Related Manuals for Westerbeke 20B TWO/30B THREE
Summary of Contents for Westerbeke 20B TWO/30B THREE
- Page 1 '( I .,p'fl' OPERATORS MAR E DIESEL E INES 20B TWO I 30B THREE ~lK)HNO~ EDITION FOUR J\N!2000...
- Page 3 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INmODUCTION Read this safety manual carefuUy. Most accidents are coused by failure follow fwuIomentol rules precau- WARNING: Fire can cause Injuty or death! tions. Know when dangerous conditWns exist and take the necessary precautions to protect yourself, your personne~ •...
- Page 4 SAFETY INSTRUCTIONS ACCIDENTAL STARIlNG TOXIC EXHAUST GASES WARNING: Al:l:ldental starling can cause Injury WARNING: carbon monoxide (CO) Is deadly gas! IiIIaIbJ • Ensure that the exhaust system is adequate to expel gases • Disconnect battery cables before servicing the engine! discharged from the engine.
- Page 5 USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-I Exhaust systems P-4 Inboard engines E-9 DC Electrical systems All installations must comply with the Federal Code of Regulations (FCR). WESTERBEKE Engines & Generators...
- Page 6 A detailed 40 page Marine Installation Manual covering gaSOline and diesel, engines and generators, Is available from your WESTERBEKE "~IWESTERBEKE Engines & Generators...
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Page 7: Table Of Contents
TABLE OF CONTENTS JS TransmissiDn ..•........... Paris IdentificatiDn ..........Lubrication ............41 Product SDftware ........... Controls ............42 PreparatiDns fDr Starting ........Shifting ............43 Engine CDntrDI Panels ......... S T O ' aI!fig peral10n ..........43 Starting PrDcedure ..........Service ............ - Page 8 PARTS IDENTIFICATION RIGHT SIDE .ft. ___ Fill COOLANT PRESSURE \~~~~~~~~~~=:;::SIDE ~;;P'---_OIl Oil Fill DIPSTICK FRONT FIlTER AMP CIRCUIT BREAKER LEFT SIDE .'LO".«'--... AIR INTAKE PLATE 1.0. THERMOSTAT ASSEMBLY \ - - - HEAT EXCHANGER - - I DC AlTERNATOR REAR 'STAIRTER MOTOR Oil DRAIN FRONT...
- Page 9 It not only makes good sense, but is imperative that appropriate representatives of Westerbeke or the sup- plier in question be consulted to determine the accuracy and currency of the product software being con- sulted by the customer.
- Page 10 Westerbeke engines are thoroughly checked and given a final run under various load conditions before leaving the factory. This is done to ensure dependable operation, long service, and a satisfied owner.
- Page 11 FOREWORD Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have you as a customer. Read this manual carefully and observe all safety precautions included throughout. Operating procedures, periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust- ment procedures are included herein so you can operate your equipment safely and properly, maintain the equipment at a high level of efficiency, and expect dependable perfonmance and long service life in return.
- Page 12 These illustrations are provided so the OINI1e/'/operator may transcribe the specifications and serial number from the I.D. plate on the that engine to one Hlustrations above. This will allow for easy reference when seeking parts, service or technical needs. WESTERBEKE Engines & Generators...
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Page 13: Preparatidns Fdr Starting
This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and stopping procedures. Follow the procedures as presented, for the conditions indicated, and will your Westerbeke engine set give you reliable performance and long service life. Fill your engine with oil up to or near the upper limit on the dipstick (the installation angle may have an effect on the dipstick reading). - Page 14 Description of Starting System All Westerbeke diesel engines use electric starters assisted by glow plugs for both normal cold weather starting. The figure belaN shows a cross-sectional view of one cylinder. The glow plug is located in the c0m- bustion chamber so...
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Page 15: Engine Cdntrdi Panels
ENGINE CONTROL PANELS WesteJbeke offers two types of control panels as optional equipment. Read the following instructions that apply to the panel you purchased with your engine. GENERAL is equipped with a Key Switch; an RPM gauge; PREHEAT and This manually-operated contro)' pauel three START buttons;... - Page 16 OFF. The oil pressure gauge will fall to zero when the gauge before electrical Switch is turned OFF. temperature gauge will once again register the engine's true temperature once elec:trical power the gauge. restored WESTERBEKE Engines & Generators...
