Westerbeke W-13 User manual

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OPERATORS MANUAL
MARINE DIESEL ENGINES
W-13, W-21 , W-27, W-33
PUBLICATION NO. 32363
t~ rWESTERBEKE
~ WESTERBEKE CORPORA TlON' 150 JOHN HANCOCKROAD
I MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
~~
NAMIA Member National Marine Manufacturers Association
z •• e

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. Symptoms of Carbon Monoxide
exposure can include:
- Dizziness
-Nausea
-Headache
- Throbbing in Temples
- Muscular Twitching
- Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
6ET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quatters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.

FOREWORD
Thank you for having selected a Westerbeke Diesel Engine for your
use.
This manual describes the procedures for proper handling and main-
tenance 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.
If you have any questions about your engine or in the event of a
failure, please contact your nearest distributor or dealer.
We look forward to your continued patronage.
LEFT SIDE~ W-21 WITH 2:1 HBW-50 TRANSMISSION
I

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 .••..•••.•••• 15
6-4 Wiring diagrarn ••.•••••.•••• 1S
7. RECOMMENDED MAINTENANCE SERVICE.19
S. TRANSMISSIONS ••••.••..••.••••••. 22
9. TROUBLESHOOTING ••••••••••.•••••• 23
10. SERVICE DATA ••••••••••.....••.•• 25
11. TABLE OF TIGHTENING TORQUES ••••• 26
2

GENERAL SPECIFICATIONS
ITEM CHARACTERISTIC W13
W2l W27 W33
Type
Vert.,4 cycle,water
cooled diesel en~ine
Combustion
chamber Swirl chamber
type
CIl
:z
No.
of cylinders
2 3 4 4
0
H
rx:IE-!
stroke (inches)
:Z~
Bore &
HC.J
2.76x3.07 2.87x3.07 2.87x3.07
3.07x3.07
t!)H
ZI%.l
Cu. In.
displacement
37
60 80
91
rx:IH
C.J
rx:I
Compression ratio
23 23
23
23
~
CIl
Firing order
1-2
1-3-2 1-3-4-2
1-3-4-2
Dry weight,
std.
(lbs) 298 374
434 498
Fuel
#2
diesel fuel
only
::1!!
Injection pump Bosch type
....:trx:l
rx:IE-!
Nozzle Throttling
type
DCIl
I%.l>t
(f.l
Injection pressure
All models:
1707
lbs.
Governor
Centrifugal
weight type
Z
0
Lubrication system
Pressure lubrication
H
E-!::E:
~rx:I
Oil filter
Filterp~Qer type
C.JE-!
HCIl
2.5 qts I 4.0 qts I 4.0 qts I 4.2 qts
~>t
~(f.l
Engine oil
capacity
::>
....:t
For accuracy, depend on dipstick markings
~ ::E:jcooling
system Forced circulation,
water cooling by
Hrx:l1
heat exchanger
....:tE-!
6 qts I 5 qts
I 8 qts I
ou)
8 ~!Coolant
capacity 8 qts
Always fill to top of filler
neck
....:t
Starter
V-HP 12-2
12-2 12-2
12-2
~
C.J::E:
Hrx:I
t:X:E-!
Alternator V-A
12-50
12-50 12-50
12-50
E-!(f.l
CJ>t
Glow plug
Sheathed trpe - all models
rx:ICIl
....:t
!
rx:I
I
lBattery capacity
60 AH
75
AH 90 AH 90 AH
3

*
*
*
*
*
*
*
*
CAUTIONS IN HANDLING ENGINE
Always use proper engine oil and watch oil pressure during opera-
tion.
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.
Pay attention to the color of exhaust gas.
Clean or replace the fuel filter and oil filter periodically.
Replenish or replace oil as specified.
SAFETY PRECAUTIONS
*
*
*
*
*
*
Never put the engine in o~eration in improperly ventilated places.
Do not touch moving parts during operation.
Do not touch hot parts such as exhaust pipe, and do not place com-
bustible materials there.
Inspect and adjust parts of the engine only after it is stopped.
Check and refill engine oil, cooling water and fuel after the
engine is brought to a stop.
In checking the level of and refilling cooling water, remove thie
pressure cap after the temperature of the water has fallen enough.
* Always use tools of proper sizes and full caution during sel
vicing.
4

BREAKING IN
Service life of your engine is dependent upon how your engine is
operated and serviced during the initial 50 hours of operation!
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.
Use caution not to overload the engine.
Inspect, maintain and service your engine in accordance wi th the
instructions in this manual.
Explanation:
"Breaking in" a new engine is basically a seating of the piston rings
to the cylinder walls. This is not accomplished by long periods of
running idle, nor by early running under full load, nor by varying
loads with intervals of fast acceleration and/or excessive speed.
Idle running may glaze the cylinder walls causing oil consumption and
smoky operation. Excessive speeds and loads may score cylinder walls
with similar results.
As indicated above, use a short warm up at idle and put engine under
moderate load and speed for the first ten hours of operation. For
the next forty hours, use approximately 70% load. This kind of care-
ful operation will result in best results from your engine.
5

