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Westerbeke Diesel W 21 Technical Manual



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 OPERATOR'S                                                         ANUAL


                WESTERBEKE

13A      18                     21 A                             27 A        33A
          Marine Diesel Engines




                           Publication # 36195
                              Edition One
                                July 1986




           AVON INDUSTRIAL PARK, AVON, MA 02322     8   TEL: (617)588-7700
           TELEX: 92-4444  FAX: (617) 559-9323  CABLE: WESTCORP
                                   FOREWORD


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

    This manual describes the procedures for proper
handling and routine maintenance of:


                 W13A, W18, W2lA, W27A and W33A


              Marine Diesel Propulsion Engines

    To obtain best operating condition and longest
life, i t is important to use it sensibly and carry
out operation and maintenance according to this
manual.

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


     If, within 60 days of submitting your Warranty
Registration Form for: your engine, you have not
received a Customer Identification Card (see below)
registering your warranty, please contact the fac-
tory in writing with Model information to include
unit serial number and commission date.

        We look forward to your continued patronage.

  from:    J.H, Westerbeke Corp.
           Avon Industria! Park
           Avon, MA 02322




                        ,-                 -- -    ------.- .. ---                ------------------

                             I~               J. H. WESTERBEKE                               COR~
                                              ","D~ IkO<."'~'"   e~"K,   .v",,,, MHO   OHa




                             CUSTOMER ID        FICATION
                              W-2lA l234C508 Pleasure Craft
          Mail                       expires 7/7/87
                                Adam Smi th
                                85 Maple Street
                                Alden, IN       12234
  PI<                   .~                                                                       ...J,

                                       1
                 TABLE OF CONTENTS
                                                           PAGE
GENERAL SPECIFICATIONS .......... 3

INSTALLATION, PREPARATION AND SUPPLY
     CAUTIONS. . . . . .  . . . . . . . . .  . . . .   LE NOT[- B

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                                                                                                                    15
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                                                          THAN MANIFOLD CAP
                                                                         '__                 ~
                                                                                '"         ---          ~   HEATER COILS ABOVE PRESSURE CAP
                                       ~                                             '-"         ,- "       ON ENGINE MANIFOLD




                                ~'~'S1~~)~'~
 REMOVE BY-PASS FROM
 ENGINE FLOW CONTROLLER


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                            HEATER BELOW ENGINE
                                                                                                                   HEATER ABOVE ENGINE
  Figure 16.              Flow Control System

                                                               22
                     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.   Check engine oil level and add as needed.

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

      B.   Check fresh water coolant levels.

           Refill up to the ADD line on coolant recovery tank.

      C.   Check transmission lUbricant level and refill as needed.
           Check your fuel supply. Check filter/water separators.

     D.    Visually check engine for loose parts (alternator belt and
           bolts etc.), damage and leaks. Correct as required.

      E.   Check operation of gauges and meters.

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

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

2.    Servicing Following Initial 50 Hours Of Operation

      A.   Renewal of engine oil.

      B.   Replacement of lube and fuel filters (two fuel filters).

     *C.   Tightening of bolts and nuts     (torque cylinder head hold-down
           bolts) 

      D.   Change transmission lubricant (HBW models initially change
           at 25 hours).

      E.   Adjust engine idle speed if needed.

     *F.   Adjustment of valve clearance.

3.    Servicing At Every 100 Hours Of Operation

      A.   Renewal of engine oil.

      B.   Replacement of oil filter.

4.    Servicing At Every 200 Hours Of Operation




                                    23
                     t of engine mounted fuel filter elements        filter
           element in electric fuel pump and secondary filter            ).
5.    Servicing At Every 500 Hours Of       at
      A.   Torque cylinder head hold-down bolts.

     *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.   Do resistance check (.2 ohms).

      E.   Removal of cooling water and flushing is suggested.

6.    Servicing At Every 800 Hours Of Operation

     *A.   Checkup of nozzles
           (See Figure 17).
           Set the  injection starting
                            +142
           pressure to 1706 -0     psi
           and eliminate undesirable
           injection conditions,    in-
           cluding "after dripping".
     "B.   Check compression pressure.

           Remove each glow plug and                 POOR
           check  cylinders,   one  by
           one, using a compression
           pressure gauge.     If the
           pressure differs by more
           than 3.0 kg/cm 2 (42.7 psi)
           between cylinders or if the
           cylinder pressure is less
           than 30 kg/cm 2 (427.0 psi)
           at 200 RPM, correct it.

     "C.   Fuel injection adjustment.

           In case of severe vibration
           during   idling,  have   it
           repaired at an authorized
           distributor or dealer who
           is equipped with a pump
           tester.                          Figure 17. Nozzle    ay Pattern

     *D.   Check tightness of nuts and bolts.




                                     24
                             TRANSMISSIONS


          All HEN models turn r      hand       lers.
          All HEN models have their own 0             d                               ticks.
              HEN       s use ATF lubricant.
          All HEW models should be shifted into gear                                  in        one          swift
          mot     - not allowed to slip in slowly.
Control Of Gearbox (See F     e 18)                                  33C CABLE                     SHIFTING LEVER


L    The  gearbox   is   suitable  for
     single   lever    remote  control
     using 33C

2.   The cable should attach at right
     angles to the actuating lever
     using     the   cable    bracket
     supplied.

