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Westerbeke Diesel W 27 Technical Manual




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OPERATORS ANUAL
18 21 A 27 A 33A
Marine Diesel Engines
Publication 36195
Edition One
July 1986
AVON INDUSTRIAL PARK AVON MA 02322 8 TEL TELEX 924444 FAX 617 5599323 CABLE WESTCORP
FOREWORD
Thank you for hav selected a Engine for your use
This manual describes the procedures for 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 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 Form for your engine you have not
received a Customer Card see 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 JH Westerbeke Corp
Avon Industria Park
Avon MA 02322
I J H WESTERBEKE COR
D IkO eK v MHO OHa
CUSTOMER ID FICATION
W2lA l234C508 Pleasure Craft
Mail expires 7787
Adam Smi th
85 Maple Street
Alden IN 12234
PI J
TABLE OF CONTENTS
PAGE
GENERAL PREPARATION AND SUPPLY
CAUTIONS I
1 BREAKING 7
2 STARTING 8
3 INSTRUMENT PANEL USE 9
3 STARTING PROCEDURES IO
4 STOPPING PROCEDURES ll
5 CAUTIONS ON STARTING
AND OPERATION 12
6 REQUIREMENTS FOR PROPER
OPERATION
61 Lubrication System 13
62 Fuel System 14
63 Wiring Diagram 15l6
64 Cooling System 19
65 Belt Tension 21
66 Domestic Hot Water 22
7 RECOMMENDED MAINTENANCE TRANSMISSIONS 25
9 WARNER HYDRAULIC TRANSMISSIONS 27
10 WALTER VDRIVES 32
11 ADJUSTMENT OF VALVE CLEARANCE 38
12 TABLE OF TIGHTENING TORQUES ll
13 42
14 LIMITED WARRANTY 43
GENERAL CHhRk STIC W13A WI8 W21A W27A W33A
Type Vert 4 cycle water cooled diesel engine
Compustion chamber Swirl chamber type
No of cylinders 2 3 3 4 4
Bore stroke inches
276x307 256x307 307x30
Cu In displacement 37 47 60 80 91
ComEression ratio 23 23 23 23 23
Firing order 12 132 132 1342 1342
Dry weight std lbs 289 345 345 424 480
Fuel 2 diesel fuel only
Injection pump Bosch type I
Nozzle I Throttling type
Injection Eressure
Governor
All models 1707
Contrifugal weight type
Lubr ication system Pressure 3
I I
Oil filter Filter paper type
Engine Oil Capac jJy qt 25 40 40 40
Engine Oil Capacity It 236 378 378 I 378 I 393
Fresh water Forced circulation water cooling by I
Cooling system heat exchanger
I I I
Coolant capaci I 6qts 5qts 5qts sqtslsqts
Engine Proper top of filler neck
i i
Starter KW I 12 12 16 16
l25O 1250
Battery capacity 90 AH
PREPARATION AND SUPPLY CAUTIONS
Check ts of installat before operating engine
1 Alignment ror to be no more OU fEELER GAGl
than one thousandth of an inch
per inch of coupling diameter
See Figure 1
2 Provide sufficient ventilation
3 Provide adequate service room ISTRAIGlfT EDGE
around engine See warranty
clauses Figure L
Checking Coupling Alignment
Fill fuel tank with CLEAN 2 diesel from a reputable Fill lubricating oil to full mark on dipstick Select readily
available lubricating oil with API spec CC or CD and SAE
suitable for your operating area
Fill cooling system with suitable mixture of water and antifreeze
to suit your temperature zone See page 19
Propulsion units fill to correct level on
dipstick with correct lubricant
Plugin Panel Harness Connection After assembly joint should be
taped to prevent corros or preferably assembled using a sili
con grease which can be obtained at an electronic store such as
Rad Shack etc
SAFETY Never operate engine with inadequate ventilat Confirm that
there are no exhaust leaks inside engine Do not touch moving parts during operation
Do not touch hot parts such as exhaust and do not ace com
bustible materials near the unit
Inspect and ust parts of the engine after it is
Check and refill engine oil cooling water transmission and fuel
ter the eng is brought to a s
recover bot tIe was supplied wi th the ine
tructions tallation Be sure that it is
Attempting to operate with the manifold as an expans
pnoses the ator to a severe steam burn if the manifold pres
sure cap is removed while the eng is hot low instructions
on 6
use tools fit corr and use caution dUK ing ser
SAE and metr sizes are on the units use
n selecting ring dware
Be sure that current carr wires ar e protected from abr as
and that all connect are t ght
as shown below in starting engine for the first time
or after a pr shutdown
1 Fill your engine th oil up to
or near the upper limit on the
dipstick Use a good grade of
oil with API specification of
CC or better For quantity of
oil you may refer to the
General Specif ions page 3
see Figure 2
gauge
2 Fill the elle
to full mark on their dipstick
with the correct lubricant
3 Your eng ine is supplied wi th a oil
coolant recovery system See
figure 3 to which the
following instructions apply
or a Fill engine completely to
the neck of the manifold
pressure cap with an antifreeze owermt 7 oi
mixture
b Open air bleed petcock on
manifold or thermostat housing
to allow air svstem to
escape while filling Close Figure 2 oil Capacity
tight after filling
c Then fill the recovery tank
to the bottom level line Need
for adding coolant is indicated
when a cold engine has coolant COOLANT RECOVERY TANK
level below the bottom level PRESSURE CAP
line
4 Fill the fuel tank with 2
Diesel fuel th 45 Cetane
rating The interior of the
fuel tank must be maintained
clean Be careful not to allow
introduction of dirt when
filling
5 NOTE Engine coolant and
transmission should be
checked at once a day
prior to eng use Visually
look over unit for any abnor
