-( £ R II .., " ~ ~*III' -t q '" D"'" OPERATORS MANUAL MARINE DIESEL ENGINES W-13, W-21 , W-27, W-33 PUBLICATION NO. 32363 t~ rWESTERBEKE ~ I WESTERBEKE CORPORA TlON' 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780 WEBSITE: WWW.WESTERBEKE.
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. A WARNING Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.
FOREWORD Thank you for having selected a Westerbeke Diesel Engine for your use. This manual describes the procedures for proper handling and maintenance of the Engine Models W13, W21, W27 and W33. To maintain your engine always in its best operating condition and to enable it to perform best, it is important to handle it properly and carry out complete maintenance according to this manual.
TABLE OF CONTENTS PAGE GENERAL SPECIFICATIONS ••.•••••••.•••• 3 CAUTIONS IN HANDLING ENGINE ••.•••..•• 4 1. BREAKING IN..................... 5 2. PREPARATIONS. • • • • • • . • • • • • • • • . • •• 6 3. STARTING PROCEDURES ••..........• 7 4. STOPPING PROCEDURES •••.•••••..•• 10 5. CAUTIONS ON STARTING AND OPERATION •••..••••.••••••••• 10 6. REQUIREMENTS FOR PROPER OPERATION 6-1 Lubrication System •.•...••• 12 6-2 Fuel System ••....•...•••.•• 13 6-3 Cooling Systern .••..•••.
GENERAL SPECIFICATIONS ITEM CHARACTERISTIC W13 W2l W27 W33 Type Vert.,4 cycle,water cooled diesel Combustion chamber Swirl chamber type en~ine CIl :z No. of cylinders 2 0 H rx:IE-! 4 4 3 :Z~ Bore & stroke (inches) ZI%.l Cu. In. displacement 37 60 80 91 Compression ratio 23 23 23 23 Firing order 1-2 1-3-2 298 374 HC.J t!)H rx:IH C.J rx:I ~ 2.76x3.07 2.87x3.07 2.87x3.07 3.07x3.07 CIl Dry weight, std.
CAUTIONS IN HANDLING ENGINE * Always use proper engine oil and watch oil pressure during operation. * Use clean fuel, free from impurities and water content. * Prevent entry of air and water into the fuel system. * In case the starter motor pinion fails to engage wi th the ring gear at the time of starting, turn on the starter swi tch again after the starter motor has come to a complete stop. * Prevent the temperature of cooling water from falling too low.
BREAKING IN Service life of your engine is dependent upon how your engine operated and serviced during the initial 50 hours of operation! is Your new engine needs 50 hours of conditioning operation for breaking each moving part in and maximizing performance and life of engine. Perform this conditioning carefully, bearing the following points in mind: CAUTION: Idle and warm up your engine from 3 to 5 minutes. * * * Avoid hasty acceleration.
PREPARATIONS Take steps as shown below in starting your engine for the first time or after a prolonged shut-down. 1. Fill your engine with oil up to or near the upper limit on the dipstick. Use a good grade of oil wi th API specification of CC or better. For quantity of oil, you may refer to the General Specifications page. However, it is best always to be guided by dipstick measurement as angle of installation has some effect. 2.
STARTING PROCEDURES Instrument panel, description and use of: Note 1: When engine is stopped after use, the water temperature and oil pressure gauges may stay at their running readings. Note 2: When engine is next to be used, turn start switch to "ON". The temperature and pressure gauges will "ZERO" and the voltmeter will register battery voltage. The electric fuel pump, mounted on the engine, will also begin to operate, purging any air accumulated in the system.
STARTING PROCEDURES 1_ Turn the starter swi tch to the "ON" position_ If making an ini tial star t after lay-up, fuel filter servicing or repairs, allow fuel pump to work 15-25 seconds to purge the system of any air. Check that clutch is in neutral and that throttle is in full forward_ 2_ Glow plug preheating with key in "ON" position, push in about 1/4 inch or enough so that voltmeter indicates discharge.
4. Starting Continuing to hold the key depressed, turn to the "START" position. The starter motor will run ther eby cr ank ing the engine. Hold throttle open until engine runs and then reduce throttle. Should the eng ine not star t even when the star ter swi tch is left at "5" position for 10 seconds, take your hand off the starter switch for 30 seconds, and then attempt to start the engine again by sufficiently preheating the glow plug.
