Westerbeke 20B TWO Tehnical Manual
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Westerbeke 20B TWO Tehnical Manual

Westerbeke 20B TWO Tehnical Manual

Marine diesel propulsion engine
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See also: Operator's Manual
TECHNICAL MANUAL
WESTERBEKE
20B TWO
30B THREE
MARINE DIESEL
PROPULSION ENGINE
Publication #037600
Edition One
April 1990
j
r~
'WESTERBEKE
J
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
I
150 JOHN HANCOCK ROAD, TAUNTON,
MA
02780-7319 U.S.A.

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  • Page 1 TECHNICAL MANUAL WESTERBEKE 20B TWO 30B THREE MARINE DIESEL PROPULSION ENGINE Publication #037600 Edition One April 1990 'WESTERBEKE WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, 02780-7319 U.S.A.
  • Page 2 SAFETY PRECAUTIONS Be sure the unit and its surroundings are well-ventilated. The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator. • Use Extreme Care When Handling Engine Fuel (A constant danger of explosion or fire exists) IWARNINGI Do not fill fuel tank(s) while the engine is running.
  • Page 3 Westerbeke must depend on such software for the design of Westerbeke's own product software. Such software may be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, of which Wester- beke rarely has notice in advance, are frequently not reflected in the supplier's software until after such changes take place.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Section ................. Page 20B TWO GENERAL SPECIFICATIONS ......9 20B TWO SYSTEM SPECIFICATIONS ......10 30B THREE GENERAL SPECIFICATIONS ...... 30B THREE SYSTEM SPECIFICATIONS ......13 20BTWO AND 30B THREE ENGINE SERVICE SPECIFICATIONS ......ENGINE OVERHAUL ............
  • Page 5 TABLE OF CONTENTS (CONTINUED) STARTER ................71 ALTERNATOR ..............78 ENGINE TROUBLESHOOTING ........85 MARINE TRANSMISSIONS ..........88 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ......89 SPARE PARTS ..............91 INDEX ................93 Westerbeke Engines...
  • Page 6 T9PEngine Oil 45° Exhaust Elbow G:ear Shift Lever 50 Amp DC Alternator Gea~ As~~mbly Adjustable Engine Battery Ground Connection Isolator ·4 Westerbeke Diesel Engines...
  • Page 7 CaP~ ,FreSh W_ Fill !VI ll'ilake Silenger Zinc I'\mJUt:i~ Fuellnjeciion~. Pump -Gear Dipstick and Oil Filler _~~~~e Engine Isolator Westerbeke Engines...
  • Page 8 Water Fill Cap Ge~r Shift l:,ever :50 Amp ~t~rnator AdJU;;'LQU',\;; :Engine Isolator Starter with Solenoid' DC .Battery Ground Connection Westerbeke Engines...
  • Page 9 . Air Intake Silel'!cer Fuel Injection Pump ThrotHe Shut-Off Connections 20 Amp DC Circuit Zinc Anode Oil Pressure /SW~l! Gear Dipstick and Oil Filler Adjustable Engine Isolator . Lube Oil Fresh Water Block Drain Plug Ho~~~ . Drain Westerbeke Engines...
  • Page 10 The unit 1.0. plate is attached to the exhaust manifold of the engine. These illustrations are provided so that the owner/operator may transcribe the specifications and serial number from the 1.0. plate on the engine to one of the illustrations above. This will allow for easy reference when seeking parts, service or technical needs. Westerbeke Engines...