3.   Both gear box lever and remote lever must be in
     neutral position when cable is at tached so that
     travel of gearbox lever will be equal forward or
     reverse.

4.   Check that actuating lever hub does not touch
     cover plate hub.    Maintain at least 0.5 mm
     (0.002") clearance.
                                                                                           -----+'"'*   --

                                                                                           Q,Smm
5.   Over travel of the actuating lever does no harm.
     However, if the travel is too short to give full
     engagement,   premature   wear,  excessive  heat                                  Figure 18.
     generation and gear failure may result.                                           Control of
                                                                                        Gearbox
                                                                DIPSTICK
6.   The position of the cover plate
     underneath the actuating lever
     is factory adjusted to ensure                                         TO CHECK OIL LEVEL

     equal lever tr avel from neutr
                                                                                                TRANSMISSION!N OPERATION
     to A and E.   DO NOT LOOSEN THE
     CAPSCREWS HOLDING THIS ASSEMBLY.
     Doing this voids transmission
     warranty.

7.   F      gearbox    with automatic
     transmiss     fluid to the level
     indicated                                          '
                    the d    lck mark                   .
                                                        . ,
                                                          ,
                                                            ,


                                                        , ,
     (See Figure 19) 

8.   Note that to check      1      ,
     the   dipstick   drops    on the                                                    FLUtD LEVEL

     housing.   It does     screw

9.   The HBW gear box can be free-
     wheeled in Neutr a1.   To stop
     propeller shaft rotat     while       ORAl' PLUG

     under sail,       the gear into
     Reverse.                                    Figure 19.                  Dipstick oil                            s


                                      25
Each   engine model               fitted    th a vari   of   tr         ss
opt        For ratio                , see table  low.



        Model      1.5:1             2:1        2.5:1   2:1 V-Drive
                                    BW-3
       W13A       HBW-IOO           HBW-50     HBW-50
                                    EW-7
        W18       HBW-IOO          HBW-50     HBW-IOO    HBW-150V
                                    BW-7
        W21A      HBW-IOO          HBW-50     HEW-IOO    HBW-150V
                                    BW 7
       W27A       HBW-IOO          HBW-IOO    HBW-150    HBW-150V
                                    BW-7
        W33A      HBW-IOO          HBW-IOO    HBW-150    HBW-150V

        Rotation-------------------Right Hand--------------------



These transmissions have their own oil sumps and dipsticks.   "5" and
"HBW" units use ATF lubricant, while HBW" units may use either 4120 or
4130 S.A.E. engine oil.

The transmissions, their dipsticks and markings are illustrated in
Figure 20 below. For dipsticks that are threaded in the case, measure
oil by dropping dipstick on the case. Do not screw in.


                              DIPSTICK




                                                             DIPSTICK




                HEW
                V- DRIVE




                           Figure 20. Transmission
                                         26
                       WARNER HYDRAULIC TRANSMISSIONS



                                      FROM COOLER
                                       (2.10:1 ONLY)




         FROM      10-13/10-14
        COOLER                                 FROM COOLER       10-17/10-18
                                               (EXCEPT 2.10:1)



1.   CONTROL LEVER POSITION
The position of the control lever on transmission when in forward
should be shifted to the point where it covers the letter "p" on the
case casting, and is located in its proper pOSition by the poppet
ball.   The Warranty is cancelled if the shift lever poppet spring
and/or ball is permanently removed, or i f the the control lever is
changed in any manner, or repositioned, or if linkage between remote
control and transmission shift lever does not have sufficient travel
in both directions.   This does not apply to transmissions equipped
with Warner Gear electrical shift control.


2.   LUBRICATION

The properties of the       1 used in the transmission are extremely
important to the proper function of the hydraulic system. Therefore,
it is extremely important that the recommended oil,        automatic
transmission fluid (ATF) , Type A or Dexron II be used.

NOTE: Be sure the cooler is properly installed when required and
the transmission conta oil before cranking or starting the engine.




                                      27
3.   FILLING AND CHECKING 'l'HE HYDRAULIC SYSTEM

The oil level should be maintained at the          mar k on the d
Check oil level prior to starting engine.    Check dai     before starting
engine.  The hydraulic circuit includes the transmiss        , o i l cooler,
cooler lines and any gauge lines connected to the circuit.               The
complete   hydr aulic circui t  must    be  filled    when    filling    the
transmission and this requires purging the system of air before the
oil level check can be made.    The air    11 be purged from the system
if the oil level is maintained above the pump suction opening while
the engine is running at approximately 1500 RPM.     The presence of air
bubbles on the dipstick indicates that the system has not been pur
of air.

New applications or a problem installation should be checked to insure
that the oil does not drain back into the transmission from the cooler
and cooler lines. Check the oil level for this drain back check only,
immediately after the engine has been shut off and again after the
engine has been stopped for more than one hour           (overnight is
excellent). A noticeable increase in the oil level after this waiting
period indicates that the oil is draining from the cooler and cooler
lines.   The external plumbing should be changed to prevent any drain
back.

