Westerbeke Diesel W 21 Technical Manual

home telephone 1 ENGINE DOES NOT START a b c d e f g h 1 Starting switch is defective Deficient drive torque of the starter motor Improper viscosity of engine oil Engine too cold Seizure of moving parts Air present in fuel system No fuel in fuel tank Fuel filter clogged 20 Amp circuit breaker tripped J y Correct connections and contacts The battery is exhausted trouble with the starter motor or dirty or loose wiring Check the viscosity and renew oil if necessary Use glowplug starting aid Rectify Purge thoroughly with electr ic fuel pump Refill Clean or renew Manually reset 2 ENGINE STALLS WHILE IN OPERATION a Fuel tank is empty b Fuel filter clogged c Air present in fuel system 3 IMPROPER OIL PRESSURE a b c d Oil shortage Oil leak through connections Oil pressure sender defective Oil filter clogged 4 ENGINE OVERHEATING a Cooling water shortage b Water leaks c Belt loose or smeared with oil d Raw water pump defective e Thermostat defective 5 BATTERY IS UNDERCHARGED a Belt tension improper b Faulty wiring circuit c Alternator not funct ing observe voltmeterd Battery faulty e Faulty voltage regulator Refill Clean or renew Retighten fuel line connections and allow electric fuel pump to run long enough to purge air thoroughly Refill Repair Replace Replace Refill Repair Clean or Repair or Replace Rectify Rectify Replace Replace Repair or 42 renew renew renew W18 W21 W18 W21 W27 5 6 4 5 MODELS W27A and W33A ADJUSTMENT OF VALVE CLEARANCE L off the air breather p from the rocker cover and then loosen off rocker cover bolts 2 Adjust the valve clearance at top dead center of compression stroke coldof each cylinder Prior to the measurement of the valve clearance retighten cylinder head bolts to spe255cified torque Give care to exact alignment of the timing mark of the gear case with that on the crankshaft pulleY1 if not the valve may be pushed up by the piston depending on the position of cam lobe W27A Bolts 12567811121314 17mm 1516 KgmBolts 349 10 14mm 1213 KgmRocker Shaft Holddown Bolts 14rnrn 1213 Kgm10mm 35 KgmNote rnrn sizes shown are socket size for head bolt 40 TDC mark Timing Mark Front a 0 0 0 225 I 5 8 2 7 13 0 0 0 0 0 10 4 3 9 0 0 0 0 4 Cylinder Head Bolt Tightening Sequence W33A Bolts 125678111213 14 22mm 1516 KgmBolts 349 10 22mm 1112 KgmRocker Shaft Holddown Bolts 14mm 35 Kgm 10mm 07 Kgm AdobeUCSMODELS Wl8 and W21A ADJUSIMENT 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 2 Align the timing mar ks on the gear case and the crankshaft pulley shown In this posi255tion 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 no specified clearance adjust by means of the adjusting screws Remember to align the timing marks properly if not the valve will interfere with the piston because of wrong cam position 3 Next the piston of No 3 cylinder comes to top dead center Turn the crankshaft 240 clockwise from the above position aligning the timing mark of the crankshaft with tha t of the gear case Then check and adjust the valve clearance 4 To check No 2 cylinder valve clearance turn the crankshaft another 240 clockwise then align the timing mar ks and check and adjust the valve clearance in a similar manner 39 Front Timing Mark 0 0 4 6 0 2 I 0 II 8 0 3 Cylinder Head Bolt Tightening Sequence Description Standard value jlO mm242 il 7 8 kg267m Cyliner i I 506 to 578 ftIbsbolt tlghtenmg torque 12 mmq 11 to 12 kg267m I I 795 to 868 rUbs3 Cylinder Head Bolt Tightening Sequence W18 W21A Bolts 45678910 11 17mm 1112 KgmBolts 12 3 14 mm 7 8 KgmNote mm size shown are socket size for head bolt Rocker Shaft Holddown Bolts Bolts 14 rom 35 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 necessary adj ust it with the adjusting screw 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 cylinder side at TDC on compression stroke of No2 cylinder 3 Each cylinder piston is at TDC on compression stroke when the timing mark on the gear case is in alignment with that on the crankshaft pulley 4 After adjustment keep the adjusting screw from turning and tighten the rocker arm nut securely NOTE Retighten the cylinder head bolts before valve clearance is adjusted 38 rfs ii Mark oT case side Front of engine r 2 o 4 o 5 o 2 cylinder W13A Bolts 12345 6 17rnrn 7 8 Kgm3 o Rocker Shaft Holddown Bolts 14mm 35 KgmNote rnrn sizes shown are socket size for head bolt 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 are four plugs the bottom part of the main housing Only two of these