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Strany 1 - WESTERBEKE

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

Strany 2 - SAFETY PRECAUTIONS

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

Strany 3 - Westerbeke Diesel Engines

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

Strany 4 - COCKPIT

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-

Strany 5 - LIFTING

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

Strany 6

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-

Strany 7

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

Strany 8 - 90'

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

Strany 9 - 6"

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

Strany 10 - . "

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

Strany 11

WESTERBEKE 40A - ELECTRICAL HARNESS 6 7 134

Strany 12

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

Strany 13 - ',

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

Strany 14

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

Strany 15

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

Strany 16 - '

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

Strany 17 - Thermostart

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

Strany 18

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

Strany 19

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

Strany 20

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

Strany 21 - FITTING

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

Strany 22 - Mechanical Fuel Lift Pump

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

Strany 23 - Fuel System

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

Strany 24

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

Strany 25 - Fuel Filter

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

Strany 26

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

Strany 27 - Circuit Breaker

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

Strany 28

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

Strany 29 - '*'14 GREEN

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

Strany 30 - ~~'b

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

Strany 31 - '§l.

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

Strany 32

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

Strany 33 - ~WARNINGI

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

Strany 34 - ===

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

Strany 35 - Cold Start Aid

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

Strany 36 - SIABI.:

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

Strany 37 - (77 - 88'C)

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

Strany 38 - 5'

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

Strany 39 - -.:::::.----...>r=~

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

Strany 40 - 130-140' F range

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

Strany 41

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

Strany 42

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

Strany 43 - % 13 23 30 35

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

Strany 44 - COO~ANT

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

Strany 45

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

Strany 46

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

Strany 47

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

Strany 48 - ,"

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

Strany 49 - :=::::=

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

Strany 50 - DIPSTICK

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

Strany 51 - : '

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

Strany 52 - (8). In this situa

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

Strany 53 - + 000 - 100) at full open

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

Strany 54 - Engines

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

Strany 55

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

Strany 56

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

Strany 57

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

Strany 58

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

Strany 59 - ~~~f~e-f:

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

Strany 60

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

Strany 61 - SPECIFICATIONS

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

Strany 62 - Westerbeke Diesel

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

Strany 63

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

Strany 64

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

Strany 65

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

Strany 66

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

Strany 67

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

Strany 68 -

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

Strany 69

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

Strany 70

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

Strany 71

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

Strany 72 - Clrcu~

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

Strany 73 - PARTS LIST

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

Strany 74

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

Strany 75

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

Strany 76 - ---'ii!l

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

Strany 77

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

Strany 78 - ~~~~~______

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

Strany 79

INDEX A ADJUSTMENTS, MAINTENANCE AND ... 57 ADJUSTME

Strany 80 - :!s---12

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

Strany 81

Fuel Injection Pump ...

Strany 82

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

Strany 83

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

Strany 84 - MANIFOLD

Shifting, Transmission ...

Strany 85

v VALVE CLEARANCE ADJUSTMENT ... 60 Ventilation

Strany 86

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

Strany 87

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

Strany 88 - "\

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

Strany 89

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

Strany 90 - .''\

\.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

Strany 91 - & 36

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

Strany 92

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

Strany 93

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

Strany 94

~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

Strany 95

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

Strany 96 - 75~~.3=

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

Strany 97

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

Strany 98 - ------'

WESTERBEKE 40A -INTAKE MANIFOLD 12 1 10 11 0

Strany 99

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

Strany 100 - '~

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

Strany 101

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

Strany 102 - '"

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

Strany 103 - :!;L;dv1

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

Strany 104

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

Strany 105

'" / 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

Strany 106

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

Strany 107

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

Strany 108

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

Strany 109

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

Strany 110

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

Strany 111

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

Strany 112 - ~:>e

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

Strany 113

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

Strany 114 - ~ESTERBEKE

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

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