4.   STARTING ENGINE

Move the shift lever to the center position where the spring-loaded
ball enters the chamfered hole in the side of the shift lever and pro-
perly locates lever in neutral position before starting engine.

5.   SHIFTING

Shifts from any selector position to any other selector posi tion may
be made at any time and    any order if the engine        is below 1000
RPM; however, it is recommended that      shifts be made at the lowest
feasible engine speed.   Move the shift lever to the extreme forward
position where the spring loaded ball enters the chamfered hole in the
side of the shift lever and proper                   lever in forward
position.

Move tr ansmi ss ion shift lever to the extreme rearward posit        where
the spr     loaded        enters the chamfered hole in the s         of the
shift lever and proper     locates it in the reverse    ition.


6. FREEWHEELING

Under sa      th the           turning, or at trolling       with one
of two eng ines shut     , the des ign of            mainta
cooling and lubr          Attempting to            gear into
reverse while under: sail to         opeller shaft rotat
no effect.     To stop      ller      t rotation while under     1, a
mechanical shaft brake       be needed.




                                     28
7. COOLING PROBLEMS

Water     sages inside of the cooler   11 somet     become c       , and
this    11 reduce cooling        i    and cause over essur ing.     Back
flushi     of the cooler        sometimes help to           the foreign
mater i    from the cooler passages.    The cooler and hose should be
thoroughly flushed or replaced in the event a failure has occurred.
Metallic particles from the failure tend to collect in the case of the
cooler and gradually flow back into the lube system.        Replace oil
cooler to prevent         nat    of the new transmission.

Water hoses may collapse and reduce or completely shut off all flow to
the cooler.  Collapsed hoses are usually caused by aging of the hoses
or improper hose installation. Hose installation should be made with
no sharp bends. Hoses should be routed so there is no possibility for
engine shifting to cause hoses to pull loose or become pinched.      A
visual inspection of hoses while under way will sometimes allow detec-
tion of faulty hoses.
Reduction or complete loss of water flow can be caused by a faulty
water pump.    A rubber water pump impeller will sometimes fail and
after: such a failure the cooler passages may be restricted by the par-
ticles of rubber from the failed impeller. Water pump cavitation may
be caused by improper or faulty plumbing or an air leak on the inlet
side of the pump. The water pump may not prime itself or: may lose its
prime when inlet plumbing is not properly installed.

It    possible for cross leaks to occur inside the cooler, permitting
oil to flow into the water or water flow into the oil.       Checking
transmiss    fluid      s at each days use will help spot such a hap-
pen   ,undetectable loss of fluid and/or emulsified fluid.




                                   29
                     ROUTINE CHECKS AND MAINTENANCE


ANNUAL CHECKS
1.   PROPELLER AND OUTPUT SHAFT ALIGNMENT:  This check should also be
made any time the propeller strikes a heavy object and after any acci-
dent where the boat is stopped suddenly.   Shaft alignment should also
be checked after the boat has been lifted by a hoist or moved on a
tr ailer.
2.  SHIFT LEVER POSITIONING: The selector controls must position the
shift lever exactly in F, N and R selection positions with the ball
poppet centered in the shift lever hole for each position.

3.   BOLT TORQUE:   Check all bolts for tightness.
4.  COOLER CONNECTIONS: Check water lines, oil lines and connections
for leakage.    Make sure lines are securely fastened to prevent
shifting.
5.  CHANGING OIL:   A seasonal oil change is recommended in pleasure
boats. Work boats require more frequent changes. Change oil any time
the oil becomes contaminated,     changes color or becomes rancid
smelling.  Automatic transmission fluids (ATF), Type A is recommended
for use.


DAILY CHECKS

1.   Check transmission oil level.

2.   Check for any signs of oil leakage in the bellhousing, at gasket
     sealing surfaces or at the output shaft oil seal.
3.   A quick visual check of the general condition of the equipment may
     cause faulty equipment to be detected.

4.   Listen for any unusual noises        and   investigate to determine the
     cause of any such noises.

     Note:   Low engine idle speed can produce drive damper chatter.

WINTER STORAGE

L    Drain water from transmission oil cooler.   This will prevent
     freezing in cooler climates, and prevent harmful deposi ts from
     collecting.


GENERAL CHECKS
1.   Check coupling alignment each time a transmission is replaced in
     the boat.




                                     30
2.   Check shift linkage      ustment to insure that the tr         ssion
        ft lever is     itioned so that the      Ing loaded        enters
     the chamfered hole in the s    of the shl t

3.   Connect an oil cooler into the cooler circuit before cranking or
     starting the engine.   various cooler circuits have been used and
     the correct cooler connections should be found from service
     literature prior to makeing the cooler installation.

4.   Use a cooler or sufficient size to insure proper cooling.

5.   Check engine rotation and transmission pump setting and the pro-
     peller rotation prior to assembling the transmission to engine.

6.   Check oil pressue and temperature     when   transmission   function
     indicates that a problem exist.

7.   Use the recommended fluid for filling the transmission.

8.   Fill the transmission prior to starting the engine.

9.   Check oil level immediately after the engine has been shut off.

10. Use a clean container for handling transmission fluid.

11. Replace cooler and lines after a transmission failure.       prior   to
    installing a new or rebuilt transmission.