  • Page 11: Two General Specifications

    20B TWO MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Engine Type Diesel, four-cycle, two-cylinder, fresh water-cooled. Vertical, in-line, overhead valve mechanism (18 hp at 3600 rpm maximum). Governor Mechanical, centrifugal weight type. Combustion Chamber Swirl type. Bore & Stroke 2.99 x 2.76 inches (76 x 70 mm) Piston Displacement 38.75 cubic inches (0.635 liters)

  • Page 12: Two System Specifications

    20B TWO MARINE DIESEL SYSTEM SPECIFICATIONS FUEL SYSTEM General Open flow - totally self-bleeding, manual priming. Fuel No.2 Diesel (cetane # 45 or better). Injector Pump In-line plunger type (Bosch type). Engine Timing 19° ±1° BTDC (spill timing) Static Injector Pressure...
  • Page 13 000 - 100) at full open throttle while underway. API SPECIFICATION OF CF OR CG-4 Lubricating Oil Grade SAE Grade SAE 20W/20 or SAE 30 exclusively. (Do not mix grades of oil or use multigrade oils!) Transmission Sump Capacity 1 qt (1 liter) Westerbeke Engines...

  • Page 14: Three General Specifications

    Temporary 25 (not to exceed 30 min.) Weight 272 Ibs (123.3 kgs) Fuel Consumption 1.0 U.S. gph (3.78 Iph) running at 2500 rpm (propeller allowing rated rpm) (approximate). Idle Speed 1000 -1200 rpm Cruise rpm 2500 - 3000 rpm Westerbeke Engines...

  • Page 15: Three System Specifications

    Raw Water Flow, at 3600 rpm 11.1 U.S. gpm (42 Ipm) approximate. (measured before discharging into exhaust elbow) System Capacity (fresh water) 4 qts (3.8 liters) LUBRICATION SYSTEM General Pressure type by Trochoid pump, gear-driven, with external pressure relief valve. Westerbeke Engines...
  • Page 16 000 - 100) at full open throttle while underway. Lubricating Oil Grade CG-4 API SPECIFICATION OF CF OR SAE Grade SAE 20W/20 or SAE 30 exclusively. (Do not mix grades of oil or use multigrade oils!) 1 qt "(1 liter) Transmission Sump Capacity Westerbeke Engines...

  • Page 17: 20Btwo And 30B Three Engine Service Specifications

    20B TWO AND 30B THREE ENGINE SERVICE SPECIFICATIONS NOTE: All dimensions and specifications contained in this section are given in inches then millimeters unless otherwise stated. For example, 0.002 (0.5 mm). Repair Limit Specified Value/Standard Cylinder Compression Pressure 398.16 psi (at 280 rpm) 355.5 psi...
  • Page 18 (1.0 mm) Valve head sinkage 0.020 (From cylinder head to bottom face) 0.5mm Valve Spring Free length 1.595 1.547 (40.5 mm) (39.3 mm) Preload/installed length 13.095 Ibs/1.398 in (5.94 kg/35.5 mm) 32.716 Ibs/1.1 02 in (14.84 kg/28 mm) Squareness Westerbeke Engines...
  • Page 19 (0 -0.03 mm) Cylindricity Within 0.0004 (0.01 mm) Gasket fitting/surface distortion Within 0.0020 0.004 (0.05 mm) (0.1 mm) Piston Type Solid type Material Aluminum alloy 0.0. (skirt end) 2.992 (76 mm) Clearance to cylinder 0.001 (Service limit) (0.3 mm) Westerbeke Engines...
  • Page 20 (2mm) 0.118 (3mm) Ring side clearance Compression No. 1 No.2 0.002 - 0.004 0.008 (0.05 - 0.09 mm) (0.2 mm) Oil ring 0.001 - 0.003 (0.03 - 0.07 mm) Ring gap 0.006 - 0.016 (0.15 - 0.40 mm) Westerbeke Engines...
  • Page 21 Under size finishing Journal U.S. 0.25 1.6817 - 1.6823 (42.715 - 42.730 mm) 0.50 1.6719 - 1.6724 (42.465 - 42.480 mm) Pin U.S. 0.25 1.5636 - 1.5642 (39.715 - 39.730 mm) 0.50 1.5537 - 1.5543 (39.465 - 39.480 mm) Westerbeke Engines...
  • Page 22 Driving method Gear drive Bearing Ball bearing (front and rear) Major diameter of cam 1.18 (30 mm) Tappet 0.0. 0.75 (19 mm) Tappet to cylinder block clearance 0.006 (Service limit) (0.15 mm) Push Rod Within 0.0118 Bend (0.3 mm) Westerbeke Engines...
  • Page 23 NBI""' ' ' ' , !' ' ' ' ' Dii' mmmwn WhWuj> ENGINE OIL [SRE SPECIFICATION OF ACCORDANCE NOTE: API CG-4 IN WITH THE THERMAL ENVIRONMENT (SEE TABLE). Oil Pressure Relief Valve Oil Pump Spring/Plunger Type Crankshaft Driven Oil Pump and Oil Filter Westerbeke Engines...
  • Page 24 NOTES Westerbeke Engines...