are magnetic The other two need not be removed see wi th SAE 30 motor oil to the proper level see INSTALLATION OIL FILLThe Zerk fitting on the external un versal joint should be greased with a light alemite lubricant see ENGINE ALIGNMENT2 WATER DRAIN A 0 0 L c Cil 111 11 n IMGillC PLc if wrOST For protection from freezing during winter layup remove the small pipe plugs located diagonally oppositeon the front and back of the housing marked Water Drain see illutrationOn the RVIO only one of the water lines going into the 6 watercooled bottom 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 V255dr 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 225 37 A pressure dr warning Ii is mounted on the instrument panel on Vdrives equipped th an oil cir255culating pump The warning light 11 stay on until the boat gets under way and the engine speed increases to suf255ficient 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 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 andor 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 andor 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 Vdrive see 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 if necessary The pump is standard on the RV48 and an optional feature on other models not available on the RV10The oil level should be checked several times during the season especially on Vdrives whitout pumps see OIL FILLA clatter or rattle the Vdrive at low RPM is due to the overriding 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 operation MAINTENANCE 1 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 36 a 2 AdobeUCSment 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 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 Vdrive must be readjusted until proper alignment is obtained Turn the pro255peller 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 and straightened Rotate the propeller shaft flange in two more 14 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 RVIO or RV20spot drill and securely tighten Recheck the flange alignment to make sure the Vdr i ve did not move out of alignment Secure the two flanges together with the heat treated bolts and special high collared lock255washers supplied GEAR SHAFT FLANGE FEELER GAGE HECK PROP SHAFT255FLANGE FLANGE ALIGNMENT SET SCREVJ WATER AND SWITCH CONNECTIONS Hook up the water lines to the two pipe connections on the Vdrive intake and exhaust lines are 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 be incorporated 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 210267F On the models equipped with an oil circulating pump the 49 oil 34 to the joint end that is on the This stance not vary th misalignment r1 since the joint is JHAl sPIN SAr lilT 1 bolted cannot movePut the 1I3lA gauge on the machined diameter of the 24 cover and sl it com255pletely around It will indicate how the engine must be moved to center 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 checked thoroughly It is possible for the spline shaft to be perfectly centered and the flexible joint to be out more than 3267 Premature failure of the 26 selfaligning bearing and seals may occur due to misalignment The zerk fitting located on the cross of the universal jointshould 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 especi if it has rubber mounts FLANGE ALIGNMENT INDEPENDENT MODELS Install the propeller shaft f arone shaft and tighten the two on the split hub none on RVIOset screw is ovided for the pr fl Spot dr 11 the propeller shaft and securely t the set screws Vdrives are supplied th adjustable mounting brackets 2way on the RVIO and RV20as standard equipment The brackets must face down255ward 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 Re200IfIi SCRw YO G243T AN KCUW MAfNl L08SN TO AiJUST BRACKETS MOl253HING HOL 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 plates Loosen the locking nuts on the adjusting screws Slightly loosen the nuts on mounting brackets just enough to be able to move the Vat are ruined impr opeller shaft Accurate al ensure a smooth operating drive train el nate many problems that arise due to misal 33 AdobeUCSWAIlER VDRIVES 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 RVIODA selflocking set screw is pro255vided 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 manufacturers instructions until the pilot diameters of the gear shaft flange and the propeller shaft flange engage freely Butt the flange fl ANCE ALiCNMEN T 