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Westerbeke Diesel 30b Three Parts Manual




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TECHNICAL MANUAL
20B TWO
30B THREE
MARINE DIESEL
PROPULSION ENGINE
Publication 037600
Edition One
April 1990
j r WESTERBEKE
J WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
I 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA
SAFETY following symbols appear in this manual to call attention Be sure the unit and its surroundings are and emphasize conditions
potentially dangerous to Use Extreme Care When Handling Engine Fuel
A constant danger of explosion or fire exists
IWARNINGI
Do not fill fuel tanks while the engine is running
The above symbol is used in the manual to warn of possible
Do not smoke or use an open flame near the engine or the
serious personal injury or loss of life fuel tank
CAUTION
Do Not Alter or Modjfy the Fuel System
The above symbol is used in the manual to caution personnel Be sure all fuel supplies have a positive shutoff valve
of possible damage to equipment
Be certain fuel line fittings are adequately tightened and
Read the manual carefully and thoroughly before attempting free of leaks
to operate the equipment Know when dangerous exist and take necessary precautions to protect personnel Make sure a fire extinguisher is
installed nearby and is
and equipment properly maintained Be familiar with its proper use Ex
tinguishers rated ABC by the NFPA are appropriate for all
Fuels exhaust gases batteries electrical equipment and applications encountered in this and hot parts are potential hazards that could
result in
serious personal injury or death Follow recommended proce
dures carefully Use Extreme Care When Servicing operate bilge blowers for at least five minutes
before Wear rubber gloves a rubber apron and eye a engine ensure no gasoline fumes are when servicing before starting
Lead acid batteries emit hydrogen a gas
which can be ignited by electrical arcing or by a lighted
Prevent Electric Shock cigarette cigar or pipe Do not smoke or allow an open
flame near the battery being serviced Shut off all electrical
Shut off electric power before accessing electrical equip equipment in the vicinity to prevent electrical arcing
ment during servicing
Use insulated mats whenever working on electrical equip
ment
Avoid Moving Parts
Make sure your clothing is dry not damp shoes and keep your skin surfaces dry when handling Do not service the unit while the unit is
running if a
electrical equipment situation arises in which it is absolutely necessary to make
operating adjustments use extreme care to avoid moving
Remove wristwatch and jewelry when working on electri parts and hot exhaust system components
cal equipment
Do not wear loose clothing or jewelry when servicing
Do not connect utility shore power to vessels AC circuits equipment avoid wearing loose jackets shirts or sleeves
except through a shiptoshore doublethrow transfer rings necklaces or bracelets that might be caught in
switch Damage to vessels AC generator may result if this moving parts
is not done
Make sure all attaching hardware is properly tightened
Be extremely careful when working on electrical com Keep protective shields and guards in their respective
ponents High voltage can cause injury or death place at all times
Do not check fluid levels or the drivebelts tension while
the unit is operating
Exhaust Gases Are Toxjc
Do not work on the equipment when mentally or physically
Ensure that the exhaust system is adequate to expel gases incapacitated by fatigue
discharged from the engine Check exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists
IMPORTANT
PRODUCT SOFTWARE software of all kinds such as brochures drawings technical data operators and parts lists and parts price lists and other
information instructions and provided from
sources other than Westerbeke is not within Westerbekes control and accordingly is provided to
Westerbeke customers only as a courtesy and service Westerbeke cannot be responsible for the content
of such software makes no warranties or with respect thereto including the or completeness thereof and will in no event be liable for any type of
damages or in connection with or arising out of the furnishing or use of such example components and subassemblies incorporated in 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 software may
be outdated and no longer accurate Routine changes made by Westerbekes suppliers of which Wester
beke rarely has notice in advance are frequently not reflected in the suppliers software until 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 most Westerbeke products include special features that frequently do not
include complete summation product software provided with Westerbeke products whether from Westerbeke or must not and cannot be relied upon
exclusively as the definitive authority on the It not only makes good sense but is imperative that appropriate of Westerbeke or
the supplier in question be consulted to determine the accuracy and currency of the product software by the
1 Westerbeke Engines
TABLE OF CONTENTS
Section Page
20B TWO GENERAL 20B TWO SYSTEM 30B THREE GENERAL 12
30B THREE SYSTEM 13
20BTWO AND 30B THREE
ENGINE SERVICE ENGINE OVERHAUL PREPARATIONS FOR OVERHAUL ENGINE DISASSEMBLY
CYLINDER HEAD CONSTRUCTION
AND SERViCiNG VALVES AND VALVE SPRINGS VALVE CLEARANCE ADJUSTMENT GEAR CASE AND OIL
PUMP TIMING GEARS CAMSHAFTS Valve and Pump PISTON AND CONNECTING ROD
CRANKSHAFT CYLINDER BLOCK FUEL INJECTION PUMP INJECTION NOZZLE
GOVERNOR SYSTEM GOVERNOR GLOW PLUG COOLING SYSTEM Engines
2
TABLE OF CONTENTS
ENGINE 85
MARINE TRANSMISSIONS 88
TABLE OF TIGHTENING TORQUES 89
SPARE PARTS 91
INDEX 93
3 Westerbeke Engines
T9PEngine Oil
45 Exhaust Elbow
Gear Shift Lever
50 Amp Gea Battery Ground Westerbeke Diesel Engines 4
FreSh W Fill CaP
VI llilake Silenger
Zinc ImJUti
Pump
Gear Dipstick
and Oil Engine Isolator
5 Westerbeke Engines
fresh Water Fill Cap
Ger Shift lever
50 Starter with Solenoid
DC Battery Ground Westerbeke Engines 6
Air Intake Silelcer Fuel Injection Pump reht Solenord
ThrotHe and
ShutOff
Amp DC Circuit
Zinc Anode
Oil Pressure
Gear Dipstick
and Oil Filler
Lube Oil
Fresh Water Block Drain Plug Drain Ho
7 Westerbeke Engines
UNIT 10 PLATES
MODEL SPEC AVO MA USA SERNO
20B TWO UNIT 10 PLATE
MODEL SPEC AVO MA 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 10 plate on the
engine to one of the illustrations above This will allow for easy reference when seeking parts service or
technical Engines 8
20B TWO MARINE DIESEL ENGINE
GENERAL Type Diesel fourcycle twocylinder fresh Vertical inline
overhead valve mechanism
18 hp at 3600 rpm Mechanical centrifugal weight Chamber Swirl 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 Timing Intake Opens BTDC
Intake Closes ABDC
Exhaust Opens BBDC
Exhaust Closes ATDC
Valve Seat Angle Intake Exhaust 45
Valve Clearance Intake 0010 inches 025 mm
engine cold Exhaust 0010 inches 025 Length 2587 inches 65710 mm
Width 1600 inches 40640 mm
Height 1975 inches 50165 Continuous 15
Temporary 25 not to exceed 30 min
Weight 228 Ibs 1034 kgs
Fuel Consumption 07 US gph 265lph running at 2500 allowing rated rpm Speed
1000 1200 rpm
Cruise rpm 2500 3000 rpm
9 Westerbeke Engines
20B TWO MARINE DIESEL SYSTEM SYSTEM
General Open flow totally manual priming
Fuel No2 Diesel cetane 45 or better
Injector Pump Inline plunger type Bosch type
Engine Timing 19 1 BTDC
spill timing Static
Injector Pressure 1991 psi 140 kgcm2
Nozzle Throttle type
Lift Pump 12volt DC lift capacity 5 ft 15 m
PN 037818
Air cleaner Plastic screen type cleanable
Air Flow engine combustion 406 cfm 11 SYSTEM
General Fresh watercooled block
with heat exchanger
Operating Temperature 170 190 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller beltdriven
PN 037015
Raw Water Pump Positive displacement rubber impeller
PN 033636 Raw Water Flow at 3600 rpm 111 US gpm 42 Ipm approximate
measured before discharging
into exhaust elbow
System Capacity fresh water 29 qts 27 SYSTEM
General Pressure type by Trochoid pump
geardriven with external pressure relief Engines 10
208 TWO MARINE DIESEL SYSTEM Oil Filter Full flow paper element spinon type
PN 036918
Sump Capacity including filter 30 US qts 29 liters
Operating Oil Pressure engine hot 15 45 psi 10 31 kgcm2
Oil Grade 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 tMI reduction type
PN 034552 DC NoLoad Current 100 amp max at 115 volts 3000 rpm min
DC Cranking Current 125 amps at 10 volts 805 rpm min engine cold
DC Alternator 12 volt DC 50 amps
PN General JS Transmission Case hardened helical gears with an
intermediate reverse gear Reversing
out by a servo double disc system
Standard Gear Ratio 2471
Propeller Shaft Direction of Rotation Right handed standard Propeller 150 x 10 P 2 blade or 15 D x 8 P 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
SAE Grade SAE 20W20 or SAE 30 exclusively Do not
mix grades of oil or use multigrade oils
Transmission Sump Capacity 1 qt 1 liter
11 Westerbeke Engines
30B THREE MARINE DIESEL ENGINE
GENERAL Engine Type Diesel fourcycle fresh Vertical inline overhead
valve mechanism