  • Page 25: Engine Overhaul

    PISTON AND CONNECTING ROD ......... 45 CRANKSHAFT ..............50 CYUNDER BLOCK ............54 FUEL INJECTION PUMP ..........56 INJECTION NOZZLE ............59 GOVERNOR SYSTEM ............62 GOVERNOR ..............65 GLOW PLUG ..............66 COOUNG SySTEM ............67 STARTER ................71 ALTERNATOR ..............78 Westerbeke Engines...

  • Page 26: Preparations For Overhaul

    3. Once at the overhaul shop, drain all lubricating oil and coolant from the engine and exchanger system. 4. Clean the engine's exterior of all dirt and oil deposits. ~1\1\'\llllllllllIIIIIHl\iI!I"H'iH::~;H~r 1\I,j' \' 'i";',' " I' . \111.1 :;" ..,,' :.*':: .. " Oil Sump Drain Heat Exchanger Drains Westerbeke Engines...

  • Page 27: Engine Disassembly

    12. Remove the oil pressure switch, the oil pressure sender, and the oil filter. 13. Remove the thermostat housing and the thermostat. 14. Remove the crankshaft pulley from the crankshaft. The basic engine assembly is now ready for disassembly, cleaning, inspection, and repair if necessary. Westerbeke Engines...

  • Page 28: Cylinder Head Construction And Servicing

    1. Cylinder head. 6. Water outlet fitting. 2. Valve guide. 7. Cylinder head gasket. 3. Cylinder head bolt (main bolt). 8. Mouth piece. 4. Cylinder head bolt (sub-bolt). 9. Thermostat. 5. Seat ring (3600 rpm specification engine). 10. Thermostat fitting. Westerbeke Engines...
  • Page 29 When removing each valve retainer, depress the retainer against the valve spring and remove the retainer lock. Identify each valve by putting a mark indicating the number of the cylinder from which the valve is removed. 11. Remove the valve stem seals. Westerbeke Engines...
  • Page 30 2. Install the valve guide by press fitting the guide ' - - from the upper side ofthe cylinder head to a height of 14 ± 0.5 mm from the valve spring seat face. Press·fitting Valve Guide Westerbeke Engines...
  • Page 31 Also, take care not to allow dust to enter the fuel line. Sequence for Tightening Cylinder Head Bolts Westerbeke Engines...

  • Page 32: Valves And Valve Springs

    VALVES AND VALVE SPRINGS ~=---':~' ~--(2) ..----@ VALVE SYSTEM COMPONENT PARTS 1. Valve stem cap. 4. Valve stem seal. 2. Retainer lock. 5. Valve spring. 3. Valve spring retainer. 6. Valve. Westerbeke Engines...
  • Page 33 I - - - - - R i d g e and damage Margin Inspection of Valve and Valve Spring Valve fatigue and damage valve spring te5ter Inspection item Standard Service limit 40.5 Free length (Dim) 5.94/35.5 -15% Load (kg/ mm) Squareness Margin (mm) Westerbeke Engines...
  • Page 34 Be careful not to damage the spring and stem seal by excessively compressing the spring when installing the valve spring. With retainer depressed to compress spring. install retainer lock. Press this surface Driving in Installing spring Installing spring retainer stem seal Installation of Valve Spring Westerbeke Engines...

