 031753 013334 013333 0316130

WESTERBEKE 40A -FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW 118

WESTERBEKE 40A - FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW REF 1 -1 1-2 2 3 4 5 5 7 8 9 1 0 1 1 12 13 14-1 14-2 15 PN 020035 019933 031758 03

_---.1 , \ \.IESTERBEKE 40A -SEA \ o V 120 \.lATER PUMP o -----N -

WESTERBEKE 40A -SEA WATER PUMP REF PN NAME REMARKS QUAN 1 011143 GASKET SEA WATER PUMP MOUNTING 1 2-1 016423 PUMP SEA WATER 1 2-2 018169 HOUSING SEA W

ru ru QP.7 43 / 45 \ 38 56 75~~.3= ~. 60 50"" ~ ~46 \ "-'\ 53 I 76 '{f '" • ::~ 'G::" ~ _____ .--'Vk

REF 1 2 3 4 5-1 5-2 6 7 8 9 1 0 1 1 12 13 14 15 16-1 16-2 17 18 1 9 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40-1 40-2 41 42 43-1 4

75 56 45 -------------~"{?. ,\Iy--" 60 \ " '-:: \53 .. / - . , ., ~ N ... 131 ~~®@ - \ \ \ 32 3029 \..,// --------~ '~-35

WESTERBEKE 40A -FUEL SYSTEM REF PN NAME REMARKS QUAN 46 012641 LINE INJECTOR 1 1 47 012645 LINE INJECTOR 2 1 48 012646 LINE INJECTOR 3 1 49 012647 LI