27 hp at 3600 rpm maximum
Governor Mechanical centrifugal weight type
Combustion Chamber Swirl type
Bore Stroke 299 x 276 inches 76 x 70 mm
Piston Displacement 5909 cubic inches 0952 liters
Firing Order 132
Direction of Rotation Clockwise when viewed from the front
Maximum Torque at 2200 rpm 43 Ibft 59 kgm
Compression Ratio 231
Compression Pressure 398 psi 28 kgcm2 at 280 rpm
Valve Timing Intake Opens BTDC
Intake Closes ABDC
Exhaust Opens BBDC
Exhaust Closes ATDC
Valve Seat Angle Intake Exhaust 450
Valve Clearance Intake 0010 inches 025 mm
engine cold Exhaust 0010 inches 025 mm
Dimensions Length 2881 inches 73177 mm
Width 1600 inches 40640 mm
Height 1975 inches 50165 mm
Inclination Continuous 150
Temporary 250 not to exceed 30 min
Weight 272 Ibs 1233 kgs
Fuel Consumption 10 US gph 378 Iph running at 2500 rpm
propeller allowing rated rpm Idle Speed 1000 1200 rpm
Cruise rpm 2500 3000 Engines 12
30B THREE MARINE DIESEL SYSTEM SYSTEM
General Open flow totally manual priming
Fuel No2 Diesel cetane 45 or better
Injector Pump Inline plunger type Bosch type
Engine Timing 19 1 BTDC
spill timing Static
Injector Pressure 1991 psi 140 kgcm
Nozzle Throttle type
Lift Pump 12volt DC lift capacity 5 ft 15 m
PN 037818
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 beltdriven
PN 037015
Raw Water Pump Positive displacement rubber impeller
PN 033636 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
geardriven with external pressure relief valve
13 Westerbeke Engines
30B THREE MARINE DIESEL SYSTEM Oil Filter Full flow paper element spinon type
PN 036920
Sump Capacity including filter 37 US qts 35 liters
Operating Oil Pressure engine hot 15 45 psi 10 31 kgcm2
Oil Grade 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
PN 034552 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
PN General JS Transmission Case hardened helical gears with an
intermediate reverse gear Reversing
out by a servo double disc system
Standard Gear Ratio 2471
Propeller Shaft Direction of Rotation Right handed standard Propeller 16 D x 10 P 2 blade or 16 D x 8 P 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
SAE Grade SAE 20W20 or SAE 30 exclusively Do not
mix grades of oil or use multigrade oils
Transmission Sump Capacity 1 qt 1 Engines 14
20B TWO AND 30B THREE ENGINE SERVICE NOTE All dimensions and contained in this section are given in inches then
millimeters unless otherwise stated For example 0002 05 mm
Specified Repair Compression Pressure 39816 psi at 280 rpm 3555 psi
28 kgcm 25 Between Cylinders maximum 3555 psi
25 kgcm
Fuel Injection Order
20BTwo 12
30B Three Timing at BTDC on Compression Stroke
Spill timing static 19 Head
Bottom surface distortion Within 0002 0004
005 mm 01 mm
Valve guide 10 IN EX 0260
66 mm
Valve seat angle IN EX 45
Valve seat width I N EX 0051 0071 0098
13 18 mm 25 mm
Valve seat sinkage 0039 Service limit
1 mm
Valve Clearance IN and EX 0010 cold
15 Westerbeke Engines
Specified Repair clearance IN EX 0010 cold
025 mm
Valve head dia IN 1051
267 mm
EX 0972
247 mm
Overall length 3701
94 mm
StemOD 0260
66 mm
Stem to guide clearance IN 1051 Service limit
267 mm
EX 0972 Service limit
247 mm
Valve face angle
Valve head thickness margin width 0039
10 mm
Valve head sinkage 0020
From cylinder head to bottom face 05mm
Valve Spring
Free length 1595 1547
405 mm 393 length 13095 Ibs1398 in
594 kg355 mm
32716 Ibs11 02 in
1484 kg28 Engines 16
Specified Repair Limit
Rocker Arm
Rocker arm 10 0472
12 mm
Rocker arm to shaft clearance 0008 Service limit
02 hole dia
Front 1654 Ball bearing hole
42 mm
NO2 1339
34 mm
No3 30B Three only 1299
33 mm
Rear 1299
33 Bore
Bore size 2992 0008
76 mm 02 mm
Oversize finish tolerance o 0001 for each oversize
0 003 Within 00004
001 mm
Gasket distortion Within 00020 0004
005 mm 01 Solid Aluminum alloy
00 skirt end 2992
76 to cylinder 0001 Service limit
03 mm
17 Westerbeke Engines
Specified 001 002 003
025 050 075 from cylinder block top surface 0035
09 mm
Piston Pin
Type Semifloating type
00 0709
18 mm
Piston pin to piston clearance 0003 Service limit
008 mm
Piston pin to connecting rod clearance Pressfit load 22046 11023Ibs
1000 500 kg
Piston Rings
Number of rings
Compression 2 No1 Chrome plated semikeystone type
No2 Tapered
Oil 1 Chrome plated ring with coil width
Compression No2 0079
Oil 0118
Ring side clearance
Compression No 1
No2 0002 0004 0008
005 009 mm 02 mm
Oil ring 0001 0003
003 007 mm
Ring gap 0006 0016
015 040 Engines 18
Specified Repair Rod
Type Forged Ibeam
Bend and twist Within 0002
005 mm
Big end thrust clearance 0004 0014
01 035 Rod Bearing
Type Aluminum metal with back metal
Oil clearance 0006 Service limit
015 001002
025 050 Fully Within 0001
003 mm
End play 0002 0007
005 0175 mm
Journal 00 1693 0006
43 mm 015 mm
Pin 00 1575 0006
40 mm 015 mm
Under size finishing
Journal US
025 16817 16823
42715 42730 mm
050 16719 16724
42465 42480 mm
Pin US 025 15636 15642
39715 39730 mm
050 15537 15543
39465 39480 mm
19 Westerbeke Engines
Specified Bearing
Type Aluminum metal with back metal
Oil clearance No2 Flanged metal
Under size 001002
025 050 method Gear drive
Front journal Ball to cylinder block hole clearance 0006 Service limit
015 mm
Major diameter of cam IN and EX 1078
2737 mm
Oil clearance 0006 Service limit
015 Pump method Gear Ball bearing front and rear
Major diameter of cam 118
30 075
19 mm
Tappet to cylinder block clearance 0006 Service limit
015 mm
Push Rod
Bend Within 00118
03 Engines 20
Oil c 30 20 10 o 10 20 30 40 50
TEMPERATURE
F 20 o 20 40 GO 80 100 120
ENGINE OIL un Dii mmmwn NBI WhWuj
SRE I
NOTE API SPECIFICATION OF CF OR CG4 IN ACCORDANCE WITH THE THERMAL
ENVIRONMENT SEE TABLE
Oil Pressure Relief Valve
Type Oil Pump
Crankshaft Driven
Oil Pump and Oil Filter
21 Westerbeke Engines
Engines 22
ENGINE FOR OVERHAUL 24
ENGINE DISASSEMBLY 25
CYUNDER HEAD SERVICING 26
VALVES AND VALVE SPRINGS 30
VALVE CLEARANCE ADJUSTMENT 33
GEAR CASE AND OIL PUMP 34
TIMING GEARS 38
CAMSHAFTS Valve and Pump 41
PISTON AND CONNECTING ROD 50
CYUNDER BLOCK 54
FUEL INJECTION PUMP 56
INJECTION NOZZLE 59
GOVERNOR SYSTEM 62
GOVERNOR 65
GLOW PLUG 66
COOUNG SySTEM 67
STARTER 78
23 Westerbeke Engines
PREPARATIONS FOR OVERHAUL
1 Shut off and disconnect all fuel lines raw water and exhaust Unbolt the engine and carefully move it to the overhaul shop
3 Once at the overhaul shop drain all lubricating oil and coolant from the engine and exchanger system
4 Clean the engines exterior of all dirt and oil 1Ij ii i
i 1111
Oil Sump Drain Heat Exchanger Engines 24
ENGINE section describes the disassembly of the engine when performing a complete overhaul of the unit which follow include the disassembly of
inspection of their components parts
repair or replacement of these parts if necessary and the reassembly of the of External Parts and Remove the exhaust manifold and related hoses as a
unit Disassemble and inspect these parts
2 Remove the heat exchanger and its related hoses and mounts from the front of the engine Have the heat
exchanger cleaned and tested at a local automotive radiator repair shop or replace it if Remove the starter motor and circuit breaker assembly
Examine the starter and have it repaired or
replaced if Remove the intake silencer fuel lines fuel pump and fuel filter with bracket assembly from its attachment
on the bell housing
5 Remove the high pressure injector lines from between the injection pump and injectors Note the location
of each line
6 Remove the transmission bell housing assembly
7 Remove the raw water pump from its mounting point on the engine
8 Remove the alternator the fresh water pumps drive belt and the alternators mounting bracket
9 Remove the fresh water circulating pumps pulley and remove the fresh water pump
10 Remove the engines Remove the water temperature switch and the water temperature sender
12 Remove the oil pressure switch the oil pressure sender and the oil filter
13 Remove the thermostat housing and the Remove the crankshaft pulley from the basic engine assembly is now ready for disassembly cleaning
inspection and repair if 25 Westerbeke Engines
CYLINDER HEAD CONSTRUCTION AND
Cylinder head a cross section
CYLINDER HEAD COMPONENT PARTS
1 Cylinder head 6 Water outlet fitting
2 Valve guide 7 Cylinder head gasket
3 Cylinder head bolt main bolt 8 Mouth piece
4 Cylinder head bolt subbolt 9 Thermostat
5 Seat ring 3600 rpm specification engine 10 Thermostat Engines 26
Cylinder Head Removal
1 Remove the high pressure injection line assembly
CAUTION
When disconnecting each injection line from the injection pump side delivery valve holder
grasp the holder with a wrench to prevent it from loosening After removing the pipe assembly
plug the nozzle holders and delivery valve holders to prevent intrusion of dust
2 Disconnect the glow plug lead wire
3 Disconnect the air breather hose
4 Remove the rocker cover
5 Remove the rocker shaft assembly
6 Loosen the cylinder head mounting bolts in the
numerical order as illustrated and remove the
cylinder head assembly including the intake and
exhaust manifold Sequence for Loosening Cylinder Head Bolts 20B
7 Remove the cylinder head gasket Clean the
cylinder head and the cylinder block surface from