  • Page 35: Valve Clearance Adjustment

    Three Cylinder Engine From the T.O.C. for the No. 1 cylinder, turn the crankshaft 240° clockwise to set the No.3 cylinder T.O.C. Further, turn the crankshaft 240° clockwise, and the No. 2 cylinder is set to T.O.C. Injection Timing Mark Westerbeke Engines...

  • Page 36: Gear Case And Oil Pump

    9. Oil pump housing. 2. Plug. 6. Relief spring. 10. Gear case gasket. 3. Gear case. 7. Oil pump inner gear. 11. High-pressure pump gear housing. 4. Front oil seal. 8. Oil pump outer gear. 12. Housing gasket. Westerbeke Engines...
  • Page 37 Check the removed parts. If any parts are found defective, repair or replace them. Cracks and damage Wear and damage © r[J) [(({W f7lr\ Wear, damage, and clearance f",~ S,rio, Thoroughly clean oil line. Smooth movement Seal surface interference Inspection of Gear Case and Oil Pump Westerbeke Engines...
  • Page 38 Governor System Inspection Check springs for fatigue. Check the governor system parts. If any parts are found defective, repair or replace them. Check shaft for flaws. Check sliding sleeve joint for wear and damage. Check weight for wear and damage. Westerbeke Engines...
  • Page 39 After installing the shaft, press-fit the expansion plug into the shaft hole in the gear case. Gear Case Installation Tightening torque O.8-1.0kg.m Tightening torque: 4-5kg.m Taper plug tightening torque: 1.5-2.2kg.m Sealant: HERMESEA H1 or THREE-BOND 1344 Gear Case Assembly Westerbeke Engines...

  • Page 40: Timing Gears

    TIMING GEARS "'4 TIMING GEAR COMPONENT PARTS 1. Crankshaft gear. 3. Camshaft gear. 2. Idle gear. 4. Injection pump camshaft gear. Westerbeke Engines...
  • Page 41 Service limit Description Clearance between bush· 0.03 - 0.07 ing and shaft Backlash between gears in mesh Description Standard value Service limit Crankshaft-Idle Idle-Camshaft 0.01 - 0.14 Idle-Fuel pump Gear Valve camshaft gear Crankshaft gear Inspecting Timing Gears Westerbeke Engines...
  • Page 42 Install the valve camshaft and injection pump camshaft. c. Install the idle gear so that timing marks on it are in alignment with marks on the other gears. d. Confirm that timing gears are in alignment with each other. Westerbeke Engines...

  • Page 43: Camshafts (Valve And Pump)

    CAMSHAFT COMPONENT PARTS 8. Tappet. 1. Camshaft (valve). 9. Push rod. 2. Camshaft gear. 3. Ball bearing. 10. camshaft (injection pump). 11. camshaft gear. 4. Woodruff key. 12. Ball bearing (rear). 5. Sunk key. 6. Camshaft stopper. 13. Snap ring. Westerbeke Engines...
  • Page 44 Disconnect the injector lines. b. Remove the injection pump assembly. c. Remove the gear case assembly. d. Remove the shaft rear cover. e. Remove the stopper bolt. f. Remove the shaft from the front of the engine. Westerbeke Engines...
  • Page 45 Cam contact surface-Wear and damage Cam lobe-Wear and damage Oldham's coupling-Wear Inspection of Camshafts Major diameter of injection pump cam Major diameter of valve cam 27.37 Standard value Standard value -0.7 Service limit Service limit -1.0 Westerbeke Engines...
  • Page 46 2. Install the camshafts in the reverse order of removal. 3. Position the timing marks on the gears in alignment with the marks on the idler gear. 4. After installation, check and adjust fuel injection Timing Gears in Alignment with Each Other timing and valve clearances. Westerbeke Engines...

