Westerbeke 13a User manual

OPERATOR'S
ANUAL
WESTERBEKE
13A • 18 • 21 A • 27 A • 33A
Marine Diesel Engines
Publication # 36195
Edition One
July 1986
AVON INDUSTRIAL PARK, AVON, MA 02322 8 TEL: [phone]
TELEX: 92-4444 • FAX: [phone] • CABLE: WESTCORP

FOREWORD
Thank you for hav selected a Westerbeke
Diesel Engine for your use.
This manual describes the procedures for proper
handling and routine maintenance of:
W13A, W18, W2lA, W27A and W33A
Marine Diesel Propulsion Engines
To obtain best operating condition and longest
life, 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 below)
registering your warranty, please contact the fac-
tory in writing with Model information to include
unit serial number and commission date.
We look forward to your continued patronage.
from:
J.H, Westerbeke Corp.
Avon Industria! Park
Avon, MA 02322
-- -
,-
------.- .. --- ------------------
I~
J. H. WESTERBEKE COR~
","D~ IkO<."'~'" e~"K, .v",,,, MHO OHa
CUSTOMER ID FICATION
W-2lA l234C508
Pleasure Craft
Mail
expires 7/7/87
Adam Smi th
85
Maple
Street
Alden, IN
12234
PI<
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1

TABLE OF CONTENTS
PAGE
GENERAL SPECIFICATIONS .•••.•...•..... 3
INSTALLATION, PREPARATION AND SUPPLY
CAUTIONS. . . . . . • . . . . . . . . . • . . . . • •• <I
1. BREAKING IN..................... 7
2. STARTING SySTEM................. 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
6-1 Lubrication System ..•.•.•.. 13
6-2 Fuel System •••••.••..•..•.. 14
6-3 Wiring Diagram ...•..•... 15-l6
6-4 Cooling System ....•••••..•. 19
6-5 Belt Tension .••••••••....•• 21
6-6 Domestic Hot Water •••...•.. 22
7. RECOMMENDED MAINTENANCE SERVICE.23
8. TRANSMISSIONS ......•••••••••••.• 25
9. WARNER HYDRAULIC TRANSMISSIONS .. 27
10.. WALTER V-DRIVES" .. ,. .. "" .... " .. '" " .... '"" ,,32
11. ADJUSTMENT OF VALVE CLEARANCE ••• 38
12. TABLE OF TIGHTENING TORQUES .••.. <ll
13. TROUBLESHOOTING ..•..••.•••••.••• 42
14. LIMITED WARRANTY .............••• 43
2

GENERAL SPECIFICATIONS
ITEH
C'HhRk
: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)
2.76x3.07 2.56x3.07
I
2.87x3.07'2.87x3.07 3.07x3.0"
Cu.
In. displacement
37 47 60 80 91
ComEression ratio 23 23 23
23 23
Firing order 1-2 1-3-2 1-3-2 1-3-4-2 1-3-4-2
Dry weight, std. (lbs) 289 345 345
424 480
Fuel
#2 diesel fuel only
I
Injection pump Bosch type
I
I Throttling type
I
Nozzle
I
Injection
Eressure
All models:
1707
Ibs~
---l
Governor
Contrifugal
weight type
I
Lubr ication
system
Pressure lubrication
I
I
Oil filter
I
Filter paper type
,
I
[3
Engine Oil Capac jJ:y qt. 2.5 4.0 4.0
I
4.0
Engine Oil Capacity It. 2.36 3.78 3.78
3.78 I 3.93
Fresh water Forced circulation, water cooling by
I
Cooling system heat exchanger
~
Coolant capaci
I
6qts
I
5qts
I
5qts
I
sqtslsqts'
L--_~A=l~w=a~vTs_=f=i=l=l_~o top of filler neck
I
i ' i
1.2 1.2 1.~~~.6
~~~~~~~~ ________ ~_1==2-.=5~0 __ L-~1~2-~5~O~ __ , __ l2-~~~5~O~.
(Engine Proper)
Starter KW
-~
1.6
12-50
s
Battery capacity
90 AH
3

INSTALLATION, PREPARATION AND SUPPLY CAUTIONS
"
*
*
*
*
*
Check ts of installat
(1) Alignment ror to be no more
than one thousandth of an inch
per inch of coupling diameter)
(See Figure 1)
(2) Provide sufficient ventilation
(3 ) Provide
around
clauses)
adequate service room
engine (See warranty
before operating engine.
O(U fEELER GAGl
ISTRAIGl-fT EDGE
Figure L
Checking Coupling Alignment
Fill fuel tank with CLEAN #2 diesel from a reputable manufacturer.
Fill lubricating oil to full mark on dipstick (Select readily
available lubricating oil with A.P.I. spec. CC or CD and S.A.E.,
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 transmission/V-drive to correct level on
dipstick with correct lubricant.
Plug-in 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 PRECAUTIONS
..
'"
..
*
Never operate engine with inadequate ventilat Confirm that
there are no exhaust leaks inside engine compartment.
Do not touch moving parts during operation .
Do
not touch hot parts such as exhaust
bustible materials near the unit.
Inspect and ust parts of the engine
, and do not
after it is
ace com-
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
p~noses the ator to a severe steam burn if the manifold pres-
sure cap is removed while the eng is hot. low instructions
on 6. )
4

*
use tools
S~A~E"
n selecting
Be sure that current
and that all connect
fit corr and use
and metr sizes are
ring dware.
caut.ion dUK ing ser-
on the unit.s, use
carr wires ar e protected from abr as
are t ght.
5

PREPARATIONS
Take as shown below in starting
or after a pr shut-down.
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).
2. Fill the transmission/V-drive
to full mark on their dipstick
with the correct lubricant.
3. Your eng ine is supplied wi th a
coolant recovery system (See
figure 3) to which the
following instructions apply:
a) Fill engine completely to
the neck of the manifold
pressure cap with an antifreeze
mixture.
b) Open air bleed petcock on
manifold or thermostat housing
to allow air svstem to
escape while filling: Close
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
level below the bottom level
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.
engine for the first time
gauge
oil
{elle!
oil
or! levE-Iqc;uge_+Y1'1
3/ld/il/erport
/ower!/m/t 7---- -- oi/
Figure 2. oil Capacity
COOLANT RECOVERY TANK
\ PRESSURE CAP
F e 3. Coolant Recovery System
6

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 con-
ditioning operation breaking in each moving part, thus helping
to maximize performance and service life of engine. Perform this con-
ditioning 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, bat-
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 RPM's for first twenty five hours
(tr ansmiss ion lubr icant should be changed on models having
HBW transmissions).
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 RPM's 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 du!:i
tial 50 hours of break Don't baby it, yet do not abuse
7
the ini-
to

DESCRIPTION OF STARTING SYSTEM
All Models use an electric
starter assisted
for both normal and cold weather
starting. 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 the
starter.
This system is common to
Westerbeke Diesels. The start
circuitry 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 Chamber
After 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
temj:'eratur e
Preheating time
A rox. 10 sec.
rox. 20 sec.
A
For
starting and s
ng eSt see
10 and 11.
13

INSTRUMENT 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 tem-
gauges 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 self-bleeding feature of these
no fittings or such in the fuel
models make it such that
remove air from the eng fuel
f ill the vessel's 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