12. Check fluid level at operating temperature.




                                   31
                              WAI/l'ER V-DRIVES


FLANGE ALIGNMENT - DIRECT COUPLED MODELS

    Install the pr     leI: shaft         on
to the propeller shaft and ti        the two
clamping bolts on the spli t hub (none on
RV-IOD). A self-locking set screw is pro-
vided for    the propeller shaft flange.
Spot dr ill the propeller        t and then
securely tighten the set screw. Many good
installations are ruined by       oper shaft
flange alignment. Accurate       gnment will
ensure a smooth operating drive train and
eliminate many problems that arise due to
misalignment.   Final alignment should not
be attempted until the boat has been
allowed to "settle" in the water.      After
the engine has been installed, adjust the
mounts   per   manufacturer's   instructions         fl ANCE ALiCNMEN T
until the pilot diameters of the gear
shaft   flange  and  the propeller     shaft
flange engage freely.      Butt the flange
faces together.   without rotating either flange, check with a feeler
gauge in at least four places as shown in the illustration.             If the
maximum feeler gauge that can slip between the flange faces at any
point is .003", the unit is properly aligned.     If a thicker gauge can
be inserted at any point, the engine must be readjusted until proper
alignment is obtained.   Turn the propeller shaft flange 1/4 of a turn
without moving the gear shaft change.     Try inserting the .003" feeler
gauge as described above.     The gap will not change if the propeller
shaft is straight.   If it increases, the shaft or flange is bent and
must be removed and straightened.      Rotate the propeller shaft
in two more 1/4 turn        ements and repeat the procedure.        The    lot
diameters must be rechecked to ensure that they still engage freely.
Secure the two flanges together with the heat treated bolts and spe-
cial high collared lockwashers supplied.


ENGINE ALIGNMENT - INDEPENDENT MODELS

    The engine must be adjusted so that the alignment of the flexible
joint is wi thin 3.   An accur ate steel rule should be used for this
purpose as shown in the i        at      On short installations using a
flexible joint assembly, the faces of the flexible joint must be
parall   within l/S". Measure this in at least four places around the
diameter without rotating the assembly.     th long installations using
the #36 tubular drive shaft (also on all RV-IOD's) the distance from
the #33A spool adapter to the bores in the universal j      nt which is
welded to the tubular shaft must be measured on both s           of the
joint. Rotate the shaft exactly 1/4 of a turn and measure to the same
joint. The four distances must be equal     thin l/S".       not measure




                                      32
                                              to the joint end that is
                                              on the
                                              This     stance         not
            :<,   /Cb'Xut.,",;~'N:'?~:.P'''~, vary     th misalignment
                           .~r"6S       r"?'1 since    the     joint   is
                                              bolted       cannot move.)
                                              Put the 1I3lA
                                              gauge on the machined
                                              diameter    of    the   *24
                                              cover and sl        it com-               -:<>.I..fIi. SCR[w YO GT
                                              pletely around. It will                   AN K:CU:W"[ M[A"'-""''''fNl



                                              indicate how the engine
                                              must be moved to center
             DEpr~   JHAl sP'.IN( S>JUST BRACKETS

ly t        the set screws.
                                                                          'MOl'HING
         V-drives are supplied     th        adjustable                      HOL[

mounting brackets (2-way on the RV-IO and RV-20) as
standard equipment.     The brackets must face down-
ward as shown in the illustration to proper
absorb propeller thrust.      The mounting plates can
be removed and rever sed to fi t        der engine bed
centers.         e installing the       ive, loosen
the nuts on the          ng brackets and check to see
that the         are in the center of the slots. Re-
tighten the nuts.     place the V-dr i ve on the engine bed, li ng it
"       " to the             shaft flange as closely as possible. F
       t down              the holes provided        the mounting plates.
Loosen the locking nuts on the adjusting screws.       Slightly loosen the
nuts on       mounting brackets just enough to be able to move the V-

                                                 at     are ruined     impr       opeller shaft
                                               Accurate al            ensure a smooth operating
drive train                                 el   nate many problems that arise due to misal


                                                            33
ment. Final              should not              until the boat has
allowed to "set       in the water.              V-dr i ve until the
diameters of the gear shaft f                    pr               t
engage freely.     Butt the           faces                 thout rotating
either flange, check      th a          gauge       least four places as
shown      the illustration.   If the maximum         gauge that can slip
between the flange faces at any point is .003", the unit is properly
aligned. If a thicker gauge can be inserted at any point, the V-drive
must be readjusted until proper alignment is obtained. Turn the pro-
peller shaft flange 1/4 of a turn without moving the gear shaft
flange. Try inserting the .003" feeler gauge as described above. The
gap will not change if the propeller shaft is stra                   If it
increases, the shaft or flange is bent and must be removed and
straightened.    Rotate the propeller shaft flange in two more 1/4 turn
increments and repeat the procedure.        The pilot diameters must be
rechecked to ensure that they still engage freely.        Tighten the nuts
on the mounting brackets and the locking nuts on the adjusting screws.
Remove the set screws from the brackets (none on RV-IO or RV-20), spot
drill and securely tighten. Recheck the flange alignment to make sure
the V-dr i ve did not move out of alignment.     Secure the two flanges
together with the heat treated bolts and special high collared lock-
washers supplied.




