Thursday, July20, 2017 L-36.com

Westerbeke Diesel 20b Two Technical Manual




NOTE: DO NOT HIT REFRESH!!! These files are big and can take a long time to load. This file is 2.36 MB. Give it time.
If there is text in the file, you can scroll it while the image loads. Enjoy

View PDF

Image Preview



Ad by Google

PDF to Text

I It
o 4
OPERATORS
MAR E DIESEL E INES
20B TWO I 30B THREE
I lKHNO I EDITION FOUR
JN2000
SAFETY PREVENT BURNS FIRE
Read this safety manual carefuUy Most accidents are
coused by failure to follow fwuIomentol rules and Know when dangerous conditWns exist and take the
A WARNING Fire can cause Injuty or precautions to protect yourself your personne Prevent flash fires Do not smoke or permit flames or
and your sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in compliance with pump or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ElECTRIC SHOCK Do not operate with a Coast Guard Approved
flame
arrester removed Backfire can cause severe injury or
death
A WARNING Do nut touch AC electrical Do not operate with the air removed
while JIIgine is mnning or when connected to shore Backfire can cause severe injury or death
power Lethal voltage Is PTJSIJnt at thestJ connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosmes and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will burn
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING ExplosiollS from fuel rapol can cause
Injuty or death
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING 00 not touch hot engine parts or Shut off the fuel service valve at the engine when servicing
the fuel system Take care in catching any fuel that might
BXhaust system components A mnning engine gets spill DO NOT allow any smoking open flames or other
vBfYhot sources of fire near the fuel system or engine when servic
ing Ensure proper ventilation exists when servicing the
Always check the engine coolant level at the coolant fuel system
recovery tank
Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
A WARNING Steam can cause Injuty or death Be certain fuel line fittings are adequately tightened and
free ofleaks
In case of an engine overheat allow the engine to cool Make sure a fire extinguisher is installed nearby and is
before touching the engine or checking the coolant properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this Engines Generators
SAFETY STARIlNG TOXIC EXHAUST GASES
A WARNING Allldental starling can cause Injury A WARNING carbon monoxide CO Is a deadly gas
If IiIIaIbJ
Disconnect the battery cables before servicing the engine Ensure that the exhaust system is adequate to expel gases
generator Remove the negative lead first and reconnect discharged from the engine Check the exhaust system
it last regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists Pay close
Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and
starting exhaust pipe nipple
Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated
installed before starting the engine
In addition to routine inspection of the exhaust system
install a carbon monoxide detector Consult your boat
BATTERY EXPLOSION builder or dealer for installation of approved detectors
For additional information refer toABYC T22 educa
A WARNING Battery explDSion can cause Injury tional information on Carbon Monoxide
If tIfIaIII
Do not smoke or allow an open flame near the battery A WARNING camon monoxide CO Is an inlllsible
being serviced Lead acid batteries emit hydrogen a odorless gas inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
areing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust sys
Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper
tive connection tenninal of the starter solenoid Do tubing resulting in exhaustlwater leakage
not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide
bums or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the symp
wristwatch rings and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning
the battery are
Always turn the battery charger off before disconnecting Vomiting Muscular twitching
the battery connections Remove the negative lead first
and reconnect it last when disconnecting the battery Dizziness Intense headache
Throbbing in temples Weakness and AVOID MOVING PARTS
A WARNING SUlfuric acid In batteries can cause A WARNING Rotating parts can cause injury
InlIlY Of death
or death
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec Do not service the engine while it is running If a situa
tion Batteries contain sulfuric acid which is destructive tion arises in which it is absolutely necessary to make
If it comes in contact with your skin wash it off at once operating adjustments use extreme care to avoid touch
with water Acid may splash on the skin or into the eyes ing moving parts and hot exhaust system components
inadvertently when removing electrolyte caps
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBUCATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that INSTAllING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their recommenda
Make sure all attaching hardware is properly tightened
Keep protective shields and guards in their respective tions when installing your engine
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 3069 Solomons Island Rd
be caught in these rotating parts Edgewater MD 21037
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARNING High noise levels can cause hearing NFPA
loss II Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Government Printing Office
Washington DC 20404
A WARNING Do not wodc on machine when you are
mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repealed
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
PI Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
WESTERBEKE
Engines Generators
installing WES1ERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations wbere the exhaust injected exhaust elbow is close to
or will be below the vessels waterline provisions must be made to install a siphon
break in the raw water supply hose to the exhaust elbow This hose must be looped a
minimwn oflO above the vessels waterline Failure to use a siphonbreak when
the ahaust numifold injection port is at Or below the load waterline will resull in
mw damage to the engine and possible flooding of the boat
If you have any doubt about the position of the exhaust elbow relative
to the vesse1s waterline under the vessels various operating conditions install A siphonbreak quires periodic inspection and cleaning to ensure
Failu to properly maintain a siphonbak can suit in damage Consull the siphonbreak proper SYSTEM
1be exhaust hose must be certified for marine use The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull
A detailed 40 page Marine Installation Manual covering gaSOline and
diesel engines and generators Is available from your WESTERBEKE
e
I Engines Generators
TABLE OF CONTENTS
Paris JS TransmissiDn 41
Product SDftware Controls 42
PreparatiDns fDr Starting Shifting 43
Engine CDntrDI Panels SaIfig
TO peral10n
Starting PrDcedure 13 Service 43
StDpping PrDcedure 14 Cooling 43
Engine BreakIn PrDcedure 15 PRM Newage TransmissiDn 43A
Operation 43A
Starting Under NDrmal CDnditiDns 16 Gear Shifting 43A
Fuel System 17 Control Cables 43B
Priming the Fuel System Electrical System 43B
Captains CDntrDI Panel Wiring Diagram 25 43B
Captains CDntrol Panel Wiring Schematic 26 Optional TransmissiDns Admirals Control Panel Wiring Diagram 27
Engine 46
Admirals ContrDI Panel Wiring Schematic 28 49
Cylinder Head Bolt Tightening 52
Engine Wiring Diagram Adjustment Df Valve Clearances Engine
Wiring Schematic InjectiDn Pump Timing Adjustment Cooling System
Layup and Thermostat 33
Sea Water Circuit 34 W20B Sea Water 34 W3DB Hot Water Tank CDnnectiDns TDrque Lubricating
System Standard TDrques Engine Oil Change 39 Spare Paris
Engines Generators
PARTS RIGHT SIDE
COOLANT PRESSURE ft Fill
POIl DIPSTICK Oil Fill
FRONT
FIlTER
AMP CIRCUIT BREAKER
LEFT SIDE
AIR INTAKE LO 10 PLATE
THERMOSTAT
ASSEMBLY
HEAT AlTERNATOR I
REAR
Oil DRAIN STAIRTER MOTOR
FRONT
WES7ERBEKE
Engines Generators
IMPORTANT
PRODUCT SOF1WARE software of all kinds such as brochures drawings technical data operators and workshop lists and parts price lists and other
related information instructions and provided from
sources other than Westerbeke is not Within Westerbekes control and accordingly is provided to Wester
beke customers only as a courtesy and service WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CON
TENT OF SUCH SOFTWARE MAKES NO WARRANTIES OR WITH INCLUDING THE ACCURACY TIMEUNESS OR COMPLETENESS THEREOF AND WILL IN NO
EVENT BE UABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH OR
ARISING OUT OF THE FURNISHING OR USE OF SUCH example components and subassemblies incorporated into Westerbekes products and supplied by
others such as engine blocks fuel systems and components electrical components pumps
and other products are generally supported by their manufacturers With their own software and depend on such software for the design of Westerbekes
own product software Such may be outdated and no longer accurate Routine changes made by Westerbekes suppliers of
which Westerbeke rarely has notice in advance are frequently not reflected in the supplierS software untO
after such changes take customers should also keep in mind the time span between printings of Westerbeke and the unavoidable existence of earlier
noncurrent Westerbeke software editions in the field most Westerbeke products include special features that frequently do not in
clude complete summation product software provided With Westerbeke products whether from Westerbeke or other sup
pliers must not and cannot be relied upon exclusively as the definitive authority on the respective product
It not only makes good sense but is imperative that appropriate 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 Engines Generators
manual contains the equipment operating procedures as well as additioual information needed to
help the operator keep the marine equipment in proper working order Study and follow the A planned maintenance program is included in this manual
adhering to the program will
result in better equipment performance and longer equipment life Proper diagnosis of a problem is the
most important step to satisfactoIy repair consequently a table is THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same The
cylinders are arranged above a closed crankcase the crankshaft is of the same general type as that of a
gasoline engine and the diesel engine has the same type of valves camshaft pistons connecting rods to a great extent a diesel engine requires the
same preventive maintenance as a The most important factors are proper ventilation and proper maintenance of the fuel cooling SYStems Replacement of
fuel and lubricating filter elements at the time periods specified is a
must and frequent checking for contamination that is water sediment or algae in the fuel system is
also essential Another important fuctor is the use of the same brand of high detergent diesel designed specifically for diesel engines Be careful not
to put gasoline in the diesel fuel does not have the same lubricating qualities as diesel fuel consequently gasoline in the fuel
lines will damage components in the lift pump assembly fuel injection pump and in the diesel engine does differ from the gasoline engine however in
its method of handling and firing of
fuel The carouretor and ignition SYStems are done away with and in their place are two components the
fuel injection pump and fuel PARTS
When contacting your Westerbke dealer parts distributor or the factory concerning your Westerbeke unit
always provide the engines model and serial number and transsmission number as they appear on the
black and silver Westerbeke plate which is mounted on the engines exhaust that component locations in the manual are the front of the engine which
is belt end The end is the rear end Left and right sides are detennined by
the engine imagine straddling the engine and facing in the same direction as the front of the engine the
left side is at your left the right side is at your engines are thoroughly checked and given a final run under various load conditions the factory
This is done to ensure dependable operation long service and a satisfied owner
Care at the factory during assembly and thorough testing have resulted in Westerbeke units being capable
of many thousands of hours of dependable service However the manufacturer cannot control the type of
treatment a unit receives in the field This part is up to the I
Engines Generators
you for selecting a Westerbeke marine product for your use We at Westerbeke are pleased to have
you as a this manual carefully and observe all safety precautions included throughout Operating 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 your unit require special attention contact your
Westerbeke dealer for assistance The Organization is trained to provide the support necessary to ensure longterm dependable within 60 days of