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 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 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 14 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 spe255cial high collared lockwashers supplied ENGINE ALIGNMENT INDEPENDENT MODELS The engine must be adjusted so that the alignment of the flexible joint is wi thin 3267 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 RVIODsthe 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 32 2 Check shift linkage ustment to insure that the tr ft lever is itioned so that the Ing loaded the chamfered hole in the s of the shl t ssion enters 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 pro255peller 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 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 acci255dent 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 shift lever exactly in F N poppet centered in the shift The selector controls must position the and R selection positions with the ball 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 ATFType 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 freezing in collecting GENERAL CHECKS from transmission oil cooler This cooler climates and prevent harmful will prevent deposi ts from 1 Check coupling alignment each time a transmission is replaced in the boat 30 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 detec255tion 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 par255ticles 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 hap255pen undetectable loss of fluid andor emulsified fluid 29 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 starting engine The hydraulic circuit includes the transmiss oil 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 excellentA 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 springloaded ball enters the chamfered hole in the side of the shift lever and pro255perly 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 enters the chamfered hole in the s the spr loaded shift lever and proper 6 FREEWHEELING Under sa th the of two eng ines shut cooling and lubr reverse while under sail no effect To stop mechanical shaft brake locates it in the reverse ition turning or at trolling the des ign of mainta Attempting to gear into to opeller shaft rotat ller t rotation while under be needed 28 where of the with one 1 a the the Each engine model opt For ratio Model 151 W13A HBWIOO W18 HBWIOO W21A HBWIOO W27A HBWIOO W33A HBWIOO fitted th a vari of tr ss see table low 21 251 21 VDrive BW3 HBW50 HBW50 EW7 HBW50 HBWIOO HBW150V BW7 HBW50 HEWIOO HBW150V BW 7 HBWIOO HBW150 HBW150V BW7 HBWIOO HBW150 HBW150V RotationRight HandThese 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 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 VDRIVE Figure 20 Transmission 26 TRANSMISSIONS All HEN models turn r hand lers All HEN models have their own 0 d HEN s use ATF lubricant All HEW models should be shifted into gear mot not allowed to slip in slowly Control Of Gearbox See F e 1833C CABLE L 2 3 The gearbox single lever using 33C is suitable for remote control The cable should attach at right angles to the actuating lever using the cable bracket supplied Both gear box lever and remote neutral position when cable is travel of gearbox lever will be reverse lever must be in at tached so that equal forward or 4 Check that actuating lever hub does not touch cover plate hub Maintain at least 05 mm 0002clearance 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 generation and gear failure may result DIPSTICK ticks in one swift SHIFTING LEVER QSmm Figure 18 Control of Gearbox TO CHECK OIL LEVEL 6 The position of the cover plate underneath the actuating lever is factory adjusted to ensure equal lever tr avel from neutr to A and E DO NOT LOOSEN THE CAPSCREWS HOLDING THIS ASSEMBLY Doing this voids transmission warranty TRANSMISSIONN OPERATION 7 F gearbox with automatic transmiss fluid to the level indicated the d lck mark See Figure 19225 8 Note that to check 1 the dipstick drops on the FLUtD LEVEL housing It does screw 9 The HBW gear box can be freewheeled in Neutr a1 To stop propeller shaft rotat while ORAl PLUG under sail the gear into Reverse Figure 19 Dipstick oil s 25 t of engine mounted fuel filter elements 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 filter 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 ohmsE Removal of cooling water and flushing is