                        (HECK

                                    SET SCREVJ
   GEAR SHAFT
    FLANGE




     FEELER'
      GAGE




           PROP. SHAFT-
               FLANGE

                 FLANGE ALIGNMENT




WATER AND SWITCH CONNECTIONS

    Hook up the water lines to the two pipe connections on the V-drive
(intake and exhaust lines are interchangeable)"     Generally, one line
from the seacock to the V-dr i ve and another from the V-dr i ve to the
intake of the engine water circulating pump are utilized.       In some
cases, scuppers through the hull are connected to and from the V-drive
to provide independent water-cooling and are actuated by the movement
of the water.    Wi th closed cooling systems, the V-dr i ve should be
incorporated into the system between the cooler and the suct       side
of the water pump.     Proper operating temperatures are from 140" to
180"F, although safe oper ating temper atur es may be as high as 210F.
On the models equipped with an oil circulating pump, the *49 oil


                                                 34
pressure           sw itch and the 12 vol t Jl4  warni   Ii                             be
hooked up         the wiri    diagram.  The switch                                     any
part of              ive or engine     ther      nal may                  used for     the
ground) 



OIL FILL

           out the lI21 oil level gauge.
Unscrew the lI12 breather cap and fill the
V-drive with SAE #30 motor oil through the
Jl12A breather elbow.   On the RV-IO only,                            ~'~ ~ rOIL LEvEL
the oil may be added by removing the plug                            ;    ~
                                                                           ,    I
                                                                             , GAGE
                                                                              (PUll UP TO
                                                                                 R(M:)VEi
in the Jl6D top cover. See table below for                           )/ f
approximate oil capacities.     The amount
varies with the angle oE installation.
The oil level should be checked wi th the
oil level gauge Eully inserted in the
                                                                            . (t:'V
                                                                     ~1f'''1 ~~
unit. The proper level is between the "HOI
and ilL" marks on the gauge. Add a 2 ounce
tube oE Molykote (molybdenum disulfide),                               I       '

which is supplied wi th each V-dr i ve Eor    #~2A BREATHER ~~ \, \          VATER LINE
                                                  ELeo."
extra lubrication and break-in.   It provi-                  ,-;~WATER DRAIN
des protection against scoring or galling
of gears, bearings and other moving parts.
Additional Molykote after break-in is not required.             Reinstall the
breather cap.    The oil level should be rechecked after the unit has
been run and allowed to sit for about a minute. Add oil if necessary.

                            RV-IO       RV-20        RV-30        RV-40        RV-48

Oil capacity                1 pint     2 pints      3 pints      4 pints       4 pints
(Approx. )


DEALER PREPARATION

    The propeller shaft and engine alignment must be checked and
corrected, iE necessary, before the boat is delivered.   Final align-
ment should not be attempted until the boat is allowed to "settle" in
the water.   The oil level must be checked and oil added i f required.
While the boat is being run, the water connections should be checked
for leaks.   The oil pressure drop switch and war ng light (iE the
V drive is equipped with an oil c culating pump) should be checked
for proper operation.   Do not transport the boat with the propeller
shaft coupling connected.  Damage to the shaft, shaEt log and V-drive
can result.




                                           35
OPERATION
    A pressure dr     warning Ii     is
mounted on the instrument panel on
V-drives equipped     th an oil cir-
culating pump. The warning light     11
stay on until the boat gets under way
and the engine speed increases to suf-
ficient RPM for the pump to maintain
pressure.    This normally occurs at
approximately 1200 RPM, but the actual
speed may vary by as much as 400 RPM.
Extended cruising at low RPM, such as
when trolling, is not harmful to the
V-drive, even though the warning light
may stay lit.     Normal operation is
between 6 to 12 PSI.    The light will
go on when the oil pressure drops
below 2 PSI.     Loss of oil and/or
insufficient oil level are the major
causes of pressure drop.       The oil
level should immediately be restored,
and while running the boat, the unit should be checked for leaks.    If
the oil level is normal and the light stays lit when the boat reaches
normal cruising speed, the wir ing should be checked for loose and/or
corroded connections.   If the wiring is correct and the light remains
lit, the #49 pressure drop switch, which is mounted on the side of the
V-drive (see illustration), should be checked for proper operation.
The switch can easily be removed and an accurate oil pressure gauge
installed in its place.   If the pressure is normal, the switch should
be replaced. If the pressure is below normal, the oil lines should be
checked for blockage.    The pump should be inspected and replaced i f
necessary.  The pump is standard on the RV-48 and an optional feature
on other models (not available on the RV-10).
    The oil level should be checked several times during the season,
especially on V-drives whitout pumps (see OIL FILL).
    A clatter or rattle     the V-drive at low RPM is due to the over-
riding of the propeller du!: ing the compression stroke of the eng ine.
Although annoying, it is not harmful.   It may be reduced by adjusting
the idle speed and/or tuning up the engine for smoother operation.


