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Westerbeke Diesel W 30 Technical Manual



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                             D"'"
 OPERATORS MANUAL
MARINE DIESEL ENGINES
W-13, W-21 , W-27, W-33



              PUBLICATION NO. 32363




    t~ rWESTERBEKE
          ~    WESTERBEKE CORPORA TlON' 150 JOHN HANCOCK ROAD
         I    MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780
              WEBSITE: WWW.WESTERBEKE.COM

        ~~
       NAMIA Member National Marine Manufacturers Association
      z e
                    CALIFORNIA
               PROPOSITION 65 WARNING
              Diesel engine exhaust and some
              of its constituents are known to
              the State of California to cause
              cancer, birth defects, and other
                      reproductive harm.




                      A    WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
- Dizziness                  - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
6ET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.


                       This WARNING DECAL is provided by
                       WESTERBEKE and should be fixed to a
                       bulkhead near your engine or generator.
                       WESTERBEKE also recommends installing
                       CARBON MONOXIDE DETECTORS in the
                       living/sleeping quatters of your vessel.
                       They are inexpensive and easily
                       obtainable at your local marine store.
                                     FOREWORD


       Thank you for having selected a Westerbeke Diesel Engine for your
use.

    This manual describes the procedures for proper handling and main-
tenance of the Engine Models W13, W21, W27 and W33.

    To maintain your engine always in its best operating condition and
to enable it to perform best, it is important to handle it properly
and carry out complete maintenance according to this manual.

    If you have any questions about your engine or in the event of a
failure, please contact your nearest distributor or dealer.

       We look forward to your continued patronage.




               LEFT   SIDE~   W-21 WITH 2:1 HBW-50 TRANSMISSION



                                         I
               TABLE OF CONTENTS
                                                     PAGE
GENERAL SPECIFICATIONS .. 3

CAUTIONS IN HANDLING ENGINE ... 4
1.    BREAKING IN..................... 5
2.    PREPARATIONS.       .         .   6

3.    STARTING PROCEDURES .......... 7
4.    STOPPING PROCEDURES ... 10
5.    CAUTIONS ON STARTING
      AND OPERATION ... 10
6.    REQUIREMENTS FOR PROPER
      OPERATION
      6-1 Lubrication System .... 12
      6-2 Fuel System ........ 13
      6-3 Cooling Systern .... 15
      6-4 Wiring diagrarn .. 1S

7.    RECOMMENDED MAINTENANCE SERVICE.19

S.    TRANSMISSIONS ..... 22
9.    TROUBLESHOOTING . 23
10.   SERVICE DATA ...... 25

11.   TABLE OF TIGHTENING TORQUES  26




                            2
                                         GENERAL SPECIFICATIONS


ITEM                    CHARACTERISTIC             W13            W2l         W27           W33

                 Type                          Vert.,4 cycle,water cooled diesel             en~ine

                 Combustion chamber            Swirl chamber type
         CIl
         :z No. of cylinders                        2              3            4             4
         0
    H
rx:IE-!
:Z~              Bore & stroke (inches)         2.76x3.07 2.87x3.07 2.87x3.07 3.07x3.07
HC.J
t!)H
ZI%.l            Cu. In. displacement              37             60           80            91
rx:IH
   C.J
    rx:I
         ~       Compression ratio                 23             23           23            23
         CIl
                 Firing order                      1-2          1-3-2        1-3-4-2       1-3-4-2

                 Dry weight, std.      (lbs)       298            374          434           498

                 Fuel                          #2 diesel fuel only

         ::1!!   Injection pump                Bosch type
....:trx:l
rx:IE-!
DCIl             Nozzle                        Throttling type
I%.l>t
         (f.l
                 Injection pressure            All models:       1707 lbs.

