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Westerbeke Diesel 14088 Wb Technical Manual



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       .,p'fl'
 OPERATORS
MAR E DIESEL E INES
 20B TWO I 30B THREE



     I ~lK)HNO~ I    EDITION FOUR
                      J\N!2000
                                              SAFETY INSTRUCTIONS
INmODUCTION                                                         PREVENT BURNS - FIRE
Read this safety manual carefuUy. Most accidents are
coused by failure to follow fwuIomentol rules and precau-
tions. Know when dangerous conditWns exist and take the
                                                                        A WARNING: Fire can cause Injuty or death!
necessary precautions to protect yourself, your personne~           · Prevent flash fires. Do not smoke or permit flames or
and your 11IIlChilUlry.                                               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 filters.
PREVENT 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 CDlIII/JctiOIlS           · Do not operate with the air cleaner/silencer removed.
    while /JIIgine is mnning, or when connected to shore              Backfire can cause severe injury or death.
    power. Lethal voltage Is PT/JSIJnt 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                    engine/generator 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 re-fueling safety instructions. Keep the vessel's
· Do not connect utility shore power to vessel's AC                   hatches closed when fueling. Open and ventilate cabin
  circuits, except through a ship-to-shore double throw               after fueling. Check below for fumes/vapor before run-
  transfer switch. Damage to vessel's 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 well·ven-
                                                                      tilated area away from spark-producing equipment and
PREVENT BURNS - HOT ENGINE                                            out of the reach of children.
                                                                    · Do not fill the fuel tank(s) 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 environment.




                                                           Engines & Generators
                                            SAFETY INSTRUCTIONS
ACCIDENTAL STARIlNG                                                  TOXIC EXHAUST GASES
    A WARNING: Al:l:ldental 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 T-22 (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 flu-like 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 sleepiness
BATTERYACm
                                                                     AVOID MOVING PARTS
    A WARNING: SUlfuric acid In batteries can cause                      A WARNING: Rotating parts can cause injury
    _In/lIlY 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

                                                                ii
                                             SAFETY INSTRUCTIONS
· 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 belt's 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 Solomon's Island Rd.
  be caught in these rotating parts.                                      Edgewater, MD 21037
                                                                       NFPA (National Fire Protection Association)
HAZARDOUS 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.
                                                                          U.S. Government Printing Office
                                                                          Washington, D.C. 20404
    A WARNING: Do not wodc on machine" when you are
    mentally or physically incapacitated by fatigue!

OPERATORS 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 manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTAllATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
      H-2 Ventilation
      P-I Exhaust systems
       P-4 Inboard engines
      E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).




                                                  ~     WESTERBEKE
                                                        Engines & Generators

                                                                 iii
                             INSTALLATION
When installing WES1ERBEKE engines and generators it is important that strict
attention be paid to the following infOlmation:

CODES AND REGUlADONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.

SI........
For installations wbere the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's 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 vessel's waterline. Failure to use a siphon-break 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 water-injected exhaust elbow relative
to the vesse1's waterline under the vessel's various operating conditions, install a
siphon-breII/c.
NOTE: A siphon-break "'quires periodic inspection and cleaning to ensure proper
operation. Failu", to properly maintain a siphon-b",ak can ",suit in catastrophic
engine damage. Consull the siphon-break mtlTIUjacru",rJor proper mtlintenance.

EXHAUST 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~                                     .