suggested 6 Servicing At Every 800 Hours Of Operation A Checkup of nozzles See Figure 17Set the injection starting 142 pressure to 1706 0 psi and eliminate undesirable injection conditions in255cluding after dripping B Check compression pressure C Remove each glow plug and check cylinders one by one using a compression pressure gauge If the pressure differs by more than 30 kgcm2 427 psibetween cylinders or if the cylinder pressure is less than 30 kgcm2 4270 psiat 200 RPM correct it Fuel injection adjustment POOR 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 D Check tightness of nuts and bolts 24 ay Pattern and add All eng ines come a connected to a heater tank engine heat th Flow Control which when properly domestic hot water from waste principle With the bypass hose removed there remains 2 connecting points A and B for 78 ID hose to and from the water heater These connections 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 automatically Installation 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 Control housing 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 exchanger Hoses 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 pressurized remote expansion tank must be installed in the circuit to become the highest point The tank kit Part Number is 24177 Install the remote expansion 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 con255nection on the hot water heater that is the return to the flow255control The cap on the engine mounted expansion tankmanifold should 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 when installed below or above the engine manifold pressure cap REMOVE BYPASS FROM ENGINE FLOW CONTROLLER TANK KIT F24177THAN MANIFOLD CAP HEATER COILS ABOVE PRESSURE CAP ON ENGINE MANIFOLD l Q HEATER BELOW ENGINE HEATER ABOVE ENGINE Figure 16 Flow Control System 22 AdobeUCSF e AdobeUCSup Raw water is driven dischar dischar nto exhaust overboard thr the heat heat from fler exhaust a belt or engine the fresh water and then is th exhaust gases where it is pressure The total system is very r able and requires only a dai check hose of the water level the system plus routine checks clamps fittings drive belts and raw water pump A zinc anode is located in the raw water side of the engine heat exchanger 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 important component 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 beltsraw water pump repair kit and raw water pump impeller kit be maintained on board for unexpected field repairs These items can be purchasedorder 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 PUMP Figure 13 Typical Westerbeke Cool tern D fNCOMING RAW WATER 20 SYSTEM L CooH Water As cooling water use soft water th few impurities such as tap water potable wateror 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 efficiency 2 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 225 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 267C 5 10 15 20 30 40 50 temperature F23 1454 224058Note It is advisable that selected on the basis of 5267C 10 267Flower than perature expected 3 Fresh water Cooling System antifreeze concentration be a temperature which is about the actual atmospheric temThe 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 19 Notes on Fuel See F e 12 for a these eng ines I t is priming system used by Westerbeke of a fuel system for the selfbleed and The Westerbeke selfbleeding fuel system is semiautomatic 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 loca255tion 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 2670267 rings supplied with the replace255ment 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 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 regularly AdobeUCSIf a water between the tend to tr fuel fue tank and the bottom filter see page 14is not inter lift any entra water will the e1ectr lift pump Inter metal par ts of and ft 11 rust Par t will on to filter s to i ect expensive results IT IS SYSTEM IS NOT COVERED FUEL pump and damaging and WELL TO REMEMBER THAT WATER DAMAGE TO THE UNDER THE WESTERBEKE WARRANTY While 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 moderate cost It is ied th fittings for either hose ng or metal tube piping All of the models covered by this manual have two replaceable fuel filters in the engine mounted fuel system One is in the base of the electric fuel pump and the other in the filter assembly located just after the discharge