                 Governor                      Centrifugal weight type
Z
0
H                Lubrication system            Pressure lubrication
E-!::E:
~rx:I
C.JE-!           Oil filter                    Filterp~Qer       type
HCIl
~>t
~(f.l
::>
....:t
                 Engine oil capacity             2.5 qts    I
                                                           4.0 qts       I
                                                                     4.0 qts   4.2 qts I
                                               For accuracy, depend on dipstick markings

~ ::E:jcooling system                          Forced circulation, water cooling by
Hrx:l1
                                               heat exchanger
....:tE-!
ou)
8 ~!Coolant                 capacity              6 qts     I
                                                            5 qts        I
                                                                      8 qts     8 qts
                                                   Always fill to top of filler neck
                                                                                       I
....:t           Starter V-HP                     12-2           12-2        12-2          12-2
~
C.J::E:
Hrx:I
t:X:E-!          Alternator V-A                   12-50          12-50       12-50         12-50
E-!(f.l
CJ>t
rx:ICIl Glow            plug                   Sheathed trpe - all models
....:t !
rx:I   I

                 lBattery capacity                60 AH          75 AH       90 AH          90 AH




                                                        3
                     CAUTIONS IN HANDLING ENGINE


*   Always use proper engine oil and watch oil pressure during opera-
    tion.

*   Use clean fuel, free from impurities and water content.

*   Prevent entry of air and water into the fuel system.

*   In case the starter motor pinion fails to engage wi th the ring
    gear at the time of starting, turn on the starter swi tch again
    after the starter motor has come to a complete stop.

*   Prevent the temperature of cooling water from falling too low.

*   Pay attention to the color of exhaust gas.

*   Clean or replace the fuel filter and oil filter periodically.

*   Replenish or replace oil as specified.




SAFETY PRECAUTIONS

*   Never put the engine in   o~eration   in improperly ventilated places.

*   Do not touch moving parts during operation.

*   Do not touch hot parts such as exhaust pipe, and do not place com-
    bustible materials there.

*   Inspect and adjust parts of the engine only after it is stopped.

*   Check and refill engine oil,        cooling   water   and   fuel   after    the
    engine is brought to a stop.

*   In checking the level of and refilling cooling water, remove thie
    pressure cap after the temperature of the water has fallen enough.

*   Always use   tools of proper   sizes    and   full    caution during       sel
    vicing.




                                    4
                                BREAKING IN


Service life of your engine is dependent upon how your engine       is
operated and serviced during the initial 50 hours of operation!




                   Your new engine needs 50 hours
                   of conditioning operation for
                   breaking each moving part in
                   and maximizing performance and
                   life of engine.    Perform this
                   conditioning carefully, bearing
                   the following points in mind:

CAUTION:

*   Idle and warm up your engine from 3 to 5 minutes.

*   Avoid hasty acceleration.

*   Use caution not to overload the engine.

*   Inspect, maintain and service your engine in accordance wi th the
    instructions in this manual.


Explanation:

"Breaking in" a new engine is basically a seating of the piston rings
to the cylinder walls.   This is not accomplished by long periods of
running idle, nor by early running under full load, nor by varying
loads with intervals of fast acceleration and/or excessive speed.

Idle running may glaze the cylinder walls causing oil consumption and
smoky operation.  Excessive speeds and loads may score cylinder walls
with similar results.

As indicated above, use a short warm up at idle and put engine under
moderate load and speed for the first ten hours of operation.      For
the next forty hours, use approximately 70% load.   This kind of care-
ful operation will result in best results from your engine.




                                     5
                              PREPARATIONS


Take steps as shown below in starting your engine for the first time
or after a prolonged shut-down.


1.   Fill your engine with oil up to
     or near the upper limit on the
     dipstick.  Use a good grade of
     oil wi th API specification of
     CC or better.    For quantity of
     oil, you may refer to        the
     General   Specifications   page.
     However, it is best always to
     be guided by dipstick measure-
     ment as angle of installation
     has some effect.

2.   Your eng ine is suppl ied wi th a                                ...
                                                                        ~\

     coolant    recovery  system    to
     which the following      instruc-         ot1levelgatJge_~"'f1
                                              and/i/lerpDrt
     tions apply:
               $

     a)   Fill engine completely to
     the neck of the manifold cap.
     b)   Then   fill   the  recovery
     tank to the bottom level line.
     Need   for  adding   coolant  is
     indicated when a cold engine
     has coolant level below the
     bottom level line.
     c)   In winter add antifreeze
     as described on page 16. Anti-
     freeze may be used year round
     if changed annually.

3.   Fill the fuel tank with Diesel
     fuel.  The interior of the fuel
     tank must be maintained clean.
     Be careful not to allow intro-
     duction of dirt when filling
     fuel.