MAINTENANCE

1.   OIL CHANGE AND JOINT LUBE

    After the first 100 hours of operat         and every season and/or
500 hours thereafter, the     1 should be changed. Run the boat to warm
up the V-drive to operating temperature. Turn off the engine. Remove
the        in the #6B bottom cover that is             ite the #438 oil
stra nero   Re    tall after draining.   Disconnect        1 hose leading
from the 11438 straine.r (leave the elbow on the stra     ). Unscrew the
strainer and clean the outs        surface.   Reinstall the strainer and
reconnect the     1 hose.   Unscrew the two #22                  that are
        on di                ite corners of     tIC main hous ng.




                                   36
     The    s can be          to see if
      are magnetic       after removal.
Touch the inside face     th a metall
    ect,      as a screwdriver.   Clean
them and reinstall.     Usually, there
                                                                 ';0.[ ( '
are four plugs      the bottom part of
                                                   A     ,,- "



                                              ,,0 L :c ~fM(J'"
the main housing.    Only two of these        Cil qRA,~"r;
                                            .1:11'( ,.     ';1;"-,,,1',,_

are magnetic.   The other two need not
be removed (see illustration). Refill
wi th SAE 30 motor oil to the proper
level (see INSTALLATION - OIL FILL).                                         n IMG'i[llC PLc<, if:
                                                                             :)IACU1AlLV (wrOS,T,
The Zerk fitting on the external un
versal joint should be greased with a
light alemite lubricant (see ENGINE
ALIGNMENT).


2.   WATER DRAIN

    For protection from freezing during winter lay-up, remove the
small pipe plugs (located diagonally opposite) on the front and back
of the housing marked "Water Drain" (see illutration).   On the RV-IO
only, one of the water lines going into the       water-cooled bottom   *6
cover must be disconnected to drain the water.


3.   FLANGE AND ENGINE REALIGNMENT

      When the boat is launched after being     drydocK., the line-up of
the v-drive to the propeller shaft flange and the engine to the V-
dr i ve should be rechecked and cor rected if necessary.    Some eng ines
wi th rubber mounts may sag and must be raised wi th adj ustments or
shims for         proper alignment (see "Flange Alignment" and "Engine
Al         .. ) 




                                     37
MODEL W13A:
ADJUSTMENT OF VALVE CLEARANCE

1.   Remove the rocker cover and
     loosen   the  rocker  arm nut.
     Check the valve clearance with
     a    feeler   gauge   and,  if                             ,>: rfs;
     necessary, adj ust it with the                             'ii
     adjusting screw.                                    Mark   o;::T
                                                          case side

2.   Adjust the intake and exhaust
     valves on No.1 cylinder side
     first at TDC on compression
     stroke   of  No.  1  cylinder:.
     Then, adjust on No. 2 cylinder



3.
     side   at TDC on compression
     stroke of No.2 cylinder.

     Each cylinder piston is at TDC
                                           -r
                                           Front of engine




     on compression stroke when the                  2                     5
                                                                               3
     timing mark on the gear case is                o                      o   o
     in alignment with that on the
     crankshaft pulley.

4.   After   adjustment,  keep  the                  4
     adjusting screw from turning                   o
     and tighten the rocker arm nut
     securely.
                                                           2 cylinder
     NOTE:   Retighten the cylinder
     head    bolts    before  valve
     clearance is adjusted.

                                        W13A
                                        Bolts *1,2,3,4,5, & 6
                                              (17rnrn 7 - 8 Kg-m)

                                        Rocker Shaft Holddown Bolts
                                              (14mm 3.5 Kg-m)

                                        Note: rnrn sizes shown are
                                        socket size for head bolt.




                                   38
MODELS Wl8 and W21A:
ADJUS'I'M.ENT OF VALVE CLEARANCE

CAUTION:
*   Adjust the valve clearance when
    the engine is cold.
* Tighten the cylinder head bolts
    to the specified torque.

1.   Pull off the air breather pipe
     from the rocker cover, and then
     loosen off rocker cover bolts.
     Adjust the valve clearance at
     top dead center of compression
     stroke of    each cylinder   as
     described below.
                                                          Timing Mark
2.   Align the timing mar ks on the
     gear case and the crankshaft
     pulley shown.     In this posi-
     tion, No. 1 cylinder is in top
     dead center of its compression
     stroke.    Check both intake and
     exhaust valve clearances of the
     cylinder.    If the valves have
                                            - Front



                                                                      0              0           0
                                                                                                 II


     no specified clearance, adjust                                   4              6           8
     by   means   of   the  adjusting                                 0              ,)          0
     screws.    Remember to align the                         ::; 2           () I        () 3
     timing marks properly; if not,
     the valve will interfere with            Cylinder Head Bolt Tightening Sequence
     the piston because of wrong cam
     position.                              Description                   Standard value
                                         ----            jlO mm          i 7 t~ 8 kgm      "
3.   Next,   the   piston of No.   3     Cylin?er he~d i            l
                                                                    I  (50.6 to 57.8 ft-Ibs.)
     cylinder    comes  to  top dead     bolt tlghtenm g :.
                                         torque
                                                            '---~'~-r
                                                         ! 12 mmq:>       11 to 12 kgm
     center.     Turn the crankshaft                     I          I (795 to 86.8 rUbs.)
     240' clockwise from the above
     position, aligning the timing
     mark of the crankshaft with                  3 Cylinder Head Bolt
     tha t of the gear case.    Then                  Tightening Sequence
     check   and   adjust  the valve
     clearance.                            W-18 & W-21A
                                           Bolts #4,5,6,7,8,9,10 & 11
4.   To check No. 2 cylinder valve               (17mm 11-12 Kg-m)
     clearance, turn the crankshaft
     another 240' clockwise,     then      Bolts #1,2, & 3
     align   the  timing mar ks   and            (14 mm 7 - 8 Kg-m)
     check  and   adjust  the   valve
     clearance in a similar manner.        Note: mm size shown are
                                           socket size for head bolt.