                        "~IWESTERBEKE
                               I Engines & Generators
                                        iv
                                                        TABLE OF CONTENTS
)   Paris IdentificatiDn ................................................2       JS TransmissiDn ....·............................................41
                                                                                  Lubrication..................................................... .41
    Product SDftware ....................................................3
                                                                                  Controls ......................................................... .42
    PreparatiDns fDr Starting ....................................7               Shifting .......................................................... .43
    Engine CDntrDI Panels .........................................9              SaI!fig
                                                                                    TO       peral10n
                                                                                                   ' ........................................... .43
    Starting PrDcedure .. .......................................... 13           Service ........................................................... .43
    StDpping PrDcedure .....................,..................... 14             Cooling .......................................................... .43
    Engine Break-In 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 ...................................21                 Troubleshooting ..............................................43B
    Electrical System ..............................................22            Maintenance/Service ..................................... .43B
    Captains CDntrDI Panel Wiring [Diagram] ........ 25                           Warranty......... _._ ........................................... 43B
    Captains CDntrol Panel Wiring [Schematic ] .....26                           Optional TransmissiDns ...................................:.44
    Admirals Control Panel Wiring [Diagram] ........27                           Engine TroubleshDDting .................................... .46
    Admirals ContrDI Panel Wiring [Schematic ] ..... 28                          Maintenance/Adjustments ............................... .49
                                                                                 Cylinder Head Bolt Tightening ......................... .52
    Engine Wiring [Diagram] ...................................29
                                                                                 Adjustment Df Valve Clearances ......................53
    Engine Wiring [Schematic ] ................................30
                                                                                 InjectiDn Pump Timing Adjustment ..................54
    Cooling System ....... ...........................................31         Lay-up and ReCDmmlsslDnmg
                                                                                                        . . . . ...........................56
     Thermostat ..................................................... .33
     Sea Water Circuit. ........................................... 34           SpecificatiDns W20B .........................................58
     Sea Water Pump.............................................. 34             SpecificatiDns W3DB .........................................61
)   Hot Water Tank CDnnectiDns ............................36                    TDrque SpecificatiDns .......................................64
    Lubricating System ............................................38            Standard TDrques ...............................................65
     Engine Oil Change ......................................... 39              Spare Paris ........................................................66




                                                                    Engines & Generators

                                                                             1
                                               PARTS IDENTIFICATION


                                                      RIGHT SIDE
                COOLANT PRESSURE    .ft. ___                                                     Fill




                                                      \~~~~~~~~~~=:;::SIDE
                                                      ~          ~;;P'---_OIl DIPSTICK Oil Fill
                                                                                                            FRONT




                                                                                        FIlTER


                                                                           AMP CIRCUIT BREAKER
                                                 LEFT SIDE
         AIR INTAKE .'LO".«'--...                                                        1.0. PLATE


         THERMOSTAT
         ASSEMBLY




                                                                                                    \ - - - HEAT EXCHANGER


DC AlTERNATOR   --I
                                                                                                    REAR




         Oil DRAIN                                                    'STAIRTER MOTOR


                               FRONT


                                                ~   WES7ERBEKE
                                                    Engines & Generators

                                                             2
                                                 IMPORTANT

                                   PRODUCT SOF1WARE DISCLAIMER

Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals,
parts lists and parts price lists (and other related information), instructions and specifications provided from
sources other than Westerbeke, is not Within Westerbeke's 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 REPRESENTATIONS WITH RESPECT
THERETO, 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 SOFTWARE.

For example, components and subassemblies incorporated into Westerbeke's products and supplied by
others (such as engine blocks, fuel systems and components, transmissions, electrical components, pumps .
and other products) are generally supported by their manufacturers With their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software. Such software,
however, may be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, of
which Westerbeke rarely has notice in advance, are frequently not reflected in the supplier'S software untO
after such changes take place.

Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software, and the unavoidable existence of earlier, non-current Westerbeke software editions in the field. Ad-
dttionally, most Westerbeke products include customer-requested special features that frequently do not in-
clude complete documentation.

In 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 representatives of Westerbeke or the sup-
plier in question be consulted to determine the accuracy and currency of the product software being con-
sulted by the customer.




                                             Engines & Generators

                                                    3
                                              GENERAL

INTRODUCTION

This 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 instructions
carefully. 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 troubleshooting table is included

UNDERSTANDING 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 and
lubricating system.

Therefore, to a great extent, a diesel engine requires the same preventive maintenance as a gasoline
engine. The most important factors are proper ventilation and proper maintenance of the fuel, lubricating
and 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 lubricating
oil designed specifically for diesel engines. Be careful not to put gasoline in the diesel fuel tank(s).
Gasoline 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 injectors.

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 injectors.

ORDERING PARTS

When contacting your Westerbke dealer, parts distributor, or the factory concerning your Westerbeke unit,
always provide the engine's model and serial number, and transsmission number as they appear on the
black and silver "Westerbeke" plate which is mounted on the engine's exhaust manifold.

Note that component locations in the manual are referenced.from the front of the engine which is the
pulley/drive belt end. (The flywheel/generator 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 right

Westerbeke engines are thoroughly checked and given a final run under various load conditions before
leaving the factory. This is done to ensure dependable operation, long service, and a satisfied owner.
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 owner/operator.




                                     ,,,,,,,WESTERBEKE
                                            I Engines & Generators
                                                    4
                                                   FOREWORD

Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have
you as a customer.

Read this manual carefully and observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust-
ment procedures are included herein so you can operate your equipment safely and properly, maintain the
equipment at a high level of efficiency, and expect dependable perfonmance and long service life in return.