4.   Engine    oil,   coolant  and
     transmission levels should be
     checked at least once a day
     prior to engine use.




                                     6
                         STARTING PROCEDURES

Instrument panel, description and use of:




Note 1:   When engine is stopped after use, the water temperature and
          oil pressure gauges may stay at their running readings.

Note 2:   When engine is next to be used, turn start switch to "ON".
          The temperature and pressure gauges will "ZERO" and the volt-
          meter will register battery voltage. The electric fuel pump,
          mounted on the engine, will also begin to operate, purging
          any air accumulated in the system.

Note 3:   The engine is now prepared for starting.




                                    7
                            STARTING PROCEDURES

1_   Turn the starter swi tch to the
     "ON" position_     If making an
     ini tial   star t after   lay-up,
     fuel     filter   servicing    or
     repairs,    allow fuel pump to
     work 15-25 seconds to purge the
     system of any air.    Check that
     clutch is in neutral and that
     throttle is in full forward_

2_   Glow plug preheating

     with key in "ON" position, push
     in about 1/4 inch or enough so
     that voltmeter indicates dis-
     charge.   Hold key in depressed
     posi tion until glow plugs are
     sufficiently hot_ Follow Table
     below for preheating time.



                         Quick-heat type (Yl14T)


            Atmospheric temperature         Preheating time

          +sc (+4lF) or higher            Approx. 10 sec_
          +SC (+4l-F) to -S-C (+23-F)      A~rox.     20 sec.
          -SoC (+23F) or lower             Approx 30 sec.

          Limit of continuous use                 1 minute




3.   Proper glow plug function is
     indicated   by   voltmeter   drop
     when key is depressed.       This
     drop will be slight but dis-
     cernible.    If no voltage drop
     is   noted,   it   may   indicate
     defective   glow   plugs   or   a
     faulty preheat circuit (check
     for loose connection).




                                      8
4.   Starting

     Continuing   to hold   the   key
     depressed, turn to the "START"
     position.    The starter motor
     will run ther eby cr ank ing the
     engine.     Hold throttle open
     until   engine  runs  and   then
     reduce throttle.



Should the eng ine not star t even when the star ter swi tch is left at
"5" position for 10 seconds, take your hand off the starter switch for
30 seconds, and then attempt to start the engine again by sufficiently
preheating the glow plug.    The starter motor should never be allowed
to run for more than 30 seconds at a time.




5.   Operation

     As   soon   as  the engine has
     started, release the key.    The
     key will automatically return
     to the "ON" position.      Leave
     the key at "ON" dur ing oper a-
     tion.    Check that with engine
     running, oil pressure and bat-
     tery     charge    voltage   are
     registering and that raw water
     is    discharging     with   the
     exhaust.


During engine operation, do not turn the key to "5 11 position.   This
may damage the starter motor.




6.   Warm-up operation

     Run a few minutes at II IDLE"
     position to assure that all
     functions are operating.  Then
     operate   under   reduced load
     until water temperature rises
     into the 140-150 range.




                                    9
                            STOPPING PROCEDURE


1.   Stop

     To stop the engine move the
     throttle control through the
     idle position to stop.    As the
     throttle is moved past idle
     there    will   be     increased
     resistance to movement because
     a spring loading must be over-
     come. Hold the throttle firmly
     against the pressure until the              W-13    W21,27,33
     engine  comes  to a complete
     stop.

2.   Starter switch off

     Wi th the eng ine stopped, turn
     the star ter key back to "OFF"
     position.    The battery will be
     discharged if the key is left
     at "ON" position.      An engine
     alarm buzzer is provided to
     warn   the    operator  of  this
     possibili ty.    Best precaution
     is always to remove the key.


                    CAUTIONS ON STARTING AND OPERATION

1.   Normal starting

     Follow the procedures below for routine starting of your engine.

     1)     Check the engine and transmission oil levels and refill if
            necessary.
     2)     Insure that you have sufficient fuel.    Keep tank as full as
            possible.
     3)     Check coo~ng water level, and refill if necessary.
            Note: Check for leaks of water or oil, particularly when
            signs of such leak are found on the bottom of the engine or
            in the drip tray.
     4)     Start the engine in accordance with the procedures given on
            the preceding pages.
     5)     Allow the engine to warm up to 140-150 F before placing the
            engine under heavy load.