submitting the Warranty Registration Form for your unit you have not received a Cus
tomer Card see below registering your warranty please contact the factory in writing with
Model information including the engines serial number and commission date
from IESTERBEkE CORPORATION
AVON INDUSTRIAL PARK
AYoN MA 02322
I WESTERBEKE
Engines Generators
Customer WESTERBEKE OWNER
MAIN STREET
Mail To HOMETOWN USA
Model30B THREESer 0103XXXX
Expires 920102 of engine is shipped from the factory mounted securely and properly crated Accessory equipment is
shipped in a separate small box usually packed within the engines accepting shipment of the engine from the company the crate should be opened and
the contents inspected for concealed damage If etther visible or concealed damage is noted you that the delivery agent sign Received in damaged
condition on the proper delivery receipt Also
check the contents of the shipment against the packing list and make sure that the proper notation is made
if any discrepancies exist These noted discrepancies are your protection against loss or damage loss or damage must be made to the carrier not to the
Westerbeke Engines Generators
UNIT 10 PLATES
MODEL SPEC AVON A USA SERNO
20B TWO UNIT 10 PLATE
MODEL SPEC AVON A USA SERNO
30B THREE UNIT 10 PLATE
The unit 10 plate is attached to the exhaust manifold of the engine These illustrations are provided so
that the may transcribe the and serial number from the ID plate on the
engine to one of the Hlustrations above This will allow for easy reference when seeking parts service or
technical needs
WESTERBEKE
Engines Generators
PREPARATION FOR section of the manual provides the operator with preparation initial starting breakin starting cold or
warm and stopping procedures Follow the procedures as presented for the conditions indicated and
your Westerbeke engine set will 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 Select lubricating oil with an API specification of
CF or CG4 and an SAE number suitable for in your operating area For the quantity
of oil needed in your engine refer to the section of this manual
LlNtT
UPPER LlIootlT
NORMAL LEVEL
Fm the transmission to the FUll mark on the dipstick
with the correct lubricant Refer to the section of this manual page 11 for
the 206 TWO and page 14 for the 306 THREE
Each unit is supplied with a coolant recovery kit 24977 as standard equipment to which the following ap
plies
A Remove the pressure cap from the engines exhaust manifold and slowly fill the engines cooling sy
tem with a mixture of water and antifreeze suitable for your temperature zone See the COOUNG SYS
TEM section of this manual Operate the engine and observe the coolant level in the manifold
Maintain this level to the base of the filler neck Once the engine reaches its operating temperature 170
190 F make sure there is coolant flowto the domestic water heaters when installed Top off the cool
ing system and install the pressure cap
B Make sure the plastic recovery tank is properly mounted near the unit with the bracket provided in a
location where it can be monitored and filled easily The recovery tank should be mounted at manifold
level or above In those installations that require It the plastic recovery tank can be mounted below the
exhaust manifolds level
C Add coolant to the plastic tank after the engine has been started and operating temperature has been
reached to make sure all air is expelled from the manifold and the engines cooling system With the
manifold filled and the pressure cap installed fill the plastic recovery tank half full MOlJitor dany and
add coolant as needed
Fill the fuel tank with a good grade of No2 diesel fuel and manually prime the fuel system up to and
including the engine When running fuel is free of air the engines fuel system is bled and the engine is
ready to start
Make sure the Installation Checks have been made in accordance with thoJe specified in the CHECKS section of this manual
Engines Generators
of Starting System
All Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold The figure belaN shows a view of one cylinder
The glow plug is located in the c0m
bustion chamber so that Its tip is in the Injector nozzles SplaY path When the glow plug is energized by the
PREHEAT button the plug glaNS red at the tip and assists in igniting the fuel The result is a rapid start with
less wear on the system is common to Westerbeke Diesels The start circuitry is designed so that the PREHEAT button
must be depressed for the time specified in the Preheat chart shaNn on page 13 Then whDe keeping the
PREHEAT button engaged the START button is depressed to crank the engine
Combustion Chamber
NOTE The START button will not energize unless the PREHEAT button is depressed When
depressing the preheat switch we are activating the glow plugs in the cylinder head so use
the preheat so as not 10 overheal the glow plugs
WESTERBEKE
Engines Generators
ENGINE CONTROL offers two types of control panels as optional the following instructions that apply to the panel you purchased with your contro
pauel is equipped with a Key Switch an RPM gauge PREHEAT and
START buttons an instrument test button three indicator lamps one for alternator discharge one for low
oil pressure and one for high engine coolant temperature and an alarm bur for low oil pressure or
high water temperature The RPM gauge is illuminated when the key switch is turned ON and remains
illuminated while the engine is in operation The key switch and the three buttons serve the I Kev Switch The Key Switch provides power only to the
instrument panel cluster Be aware that
the key switch does not shutdown the engine when the key is turned OFF Refer to the STOPPING
PROCEDURE section of this manual
2 PREHEAT The PREHEAT button energizes the alternators regulator the engines glow plugs
and bypasses the engines oil pressure alarm switch In addition this button energizes the START
button
3 START The START button when pressed energizes the staners solenoid which cranks the
engine This button will not operate electrically unless the PREHEAT button is pressed and held at
the same time
4 Test Button The Test Button located above the key switch tests the alternator the oil pressure
and the water temperature control circuits When this button is pressed the alternator the oil
pressure and the water temperature indicator lights illuminate in addition to sounding the buzzer
Engines Generators
S AIann The alarm is located above the test button and wiUsound if the engines oil pressure falls
below IS psi In this event the alarm will emit a pulsating signal The alarm will also sound if the
water temperature in the fresh water cooling circuit rises to 205 0 F In this event the alarm will emit
continuous signals
NOTE The alarm will sound when the Key Switch is turned ON This sounding is nonnal for
the engines covered in this manual Once the engine starts and the engines oil pressure reaches 15
psi the alarm will silence
6 Water TenJlmture GaUge This gauge is graduated in degrees Fahrenheitand is illuminated
whiIe the Key Switch is turned ON The engines normal operating temperature is 170 1900 F
17880 C
Oil Presswe Gauge This gauge is graduated in pounds per square inch pSI and is illuminated
wbilc the Key Switch is turned ON The engines normal operating oil pressure ranges between
3060PSL
NOTE When the engine is manually shut down and the engines Key Switch is turned OFF the
water tewperature gauge will continue to register the last temperature reading indicated by the
gauge before electrical power was turned OFF The oil pressure gauge will fall to zero when the Key
Switch is turned OFF The temperature gauge will once again register the engines true temperature
once electrical power is restored to the gauge
WESTERBEKE
Engines Generators
Admirals control panel is equipped with a key switch and an RPM gauge with an ELAPSED
TIME meter which measures the engines running time in HOURS and in 110 hours The panel also includes
a water temperature gauge which indicates water temperature in degrees Fahrenheit WATER F an on
pressure gauge which measures the engines on pressure in pounds per square inch OIL PSI and a DC
control circuit voltage gauge which measures the systems voltage VOLTS All gauges are illuminated when
the key switch is tumed ON and remain Diuminated while the engine is in operation The panel also contains
two rubberbooted push buttons one for PREHEAT and one for START
1 Key Switch The Key Switch provides power only to the instrument cluster Be aware that the key switch
does not shutdown the engine when the key is tumed OFF Refer to the STOPPING PROCEDURE
section of this manual
2 PREHEAT The PREHEAT button energizes the alternators exciter the engines glow plugs and bypas
sesthe engines protective oil pressure switch In addition this button energizes the START button
3 SIABI The START button when pressed energizes the starters 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
5 AIaon The aIann is located above the test button and wUl sound if the engines oil pressure fails below
15 psi In this event the alarm will emit apulsating signal The alarm will also sound if the water tempera
ture in the fresh water cooling circuit rises to 2100 F In this event the alarm will emit continuous sig
NOTE The alarm will sound when the Key Switch is turned ON This sounding is nor
mal for the engines covered in this manual Once the engine starts and the engines
oil pressure reacheS 15 psi the alarm will silence
6 Gauge This gauge is graduated in degrees Fahrenheit and is Dluminated while the
Key Switch is tumed ON The engines norrnaI operating temperature is 170 1900 F 77 88C
7 OD pressure Gauge This gauge is graduated in pounds per square inch PSI and is Dluminated while
the Key Switch is turned ON The engines normal operating 011 pressure ranges between 30 60 PSI
NOTE When the engine is manually shut down and the engines Key Switch is turned OFF
the water temperature gauge witl continue to register the last temperature reading indicated
by the gauge before electrical power was tumed OFF The all pressure gauge witl fall to zero
when the Key Switch is turned OFF The temperature gauge will once again register the
engines true temperature once electrical power is restored to the gauge
NOTE A separate alarm buzzer with harness is supplied with every Admiral Panel The in
staller is responsible for electrically connecting the buzzer to tle fourpin connection on the
engines electrical hamess The installer is also responsible for installing the buzzer in a loca
tion will be dry and where it witl be audible to the operator should it sound whDe the engine is
running The buzzer will sound when the ignition key is turned ON and should sHenee when
the engine has started and when the engines oil pressure rises above 15 psi
Wo WESTERBEKE
Engines Generators
STARnNG 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 oclock prime the engines fuel system at the mechanical fuel
pump to bleed all the air from the fuel system if needed see page 39
Depress and hold the PREHEAT switch Preheat according to the following chart
Atmospheric Temperature Preheating Time
41 F 5 C or higher Approx 05 sec
41 F 5 C to 23 F SO C Approx 10 sec
23 F 5 C or lower Apprax 15 sec
Umit of continuous use 30 seconds
before glow plug function is indicated by a voltmeter drop when the PREHEAT switch Is depressed This
drop will be slight but discernible If no voltage drop is noted it may indicate defective glow plugs or a faul
ty preheat circuit check for loose holding the PREHEAT button depressed depress the
START button The starter motor wil run thereby cranking
the engine As soon as the engine runs release the START
button and PREHEAT button Check your proper engine operation Make sure sea water dischar
ges along with the exhaust the engine not start when the START button is
depressed for 10 to 12 seconds release both buttons and
wait 30 seconds repeat the previous procedure Never run
the starter motor for more than 30 seconds at a time
CAUTION
Prolonged cranking intervals without the engine starting can resuh In filling the engine
mounted exhaust system with sea water coolant This may happen because the sea
water pump is pumping sea water through the sea water cooling system during crank
ing This sea water can enter the engines cylinders by way of the exhaust manifold
once the exhaust system fills Prevent this from happening by closing the sea water
supply throughhull shutoff drain the exhaust muffler and correct the cause for the ex
cessive engine cranking needed to obtain a start Engine damage resuhing from this
type of sea water entry is not a warrantable issue the should keep this
in mind
Engines Generators
Once the engine starts run1t at Idle for a few minutes to warm up the englneand check Instruments for
proper oil pressure and battery charging voltage Never attempt to engage the starter whOa the engine Is
running
NOTE Some unstable running may occur In a cold engine but this condition should smooth