which the gasket has been removed
8 Remove the injector assemblies and glow plugs
from the cylinder head
9 Remove the intake manifold from the cylinder head
10 Remove the valve retainers valve springs and
valves from the cylinder head
Sequence for Loosening Cylinder Head Bolts
CAUTION
When removing each valve retainer depress the retainer against the valve spring and remove
the retainer lock Identify each valve by putting a mark indicating the number of the cylinder
from which the valve is removed
11 Remove the valve stem seals
27 Westerbeke Head Inspection and Repair
Check cylinder head surface for warpage between
Check guide for ware and damage bolt holes within O05mm
Check for valve contact Check for cracks damage
wear damage and sink of seat face water leak and remove oil sludge
sealant deposit carbon Guide Replacement 625
If a valve guide is found defective replace it
1 Remove the valve guide by pressing at its upper i
end and pull it out to the valve seat side I
2 Install the valve guide by press fitting the guide
I
from the upper side ofthe cylinder head to a height
of 14 05 mm from the valve spring seat face
Pressfitting Valve Engines 28
Valve Seat Repair
Valve sinkage
If a valve seat is found defective reface it or
replace the cylinder head
Sinkage of valve Interface
and wear
Standard Service limit
05 mm 15 mm
Checking Valve Sinkage
CAUTION
When checking valve sinkage the valve guide
must be in normal condition Resurface the
valve seat so that it contacts the midportion of
the valve face
Resurfacing Valve Seat Common to intake and exhaust Seat of the cylinder head is in the reverse
order of removal Pay attention to the Renew the cylinder head gasket No application
of sealant is necessary On the upper front of the
gasket is engine model to which that gasket is
applicable Be careful not to confuse it with a
gasket for another engine model
2 Tighten the cylinder head bolts in the numerical Sequence for Tightening Cylinder Head Bolts
order shown in the figure at right going through
that order two or three times Tighten each bolt a
little at a time until all are tightened to the specified
torque
3 When connecting the injector line assembly
loosen the pipe clamp When tightening the nut
at each end of the pipe grip the nozzle holder or
delivery valve holder with a wrench to prevent it
from being turned together with the nut Also take
care not to allow dust to enter the fuel line
Sequence for Tightening Cylinder Head Bolts
29 Westerbeke Engines
VALVES AND VALVE SPRINGS
VALVE SYSTEM COMPONENT PARTS
1 Valve stem cap 4 Valve stem seal
2 Retainer lock 5 Valve spring
3 Valve spring retainer 6 Engines 30
Valve Removal
1 Dismount the cylinder head assembly
2 Depress the valve retainer to compress the valve spring and remove the retainer lock
3 Remove the Inspection and Repair
If any parts are found defective repair or replace them
Q Wear and damage
Without for
Dents and wear
I R i d g e and damage
of Valve and Valve Spring
Valve fatigue and damage
Inspection item Standard Service limit valve spring te5ter
Free length Dim 405 I
Load kg mm 594355 15
Squareness 2 3
Margin mm 10 05
31 Westerbeke Engines
1 If the valve face is found worn down resurface it
with a valve refacer If the margin of the resur
faced valve exceeds the service limit replace the
valve I
2 If the valve stem end has been indented by wear
flatten it with an oil stone
Margin
45
Inspecting and Valve Spring Install the valves and valve springs referring to notes shown in the figure below
2 Mount the cylinder head assembly
3 Adjust the valve clearances
CAUTION
Be careful not to damage the spring and stem seal by excessively compressing the spring
when installing the valve spring
With retainer
depressed to compress
spring install
Press this surface retainer lock
Driving in Installing spring Installing spring retainer
stem of Valve Engines 32
VALVE CLEARANCE Clearance head bolts lIlUSt be retightened before adjust
ing the valve clearance When retightening the cylinder
head bolts draw out coolant loosen the bolts slightly
and then retighten the bolts to the specified torque in the 4
numerical order illustrated at right o
Tightening torque M10 bolt 542 615 Ibft
0 2 0 1
75 85 kgm
M8 bolt 108 159 Ibft Cylinder Head Bolt Tightening Sequence 208
20 30 kgm
The rocker assembly the rocker arms shaft and stays
is to be kept removed when the cylinder head bolts stay tightening torque M8 bolt 108 159 Ibft
15 22 kgm
1 Set the cylinder to be adjusted to the top dead center
of the compression stroke
Valve clearance 00098 in 025 mm cold for Cylinder Head Bolt Tightening Sequence 308
both intake and exhaust valves
ADJUST EXHUSl VUVES TO 0012 INCH
11111
2 The top dead center of the compression stroke can
ADJUST INTAKE VALVES TO 0010 ISCHES
be obtained by aligning the TOC Top Oead Center 02 MM
mark notch on the crankshaft pulley with the mark
on the gear case
3 First align the TOC mark for the No 1 cylinder
Confirm that the valves do not move up and down
when the crankshaft is turned about 20 in the normal
direction of rotation and in the reverse When setting the top dead center for the 3 cylinder
engine perform as follows
a Two Cylinder Engine From TOC for the NO1
cylinder turn the crankshaft 180 clockwise and the
NO2 cylinder is set to TOC
b Three Cylinder Engine From the TOC for the No
1 cylinder turn the crankshaft 240 clockwise to set
the No3 cylinder TOC Further turn the
crankshaft 240 clockwise and the No 2 cylinder
is set to TOC
Injection Timing Mark
33 Westerbeke Engines
GEAR CASE AND OIL PUMP
GEAR CASE COMPONENT PARTS
1 Bushings 5 Relief plunger 9 Oil pump housing
2 Plug 6 Relief spring 10 Gear case gasket
3 Gear case 7 Oil pump inner gear 11 Highpressure pump gear housing
4 Front oil seal 8 Oil pump outer gear 12 Housing Engines 34
Gear Case and Oil Pump Removal and Remove the crankshaft pulley
2 Remove the fan and fan belt
3 Remove the tierod cover from the side face of the injection pump
4 Remove the tie rod and tie rod spring Be careful not to let the spring fall into the case
5 Remove the governor cover assembly
6 Remove the water pump assembly
7 Remove the Remove the pump housing
9 Remove the gear case the removed parts If any parts are found defective repair or replace them
Cracks and damage
Wear and damage
W f7lr Wear damage and Srio f
Smooth movement
Seal surface interference
Thoroughly clean oil of Gear Case and Oil Pump
35 Westerbeke Oil Seal Remove the front oil seal
2 Pressfit the new front oil seal
CAUTION
Apply a thin coat of engine oil to the circumference and lip of the oil Shaft Bushings Remove the expansion plug and draw the bush
ings out
2 Pressfit the new bushings into positions shown in
the figure at right
To be flush with To be in contact
this plane with bottom
Press fitting Governor Shaft System Inspection
Check springs
for the governor system parts If any parts are
found defective repair or replace them
Check shaft
for flaws
Check sliding sleeve
joint for wear and damage
Check weight for wear and Engines 36
Governor Levers Disassembly and Reassembly
Expansion plug Grooved pin Projection
1 Removal of the shaft approx2mm
a Remove the expansion plug taking care not to
scratch the gear case
b Pull out the grooved pin
Section AA
2 Installation of the shaft Gear case
a Install the shaft in the reverse order of removal Installing Governor Shaft
b After installing the shaft pressfit the expansion plug
into the shaft hole in the gear case
Gear Case Tightening torque
Tightening torque
45kgm
Taper plug tightening
torque Sealant HERMESEA
H1 or THREEBOND 1344
Gear Case Assembly
37 Westerbeke Engines
TIMING GEARS
TIMING GEAR COMPONENT PARTS
1 Crankshaft gear 3 Camshaft gear
2 Idle gear 4 Injection pump camshaft Engines 38
Timing Gears Removal
1 Pry the snap ring out and remove the idle gear
2 Remove the valve camshaft and injection pump cam
shaft on which the respective gears are Remove the gears from the shafts
3 Remove the crankshaft Remove the gear from the
Gears Inspection
Injection pump
Check the removed gears If any gear is found defective camshaft gear
replace it r Check tooth faces
and end surfaces
for wear and damage
Idle gear bushing
Description Standard value Service limit
Clearance between bush
ing and shaft 003 007 02
Backlash between gears in mesh
Description Standard value Service limit
IdleCamshaft 001 014 03
IdleFuel pump Gear
Valve camshaft gear
Crankshaft gear
Inspecting Timing Gears
39 Westerbeke Gears Pressfit the crankshaft gear onto the shaft
2 Pressfit the valve camshaft gear and injection
pump camshaft gear onto the respective shafts
3 Install the gears in the following sequence
a Turn the crankshaft to set the No 1 cylinder to
top dead center on compression stroke
Idler Gear
b Install the valve camshaft and injection pump Note timing marks12
camshaft
c Install the idle gear so that timing marks on it are
in alignment with marks on the other gears
d Confirm that timing gears are in alignment with
each Engines 40
CAMSHAFTS Valve and Pump
CAMSHAFT COMPONENT PARTS
1 Camshaft valve 8 Tappet
2 Camshaft gear 9 Push rod
3 Ball bearing 10 camshaft injection pump
4 Woodruff key 11 camshaft gear
5 Sunk key 12 Ball bearing rear