Should your unit require special attention, contact your Westerbeke dealer for assistance. The Westerbeke
Service Organization is trained to provide the support necessary to ensure long-term dependable perfor-
mance.

If, within 60 days of submitting the Warranty -Registration Form for your unit, you have not received a Cus-
tomer Identification Card (see below) registering your warranty, please contact the factory in writing with
Model information, including the engine's serial number and commission date.



                 from:    IESTERBEkE CORPORATION
                          AVON INDUSTRIAL PARK
                          AYoN. MA 02322




                                          I~         ,WESTERBEKE
                                                    , Engines &.Generators
                                       Customer Identification
                                       WESTERBEKE OWNER
                                       MAIN STREET
                         Mail To:      HOMETOWN, USA
                                       Model30B THREE.Ser. #0103XXXX
                                       Expires 9/20102 '




Inspection of Equipment

The engine is shipped from the factory mounted securely and properly crated. Accessory' equipment is
shipped in a separate small box, usually packed within the engine's crate.

Before accepting shipment of the engine from the transportation company, the crate should be opened and
the contents inspected for concealed, damage. If etther visible or concealed damage is noted, you should
require 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. Claims
conceming loss or damage must be made to the carrier, not to the Westerbeke Corporation.




                                               Engines & Generators

                                                      5
                                            UNIT 1.0. PLATES




       ·       MODEL             SPEC                AVON "A USA               SER.NO..



                                       20B TWO UNIT 1.0. PLATE




       ·       MODEL             SPEC                AVON .. A USA             SER.NO..



                                      30B THREE UNIT 1.0. PLATE



The unit 1.0. plate is attached to the exhaust manifold of the engine. These illustrations are provided so
that the OINI1e/'/operator may transcribe the specifications and serial number from the I.D. 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

                                                      6
                                      PREPARATION FOR STARTING

This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or
warm), and stopping procedures. Follow the procedures as presented, for the conditions indicated, and
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 readily
available lubricating oil with an API specification of
CF or CG-4 and an SAE number suitable for the
temperature in your operating area. For the quantity
of oil needed in your engine, refer to the ·SYSTEM
SPECIFICATION" section of this manual.
                                                                                                          r-
                                                                     '1;~_;;;;;_,;:;_;;:_;:;:,:",;::_;_;;:,
                                                                        1d.....,=-:-::-=rl_~L""OWER L:lNt:T
                                                                                                               UPPER L:lIoot:lT

                                                                                                               (NORMAL    LEVEL)




Fm the transmission to the FUll mark on the dipstick
with the correct lubricant (Refer to the "SYSTEM
SPECIFICATIONS" 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 engine's exhaust manifold and slowly fill the engine's 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 manifold's 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 engine's 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 No.2 diesel fuel and manually prime the fuel system up to and
including the engine. When running fuel is free of air, the engine's 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 "INSTALLA-
TION CHECKS" section of this manual.




                                                Engines & Generators

                                                       7
Description of Starting System

All Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold weather
starting. The figure belaN shows a cross-sectional view of one cylinder. The glow plug is located in the c0m-
bustion chamber so that Its tip is in the Injector nozzle's 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 starter.

This 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 Intermittently so as not 10 overheal the glow plugs.




                                         ~      WESTERBEKE
                                                Engines & Generators

                                                       8
                                     ENGINE CONTROL PANELS

WesteJbeke offers two types of control panels as optional equipment.
Read the following instructions that apply to the panel you purchased with your engine.




GENERAL

This manually-operated 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 bu=r 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 following
functions:

    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 alternator's regulator, the engine's glow plugs,
    and bypasses the engine's oil pressure alarm switch. In addition, this button energizes the START
    button.

    3. START: The START button, when pressed, energizes the staner's 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

                                                  9
   S. AIann: The alarm is located above the test button and wiUsound if the engine's 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 engine's oil pressure reaches 15
psi, the alarm will silence.

  ·6. Water Ten!Jl!m!ture GaUge: This gauge is graduated in degrees Fahrenheitand is illuminated
   ·whiIe the Key Switch is turned ON. The engine's normal operating temperature is 170 - 1900 F
    (17-880 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 engine's normal operating oil pressure ranges between
    30-60PSL

   ·NOTE: When the engine is manually shut down, and the engine's 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 engine's true temperature
   once elec:trical power is restored to the gauge.