- Page 17 In addition, this button energizes the START button. SIABI: The START button, when pressed, energizes the starter's solenoid which cranks the engine. This button will not operate electrically unless the PREHEAT button is pressed and held at the same time. WESTERBEKE Engines & Generators...
- Page 18 The buzzer will sound when the ignition key is turned ON and should sHenee when the engine has started and when the engine's oil pressure rises above 15 psi. WESTERBEKE 'Wo¥: Engines & Generators...
- Page 19 STARnNG PROCEDURE Place the transmission in the NEUTRAL position and advance the throttle to its full open position for a cold engine. and partially open for a warm engine. Tum the Key Switch to the ON position (2 o'clock); prime engine's fuel system at mechanical fuel fuel...
- Page 20 Key Switch OFF which tums OFF an electrically run Fuel Run Solenoid. This electrical shut off option is in- stalled at the factory upon the specific request/order of the owner.) THROTTLE CO.TRll LEVEl P.SITIOIlFi..-'l~_-;::=C;~~~ SJOP ••• POSInOIl STOP tunol LEVEl "'" WESTERBEKE Engines & Generators...
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Page 21: Engine Break-In Prdcedure
5O-hour break-in period. (Don't baby the not abuse engine, it). WESTERBEKE Engines & Generators... -
Page 22: Starting Under Ndrmal Cdnditidns
RISE ENOUGH - AIIowthe rJow plugs operate sulliclentlyto starting during preheat period when- aid in fINer temperature the intake air low and when the compression temperature does rise enough. Reterto chart in the "STARTING PROCEDURE" section, the preheat found WESTERBEKE Engines & Generators... -
Page 23: Fuel System
In can cause - fuel which warrantable through Westerbeke. typical fuel filter/Water separator IIUSIrated This In this diagram. Raycor SOOMA. In mind Model that if separator type... -
Page 24: Priming The Fuel System
Engine damage resuHing from this type of sea water entry is not a warrantable issue; the owner/operator should keep this in mind. -.v: WESTERBEKE Westerbeke Diesel Engines Engines & Generators... - Page 25 The illustration that follows is an exploded view of the 20B TWO's fuel system. This system is similar to the 30B THREE's fuel system in that it has only one less fuel injector and one less pumping element in the injector pump. WESTERBEKE ...v' Engines & Generators...
- Page 26 The Westerbeke fuel system bleed Is manual In operation. WhOe Is unlikely that the operator will be forced service system at sea, the possibDity does exist Therefore. we recommended that a replacement fuel be carried filter on board at all times.
- Page 27 Idle speed and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump. Other types of adjustments or repairs must be performed by a qualified injection service shop . ., IIC (+) CozmecUo,. Pump Ground Wire r""<:--Engine Mounted Fuel Filter . . . WESTERBEKE Engines & Generators...
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Page 28: Electrical System
ELECTRICAl SYSTEM Engine 12-Volt DC Control Circuit The Westerbeke modles 20B TWO and 30B THREE propulsion engines each have a 12-Volt DC elec- trical control circu~, as shown on the wiring diagrams which follOW. Refer to these diagrams when trou- bleshooting or servicing electrical components on the engine. - Page 29 Illustrated below is a wiring harness for the 30B THREE's electrical system. The wiring hamess for the 20B TWO's electrical system differs only in that it has one less glow plug terminal. Optional Fuel Run Solenoid WESTERBEKE Engines Generators &...
- Page 30 The charging system consists of an alternator with an internal voltage regulator, an engine-mounted circuit breaker, a battery and connecting wires. Because of the use of IC's (integrated circuits), the eleCtronic voltage regulator is very compact and built into the rear bracket of the alternator. Charging Voltage Test you suspect that the alternator is not producing enough voltage to charge...
- Page 31 ; LA"'P ..sw",. ",ST - II ..c> • I ~L w~<ir ~~ i •. i ",,,woe. ~,""T TII,IoIOM(T[1: i J !. i-..ao, , . . . s .. "..·1tI ... "I!!!!._ " ~------------------------------~ I"""WESTERBEKE , Engines & Generators...
- Page 32 WITH A RA1IHG Of" I7SAMPS AT IZvoe Wlt.1..SERVE TttIS FUNCTION. THIS SWITCH 5HCIULO NOT 8E USUI TO MAKE CoR 8REAIt THE OACUIT. z rs 1 ..WlIi;E liZ JII,UG """,5£,. SOIOUI.D 8E INSUL.ATEO. ,..'WESTERBEKE Engines & Generators...