malities correct as needed
F e 3 Coolant Recovery System
BREAKING IN YOUR NEW ENGINE
While eng has had a ninum of one hour of test operat
to demonstrate accurate assembly and correct operation of all systems
it still requires break time
Service life of your engine is dependent on how your engine is
operated and serviced during initial hours of operation
Your new engine needs approximately fifty hours of initial operation breaking in each moving part thus helping
to maximize performance and service life of engine Perform this carefully keeping the following points in mind
1 Star t eng ine run at a fast idle while checking that all
systems are functioning sea water pump oil pressure bat
tery charge
2 Warm engine prefer ably by running propeller at fast idle
while tied down until water temperature gauge moves into the
130 140 degree range
3 Then use engine at varying RPMs for first twenty five hours
tr ansmiss ion lubr icant should be changed on models having
HBW 4 Avoid rapid acceleration especially with a cold engine
5 Use caution not to overload engine Grey or black smoke and
inability of engine to reach rated RPM is a sign of overload
6 Next twentyfive hours may be run at varying RPMs with short
runs at top RPM Avoid prolonged in a new engine is basically a seating of the piston rings
to the cylinder walls This is not accomplished by periods of
running idle nor by early running under full load
Idle running may glaze the inder s causing oil consumption and
smoky oper at Excessive and loads may score inder
wi th similar results espec with the engine
As indicated above operate the engine in moderat dui the ini
tial 50 hours of break Dont baby it yet do not abuse to
OF STARTING SYSTEM
All Models use an assisted
for both normal and cold F e 4 is a cross
section through one inder
The glow plug enters the com
bustion chamber so that the end
is in the spray path of the
ector nozzle When the glow
plugs are energized by the pre
heat button they glow red at the
tips and assist rapid ignition of
the fueL The result is rapid
starts with less wear on This system is common to
Westerbeke Diesels The is designed so that
first the preheat button must be
depressed for the time specified
in the glow plug use chart shown
below Figure 4 Combustion which and while keeping the preheat button engaged
the start
button is depressed to crank the engine
NOTE Starter button will not energize unless preheat is
depressed
Glow Use Data
Atmospheric temjeratur e Preheating time
A rox 10 sec
rox 20 sec
For starting and s ng eSt see 10 and 11
PANEL Descr ion and uSe of
Figure 5 Instrument Panel
Note 1 When engine is stopped after use the water temperature and
oil pressure gauges may stay at their running 2 When engine is next to be uSed turn keyswitch ON The tem
perature and pressure gauges will ZERO and the voltmeter
11 register battery voltage The electric fuel pump
mounted on eng ine 11 also beg to operate purging
any r accumulated in the and the engine hour meter
11 begin to 3 The eng is now prepared for 4 FOR INITIAL STARTS
The selfbleeding feature of these models make it such that
no fittings or such in the fuel need be to
remove air from the eng fuel The oper a tor need
f ill the vessels fuel tanks and prime any
fil ator tank and
Then turn On engine act Ing the
lc fUel on the engine and it to operate
30 60 Seconds to pr the eng fUel tern and bleed any
r it out thr the return
STARTING Place tr ss neutral throttle f
m eng ine par tia Press Preheat button and hold for the
number of seconds ind on Page 8 in Glow Plug Use Data
2 While still engaging Preheat button press Start button
3 The starter will crank the engine which should start in 10 seconds
or less
4 As soon as the engine starts release buttons and throttle back to
a moderate warm up speed
5 Should the engine NOT start even though cranking for 10 seconds
release the buttons for 30 seconds and repeat the sequence by
preheating the glow plugs sufficiently The starter motor should
never be run more than 30 seconds at a time
NOTE Excessive cranking without a start may place excess cooling
water into the exhaust that cannot be expelled filling the
exhaust and entering the engine cylinders producing a hydraulic
lock Avoid this by shutting off the raw water thru hull and open
immediately once engine starts
6 Proper glow plug function is
indicated by voltmeter drop
when Preheat button is
depressed See Figure 6
This drop will be slight but
discernible If no voltage
drop is noted it may indicate
defecti ve glow plugs or a
faulty preheat circuit check for loose connection
Figure 6 voltmeter Gauge
7 As soon as the engine has started release both Start and Preheat
buttons Check that with eng runni oil pressure and battery
charge voltage are registering and that raw water is discharging
with the exhaust
Note An alarm buzzer is supplied with every unit and is the
of the ins to electrically connect the alarm
buzzer to the two tagged terminal connection on the engine
electrical harness and install the buzzer in a dry location so
that it will be audible to the operator should it sound during
engine operation This buzzer will sound when the ignition
key is turned on and should silence when the engine is started and
1 pressure rises above 15 Ibs
8 To warm up engine run a few minutes at idle to make checks in 7