                                    ~      WESTERBEKE
                                           Engines & Generators

                                                10
                                              Admirals Panel

General

This manually-controlled control panel is equipped with a key switch and an RPM gauge with an ELAPSED
TIME meter which measures the engine's running time in HOURS and in 1'10 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 engine's on pressure in pounds per square inch (OIL PSI), and a DC
control circuit voltage gauge which measures the system's 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 rubber-booted 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 alternator's exciter, the engine's glow plugs, and bypas-
     sesthe engine's protective oil pressure switch. In addition, this button energizes the START button.

  3.   SIABI: The START button, when pressed, energizes the starter's solenoid which cranks the engine.
       This button will not operate electrically unless the PREHEAT button is pressed and held at the same
       time.              .




                                         ~      WESTERBEKE
                                                Engines & Generators

                                                     11
 5. AIaon: The aIann is located above the test button and wUl sound if the engine's 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-
    nal.

     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 engine's
     oil pressure reacheS 15 psi, the alarm will silence.

*6. WaterTemperatyre Gauge' This gauge is graduated in degrees Fahrenheit and is Dluminated while the
    Key Switch is tumed ON. The engine's norrnaI operating temperature is 170 - 1900 F (77 - 88"C).

*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 engine's normal operating 011 pressure ranges between 30 - 60 PSI.

    *NOTE: When the engine is manually shut down, and the engine's 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
    engine's 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 tl\e four-pin connection on the
    engine's 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 engine's oil pressure rises above 15 psi.




                                         'Wo¥:   WESTERBEKE
                                                 Engines & Generators

                                                     12
                                          STARnNG PROCEDURE

Place the transmission in the NEUTRAL position and advance the throttle to its full open position for a cold
engine. and partially open for a warm engine.

Tum the Key Switch to the ON position (2 o'clock); prime the engine's 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 cranking


Proper 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 connections).


WhOe 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 instrumentation
for proper engine operation. Make sure sea water dischar-
ges along with the exhaust discharge.


Should 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 engine's cylinder's by way of the exhaust manifold
      once the exhaust system fills. Prevent this from happening by closing the sea water
      supply through-hull shut-off, 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 owner/operator should keep this
      in mind.



                                                 Engines & Generators

                                                      13
Once the engine starts, run.1t at Idle for a few minutes to warm up the englne.and 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 f!7 - 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
engine's controls. Know the location of this control before attempting to start the engine. To stop the en-
gine, pullout on thi.s 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 restart.

With the engine stopped, tum the key switch turned to the OFF position (12 o'clock). If the Key Switch is left
ON, the battery will discharge. An engine alarm buzzer is provided to warn the operator of this condition
(Key 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 request/order of the owner.)



                                                      THROTTLE CO.TRll
                                                          LEVEl




                          SJOP   P.SITIOIlFi..-'l~_-;::=C;~~~



                          ···
                        POSInOIl




                        STOP
                        tunol
                        LEVEl




                                         "'" WESTERBEKE
                                                Engines & Generators

                                                     14
    Engine Break"n Procedures

    Although your engine has experienced a minimum of one hour of test operations to ensure accurate as-
    semblyand proper operation of all systems, break-in 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 functioning.

      2. Allow the engine.to warm up (preferably by running at fast idle) until the water temperature gauge moves
         into the 130-140" 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 break-in period.
)   Brealdng-in 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 5O-hour break-in period. (Don't baby the
    engine, but do not abuse it).




                                          ~      WESTERBEKE
                                                 Engines & Generators

                                                      15
Starting Under Normal Conditions

FolloW 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 tank(s) as full as possible. Check the fuel filters
     and water separators for the presence of conIaminants and/or water. Drain and clean them as needed.

  3. Check the coolant level in the plastic recovery tank. Add coolant solution as needed.

    . NOTE: Ext eS5'18 loss of coolant from the plastic rect:Pery 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 engine.

Start the engine in accordance with the "STARTING PROCEDURE" instructions found in this manual.
Allow the engine's operating temperature to reach 140 · 150 F before operating the engine underway.


Startillg Under Cold ConcrJtions

Under exIremeIy cold temperatures. the following conditions can occur. Follow the insIrucIions listed below
when opetatillQ ycu engine in cold weather.

LUBRICATING OIL TURNS VISCOUS· Make certain that the lubricating oil used conforms with the ratings for the
prevailing atmospheric temperature. Refer to the "LUBRICATION SYSTEM" section of this manual.


VOLTAGE ACROSS THE BATTERY TERMINALS DROPS- Make certain that the battery is fully charged to
minimize voltage drop across the battery terminals.