6 Camshaft stopper 13 Snap ring
41 Westerbeke Camshaft Removal
1 When it is necessary to remove only the valve camshaft use the following procedure
a Dismount the cylinder head assembly
b Pull out the push rods
c Pull out the tappets
d Remove the gear case assembly
e Remove the camshaft stopper bolt
f Draw the camshaft assembly out
2 Removal of the injection pump camshaft
a Disconnect the injector lines
b Remove the injection pump assembly
c Remove the gear case assembly
d Remove the shaft rear cover
e Remove the stopper bolt
f Remove the shaft from the front of the Engines Cam lobeWear
and damage
Bend
faceWear
and damage
Journal bearingWear
and damage
Each ball
bearingWear
and noise
Cam contact
surfaceWear
and damage
Cam lobeWear
and damage
Oldhams of Camshafts
Major diameter of injection pump cam Major diameter of valve cam
Standard value 30 Standard value 2737
Service limit 07 Service limit 10
43 Westerbeke installing the camshafts give care to the Coat the bearings and cam lobes with oil
2 Install the camshafts in the reverse order of
removal
3 Position the timing marks on the gears in alignment
with the marks on the idler gear
4 After installation check and adjust fuel injection Timing Gears in Alignment with Each Other
timing and valve Engines 44
PISTON AND CONNECTING ROD
Os J
3 1l1
PISTON AND CONNECTING ROD COMPONENT PARTS
1 Piston ring No1 5 Piston pin 8 Connecting rod cap
2 Piston ring No2 6 Connecting rod 9 Connecting rod bolt
3 Oil ring 7 Connecting rod bearing 10 Connecting rod nut
4 Piston
45 Westerbeke and Connecting Rod Removal
1 Remove the cylinder head assembly
2 Remove the oil pan
3 Remove the oil screen
4 Chalk the cylinder number on the side face of the big end of each connecting rod to prevent confusion
of connecting rods
5 Remove the connecting rod cap from each piston
Pressing
and rod assembly and draw the assembly upward
from the cylinder Take care not to allow the con
necting rod to scratch the crankshaft pin and
cylinder Keep the removed parts connecting rod
rod cap piston etc classified by cylinders FRONT
mark arrow
6 Remove the rings from each piston with the piston
Piston
ring pliers
7 Using the piston setting tool pull out the piston pin
from each piston Removing Piston Pin
Piston and Connecting Rod the removed parts If any parts are found defective replace or repair them
Bend and twist
Big end play
08 Standard 01 O35mm
Damage wear
and ring gap
Wear seIzure and streaks
Clearance between piston and cylinder tf
Contact and seizure
Flaking and fusion
Wear of pston ring grooves Oil clearance
Standard Damage and wear V
of Piston and Connecting Engines of piston ring gaps Put each piston ring
into the cylinder bore and push the ring with the piston
to position the ring on square with the cylinder wall
Measure the ring gap with a feeler gauge If the meas
urement exceeds the service limit replace that piston Piston
ring
o Cylinder
CAUTION
Ring
When only the replacement of rings is to be Ring gaps
made without reboring honing of the cylinder
position the ring to be measured at the least worn Measuring Ring Gap
place of the cylinder skirt Install the new rings
having the same size as the piston Piston rings
Ring Standard Service limit
available for servicing are sized into three clas
ses STD 025 OS and 050 OS All rings 015040 of ring groove in piston Measure the for each
piston ring set in the ring groove in
the piston If the service limit is exceeded replace the
ring with a new one
Measuring Ring Side Clearance
Ring Standard Service limit
No I 03
Piston and Connecting Rod Installation No2 005009 02
Oil 003007 02
When reassembling the piston and connecting rod and
Note No I ring is of the semikey stone the piston and rod assemblies in the pay attention to the following
Pressing
1 Reassemble the piston and connecting rod using
the Piston Pin Setting Tool by pressing the piston
pin in to the set position
FRONT
mark arrow
Description Standard Piston
Pin pressfitting force
1000500kg
at a normal Installation of Piston and Connecting Rod
47 Westerbeke Engines
Pressing
Push rod
Connecting rod
FRONT mark arrow
Tool body
2 Installation of piston rings
FRONT mark
Ring set positions
No1 ring
No2 ring
oil ring
d r mark and
OS size mark
r mark and
OS size mark
Rod front
mark
OS size
paint
Align notches
accurately with
each other
Color of STO Without color
O25White
O50Blue
Tightening torque O
3235kgm of Piston Rings and Connecting Rod Engines 48
3 Set the piston ring gaps to the proper positions as
shown in the figure at right Coat the rings and
cylinder wall with oil
Olriif
No1 ring gap
Front
No2 ring gap J 0 0011
expander of oil
ring
Proper Arrangement of Ring Gaps
4 Using a piston ring compressor to compress the rings into the grooves push the piston and rod assembly
down into the cylinder Be careful not to break the rings by excessively knocking the head of the piston
Note that the front marks on the piston and connecting rod are toward the engine front
5 Coat the bearing surface of the connecting rod caps
with engine oil Fit each cap to the connecting rod
using match marks put before removal as a guide
In the case of a new rod which does not have a mark Connecting
position the notches provided for preventing the Rod
bearing from rotating on the same side
I I
49 Westerbeke Engines
CRANKSHAFT COMPONENT PARTS
1 Key 6 Washer 11 Rear oil seal case
2 Crankshaft 7 Spring washer 12 Gasket
3 Crankshaft gear 8 Flywheel 13 Flywheel bolt
4 Crankshaft pulley 9 Ring gear
5 Nut 10 Rear oil Engines Removal
1 Loosen the flywheel bolts and remove the flywheel
2 Loosen the crankshaft pulley nut and remove the
pulley
3 Remove the rear oil seal case assembly
4 Remove the main bearing caps
5 Take out the the removed parts If any parts are found defective repair or replace them
Journals and pins Damage and uneven wear
Cracks clogging of oil hole and bend
Wear of journal contact surface
Wobble
Damaged to
tooth face
Wear and of Crankshaft and Flywheel
51 Westerbeke the crankshaft for wear To check the
crankpins and main journals for tapering wear wear the diameter of each crankpin or
main journal should be measured at two places along
the crankpin or main journal in two directions A and
B each place as shown in the figure at right If
necessary regrind the crankpins and main journals to
the next under size If any crankpin or main journal
has been worn out beyond the service limit replace
the crankshaft
Checking Crankshaft for Wear
Diameter of crankpin and main journal mm Undersize diameters mm
Description Standard Service limit Description Main journal Crankpin
Main journal
43 070 025 US 39 71539 730
Crankpin dia 40 070 050 US of the crankshaft oil clearance Oil
clearance is calculated by subtracting the diameter of
main journal or crankpin from the inside diameter of
the main bearing or rod bearing To check the main
bearings and rod bearings for tapering wear and out
ofround wear the inside diameter of each main bear
ing or rod bearing should be measured after its 2
bearing cap is fastened to the specified torque at two
places along the bearing and in two directions A and
B each place as shown in the figure at right If
necessary replace the worn bearing with a new one
If the oil clearance still exceeds the service limit
Measuring Main Bearing 10
regrind the crankshaft to the next under size and
replace the bearing with one of the sizes
CAUTION
A crankshaft which has been sized cannot be reground to any under size
Tightening torque kgm Oil clearance mm
Description Standard Description Service limit
Main bearing cap bolt 5055 Main bearing 010
Rod bearing cap nut 3235 Rod bearing O Engines
Rear Oil Seal Pry the oil seal out with a Drive in a new oil seal to the oil seal case
When installing the crankshaft pay attention to the notes given in the figure below
Cap tightening Thrust bearing only
torque 50 55kgm for No2 cap
Direction of
installation of cap
J Side seals coated
7ONO
with sealant
J Round end down
Front
Make cap flush with
cylinder block end face
common to front and
rear end faces
Crankshaft end
play of 53 Westerbeke Engines
CYLINDER BLOCK
CYUNDER BLOCK COMPONENT PARTS
1 Cylinder block 5 Main bearing 9 Idler gear shaft
2 Front plate 6 Starter bracket 10 Oil filter shaft
3 Bearing cap 7 Rear oil seal 11 Oil level gauge guide
4 Cover 8 Oil seal Engines 54
Cylinder Block the cylinder block If it is found defective repair or replace the Bore mm
Mgdel Standard A pprox10mm
from upper end
20B 76 003 00
30B 76 003 00 Front
Center
Wear Umit Before Rebore 002 mm Lower
Direction of
measuing
Measuring position
Cylinder Bore Measuring reboring a cylinder use the following Select a piston size 025 as or 050 as
2 Measure the piston diameter I
3 Reboring finish dimension piston 00
clearance honing allowance 02 mm
Measure
diameter
here Lr
55 mm
Clearance between piston and cylinder
Standard 0071 0084 mm AD
Measuring Piston Diameter
CAUTION
When it is necessary for a cylinder to be rebored to the next over size the remainders must
also be rebored to the same over size
55 Westerbeke Engines
FUEL INJECTION PUMP
INJECTION PUMP COMPONENT PARTS
1 Union collar 8 Delivery valve 15 Plunger