above Then ate under reduced load 50 to 60 percent until
operating temperature rises into the 140 150 range
STOPPING PROCEDURES
L Model W13A See F e 7
a To stop the engine move the
throt control thr the
idle position to stop As the
THROTTLE COfJTROL
throttle is moved past idle THROTTLE LEVER
there will be increased
resistance to movement because
a spring loading must be over
come Hold the throttle firmly
against the pressure until the
engine comes to a complete
stop
b with the engine stopped
turn the key back to OFF
position The battery will be
discharged i f the key is left
at ON position An engine
alarm buzzer is provided to
warn the operator of this HIGH SPEED LIMIT SET SCREW ADJUSTMENT
possibility Best precaution
is always to remove the key
Figure 7 Model Wl3A Idle position
2 Models W18 W2lA W27A and W33A See Figure 8
a Each model has a manual shutofL A T handle or knob is
pulled to shut off fuel Simply pull the shutoff and hold out
until the engine stops completely Then PUSH THE STOP CONTROL
BACK TO THE RUN POSITION
b With the engine stopped it is necessary to turn off the
keyswitch If you fail to do this the panel remains energized
and the electric fuel pump continues to run This oversight
results in a dead battery
c While an engine alarm buzzer is provided to warn the operator
if this happens the best precaution is always to remove the key
THROTTLE CONTROL
THROTTLE LEVER
HIGH SPEED ADJUSTMENT
Figure 8 Models W18
W21A W27A and W33A
LOW IDLE ADJUSTMENT
CAUTIONS ON STARTING AND OPERATION
1 Normal Starting
Follow the procedures below for routine starting of your engine
a Check the engine and transmission lubricant levels and fill
if necessary
b Insure that you have sufficient fueL Keep tank as full as
possible
c Check cooling water level and fill if necessar
NOTE Check for leaks of water or oil par t ar ly when
signs of such leaks are found on the bottom of the engine or
in the drip tray
d Start the engine in accordance with the procedures given on
the preceding pages
e 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 adver se condi tions occur as the atmospher ic
temper ature drops dramatically and the eng ine must under such
conditions be started by taking steps described below
a LUBRICATING OIL TURNS VISCOUS Make certain that viscosity
SAEis proper for the prevailing atmostpheric temperature
Study page 13
b VOLTAGE ACROSS BATTERY TERMINALS DROPS Check that the bat
tery is fully charged
c THE TEMPERATURE OF INTAKE AIR IS LOW AND COMPRESSION
TEMPERATURE DOES NOT RISE ENOUGH Allow the glow plug to
operate suffeciently to aid starting See table on page 8
3 Cautions During Operation
a Confirm that the oil pressure is normal during normal operation
b Confim 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
cj Check for abnormal noise such as knocking friction or
leaking sounds vibration and blowback sounds Investigate
and correct
d Check for leaks of fuel lubricant and coolant
e A knocking sound is normal while the engine is cold during
quick acceleration and at idle This is produced by the com
bustion of diesel fuel the inders under compresssion as
the cylinder temperature rises to normal operating range
This combustion is better regulated and more efficient pro
ducing less noise
FOR PROPER SYSTEM
L i n e Oil
For eng ine lubr use lubricating oil designated for diesel
service Is are c ified according to the API
Specificat serv grades CA CB CC and CD The use of
CC or hHJL ades pr ed by wellknown makers is recom
mended be used ine Oil Viscosi SAEi
Use oil having viscosity best suited to the atmospheric tem
perature Use of an allseason oil SAEIOW30 with minimum visco
sity change under different temperatures is suggested
Atmospheric temperature Viscosity
20C 6SF or higher SAE 30 or 10W30
SC HF 20C 68F SAE 20 or 10W30
SC HOF or lower SAE lOW30
NOTE Do not use engine lube oil th an SAE greater than 30 in
generator engines
3 Oil Pressure
The oil pressure during operat of the engine is indicated by
the oil pressure gauge
During normal operat Oil pressure will range between
40 and 70 PSI
At idle soee1 20 35 PSI
At the time of crank Pressure will rise proportion
with speed
4 Eng oil to lude filter
To renew engine oil dischar old I through the sump drain hose
attached at front of engine ile eng is still warm
Drain old 1 ly replace the hose plug the securely
Proceed to Step S oil filter change before completing step 4
Add fresh 1 through the 1 filler cap on the valve cover or
side 1 filler on some models After refilling oil idle the
engine for sever minutes and stop Then check the quantity of
oil by the 1 dip stick Fill to but not over the high mark
on the d i c k observe old 1 as it is removed A
yellowgrey ion ind presence of water in the 1
While th condit is rare it does require pI attention to
prevent sel a mechan
OIL IILTER
5 acement of oil Filter
See F e 9
When removing the used filter
cover over with a plastic bag
This 11 allow both filter
element and spilled oil to be Q
collected cleanly without
spilling oil in the bilge
Being a replaceable cartridge OIL PRESSURE SWITO
type the oil filter requires
no cleaning inside
In installing the oil filter
element apply engine oil
thinly onto the Oring and OIL DRAIN SYSTEM
then tighten it by hand firmly Figure 9 r
Oil Filter and oil Drain System