2.   Starting under cold conditions

     The following three adverse condi tions concur as the atmospher ic
     temper a-ture drops exceedingly, and the engine must, under such
     conditions, be started by taking steps described below:


                                      10
          LUBRICATING OIL TURNS VISCOUS      Make certain that oil used
          is adequate for the prevailing atmospheric temperature.
          Check the oil also for deterioration.

          VOLTAGE ACROSS BATTERY TERMINALS     DROPS        Check that the
          battery is fully charged.

          THE TEMPERATURE OF INTAKE AIR IS LOW AND COMPRESSION
          TEMPERATURE DOES NOT RISE ENOUGH      Allow the glow plug to
          operate sufficiently to aid starting. See table on page 8.


3.   Cautions during operation

     Confirm that the oil pressure is normal during normal operation.
     Confirm that exhaust gas is as follows:

     *    While engine is cold .. White smoke
     *    When the engine grows warm .......... Almost smokeless
     *    When the engine is overloaded  Some black smoke

     Check for abnormal noise such as knocking,        fr iction or   leaking
     sounds, and vibration and blow-back sounds.

     Check for leaks of fuel and engine oil.

     A knocking sound is heard while the engine is cold, during quick
     acceleration and at idle. Confirm that no knocking sound is heard
     in other cases.




                   LEFT SIDE} W-33 WITH 2:1 VEE DRIVE
                                   11
                     REQUIREMENTS FOR PROPER OPERATION


LUBRICATION SYSTEM

1.   Engine oil

     For engine lubrication, use diesel engine oil. Diesel engine oils
     are classified according to the API Specifications into grades CA,
     CB, CC and CD. Anyone of them is usable, but use of CC or higher
     grades prepared by well-known makers is recommended.

2.   Engine oil viscosity

     Use oil having viscosity best suited to the atmospheric tem-
     perature.  Use of an all-season oil SAEIOW-30 with minimum visco-
     sity change under different temperatures is suggested.



          Atmospheric temperature                        Viscosity

          20C (6aF) or higher                     SAE 30 or lOW-30

                                                    SAE 20 or 10W-30

          SC (41F) or lower                       SAE 10W-30



 3. Oil pressure

     The oil pressure dur ing operation of the engine is indicated by
     the oil pressure gauge.

     During normal operation  Oil pressure will range between
                                          50 and 70 PSI.

     At the time of cranking  Pressure will rise proportion-
                                         ately with speed.

4.   Engine oil change

     To renew engine oil, discharge old oil through the sump drain hose
     attached at front of engine while engine is still warm.
     Drain old oil completely, replace the hose, plug the end securely
     and add fresh oil through the oil inlet port on the valve cover.
     After refilling oil, idle the engine for several minutes and stop.
     Then check the quanti ty of oil by the oil level gauge.    F ill to
     but not over the high mark on the dipstick.




                                     12
5.   Replacement of oil filter
     Being a replaceable cartridge
     type, the oil filter requires
     no cleaning inside.
     In installing the oil filter,
     apply engine oil thinly on to
     the O-ring, and then tighten it
     by hand firmly.
     When removing the used filter,
     cover over with a plastic bag.
     This will allow both filter
     element and spilled oil to be
     collected cleanly without
     spilling oil in the bilge.
     Note A:   After market filters are not recommended since the
               material standard or diameters of important items might
               be entirely different from genuine parts.
     Note B:   Immediately after filter change and oil fill, run engine
               to ensure that oil pressure is normal and that there are
               no oil leaks.

FUEL SYSTEM
1.   Diesel fuel
     USE #2 DIESEL FUEL.   NEVER USE KEROSENE OR HEAVY OIL.
     In cold weather, particularly, much water vapor is produced when
     much air is present in the fuel tank. The tank, therefore, should
     be kept full as much as possible.
     The fuel tank, furthermore, needs to be kept completely free of
     dirt and water.
2.   To this end, it is most
     desirable that a primary fuel
     filter of the water entrapment
     type be installed between the
     fuel tank and engine. Such a
     filter is available under part
     # 32974. (See your local
     dealer.)
     Water entrapment filter #32974
     is shown opposite. Inspect
     frequently for presence of
     water in the clear bowl. Drain
     it off by loosening the air
     vent and opening the drain.