out as the operating temperature of 170 1goo F f7 88 C Is reached
STOPPING PROCEDURE
A manual pull type stop control tee handle or knob Is provided by the installer in a location close to the
engines controls Know the location of this control before attempting to start the engine To stop the en
gine pullout on this tee handle or knob fully and hold it out untO the engine comes to a complete stop Push
back on this control to retum it to the engine run position otherwise the erigine will not the engine stopped tum the key switch turned to the OFF
position 12 oclock If the Key Switch is left
ON the battery will discharge An engine alarm buzzer is provided to warn the operator of this Switch ON The best method of preventing the battery
from discharge is to remove the key from the
Key Switch after stopping the engine
CAUTION
DO NOT attempt to shutdown the engine bytumingthe Key Switch OFF The Key Switch only
provides power to the instrument panel the engine will continue running even if the Key Switch
is turned OFF Shut down the engine by pUling the stop control out fully
An optional key shut off package is available that allows the operator to shut off the engine by tuming the
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 requestorder of the owner
THROTTLE COTRll
LEVEl
SJOP
POSInOIl
STOP
tunol
LEVEl
WESTERBEKE
Engines Generators
Engine Breakn Procedures
Although your engine has experienced a minimum of one hour of test operations to ensure accurate as
semblyand proper operation of all systems breakin time Is required The service life of your engine is de
pendent upon how the engine Is operated and serviced during its initial 50 hours of use
Your new engine requires approximately 50 hours of initial conditioning operation to break in each moving
part in order to maximize the performance and service life of the engine Perform this conditioning careful
ly keeping in mind the following
1 Start the engine according to the STARTING PROCEDURE section found in this manual Run the
engine at fast idle while checking that all systems sea water pump oil pressure battery charging
are 2 Allow the engineto warm up preferably by running at fast idle until the water temperature gauge moves
into the 130140 F range
3 Whle using the vessel run the engine at varying engine speeds for the first 25 hours
4 Avoid rapid acceleration especially with a cold engine
5 Use caution not to overload the engine The presence of a gray or black exhaust and the inabDity of
the engine to reach Its full rated speed are signs of an overload
6 DurIng the next 25 hours the engine may be operated at varying engine speeds with short runs at full
rated rpm Avoid prolonged idling during this breakin period
Brealdngin a new engine basically involves seating the piston rings to the cylinder walls This cannot be ac
complished by long periods of running at Idle nor by earfy running at full rpm
Idle running may glaze the cylinder walls resutting in excessive aD consumption and smoky operation ex
cessive speed or heavy ovedoading especially with a cold engine may cause scoring of the cylinder walls
producing similar results
As indicated above operate the engine in moderation during the 5Ohour breakin period Dont baby the
engine but do not abuse it
WESTERBEKE
Engines Generators
Starting Under Normal the procedure below for normal starting of the engine
1 Check the engine and tlanSmission lubricant levels and fill if necessary
2 Make san there is suIIicient fuel on board Keep fuel tanks as full as possible Check the fuel filters
and water separators for the presence of conIaminants andor water Drain and clean them as needed
3 Check the coolant level in the plastic recovery tank Add coolant solution as needed
NOTE Ext eS518 loss of coolant from the plastic rectPery tank indicates a cooling system
leak Checkthe entine cooling system and pressurize the system to locate the leak In cases
of lDCCessive coolant Joss the system must be refilled as outlined under the PREPARATION
FOR STARTING section of this manUal
4 Checkfor 01 and fuel leaks particUarty if signs of such leaks are found on the bottom of the engine or
below the the engine in accordance with the STARTING PROCEDURE instructions found in this manual
Allow the engines operating temperature to reach 140 150 F before operating the engine Under Cold exIremeIy cold temperatures the following
conditions can occur Follow the insIrucIions listed below
when opetatillQ ycu engine in cold OIL TURNS VISCOUS Make certain that the lubricating oil used conforms with the ratings for atmospheric
temperature Refer to the LUBRICATION SYSTEM section of this ACROSS THE BATTERY TERMINALS DROPS Make certain that the battery is fully charged to
minimize voltage drop across the battery TEMPERATURE OFTHE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOT
RISE ENOUGH AIIowthe rJow plugs to operate aid in starting during the preheat period when
fINer the temperature of the intake air is low and when the compression temperature does not rise the preheat chart found in the STARTING PROCEDURE
section
WESTERBEKE
Engines Generators
FUEL SYSTEM
Diesel Fuel
Use No 2 diesel fuel with a cetane rating of 45 or higher Never use kerosene or home heat
ing 01
In cold weather particularly water vapor is produced by condensation when air is present
In the fuel tank Keep fuel tanks full and completely free of dirt and water
Fuel FUterWater Separators
A primary fuel liter of the water separating type l1llm be installed between the fuel tank and
the engine To remove water and other contaminants from the fuel before they can be carried
to the fuel system on the engine
Most insIaIIers included with the gen
erator insIaIIaIion package a type of
fIterWater separator for they are aware
of the probeIms contaminants In the
fuel can cause all of which are not
warrantable through Westerbeke
A typical fuel filterWater separator is
IIUSIrated In this diagram This is the
Raycor Model SOOMA In mind
that if a water separator type filter is not
installed betWeen the fuel supply tank
and fuel system any
water in the fuel will affect the fuel
pump engine filter and injection
equipment The is
responsible for making certain the fuel
reaching the engines injection equip
ment is free of impuritieis This process
is accomplished by intstalling and
maintaining a proper tion system
In addition any gasoline in the fuel
system will damage the engines fuel
injection pump assembly and injectors
as gasoline does not have the same Fuel FilterWater Separator
lubricaticg qualities as diesel fuel
If a filterWater separator is not installed between the fuel tank and the fuel
system water in the fuel system wl1l inhibit proper starts and particles will pass on to the lift
pumps filter eventually clogging it and pass on into the engines injection equipment
Notes on Fuel System
iWARNINGI
Shut off the fuel service valve althe tank when servicing the fuel system Take care in catching
any fuel that may spDi from within the pump when the base is removed DO NOT allow any
smoking open flames or other sources of fire near the fuel system when servicing Ensure
proper ventDiation exists when serviCing the fuel system
y WESTERBEKE
Engines Generators
Priming the Fuel System
The models covered by this manual have a single replaceable fuel filter in the engine
mounted fuel system This filter Is located between the engine mounted electric fuel pump
and the inlet to the fuel injection pump The exploded view below shows this filter element
as Item 21 SeNicing this filter element is explained a few pages further in this manual
When the titer element in this cannister has been changed the air in the system is bled out
by simply turning on the panel key switch which energizes the fuel pump The pump delivers
fuel to the system which pushes the air out AIIowthe fuel pump to operated for on minute to accomplish this
Prolonged cranking intervals without the engine starting can resuH in filling the
exhaust system with sea water coolant This may happen
because the sea water pump is pumping sea water through the sea water
cooling system during cranking This sea water can enter the engines
cylinders byway of the exhaust manifold once the exhaust system fills Prevent
this from happening by closing the sea water supply throughhull shutoff drain
the exhaust muffler and correct the cause for the excessive engine cranking
needed to obtain a start Engine damage resuHing from this type of sea water
entry is not a warrantable issue the should keep this in mind
v WESTERBEKE Westerbeke Diesel Engines
Engines Generators
Notes on the Fuel System
The illustration that follows is an exploded view of the 20B TWOs fuel system This system is similar to
the 30B THREEs fuel system in that it has only one less fuel injector and one less pumping element in
the injector pump
v WESTERBEKE
Engines Generators
The Westerbeke fuel system bleed Is manual In operation WhOe it Is unlikely that the operator will be forced
to service the system at sea the possibDity does exist Therefore we recommended that a replacement fuel
filter be carried on board at all times Each fuel filter comes with two Oring gaskets Select the part number
for this fuel filter from your Parts Ust and purchase spares from your local Westerbeke Dealer or a leak should develop at a fuel banjo or sealing
washer location that cannot be remedied by a slight tighten
Ing of the filter cup retainer replace the filter along with the Orings supplied with the new the Fuel Filter the first 50 hours of operation loosen
the toter cup retainer and remove the toter cup Be careful in
carhing any fuel that may spill from within the filter cup Discard the old filter element and the old the filter cup and install the new filter along
with the new Orings Carefully replace the filter cup and
retainer Take care not to cross thread the retainer when threading on to the filter bracket
NOTE DO NOT overtlghten the titer cup retainer excessive tightening can strip the soft
aluminum threads on the fuel filter ALUMtNUM
TREADS
FL TR CUP
Mer the first SOhour change the change period may be increased to 200 hours or once per season
WESTERBEKE
Engines Generators
Fuel Injection Pump
The fuallnJectIon pump Is one of the most Important components of the diesel engine and
ttoarerore caBs for the utmost caution In handling Furthermore the fueJlnJection pump has
been thoroughly benchtesIecI and should not be tamperBd with
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
rEngine Mounted Fuel Filter
WESTERBEKE
Engines Generators
ELECTRICAl 12Volt DC Control Circuit
The Westerbeke modles 20B TWO and 30B THREE propulsion engines each have a 12Volt DC elec
trical control circu as shown on the wiring diagrams which follOW Refer to these diagrams when or servicing electrical components on the engine
CAUTION
To avoid damage to the battery charging circuit never shut off the engine battery switch whDe
the engine is running
However shut oIfthe engine battery switch to avoid electrical shorts when working on the en
gine electrical minimum recommended capacity of the battery used in the engines 12Volt DC control circuit is 90
125 AmperHlours minlmum
CAUTION
When the battery with an external charger be sure to disconnect the battery
cables from the battery Leaving the charging circuit connected whDe wDl
damage the aItemators CAUTION
When testing the alternator circuit charging circuit do not use a highvoltage tester such as
a megger damaged diodes could resuil
During highspeed operation of the engine do not disconnect the positive terminal of the bat
tery from the B terminal of the alternator nor disconnect the negative terminal of the battery
from the ground
When cleaning the engine with a steam cleaner be careful to keep steam away from the alter
nator
WESTERBEKE
Engines Generators
below is a wiring harness for the 30B THREEs electrical system The wiring hamess for the
20B TWOs electrical system differs only in that it has one less glow plug Optional Fuel
Run Solenoid
WESTERBEKE
Engines Generators
The charging system consists of an alternator with an internal voltage regulator an a battery and connecting of the use of ICs integrated circuits
the eleCtronic voltage regulator is very compact and is built
into the rear bracket of the Voltage Test
If you suspect that the alternator is not producing enough voltage to charge the engines battery perform
the following voltage test
ANPHETER
for Charging Voltage Test
1 Using a voltmeter connect the voltmeters red wire dip to the B output terminal on the alternator Refer
to the schematic shown above
2 Connect the other wire dip to a ground on the engine
3 Stan the engine and increase the engines speed to 2000 rpm Now record the reading given by the
voltage reading for a properly operating alternator should be between 135 to 145 volts If your alter
nator is over or under charging have it replaced or rebuilt by a reliable service shop
NOTE Before removing the alternator for repair rnake sure 12Volts excitation is present at
the R terminal should the above test show only battery voltage at the B output Engines Generators