Note A Generic 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 HOME HEATING OIL
In cold weather particularly water vapor is pcoduced by conden
sation when 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 Fuel Filter
It is required that a primary
fuel filter See Figure 10 of
the water entrapment type be
installed between the fuel tank
and the engine Such a filter
is available under Part 32974
from your local Westerbeke
or your boat TUBE PIPING
builder This filter adapted
for boat builder use comes
complete with fittings for
either hose or metal tubing FUEL FILTER
Mount an accessible place
inspect often and drain off any
accumulated water and debris 1
F e 10
Sed water Trap 32974
F e II
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IJ H WkP
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1222B41 33585
If a water tr fuel filter see page 14 is not the fue tank and lift any entra water will
tend to the bottom the e1ectr lift pump Inter metal
par ts of ft 11 rust Par t will on to filter s
and to i ect pump and damaging and
expensive results IT IS WELL TO REMEMBER THAT WATER DAMAGE TO THE
FUEL SYSTEM IS NOT COVERED UNDER THE WESTERBEKE many boat builders do supply a water trapfilter there are some
who do not I t is to event such ssion that Westerbeke offer s a
sed wate trapf Iter as a desirable optional extra at It is ied th fittings for either hose ng
or metal
tube piping
All of the models covered by this manual have fuel filters in the engine mounted fuel system One is in
the base of the electric fuel pump and the other in the located just after the discharge side of the electr Ie fuel
pump These are shown on Figure 12 showing a typical An Series selfbleeding feature of these models fuel systems allows for of these filters Simply
remove and replace the filter ele
ments Take care to catch any fuel when removing filter your keyswitch ON and allow the electric fuel pump to operate for
20 30 seconds to prime and bleed air from the system NO be opened Then proceed to start the engine as yOU If the engine fails to start stop and
wait a few moments
then repeat the bleed procedure as above
INJECTION PUMP
ELECTRC FUEL UFT PUMP
FUEL PUMP FILTER THROTTLE LEVER
OPTIONAL FUEUWATER FUEL LINE
OIL PUMP
F e 12 Fuel 17 OIL FILTER
3 Notes on Fuel
See F e 12 for a of a fuel system for
these eng ines I t is the selfbleed and
priming system used by Westerbeke
The Westerbeke selfbleeding fuel system is in
operation While it is unlikely that the operator will be forced
to service the system at sea the possibility does exist
Therefore it is recommended that banjo washers injector seat
washers electric lift pump filter and gasket fuel filter and
gasket be carried on board at all times Select the parts for
your engine from the Parts List and purchase spares from your
local Westerbeke Dealer or Distributor For example hardware kit
133093 will supply fuel system washers for All A series models
If a leak should develop at a fuel banjo or sealing washer loca
tion and cannot be remedied by a simple tightening of the fitting
replace the washers
4 Replacing Filter Elements
After the first 50 hours of operation remove discard and replace
the fuel filter elements in the electr ic fuel pump and engine
mounted filter asembly
Install new sealing gasket or 0 rings supplied with the replace
ment filter elements
Arter the first 50 hour change the change period should be every
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 therefore calls for the utmost caution in
handling Furthermore the fuel injection pump has been
thoroughly bench tested and should not be tampered with
Idle speed and timing adjustment are the only adjustments the ser
vicing dealer can perform on the injection pump Other types of
adjustments or repairs must be performed by a qualified inject
service shop
To obtain long and satisfactory service life from of your injec
tion pump
1 Always use the correct grade fuel 2 Diesel
2 Filter the fuel to remove any water or impurities
3 Clean and renew the fuel filters SYSTEM
L CooH Water
As cooling water use soft water th few impurities such as tap
water potable water or rainwater 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 Antifreeze
It is recommended that a freshwater and antifreeze xture be used
year round Use an antifreeze that is compatible with aluminum
cooling system components Keep mind that water when it
freezes expands to break the engine heat exchanger and the engine
block So maintain an antifreeze mixture in the cooling system
year round Do not be caught short
Antifreeze of por quality or without rust inhibitor
will cause corrOSlon of the cooling system Always use
antifreeze prepared by a reliable maker Never use it mixed
with antitreeze 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 or
PRESTONE with rust inhibitor
Mix the antifreeze and fresh water thoroughly before adding
it to the cooling system
ANTIFREEZE ADDITION DATA
Antifreeze
Concentration 13 23 30 35 45 50 60
Freezing C 5 10 15 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 10 F lower than the actual atmospheric tem
perature expected
3 Fresh water Cooling System
The system consists of a belt driven circulating pump and a heat
exchanger The mixture is circulated
throught the engine block where it picks up heat it and passes