                                      13
3.   Notes on fuel system
     See below a typical exploded view of a fuel system. The one shown
     is for the W13. Those for the W21, W27 and W33 are similar except
     for the number of cylinders.




     The Westerbeke self-bleeding fuel system is automatic in opera-
     tion.  Therefore, it is unlikely that the operator will be forced
     to service the system at sea.

     For. that unlikely possibility, however, it is recommended that the
     following parts be carried onboard.

     Banjo washers 11, 30, 31, 33, 34, 45
     Injector seat washers 42
     Lift pump filter and gaskets 6, 7, 8
     Fuel filter element and gaskets 13, 14 ,15


                                   14
     If a leak should develop at a banjo or washer that cannot be
     remedied by a simple tightening of the screw, renew the washers.
     The engine can be started by taking the steps described on pages 8
     and 9. In cases where the engine cannot be started easily, loosen
     two injection nuts on the nozzle side, turn the speed control
     lever to "full open" position, turn the starter motor and then
     tighten the nuts firmly.

4.   Cleaning fuel filter and replacing filter element

     After the first 50 hours of operation, loosen the retainer ring
     #16 and discard filter element #15. Clean bowl #17 and re-install
     new filter, using new gasket #13 and #14.

     This same treatment is required of the filter element #6 in the
     fuel lift pump.   Similarly, replace n.ew filter element #6 using
     new gasket #7 and #8.

     After the first 50 hour change, the change period may be increased
     to 200 hours or once per season.

5.   Fuel injection pump

     The fuel injection pump is one of the most important components of
     the diesel engine and thus it calls for the utmost caution in
     handling.      Furthermore,  the  fuel  injection pump has been
     thoroughly shop-adjusted and should never be readjusted care-
     lessly.
     Such adjustment, whenever necessary, should be performed at an
     author i zed service station as a precision pump tester and skills
     are required.

     To obtain long and satisfactory use of your injection pump:

          Always use fuel which is free from impurities.
          Clean and renew the fuel filter periodically.
          Inspect water entrapment filter regularly.



COOLING SYSTEM

1.   Cooling water

     As cooling water, use soft water with least impurity content   such
     as tap water (potable water) or rainwater, and never use       hard
     water or foul water.   Use of hard water or water containing   much
     impurity will lead to collection of scale in the engine and    heat
     exchanger with resultant decline in cooling effects.

2.   Antifreeze

     In cold districts, care should be takeri to prevent cooling water
     from freezing.   Cooling water when frozen expands to break the

                                   15
     heat exchanger and the cylinder block, and it is essential that
     antifreeze be added to cooling water in a quantity being propor-
     tional to the lowest temperature of the d~str ict.    It is recom-
     mended that the antifreeze mixture be used throughout the year.

         *Antifreeze of poor quality will cause corrosion of the
          cooling system, and thus always use antifreeze prepared by a
          reliable maker, and never use it mixed with antifreeze of a
          different brand.

         *Make sure that the cooling system of the engine is cleaned
          well before adding antifreeze.

         *Recommended antifreeze for year round use is ZEREX Long Life
          Coolant (antirust contained).


                          ANTIFREEZE ADDITION DATA

     Antifreeze
     Concentration %        13     23          30      35       45       50        60

     Freezing      C       -5    -1"         -IS     -20      -30      -40     -50
     temperature (  F)    (23)   (14)          (5)   (-4)    (-22)    (-40)   (-58)


     Note:      It   is   advisable that antifreeze  concentration be
                selected on the basis of a temperature which is about
                5C   (lOF)  lower than the actual atmospheric tem-
                perature.

3.   Alternator belt tension

     The alternator belt is properly
     tense if     it deflects 10 to
     12 mm (0.39 to 0.47 in) as it
     is depressed with a finger be-
     tween the pulley and pulley of
     the     long    distance    side.
     Excess i ve  tens ion  can  cause
     quick wear of the belt and
     bearings of the water pump and
     the   alternator.       Excessive
     slackness or presence of oil on
     the belt, on the other hand,
     can lead to engine overheating
     and insufficient charging due
     to a slipping belt.