STOPPING PROCEDURE 1. Stop To stop the engine move the throttle control through the idle position to stop. As the throttle is moved past idle there will be increased resistance to movement because a spring loading must be overcome. Hold the throttle firmly against the pressure until the engine comes to a complete stop. 2. W-13 W21,27,33 Starter switch off Wi th the eng ine stopped, turn the star ter key back to "OFF" position. The battery will be discharged if the key is left at "ON" position.
LUBRICATING OIL TURNS VISCOUS Make certain that oil used is adequate for the prevailing atmospheric temperature. Check the oil also for deterioration. VOLTAGE ACROSS BATTERY TERMINALS battery is fully charged. DROPS Check that the THE TEMPERATURE OF INTAKE AIR IS LOW AND COMPRESSION TEMPERATURE DOES NOT RISE ENOUGH Allow the glow plug to operate sufficiently to aid starting. See table on page 8. 3. Cautions during operation Confirm that the oil pressure is normal during normal operation.
REQUIREMENTS FOR PROPER OPERATION LUBRICATION SYSTEM 1. Engine oil For engine lubrication, use diesel engine oil. Diesel engine oils are classified according to the API Specifications into grades CA, CB, CC and CD. Anyone of them is usable, but use of CC or higher grades prepared by well-known makers is recommended. 2. Engine oil viscosity Use oil having viscosity best suited to the atmospheric temperature.
5. Replacement of oil filter Being a replaceable cartridge type, the oil filter requires no cleaning inside. In installing the oil filter, apply engine oil thinly on to the O-ring, and then tighten it by hand firmly. When removing the used filter, cover over with a plastic bag. This will allow both filter element and spilled oil to be collected cleanly without spilling oil in the bilge.
3. Notes on fuel system See below a typical exploded view of a fuel system. The one shown is for the W13. Those for the W21, W27 and W33 are similar except for the number of cylinders. The Wes·terbeke self-bleeding fuel system is automatic in operation. Therefore, it is unlikely that the operator will be forced to service the system at sea. For. that unlikely possibility, however, it is recommended that the following parts be carried onboard.
If a leak should develop at a banjo or washer that cannot be remedied by a simple tightening of the screw, renew the washers. The engine can be started by taking the steps described on pages 8 and 9. In cases where the engine cannot be started easily, loosen two injection nuts on the nozzle side, turn the speed control lever to "full open" position, turn the starter motor and then tighten the nuts firmly. 4.
heat exchanger and the cylinder block, and it is essential that antifreeze be added to cooling water in a quantity being proportional to the lowest temperature of the d~str ict. It is recommended that the antifreeze mixture be used throughout the year. *Antifreeze of poor quality will cause corrosion of the cooling system, and thus always use antifreeze prepared by a reliable maker, and never use it mixed with antifreeze of a different brand.
4. Fresh water cooling system (See Note 5 on page 6.) The system consists of a sea water pump which pumps raw sea water through a heat exchanger to remove heat from the coolant. The raw water is discharged overboard through the exhaust line. The engine coolant (fresh water with or without antifreeze) is circulated by the fresh water pump in continuous circuit. Pumped through the cylinder block, cylinder head, heat exchanger and back to the fresh water pump.
WIRING DIAGRAM Your engine is of l2V system and its electric circuit is as shown in the diagram below. For installing electrical parts, connect them correctly by referring to the diagram and at the same time check for damaged wire sheathing Care must always be and confirm that grounding is provided properly. taken while working on the electrica~ system. Never shut the engine battery switch off while the engine is running. Damage to the alternator will result should this be done • .
RECOMMENDED MAINTENANCE SERVICE Check and service your engine at specified intervals to maintain it in its best conditions and permit it to perform as it should. As for those asterisked items, it is suggested that you have them performed by an authorized distributor or dealer. 1. Daily inspection before use A. Checkup of engine oil level and refilling No refill is required if the level is near the upper limit line of the gauge. B. Checkup of cooling water and refilling Refill up to the filler cap neck.