THE TEMPERATURE OFTHE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOT
RISE ENOUGH - AIIowthe rJow plugs to operate sulliclentlyto 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 enough.
Reterto the preheat chart found in the "STARTING PROCEDURE" section,




                                    ~      WESTERBEKE
                                           Engines & Generators

                                                16
                                                 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 tank(s) 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
      fIter/Water 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 filter/Water 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 engine·mounted fuel system, any
)     water in the fuel will affect the fuel
      pump, engine filter, and injection
      equipment. The owner/operator is
      responsible for making certain the fuel
      reaching the engine's injection equip-
      ment is free of impuritieis. This process
      is accomplished by intstalling and
      maintaining a proper filtration/separa-
      tion system.

      In addition, any gasoline in the fuel
      system will damage the engine's fuel
      injection pump assembly and injectors
      as gasoline does not have the same                              Fuel Filter/Water Separator
      lubricaticg qualities as diesel fuel.

      If a filter/Water separator is not installed between the fuel tank and the engine-mounted fuel
      system, water in the fuel system wl1l inhibit proper starts and particles will pass on to the lift
      pump's filter, eventually clogging it and pass on into the engine's 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

                                                     17
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. SeNic:ing 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 approximately
 on minute to accomplish this.




                                                      21




     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 cranking. This sea water can enter the engine's.
     cylinders byway of the exhaust manifold once the exhaust system fills. Prevent
     this from happening by closing the sea water supply through-hull shut-off, 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 owner/operator should keep this in mind.




                              -.v: WESTERBEKE                                Westerbeke Diesel Engines
                                    Engines & Generators

                                         18
Notes on the Fuel System

The illustration that follows is an exploded view of the 20B TWO's fuel system. This system is similar to
the 30B THREE's fuel system in that it has only one less fuel injector and one less pumping element in
the injector pump.




                                   ...v'   WESTERBEKE
                                           Engines & Generators

                                               19
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 O-ring gaskets. Select the part number
for this fuel filter from your Parts Ust and purchase spares from your local Westerbeke Dealer or Distnbutor.

If 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 O-rings supplied with the new filter.


Replacing the Fuel Filter Element

After the first 50 hours of operation, loosen the toter cup retainer and remove the toter cup. Be careful in
car..hing any fuel that may spill from within the filter cup. Discard the old filter element and the old O-rings.
Clean the filter cup and install the new filter along with the new O-rings. 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 over-tlghten the titer cup retainer; excessive tightening can strip the soft
      aluminum threads on the fuel filter assembly.




                                                                ALUM:tNUM
                                                               T"READS




                                                              ~F':L T"R   CUP




Mer the first SO-hour change. the change period may be increased to 200 hours or once per season.




                                       ~       WESTERBEKE
                                               Engines & Generators

                                                    20
     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 bench-tesIecI 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




                            r""<:--Engine Mounted Fuel Filter




)
                                       . . . WESTERBEKE
                                              Engines & Generators

                                                   21
                                          ELECTRICAl SYSTEM

Engine 12-Volt DC Control Circuit

The Westerbeke modles 20B TWO and 30B THREE propulsion engines each have a 12-Volt DC elec-
trical control circu~, as shown on the wiring diagrams which follOW. Refer to these diagrams when trou-
bleshooting or servicing electrical components on the engine.


                                                 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 circuit


Battery Specification

The minimum recommended capacity of the battery used in the engine's 12-Volt DC control circuit is 90-
125 AmperHlours (minlmum)_


                                                 CAUTION

     When quick-charging the battery with an external charger, be sure to disconnect the battery
     cables from the battery_ Leaving the charging circuit connected whDe quick-charging wDl
     damage the aItemator's diodes.


Alternator

                                                 CAUTION

      When testing the alternator circuit (charging circuit), do not use a high-voltage tester such as
      a megger; damaged diodes could resuil

      During high-speed 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

                                                    22
Illustrated below is a wiring harness for the 30B THREE's electrical system. The wiring hamess for the
20B TWO's electrical system differs only in that it has one less glow plug terminal.




                             Optional Fuel
                             Run Solenoid




                                     ~       WESTERBEKE
                                             Engines & Generators

                                                  23
The charging system consists of an alternator with an internal voltage regulator, an engine-mounted circuit
breaker, a battery and connecting wires.

Because of the use of IC's (integrated circuits), the eleCtronic voltage regulator is very compact and is built
into the rear bracket of the alternator.


Charging Voltage Test

If you suspect that the alternator is not producing enough voltage to charge the engine's battery, perform
the following voltage test.




