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