Captains Panel DC Control Circuit Wiring Diagram 36467
page 1 of2
OIAGRAM
TEMP
SMOo
SWITeK
i Ell
PZ 0
I i
r
r r ff
0 T J
I roff
SUItT LAP I
ST sw I
I 0
I
I L i
woe i T wir
s I
1tI
i I
Engines Generators
CapIains Panel DC Control Circuit Wiring Diagram 36467
page 2 of2
woe SCHEMATIC
DIAGRAM
starrEIl
r
CIOWfIWGS J
ia
l scuooo
L
t OJSNCIl
START T Mer 10 ON 1IOSmON ntE ALARM WSIL SOUNDOIl PIiIESSURE 1ItO
aTTEIIW 0tAAGE IfGICA1QRS WILL UGWT
zPIISM PREHUT swaTCH fOA5 TO 3DSCOltOS AS REQuIRED AIut WILL SToP
11 CCNTCNUNG 10 PUSM pqHAT SWITCNIlUSM Ttl STAAT WITe ALSO
WItEN ntE etGlNE STAATS AEIASE TM STAltT SWITCH ONLY
N THE OIL ESSURE INDICATOR AMP GOS OUT RtLEsE THE
PltEItUT SWITCM
TUCItI THE ICr 10 1ME OFF fltlS PClODuCT IS JIROTECTO 8T NAHUM RUET OACU1T BREAKER LOCATED HEAA
TIlE CURRENT gAAIH WILL CAUSE THE BAEAItA TO TAIl AltD TloE
OGIt WILL SMUT OOWH THE MUST 8 SURE THAT ntE I ENGIN ARE NSTAuO TO PREvEIn CONTACT BTWEEt ELECTAICJL
DEVICES MD OttoOFF SWITCM 5MOUCD IE INSTAUD eETVEEN THE lBATTEAv 11 STAATEA TO
QlSCOuICT TM BATTEAT IN AN EMERGENCY AND WMH LAIllIG nt
04T A SWITCK
WITH A aJNntUOUS RA1IHG Of I7SAMPS AT IZvoe Wlt1SERVE TttIS FUNCTION THIS
SWITCH 5HCIULO NOT 8E USUI TO MAKE CoR 8REAIt THE OACUIT
1 WlIiE liZ JIIUG z rs 5 MI SOIOUID 8E I Engines Generators
Admirals Panel DC Control Circuit Wiring Diagram 36844
page 1 of2
ALfERNATOR
WIRING DIAGRAM 35 A 40 A 10 A
WATEII
swmtI I
LT BWE I
WITCH
J
USED ON SOlE MODELS
SENDER
I NEUlIIAI
I EIIGINE BLOCK
I t
IIII
II II
I I
ADMIRAl
PANEL
I START PREHEAT
WlTCH swrTCH
OaA
WESTERBEKE
Engines Generators
Admirals Panel DC Control Circuit Wiring Diagram 36844
page 2 of2
SCHEMATIC DIAGRAM
12 VOLT DC
20A UFTPUMP
I FUELSOL
P SNDR
JJsz
WTSW
52 51 51 51 sl
TACH1
fSTART I
lJNI WT
1 OP
THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCAlEl NEAR THE
STARTER EXCESSIVE CURRENT DRAIN WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE
WILL SHUT DOWN THE BUILDERIOWNER MUST BE SURE THAT THE INSTRUMENT PANEl
WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL
DEVICES AND AN ONOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO DIS
CONNECT THE BATTERY IN AN EMERGENCYAND WHEN LEAVING THE BOAT A SWITCH WITH
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 WESTERBEKE
Engines Generators
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
NOTE
AN ONOFF SWITCH IOCIT
SHOULD BE IN J
STALLED BETWEEN
THE BAmRY AND
STARTER TO DiS
CONNECT THE BAT Al
TERY IN AN EMER
GENCY AND WHEN THE BOAT
A SWITCH WITH OF 175
AMPS AT 12 VOC
WILL SERVE THIS P No
fUNCTION THIS
SWITCH SHOULD
NOT BE USED TO
ADMIRAL
PANEL 39600
MAKE OR BREAK
THE CIRCUIT Ll Fi J iJ M P
iY1 c f
B It r so L
2Lj3g 3
5 0 I 2
OIl w Tc
CAPTAIN j 7323
PANEL
Engines Generators
DC ELECTRICAL SYSTEM
WIRING SCHEMAnC 39144
11 nAar
nclOC
rtJ eI
u ato
I I
n
U6nli
iI Ir
JJi17
IzgC uRnO r
L
a u
MUVIM 59 MtP 61 T
I
IACTlO
ADMIRAL
PANEL
14
10 AMP ALT
1 I
I
raelllAl
ITCII
II t
n CAPTA I N
PANEL
114 LT ILU
i 01
n D
CII 10
51 AMP AI TfRNAIOA
PRfSIQr lIE 72 AMp AI T
TUOUO AlTUIIUOR 011 THE
138 rl UC tx 711 II ue ct
1011 n Qac II
114 eRA
I Plld
At iihlil
n 14 LT

oc oo
UN I VFRSA pROPULSION
OPTIONAl AI TfRNAIQRS
pRESTO lIE 51 AMp All
UIA I lItt 01
fMa K ry I I n na
v WESTERBEKE
Engines Generators
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 The heat is transferred ex
ternally from the fresh water to sea water by means of a heat exchanger simOar in function to an automo
tive radiator Sea water flows through the tubes of the heat exchanger whOe fresh water flows around the
tubes engine heat transferred to the fresh water is conducted through the tube walls to the sea water which
is then pumped into the exhaust system where finally it is discharged overboard In other words the engine
is cooled by fresh water the fresh water is cooled by sea water and the sea water canries the transferred
heat over the side through the exhaust system The fresh water and sea water circuits are independent of
each other Using only fresh water within the engine allows the cooling water passages to stay clean and
free from harmful deposits The two independent circuits and their components are discussed in the follow
ing Fresh Water Circuit
NOTE Referto paragraphs A and B in this section on the recommended antifreeze and water
mixture to be used as the fresh water coolant and for infonnation on filling the fresh water
system
Fresh water Is pumped through the engine by a beItdriven circulating pump absorbing heat from the en
gine The fresh water coolant circulates through the engines block absorbing heat then passes through
the thermostat into the exhaust manifold to the heat exchanger where it is cooled and then is returned to
the engine block through the suction side of the fresh water circulating pump When the engine is started
cold external fresh water flow Is prevented by the closed thennostat although some fresh water flow is
bypassed around the thermostat to prevent exhaust manifold from overheating As the engine wanns up
the thermostat gradually opens allowing full flow of the engines fresh water coolant to flow unrestricted to
the extemaJ portion of the cooling system
A Fresh Water Coolant Antifreeze Mixture
A freshwater and antifreeze mixture should be used yearround Water when it freezes expands sufficient
ly to split the heat exchanger and crack the engine block A mixture of proper concentra
tion will prevent freezing
Use soft water with few impurities such as tap water potable water or rainwater Never use hard or foul
water Use of hard water or water containing impurities wIll lead to the collection of scale in the engine and
heat exchanger which wJli reduce the cooling systems efficiency
Antifreeze of poor quality or without rust inhibitors will cause corrosion within the cooling system Always
use antifreeze which is compatible with aluminum cooling system components and is made by a reliable
manufacturer Never mix different brands of antifreeze
Make sure the engines cooling system is well cleaned before adding antifreeze Recommended antifreeze
for year round use is ZEREX or PRESTONE with rust inhibitors
In order to control the concentration of the mixture mix the antifreeze and freshwater thoroughly before ad
ding it to the cooling system
Engines Generators
ANTIFREEZE CONCENTRATION DATA
Antifreeze
Concentration Ib 13 23 30 35 45 50 60
Freezing OF 23 14 5 4 22 40 58
Temperature C 5 10 15 20 30 40 50
NOTE An antHreeze COIlCei Ibation shouldbe selected on the basis of a temperature which
Is about 100 F 50 C lower than the actual atmospheric temperature expected
B Filing the Fresh water System
A coolant recmery tank kit Is supplied with each Westerbeke diesel engine The purpose of this recovery
tank is to allow for engine coolant expansion and contraction during engine operation without the loss of
coolant and without introducing air into the cooling system
This coolant recovery tank should be installed at or above engine manifold level in a location where it can
be easIy monitored and where coolant can be easily added if needed see the figure below A mounting bracket is supplied with each kit along with a
3Oinch length of clear plastiC hose and clamps
to connect the hose beWleen the engines manifold fitting to the hose spud on the base of the recovery tank
FUNCTION OF MANIFOLD PRESSURE CAP
COOLANT the engine when heated during engine operation will the springloaded cap and enter the recavery tank via the hose connecting the recovery
tank to the the engine is shut down and cools a small check valve in the pressure cap is opened by the contrac
tion of the engine coolant allowing some of the coolant in the recovery tank to be drawn back into the system free of air and without loss
Periodically check that the passage A between the goo fitting
on the manifold and the filler neck in the manifold is clear so coolant can flow in either WESTERBEKE
Engines Generators
COOLANT RECOVERY TANK
COIOLNT PASSAGE
EXIAUln MANIFOLD
Coolant Recovery Tank Recommended FBI the fresh water system as follows
1 Remove the pressure cap from the manifold
2 Pour a clean antifreeze mixture into the manifold and allow enough time for the coolant to fill the fresh
water cooling system
3 Start the engine and allow It to corne up to Its operating temperature Monitor the coolant in the manifold
and add antifreeze coolant as air is expelled Once all air is expelled from the system fill the manifold to
the filief neck and install the pressure cap
4 Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway be
tween the ADD mark and the MAX mark Replace the plastic cap
5 Run the engine and observe the coolants expansion flow into the plastic recovery tank
6 Check for leaks between the pressure capfiller neck and then plastic recovery tank Stop the engine and
allow it to cool Coolant should be drawn back into the cooling system as the engines temperature comes
down
7 Add coolant to the recovery tank as required to top off the fresh water coolant system
Thermostat
Generally thermostats are of two types One is simply a choking device which opens and closes as the
engines temperature rises and falls The second type has a bypass mechanism Usually this is a disc on
the bottom of the thermostat which moves downward to close off an intemal bypass passage within the
head Since 1980 each type of thermostat has a hole punched through it The hole is a bypass to prevent
the exhaust manifold from overheating during the engines warmup Replacement thermostats must have
this design v WESTERBEKE
Engines Generators
Sea Water Circuit
The sea water flow is created by a displacement neoprene Impeller pump
The pump draws sea ocean
through the sea cock and sea water strainer and
passes the water to the heat exchangers sea
water inlet The sea water passes through the tubes absorbing heat from the fresh
water c1rcUating around the tubes The sea water
is then discharged from the cooling system over
board through the wet exhaust sys
tem CLEAH
HEW OR
A zinc anode or pencI is located in the sea water AHODE REPLACE REPLACE c1rcuitwithin the heat exchanger The pur
pose 01 the zinc anode is to sacrifice itself to Zinc Anode action taking place in the sea water
cooling circuit thereby reducing the effects of electrolysis on other components of the system The condi
tion of the zinc anode should be checked monthly and the anode cleaned or replaced as required Spare
anodes should be carried on board Zinc anode debris should be cleaned from the area inside of the where the zinc is located If this zinc debris is
allowed to accumulate it will block the tube open
ings through which the cooling sea water should flow
Sea Water Pump
The sea water pump is a selfpriming gearclriven rotary pump with a nonferrous housing and a The impeller has flexible vanes which wipe against a
curved cain plate within the impeller the pumping action On no account shoUd this pump be run dry There should always be a and impeller cover gasket
aboard an impeller kit Sea water pump impeller faUures occur sea water is not present during engine operation Such falures are not warrantable and
operators are caulioned to rnake sure sea water flow is present at and Water Pump Drive Belt Tension
IWARNINGI
Never attempt to adjust the drive belts ten
sion whUe the engine is in operation
CAUTION
Excessive alternator and water pump drive
belt tension can cause rapid wear of the belt
and reduce the service life of the fresh water
pump and alternator shaft bearings Exces
sive slack or the presence of oU on the belt
can cause belt slipping resulting in high
operating temperature as well as insufficient
alternator output
Engines Generators
The alternator and water pump drive belt is properly adjusted if the belt can be deflected no less than 38
inch and no more than 12 inch 10 mm 12 mm as the belt is depressed with the thumb at the midPoint be
tween the two pulleys on the longest span of the belt See the illustration on the previous page A spare
drive belt should be carried on board Refer to the SPARE PARTS section of this illustration below shows the cooling system components for the 306
THREE engine The 206 TWOs
cooling system is much the same Refer to the Parts Ust for each components name and part number
Cooling System Components Exploded View
WESTERBEKE
Engines Generators
DOMESTIC HOT WATER TANK CURRENT MODEL ENGINES
Simply cut into the existing hose at the thermostat
FROM housing and insert two connectors part 302391
into the two pieces of hose Couple the hoses from
the water tank to the other end of the connectors and
tighten the hose clamps It wont matter which hoses
run to and from the tank
FROM WA7fR TANK
EXISTING
THERMOSTAT should rise continuously from their low point at the heater to the engine so that trapped air will from the heater to the engine If
trapped air is able rise to the heater then an air bleed petcock
must be inslalled at the higher fitting on the heater for bleeding air whUe filling the system Avoid loops in
hose runs which wli trap air
NOTE If any portion of the heating circuit rises above the engines own pressure cap then