through a thermostat which maintains engine operating temperature
It then flows through the exhaust mani picking up more heat
and passes through the heat exchanger where it is cooled and then
returned to the block to repeat its path
Raw water is the heat a belt or engine
driven up heat from the fresh water and then is
dischar nto exhaust fler th exhaust gases where it is
dischar overboard thr exhaust total system is very r able and requires only a dai check
of the water level the system plus routine checks hose
clamps fittings drive belts and raw water pump
A zinc anode is located in the raw water side of the engine This anode will deter iorate from electrolysis action
taking place in the raw water circuit This anode should be
checked monthly Cleaned and replaced as needed An of the raw water circuit is the raw water pump Inspect
this pump seasonally for wear and impeller deteriorat Repair
or replace components as needed
It is recommended therefore that zinc anodes water pump
belts raw water pump repair kit and raw water pump impeller kit
be maintained on board for unexpected field repairs These items
can be ed through local dealer s Refer to your
models parts list for correct item part numbers
MODEL W13A ONLY
HEAT EXCHANGER THERMOSTAT
FLOW CONTROLLER
TO HOT WATER TANK
OVERHEAT ALARM
FRESH WATER 13 Typical Westerbeke Cool tern
fNCOMING RAW WATER
4 Alternator t and Water Tension SeE Fi e 14
The belts are ten
sioned when 10 to APPROX DEFLECTON
12 mm 039 to 047 in as
ar e essed th a
finger between the pu and
pulley of the long distance
side Excessive tension 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
insufficient charging due to a CJ
slipping alternator belt and
rapid wear of the belt 1
Figure 14
Alternator Belt and Water Pump Tension
CAUTION
Never attempt to adjust tension of any drive belt while the
engine is in DIAGRAM
Your engine has a 12 volt DC startrun circuit A pictoral schematic
of this is illustrated in Figure 11 study it and learn to the system installing electrical parts connect them correctly by referring
to the electrical diagram and at the same time check for damaged and confirm that grounding is provided properly Care must
always be taken while working on the electrical SHUT THE ENGINE BATTERY SWITCH OFF WHILE THE ENGINE IS TO THE BATTERY CHARGING ALTERNATOR WILL
RESULT SHOULD THIS BE
DONE
REMOVE RETURN BEND FROM
F e 15 at right shows a Flow Control mechanism and
its bypass connect for normal
use If it is desired to connect a
hot water heater remove the bypass
hose altogether as instructed on
the following page Study Figure 15 F Control Mechanism
All eng ines come a th Flow Control which when to a heater tank domestic
hot water from waste
engine With the bypass hose removed there remains 2 A and B for 78 ID hose to and from the water heater assure a flow of hot water through the
heater at all times
and yet preclude excessive restriction of engine cooling water flow
caused by the heater all simply and The heater should be mounted conveniently close to the
engine either in high or low position so that connecting hoses from
heater to engine can run in a reasonably direct line without loops
which might entrap air Connection Point A on the Flow should connect to the lower of the two connections on the
water heater while the upper connection on the heater returns to B
nearest to the heat should rise continuously from their low point at the heater to
the engine so that trapped air will rise naturally from the heater to
the engine If tr apped air should rise to the heater then an air
bleed petcock must be installed at the higher fitting on the heater
for bleeding air while filling the system Avoid loops in hose runs
which will trap air and avoid this problem Trapped air will stop
water circulation from the engine flow control to or from the heater
If any portion of the engine cooling water circuit to or from the
heater rises above the engines own pressure cap then the expansion tank must be installed in the circuit to become the
highest point The tank kit Part Number is 24177 Install the tank in a convenient location such as a sail locker for ease
of checking fresh water coolant level Connect the remote tank with a
single hose 58 ID 78 ID to a tee fitting directly at the con
nection on the hot water heater that is the return to the The cap on the engine mounted expansion not be opened once the remote system is
installed and filled
The hose connection from the heater to the remote expansion tank
should be routed and supported so as to rise continuously from the
heater to the tank enabling any air in the system to rise up and out
Figure 16 below illustrates domestic water heater connections below or above the engine manifold pressure cap
TANK KIT F24177
l Q
THAN MANIFOLD CAP
HEATER COILS ABOVE PRESSURE CAP
ON ENGINE MANIFOLD
REMOVE BYPASS FROM
ENGINE FLOW CONTROLLER
B
HEATER BELOW ENGINE
HEATER ABOVE ENGINE
Figure 16 Flow Control System
RECOMMENDED MAINTENANCE 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 filterwater 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 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 holddown
bolts
D Change transmission lubricant HBW models initially change
at 25 hours
E Adjust engine idle speed if needed
F Adjustment of valve Servicing At Every 100 Hours Of Operation