  • Page 47: Piston And Connecting Rod

    PISTON AND CONNECTING ROD COMPONENT PARTS 1. Piston ring No.1. 5. Piston pin. 8. Connecting rod cap. 2. Piston ring No.2. 6. Connecting rod. 9. Connecting rod bolt. 3. Oil ring. 7. Connecting rod bearing. 10. Connecting rod nut. 4. Piston. Westerbeke Engines...
  • Page 48 • Contact and seizure - - - - - ~ Standard:O.07-0.115mm • Flaking and fusion • Wear of p,ston ring grooves • Oil clearance Standard: O.022-0.052mm -------V Damage and wear ® ___ - - Damage Inspection of Piston and Connecting Rod Westerbeke Engines...
  • Page 49 1. Reassemble the piston and connecting rod, using the Piston Pin Setting Tool, by pressing the piston pin in to the set position. FRONT mark (arrow) Piston Description Standard Pin press·fitting force 1000±500kg (at a normal temperature) Installation of Piston and Connecting Rod Westerbeke Engines...
  • Page 50 OS size mark --.------~ Rod front mark OS size identification paint Align notches - accurately with each other. Color of discrimination STO =Without color O.25=White O.50=Blue Tightening torque: ____ {O"\ 3.2-3.5kg.m Installation of Piston Rings and Connecting Rod Cap Westerbeke Engines...
  • Page 51 Connecting position the notches (provided for preventing the bearing from rotating) on the same side. ~cap ® Westerbeke Engines...

  • Page 52: Crankshaft

    CRANKSHAFT COMPONENT PARTS 11. Rear oil seal case. 1. Key. 6. Washer. 2. Crankshaft. 7. Spring washer. 12. Gasket. 3. Crankshaft gear. 8. Flywheel. 13. Flywheel bolt. 4. Crankshaft pulley. 9. Ring gear. 10. Rear oil seal. 5. Nut. Westerbeke Engines...
  • Page 53 Inspect the removed parts. If any parts are found defective, repair or replace them. • Journals and pins- Damage and uneven wear • Cracks. clogging of oil hole, and bend • Wear of journal contact surface Wobble Damaged to tooth face Wear and damage Inspection of Crankshaft and Flywheel Westerbeke Engines...
  • Page 54 A crankshaft which has been sized cannot be reground to any under size. (kgm) (mm) Tightening torque Oil clearance Description Standard Description Service limit Main bearing cap bolt Main bearing 0.10 5.0""'5.5 Rod bearing cap nut Rod bearing 3.2""'3.5 O. 15 Westerbeke Engines...
  • Page 55 , 7-' O NO "' " with sealant Direction of installation of cap -\ 9 Front Round end down Make cap flush with cylinder block end face (common to front and rear end faces) Crankshaft end play: 0.05-0.175 Installation of Crankshaft Westerbeke Engines...

  • Page 56: Cylinder Block

    9. Idler gear shaft. 1. Cylinder block. 5. Main bearing. 10. Oil filter shaft. 6. Starter bracket. 2. Front plate. 11. Oil level gauge guide. 3. Bearing cap. 7. Rear oil seal. 4. Cover. 8. Oil seal case. Westerbeke Engines...
  • Page 57 Clearance (between piston and cylinder) Standard: 0.071 - 0.084 mm (A-D) Measuring Piston Diameter CAUTION When it is necessary for a cylinder to be rebored to the next over size, the remainders must also be rebored to the same over size. Westerbeke Engines...