     CAUTION:
          Never attempt to adjust        tension of     the   fan     belt while    the
          engine is in operation.




                                         16
4.   Fresh water cooling system   (See Note 5 on page 6.)

     The system consists of a sea water pump which pumps raw sea water
     through a heat exchanger to remove heat from the coolant. The raw
     water is discharged overboard through the exhaust line.

     The engine coolant (fresh water with or without antifreeze) is
     circulated by the fresh water pump in continuous circuit.   Pumped
     through the cylinder block, cylinder head, heat exchanger and back
     to the fresh water pump.

     The total system is very reliable and requires only a daily check
     of the water level in the system plus routine check of hose clamps
     and fittings.

     It is likely that zinc electrodes will waste away from contact
     wi th sea water.   It is also possible for the raw water pump
     impeller to fail due to lack of sea water or deterioration.     An
     early sign of impeller failure is less water and more steam at the
     exhaust through hull fitting.

     I t is recommended, therefore, that zinc electrodes, an impeller
     kit, a pump belt and a thermostat with gasket be kept onboard at
     all times.    These parts should be ordered from your nearest
     stocking dealer and used as inspection dictates.


                                   17
     WIRING DIAGRAM

     Your engine is of l2V system and its electric circuit is as shown in
     the diagram below.

     For installing electrical parts, connect them correctly by referring
     to the diagram and at the same time check for damaged wire sheathing
     and confirm that grounding is provided properly. Care must always be
     taken while working on the electrica~ system.

     Never shut the engine battery switch off while the engine is running.
     Damage to the alternator will result should this be done 
                                                                                                              .,CYEMAnc                   DIAGRAM



                                                                                                    + IZVDe    fI ...i'T'f,. ...


                                                                                                                                   STo\RT 500L       ST~A:rtA           
                                                                                                    t--------t


                                                                                                                                      "1.'1' (IIitN"TOA



                           WIP: NG   DIAGRAM                                                             ',.                       @      OUTPUT


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                              W.T.~cNOER             &IHI                      .RH

                                ~
                                 ~.,[1..
                                                      I~
                                             C::_-="-+-I---.
                                                     !!JIHj

                                                      \0 ,
                                                                        ~
                                                                       AL"rERNATOR
                                                                           0



                                                              




                                                                                         @
                                                                                     PR(-H(AT SOL

            @SI!["'OTE-a
       o.P.5ENCER




            '------+--I--...5~'~    ______!___1- _              --
"OT 1)5[0
                     RECOMMENDED MAINTENANCE SERVICE


Check and service your engine at specified intervals to maintain it in
its best conditions and permit it to perform as it should.      As for
those asterisked items, it is suggested that you have them performed
by an authorized distributor or dealer.


1.    Daily inspection before use

      A.   Checkup of engine oil level and refilling

           No refill is required if the level is near the upper limit
           line of the gauge.

      B.   Checkup of cooling water and refilling

           Refill up to the filler cap neck.

      C.   Check your fuel supply

      D.   Checkup of gauges and meters

           After starting your eng ine, check oil pressure,      water   tem-
           perature and voltage reading.

      E.   Checkup for loose parts (fan belt or bolt, etc.), damage and
           leaks

      F.   Checkup for abnormality with exhaust gas, noise and vibration


2.    Servicing following initial 50 hours of operation

      A.   Renewal of engine oil

      B.   Replacement of oil filter
      C.   Renewal of cooling water

      D.   Adjustment of valve clearance    (See SERVICE DATA)

     *E.   Tightening of bolts and nuts

     *F.   Adjustment of engine idle


3.    Servicing at every 100 hours of operation

      A.   Renewal of engine oil

     B.    Replacement of oil filter



                                       19
      C.   Cleaning of fuel filter
      D.   Adjustment of engine idle


4.    Servicing at every 200 hours of operation

      A.   Replacement of engine mounted fuel filter elements
      B.   Replacement of fuel filter (cartridge type)


5.    Servicing at every 400 hours of operation
      A.   Cleaning of fuel tank
     *B.   Adjustment of valve clearance
     *C.   Checkup of starter motor, alternator and regulator
           Check the brush and surface of commutator for the degree of
           wear.  Replace the brush if it is worn beyond the limits of
           wear.