A Renewal of engine oil
B Replacement of oil filter
4 Servicing At Every 200 Hours Of 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 holddown 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 Servicing At Every 800 Hours Of Operation
A Checkup of nozzles
See Figure 17
Set the injection starting
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 30 kgcm 2 427 psi
between cylinders or if the
cylinder pressure is less
than 30 kgcm 2 4270 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
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 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 05 mm
0002 clearance
QSmm
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
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
Each engine model fitted th a vari of tr ss
opt For ratio see table low
Model 151 21 251 21 VDrive
W13A HBWIOO HBW50 HBW50
W18 HBWIOO HBW50 HBWIOO HBW150V
W21A HBWIOO HBW50 HEWIOO HBW150V
BW 7
W27A HBWIOO HBWIOO HBW150 HBW150V
W33A HBWIOO HBWIOO HBW150 HBW150V
transmissions have their own oil sumps and dipsticks 5 and
HBW units use ATF lubricant while HBW units may use either 4120 or
4130 SAE engine oil
The 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
V DRIVE
Figure 20 Transmission
WARNER HYDRAULIC FROM COOLER
2101 ONLY
FROM 10131014
COOLER FROM COOLER 10171018
EXCEPT 2101
1 CONTROL LEVER POSITION
The position of the control lever on transmission when in 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
andor ball is permanently removed or i f the the control lever is
changed in any manner or repositioned or if linkage between 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 properties of the 1 used in the transmission are to the proper function of the hydraulic system Therefore
it is extremely important that the recommended oil 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
3 FILLING AND CHECKING lHE 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 The hydraulic circuit includes the transmiss o i l lines and any gauge
lines connected to the circuit The
complete hydr aulic circui t must be filled when filling 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 after the engine has been shut off and again after the
engine has been stopped for more than one hour overnight A noticeable increase in the oil level after this indicates that the oil is
draining from the cooler and cooler
lines The external plumbing should be changed to prevent any STARTING ENGINE
Move the shift lever to the center position where the enters the chamfered hole in the side of the shift lever and pro
perly locates lever in neutral position before starting engine
5 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 engine speed Move the shift lever to the extreme where the spring loaded ball enters
the chamfered hole in the
side of the shift lever and proper lever in 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 sa th the turning or at trolling with one
of two eng ines shut the des ign of 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
7 COOLING 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 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 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 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 possible for cross leaks to occur inside the cooler to flow into the water or water flow into the oil
fluid s at each days use will help spot such a hap
pen undetectable loss of fluid andor emulsified fluid
ROUTINE CHECKS AND 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 leakage Make sure lines are securely fastened to CHANGING OIL A seasonal oil change is
recommended in Work boats require more frequent changes Change oil any time
the oil becomes contaminated changes color or becomes Automatic transmission fluids ATF Type A is 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 STORAGE
L Drain water from transmission oil cooler This will prevent
freezing in cooler climates and prevent harmful deposi ts from
CHECKS
1 Check coupling alignment each time a transmission is replaced in
the boat
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 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 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 Check fluid level at operating 31
WAIlER 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
RVIOD A selflocking set screw is pro
vided for the propeller shaft flange
Spot dr ill the propeller t and then
securely tighten the set screw Many are ruined by oper shaft
flange alignment Accurate gnment will
ensure a smooth operating drive train and
eliminate many problems that arise due 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 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 is obtained Turn the propeller shaft flange 14 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 is straight If it increases the shaft or flange is bent and
must be removed and straightened Rotate the propeller shaft
in two more 14 turn ements and repeat the procedure The lot
diameters must be rechecked to ensure that they still engage the two flanges together with the heat treated bolts and spe
cial high collared lockwashers ALIGNMENT INDEPENDENT MODELS