a pressurized aluminum remote expansion tank must be installed in the circuit to become
the highest point The remote expansion tanks part number is 24177 Tee the remote
expansion tank into the heater circuit at the heater connection choosing the higher of the
two for the return Tee right at the heater and plumb a single line up to the tanks location
and the other back to the engines flow control Install the remote expansion tank in a
convenient location such as in a sail locker so the fresh water coolant level can easily be
checked The remote expansion tank will now serve as a check and system fill point The
plastic coolant recovery tank is not used when the remote expansion tank kit is installed
since this tank serves the same pressure cap on the engines manifold should be installed once the engines cooling system is filled with
coolant Fmish IDling the cooling system from the remote tank once the system is filled and is free of air and
exhibits good coolant circuIaIion During engine operation checking the engines coolant should be done
at the remote tank and not at the engine manifold cap
The hose connection from the heater to the remote expansion tank should be routed and supported so as
to rise continuously from the heater to the tank enabling any air in the system to rise
WESTERBEKE
Engines GeneratolS
EARLY MODEL ENGINES
Domestic Hot Water
Both the 20B TWO and the 30B THREE en
gines are equipped with a domestic hot water
connection If the wishes to
connect a hot water heater remove the
bypass hose and connect a heater as
described In the Instructions presented
below
General WIth the bypass hose part
30962 removed there remain two connect
ing points A and B for hoses to run to and
from the water heater These connections
assure a flow of hot water through the heater
at all times but do not restrict the engines
cooling water
Row Controller
Installation The heater should be mounted conveniendy either in a high or low position in relation to the an
gine so that the Connecting hoses from the heater to the engine can run in a ieasonabIy direct line without
any loops which might trap air Connection point A on the Row Control housing should connect to the lower
of the two connections on the water heater whDe the upper connection on the heater returns to connection
B nearest to the heat exchanger
REMaTE EIrANSIOI TARr
PRESSURE CAP IS RITED
LOIER TIAN MANIFOLD CAP KEATER calLS ABOYE
PRESSURE CAP ON EN611E
BEATER COILS BELOI
REMOYE RETURN BENO FROM PRESSORE CAP ON EIINE
ENINE FLOW CONTROLLER MANIFOlO
RIR BLEED PETCOCl
HERTER BELOW ENINE
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
LUBRICATION Oil
For engine lubrication use lubricating oil designated for diesel service These oils according to the API into service grades CF and CG4 The use of
CF or higher CG4 grades made by wellknown manufactures is recommended The oil
selected should be used Oil Viscosity SAE Number
Use an oD having a viscosity best suited to the atmospheric temperature Use of an allseason oil SAE 1OW
30 with minimum viscosity change under different temperatures is suggested
Atmospheric Temperature Viscosity
68 F 20 C or higher SAE 30 or 10W30
41 F 5 C 68 F 20 C SAE 20 or 10W30
41 F5 C or lower SAE 10W30
NOTE Do not use an engine lubricating on with an SAE number greater than 30 in the engine
Oil Pressure
The oD pressure during operation of the engine is indicated by the on pressure gauge on the Admiral normal operation the on pressure will range
between 30 and 55 psi At idle speed the oil pressure
witl range between 15 and 30 psi At the time of cranking the oil pressure will rise with speed
NOTE A newly started cold engine can have an oil pressure reading upwards of 55 psi A
warmed engine can have an oil pressure reading as low as 15 psi These readings may also
vary depending upon the speed at which the engine is running
Engines Generators
Engine Oil Change to include filter
1 Draining the Oil Sump
Remove the oil drain hose from its and lower it into a container and allow the
oil to drain or attach a pump to the end of the drain
hose and pump the old oil out Make sure the oil
drain hose is properly secured in its holder after
all of the old oil has been observe the old oil as it is removed A yel
lowgray emulsion indicates the presence of water
in the oil Although this condition is rare it does
require prompt attention to prevent Call a competent mechanic should
water be present in the oH Sea water present in
the oil can be the result of a fault in the attached to the engine andor a siphoning
l y
through the sea water cooling circuit into the ex
tiaust filling it up into the Replacement of the Oil Filter
When removing the used oil filter you may find it
helpful and cleaner to punch a hole in the upper
and lower portion of the old filter to drain the oil
from it into a container before removing it This
helps to lessen spRiage A small style should be helpful in removing the old
oil filter Place some paper towels and a plastic
bag around the filter when unscrewing it to catch
any oil left in the filter Oil or any other fluid on the
engine reduces the engines cooling keep your engine clean Inspect the old
oil filter as it is removed to make sure that the rub
ber sealing gasket came off with the old oil filter If
this rubber sealing gasket remains sealed against
the engine block gently remove it The replace
able oil filter requires no cleaning in
side so it may be properly disposed of
When installing the new oil filter element wipe the filter gaskets sealing surface on the engine block free of
oil and apply a thin coat of clean engine oil to the rubber gasket on the oil filter Screw the filter onto the
threaded oil filter stUb and then tighten the filter firmly by hand
NOTE GeneriC filters are not recommended as the material standards or diameters of im
portant items on generic parts might be entirely different from genuine parts Immediately
after an oil filter change and oil fill run the engine for a few minutes to make sure the oil pres
sure is nonmal and that there are no oil leaks around the new oil filter
WESTERBEKE
Engines Generators
3 Filling the on Sump
Add fresh oil through the oil filler cap on the valve cover
After refilling the oil run the engine for a few moments Oil Filler Cap
while checking the engines oil pressure Make sure there
Rocker over
is no leakage around the new oil filter or from the oil and stop the engine Fill to but not cover the high
mark on the dipstick should the engine require additional oil
Oil Dipstick
lower
v WESTERBEKE
Engines Generators
JS General
The gear ratio is 247 to 1 The JS transmission is made of a lightweight cor
aluminum alloy suitable for the marine environment This manual transmission rotates op
pose to the engine when in forward gear The JS transms power w casehardened helical gears and
in reverse an intermediate gear The reversing process is carried out by a seNO double disc system For
safety reasons the transmission is NOT filled with lubricating oR for shipment Before leaving the factory
however each transmission is thoroughly tested wh oil in the transmission This testing among other
things provides all internal partswh a coating of oil This oR acts as a preseNative providing reliable protec
tion against corrosion for at least one year if the transmission is properly stored
UAI loa
tollTlIL
OIl UIII
PUtO
6 mm Allen Head
Lubrication
The JS transmission is an type Fmthe transmission up to or near the top of th
machined notch cut on the dipstick with SAE 20 W20 or SAE 30 weight engine oil exclusively
Multigrade oils are not to be used in this transmission DO NOT mix grades of oil Lubricating oils should
have an API specification of CF CG4 SD or SE
The oil capacity for the JS transmission is approximately 10 quart 10 Ier Check the oil level daily after
the engine has been warmed and stopped The oil level should be maintained at the top of the machined
flat on the dipstick when the dipstick is completely inserted into the transmission housing Make sure that
the two Oring gaskets on the dipstick are in good shape These Orings will help keep the dipstick in place
Change the transmission oil after the first 30 hours of engine operation and thereafter every 250 hours or
once per year minimum The JS has a 6 mm Allan Hex wrench drain plug for draining the old oR To make
sure most of the old oil will drained from the transmission run the engine in NEUTRAL for approximately 10
to 15 minutes so the oil may warm and flow better from the transmission This oil may also be removed by
inserting a small tube through the dipstick opening where the oil is added and attaching a pump onto the
tube so the oil may be sucked out The operating oil temperature must not exceed 250 F 120 C
Engines Generators
between the coupling and the propeller shafts coupling can create Make sure the alignment procedures outlined in the Propeller Shaft Coupling the
the Alignment of the Engine in the Westerbeke installation manual are adhered to
Controls
The only controls requirjd to operate is a single lever remote con
ERR BOX SHXFT LEVER
trol cable The cable should be attached
to the gear box lever using the cable
bracket supplied with the unit Both the
gear box lever and the remote control
lever must be in the NEUTRAL position
when the cable is attached to the gear
box lever This allows the remote cable
an equal throw distance to shift the gear
box into FORWARD or into REVERSE
from the NEUTRAL position without run
ning out of cable Allow approximately 1
12 inches of cable throw from the
NEUTRAL position on the gear box levertothe each of the two drive EIOSE
aTIIL
positions
NOTE If the throw distance or
travel of the remote cable is too
short the gear box lever cannot
fully engage the transmission into
OIPST
FORWARD or REVERSE In this
situation the inter
nal clutches will wear prematurely
and the transmission may over
heat and eventually faU
NOTE Excessive throw distance in
the remote control lever is not
detrimental to the Note that the position of the remote
control lever should align with the
NEUTRAL marking on its bracket
when the transmission is really in AT
BRACKET
NEUTRAL
Engines Generators
Shifting
To shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever A
gentle throw may not carry enough force to actually shift the internal gears A genUe throw is
signalled by the transmission not engaging into the desired drive Make sure the remote control lever is lubri
cated at lease once each operating season Shift the transmission whOe the engine is running at 1200 rpm
or below
CAUTION
NEVER remove or loosen the twobolt gear box lever cover from transmission The position
of this plate and the actuating lever inside of the transmission has been finely adjusted at the
factory to ensure equal throw distance of internal mechanisms Loosening of this covers
capscrews voids the warranty
Sailing Operation
JIle JS transmission should be left in its NEUTRAL position whOe saDing Leaving the transmission in
NEUTRAL whOe saDing alleviates unnecessary drag on the vessel because the propeller is able to freewheel
spin However it the transmission is left in its FORWARD gear whOe saDing the transmission will not be
damaged Leaving the transmission in NEUTRAL is just good saOing practice
Service
If any seal on the transmission shows signs of leaking have the transmission looked at by a qllllified Wester
beke Dealer This problem especially conceming the rear seal is often contributed to an improper align
ment of the coupling and the propeller shafts coupling
Never loosen the gear box lever cover screws except in the course of qualified servicing this upsets criti
cal Disassembly of the transmission in the field is not recommended If an overhaul or repair is needed the
WOI1 shciuId be done by Westerbeke or an authorized Westerbeke service center
Cooling
The JS transmission is sea watercooled Sea water enters the transmission through a stainless steel inlet
pipe located at the base of the bell housing This water helps to cool the lubricating oil
Engines Generators
THE MODEL 120 HAS A BREATHER PRM NEWAGE FITTING ON THE TOP OF THE CASE
MODELS 80 AND 120
SERIAL NUA4BEI Push a suction pump hose down through the dipstick hole
DIFSTIlK 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 Remove the drain plug
A 8MM HEX PLUG
from the bottom of the transmission I with sealing
washer and allow the oil to drain into a container then
reinstall the plug with its sealing washer Wipe down the
transmission and properly dispose of the used oil After
running the engine shut down and recheck the oil level
NOTE W7zen changing the oil take care not to lose the drain
plug sealing washer The drain plug will leak withaw this
sealing washer
A WARNING Never pull out the dipstick while the
engine is running Hot fluid will splash from the
dipstick hole This could cause severe bums
DAILY OPERATION
INITIAL OPERATION o Check the transmission oil
Before getting started remove the dipstick and fill the gear o Visually check the gear shift linkage and