     *D.   Checkup of glow plugs

           Check the glow plugs for blow-out.
      E.   Removal of cooling water and flushing is suggested.

6.    Servicing at every 800 hours of operation
     *A.   Checkup of nozzles

           Set the injection starting
                            +142
           pressure to 1707 -0    psi
           and eliminate undesirable
           injection conditions in-
           cluding "after dr ipping".




                                                                GOOD

                                       20
*B.   Checkup of compression pressure

      Remove each glow plug and check cylinders, one by one, using
      a compression pressure gauge.    If the pressure differs by
      more than 2.5 kg/cm 2 (35.6 psi) between cylinders or if the
      cylinder pressure is less than 26 kg/cm 2 (369.8 psi) at
      320 RPM for the W13 and at 280 RPM for the W21, W27 and W33,
      correct it.

*C.   Fuel injection adjustment

      In case of severe vibration during idling, have it repaired
      at an authorized distributor or dealer which is equipped with
      a pump tester.

*D.   Checkup of alternator and regulator

      Regulate the voltage and current by use of a circuit tester.

*E.   Checkup of starter motor pinion and flywheel ring gear

      Rectify the chamfered area that has been severely damaged by
      use of an oil stone or some pencil grinder, and replace the
      part if it is damaged allover.

*F.   Tightening of bolts and nuts




        RIGHT FRONT QUARTER   1   W-21 WITH 2:1 REDUCTION GEAR

                                      21
                                TRANSMISSIONS


Each engine model may be fitted with a variety                   of   transmission
options. For ratio and/or type, see table below.


                                                                 V-Drive
    Model      1:1     1.5:1          2:1        2.5:1             2:1
                                      BW-3
    W13     S-lOOO    HBW-100        HBW-50      HBW-50          HBW150V
                                                  BW-7
   W21      S-lOOO    HBW-100        HBW-50     HBW-100          HBW150V
                                                  BW-7
    RD-60   S-lOOO    HBW-100        HBW-50     HBW-100          HBW150V
                                                  BW-7
   W27      S-lOOO    HBW-100       HBW-100     HBW-150          HBW150V
                                                  BW-7
    RD-80   S-lOOO    HBW-100       HBW-100     HBW-150          HBW150V
                                                  BW-7
   W33     S-lOOO     HBW-100       HBW-100     HBW-150          HBW150V
              Left
    Rotation Hand     --------------Right Hand----------------

These transmissions have their own oil sumps and dipsticks.   "s" and
"HBW" units use ATF lubricant, while "BW" units may use either ATF or
30 weight engine oil.

The transmissions, their dipsticks and markings are illustrated in the
sketches below.   For dipsticks that are threaded in the case, measure
oil by dropping dipstick on the case. Do not screw in.




                                                            5-1000




            HBW-100
            V-ORIVE




                                      BW-3
                                                          BW-7



                                      22
                               TROUBLESHOOTING


1.   ENGINE DOES NOT START

               PROBLEM                            REMEDY

a.   Starting switch is defective    Correct connections and contacts

b.   Deficient drive torque .)f      The battery is exhausted, trouble
     the starter motor               with the starter motor, or dirty or
                                     loose wiring

c.   Improper viscosity of engine    Check the viscosity and renew oil
     oil                             if necessary

d.   Engine too cold                 Use glowplug starting aid

e.   Seizure of moving parts          Rectify

f.   Air present in fuel system      Purge thoroughly with electric fuel
                                     pump

g.   No fuel in fuel tank            Refill

h.   Fuel filter clogged             Clean or renew


2.   ENGINE STALLS WHILE IN OPERATION

              PROBLEM                             REMEDY

a.   Fuel tank is empty              Refill

b.   Fuel filter clogged             Clean or renew

c.   Air present in fuel system      Retighten fuel line connections to
                                     allow electric fuel pump to run long
                                     enough to purge air thoroughly