The engine must be adjusted so that the alignment of the 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 lS 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 RVIODs 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 14 of a turn and measure to the same
joint The four distances must be equal thin lS not measure
to the joint end that is
on the
This stance not
vary th misalignment
r6S r1 since the joint is
bolted cannot move
Put the 1I3lA
gauge on the machined
diameter of the 24
cover and sl it com IfIi SCRw YO GT
pletely around It will AN KCUW indicate how the engine
must be moved to center
DEpr JHAl sPIN SAr
lilT 1 the spline shaft in the
oil Remeasure
the joints to see if
they are still parallel within lS It is
important that both alignments be It is possible for the spline shaft
to be perfectly centered and the flexible joint
to be out more than 3 Premature failure of the
26 selfaligning bearing and seals may occur due
to misalignment The zerk fitting located on
the cross of the universal joint should be
greased with a light alemite lubricant The
above procedure should be repeated after the boat
has been placed in operation It is possible for
the engine to slightly shift and settle espe
ci if it has rubber ALIGNMENT INDEPENDENT MODELS
Install the propeller shaft f
arone shaft and tighten the two
on the split hub none on RVIO
set screw is ovided for the pr
L08SN TO
fl Spot dr 11 the propeller shaft and secure AiJUST BRACKETS
ly t the set screws
MOlHING
Vdrives are supplied th adjustable brackets 2way on the RVIO and RV20 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 Vdr 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 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 train el nate many problems that arise due to misal
ment Final should not until the boat has
allowed to set in the water Vdr i ve until the
diameters of the gear shaft f pr t
engage freely Butt the faces thout 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 If a thicker gauge can be inserted at any point the Vdrive
must be readjusted until proper alignment is obtained Turn the pro
peller shaft flange 14 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 Rotate the propeller shaft flange in two more 14 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 the set screws from the brackets none on RVIO or RV20 spot
drill and securely tighten Recheck the flange alignment to make sure
the Vdr i ve did not move out of alignment Secure the two with the heat treated bolts and special high collared lock
washers HECK
SET SCREVJ
GEAR SHAFT
FLANGE
FEELER
GAGE
PROP SHAFT
FLANGE
FLANGE AND SWITCH CONNECTIONS
Hook up the water lines to the two pipe connections on the and exhaust lines are Generally one line
from the seacock to the Vdr i ve and another from the Vdr 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 Vdrive
to provide independent watercooling and are actuated by the movement
of the water Wi th closed cooling systems the Vdr i ve should into the system between the cooler and the suct side
of the water pump Proper operating temperatures are from 140 to
180F 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
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 the lI12 breather cap and fill the
Vdrive with SAE 30 motor oil through the
Jl12A breather elbow On the RVIO only rOIL LEvEL
the oil may be added by removing the plug
GAGE
PUll UP TO
RMVEi
in the Jl6D top cover See table below for f
approximate oil capacities The amount
varies with the angle oE oil level should be checked wi th the
oil level gauge Eully inserted in the
1f1
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 Vdr i ve Eor 2A BREATHER VATER LINE
ELeo
extra lubrication and breakin It provi WATER DRAIN
des protection against scoring or galling
of gears bearings and other moving Molykote after breakin 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
RVIO RV20 RV30 RV40 RV48
Oil capacity 1 pint 2 pints 3 pints 4 pints 4
DEALER PREPARATION
The propeller shaft and engine alignment must be checked 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 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 coupling connected Damage to the shaft shaEt log and Vdrive
can result
A pressure dr warning Ii is
mounted on the instrument panel on
Vdrives 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 This normally occurs 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
Vdrive 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 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 cruising speed the wir ing should be checked for loose connections If the wiring is
correct and the light remains
lit the 49 pressure drop switch which is mounted on the side of the
Vdrive see should be checked for proper switch can easily be removed and an accurate oil pressure 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 RV48 and an optional feature
on other models not available on the RV10
The oil level should be checked several times during the on Vdrives whitout pumps see OIL FILL
A clatter or rattle the Vdrive 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 andor tuning up the engine for smoother OIL CHANGE AND JOINT LUBE
After the first 100 hours of operat and every season andor
500 hours thereafter the 1 should be changed Run the boat to warm