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 measure-
ment as angle of installation
has some effect.
2. Your eng ine is suppl ied wi th a
coolant recovery system to
which the following instruc-
tions apply:
$
a) Fill engine completely to
the neck of the manifold cap.
b) 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.
c) In winter add
as described on page
freeze may be used
if changed annually.
antifreeze
16. Anti-
year round
3. Fill the fuel tank with Diesel
fuel. The interior of the fuel
tank must be maintained clean.
Be careful not to allow intro-
duction of dirt when filling
fuel.
4.
Engine oil, coolant
transmission levels should
checked at least once a
prior to engine use.
and
be
day
6
ot1levelgatJge_~"'f1
and/i/lerpDrt
...
~\

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 volt-
meter will register battery voltage. The electric fuel pump,
mounted on the engine, will also begin to operate, purging
any air accumulated in the system.
Note 3: The engine is now prepared for starting.
7

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 dis-
charge. Hold key in depressed
posi tion until glow plugs are
sufficiently hot_ Follow Table
below for preheating time.
Quick-heat type (Yl14T)
Atmospheric
temperature Preheating
+s·c (+4l·F)
or
higher Approx.
10
+S·C
(+4l-F)
to
-S-C (+23-F)
A~rox.
20
-SoC
(+23·F)
or lower Approx 30
time
sec_
sec.
sec.
Limit of continuous use 1 minute
3.
Proper glow
plug function is
indicated
by voltmeter drop
when key
is
depressed. This
drop will
be
slight
but dis-
cernible.
If no voltage
drop
is noted,
it may
indicate
defective glow plugs
or
a
faulty
preheat
circuit (check
for
loose connection).
8

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. The starter motor should never be allowed
to run for more than 30 seconds at a time.
5. Operation
As soon as the engine has
started, release the key. The
key will automatically return
to the "ON" position. Leave
the key at "ON" dur ing oper a-
tion. Check that with engine
running, oil pressure and bat-
tery charge voltage are
registering and that raw water
is discharging with the
exhaust.
During engine operation, do not turn the key to "5
11
position.
may damage the starter motor.
6. Warm-up operation
Run a few minutes at II IDLE"
position to assure that all
functions are operating. Then
operate under reduced load
until water temperature rises
into the 140-150· range.
9
This

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 over-
come. Hold the throttle firmly
against the pressure until the
engine comes to a complete
stop.
2. 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. An engine
alarm buzzer is provided to
warn the operator of this
possibili ty. Best precaution
is always to remove the key.
W-13
CAUTIONS ON STARTING AND OPERATION
1. Normal starting
W21,27,33
Follow the procedures below for routine starting of your engine.
1) Check the engine and transmission oil levels and refill if
necessary.
2) Insure that you have sufficient fuel. Keep tank as full as
possible.
3) Check coo~ng water level, and refill if necessary.
Note: Check for leaks of water or oil, particularly when
signs of such leak are found on the bottom of the engine or
in the drip tray.
4) Start the engine in accordance with the procedures given on
the preceding pages.
5) 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 adverse condi tions concur as the atmospher ic
temper a-ture drops exceedingly, and the engine must, under such
conditions, be started by taking steps described below:
10

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 DROPS
battery is fully charged.
Check that the
THE TEMPERATURE OF INTAKE AIR IS
TEMPERATURE DOES NOT RISE ENOUGH
operate sufficiently to aid starting.
3. Cautions during operation
LOW AND COMPRESSION
Allow the glow plug to
See table on page 8.
Confirm that the oil pressure is normal during normal operation.
Confirm 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
Check for abnormal noise such as knocking, fr iction or leaking
sounds, and vibration and blow-back sounds.
Check for leaks of fuel and engine oil.
A knocking sound is heard while the engine is cold, during quick
acceleration and at idle. Confirm that no knocking sound is heard
in other cases.
LEFT SIDE} W-33 WITH 2:1 VEE DRIVE
11