3.   IMPROPER OIL PRESSURE

              PROBLEM                             REMEDY

a.   Oil shortage                    Refill

b.   Oil leak through connections    Repair

c.   Oil pressure switch             Replace
     defective




                                     23
4.   ENGINE OVERHEATING
---------------~~~~----------r_--------------~~~~-----------------
                   PROBLEM                                     REMEDY
a.   Cooling water shortage              Refill

b.   Water leaks                         Repair

c.   Belt loose or smeared with          Clean or renew
     oil

d.   Raw water QumQ defective            ReQair or renew


5.   BATTERY IS UNDERCHARGED
---------------~~--=_--------~r_--------------~~~~-----------------
                   PROBLEM                                     REMEDY
a.   Belt tension improper               Rectify

b.   Faulty wiring circuit               Rectify

c.   Alternator not functioning          Replace
     (observe voltmeter)

d.   Battery faulty                      Replace

e.   Faulty voltage   reg~u~l~a~t~o~r~__~~R~eQair   or renew




                    RIGHT SIDE) W-27 WITH 2:1 VEE DRIVE

                                         24
                                  SERVICE DATA



1.   Valve clearance (engine cold)                 0.25 rom (0.010 in.)
     (both intake and exhaust)

2.   Compression pressure

                            W13                    32 kg/cm 2 at 320 RPM

                            W21 - W27 - W33        32 kg/cm 2 at 280 RPM

3.   Engine oil capacity (including
     oil filter
                         W13                       2.8    liters    (0.74   U   S   gal)
                         W21                       3.5    liters    (0.93   U   S   gal)
                         W27                       4.5    liters    (1.19   U   S   gal)
                         W33                       5.0    liters    (1.32   U   S   gal)

4.   Firing order

                            W13                    1-2
                            W21                    1-3-2
                            W27 - W33              1-3-4-2

5.   Injection timing -     BTDC    of   compression   stroke      when   started      at
     smoke set position.
                           Marine Engine           23 + 1.5
                                                       -
                                                   19 + 1.5
                           Generator

6.   Injection starting pressure                          +142
                                                   1707      0 psi

7.   Cooling water capacity (in engine
     body alone)
                         W13                       2.1    liters    (0.56   U   S   gal)
                         W21                       3.0    liters    (0.79   U   S   gal)
                         W27                       3.5    liters    (0.92   U   S   gal)
                         W33                       3.7    liters    (0.98   U   S   gal)




                                         25
                        TABLE OF TIGHTENING TORQUES


                                                            Ib/ft.


Cylinder head bolt (MI0) W21, W27, W33          7-8       SO.7-S7.9

                     (M12) W21                 11-12      79.6-86.8

                           W13, W27            12-13      86.8-94.0

                     (M14) W33                 lS-16     108.S-11S.7

Crank pulley nut W13                           lS-20     108.5-144.6

                 W21, W27, W33                 20-25     108.S-180.8

Main bearing cap bolt W21, W27, W33           S.O-S.S     36.2-43.4

Connecting rod cap nut W13, W21, W27          3.2-3.S     23.1-2S.3

Connecting rod cap bolt W33                  11.S-12.S    83.2-90.4

Flywheel bolt                                11.S-12.5    83.2-90.4

Oil pan drain plug                              S-6       36.2-43.4

Oil filter                                    1.1-1.3      8.0-9.4

Delivery valve holder    (injection pump)       4-S       28.9-36.2

Holder mounting bolt, nozzle                  1.S-2.0     10.8-14.S

Holder body and retaining nut, nozzle           6-8       43.4-S7.9

Glow plug                                     1.S-2.0     10.8-14.S

General screw tightening torque       M6        0.7          5.1

                                      M8        1.7         12.3

                                      MI0       3.S         25.3

                                      M12       6.4         46.3

                                      M14       9.S         68.7




                                       26
             WESTERBEKE GENUINE PARTS


     "WESTERBEKE GENUINE PARTS II are super ior and
reliable because they have been produced under an
excellent quali ty control system and have passed
the standard after strict inspection.

     After market parts are not recommended from
the viewpoint of their material standard and manu-
facturing   method which may be entirely different
from those of genuine parts.

     "WESTERBEKE GENUINE PARTS II are available from
our authorized distributors and dealers.      Please
order your spare parts from your nearest distribu-
tor or dealer.




    LEFT SIDE) W-13 WITH 2:1 BW-3 TRANSMISSION


                         27


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