  • Page 58: Fuel Injection Pump

    3. Delivery valve holder. 10. Seat valve. 17. Adjusting shim. 4. Valve spring. 11. Plunger barrel. 18. Tappet roller. 5. Holder stopper. 12. Sleeve. 19. Pin. 6. Housing. 13. Upper seat. 20. Control rack. 7. O-ring. 14. Plunger spring. 21. Stop wire bracket. Westerbeke Engines...
  • Page 59 © fj-- should kept classified by cylinders and im- Wear and scratch mersed in clean fuel. Control rack-- movement Plunger-Interference (Catching) 11" wear, scratch, Injection Pump Inspection rust, seizure ® Interference, , ri?Jc:::::, wear Inspection of Injection Pump Westerbeke Engines...
  • Page 60 Position the plunger so that the part number stamp on its flange faces the direction opposite to the rack side. (Engage the feed hole Rack side with the plunger lead.) After installation, check for proper injection timing. Direction of Installation of Plunger Westerbeke Engines...

  • Page 61: Injection Nozzle

    INJECTION NOZZLE @:_-- <9 NOZZLE HOLDER ASSEMBLY COMPONENT PARTS 1. Body subassembly. 5. Distance piece. 2. Shim washer. 6. Nozzle assembly. 3. Pressure spring. 7. Retaining nut. 4. Pin. Westerbeke Engines...
  • Page 62 3. Tighten the nozzle holder body fully by hand. Poor contact and break While immersed 4. Grip the nozzle holder in a vise. Tighten the retain- in kerosene. check for smooth ing nut to the specified torque. sliding. Tightening torque: 3.5 - 4.0 kgm Inspecting Nozzle Westerbeke Engines...
  • Page 63 1. Clean the nozzle holder fitting surface of the cylinder head. Install the nozzle holder with a gasket interposed. Tightening torque: 5.0 - 6.0 kgm 2. Connect the fuel return pipe and injection pipe. Tightening torque: Injection pipe 2.5 -3.5 kgm Fuel return pipe 2.5 -3.0 kgm Westerbeke Engines...

  • Page 64: Governor System

    26. Grooved pin (3 x 14). 6. Stopper 17. Speed control lever assembly. 27. Torque spring test. 7. Governor spring. 18. Cover assembly. 28. Sealing cap. 8. Governor shaft. 19. Governor cover gasket. 9. Governor lever. 20. Return spring. 10. Tie-rod. Westerbeke Engines...
  • Page 65 4. Install the torque spring set sealing cap and stake the cap to prevent loosening. Number of loosening turns (N) 20B Two & 30B Three Torque spring set Torque Spring Set Assembly 2. Spring 1. Spring . tr...
  • Page 66 If any parts are found defective, replace them. CAUTION If the governor is assumed to be malfunctioning, check the bearing on the gear case side, too. Westerbeke Engines...

  • Page 67: Governor

    No deflection exceeding 20 mm is permitted for the governor spring installed. Install the governor spring lever and speed control lever so that the play of angle between levers (standard: 5°) is minimized. 5' (Standard) No play exceeding 5' permitted Instaling Speed Control Lever Westerbeke Engines...

  • Page 68: Glow Plug

    Glow Plug Inspection Check for conduction between the glow plug terminal and body. Ifthe plug is not conductive at all or shows a large resistance, replace the plug. Glow plug tightening torque: 1.5 - 2.0 kgm. Checking Glow Plug Westerbeke Engines...

  • Page 69: Cooling System

    COOLING SYSTEM Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw waterflow through their independent cooling circuits. Refer to your generator's Parts List for part numbers and part descriptions if you need to order cooling system parts for your engine.
  • Page 70 Install the impeller by positioning the hub pin to align with the slot in the drive shaft. Move the blades to conform to the curved cam plate and push the impeller into the pump's housing. Westerbeke Engines...
  • Page 71 (ref 14) out. Then, push the bearing side seal out that side. g. Supporting the bearings inner face (ref 2), push the shaft (ref 8) out of the bearings. NOTE: Inspect all parts and replace those showing wear or corrosion. Westerbeke Engines...
  • Page 72 9 and 10). Push the assembly into the housing with the drive screw mating in the slot of the drive shaft. f. Install the cover gasket (ref 11), cover (ref 12), and secure them with the six cover screws (ref 13). Westerbeke Engines...