up the Vdrive 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 strainer 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
The s can be to see if
are magnetic after the inside face th a metall
ect as a screwdriver Clean
them and reinstall Usually there
are four plugs the bottom part of
A
0 L c fMJ
the main housing Only two of these Cil qRAr
111 magnetic The other two need not
be removed see Refill
wi th SAE 30 motor oil to the proper
level see INSTALLATION OIL FILL n IMGillC PLc if
IACU1AlLV wrOST
The Zerk fitting on the external un
versal joint should be greased with a
light alemite lubricant see WATER DRAIN
For protection from freezing during winter layup remove the
small pipe plugs located diagonally opposite on the front and back
of the housing marked Water Drain see illutration On the RVIO
only one of the water lines going into the watercooled bottom 6
cover must be disconnected to drain the water
3 FLANGE AND ENGINE REALIGNMENT
When the boat is launched after being drydocK the lineup of
the vdrive 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
MODEL 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 oT
case side
2 Adjust the intake and exhaust
valves on No1 cylinder side
first at TDC on compression
stroke of No 1 cylinder
Then adjust on No 2 side at TDC on compression
stroke of No2 cylinder
Each cylinder piston is at TDC
Front of engine
on compression stroke when the 2 5
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 12345 6
17rnrn 7 8 Kgm
Rocker Shaft Holddown Bolts
14mm 35 Kgm
Note rnrn sizes shown are
socket size for head bolt
MODELS Wl8 and OF VALVE 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
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 Cyliner hed i l
I 506 to 578 ftIbs
cylinder comes to top dead bolt tlghtenm g
torque
12 mmq 11 to 12 kgm
center Turn the crankshaft I I 795 to 868 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 W18 W21A
Bolts 11
4 To check No 2 cylinder valve 17mm 1112 Kgm
clearance turn the crankshaft
another 240 clockwise then Bolts 12 3
align the timing mar ks and 14 mm 7 8 Kgm
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 35 Kgm
MODELS W27A and 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
a 0 0 0
0 0 0 0 0
10 4 3 9
0 0 0 0
4 Cylinder Head Bolt
Tightening Sequence
W27A W33A
Bolts Bolts
17mm 1516 Kgm 14
22mm 1516 Kgm
Bolts 349 10
14mm 1213 Kgm Bolts 349 10
22mm 1112 Kgm
Rocker Shaft Holddown Bolts
14rnrn 1213 Kgm Rocker Shaft Holddown
10mm 35 Kgm Bolts
Note rnrn sizes shown are socket 14mm 35 Kgm
size for head bolt 10mm 07 Kgm
OF TIGHTENING TYRfTP kqm IbfL
inder head bolt W18 W21 W27 W33 7 8 507 579
M12 W18 W21 11 796 868
W13 W27 12 13 868 940
M14 W33 15 16 1085 1157
M14 W33 34910 11 12 796 868
See drawing on Page Cylinder Head pulley nut W13 15 20 1085 1446
W18 W21 W27 W33 20 25 1085 1808
Main bearing cap bolt WlS W21 W27 W33 50 55 362 rod cap nut W13 W18 W21 W27 32 35 231 rod cap bolt W33 55
60 379 430
Flywheel bolt with separate washers 115 125 832 904
Flywheel bolt washer attached 13 14 950 1000
Oil pan drain plug 5 6 362 434
Oil filter 11 13 SO 94
Delivery valve holder injection pump 4 5 2S9 362
Holder mounting bolt nozzle 15 20 10 S 145
Holder body and retaining nut nozzle 6 8 434 579
Glow plug 15 20 10S 145
UNLESS OTHERWISE 6T
6mm boltnut 07 10 5 7
Smm boltnut 16 23 12 17
10mm boltnut 32 47 23 24
12mm boltnut 56 82 41 59
14mm boltnut 77 105 56 76
Grade 8T and 88
6mm boltnut S 12 6 9
8mm boltnut 18 27 13
10mm boltnut 37 55 27
12mm boltnut 64 95 46
14mm boltnut 104 140 75 101
Grade 5 capscrew
14 UNe 12 15 9 11
14 UNF 15 18 11 13
516 UNC 25 28 18 20
516 UNP 29 32 21 23
38 UNe 37 46 28 33
38 UNF 41 48 30 35
716 UNe 61 68 44 49
716 UNF 69 76 50 55
12 UNC 94 101 68 73
12 UNF 101 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 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 Cooling water shortage Refill
b Water leaks Repair
c Belt loose or smeared with Clean or renew
d Raw water pump defective Repair or renew
e Thermostat defective Replace
5 BATTERY IS 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
1 Wmanlv Ihligation aflll Duration
Westerbeke warrants to the original consumer that all standard Westerbeke marine 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 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 costs prepaid which we adjudge defective in
materials or workmanship we may
reimburse at OUf discretion a portion of labor costs incurred to repair defective parts or products on site If you of replacement parts to you prior
to our determination of cause of failure such shipment will be sent COD
3 Notification
If you encounter a problem with 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 owners 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 tuneup valve adjustment oil and water
leaks or any other normal service items
g specially manufactured products provided to customer 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 BY INCLUDING WARRANTIES OF OR FITNESS IS IN EFFECT
ONLY FOR THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST NO 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 FROM THE USE OR INSTALLATION OF ITS 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 6l83
J H WESTERBEKE CORP
PARK AVON MASS 0232 SHI SGIl nao
CABL WESTCORP AVON rJfX 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.