Westerbeke 33a Service Manual

TECHNICAL MANUALWESTERBEKE13 - 21 - 27 - 33MARINE DIESEL ENGINESEdition TwoOctober 1981

The alignment is correct when the shaft canbe slipped backward and forward into thecounterbore very easily and when a feeler gauge indicates that the

SINGLE PASS MANIFOLDNote: Drawing is indicative only. Specific models may vary in detail.

SECTION STRANSMISSIONSHBW SHORT PROFILE SAILING GEARDESCRIPTION1. BRIEF DESCRIPTIONThe Type HBW Short Profile Sailing Gears are equipped with a positi

An oil filler screw with dipstick and an oil drain plug are screwed into the gear casing. The fillerscrew is provided with a breather hole.The shaft f

- FUNCTIONThe transmission uses a positively driven, mechanically operated multiple-disc clutch system mountedon the output shaft.The thrust force req

5. SHAFT BEARINGSBoth the input and the output shafts are carried in amply dimensioned taper roll bearings.The intermediate gear and the movable gears

2. PAINTING THE GEARBOXALWAYS COVER THE RUNNING SURFACES AND SEALING LIPS OF THE RADIAL SEALINGRINGS ON BOTH SHAFTS BEFORE PAINTING. Make certain that

6. OPERATION OF GEARBOXGear changing requires only minimum effort. The gearbox is suitable for single lever remote control.Upon loosening the retainin

The position of the cover plate underneath the actuating lever is factory-adjusted to ensure equal levertravel from neutral position to A and B. There

2. OPERATING TEMPERATUREThe maximum permissible temperature of the transmission oil is 130'C. If this temperature is to beexceeded, an optional o

2. OIL QUANTITYHBW 5 approximately 0.4 literHBW 10 approximately 0.6 literHBW 20 approximately 0.8 literHBW 50 approximately 0.3 literHBW 100 approxim

It is essential not to hang too much weight in the form of exhaust system components rigidlyfrom the engine manifold. Generally, it is permissible to

BW TRANSMISSIONS(BW3, BW&, BW12)These manual transmissions rotate opposite to the engine when in forward gear. Shifting effort is verylow. The inp

SECTION TGENERATOR SETSMANUAL STARTER DISCONNECT (TOGGLE SWITCHES)

MANUAL STARTER DISCONNECT (TOGGLE SWITCHES)GENERAL:This manually controlled series of Westerbeke marine diesel generators is equipped with toggleswitc

REMOTE ENGINE OPERATION:For remote operation of the generator system, the same three switches are used. The PREHEAT andSTART switches are connected in

TROUBLESHOOTINGMANUAL STARTER DISCONNECT (TOGGLE SWITCHES)CIRCUIT PROTECTION:The engine control system is protected by a 20 amp manual reset circuit b

Battery runs down High resistance leak to ground Check wiring. Insert sensitive (0-.25amp) meter in battery lines. (Do notstart engine.) Remove connec

4.4 - 7.7 - 11.1 - 12.5 KW GENERATOR SETSTECHNICAL DATA4.4KW 115 VAC 34.7 AMP at 115 VAC7.7 KW 115 or 115/230 VAC 33.5 AMP at 230 VAC11.1KW 115 or 115

FLASHING THE FIELDThe generator is equipped with a silicon rectifier for excitation and to flash the field, connect a 12 voltbattery between ground an

Checking The Back Pressure1. Exhaust pipe flange2. Exhaust line3. Transparent plastic hose, partly filled with water.Measurement "A" may not

FUEL PIPINGWe recommend copper tubing together with suitable fittings, both for the supply line and thereturn line. Run the tubing in the longest piec

The transmission control lever may be connected to the pilot station by a flexible, sheathed cableand controlled by a Morse type lever. The single-lev

OPERATIONPREPARATION FOR FIRST STARTThe engine is shipped "dry"...with lubricating oil drained from crankcase and fluid from thetransmission

BLEEDING PROCEDURES BY MODEL1. Initial Engine Start-up (Engine stoppage due to lack-of fuel)a. Insure that the fuel tank(s) is filled with the proper

W50 injection pump only. Open the 5/16 bleed screw (Bleed Point D) on the injector line banjo boltone or two turns and, with, the throttle full open

PREPARATION FOR STARTING1. Check water level in expansion tank. It should be lh to 2 in. below the top of the tankwhen cold.2. Check the engine sump o