side of the electr Ie fuel pump These are shown on Figure 12 showing a typical An Series fuel system The selfbleeding feature of these models fuel systems allows for easy servicing of these filters Simply remove and replace the filter ele255ments Take care to catch any fuel when removing filter elementsTurn your keyswitch ON and allow the electric fuel pump to operate for 20 30 seconds to prime and bleed air from the system NO fittings should be opened Then proceed to start the engine as yOU normally would 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 SEPARATOR FUEL LINE OIL PUMP F e 12 Fuel 17 OIL FILTER Diagram f9JL5 Pd J3U D Eii c1 IX 256 AN 9rP253irc rffr f247JffAIOP IN THIS liNE TO PIStorYIEer DIi7foOF fNOIVIPrAL CBANKIi CYCiE SIOUZD Nor243xiiio 50 SEaWDS A SINlrCfI WITH CONTiNUOUS 255IiiATlNcoF 6E YJ IV L TO f2tf5 1WEY247i 251 IECIIC3Ii 243NGIE 8t 0 cj 225 251 FOR WIRiNG OF AUXIUA2Y ALTEGNATOeS SeE NE 232 l20 AP 1123 I 200iZu 247f535 C c 247YLo 6 4 256 IF jAI ARtE Reqp TO S TAFT ZRO0 HE OIL PR243SSURE 1267IANIOLD TO A NEIlRty autKHEAO AN243 256 J247i 243tECTRICAL T A 243 0ZLcON c Te243 CAUTION 16 1 PRObUcr IS PROTCC CII243u I S TA R T C LOS TO THe SOURCE OF CURRENT AS POSSt8L200 EIreii5SIVE cURRiiNr INSTRUMENT PANEf TolXP IN HirVENr 1psr1243friLrL YIOP243 fQyN TH243gpefD S243A KER llr200IEffflL Y THEREFORe me QWNEI2 flJfT Bg dtif200 lNsrRUMEN r yiy i2ING JEAjfP f247 VENT CON TA C r 2ii WEEN eCR Ie AtfJlc Vtf WC200t I 0 I I ITEM DESCRImoN I IJ H WkP I c it 33585 AdobeUCSF e II Mar ine ine ring Diagram NOT USEO II LE NOTB ER SeND T p CH OL 256 SvCH I NG Fl o AARM I I e FUEL SOL oSwS 70NIOO A f CRCC un CAAA A 121w 711 J3ill NS2 N0W0G GA SEE N012433 rg PEATE SENGER ioCP 1f3 247 1 2674 OilO ElPN CU L I lEn 0 i K ceA A eRN 8RN I A g I 15 AL TfRNATOR 1 AMP rAH REG GRN I r tA BlK4 9LlTTR I 0 CPTIO R AMMETSR A A A A L PREHEAT SOL I rii WHT C B NOTS R EE NorE 2 voc 0 I I RED 30 epRY REf URN I UITRAL SAfen SWlrCH I 0 PuR BRN ot 0 m 0 0 w R243O b iT A AdobeUCSOIL IILTER acement of oil Filter See F e 9When removing the used filter cover over with a plastic bag This 11 allow both filter element and spilled oil to be collected cleanly without spilling oil in the bilge Being a replaceable cartridge type the oil filter requires no cleaning inside In installing the oil filter element apply engine oil thinly onto the Oring and then tighten it by hand firmly Q OIL PRESSURE SWITO267 e OIL DRAIN SYSTEM 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 2 USE 2 DIESEL FUEL NEVER USE KEROSENE OR HOME HEATING OIL In cold weather particularly water vapor is pcoduced by 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 Fuel Filter It is required that a primary fuel filter See Figure 10of 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 representative or your boat builder This filter adapted for boat builder use comes complete with fittings for either hose or metal tubing Mount an accessible place inspect often and drain off any accumulated water and debris TUBE PIPING FUEL FILTER 1 F e 10 Sed water Trap ind CAUTIONS ON STARTING AND OPERATION 1 Normal Starting Follow the procedures below for routine starting of your engine aCheck the engine and transmission lubricant levels and fill if necessary bInsure that you have sufficient fueL Keep tank as full as possible cCheck 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 dStart the engine in accordance with the procedures given on the preceding pages eAllow the engine to warm up to 140267 150267 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 aLUBRICATING OIL TURNS VISCOUS Make certain that viscosity SAEproper for the prevailing atmostpheric temperature Study page 13bVOLTAGE ACROSS BATTERY TERMINALS DROPS Check that the bat255tery is fully charged cTHE TEMPERATURE OF INTAKE AIR IS LOW TEMPERATURE DOES NOT RISE ENOUGH Allow operate suffeciently to aid starting See AND COMPRESSION the glow plug to table on page 83 Cautions During Operation aConfirm that the oil pressure is normal during normal operation bConfim that exhaust gas is as follows While engine is cold 225225225225 White smoke When the engine grows warm 225225225225 Almost smokeless When the engine is overloaded 225225225 Some black smoke cj Check for abnormal noise such as knocking friction or leaking sounds vibration and blowback sounds Investigate and correct dCheck for leaks of fuel lubricant and coolant eA knocking sound is normal while the engine is cold during quick acceleration