9 Gasket 16 Lower seat
3 Delivery valve holder 10 Seat valve 17 Adjusting shim
4 Valve spring 11 Plunger barrel 18 Tappet roller
5 Holder stopper 12 Sleeve 19 Pin
6 Housing 13 Upper seat 20 Control rack
7 Oring 14 Plunger spring 21 Stop wire Engines 56
Injection Pump Inspection while on the Engine Inspection Inspection procedure Criterial
Idling speed Measure engine speed 900 sgrpm
Never attempt to disassemble the pump unless it is
necessary If the pump is assumed defective it is I Quickly accelerate
No remarkably to replace the pump assembly Exhaust smoke color engine without load
smoke exhaust permitted
2 Apply load to engine
Fuel cut off Turn ignition switch to OFF A solenoid Pump Removal
solenoid from ON sound
1 Disconnect the fuel injection pipes
2 Remove the tierod clip cover
Remove the tierod clip and tierod IJ Pipes
I I I
Injection Pump Disassembly Me
1 Remove the stopper plate
2 Unscrew the delivery holder Take out the delivery
valve and valve spring
3 Remove the tappet roller and stopper pin
4 Remove the tappet plunger spring etc
CAUTION
When replacing the plunger barrel delivery
valve etc do not loosen the adjusting screw and
plate for each cylinder When those parts have
been replaced it is necessary to measure fuel 0 injection quantity by utilizing a pump
tester and and cam box All parts removed from the pump

should be kept classified by cylinders and im fj Wear and
scratch
mersed in clean fuel
Control rack
movement
Catching
wear Pump Inspection rust seizure
riJc
wear
Inspection of Injection Pump
57 Westerbeke Pump Assembly
1 Insert the plunger barrel into the housing
2 Install the delivery valve and valve spring Temporarily tighten the holder
3 Insert the control rack
4 Insert the control pinion Align the matchmark on the rack with that on the pinion
5 Install the spring upper seat
6 Insert the plunger spring
7 Fit the lower seat to the plunger Insert the plunger into the barrel side
8 Depress the tappet roller assembly and install the stopper pin
9 Tighten the delivery holder
Tightening torque 35 39 Pump the injection pump assembly in the reverse order
of removal
Stamp
CAUTION
When installing the plunger barrel engage the
dowel pin on the housing side with the groove in
the barrel Position the plunger so that the part
number stamp on its flange faces the direction
opposite to the rack side Engage the feed hole Rack side
with the plunger lead After installation check
for proper injection timing Direction of Installation of Engines 58
INJECTION NOZZLE
9
NOZZLE HOLDER ASSEMBLY COMPONENT PARTS
1 Body subassembly 5 Distance piece
2 Shim washer 6 Nozzle assembly
3 Pressure spring 7 Retaining nut
4 Pin
59 Westerbeke Nozzle Removal
1 Disconnect the injection pipe and fuel return pipe
2 Remove the injection nozzle assembly from the cylinder head
CAUTION
Attach an number tag to the removed injection nozzle Plug the openings from
which the pipes are disconnected and the nozzle is removed to prevent intrusion of dust
water and other foreign particles into the pipes and combustion Nozzle the removed nozzle assembly is assumed defective disassemble the assembly and
repair or replace the
faulty parts
1 Grip the nozzle holder body in a vise Loosen the retaining nut Never vise the retaining nut to prevent
Take out the shim washer pressure spring distance piece and nozzle assembly
CAUTION
Scrape off carbon deposits with a wooden spatula Keep the removed parts immersed in
washing oil kerosene Take special care not to scratch the needle valve in the nozzle
Nozzle the removed parts If any part is found defec
tive replace Nozzle Assembly
Fatigue and
1 Insert the nozzle assembly into the retaining nut so gl break
that the nozzle is perfectly seated in the nut
2 Place the distance piece retaining pin pressure
spring and shim washer on the nozzle assembly
3 Tighten the nozzle holder body fully by hand Poor contact Deformation
and break
While immersed
4 Grip the nozzle holder in a vise Tighten the retain in kerosene
check for smooth
ing nut to the specified torque sliding
Tightening torque 35 40 kgm
Inspecting Nozzle
Westerbeke Engines 60
Injection Nozzle injection start pressure by increasing or
decreasing the thickness of the shim washer to be Tightening torque
Tightening torque
Varying shim thickness by 01 mm causes start pressure to change 10 kgcm
10 kinds of shims available from 125 mm to 17 mm in
thickness 005 mm step
Injection start pressure
Return pipe
Standard
Assembling the Nozzle
Allowable limit 130 kg an or Nozzle Clean the nozzle holder fitting surface of the cylinder head Install the nozzle holder with a gasket
interposed
Tightening torque 50 60 kgm
2 Connect the fuel return pipe and injection pipe
Tightening torque
Injection pipe 25 35 kgm
Fuel return pipe 25 30 kgm
61 Westerbeke Engines
GOVERNOR SYSTEM
GOVERNOR SYSTEM COMPONENT PARTS
1 Sealing metal 11 Tierod clip 21 Stop lever assembly
2 Sealing wire 12 Tierod cover 22 Oring
3 Low and high speed 13 Tierod cover gasket 23 Snap ring
4 Governor spring 14 Tension lever 24 Stop lever
5 Sliding shaft 15 Start spring 25 Grooved pin 3 x 20
6 Stopper 16 Governor spring lever 26 Grooved pin 3 x 14
7 Governor spring 17 Speed control lever assembly 27 Torque spring test
8 Governor shaft 18 Cover assembly 28 Sealing cap
9 Governor lever 19 Governor cover gasket
10 Tierod 20 Return Engines 62
Torque Spring Set Installation Torque spring set
Install and adjust the torque spring set using the follow
ing Set the speed control lever to the high idling speed
position by adjusting the high speed set bolt Turn in this torque spring
set until engine speed
2 Turn in the torque spring set until engine speed drops drops about 50rpm from
highidling speed
about 50 rpm from high idling speed
Adjust to specified
3 From this position turn back the torque spring set number of loosening
turns N
by the specified number of turns N Lock the Sealing cap
Stake after setting Number of loosening
torque spring set at that position with the special nut
4 Install the torque spring set sealing cap and stake
the cap to prevent loosening
Number of loosening
turns N
20B Two 30B Three 22
Torque spring Spring Set Assembly
2 Spring 1 Spring
When the torque spring set has been disassembled or tr component parts have been replaced
reassemble mark
and adjust the torque spring set using the Assemble the torque spring set as shown in the
figure Using the adjusting screw 5 adjust the
projection 8 of the torque spring stopper 1 from 6 Torque spring
the spring case 2 to get the specified projection
Assembling torque spring set
2 To measure the projection 8 keep the torque
spring set in vertical position as illustrated Put the
dial gauge probe against the spring stopper 1 at A Height of spring stopper B Height of case
the center of its end face using a small dial gauge
having the sensitive probe which does not com
press the torque spring when pushed against the
spring stopper end
Measuring spring stopper projection 0
63 Westerbeke Engines
3 Leaving the dial gauge set condition unvaried depress the spring stopper 1 and slide the torque spring
set support spring case 2 Read the deflection of dial gauge which corresponds to the projection of the
spring stopper from the spring case Measurement should be made two or three times repeatedly to
make sure of accurate measure For the models which do not require any torque spring action set the
projection 8 to a value in the range of 0 to 04
4 After adjustment tighten nut 4 to a torque of 08 to 12 kgm
5 Check to see that the spring stopper 1 can be depressed smoothly and that the end face of the stopper
1 can become flush with the end face of the spring case 2
6 For the purpose of of projection 8 apply paint of the color specified to the surface shown
in the figure at the right of paragraph 1
MQdeL projection 8 mm color
206 Two 306 Three o 04 Red
Replace the gear case and inspect the governor When removing the gear case be sure to remove the
tierod cover by the side of the fuel pump and disconnect the tierod from the rack If any parts are replace them
CAUTION
If the governor is assumed to be check the bearing on the gear case side
Engines 64
GOVERNOR
Check springs GJ Check levers for
smooth movements
for fatigue
Check springs
for fatigue
Check weight for
wear and damage
Check shaft
for flaws Check sliding sleeve
for wear damage
Check sliding sleeve and smooth movement
joint for wear and damage
Inspection Governor System Removal and remove the levers pull out the grooved pins which have been driven into the governor lever stop lever
and speed control lever Loosen the bolts fastening the levers and the levers and shafts one after another checking for proper pressfitting each
grooved pin check the shaft for smooth rotation Coat the Orings with oil them No deflection exceeding 20 mm is permitted for the governor spring
installed Install the
governor spring lever and speed control lever so that the play of angle between levers standard 5
5 Standard
No play exceeding
5 Instaling Speed Control Lever
65 Westerbeke Engines
GLOW PLUG
Glow Plug for conduction between the glow plug terminal and body Ifthe plug is not conductive at all or shows