SECTION INDEXGENERALIntroduction OperationInstallation MaintenanceENGINE OVERHAULOTHER OVERHAULMarine Engine Electrical SystemCooling System (External

NOTE: Always be sure that the starter pinion has stopped revolving before again re-engaging the starter;otherwise, the flywheel ring gear or starter p

TEN MUST RULESIMPORTANT..for your safety and your engine's dependability.IMPORTANTALWAYS -1. Keep this Manual handy and read it whenever:;.in dou

MAINTENANCEPERIODIC ATTENTION:„After you have taken delivery of your engine, it is important that you make the following checks rightafter the first f

CAUTION: The use of different brands of lubricating oils during oil changes has been known tocause extensive oil sludging and may in many instances ca

14. Disconnect battery and store in fully charged condition. Before storing the battery, the batteryterminals and cable connectors should be treated t

LUBRICATING OILSLubricating oils are available for Westerbeke Diesel engines which offer an improved standardof performance to meet the requirements o

ENGINE OVERHAULThe following sections contain detailed information relating to the proper operationcharacteristics of the major components and systems

GENERAL SPECIFICATIONSMODEL,--MARINE W13 W21 W27 W33 - GENERATOR 4.4KW 7.7KW 11.1KW 12.5KWTYPE 4 Cycle, Water Cooled, Vertical OverheadValve Type Di

TABLE OF TIGHTENING TORQUE kg- m lb ft.Cylinder head bolt (M10) W21, W27, W33 7-8 50.7-57.9(M12) W21 11-12 79.6-86.8W13, W27 12-13 86.8-94.0(M14) W33

STD. REPAIR SERVICEVALUE LIMIT LIMIT1. Compression pressure @ 280 RPM 32Kg/cm226Kg/cm2 32Kg/cm22. Compression pressure differencebetween cylinders (m

IMPORTANTPRODUCT SOFTWARE NOTICEProduct software of all kinds, such as brochures, drawings, technical data, operator's and workshopmanuals, parts

STD. REPAIR SERVICEVALUE LIMIT LIMITb. Valve head diameter (Exhaust)W13 25.0 mmW21, W27 25.2 mmW33 28.0 mmc. Overall length W13 103.0 mmW21, W27 114.5

STD. REPAIR SERVICEVALUE LIMIT LIMITCylinder boreW13 70.0 mm +0.2 mm +0.95 mmW21, W27 73.0 mm +0.2 mm +0.95 mmW33 78.0 mm +0.2 mm +1.20 mmCylinder bor

STD. REPAIR SERVICEVALUE LIMIT LIMITRing widthCompression ringsW13 2. 5 mmW21, W27, W33 - Nos. 2 & 3 2.0 mmOil ring 4.0 mmRing side clearanceCompr

STD. REPAIR SERVICEVALUE LIMIT LIMITUndersize finish dimensionsJournal W13 U.S. 0.25 58.695-58.710 mmU.S. 0.50 58.445-58.460 mmU.S. 0.75 58.195-58.210

STD. REPAIR SERVICEVALUE LIMIT LIMITOil clearance 0.15mm20. Pump CamshaftDriving method Gear driveBearing Front: ball bearingRear: cylinder block hole

STD. REPAIR SERVICEVALUE LIMIT LIMITc. Fuel injection pump rate atstart set (MS)W13 150 RPM: 33.5 +/- 5.Omm3/strokeW21 150 RPM: 37.5 +/- 5.Omm3/stroke

ADJUSTMENTS(1) Adjustment of Valve ClearancePull off the air breather from the rocker cover, and thenloosen off rocker cover bolts. Adjust the valvec

Adjustments of High Speed (No Load)Set the engine to a no-load high speed with theHIGH SPEED set bolt. This speed is set by the factoryand should not

CONSTRUCTION AND SERVICING OF CYLINDER HEADCONSTRUCTION1. Cylinder HeadThe cylinder head is an overhead valve head produced from a high rigidity speci

SERVICING THE CYLINDER HEADDISASSEMBLYDisconnect the air breather hose.Disconnect the fuel injection pipes.Remove the air intake silencer, intake mani

INTRODUCTIONIMPORTANTTHIS MANUAL IS A DETAILED GUIDE TO THE INSTALLATION,START-UP, OPERATION AND MAINTENANCE OF YOUR WESTERBEKE MARINEDIESEL ENGINE. T

INSPECTION1. Cylinder HeadPrior to washing the cylinder head, check for cracks,damage and water leaks.Check to see if the oil passageway feeding lube