4. 5. C. Cleaning of fuel filter D. Adjustment of engine idle Servicing at every 200 hours of operation A. Replacement of engine mounted fuel filter elements B. Replacement of fuel filter (cartridge type) Servicing at every 400 hours of operation A. Cleaning of fuel tank *B. Adjustment of valve clearance *C. Checkup of starter motor, alternator and regulator Check the brush and surface of commutator for the degree of wear. Replace the brush if it is worn beyond the limits of wear. *D.
*B. Checkup of compression pressure Remove each glow plug and check cylinders, one by one, using a compression pressure gauge. If the pressure differs by more than 2.5 kg/cm 2 (35.6 psi) between cylinders or if the cylinder pressure is less than 26 kg/cm 2 (369.8 psi) at 320 RPM for the W13 and at 280 RPM for the W21, W27 and W33, correct it. *C.
TRANSMISSIONS Each engine model may be fitted with a variety options. For ratio and/or type, see table below. Model 1:1 W13 S-lOOO HBW-100 2:1 BW-3 HBW-50 W21 S-lOOO HBW-100 HBW-50 RD-60 S-lOOO HBW-100 HBW-50 W27 S-lOOO HBW-100 HBW-100 RD-80 S-lOOO HBW-100 HBW-100 S-lOOO Left Rotation Hand HBW-100 HBW-100 W33 1.5:1 of transmission V-Drive 2:1 2.
TROUBLESHOOTING 1. ENGINE DOES NOT START PROBLEM REMEDY a. Starting switch is defective Correct connections and contacts b. Deficient drive torque .)f the starter motor The battery is exhausted, trouble with the starter motor, or dirty or loose wiring c. Improper viscosity of engine oil Check the viscosity and renew oil if necessary d. Engine too cold Use glowplug starting aid e. Seizure of moving parts Rectify f. Air present in fuel system Purge thoroughly with electric fuel pump g.
4. ENGINE OVERHEATING ---------------~~~~----------r_--------------~~~~----------------- PROBLEM REMEDY a. Cooling water shortage Refill b. Water leaks Repair c. Belt loose or smeared with oil Clean or renew d. Raw water QumQ defective ReQair or renew 5. BATTERY IS UNDERCHARGED ---------------~~--=_--------~r_--------------~~~~----------------- PROBLEM REMEDY a. Belt tension improper Rectify b. Faulty wiring circuit Rectify c.
SERVICE DATA 1. Valve clearance (engine cold) (both intake and exhaust) 2. Compression pressure 3. 4. 0.25 rom (0.010 in.) W13 32 kg/cm 2 at 320 RPM W21 - W27 - W33 32 kg/cm 2 at 280 RPM Engine oil capacity (including oil filter W13 W21 W27 W33 2.8 3.5 4.5 5.0 Injection timing smoke set position. BTDC of compression stroke S S S S gal) gal) gal) gal) Injection starting pressure Cooling water capacity (in engine body alone) W13 W21 W27 W33 25 when started at 23· + 1.5· 19· + 1.
TABLE OF TIGHTENING TORQUES Ib/ft. 7-8 SO.7-S7.9 11-12 79.6-86.8 12-13 86.8-94.0 lS-16 108.S-11S.7 lS-20 108.5-144.6 20-25 108.S-180.8 Main bearing cap bolt W21, W27, W33 S.O-S.S 36.2-43.4 Connecting rod cap nut W13, W21, W27 3.2-3.S 23.1-2S.3 Connecting rod cap bolt W33 11.S-12.S 83.2-90.4 Flywheel bolt 11.S-12.5 83.2-90.4 S-6 36.2-43.4 1.1-1.3 8.0-9.4 4-S 28.9-36.2 1.S-2.0 10.8-14.S 6-8 43.4-S7.9 1.S-2.0 10.8-14.S M6 0.7 5.1 M8 1.7 12.3 MI0 3.S 25.3 M12 6.
WESTERBEKE GENUINE PARTS "WESTERBEKE GENUINE PARTS II are super ior and reliable because they have been produced under an excellent quali ty control system and have passed the standard after strict inspection. After market parts are not recommended from the viewpoint of their material standard and manufacturing method which may be entirely different from those of genuine parts. "WESTERBEKE GENUINE PARTS II are available from our authorized distributors and dealers.