a large resistance replace the plug
Glow plug tightening torque 15 20 kgm
Checking Glow Engines 66
COOLING below is a typical Westerbeke engine cooling system Both fresh water and raw waterflow through
their independent cooling circuits Refer to your generators Parts List for part numbers and part you need to order cooling system parts for your
engine
INJECTED E PRESSURE CAP
EXHAUST MANIFOLD
WATER
r TEMPERATURE
1 SWITCH
INCOMING
RAW WATER
FRESH WATER
FRESH WATER DRAIN
RAW WATER
RAW WATER DRAIN
Typical Cooling System
67 Westerbeke Water Pump Drive BeH models come equipped with belt guards that cover over the belts on the front of
the engine
Out of sightout of mind The belt guard is not installed for that purpose Operators are advised that
the inspection service and maintenance spoken of below should be followed
IWARNINGI
Never attempt to adjust the drive belts tension while the engine is in operation
CAUTION
Excessive water pump drive belt tension can cause rapid wear of the belt and reduce the
service life of the fresh water pumps bearings Excessive slack or the presence of oil on the
belt can cause belt slipping resulting in high operating 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 between the two
pulleys on the longest span of the belt A spare drive belt should be carried on board
Raw Water Pump
The raw water pump is a selfpriming geardriven rotary pump with a nonferrous housing and a The impeller has flexible vanes which wipe against a
curved cam plate within the impeller the pumping action On no account should this pump be run dry There should always be a
spare impeller and impeller cover gasket aboard an impeller kit Impeller failures occur when water is not present Such failures are not warrantable
and the operators are cautioned to make sure
raw water flow is present at startup Know your pump know its location on the engine and know how to
change the impeller in it
CURVED CAM PLATE
RAW WATER the impeller with the aid of two small screwdrivers as illustrated and carefully pry the impeller
out of the pump Install the impeller by positioning the hub pin to align with the slot in the drive shaft
Move the blades to conform to the curved cam plate and push the impeller into the pumps Engines 68
Raw Water Pump Overhaul
Raw water pump 033636 repair instructions are as pump as removed from the engine will have hose attachment nipples threaded into the its inlet and
outlet port They may be left in place or removed if they interfere with the pump disassembly Note the
port location and positioning if Remove the six cover plate screws ref 13 cover plate ref 12 and the cover plate gasket ref 11
NOTE Screw material should be stainless steel part number 034463 Also replacement of
the cover plate gasket is recommended however if you are going to reuse it keep the gasket
submerged in water until the pump is reassembled If its allowed to dry the gasket will shrink
and not be reusable
b Remove the impeller ref 9 with its drive screw ref 10 from the pump housing
c Remove the screw ref 4 and sealing washer ref 5 and draw the cam ref 6 from the pump housing
d Remove the circlip ref 3
e Support the pump housing at the mounting flange end on an arbor press and with a drift press out the
shaft ref 8 and bearings ref 2 from the pump housing from the impeller end
f With the pump housing supported push the seals ref 7 out of the pump housing Push the impeller side
seal out that side and then lift the spacer ref 14 out Then push the bearing side seal out that side
g Supporting the bearings inner face ref 2 push the shaft ref 8 out of the bearings
NOTE Inspect all parts and replace those showing wear or 69
Westerbeke Install the seals ref 7 and spacer ref 14 in the pump housing Push the impeller side seal into the
housing Rotate the pump and install the spacer ref 14 against the seal face Push the bearing side
seal into the housing from the bearing side
NOTE The seals flat surfaces having printing and numbers face towards each other
b Install shaft ref 8 into bearings Support bearings ref 2 at their center race Push the shaft into the
bearings pushing at the impeller drive slot end using the base of the drive slot Push the shaft through
both of the bearings flush against each other so the flat sided end of the shaft extends beyond the second
bearing center race 15 mm 1932 in 5 mm 1132 in
c Support the pump housing at the impeller side Apply a small amount of petroleum jelly to the seals ref
7 inner lips and to impeller shaft ref 8 Carefully install the shaft rotating it through the seals till the
bearings contact the housing from the bearing end Use a pushing tool that will push this shaft and
bearing assembly into the pump housing by applying pressure against the outer bearing race Push the
assembly into the housing until the bearings seat fully in the housing Install the circlip ref 3
d Position the cam ref 6 in the housing and secure it in place with the screw ref 4 and sealing washer
ref 5
NOTE Use a small amount of Permatex 1 on the inner cam surface and screw threads
Remove any excess from the impeller housing
e Apply a light film of silicone or petroleum jelly to the inner surface of the housing for the impeller
NOTE Just coat the surface do not over apply Install the impeller with the drive screw ref
9 and 10 Push the assembly into the housing with the drive screw mating in the slot of the
drive shaft
f Install the cover gasket ref 11 cover ref 12 and secure them with the six cover screws ref Engines 70
STARTER
I lID
STARTER COMPONENT PARTS
1 Front bracket assembly 6 Through bolt 11 Gear
2 Lever assembly 7 Armature 12 Yoke assembly
3 Spring set 8 Rear bearing 13 Brush holder assembly
4 Center bracket assembly 9 Pinion 14 Rear bracket
5 Switch assembly 10 Pinion shaft 71 Westerbeke Adjustment and Repair
If any abnormality is assumed by the following tests
adjust the starter or disassemble and repair it
Push back
Lightly
1 Pinion gap inspection
a Interpose a battery 12 V between the starter
terminallS and the starter body and the pinion
will protrude and stop
O520mm
CAUTION
Never apply battery voltage for over 10 seconds Inspecting Pinion Gap
b Lightly push the pinion back and measure the return stroke called pinion gap
c If the pinion gap is not within the standard range 05 to 20 mm adjust it by increasing or decreasing
the number of packings on the magnetic switch The gap is decreased as the number of packings
Noload test
a Connect the ammeter voltmeter and battery to
the starter as b When the switch is closed the pinion must
protrude and the starter must run smoothly at
3000 rpm or more Ifthe current or starter speed
is out of disassemble the starter
and repair it
Noload Test
CAUTION
Use thick wires as much as possible and tighten every terminal securely This is a solenoid
shift type starter which makes a rotating sound larger than that of a directdrive type starter
When detecting starter rotation at the pinion tip take care of protrusion of the Engines 72
3 Magnetic switch
Perform the following tests If any test result is not
satisfactory replace the magnetic switch assembly
a Disconnect the wire from terminal M
b Attraction test
Connect a battery to the magnetic switch terminals
Sand M The pinion must protrude
Starter
CAUTION
Attraction Test
Do not apply battery current for more than 10
seconds
c Holding test
With a battery connected to the magnetic switch
terminal S and to the starter body manually pull
out the pinion fully The pinion must remain at that
position even when released from holding by hand
Starter
CAUTION
Holding Test
Do not apply battery current for more than 10
seconds
d Return test
With a battery connected to the magnetic switch
terminal M and to the starter body manually pull
out the pinion fully The pinion must return to its
original position when released from holding by
Starter
hand
CAUTION
Return Test
Do not apply battery current for more than 10
seconds
73 Westerbeke Disconnect the wire from the magnetic switch terminaI M
2 Loosen the two screws fastening the magnetic switch Remove the magnetic switch assembly
3 Remove the two through bolts and two screws fastening the brush holder Remove the rear bracket
4 With two brushes brought in a floating state remove the yoke and brush holder assembly Then pull the
armature out
5 Remove the cover pry the snap ring out and remove the washer
6 Unscrew the bolts and remove the center bracket At the same time washers for pinion shaft end play
adjustment will come off
7 Pull out the reduction gear lever and lever spring from the front bracket
8 On the pinion side pry the snap ring out and pull out the pinion and pinion shaft
9 At each end of the armature remove the ball bearing with a bearing puller It is impossible to replace the
ball bearing pressfitted in the front bracket If that bearing has worn off replace the front bracket
Engines 74
Starter Break and short circuit
Wear and
chipping
Bearing Play noise
and rough rotation
Bearing Play noise Break and short circuit
and rough rotation
Inspect about the following
Description Standard Service limit Description Standard Service limit
Depth of under cut 05 mm 02 mm Height of brush 17 mm 6 mm