box with engine oiLUse a heavy duty engine oil with an API of CF or CG4 or better For D Start the
engine in neutral allowing a few minutes
recommended oil viscosity see the following chart at idle to warm the oil
o Shift into gear
Operating Temperature Oil Viscosity NOTE Too Iowan idle speed will produce a chanering noise
Above 68 F 20 C SAE 30 10W30 or lSW40 from the transmission gear and damper plate In such cases
the idle speed should be increased
41 68 F 520 C SAE 20 or 10W30
Below 41 F 5 C SAE 10W30 GEAR SHIFTING
The engine most be at idle Pause in neutral before selecting
ahead or astern Transmission models PRM 80 and 120 ate
ideal for single lever engine controls controlling both the
A CAUTION DO not allow two or more brands of thronle and the gear shift at one time
engine oil to mix Each brand contains its own
additives additives of different brands could react in
the mixture to produce properties hannful to your A WARNING When shifting gears bring the engine
transmission throttle to idle and pause in neutral before shifting
ahead or astem
Fill the transmission with the recommended capacity oil
model PRM8010 US pint O6L model PRM 12014 US
pints O8L
LOCKING THE PROPELLER
Locking of the propeller shaft by an additional brake is not
NOTE Always clean the area arowui the dipstick plug before required Use the geat shift lever position opposite your
filling with oil Replace the dipstick by screwing it down direction of travel for this purpose Never put the gear shift
Run the engine to warm up the oil and after shutting down the in the position corresponding to the direction of travel of
engine recheck the oil level the boat
CHANGING THE TRANSMISSION OIL WHEN UNDER SAIL OR BEING TOWED
Change the oil for the first time after about 25 hours of Rotation of the propeller without load such as when the
operation then every 250 operating hours or at least boat is being sailed being towed or anchored in a river as
once a year or when you change engine oil Check for well as operation of the engine with the propeller stopped
leaks and make visual inspection of the shift cables and for charging the battery will have no detrimental effects
shaft coupling on the transmission
Engines Generators
PRM NEWAGE MODELS 80 AND 120
NEUTRAL
CONTROL CABLES FORWARD B A REVERSE
NOTE When installing the transmission I11i1ke certain that
shifting is not impeded by restricted movability of the
Bowden cable or rod linknge by unsuitably positioned guide
sheaves too small a bending radius etc
The control cable or rod should be aminged at right angle to
the actuating shift lever when in the neutral position The
neutral position of the operating lever on the control console
should coincide with the neutral position of this lever A greater amount of shift lever travel is in no way
detrimental and is recommended However if the lever
The shifting travel as measured at the pivot point of the actu
travel is shorter proper clutch engagement might be impeded
ating lever between the neutral position and end positions A
which in tum would mean premature wear excessive heat
and B should be at least 35mm for the outer and 30mm for generation and clutch plate failure This would be indicated
the inner pivot point by slow clutch engagement or no engagement at all
NOTE Check for proper lever travel at least each season
ProIIJem Probable Cause Excessive noise at low speeds
1 Engine idle speed too low 1 Increase idling speed
Excessive noise at all speeds 1 1 n
coupling necessary
2 Shatt misalignment 2 Check alignment with feeler gauge
3 Prop out of balance 3 Remove check pitch balance and weight
Oil level needs constant topping off 1 Power to high 1 Compare engine and transmission data
2 Oil leak 2 Inspect seals drain etc for oil leaks
Difficully in moving lever control 1 Poor installation of cable 1 Check installation remove sharp bends and turns
2 Faully cable 2 Repce
Escape of pressure from gearbox 1 Defective breather 1 Inspect breather Model 120 contact a Distnbutor or your
when dipstick is removed Model 120 WESTERBEKE dealer
If a major problem should occur contact your WESTERBEKE
Make certain the transmission oil is changed annUally dealer or a NEWAGE distributor To avoid prejudicing warranty
If the oil should become contaminated by water or the rights do not undertake repair work on the gearbox without
gearbox suffers major mechanical damage the gearbox first contacting NEWAGE TRANSMISSIONS liMITED or a
must be thoroughly flushed out and refilled with fresh NEWAGE distributor listed above or your WESTERBEKE
oil to the correct dealer
NEWAGE TRANSMISSIONS LID has distributors around Warranty
the world Listed here are those in the United States Newage transmission limited warrants that all PRM Newage
Transmissions will be free from defects in material and
AUanti Marine Gear Supply tnc
workmanship under normal use and service for a period of
418 Boston Street twenty four months
Topsfield MA 01933
Tel 9788871101 All PRM Transmissions must be correctly installed aligned
Fax 9788875599 and maintained
Transmission Marine
223 Southwest 33 Court
Hamilton Jet PO Box 21086
1111 NW Ballard Way Ft Lauderdale FL 333351086
SeaHle WA 98107 Tel 2067848400 Fax 9544671525
Fax 2067837323 Or contact your WESTERBEKE dealer
y WESTERBEKE
Engines Generators
OPTIONAL HBW l50V HBW50 100
All HBW models tum right hand propellers
All HBW models have their own oil sumps and dipsticks
All HBW models use ATF lubricant
All HBW models should be shifted into gear in one swift motion not allowed to
slip in slowly
Control of Gearbox
1 The gearbox is suitable for single
lever remote control using 33C cable
2 The cable should attach at J
right angles to the actuating lever
using the cable bracket supplied
3 Both gear box lever and remote o
lever must be in neutral position when
cable is attached so that travel of gearbox
lever will be equal forward or reverse
4 Check that actuating lever hub does not touch cover plate hub
Maintain at least 05 mm 0002 clearance
5 Over travel of the actuating lever does no harm However
if the travel is too short to give full engagement premature
wear excessive heat generation and gear failure may result
Control of
Gearbox
Westerbeke Diesel Engines
WESTERBEKE
Engines Generators
6 The position of the cover plate underneath the
adaIing 1ever is factory adjusted to ensure lever travel
from neutraI to A and B DO NOT LOOSEN TIm CAP
SCREWS HOLDING nus ASSEMBLY Doing this
voids transmission warranty
7 Fill gearbox with automatic trnn9DiSion fluid to
the lew indiratrd by the dipstick mark See the
illusbalion to the right
8 Note tbat to check oil level the dipstick drops
on the housing It does not SCJeW in
9 The HBW gear box can be fnewheeled in Neutral
To stop propeIIer shaft roIation while UDder saiI place
the gear into Reverse
NOTE The transmission is vented through a small hole in the dipstick Keep this vent clear
Transmission Gear Ratios
20BOnIy HBW50 30B HBWIOO 1481 30B
HBWI50V These transmissions each have their own oil sumps and dipsticks The HBW transmission
uses Automatic Transmission Fluid ATF type A or Dextron II or III
Engines Generators
ENGINE tables which follow indicate procedures based upon certain problem indicators the
probable causes of the problems and the to overcome these that the engines control system electrical system is protected by a 2OAmpere manual reset
located on the rear lifting probable Calise switch ON 1 Battery OFF
1 Tum Battery ON
but no panel or
test function
2 20 Amp circuit 2 Reset the breaker
breaker is tripped by pushing in the button
3 Loose battery 3 Check the connection
cable connection to the starter and the
connection to the ground
stud on the bell switch is de 1 Faulty solenoid 1 Connection for 12 volts at
pressed no preheat connections or switch S terminal of the solenoid is
solenoid activation faulty
no electric fuel pump or
alternator excitation 1 Check the preheat switch
2 Faulty connection or 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
pmblem probable Cause switch Is de 1 Connection to 1 Check connection S at the
pressed no starter solenoid faulty starter solenoid for 12 with the switch depressed
2 Faulty START switch 2 Check switch with an
ohmmeter
3 Faulty solenoid 3 Twelve volts Is present
at the S terminal of the
starter solenoid
4 Loose battery 4 Check battery connections
connection at both the and ground
S Low batteries S Check battery charge state
Low voltage at the solenoids
S terminal with no cranks 1 Shutoff valve at 1 Retum shutoff valve to
but does not start fuel tank its ON position Now bleed
the fuel system
2 Faulty fueling system 2 Check for fuel
to engine
3 Air is in the fuel 3 Bleed the fuel system
system Locate the leak and correct
4 Fuel pump is not 4 Check pump operation
operating
S Fuel filters are clogged 5 Cleanrepace filters
6 Blockage in exhaust 6 Remove exhaust hose
from the engine and crank
to to stop 1 Mechanical Run 1 Stop engine by man
linkage disconnected ually moving the
RUN linkage to STOP
That faRing
shut OFF fuel and air
Engines Generators
Pwblem prmable Cause Stops 1 Fuel starvation 1 Check to see that the
Fuel shutoif is turned shutoff valve at the
OFF fuel tank is ON
2 Fuel pump is 2 Inspect the fuel pump to see
inoperative if it is pumping Manually
prime the system and check
the return flow
3 Water is in the 3 Pump water out of the
fuel bottom of the fuel tanks and
change the fuel filters and
bleed the fuel system
4 Exhaust system is 4 Check exhaust system for
restricted some type of blockage
such as carbon buildup at
the exhaust elbow Check
for a fault in the muffler
Check for a collapsed
exhaust runs down 1 Alternator output 1 Check drive belt tension
is low Make an output check
with a voltmeter at the B
terminal on the alternator
2 Fajjty alternator 2 Voltage leak through
the alternator when oot
operating
3 Bad battery 3 Connections are corroded
connectlons or loose at the battery orand
at the engine
I Engines Generators
MAINTENANCE AND section contains a scheduled preventive maintenance program and several adjustment procedures the
can perform without the benefit of sophiSticated and expensive tools and the preventive maintenance in accordance with the schedules listed in the
following to these scheclldes will ensure the eqUipment is maintained in the best possible condition and
that it wDi perform to expectations Those items marked by an asterisk are recommended to be per
formed by an authorized dealer or before each use
1 Check the oil sump level Maintain the oil level at or near upper level mark on dipstick
2 Check the coolant level in the plastic recovery tank Maintain this level at or above the level marked
3 Check the lubricant level and add additional lubricant as needed
4 VISUally Inspect the unit check for loose belts chafed or broken wires loose brackets and fittings
damaged hoses loose clamps and other equipment not properly secured
5 Check the fuel supply Fill tanks with a good grade of No2 diesel fuel if required
6 Chectthe separator Drain and service as required A separator
is optional but strongly 7 Check the engines gauges or lights for proper oD pressure operating temperature and starting bat
tery charging voltage once the engine is operating
8 Check the alternators output gauge rt installed for proper DC the condition of the zinc anode in the heat exchangers sea water circuit Oean or
replace the anode
as required Keep the area inside the heat exchanger clean of zinc anode After Initial 50 Hours of Operation
1 Change the engines lubrication oU and on filter
2 Replace the fuel filter element in the onengine filter and in the optional separator if a
separator has been v WESTERBEKE
Engines Generators
3 Torque the cylinder head holddown bolts
4 Adjust valve clearances
5 Adjust the aJtemator and water pump drive belt tension if required
6 LiIbricate the throttle the RUN linkage cable and the remote control cable
7 Change the transmission lubricant
8 Adjust the engines idle speed 1000 1200 After Every 100 HoIDS of Operation
1 Change the engines lubricatlon oD and oi filter
2 Adjust the aItemator and water pump drive belt tension if After Every 250 Hours of the fuel liter elements in the OIHIngine fuel filter and in the
optional After Every 500 HoIDS of OperatIon
1 Torque the cylinder head holddown bolts
2 Adjust the valve clearances
3 Crain flush and refill the fresh water cooling system
4 Check the condition of the starter motor drive pinion lubricate pinion
5 Check the resistance of the glow plugs
NOTE Items marked by an asterisk should be performed by a competent mechanic
6 of the sea water pump Examine the pumps impeller and other pump components
for wear Replace worn components as needed
7 Check the condition of the water injected exhaust elbow Inspect for corrosion and carbon buildup
clean as needed Replace if corrosion is I Engines Generators
Servicing After Every 800 Hours 01 Operation
1 Remove and check fuel injectors
Injector spray pressure
1991 psi 140 psi
140 kglcm2 10 kglcrif I
I POOR
NOTE poor fuel quality and contaminants will
shorten the injector and injector pump service