- Page 33 -----. -. -II "'/~ L...!=:::'I-h\~ ~'''''''_~ ADMIRAl PANEL. '>-C!!!~;...' -/TACHOMETER START PREHEAT ~WlTCH swrTCH ~"OaA {~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J WESTERBEKE Engines & Generators...
- Page 34 A CONllNUOUS RATING OF 175 AMPS AT 12 VOLTS DC WILL SERVE THIS FUNCTION. THIS SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT. 3. THE GRAY WIRE AT PLUG #215 UNUSED AND SHOULD BE INSULATED. WESTERBEKE Engines &...
- Page 35 DC ELECTRICAL SYSTEM WIRING DIAGRAM ##39144 This diagram illustrates the 12 VDC negative ground electrical circuiL Two optional instrument panels are also shown: the Captains Panel and the Admirals Panel. r-----P1~~ '~" NOTE: AN ON-OFF SWITCH IOCIT( ' : • SHOULD BE IN- •...
- Page 36 51 AMp OPTIONAl AI TfRNAIQRS@ UIA. I ..<lItt ••• " ..01 • !"'n ""'na'!' .." ..'fMa ' K " '('ry ' " I I WESTERBEKE -..v' Engines & Generators...
- Page 37 COOUNG SYSTEM Description Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water which circulates throughout the engine. This circulating fresh water cools the engine block and Its internal moving parts.
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Page 38: Cooling System
100 F (50 C) lower than the actual atmospheric temperature expected. water the Fresh System Filing A coolant recmery tank kit Is supplied with each Westerbeke diesel engine. The purpose of this recovery tank is allow for engine coolant and contraction, during engine operation, without the loss of... -
Page 39: Thermostat
Since 1980, each type of thermostat has a hole punched through The hole is a bypass to prevent the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have this design characteristic..v- WESTERBEKE Engines & Generators... -
Page 40: Sea Water Circuit
Sea Water Circuit sea water flow is created a gear-clriven, positive displacement, neoprene Impeller pump. pump draws sea waterdirectlyfromthe ocean through the sea and sea water strainer and cock passes the water to the heat exchanger's sea inlet. The sea water passes through the heat water... - Page 41 The illustration below shows the cooling system components for the 306 THREE engine. The 206 TWO's cooling system is much the same. Refer to the Parts Ust for each component's name and part number. Cooling System Components, Exploded View WESTERBEKE Engines & Generators...
- Page 42 WESTERBEKE Engines & GeneratolS...
- Page 43 RIR BLEED PETCOCl HERTER BELOW EN&INE The illustrations shown above are Row Control deSigns that have been adapted to operate with the single pass manifolds installed on the 206 TWO and the 306 THREE engines. WESTERBEKE -.¥" Engines & Generators...
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Page 44: Lubricating System
LUBRICATION SYSTEM Engine Oil For engine lubrication, use lubricating oil designated for diesel service. These oils are classified according to the API specifications into service grades CF and CG-4. The use of CF or higher (CG-4) grades, made by well-known manufactures is recommended. The oil selected should be used thereafter. -
Page 45: Engine Oil Change
"'" WESTERBEKE Engines & Generators... - Page 46 Fill to, but not cover, the high mark on the dipstick, should the engine require additional oil. Oil Dipstick lower Crankcase -..v: WESTERBEKE Engines & Generators...