  • Page 73: Starter

    6. Through bolt. 11. Gear. 2. Lever assembly. 7. Armature. 12. Yoke assembly. 3. Spring set. 8. Rear bearing. 13. Brush holder assembly. 4. Center bracket assembly. 9. Pinion. 14. Rear bracket. 5. Switch assembly. 10. Pinion shaft assembly. Westerbeke Engines...
  • Page 74 Use thick wires as much as possible and tighten every terminal securely. This is a solenoid shift type starter which makes a rotating sound larger than that of a direct-drive type starter. When detecting starter rotation at the pinion tip, take care of protrusion of the pinion. Westerbeke Engines...
  • Page 75 "M" and to the starter body, manually pull out the pinion fully. The pinion must return to its original position when released from holding by Starter hand. CAUTION Return Test Do not apply battery current for more than 1 0 seconds. Westerbeke Engines...
  • Page 76 9. At each end of the armature, remove the ball bearing with a bearing puller. It is impossible to replace the ball bearing press-fitted in the front bracket. If that bearing has worn off, replace the front bracket assembly. Westerbeke Engines...
  • Page 77 S and M and between terminals S and body. There should be a low resistance found 1 - 2 ohms. If no resistance is found the circuit is open. The solenoid should be replaced. Checking Magnetic Switch Westerbeke Engines...
  • Page 78 O.5mm maximum - - f l .. - - a. Fit the pinion shaft, reduction gear washer and snap ring to the center bracket. Adjusting Pinion Shaft End Play Westerbeke Engines...
  • Page 79 1. Armature shaft gear and reduction gear. 2. All bearings. 3. Bearing shaft washers and snap rings. 4. Bearing sleeves. 5. Pinion. 6. Sliding portion of lever. CAUTION Never smear the starter fitting surface, terminals, brushes, or commutator with grease. Westerbeke Engines...

  • Page 80: Alternator

    ALTERNATOR ALTERNATOR COMPONENT PARTS 5. Rear bearing. 9. Rectifier assembly. 1. Pulley. 2. Front bracket assembly. 6. Stator. 10. Rear bracket assembly. 11. Condenser assembly. 3. Front bearing. 7. Terminal set. 8. Regulator assembly. 4. Rotor assembly. Westerbeke Engines...
  • Page 81 3. Output inspection. a. Disconnect the grounding cable from the battery. b. Interpose an ammeter between the battery and alternator terminal "B." Ground the terminal"B" through a voltmeter. c. Connect the battery grounding cable. d. Start the engine. Westerbeke Engines...
  • Page 82 Se careful not to insert the blade too deep. 3. Grip the rotor in a vise, remove the pulley nut, and pull out the pulley, fan, and spacer. 4. Pull out the rotor assembly from the front bracket. Westerbeke Engines...
  • Page 83 If there is equal resistance in both directions, the diode is suspected to be defective. Replace the rectifier assembly. c. Check every diode for conduction. Westerbeke Engines...
  • Page 84 Checking Stator Coil for Conduction b. Check for conduction between each lead wire and stator core. If any conduction is found, the stator coil is suspected to be poor in insulation. Replace the stator coil. Checking Stator Coil for Insulation Westerbeke Engines...
  • Page 85 (Leave the nuts removed from the bolts.) b. Push the alternator backward. Measure the clearance between the alternator rear bracket and gear case bracket to determine the number of spacers to be inserted into the clearance (0.2 mm maximum). Westerbeke Engines...
  • Page 86 NOTES Westerbeke Engines...