                                                         ANPHETER
                                   r-__________~e{A e




                                 Interconnections for Charging Voltage Test


1. Using a voltmeter, connect the voltmeter's 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 engine's speed to 2000 rpm. Now record the reading given by the
  voltmeter.

The voltage reading for a properly operating alternator should be between 13.5 to 14.5 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 12-Volts excitation is present at
      the R terminal should the above test show only battery voltage at the B output terminal.




                                            Engines & Generators

                                                  24
                         Captains Panel DC Control Circuit Wiring Diagram #36467
                                              page 1 of2



                                                                                  OIAGRAM
                                                                                                                                   .,
                                                                                          .
                                                                                                                                    I
                                                                                                                                    I
                                                          ...,..
                                                          T£~P.
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                                                                                      TEMP.
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                                                    rf-....
                                                          S£MO;o:~
                                                                                      SWITeK

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                                                             I
                                                  -----. -. -II       II
                                                                            ,      I
                                                                            I      I
                                               "'/~
                                      L...!=:::'I-h\~ ~'''''''_~                         ADMIRAl
                                                                                         PANEL.
                                      '>-C!!!~;...'-/TACHOMETER
                                              I    START        PREHEAT
                                              ~WlTCH            swrTCH

                                                   ~"OaA {~
                 ____________________ J



                                         ~        WESTERBEKE
                                                  Engines & Generators

                                                           27
        Admirals Panel DC Control Circuit Wiring Diagram # 36844
                              page 2 of2


                                SCHEMATIC DIAGRAM
 .... 12 VOLT DC




     C8
   ~ 20A                                                         UFTPUMP
                      ~~~~~----~-{P~--4
                                                           I
                                                           I  FUELSOL.
                                                           I._-;@-__
                         D.P.
                                                 '----,          ~.P. SNDR.
                         lIN.
                                                               "-'
                                                        W.T.SNDR.




                      .JJsz
                                                                 W.T.SW.           ..!
                                                         ,---+;@"..----.."""
                                  52   51   51    51                       s,l
                         "
                                                                       TACH·'1
          f;:]START                                              \§I
          l.!J$NI.                                     ~-;----      W.T.
                                                                              II



   _-'-..6--1
         1                                       '---+-~~O.P.
                                                                 \QI
                                                                              i
                                                                              I
   I-P~EATSW.




NOTE:

1. THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCA"lEl 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 SALTWATER.

2. AN ON-OFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO DIS-
   CONNECT THE BATTERY IN AN EMERGENCY,AND 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 INSULATED.




                      ~         WESTERBEKE
                                Engines & Generators

                                       28
                            DC ELECTRICAL SYSTEM
                                   WIRING DIAGRAM ##39144
              This diagram illustrates the 12 VDC negative ground electrical
              circuiL Two optional instrument panels are also shown: the
              Captains Panel and the Admirals Panel.       .




                       r-----P1~~


      NOTE:           '~"
AN ON-OFF SWITCH IOCIT( ' : ·
SHOULD BE IN-             · .J
STALLED BETWEEN
THE BAmRY AND          ,
STARTER TO DiS,
CONNECT THE BAT' .   +A£"l
TERY IN AN EMER,          ~"'="
GENCY AND WHEN            Ulilll
LEAVING THE BOAT
A SWITCH WITH A
CONTINUOUS
RATING OF 175
AMPS AT 12 VOC
WILL SERVE THIS                                                                    /2t'S(STlJ2...        P. No
fUNCTION, THIS
SWITCH SHOULD
NOT BE USED TO
                                                                         ADMIRAL
                                                                         PANEL      39'60<0
MAKE OR BREAK
THE CIRCUIT,                                                                       L.l F'i    \"J iJ M   P
                                                                                    ~iY1     'c '( f;"
                                                                                   ? {/..B I+~t\- r      so L    .
                                                                                      '2Lj-3"g 3


                                                                                         :5 0 I 2--,"
                                                                                     OIl.      ';:,w  \Tc«
                                                                         CAPTAIN             'j 73'2,,3
                                                                         PANEL




                                          o



                      ______~___~~U _____,
                      _~


                                         Engines & Generators

                                              29
                                      DC ELECTRICAL SYSTEM
                                                   WIRING SCHEMAnC #39144


      +11_                            nAar
                                    c-,,
                                      ~.
                                                                   ";;:'"                                 -
                                    ,
                                    ,  ,                             "
                                                                ~--------                         ---          ---,
                                       -           nclOC.'
                                           r-~-·


                                    rtJ. ,                                eI._~""


                                           ---                       ...u ..ato.