                                           Rocker Shaft Holddown Bolts

                                          Bolts (14 rom 3.5 Kg-m)




                                    39
MODELS W27A and W33A:
ADJUSTMENT OF VALVE CLEARANCE

L         off the air breather p
     from the rocker cover, and then                                 TDC mark
     loosen off rocker cover bolts.

2.   Adjust the valve clearance at
     top dead center of compression
     stroke (cold) of each cylinder.
     Prior  to the measurement of
     the valve clearance,  retighten
     cylinder head bolts to spe-
     cified torque.    Give care to
     exact alignment of the timing
     mark of the gear case with that                         Timing Mark
     on the crankshaft pulleY1 if
     not, the valve may be pushed up        Front
     by the piston, depending on the
     position of cam lobe.                  ""

                                           ~i!"
                                                             a         0        0        0
                                                             
                                                             8
                                                                       I

                                                                       2
                                                                                5
                                                                                7
                                                                                         "
                                                                                         13
                                                    0        0         0        0        0
                                                        10       4         3         9
                                                        0        0         0        0



                                                    4 Cylinder Head Bolt
                                                     Tightening Sequence

     W-27A                                 W-33A
     Bolts 1,2,5,6,7,8,11,12,13,&14        Bolts
           (17mm 15-16 Kg-m)               1,2,5,6,7,8,11,12,13, & 14
                                                 (22mm 15-16 Kg-m)
     Bolts 3,4,9 & 10
           (14mm 12-13 Kg-m)               Bolts 3,4,9, & 10
                                                (22mm 11-12 Kg-m)
     Rocker Shaft Holddown Bolts
            14rnrn (12-13 Kg-m)            Rocker Shaft Holddown
            10mm (3.5 Kg-m)                Bolts
     Note:  rnrn sizes shown are socket          14mm 3.5 Kg-m
     size for head bolt.                         10mm 0.7 Kg-m




                                      40
      OF TIGHTENING   T(YR()fTP                 kq-m            Ib-fL


   inder head bolt       ) W18, W21, W27, W33   7 - 8        50.7 - 57.9
                    (M12) W18, W21             11 -          79.6 - 86.8
                           W13, W27            12 - 13       86.8 - 94.0
                    (M14) W33*                 15 - 16      108.5 -115.7
                    (M14 ) W33 (#3,4,9,10)*    11 - 12       79.6 - 86.8
                   "(See drawing on Page       "Cylinder Head" Section.)
Crank pulley nut W13                           15 - 20      108.5 -144.6
                 W18, W21, W27, W33            20 - 25      108.5 -180.8
Main bearing cap bolt WlS, W21, W27, W33      5.0 -  5.5     36.2 - 43.4
Connecting rod cap nut W13, W18, W21, W27 3.2 -      3.5     23.1 - 25.3
Connecting rod cap bolt W33                   5.5 -  6.0     37.9 - 43.0
Flywheel bolt - with separate washers       11.5 - 12.5      83.2 - 90.4
Flywheel bolt - washer attached                13 - 14       95.0 -100.0
Oil pan drain plug                              5 -  6       36.2 - 43.4
Oil filter                                    1.1 -  1.3      S.O - 9.4
Delivery valve holder (injection pump)          4 - 5        2S.9 - 36.2
Holder mounting bolt, nozzle                  1.5 -  2.0     10. S - 14.5
Holder body and retaining nut, nozzle           6 -  8       43.4 - 57.9
Glow plug                                     1.5 -  2.0     10.S - 14.5


UNLESS OTHERWISE INDICATED
Grade 6T
     6mm bolt/nut                            0.7 - 1.0          5   -    7
     Smm bolt/nut                            1.6 - 2.3         12   -   17
    10mm bolt/nut                            3.2 - 4.7         23   -   24
    12mm bolt/nut                            5.6 - 8.2         41   -   59
    14mm bolt/nut                            7.7 -10.5         56   -   76
Grade 8T and 8.8
     6mm bolt/nut                             . S - 1.2         6 -  9
     8mm bolt/nut                            1.8 -  2.7        13   -
                                                                    20
    10mm bolt/nut                            3.7 -  5.5        27   -
                                                                    40
    12mm bolt/nut                            6.4 - 9.5         46   -
                                                                    69
    14mm bolt/nut                           10.4 -14.0         75 -101
Grade 5 capscrew
    1/4 UNe                                  1.2 - 1.5          9   -   11
    1/4 UNF                                  1.5 - 1.8         11   -   13
    5/16 UNC                                 2.5 - 2.8         18   -   20
    5/16 UNP                                 2.9 - 3.2         21   -   23
    3/8 UNe                                  3.7 - 4.6         28   -   33
    3/8 UNF                                  4.1 - 4.8         30   -   35
    7/16 UNe                                 6.1 - 6.8         44   -   49
    7/16 UNF                                 6.9 - 7.6         50   -   55
    1/2 UNC                                  9.4 -10.1         68   -   73
    1/2 UNF                                 10.1 -ILl          73   -   80
               PROBLEM              J                     ,y