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Page 47: Js Transmissidn
JS TRANSMISSION General The transmission's gear ratio is 2.47 to 1. The JS transmission is made of a lightweight. l:Iigh-strength, cor- rosion-resistant aluminum alloy suitable for the marine environment. This manual transmission rotates op- pos~e transm~s ~ to the engine when in forward gear. The JS power case-hardened helical gears and, in reverse, an intermediate gear. -
Page 48: Controls
Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious problems. Make sure the alignment procedures outlined in the "Propeller Shaft Coupling", the "propeller" and the "Alignment of the Engine" in the Westerbeke installation manual are adhered to. Controls... -
Page 49: Shifting
Disassembly of the transmission in the field is not recommended. If an overhaul or repair is needed, the shc:iuId WOI1< be done by Westerbeke or an authorized Westerbeke service center. Cooling The JS transmission is sea water-cooled. Sea water enters the transmission through a stainless steel inlet pipe located at the base of the bell housing. -
Page 50: Prm Newage Transmissidn
PRM NEWAGE TRANSMISSIONS THE MODEL 120 HAS A BREATHER FITTING ON THE TOP OF THE CASE MODELS 80 AND 120 NUA4BEI~' Push a suction pump hose down through the dipstick hole . SERIAL --DIF'STIl:K 112· HEX PLUG to the bottom of the housing and suck out the oil. (If space MODEL 80 (MODEL 120 USES allows, use the transmission drain). -
Page 51: Control Cables
(Model 120) WESTERBEKE dealer. MAINTENANCE/SERVICE If a major problem should occur, contact your WESTERBEKE dealer or a NEWAGE distributor. To avoid prejudicing warranty Make certain the transmission oil is changed annUally. rights, do not undertake repair work on the gearbox without... -
Page 52: Optional Transmissidns
5. Over travel of the actuating lever does no harm, However, - j , - if the travel is too short to give full engagement, premature o.s "'''' wear, excessive heat generation and gear failure may result. Control of Gearbox Westerbeke Diesel Engines WESTERBEKE Engines & Generators... - Page 53 6. The position of the cover plate underneath the ad»aIing 1ever is factory to ensure lever travel adjusted from to A and B. DO NOT LOOSEN TIm CAP neutraI SCREWS HOLDING ASSEMBLY. Doing this voids transmission warranty. 7. Fill with automatic trnn9DiS<:ion fluid to gearbox the lew! indiratrd by the dipstick mark.
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Page 54: Engine Troubleshddting
2. Check for 12 volts at the tripped 10 Amp breaker 10 Amp breaker. Check on the I terminal on the for 12 volts at the R terminal preheat solenoid. on the alternator when the the preheat button is pushed. WESTERBEKE Engines & Generators... - Page 55 pmblem probable Cause YerjfjcatignlBemedy START switch 1. Connection to 1. Check connection S pressed: no starter solenoid faulty. starter solenoid for 12 volts engagement. with the switch depressed. 2. Faulty START switch. 2. Check switch with an ohmmeter. 3. Faulty solenoid. 3.
- Page 56 Make an output check a voltmeter the B with terminal on the alternator. 2. Fajjty alternator. 2. Voltage leak through the alternator when operating. Bad battery 3. Connections are corroded connectlons. or loose at the battery or/and the engine. ''''''''WESTERBEKE Engines & Generators...
- Page 57 Hours of Operation After 1. Change the engine's lubrication oU and on filter. 2. Replace the fuel filter element in the on-engine filter and in the optional water/sediment separator, if a separator has been installed..v: WESTERBEKE Engines Generators &...
- Page 58 "3. Torque the cylinder head hold-down bolts. *4. Adjust clearances. valve 5. Adjust the aJtemator and water pump drive belt tension, required. LiIbricate the throttle, RUN linkage cable, and the transmission's remote control cable. 7. Change the transmission's transmission lubricant. 8.
- Page 59 NOTE: Operating in and/or tropical waters may require that a heat exchanger cleaning silty more often than ~ery 1000 hours. performed *2. Check the injection pump's timing . WESTERBEKE ..-v' Engines & Generators...
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Page 60: Cylinder Head Bolt Tightening
Rocker shaft hold-down All Main bolts are 14 mm across the bolt head lIats. All Sub bolts are 12 mm across the bolt head lIats. Rocker shaft hold-down bolts are 12 mm across the bolt head lIats WESTERBEKE Engines & Generators... -
Page 61: Adjustment Df Valve Clearances
No.3 cylinder. Rotate the crankshaft an additional 240° clockwise to position the No.2 cylinder at TDC. Adjust the valve clearances for both intake and exhaust valves for the No.2 cylinder. WESTERBEKE -..yo Engines & Generators... -
Page 62: Injectidn Pump Timing Adjustment
DELIVERY VRLVE HOLDER SPRING DELIVERY VALVE -=:::"":l:7Ttl B R R R EL :ni>-":"-'-"7.:~- CO" T R 0 L R A C I CONTROL PINION PLUNGER SPRING Cutaway View of the 30B THREE's Fuel Injection Pump WESTERBEKE "WIV' Engines & Generators... - Page 63 Adjust injection timing adding or removing from pump: shim thickness under the injection mm of shim thickness is equivalent to ap- proximately 1 change injection timing. addition of shim thickness retards timing. whereas the removal 01 shim advances thickness timing. Marks Injection Timing Engines &...