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                                                                   51     AMP            AI    TfRNAIOA
                                                                                                                         -~PRfSIQr lIE              72 AMp         AI T
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                                                                                                                         1_14      eRA


                                                                                                 ., ,8

                                                                ".
                                                                                                                         I'        Plld

          ,!At :iihli!l
              ...n                                                                                                    1'4 LT         8
',·,'-:'','::-::',·,"J.',W,' "                                                           ,~
                                                                                            y"\
through the sea water cooling circuit into the ex-
tiaust, filling it up into the engine.




2. 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 automotive
fHterwrench 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 engine's cooling ability.
Please 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 cartridge-type oil filter requires no cleaning in-
side, so it may be properly disposed of.

When installing the new oil filter element, wipe the filter gasket's 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

                                                         39
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 engine's oil pressure. Make sure there
                                                                     Rocker [over
is no leakage around the new oil filter or from the oil dra.in
system, and stop the engine. Fill to, but not cover, the high
mark on the dipstick, should the engine require additional oil.


                                                                  Oil Dipstick




                                                                   lower

                                                                           Crankcase




                                     -..v: WESTERBEKE
                                            Engines & Generators

                                                 40
                                                  JS TRANSMISSION

    General

    The transmission's gear ratio is 2.47 to 1. The JS transmission is made of a lightweight. l:Iigh-strength, cor-
    rosion-resistant aluminum alloy suitable for the marine environment. This manual transmission rotates op-
    pos~e to the engine when in forward gear. The JS transm~s ~ power w~ case-hardened 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 w~h oil in the transmission. This testing. among other
    things, provides all internal partsw~h 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.




                                                                                      ULL
                                                                                      IIDO$1I1G




                                    UAI loa
                                    tollTlIL
                                    LE'U




)

                                                                                   OIl ,UIII
                                                                                   PUtO
                                                                                   (6 mm Allen Head)




    Lubrication

    The JS transmission is an immersion-lubricated type. Fmthe transmission up to or near the top of th~
    machined notch cut on the dipstick with SAE 20, W/20, 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. CG-4. SD, or SE.

    The oil capacity for the JS transmission is approximately 1.0 quart (1.0 I~er). 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 O-ring gaskets on the dipstick are in good shape. These O-rings 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

                                                         41
 Alignment


Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious
problems. Make sure the alignment procedures outlined in the "Propeller Shaft Coupling", the "propeller"
and the "Alignment of the Engine" in the Westerbeke installation manual are adhered to.


 Controls

The only controls requirj!d to operate the
t/ansmission 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
  1/2 inches of cable throw from the
  NEUTRAL position on the transmission's
  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
                                                                                                      O:IPST
        FORWARD or REVERSE. In this
        situation, the transmission's 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 transmission.
       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

                                                   42
    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 transmission's 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 two-bolt 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 cover's
          capscrews voids the transmission's 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 qll!llified Wester-
    beke Dealer. This problem, especially conceming the rear seal, is often contributed to an improper align-
    ment of the transmission's coupling and the propeller shaft's coupling. .     .


    Never loosen the gear box lever cover screws, except in the course of qualified servicing; this upsets criti-
    cal adjustments.

    Disassembly of the transmission in the field is not recommended. If an overhaul or repair is needed, the
    WOI1< shc:iuId be done by Westerbeke or an authorized Westerbeke service center.

    Cooling

    The JS transmission is sea water-cooled. Sea water enters the transmission through a stainless steel inlet
    pipe located at the base of the bell housing. This water helps to cool the transmission's lubricating oil.




                                                  Engines & Generators

                                                         43
         THE MODEL 120 HAS A BREATHER         PRM NEWAGE TRANSMISSIONS
         FITTING ON THE TOP OF THE CASE
                                                          MODELS 80 AND 120
. SERIAL NUA4BEI~'                                                           Push a suction pump hose down through the dipstick hole
                                             --DIF'STIl:K 112· HEX PLUG      to the bottom of the housing and suck out the oil. (If space
                                                 MODEL 80 (MODEL 120 USES    allows, use the transmission drain). 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                    transmission.
        API classification of CF or CG-4 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, 10W-30 or lSW-40          from the transmission gear and damper plate. In such cases
                                                                             the idle speed should be increased
             41" - 68" F (5·-20" C)            SAE 20 or 10W-30
               Below 41" F (5· C)                 SAE 10W-30                 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 PRM80-1.0 U.S. pint (O.6L), model PRM 120-1.4 U.S.
        pints (O.8L).
                                                                             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, re-check 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

