WESTERBEKE 60 Marine Diesel Engine Service Repair Manual

TECHNICAL MANUAL AND PARTS LIST WESTERBEKE 15 hp Mini-Diesel Engine MODEL FOUR-60 Publication Number 16521 Issue Date June 1, 1972 ~r-.v- 'WESTERBEKE WESTERBEKECORPORATION j MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 Downloaded from www.Manualslib.com manuals search engine

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 mechanism 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 reduction 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 however, 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 is stamped on the name plate affixed to the exhaust manifold. Downloaded from www.Manualslib.com manuals search engine

( WESTERBEKE MODEL FOUR-60 INTRODUCTION PHOTOGRAPHS 15 h. p. Mini Diesel Engine TABLE OF CONTENTS INSTALLATION DRAWINGS ..•...•...•..•.• .... ••.•. GENERAL DATA ............................... . INSTALLA TION ................................ . OPERATION .................................. . LUBRICATION SYSTEM COOLINGSYSTEM ........ • ...... • ............... FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAO TRANSMISSION SSL TRANSMISSION Page No. 2 4 5 6 9 17 SECTION A SECTION B SECTION C 45 62 3 Downloaded from www.Manualslib.com manuals search engine

SURGE TAtiK COLO START SOLENOID Cll PRESSURE SWITCH TAQ-!OMETER DRiVE \ (Remove after installation) FILLER CAP ------.. ALTERNATOR OPTIONAL !l.IR CLEA.'lER OIL SUM? DRAm PIPE PRIMARY FUEL FILTER FUEL l PUM? PRIMING LEVER LIFTING SRACKET lIJSRICATICN on. .J:L-~------ FIllER CA? HEAT EXCHANGER BLEED SCRE'" SECONDARY FUEL FILTER BLEED SCRE'w' FUEL INJECTOR UNION NUT COLO STMT SLOW PLUS FRESH WATER PlJYP ADJUSTABLE ===---- FLEX ~tCtItm STARTER SOLENOID STARTER MOTOR PROPELLER SHAFT COUPLING 4 STARBOARD AND PORT VIEWS -FOUR 6o/sAO Downloaded from www.Manualslib.com manuals search engine

STARBOARD 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 below propeller shaft line to 4 3/4 inches. 4A Downloaded from www.Manualslib.com manuals search engine

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INSTALLATION DRAWINGS -- Z3 k- - Four-60/SAO Reverse and Reduction Gear 1-------.>1,1-----'1 I I- -.~- J I ~ _ _"..LB2IJL._ §=--i~ 1-. ___ .. 7~=----:. fRONT .1 ",,*.&o-_~-_ ... ~_ -_ -_-_ -,4,\oJi _____ '_; __ ~_~ .. -_~~-... ~j 1--------- -----34l- -- ------ Four-oo/SSL Reverse Gear 5 Downloaded from www.Manualslib.com manuals search engine

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. l-compression Nos. 2 and 3-compression Nos. 4 and S-oil scraper Piston ring fitted gap: No. l-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 .. Connecting rods Length between centres Side clearance on crankshaft .. Crankshaft and bearings Journal dIameter Crankpin diameter Main bearing clearance Big-end bearing clearance 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 mm.). 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. ('254 to '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. (-0025 to -0127 nun.). 5·75 in. (146'05 mm.). -006 to -010 in. ('152 to ·254 mm.). 2-0005 to 2·001 in. (50'8l3 to 50·825 mm.). 1·7505 to 1·7510 in. (44-462 to 44·475 mm.). ·001 to ·0027 in. ('025 to ·068 mm.). ·001 to ·0027 in. ('025 to ·068 mm.). ·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 1·75075 in. (44·456 to 44·469 mm.). ·001 to ·002 in. ('025 to ·051 mm.). Downloaded from www.Manualslib.com manuals search engine

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 compress to fitted length-valve open Rocker shaft diameter Rocker shaft to bush clearance Tappet diameter F1ywbeel 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 pu"mp spindle Interference fit in hub .. Interference fit in vane Inlet Exhaust 5° B.T.D.C. 45° B.B.D.C. 30° A.B.D.C. 5° A.T.D.C. 45° 45° ·075 in. (1'906 mm.) ·075 in. (1'906 mm.) ·00 15 to ·0025 in. ·002 to ·003 in. ('038 to ·062 mm.) (·051 to ·076 mm.) ·012 in. (·305 mm.) ·012 in. (·305 mm.) ·276 in. (7'01 mm.) ·276 in. (7'01 mm.) ·018 to ·038 in. ·018 to ·038 in. (·457 to ·965 mm.) (·457 to ·965 mm.) Inner Outer 1·672 in. (42-471 mm.) 2·047 in. (52 mm.) 1-165 in. (29·6 mm.) 1·328 in. (33·746 mm.) ·889 in. (22·576 mm.) 1·052 in. (26·746 mm.) 28·7 lb. (13 kg.) 43 lb. (19·5 kg.) ·5615 to ·5625 in. (14·263 to 14·288 mm.). ·0005 to ·002 in. (·013 to ·051 mm.). ·81125 to ·81175 in. (20'606 to 20·618 mm.). 94. 200 to 230 0 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 mnL). 13·5 lb. (6'127 kg.). 15 lb./sq. in. (1'05 kg./cm. 2 ). 50 lb./sq. in. (3'52 kg./cm. 2 ). it in. (10·72 mm.) 1 in. (12·7 mm.). 40°. 1 in. (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 Downloaded from www.Manualslib.com manuals search engine

WESTERBEKE 60 Marine Diesel Engine Service Repair Manual

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