Commutator O D 387 mm 10 mm Spring pressure 3 kg
1 Inspect the magnetic switch for terminals S and M and between terminals S
and body There should be a low resistance found 1
2 ohms If no resistance is found the circuit is open
The solenoid should be Checking Magnetic Switch
75 Westerbeke Engines
2 Inspecting the armature
a Check the armature with a growler tester If its
short circuited replace the armature Also check
for insulation between the commutator and its
shaft If poorly insulated replace the armature
b Measure the commutator 00 and the depth of
undercut Repair or replace it if the service limit
is exceeded Also check the commutator out
side surface for dirtiness and roughness If
rough polish the commutator with finegrain
Checking Armature Coil
Brush holder inspection
a Check the brushes If worn out beyond the ser
vice limit replace the brushes
b Check the brush spring tension If decreased
beyond the service limit replace the springs
c Check for insulation between the positive brush
holder and holder base If poorly insulated
replace the holder assembly Also check the
brush holders for proper staking
4 Field coil inspection
a Check for insulation between one end brush of
coil and yoke
b Check for conduction between both ends
brushes of coil
c Check the poles and coil for tightness
Checking Field Coil
Starter Adjustment and Assembly
Adjusting the starter assembly in the reverse order washer
of disassembly giving care to the Pinion shaft end play adjustment Set the end play
thrust gap to 05 mm or less by inserting an adjust
ing washer between the center bracket and reduc
tion gear
O5mm maximum
f l
a Fit the pinion shaft reduction gear washer and
snap ring to the center bracket
Adjusting Pinion Shaft End Engines 76
b Measure end play by moving the pinion shaft in the axial direction If the end play exceeds 05 mm
increase the number of adjusting washers inserted
2 Greasing
Whenever the starter has been overhauled apply grease to the following parts
1 Armature shaft gear and reduction gear
2 All bearings
3 Bearing shaft washers and snap rings
4 Bearing sleeves
5 Pinion
6 Sliding portion of lever
CAUTION
Never smear the starter fitting surface terminals brushes or commutator with grease
77 Westerbeke Engines
CD I
ALTERNATOR COMPONENT PARTS
1 Pulley 5 Rear bearing 9 Rectifier assembly
2 Front bracket assembly 6 Stator 10 Rear bracket assembly
3 Front bearing 7 Terminal set 11 Condenser assembly
4 Rotor assembly 8 Regulator Engines OnEngine Erroneous handling can cause damage to the charging circuit and
other troubles so avoid the following
a Never connect the battery in reverse
b Do not use a megger and other highvoltage testers
c When recharging the battery disconnect the battery cable from the alternator
d Never disconnect the lead wire from the alternator terminal B while the engine is running
e Never ground the alternator terminal B to which battery voltage is always applied
f Never short circuit or ground terminal L
g When using a steam cleaner be careful not to direct steam directly to the Checking for regulated Voltage
a Interpose an ammeter between the positive ter
minal of the battery and terminal B or the alter Ammeter
nator
b Ground the alternator terminal L through a
voltmeter
c Note that the voltmeter indicates zero volts when
the key switch is in the OFF position The
voltmeter will indiCate a voltage considerably
lower than battery voltage when the key switch
is in the ON position while the engine is Checking for Regulated Voltage
stopped
d Shortcircuit the ammeter and start the engine
e Read the voltmeter indication regulated voltage under the following test conditions Ammeter
indication is below 5 A engine speed is at 1800 rpm and 2500 rpm and lamps are switched off
Regulated voltage shows a tendency to decrease as alternator temperature Output inspection
a Disconnect the grounding cable from the battery
b Interpose an ammeter between the battery and alternator terminal B Ground the terminalB through
a voltmeter
c Connect the battery grounding cable
d Start the engine
79 Westerbeke Engines
e Apply all load Including the lamps
Ammeter
f Increase engine speed until normal alternator speed is attained Read the maximum indication of the
ammeter at 135 V of voltmeter indication Output
current must conform to the Checking for Removal
Terminal Current I Speed
voltage V A I rpm
1 Disconnect the battery cable I 1300
15A 14 0 I maximum
2 Disconnect the lead wire from terminal S on the back Noload I 35A
1300
of the alternator output 1
14 8 I
I maximum
50A 135 24 1300
maximum
3 Disconnect the alternator connector
15A 14 15 2500
maximum maximum
4 Loosen the alternator brace bolt and support bolt
Loaded 30 2500
Push the alternator toward the engine and remove the output 35A 14
maximum maximum
fan belt
50A 135 50 2500
maximum maximum
5 Dismount the Remove the three through bolts
2 Heat the rear bracket around the rear bearing up to
50 60 C with a solder iron and separate the bracket
from the stator coil
CAUTION
Pry open the alternator with a screwdriver blade inserted into the clearance between the stator
core and front bracket Se careful not to insert the blade too deep
3 Grip the rotor in a vise remove the pulley nut and pull out the pulley fan and spacer
4 Pull out the rotor assembly from the front Engines 80
5 Unsolder the stator coil lead wires Remove the stator assembly
CAUTION
Never heat the lead wires long to prevent damage to diodes
6 Disconnect the capacitor from terminal liB II
7 Loosen the screws fixing the rectifier and remove the the disassembled parts if any part is found defective replace it
Deformation Break and
and damage short circuit
I t
I Wear and roughness
Wear
Break and
short circuit
Wear to limit line
Inspection of Inspecting the diodes
a Connect a circuit tester ohmmeter across the lead wire and case of the diode to be tested The diode
is considered normal if its resistance is large in either direction and small in the reverse direction
b If there is equal resistance in both directions the diode is suspected to be defective Replace the rectifier
assembly
c Check every diode for 81 Westerbeke Engines
2 Inspecting the field coil
a Check for conduction between slip rings If there
is no conduction the field coil is suspected to be
broken Replace the field coil
Checking Field Coil for b Check for conduction between a slip ring and
shaft or core If any conduction is found the
field coil is suspected to be poor in insulation
Replace the field coil
Checking Field Coil for Inspecting the stator coil
a Check for conduction between lead wires of the
stator coil If there is no conduction the stator
coil is suspected to be broken Replace the
stator coil
Checking Stator Coil for b Check for conduction between each lead wire
and stator core If any conduction is found the
stator coil is suspected to be poor in insulation
Replace the stator coil
Checking Stator Coil for Engines 82
AHernator the alternator assembly in the reverse order of disassembly giving care to the The rear bearing has an eccentric groove Install the snap
ring so that its projection fits in with the deepest
part of the groove
2 When installing a new rear bearing pressfit the bearing with its groove facing the slip ring side
3 When press fitting the rear bearing into the rear
bracket heat the bracket
CAUTION
Pass a wire through the small hole in the rear
bracket to lift the brushes before installing the
rotor to the rear bracket Remove the wire after
the rotor is Installation
lifting the alternator in the reverse order of removal
1 When Installing the support bolts Insert the
spacer In place using the following procedure
a Push In the support bolts to the normal position
Leave the nuts removed from the bolts
b Push the alternator backward Measure the
clearance between the alternator rear bracket
and gear case bracket to determine the number
of spacers to be inserted into the clearance 02
mm 83 Westerbeke Engines
Engines 84
ENGINE possjble Cause is depressed 1 Connection or 1 Check for 12 volts at
no preheat switch PREHEAT switch and at the
S terminal on the preheat
solenoid
2 Preheat solenoid 2 No activation with 12 volts
at the S terminal Tap solenoid
with a mallet to determine if it
is stuck internally Solenoid
should produce a click when
activated and 3 Glow plugs are 3 Twelve volts is present at
faulty the glow plugs Remove each
plug and check the resistance
of the plugs with an ohmmeter
15 22 is depressed 1 Faulty connections 1 Check for 12 volts at the
fuel pump does not or bad pump fuel pump If 12 volts are
present the
pump is possibly faulty
Tap pump with a mallet
Pumps plunger may be stuck
Check for which will affect the pump
Start is depressed 1 Fuel solenoid or 1 Check for 12 volts at lead
no fuel delivery to injectors connections to it are positive terminal at the back
faulty of the fuel solenoid when the
PREHEAT button is depressed
Twelve volts with no activation
indicates a faulty solenoid
2 Voltage problem 2 Less than 10 volts found at the
lead terminal on the solenoid
will not properly activate the
solenoid and will cause a failure
Check for low batteries or voltage