undesirable injection conditions including
115 Wiii
COOl
after dripping
2 Check the compression pressure Remove
each rNi plug and check each cylinders c0m
pression pressure The engines cranking
speed is at 280 rpm
20B TWO 30B THREE
Standard Minimum
389 psi 312 psi
28kglcm 22 kglcm2 Maximum difference between cylinders 355 psi 25 kglcm2
3 Check the a1temator for proper operation
4 Check the tightness of bolts nuts and After Every 1000 HoUrs 01 Operation
1 Remove clean and pressure test the primary heat exchanger A local automotive radiator shop should
be able to clean and test the heat exchanger
NOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning
be performed more often than ery 1000 hours
2 Check the injection pumps timing
v WESTERBEKE
Engines Generators
Cylinder Head Bolt Tightening Sequence
CAUTION
rlghten the cylinder head bolts to the specified torque before the valves are adjusted
NOTE The rocker shaft assembly should be removed to allow access to the cylinder head
bolts
2CYLIHDER 28B TWO 3CYLINDER 38B THREE
UNDERLYIN6
ENGINE
FRONT FROHT
0 0
SUB BOLTS
2 Cylinder 3 CyRnder
2OBTWO 30BTHREE
Cylinder Head Bolt rlghtening Sequence
Torque the cylinder head bolts in the numbered sequence shown in the Rlustration shown above The engine
should be cold Before torquing each head bolt loosen the bolt slightly and then tighten the bolt to the
specified torque
Torque 20B TWO Bolts 1 and 2 20 to 30 kgm
Bolts 3 4 5 6 7 and 8 542 to 6141bft 75 to 85 kgm
30B THREE Bolts 1 2 and 3 144 to 217 Ibft 20 to 30 kgm
Bolts 456789 10 and 11 542 to 6141bft 75 to 85 kgm
Rocker shaft holddown bolts 108to 1591bft 15 to 22 kgm
All Main bolts are 14 mm across the bolt head lIats
All Sub bolts are 12 mm across the bolt head lIats
Rocker shaft holddown bolts are 12 mm across the bolt head lIats
WESTERBEKE
Engines Generators
of Valve Clearances
CAUTION
TIghten the cylinder head bolts to the specified torque before making valve Adjust the valve clearances when the engine is cold
Intake 0010 inches 025 mm
Exhaust 0010 inches 025 mm
1 Pull off the air breather pipe from the rocker cover and
take off the rocker cover bolts Adjust the valve clearan
ces at TOC Top Dead Center for each cylinder when ADJUST VALVES TO 0010 IICHES
they are on their compression stroke 125 MMl
2 Adjust all valve clearances attheTop Dead Center TDC
of the compression stroke for each cylinder Take care
to align the TOC timing mark on the crankshaft pulley ex
actly with the indicator mark on the gear case as shown
on the Dlustration below If these marks are not exactly
aligned the valves may be pushed up by the piston
depending on the position of the cam lobe
3 Confirm that the valves do no move up or down when the
crankshaft is turned slightly in either direction from the
TOCmark
4 Align the mark as shown for TOC for the No 1 cylinder
on its compression stroke and adjust the valve clearan
ces for both Intake and exhaust valves for the No 1
cylinder with the engine cold
5 When setting TOC for the No2 cylinder or the No3
cylinder for the 30B THREE proceed as follows
A For the lOB TWO engine 2 cylinder from TOe for the
No 1 cylinder rotate the crankshaft 180 clockwise
as viewed from the front of the engine and adjust the
valve clearances for both intake and exhaust valves for
case
Milk on
the No2 cylinder
B For the 30B THREE engine 3 cylinder from TOC for
the No 1 cylinder rotate the crankshaft 240 clockwise
as viewed from the front of the engine to position the
No 3 cylinder at TOC Adjust the valve clearances for
both intake and exhaust valves for the No3 cylinder
Rotate the crankshaft an additional 240 clockwise to position the No2 cylinder at TDC Adjust the
valve clearances for both intake and exhaust valves for the No2 yo WESTERBEKE
Engines Generators
Injection Pump TIming Adjustment Spill fuel injection timing will result in hard engine starting and poor engine performance Adjust the in
jection timing as follows
NOTE The shutoff lever throttle must be in the RUN position while making the adjustment
or no fuel will flow to the fuel injection pump
Refer to the cutaway view of the fuel Injection pump Remove the cylinder glow plugs to allow the to be easBy rotated whDe making this adjustment
Rotate the engine so as to position the No 1
piston at approximately the beginning of its compression stroke Remove the high pressure injector line from
betweer1 the Injector pump and the No 1 injector Carefully remove the delivery valve holder from the pump
and lift out the delivery valve spring Carefully reinstall the delivery valve holder and tighten it in the the No 1 high pressure injector line to
the delivery valve holder but do not connect it to the No 1
injector rather swing the line out away from the engine so that during the timing check fuel will flow from
this line and into a bucket and not on the work the priming lever on the fuel lift pump Working this lever will prime the injector pump and fuel
will flaw from the No 1 injector line Continue priming slowly and rotate the engines crankshaft in its nor
mal direction of rotation moving the No 1 piston up on its compression stroke Observe the fuel flow from
the No 1 injector line as the crankshaft is slowly turned The instant the fuel flow stops marks the injection Check that the 19 BTDC timing mark on
the crankshaft pulley is in alignment with the on the front cover The injection timing should be within 05
DELIVERY VRLVE HOLDER
SPRING
DELIVERY
VALVE
BRRREL CO TR0 L RACI
CONTROL
PINION
PLUNGER SPRING
Cutaway View of the 30B THREEs Fuel Injection Pump
WIV WESTERBEKE
Engines Generators
Adjust the injection timing by adding or removing
shim thickness from under the injection pump 1
mm of shim thickness is equivalent to ap
proximately 10 01 change In injection timing The
addition of shim thickness retards the timing
whereas the removal 01 shim thickness advances
the timing
Injection Timing Marks
Engines 55
LAYUP Fuel System owners rely on their boatyards to prepare their craft
Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off of higher A fuel conditioner
such as STABIL or for long periods of inactivity Others prefer to stabilizer should be added Change the element in layup preparation
themselves separator and clean the metal bowl
The procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Clean
own layup and or you may use them as a up any spilled fuel
check list if others do the procedures Fuel System procedures should afford your engine protection
Top off your fuel tanks with No2 diesel fuel Fuel a layup and also help familiarize you with the such as BIOBOR and STABIL should be
added at this time needs of your engine control algae and condition the fuel Care should be taken
If you have any questions regarding layup procedures call that the additives used are compatible with the primary fuel
your local servicing dealer he will be more than willing to tilterwater separator used in the system Change the assistance
in your primary fuel tilterwater separator if the fuel system
has one and clean the separator sediment Shaft Coupling Propulsion Engine
Change the fuel tilter elements on the engine and bleed the
The transmission and propeller half couplings should always fuel system as needed Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled for 5 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water and during system Check for any leaks that may have been created in
storage in the cradle The flexibility of the boat often puts a the fuel system during this servicing correcting them as
severe strain on the propeller shaft or coupling or both while needed Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water In some cases the allow movement of the treated fuel through the has actually been bent by these
strains This does not equipment on the engine
apply to small boats that are hauled out of the water when
not in use unless they have been dry for a considerable Raw Water Cooling of time
Close the throughhull seacock Remove the raw water intake
Fresh Water Cooling Circuit hose from the seacock Place the end of this hose into a tive
gallon bucket of clean fresh water Before starting the engine
A 5050 solution of antifreeze and distilled water is check the zinc anode found in the primary heat exchanger for use in the
coolant system at all times the engine and clean or replace it as required and also clean
This solution may require a higher concentration of any zinc debris from inside the heat exchanger where depending on the areas
winter climate Check the zinc anode is located Clean the raw water to make sure the antifreeze protection is adequate
Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed drain an appropriate fresh water through the system When the bucket is empty
amount from the engine block and add a more concentrated stop the engine and retill the bucket with an Operate the engine to ensure a
complete circulation solution slightly stronger than needed for winter freeze
and mixture of the antifreeze concentration throughout the protection in your area
cooling system Now recheck the antifreeze solutions strength
Start the engine and allow all of this mixture to be System through the raw water system Once
the bucket is empty stop
With the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the raw
sump Remove and replace the oil tilter and till the sump water circuit from freezing during the winter layup as well
with new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for the
Remove the impeller from your raw water pump some
oil changing procedure Run the engine and check for proper antifreeze mixture will accompany it so catch it in a bucket
oil pressure and make sure there are no leaks Examine the impeller Acquire a replacement if needed and
a cover gasket Do not replace the impeller into the pump
until but replace the cover and gasket
A CAUTION 011 nllt leave the engines old engine Cylinder Lubrication Gasoline
IIIIn the SII1IIP llvel the layup period Engine oil and
deposits combine til produce hannful With the engine running remove the flame arrester and spray
fogging oil into the open air intake The fogging oil will stall
chemicals which can reduce the life of YOUI engines
out the engine as it coats the valves cylinders and spark
internal paris plugs for winter
WESTlRBEKE
Engines Generators
LAYUP Starter Motor SPARE PARTS
Lubrication and cleaning of the starter drive pinion is advis Layup 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 Check your basic
remove the starter Take care in properly replacing any electri spares kit and order items not on hand or replace those items
cal connections removed from the starter used during the layup such as filters and zinc anodes Refer
to the SPARE PARTS section of tltis manual
Cylinder Lubrication Diesel
If you anticipate a long layup period 12 months or more WESTERBEKE recommends removing the glow plugs or The
of your WESTERBEKE engine after a
fuel injectors for access to the cylinders Squirt light seasonal layup generally follows the same procedures as
lubricating oil into the cylinders to prevent the piston rings those described in the PREPARATIONS FOR STARTING sec
from stiCking to the cylinder walls Rotate the engine by hand tion regarding preparation for starting and normal starts
two revolutions then replace the glow plugs or injectors However some of the layup procedures will need to be
Make sure you have a replacement if removing the injector counteracted before starting the engine
sealing washer for the injector and fuel line return 1 Remove any rags that were placed in the exhaust intake
manifold or flame arrester
NOTE If engine storage is going to be a lengthy one 12
months or beyond it is wise 1lJ rotate the engine by hand two 2 Remove the raw water pump cover and gasket and discard
complete tums every additional 4 months to allow the iiec the old gasket Install the raw water pump impeller
tion pump components to move This will help prevent their removed during layup or a replacement if required
sticking during extended storage periods Install the raw water pump cover with a new cover gasket
3 Reinstall the batteries that were removed during the lay
Intake Manifold and ThruHull up and reconnect the battery cables making sure the
Place a clean cloth lightly soaked in lubricating oil in the terminals are clean and that the connections are tight
opening of the intake manifold to block the opening Do not Check to make sure that the batteries are fully charged
shove the cloth out of sight If it is not visible at 4 Remove the spark plugs wipe clean regap and install
and an attempt is made to start the engine to proper tightness Gasoline
you may need the assistance of a servicing dealer Make a S Check the condition of the zinc anode in the raw water
note to remove the cloth prior to startup The throughhull circuit and clean or replace the anode as needed Note
exhaust port can be blocked in the same manner that it is not necessary to flush the water
Intake Manifold Gasoline solution from the raw water coolant system When the