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 tem-
perature. Use of an all-season oil SAEIOW-30 with minimum visco-
sity change under different temperatures is suggested.
Atmospheric temperature
Viscosity
20·C (6a·F) or higher SAE 30 or lOW-30
SAE 20 or 10W-30
S·C (41·F) or lower SAE 10W-30
3. Oil pressure
The oil pressure dur ing operation of the engine is indicated by
the oil pressure gauge.
During normal operation •••••••••••• Oil pressure will range between
50 and 70 PSI.
At the time of cranking •••••••••••• Pressure will rise proportion-
ately with speed.
4. Engine oil change
To renew engine oil, discharge old oil through the sump drain hose
attached at front of engine while engine is still warm.
Drain old oil completely, replace the hose, plug the end securely
and add fresh oil through the oil inlet port on the valve cover.
After refilling oil, idle the engine for several minutes and stop.
Then check the quanti ty of oil by the oil level gauge. F ill to
but not over the high mark on the dipstick.
12

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.
Note A:
After market 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 HEAVY OIL.
In cold weather, particularly, much water vapor is produced when
much
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. To this end, it is most
desirable that a primary fuel
filter of the water entrapment
type be installed between the
fuel tank and engine. Such a
filter is available under part
# 32974. (See your local
dealer.)
Water entrapment filter #32974
is shown opposite. Inspect
frequently for presence of
water in the clear bowl. Drain
it off by loosening the air
vent and opening the drain.
13

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 opera-
tion. 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.
Banjo washers 11, 30, 31, 33, 34, 45
Injector seat washers 42
Lift pump filter and gaskets 6, 7, 8
Fuel filter element and gaskets 13, 14 ,15
14

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. Cleaning fuel filter and replacing filter element
After the first 50 hours of operation, loosen the retainer ring
#16 and discard filter element #15. Clean bowl #17 and re-install
new filter, using new gasket #13 and #14.
This same treatment is required of the filter element #6 in the
fuel lift pump. Similarly, replace n.ew filter element #6 using
new gasket #7 and #8.
After the first 50 hour change, the change period may be increased
to 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 thus it calls for the utmost caution in
handling. Furthermore, the fuel injection pump has been
thoroughly shop-adjusted and should never be readjusted care-
lessly.
Such adjustment, whenever necessary, should be performed at an
author i zed service station as a precision pump tester and skills
are required.
To obtain long and satisfactory use of your injection pump:
Always use fuel which is free from impurities.
Clean and renew the fuel filter periodically.
Inspect water entrapment filter regularly.
COOLING SYSTEM
1. Cooling water
As cooling water, use soft water with least impurity content such
as tap water (potable water) or rainwater, and 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 effects.
2. Antifreeze
In cold districts, care should be takeri to prevent cooling water
from freezing. Cooling water when frozen expands to break the
15

heat exchanger and the cylinder block, and it is essential that
antifreeze be added to cooling water in a quantity being propor-
tional to the lowest temperature of the d~str ict. It is recom-
mended that the antifreeze mixture be used throughout the year.
*Antifreeze of
cooling system,
reliable maker,
different brand.
poor quality will cause corrosion of the
and thus always use antifreeze prepared by a
and never use it mixed with antifreeze of a
*Make sure that the cooling system of the engine is cleaned
well before adding antifreeze.
*Recommended antifreeze for year round use is ZEREX Long Life
Coolant (antirust contained).
Antifreeze
Concentration %
Freezing
temperature
·C
( • F)
ANTIFREEZE ADDITION DATA
13
-5
(23)
23
-1"
(14)
30
-IS
(5)
35
-20
(-4)
45
-30
(-22)
50
-40
(-40)
60
-50
(-58)
Note: It is advisable that antifreeze concentration be
selected on the basis of a temperature which is about
5·C (lO·F) lower than the actual atmospheric tem-
perature.
3. Alternator belt tension
The alternator belt is properly
tense if it deflects 10 to
12 mm (0.39 to 0.47 in) as it
is depressed with a finger be-
tween the pulley and pulley of
the long distance side.
Excess i ve tens ion 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
and insufficient charging due
to a slipping belt.
CAUTION:
Never attempt to adjust tension of the fan belt while the
engine is in operation.
16

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.
The total system is very reliable and requires only a daily check
of the water level in the system plus routine check of hose clamps
and fittings.
It is likely that zinc electrodes will waste away from contact
wi th sea water. It is also possible for the raw water pump
impeller to fail due to lack of sea water or deterioration. An
early sign of impeller failure is less water and more steam at the
exhaust through hull fitting.
I t is recommended, therefore, that zinc electrodes, an impeller
kit, a pump belt and a thermostat with gasket be kept onboard at
all times. These parts should be ordered from your nearest
stocking dealer and used as inspection dictates.
17

WIRING DIAGRAM
Your engine is of l2V system and its electric circuit is as shown in
the diagram below.
For installing electrical
to the diagram and at the
and confirm that grounding
taken while working on the
parts, connect them correctly by
same time check for damaged wire
is provided properly. Care must
electrica~ system.
referring
sheathing
always be
Never shut the engine battery switch off while the engine is running.
Damage to the alternator will result should this be done •
@SI!["'OTE-a
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