loss in small electrical wiring or
corroded 3 Shut off lever 3 Check that shut off lever is
returned to the run 85 Westerbeke Engines
EauI1 Possjble Cause switch is de 1 Connection to starter 1 Check connection S at the
pressed no starter solenoid faulty starter solenoid for 12 with the switch does not
crank 2 Faulty start switch 2 Check switch with an
ohmmeter
3 Faulty preheat 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
5 Low batteries 5 Check battery charge state
Low voltage at the solenoids
S terminal with no activation
6 Sea water in 6 Remove exhaust hose at exhaust
cylinders elbow and drain water Correct
the cause of sea water cranks 1 Shutoff valve at 1 Return 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
it Check return fuel for no
air present
4 Fuel pump is not 4 Check pump operation
operating Check for 12 volts at pump
5 Fuel filters are clogged 5 Oeanreplace filters
6 Fuel solenoid not working 6 Check 12 volts present at
optional to stop 1 Fuel solenoid faulty 1 Stop engine by man
optional ually shutting off
fuel and air
2 Shut off cable 2 Cable not operating shut
off Engines 86
possjble Cause Stops 1 Fuel starvation 1 Check to see that the
Fuel shutoff is turned shutoff valve at the
off fuel tank is on
2 Fuel pump is 2 Inspect the fuel pump for
inoperative 12 volts and see if it is
pumping
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 DC charge circuit faulty 1 Perform DC voltage check
of charge circuit
2 Bad battery 2 Connections are corroded
connections or loose at the battery andor
at the exhaust smoke 1 Engine is 1 Check generator data plate
overloaded for rating and monitor the load
that is producing the black
exhaust smoke
2 Poor fuel quality or 2 Check fuel filters Make sure
incorrect fuel you are using 2 diesel fuel
3 Faulty injectors 3 Remove and test injectors
4 Lack of air 4 Check air intake for
restrictions Make sure
adequate combustion air is
present
87 Westerbeke Engines
MARINE standard transmission on the 20B Two and 30B Three is the JS Gear Contact Westerbeke Corpora
tion factory for overhaul MARINE GEAR
ZF INDUSTRIES MARINE US SW 42ND STREET
FORT LAUDERDALE FL 33312
TEL WARNER MARINE INDUSTRIAL THEODORE RICE BLVD
NEW BEDFORD MA 02745
TEL Westerbeke Engines 88
TABLE OFSTANDARD HARDWARE TIGHTENING stated otherwise for a specific assembly use the following torque values when tightening
Pitch Ibft kgm
rad4T
6mni bolt headnut 1 29 51 04 07
8mm bolt headnut 125 72 116 10 16
10mm bolt headnut 125 137 224 19 31
10mm bolt headnut 15 130 217 18 30
12mm bolt headnut 125 ISO 253 398 35 55
12mm bolt headnut 15 253 398 35 55
12mm bolt headnut 175 217 362 30 50
13mm bolt headnut 15 325 506 45 70
14mm bolt headnut 15 362 579 50 80
14mm bolt headnut 2 340 557 47 77
16mm bolt headnut 15 542 796 75 110
16mm bolt headnut 2 514 767 71 6mm bolt headnut 1 43
65 06 09
8mm bolt headnut 125 108 159 15 22
10mm bolt headnut 125 217 325 30 45
10mm bolt headnut 15 195 304 27 42
12mm bolt headnut 125 ISO 362 579 50 80
12mm bolt headnut 15 362 506 50 70
12mm bolt headnut 175 347 492 48 68
rad 7T aT and aa
6mm bolt headnut 1 58 87 08 12
8mm bolt headnut 125 145 217 20 30
10mm bolt headnut 125 289 398 40 55
10mm bolt headnut 15 268 376 37 52
12mm bolt headnut 125 ISO 542 759 75 105
12mm bolt headnut 15 506 651 70 90
12mm bolt headnut 175 434 615 60 85
13mm bolt headnut 15 579 868 80 120
14mm bolt headnut 15 723 1085 100 150
14mm bolt headnut 2 687 1013 95 140
16mm bolt headnut 15 1085 1664 150 230
16mm bolt headnut 2 10131591 140 220
rad cacrw
14 UNC 9 11 12 15
14 UNF 11 13 15 18
516 UNC 18 20 25 28
516 UNF 21 23 29 32
38 UNC 28 33 37 46
38 UNF 30 35 41 48
716 UNC 44 49 61 68
716 UNF 50 55 69 76
12 UNC 68 73 94 101
12 UNF 73 80 101 111
89 Westerbeke Engines
Socket Size Lbft lm
Cylinder head bolt M 10 14 mm 54 61 75 85
M 8 12 mm 14 22 20 30
Rocker shaft hold down bolts M 8 12 mm 11 16 15 22
See the Cylinder Head section of this pulley nut
50BCD M 16 24 mm 723 867 10 12
Oil pan drain plug M 18 362 434 50 60
All Models
Oil filter 80 94 11 13
All Models or tighten firmly by valve holder M 16 17 mm 253
282 35 pump All nozzle mounting M 20 21 mm 362 434 50 60
All Models fo Engine
Fuel Solenoid Locknut M 30 36 mm 289 362 40 50
Glow plug M 10 12 mm 108 145 15 20
All spray Pressure 140 100 kgcm2 1990 psi Compression 28 kgm 2 at 280 rPm
398 M1017 MM 60 65 83 89
FLYWHEEL BOLTS
Tightening Torque for Common Bolts and Nuts
Head mark
Designation of screw thread
4 7 10
M6 0305 08 10 10 13
M8 1013 15 22 25 35
MIO 1825 30 42 50 70
MI2 3042 55 75 95120
MI4 5070 8 O 110 160190
NOTE M8 indicates Metric 8 mm thread diameter
Westerbeke Engines 90
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 voyage Please
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 secondary fuel filter element
4 A water pump belt
5 Hose clamps
6 A spare oil filter with a spare quart of diesel service engine oil along with a gallon of premixed antifreeze
7 A few zinc anodes and heat exchanger end plate gaskets
8 An oil pressure parts listed below whose life expectancy 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
1 Fuel injectors
2 Glow plugs
3 Cooling system hoses
4 A starter
5 A 20 amp DC circuit breaker
6 An electric fuel pump
7 A raw water pump
8 Battery terminal connectors
9 A fuel run solenoid spare parts listed directly above are those we recommend be carried on 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
on 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
91 Westerbeke Engines
Engines 92
INDEX
ALTERNATOR 78
Alternator Assembly 83
Alternator Disassembly 80
Alternator Inspection 81
Alternator Installation 83
Alternator OnEngine Inspection 79
Alternator Removal 80
CAUTION
A SIZED CRANKSHAFT CANNOT BE REGROUND TO ANY UNDERSiZE 52
APPLY THIN COAT OF ENGINE OIL TO OIL SEAL CIRCUMFERENCE AND LIP 95
BEFORE INSTALLING ROTOR TO REAR 83
CHECKING VALVE SiNKAGE INJECTOR LINES 27
DO NOT APPLY BATTERY VOLTAGE OVER 10 SECONDS CONTINUOUSLy 72 73
EXCESSIVE FRESH WATER PUMP DRIVE BELT TENSION 95
IF GOVERNOR ASSUMED CHECK BEARING OR GEAR CASE SIDE 64
INSTALLING THE PLUNGER BARREL 58
NEVER HEAT LEAD WIRES LONG 81
REMOVING VALVE RETAINERS OF RINGS WITHOUT REBORING HONING 47
REPLACING THE PLUNGER 57
SCRAPE OFF CARBON DEPOSiTS 60
SMEARING GREASE AFTER STARTER OVERHAUL 77
TAG INJECTION NOZZLE AND PLUG OPENINGS 60
USE THICK WIRES 72
WHEN INSTALLING VALVE SPRING DO NOT OVERCOMPRESS 32
WHEN PRYING OPEN ALTERNATOR DO NOT INSERT SCREW DRIVER TOO DEEP 80
WHEN REBORING A CYLINDER TO OVERSIZE REMAINDER MUST ALSO BE REBORED 55
Camshaft 20
CAMSHAFTS Valve and Pump 41
Camshafts Inspection 43
Camshafts Installation 44
Connecting Rod 19
Connecting Rod Bearing 19
COOLING SySTEM 67
CRANKSHAFT 50
Crankshaft Inspection 51
Crankshaft Rear Oil Seal Replacement 53
Crankshaft Removal 51
CYLINDER 54
Cylinder Block Inspection 55
93 Westerbeke Bore 17
Cylinder Compression Pressure Head HEAD CONSTRUCTION AND SERVICING Head Inspection and Repair Head Removal Reboring o
Difference Between Cylinders maximum 15
ENGINE DISASSEMBLY OVERHAUL SERVICE 20B TWO 30B THREE 15
ENGINE F
Fresh Water Pump Drive Belt Tension Oil Seal Replacement Injection Order INJECTION PUMP G
GEAR CASE AND OIL PUMP Case and Oil Pump Removal and Inspection Case 20B TWO 30B THREE PLUG Plug Inspection Levers Disassembly and
Reassembly Removal and Installation Shaft Bushings Replacement SYSTEM System Inspection Westerbeke Engines
94
INJECTION NOZZLE 59
Injection Nozzle Adjustment 61
Injection Nozzle 60
Injection Nozzle Disassembly 60
Injection Nozzle Inspection 60
Injection Nozzle Installation 61
Injection Nozzle Removal 60
Injection Pump Assembly 58
Injection Pump Camshaft 20
Injection Pump Disassembly 57
Injection Pump Inspection 57
Injection Pump Inspection while on Engine 57
Injection Pump Installation 58
Injection Pump Removal 57
Injection Timing at BTDC on Compression Stroke 15
MARINE TRANSMISSIONS 88
Main Bearing 20
Oil Specification 21
PRODUCT SOFTWARE DISCLAIMER 1
Piston 17
PISTON AND CONNECTING ROD 45
Piston and Connecting Rod Inspection 46
Piston and Connecting Rod Installation 47
Piston and Connecting Rod Removal 46
Piston Pin 18
Piston Rings FOR OVERHAUL 24
Push Rod 20
Raw Water Pump 68
Raw Water Pump OverhauL 69
Removal of External Parts and Subassemblies 25
Rocker Arm 17
95 Westerbeke Engines
SPARE PARTS STARTER Starter Adjustment and Starter Adjustment and Repair Starter Disassembly Starter SYSTEM 20B TWO
SYSTEM 30B THREE T
TABLE OF CONTENTS TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Tappet TIMING GEARS 38
Timing Gears Inspection Timing Gears Installation
Timing Gears Removal Torque Spring Set Assembly Torque Spring Set Installation u
UNIT 10 PLATES v
Valve and Valve Spring Installation Valve Camshaft Removal 42
Valve Clearance IN and EX VALVE GLEARANCE ADJUSTMENT Valve Guide Replacement Valve Inspection and Repair Valve Removal 31
Valve Seat Installation Valve Seat Repair Valve Spring Valves VALVES AND VALVE SPRINGS
IWARNINGI
DO NOT ADJUST DRIVE BELT TENSION WITH ENGINEON 68
Westerbeke Engines 97 Westerbeke Engines

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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.