  • Page 87: Engine Troubleshooting

    Check for low batteries or voltage loss in small electrical wiring or corroded connections. 3. Shut off lever. 3. Check that shut off lever is returned to the run position. Westerbeke Engines...
  • Page 88 6. Check 12 volts present at (optional). solenoid. Failure to stop. 1. Fuel solenoid faulty 1. Stop engine by man- (optional). ually shutting off fuel and air. 2. Cable not operating shut 2. Shut off cable. off lever. Westerbeke Engines...
  • Page 89 2. Check fuel filters. Make sure incorrect fuel. you are using #2 diesel fuel. 3. Faulty injector(s). 3. Remove and test injectors. 4. Lack of air. 4. Check air intake for restrictions. Make sure adequate combustion air is present. Westerbeke Engines...

  • Page 90: Marine Transmissions

    MARINE TRANSMISSIONS JSGear The standard transmission on the 20B Two and 30B Three is the JS Gear. Contact Westerbeke Corpora- tion factory for overhaul information. HURTH MARINE GEAR ZF INDUSTRIES MARINE US HEADQUARTERS 3131 SW 42ND STREET FORT LAUDERDALE, FL 33312 TEL.

  • Page 91: Table Ofstandard Hardware Tightening Torques

    3.7 - 4.6 3/8 UNF 30 - 35 4.1 - 4.8 7/16 UNC 44- 49 6.1 - 6.8 7/16 UNF 50 - 55 6.9 - 7.6 1/2 UNC 68 - 73 9.4 -10.1 1/2 UNF 73 - 80 10.1 -11.1 Westerbeke Engines...
  • Page 92 Designation of screw thread 1.0- 1.3 0.3---0.5 " 0.8-- 1.0 1.0-1.3 1.5-- 2.2 2.5- 3.5 1.8-2.5 3.0--- 4.2 5.0 ..7.0 '9.5--12.0 3.0,,:,",4.2 5.5- 7.5 5.0--7.0 8. O- 11.0 16.0-19.0 NOTE: M8 indicates Metric. 8 mm thread diameter Westerbeke Engines...

  • Page 93: Spare Parts

    From the list provided directly above and from these inquiries, you can determine what spare parts may be needed. In addition, if you are planning a long ocean voyage, consult your local Westerbeke dealer for a listing of the Westerbeke dealers located on your route.
  • Page 94 NOTES Westerbeke Engines...

  • Page 95: Index

    Connecting Rod Bearing ..........................19 COOLING SySTEM ............................. 67 CRANKSHAFT ............................. 19 & Crankshaft Inspection ..........................51 Crankshaft Rear Oil Seal Replacement ...................... 53 Crankshaft Removal ..........................: ..51 CYLINDER BLOCK ..........................17 & Cylinder Block Inspection ........................... 55 Westerbeke Engines...
  • Page 96 Cylinder Reboring ............................Difference Between Cylinders (maximum) ............... '" ....... 15 ENGINE DISASSEMBL Y ..........................25 ENGINE OVERHAUL ........................... ENGINE SERVICE SPECIFICATIONS, 20B TWO & 30B THREE ............... 15 ENGINE TROUBLESHOOTING ........................85 Fresh Water Pump Drive Belt Tension ......................68 Front Oil Seal Replacement.
  • Page 97 Piston Rings ..............................18 PREPARATIONS FOR OVERHAUL ......................24 Push Rod ..............................20 Raw Water Pump ............................68 Raw Water Pump OverhauL ............'" ............69 Removal of External Parts and Subassemblies ..................25 Rocker Arm ........................, ......17 Westerbeke Engines...
  • Page 98 Starter Adjustment and Assembly ....•....................76 Starter Adjustment and Repair ........................72 Starter Disassembly ............................. 74 Starter Inspection ............................75 SYSTEM SPECIFICATIONS, 20B TWO ...................... 10 SYSTEM SPECIFICATIONS, 30B THREE ....................13 TABLE OF CONTENTS ..........................2 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ..............89 Tappet ....•.•............................
  • Page 99 NOTES Westerbeke Engines...

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