- Page 64 LAY-UP RECOMMISSIONING & Fuel System [Gasoline] Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with gasoline of 89 octane unleaded of higher. A fuel conditioner such as STABIL gasoline including engines and generators, for lay-up during the off- season or for long of inactivity.
- Page 65 Lay-up time provides a good opportunity to inspect your able, if access to the starter permits its easy removal. Make WESTERBEKE engine to see if external items such as drive sure the battery connections are shut off before attempting to belts or coolant hoses need replacement.
- Page 66 W 20B TWO MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Type Engine Diesel, four-cycle, two-cylinder, fresh water-cooled, vertical, in-line (18 hp at 3600 rpm maximum) Governor Mechanical, centrifugal weight'type Valve Mechanism Overhead Swirl chamber type Combustion Chamber Bore & Stroke 2.99 2.76 inches (76 70 mm) Piston Displacement 38.75 cubic inches (0.635 liters)
- Page 67 11.1 U.S. gpm (42Ipm) approximate. Row, 3600 (measured before discharging into exhaust elbow) System Capacity (fresh water) 2.9 qts (2.7 liters) LUBRICATION SYSTEM Pressure type by TrOChoid pump, General gear-driven, with external pressure relief valve. I~/WESTERBEKE Engines Generators & Westerbeke Engines...
- Page 68 W 208 TWO SYSTEM SPECIFICATIONS Operating OD Pressure 15.0 - 45.0 psi (1.0 - 3.1 kg/cm (engine hot) Grade API specification of CF or CG-4 Sump Capacity (including fmer) 3.0 U.S. qts. (2.8 liters) ELECTRICAL SYSTEM StartIng Battery 12-VoIt; 35 A-H, (-) negative ground (recommended) (45 A-H cold areas) Battery Capacity...
- Page 69 W 30B Tl-IREE MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Engine Type· Diesel, four-cycle, three-cylinder, fresh water-cooled, vertical, in-line (27 hp at 3600 rpm maximum) Mechanical, centrifugal weight type Govemor Valve Mechanism Overhead SwIrl type Combustion Chamber chamber Bore & Stroke 2.99 x 2.76 inches (76 x 70 mm) Piston Displacement 59.09 cubic inches (0.952 Itters)
- Page 70 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.<Jriven, with extemal pressure relief valve. -.v WESTERBEKE Engines & Generators...
- Page 71 (3600 + 000 - 100) at full open throttle while underway. API specification of CF or CG-4 Lubricating Oil Grade SAEGrade SAE 2OW/20 or SAE 30 exclusively. (Do not mix grades oil or use multigrade oils!) Transmission Sump Capacity (1 liter) WESTERBEKE Engines Generators &...
- Page 72 (If removed) are to have a thin oil film wiped on them before they are retorqued. If have not been removed and need only to be retorqued. then bolts is needed. Refer to page 69 for the location of the main and sub bolts. WESTERBEKE Engines & Generators...
- Page 73 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES stated otherwise for a specific assembly, use the following torque values when tightening stand- Unless ard hardware. Ib-ft kg-m Pitch Grade4T bolt 0.4- 0.7 head/nut 2.9 - 5.1 bolt 1.25 7.2- 11.6 headlnut 1.0 - 1.6 bolt 10mm headlnut...
- Page 74 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 75 Declaration of Conformity EMC 8913361EEC Application of Council Directive(s) ENS0081-1 Standard(s) to Which Conformity ENs0082-2 is declared ENS5020 Westerbeke Corporation Manufacturers Name 150 John Hancock Road Manufacturers Address Myles Standish Industrial Park Taunton, MA 02780-7319, USA Marine Diesel Engine Type of Equipment...
- Page 76 .II'I'E ..'I'.ONAL NE CER'I'.F.CA'I'.ON .NS'I'.'I'U'I'E .MA • • e. eox e Rond PoInt IId'MMWn UNO BRUXEU.ES ..,!ilf ~z.zsa.= CER TIFICA TE that Directive We hereby certify the engine stated below meets the EC 94I25IEC. including powoer declaration In aeeordanee with ISO 8665...