4. ValveCheck the valve face and stem for excessive wear, damage anddeformation. Correct or replace if defective.If valve head thickness has decreased

Apply oil to the valve stem and insert the valve stem into the valve guide. Install the spring,retainer and retainer lock in order of mention.To assem

CONSTRUCTION AND SERVICING OF CYLINDER BLOCK ASSEMBLY1. Cylinder BlockThe cylinder block is a special cast iron casting and is of a full jacket type f

The gear case is an aluminum casting and is attached on the front end of the cylinder blockthrough the front plate. The case houses the injection pump

7. Camshaft and Timing GearThe camshaft is a high carbon steel forging. Thecam surface and journals areinduction-hardened to improve wearresistance. T

SERVICINGDisassemblyFor removal of the cylinder head and related parts, refer to "Cylinder Head".For the removal of the water pump and elect

Remove the connecting rod big end bolt nuts (bolts on the W33), then remove the bearing cap.Push tie piston and connecting rod assembly upward out of

Check the water jacket for scales and rust. Clean if necessary.Check the cylinder wall for scratches, damage andwear. If defective, correct the cylind

Measure the piston ring gap clearance. Replace the ring if the gapis too large. To measure, insert the ring into the least worn place ofthe cylinder b

4. CrankshaftMeasure crankshaft bend. If excessive, replacethe crankshaft.Check the journals and pins for damage, seizureand other faults. If the jou

Install the main bearings and connecting rod bearings to thecylinder block and connecting rod respectively. Tighten bolts tospecification and measure

6. Timing Gears and Injection Pump GearCheck each gear for incorrect tooth contact, wear and damage. Replace if defective. Also checkthe Oldham's

(1) When the camshaft front bushing needs to bepressed in, align the bushing oil hole with the oilhole in the cylinder block as illustrated. To alignt

(6) Check the crankshaft end play.(7) Apply sealant to outside surface of side seals. Press the side seals into the front and rear caps.(Insure the ra

(9) The piston and the connecting rod should beassembled as described below using Piston PinSetting Tool (Special Tool), except the W33. (Seebelow.)In

(10) The piston rings differ in shape from one another. Be careful to install them in proper positionsand directions as illustrated and with the stamp

(15) With the idler gear mating mark "1"properly aligned with the crankshaftmating mark "1", install the idler gearonto the idler

Insert the o-ring properly into the o-ring groove in the drive gear sleeve.Apply white lube to the outside surface of drive gear shaft (specially to t

LUBRICATION SYSTEMThe lubrication system is a full-force type using a trochoid gear pump fitted with a full-flow oilfilter. The oil pump is driven thr

SERVICINGDisassembly(1) 0i1 FilterIf the oil filter is on too tight to remove by hand,remove using a filter wrench (commerciallyobtainable).(2) Oil Pu

Rotor Clearance: Check an outer rotor to inner rotor clearance using the feeler gauge. Ifexcessive, replace the rotor assembly.Rotor to Cover Clearanc

FUEL SYSTEMFuel from the fuel tank is drawn to the engine by means of an engine mounted 12 volt electricfuel pump/filter. It is also filtered by an en

(a) Fuel Injection ControlFuel injection rate is controlled by changing therelative positions of the plunger lead and barrel. The plungeris rotated by

(d) Delivery Valve OperationThe delivery valve functions to deliver the fuel tothe injection pipe after the fuel pressure hasincreased sufficiently hi

(b) When removing the plunger, first take out the spring retainer (6) from the plunger tube (12). Thenremove the washer (7), 0-ring seal (8), valve (9

(1)Remove the delivery valve holder.(2)Take out the valve spring, valve and O-ring.(3)Take out the gasket and valve seat.(4)Spread the lock plate of t

INSPECTION(1)Fuel Filter (Secondary)Check the element for clogging and dirtiness. Replace if it is, seriously damaged. Regular elementreplacement inte

(c)Control Rack and PinionIf the rack and pinion have any worn or damaged teeth, replace. (d)TappetCheck the tappet O.D. roller and shaft for wear and

(d)Install the control rack.(e) Install the pinion with its deep root tooth alignedwith an aligning mark on the rack.(f) Install the spring upper sea

INSTALLATIONFOREWORDSince the boats in which these engines are used are many and varied, details of engineinstallation are equally so. It is not the

(d)Check fuel injection timing. For adjustment procedure, refer to Adjustment in the GENERAL section.(5)Partial Reassembly of Nozzle and Nozzle Holder