1.   ENGINE DOES NOT START

a.   Starting switch is defective       Correct connections and contacts
b.   Deficient drive torque of          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 electr ic fuel
                                        pump
g.   No fuel in fuel tank               Refill
h.   Fuel filter clogged                Clean or renew
1.   20 Amp circuit breaker             Manually reset
     tripped

2.   ENGINE STALLS WHILE IN OPERATION

a.   Fuel tank is empty                 Refill
b.   Fuel filter clogged                Clean or renew
c.   Air present in fuel system         Retighten fuel line connections and
                                        allow electric fuel pump to run long
                                        enough to purge air thoroughly

3.   IMPROPER OIL PRESSURE

a.   Oil shortage                       Refill
b.   Oil leak through connections       Repair
c.   Oil pressure sender                Replace
     defective
d.   Oil filter clogged                 Replace


4.   ENGINE OVERHEATING

a.   Cooling water shortage             Refill
b.   Water leaks                        Repair
c.   Belt loose or smeared with         Clean or renew
     oil
d.   Raw water pump defective           Repair or renew
e.   Thermostat defective               Replace

5.   BATTERY IS UNDERCHARGED

a.   Belt tension improper              Rectify
b.   Faulty wiring circuit              Rectify
c.   Alternator not funct   ing         Replace
     (observe voltmeter)
d.   Battery faulty                     Replace
e.   Faulty voltage regulator           Repair or renew



                                        42
1.  W"manlv (Ihligation aflll Duration
    Westerbeke warrants to the original consumer                 that all standard Westerbeke marine enl,in,es
generator sets manufactured or supplied    us will be free from defects in material and workmanship for a
one year: from date of commission, or date of purchase on repower, OR fifteen hundred (1500) hours on Commercial
Generators, only (whichever occurs first),

2,  Remedy
    Westerbeke will elect to repair or replace free of charge to you any product or part returned to our factory
transportation costs prepaid which we adjudge defective in materials or workmanship, Alternatively, we may
reimburse at OUf discretion a portion of labor costs incurred to repair defective parts or products on site. If you request
shipment of replacement parts to you prior to our determination of cause of failure, such shipment will be sent CO,D,

3,   Notification
     If you encounter a problem wit.h your Westerbeke engine or generator set within the warranty period as stated
above, contact your nearest authorized Westerbeke Master Distributor directly, by telephone or letter.

Be prepared    to furnish the following information:
         a.    number of hours on unit
         b,    date of commission, date of purchase
         c.    owner's office and home telephone
          d.   model number, serial number
          e.   name of vessel
          L    present location of vessel or product
          g,   name and address of builder
          h,   boat model name
          i.   who performed prior servicing, installation
          j,   description of current problem
          k.   any service outlet consulted and their diagnosis

4,   Exclusions
     This warranty shall not apply to:
       a) failures due to wear and tear, misuse, accident or negligence, including but not limited to improper storage
           or installation, inadequate maintenance, overloading and insufficient lubrication;
       b) consequential harm caused by overheating of engine cooling water or loss of engine lubricating pressure
           (these conditions should be constantly monitored by engine instruments andlor alarms);
       c) consequential harm caused by improper installation or failure of accessories attached to OUf product, such
           as water heaters and refrigeration compressors;
       d) products altered or modified in a manner not authorized in writing by Westerbeke;
       e) products damaged in transit;
       f) replacement of engine fluids, filter elements or vee belts, engine tune-up, valve adjustment, oil and water
           leaks. or any other normal service items;
       g) specially manufactured products provided to customer specifications;
       h) fuel systems, cooling systems, exhaust systems, electrical systems and cable control systems beyond the
           connection points on the product.

5, Applicatlon 01 Warranty
   THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES, ANY WARRANTY
IMPLIED BY          INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS, IS IN EFFECT
ONLY FOR THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST PARAGRAPH
ABOVE, NO REPRESENTATIVE OR PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY OR
TO ASSUME FOR WESTERBEKE ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ITS
PRODUCTS, WESTERBEKE WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES
RESULTING FROM THE USE OR INSTALLATION OF ITS PRODUCTS,
SOME STATES DO NOT ALLOW LIMITATiONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR
THE EXCLUSIONS OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE LIMITATIONS AND EXCLUSION MAY NOT APPLY TO YOU, THIS WARRANTY GIVES YOU
SPECIFIC LEGAL        AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM
STATE TO STATE,

PIN 21479                                                                                                              6/l/83
                                                   J. H. WESTERBEKE CORP.
                                                   Ii.VOIIIMDUSTRIA< PARK, AVON, MASS. 023~2         {SHI SGIl   nao
                                                               CABL/';' WESTCORP, AVON,   rJ;:~fX_    92 4444


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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.