engine is put into operation the system will selfflush in a
Clean the filter screen in the flame arrester and place a clean short period of time with no adverse affects Also open up
cloth lightly soaked in lube oil around the flame arrester to the heat exchanger ends and clear out any accumulated
block any opening Also place an oilsoaked cloth in the debris
throughhull exhaust port Make a note to remove cloths prior
to startup 6 Check the transntission fluid if it had been topped off
during the layup lower the level of the fluid to normal
Transmission Propulsion Engine Propulsion Engine
Check or change fluid in the transntission as required If the 7 Make certain all electrical connections and switches are
engine is to be layed up 12 months or more fill the transmis in the correct position and there are noloads on the
sion to the very top to prevent corrosion Lower the fluid to generator at start up Generator
its normal at Wipe off grime and grease 8 Start the engine in accordance with the procedures
and touch up unpainted areas Protect coupling and output described in the PREPARATIONS FOR STARTING
flange with an anticorrosion coating Refer to the section of tltis manual
TRANSMISSION SECTION in tltis manual for additional
infonnation
Batteries
If batteries are to be left on board during the layup period
make sure they are fully charged and will remain that way to
prevent them from freezing If there exists any doubt that the
batteries will not remain fully charged or that they will be
subjected to severe environmental conditions remove
the batteries and store them in a warmer more compatible
environment
I Engines Generators
W 20B TWO MARINE DIESEL ENGINE
GENERAL Type Diesel fourcycle twocylinder fresh vertical inline 18 hp at
3600 rpm Mechanical centrifugal Mechanism Chamber Swirl
chamber type
Bore Stroke 299 x 276 inches 76 x 70 mm
Piston Displacement 3875 cubic inches 0635 Order of Rotation Clockwise
when viewed from the Torque at 2200 rpm 30 Ibft 415 Ratio Pressure 398 psi 28 kgcm2
at 280 rpm
Valve Seat Angle Intake 45
Exhaust 45
Valve Clearance Intake 0010 inches 025 mm
engine cold Exhaust 0010 inches 025 Height 1975 inches 50165 mm
Width 1600 inches 40640 mm
Length 2587 inches 65710 Continuous 14
Temporary 25 not to exceed 30 min
Dry Weight 228lbs 1034 kgs
Fuel Consumption 07 US gph 265Iph running at
propeller allowing 2500 rpm RPM
Idle Speed 1000 1200 rpm
Cruise RPM 2500 3000 rpm
Engines Generators
20B TWO MARINE DIESEL SYSTEM FUEL SYSTEM
General Open flow totally manual priming
Fuel No2 Diesel cetane 45 or better
Injector Pump InIlne plunger type Bosch type
Engine Timing 19 t 1 BlDC
spUi timing Static
Injector Pressure 1991 psi 140 kgcm2
Nozzle Throttle type
U1tPump 12volt DC lift capacity 5 ft 15 m
PN 037818
Air cleaner Plastic screen type cleanable
Air Row engine combustion 406 cfm 11 cmm
COOUNG SYSTEM
General Fresh watercooled block
with heat exchanger
Operating Temperature 170 1900 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller beltdriven
PN 037015
Raw Water Pump Positive displacement rubber impeller
PN033636 Raw Water Row at 3600 rpm 111 US gpm 42Ipm approximate
measured before discharging
into exhaust elbow
System Capacity fresh water 29 qts 27 liters
LUBRICATION SYSTEM
General Pressure type by TrOChoid pump
geardriven with external pressure relief valve
I Engines Generators
Westerbeke Engines
W 208 TWO SYSTEM Operating OD Pressure 150 450 psi 10 31 kgcm2
engine hot
CD Grade API specification of CF or CG4
Sump Capacity including fmer 30 US qts 28 SYSTEM
StartIng Battery 12VoIt 35 AH negative ground
recommended 45 AH cold areas
Battery Capacity 90 125 StartIng Aid Glow plug sheathed type
Starter Motor 12VoIt 12KW solenoid actuated shift
DC NoLoad Current 100 Amps at 115 Volts 3000 rpm min
Cold Cranking Current 125 Amps at 10 Volts 805 rpm min
Alternator 12Volt DC 50 Amps
Regulator Internal regulator built into General JS Transmission Casehardened helical gears
with an intermediate
reverse gear Reversing carried out by a servo
double disc system
Standard Gear Ratio 2471
Propeller Shaft
Direction of Rotation Right handed standard Propeller 140 X 11 P 2 blade or 14 D x 9 P 3 blade
USing JS transmission Propeller should allow the engine to reach
2471 reduction its full rated RPM 3600 000 100 at full open
throttle while underway
Lubricating on Grade API specification of CF or CG4
SAE Grade SAE 20W20 or SAE 30 exclusively
DO NOT mix grades of on
DO NOT use multigrade OilS
Transmission Sump
Capacity 1 qt 1 liter
Engines Generators
W 30B TlIREE MARINE DIESEL ENGINE
GENERAL Type Diesel fourcycle fresh vertical inline 27 hp at 3600 rpm
Mechanical centrifugal weight type
Valve Mechanism Chamber SwIrl chamber type
Bore Stroke 299 x 276 inches 76 x 70 mm
Piston Displacement 5909 cubic inches 0952 Order of Rotation
Clockwise when viewed from the Torque at 2200 rpm 43 Ibft 59 Ratio Pressure 398
psi 28 kglcm 2 at 280 rpm
Valve Seat Angle Intake 45
Exhaust 45
Valve Clearance Intake 00098 inches 025 mm
engine cold Exhaust 00098 inches 025 Height 1975 inches 50165 mm
WKlth 1600 inches 40640 mm
Length 2881 inches 73177 Continuous 14
Temporary 25 not to exceed 30 min
Dry Weight 272 Ibs 1233 kgs
Fuel Consumption 119 US gph 45 Iph running at
Propeller allowing 2500 rpm RPM
Idle Speed 1000 1200 rpm
Cruise RPM 2500 3000 rpm
I Engines Generators
30B THREE MARINE DIESEL SYSTEM SYSTEM
General Open flow totally manual priming
Fuel No2 Diesel cetane 45 or better
Injector Pump InIlne plunger type Bosch type
Engine Timing 19 1BTDC
spDI timing Static
Injector Pressure 1991 psi 140 kgtcm2
Nozzle ThrotUe type
Lift Pump 12volt DC lift capacity 5 ft 15 m
PN037818
Air cleaner Plastic screen type cleanable
Air Flow engine combustion 604 cfm 17 cmm
COOUNG SYSTEM
General Fresh watercooled block
with heat exchanger
Operating Temperature 170 190 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller PN 037015
Raw Water Pump Positive displacement rubber impeller
PN033636 Raw Water Flow at 3600 rpm 111 US gpm 42 Ipm approximate
measured before discharging
Into exhaust elbow
System Capacity fresh water 4 qts 38 SYSTEM
General Pressure type by Trochoid pump
gearJriven with extemal pressure relief valve
v WESTERBEKE
Engines Generators
30B THREE MARINE DIESEL SYSTEM OUFilter Full flow paper element spinon type
PN036920
Sump Capacity Qncluding filter 37 US qts 3Sliters
Operating 011 Pressure engine hot 15 45 psi 10 31 kgcmlJ
OUGrade API specification of CF or SYSTEM
Starting Battery 12volt 26 AH negative ground
recommended 35 AH in cold areas
Battery Capacity 90 125 Starter 12Volt 12 KW reduction type
PN034552 DC NoLoad Current 100 amp max at 115 volts 3000 rpm min
DC Cranking Current 190 amps at 10 volts 805 rpm min engine cold
DC Alternator 12 volt DC 50 amps
General JS Transmission Case hardened helical gears with an
intermediate reverse gear Reversing
out by a selVO double disc system
Standard Gear Ratio 2471
Propeller Shaft Direction of Rotation Right handed standard Propeller 180 x lIP 2 blade or 180 x 9P 3 blade
using JS transmission 2471 reduction propeller should allow the engine to reach its
full rated rpm 3600 000 100 at full open
throttle while underway
Lubricating Oil Grade API specification of CF or CG4
SAEGrade SAE 2OW20 or SAE 30 exclusively Do not
mix grades of oil or use multigrade oils
Transmission Sump Capacity 1 qt 1 liter
WESTERBEKE
Engines Generators
TORQUE Lbt head bolt main wet M10 14 5423 6146
75 head bolt sub wet MS 12 1446 2169 2030
See the CylInder Head Boh TIghtening rod cap nut M8 14 2314 2531 32 35
Flywheel bolt M10 17 6146 6869 pulley nut M16 24 7231 8677
100 120
Main Bearing cap bolt M10 17 3615 3977 shaft hoIddown bolt M8 12 1085 1591
15 22
Rocker CCNer nut M6 10 362506 holder flttIngto engine M20 21 3615 4338
union coIortilClng nut M12 17 1808 2169 retaining nut M16 21 2531 2S92
3540
Fuel injection pipe nut M12 17 1808 2531 valve holder M16 17 2531 2820
35 pump hollow screw M10 14 723 1085 locknut M30 36 2892 3615
temperature gauge joint M16 23 1446 2169 2030
01 filer M20 17 795940 1113
00 relief plug M18 22 2892 3615 4050
01 drain hose plug 18 19 3615 4338 50 60
Glow plug M10 12 1085 1446 15 20
Glow plug lead wire fitting nut M4 7 0723 108 01 015
NOTE Hardware listed on the previous page is metric with values given as in the following
example Flywheel boItM10 17 M10 diameter 17 indicates
17 mm across the flats of the bolt head
Wet indicates that the bolts If removed are to have a thin oil film wiped on them before
they are retorqued If the bolts have not been removed and need only to be retorqued then
no aD is needed Refer to page 69 for the location of the main and sub bolts
WESTERBEKE
Engines Generators
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES
Unless stated otherwise for a specific assembly use the following torque values when tightening stand
ard hardware
Pitch Ibft kgm
Grade4T
6mm bolt headnut 1 29 51 04 07
8mm bolt headlnut 125 72 116 10 16
10mm bolt headlnut 125 137 224 19 31
10mm bolt headlnut 15 130 217 18 30
12inril bolt headlnut 125 OSO 253 398 35 55
12mm bolt headlnut 15 253 398 35 55
12mm bolt headlnut 175 217 362 30 50
13mm bolt headlnut 15 325 SO6 45 70
14mm bolt headnut 15 362 579 50 80
14mm bolt headlnut 2 340 557 47 77
16mm bolt headlnut 15 542 796 75 110
16mm bolt headlnut 2 514 767 71 106
Grade IiI
6mm bolt headlnut 1 43 65 06 09
8mm bolt headlnut 125 108 159 15 22
IOmm bolt headlnut 125 217 325 30 45
101nm bolt headnut 15 195 304 27 42
12mrn bolt headlnut 125 OSO 362 579 50 80
12mm bolt headlnut 15 362 SO6 50 70
12mm bolt headlnut 175 347 492 48 68
Glilda II III 11l1li B B
6mm bolt headlnut 1 5887 08 12
8mm bolt headlnut 125 145 217 20 30
10mm bolt headnut 125 289 398 40 55
10mm bolt headnut 15 268 376 37 52
12mm bolt headlnut 125 OSO 542 759 75 105
12mm bolt headlnut 15 SO6 651 70 90
12mm bolt headlnut 175 434 615 60 85
13mm bolt headlnut 15 579 868 80 120
14mm bolt headlnut 15 723 1085 100 150
14mm bolt h8adJnut 2 687 1013 95 140
16mm bolt headlnut 15 1085 1664 150 230
16mm bolt headlnut 2 1013 1591 140 220
Gradali capsr
14UNC 9 11 12 15
14UNF 11 13 15 18
516UNC 18 20 25 28
516UNF 21 23 29 32
38UNC 28 33 37 46
38UNF 30 35 41 48
716UNC 44 49 61 68
716UNF SO 55 69 76
12UNC 68 73 94 101
12 UNF 73 80 101 111
Engines Generators
SPARE PARTS
Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than
your home port certain spare parts should be kept on board to help minimize delays in your refer to your engines Parts List for part numbers when
ordering spare parts Listed below are
those spare parts that should be carried on board at all times
1 An Impeller kit
2 A Fuel System hardware kit
3 A Seconclruy Fuel Filter
4 An Water Pump Belt
5 Hose Clamps
6 A Spare Oil Filter with a Spare Quart of Diesel Service Engine Oil along with a Quart of
Transmission Oil and a Gallon of Premixed 7 Zinc Anodes
8 Heat Exchanger End Cap Gaskets
9 Oil Pressure Switch and parts whose life epectancy cannot be accurately should be carried on board in
addition to those listed above especially if the vessel is to be taken on long ocean voyages These parts
are listed below
1 Fuel Injectors or injector nozzles these can be installed by injection shop
2 Glow plugs
3 Cooling System Hoses
4 An Alternator
5 A Starter
6 A 20 Amp DC Circuit Breaker
7 A Fuel Lift Pump
8 A Raw Water Pump
9 Battery Terminal spare parts listed directly above are those we recommend be carriedon board during long You may wish to ask other boat owners who
have similar crafts and who have completed long
ocean voyages as to what spare parts they carried on board and what parts were needed at specific times of
the voyage 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 for a listing of the Westerbeke dealers located on your
route
WESTERBEKE
Engines Generators
Engines Generators
Declaration of of Council Directives EMC to Which Conformity ENS00811
is declared ENs00822
Name Westerbeke Address 150 John Hancock Road
Myles Standish Industrial Park
Taunton MA 027807319 USA
Type of Equipment Marine Diesel Name Westerbeke Marine
Diesel 12CTWO 20BTWO 30BTHREE
3SCTHREE 44AFOUR 63DFOUR
82BFOUR 80N4 11OT4 120N6
Options The equipment listed is only for use in Marine Applications aboard boats
2 The equipment listed must be located below decks on the vessel and
Permanently installed in its location
3 The equipment listed must be wired to the grounding system of the vessel
I the undersigned hereby declare that the equipment specified above conforms to
the above Directives and Taunton Massachusetts September 25 2001 Carleton F Bryant
FuU Name
Chief Operating Officer
IONAL MA NE Rond PoInt IIdMMWn e eox e
a UNO BRUXEUES
zzsa
CER TIFICA TE
We hereby certify that the engine stated below meets the EC Directive 94I25IEC including
powoer declaration In aeeordanee with ISO 8665
for model year
2000
Inboard
lAwIl Highest 1 2 3 4 Lowest Output 5
Power kW 11
Propeller Shd Power kW 10
a600
Th
1
INome U
IDNWESTEROO7
Nome
EU Noti6ad Body No
Ulrich Heinemann
Managing Director
0609
011 12000

Ad by Google

Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.