and at idle This is produced by the com255bustion of diesel fuel the inders under compresssion as the cylinder temperature rises to normal operating range This combustion is better regulated and more efficient pro255ducing less noise 12 STOPPING PROCEDURES L Model W13A See F e 7aTo stop the engine move the throt control thr the idle position to stop As the throttle is moved past idle there will be increased resistance to movement because a spring loading must be over255come Hold the throttle firmly against the pressure until the engine comes to a complete stop THROTTLE COfJTROL THROTTLE LEVER bwith the engine stopped turn the key back to OFF position The battery will be discharged if the key is left at ON position An engine alarm buzzer is provided to warn the operator of this possibility Best precaution is always to remove the key HIGH SPEED LIMIT SET SCREW ADJUSTMENT Figure 7 Model Wl3A Idle position 2 Models W18 W2lA W27A and W33A See Figure 8aEach 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 bWith the engine stopped it is necessary keyswitch If you fail to do this the panel and the electric fuel pump continues to run results in a dead battery to turn off the remains energized This oversight cWhile an engine alarm buzzer is provided to warn the operator if this happens the best precaution is always to remove the key THROTTLE CONTROL HIGH SPEED ADJUSTMENT Figure 8 Models W18 W21A W27A and W33A LOW IDLE ADJUSTMENT THROTTLE LEVER 11 PROCEDURES 1 Place tr ss neutral throttle f m eng ine par tia number of seconds ind Press Preheat button and hold for the 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 6This drop will be slight 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 responsibility 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 percentuntil operating temperature rises into the 140267 150267 range 10 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 readings Note 2 When engine is next to perature and pressure 11 register battery mounted on eng ine any r accumulated in 11 begin to function be uSed turn keyswitch ON The tem255gauges will ZERO and the voltmeter voltage The electric fuel pump 11 also beg to operate purging the and the engine hour meter Note 3 The eng is now prepared for starting Note 4 FOR INITIAL STARTS The selfbleeding feature of these no fittings or such in the fuel models make it such that remove air from the eng fuel f ill the vessels fuel tanks and fil ator Then turn On engine lc fUel on the engine and 30 r 60 Seconds to pr the eng fUel it out thr the return 9 need be to The oper a tor need prime any tank and act Ing the it to operate tern and bleed any F e 4 BREAKING IN YOUR NEW ENGINE While eng has had a ninum of one hour of test operat to demonstrate accurate assembly it still requires break time and correct operation of all systems 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 systems are functioning sea tery charge idle while checking that all water pump oil pressure bat2 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 transmissions4 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 idling Explanation Breaking in a new engine is basically a seating of the to the cylinder walls This is not accomplished by running idle nor by early running under full load piston rings periods of Idle running smoky oper at wi th similar may glaze the Excessive results espec inder s causing oil consumption and and loads may score inder with the engine As indicated above operate the engine in moderat dui tial 50 hours of break Dont baby it yet do not abuse 7 the ini255to F e use tools n selecting Be sure that current and that all connect fit corr and use and metr sizes are ring dware caution dUK ing ser255on the units use carr wires ar e protected from abr as are t ght 5 AdobeUCSa s AdobeUCS23 23 23 23 Engine Oil Capac jJy qt 25 40 40 I 40 Engine Oil Capacity It 236 378 378 AdobeUCS 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 it 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 your warranty please contact the fac255tory 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 J H WESTERBEKE v MHO OHa CUSTOMER ID FICATION W2lA l234C508 Pleasure Craft Mail expires 7787 Adam Smi th 85 Maple Street Alden IN 12234 PI J 1 ANUAL WESTERBEKE 13A 225 18 225 21 A 225 27 A 225 33A Marine Diesel Engines Publication 36195 Edition One July 1986 AVON INDUSTRIAL PARK AVON MA 02322 8 TEL 617TELEX 924444 225 FAX 6175599323 225 CABLE WESTCORP