(c) After-spilling TestAn injection nozzle is considered defective if itspills fuel accumulated on the bottom of thenozzle after chattering test. Repl

GOVERNOR SYSTEMl: CONSTRUCTIONOperation of the governor maintains the engine speed constant as the centrifugal force acting on thegovernor weights, a

2. SERVICINGDisassembly1. Remove the alternator belt. (Refer to COOLING SYSTEM.)2. Remove the crankshaft pulley nut, and then remove the pulley.3. Rem

Reassembly4. Needle Bearing Check the needle bearing supporting the governor lever shaft in the gear case for damage.Reassembly is just the reverse of

ELECTRICAL SYSTEMCONSTRUCTION1. StarterThe starter can be roughly divided into the followingsections:(a) A motor section which generates a drivepower.

2. Alternator (50 amp 12 volt)The alternator is a three phase AC generator with a diode rectifier and is driven by the crankshaftthrough a pulley and

DISASSEMBLY1. Starter(a) Turn the engine battery selector switch to the off position. (b) Disconnect wiring from Band S terminals on the starter. (c)

(c) Brushes and Brush Holders(i) Check brushes. If the brushes are wornover the service limit, replace. (See"Service Standards".)(ii) With t

(f) Solenoid SwitchThe solenoid switch must be conducting between S and M terminals and between S terminaland body.(g) Overrunning ClutchIf the pinion

In case it is necessary to hoist the engine either front end upwards or reverse gear end upwards,the attachment of slings must be done very carefully

(k) Pinion Shaft Thrust GapA pinion shaft thrust gap is an axial play of theshaft. Adjust the gap to less than 0.5 mm by theadjusting washer between t

(ii) Holding TestWith the battery connected between the S terminal of thesolenoid switch and the body, manually move the pinionout of the stopper posi

Because of the use of IC's (integrated circuits), the electronic voltage-regulator is verycompact and is built in the rear bracket of the alterna

Description Standard value Charging voltage 14.4 +0.3V at 20'C (68'F)Temperature compensation -O.1V/10'C (50&apos

Disassembly1. After removing the three through bolts, insert a screwdriver between the front bracket and stator.While prying it, remove the front brac

3. Insert a #2 Philips screw driver through thisopening and remove the two screws holdingthe rectifier.4. Remove the nut anchoring the "B" t

2. Check for continuity betweenthe field coil and slip ring. Ifthere is no continuity, the fieldcoil is defective. Replace therotor assembly.3. Check

Rectifier Assembly(+) Heatsink Assembly TestCheck for continuitybetween the (+)heatsink and statorcoil lead connectionterminal with anohm-meter. If th

Brush and Brush Rig1. Check the length of the brush. A brush worn down to the service limit line should be replaced.Description Standard value Service

4. Glow Plug'When the positive cable of the battery is connected to the glow plugterminal and the negative cable of the body, the glow plug must

For all engine models, a propeller half-coupling, bored to shaft size for the specific order, issupplied. The coupling either has a keyway with set sc

MAINTENANCE1. Judging , Engine Overhaul PeriodGenerally the time at which an engine should be overhauled is determined by lowered engine power,decreas

2. Measuring Compression Pressure1. Remove the glow plug of cylinder to be measured.2. Attach a pressure gauge adapter in the screw hole of the gl

5. Disassembling CautionsWhen disassembling, keep in mind the following cautions. Note that the order of disassembly andreassembly will vary with ch

OTHER OVERHAULCONTENTS SECTIONMARINE ENGINE ELECTRICAL SYSTEM QActivation by Keyswitch (1980 onwards)COOLING SYSTEM EXTERNAL RTRANSMISSIONS SType H

SECTION QMARINE ENGINE ELECTRICAL SYSTEMACTIVATION BY KEY SWITCHThis system is supplied on most Westerbeke engines beginning May, 1980. Essentially, a

SECTION RCOOLING SYSTEM (EXTERNAL)1. DESCRIPTIONWesterbeke marine diesel engines are equipped with fresh water cooling. Transfer of heat from enginefr

5. SEA WATER PUMP IMPELLER REPLACEMENTThe following instructions are general and indicative only. Specific instructions where applicable maybe package

8. THERMOSTATGenerally, thermostats are of two types. One is simply a choking device which opens and closes as theengine temperature rises and falls.

c. Remove water connectors from the ends of the manifold and the end plates. Be sure to notethe proper location and arrangement of each for proper rep