                                                                        43A
                                               PRM NEWAGE TRANSMISSIONS
                                                               MODELS 80 AND 120
                                                                                                                    N
                                                                                                                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.
    TROUBLESHOOTING
      ProIIJem                                            Probable Cause                                       Verificalioll/llemedy
      Excessive noise at low speeds.            1. Engine idle speed too low.                 1. Increase idling speed.
      Excessive noise at all speeds.            1. Defectivecoupling.                         1.   Inspect/rep~ce           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.   Rep~ce.

      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.


    MAINTENANCE/SERVICE                                                            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 re-filled with fresh                        NEWAGE distributor (listed above) or your WESTERBEKE
    oil to the correct specifications.                                             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: 978,887-1"101                                                             All PRM Transmissions must be correctly installed, aligned
    Fax: 978-887-5599                                                              and maintained.
                                  Transmission Marine
                                  223 Southwest 33 Court
    Hamilton Jet                  P.O. Box 21086
    1111 NW Ballard Way           Ft. Lauderdale, FL 33335·1086
    SeaHle, WA 98107              Tel:954-467'1540
    Tel: 206-784-8400             Fax: 954-467-1525
    Fax: 206-783-7323                  Or contact your WESTERBEKE dealer.



                                                               ,..y-     WESTERBEKE
                                                                         Engines & Generators

                                                                                 438
                                OPTIONAL TRANSMISSIONS




               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.
                                                                           o
 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 0.5 mm (0.002") clearance.

 5. Over travel of the actuating lever does no harm, However,
                                                                                  -j,-
 if the travel is too short to give full engagement, premature
                                                                                    o.s "''''
 wear, excessive heat generation and gear failure may result.
                                                                               Control of
                                                                                Gearbox




 Westerbeke Diesel Engines
                                    ~    WESTERBEKE
                                         Engines & Generators

                                               44
    6. The position of the cover plate underneath the
    ad»aIing 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 trnn9DiS<:ion 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 fn:ewheeled 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          . 2.05:1,2.72:1
             30B                                 HBWIOO           1.48:1, 1.79:1,2.72:1
             30B                                 HBWI50V          1.77:1,2.13:1,2.99:1

    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

                                                     45
                                    ENGINE TROUBLESHOOTING


Introduction

The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the
probable causes of the problems, and the recommendations to overcome these problems.

Note that the engine's control system (electrical system) is protected by a 2O-Ampere manual reset circuit
breaker located on the rear lifting bracket




problem                                 probable Calise                    yerificatjonffiemedy

Key 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 housing.



PREHEAT 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

                                              46
pmblem                 probable Cause                YerjfjcatignlBemedy

START switch Is de-   1. Connection to               1. Check connection S at the
pressed: no starter      solenoid faulty.               starter solenoid for 12 volts
engagement.                                             with the switch depressed.

                      2. Faulty START switch.        2. Check switch with an
                         ohmmeter.

                      3. Faulty solenoid.            3. 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 solenoid's
                                                        S terminal with no activation.


Engine cranks,        1. Shut.off valve at           1. Retum shut.off 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.

                      4. Fuel pump is not            4. Check pump operation.
                         operating.

                      S. Fuel filters are clogged.   5. Clean/rep/ace filters.

                      6. Blockage in exhaust.        6. Remove exhaust hose
                                                        from the engine and crank
                                                        to start.



Failure 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

                                47
Pwblem                 prmable Cause                yerificatipofBemedy

Engine Stops.          1. Fuel starvation.          1. Check to see that the
                          Fuel shut-oif is turned      shut-off 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 tank(s) 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 hose.



Battery 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 or/and
                                                       at the engine.




                     ''''''''WESTERBEKE
                         I Engines & Generators
                                  48
                                   MAINTENANCE AND ADJUSTMENTS

Introduction

.This section contains a scheduled preventive maintenance program and several adjustment procedures the
 owner/operator can perform without the benefit of sophiSticated and expensive tools and instruments.


Preventive Maintenance

Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
Adherence to these schecll.des 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 distributor.


Daily (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
     ADD.

  3. Check the transmission's 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 tank(s) with a good grade of No.2 diesel fuel, if required.

  6. Chect-":"-'-"7.:~- CO" TR0 L RACI

                  CONTROL
                  PINION



                 PLUNGER SPRING


                           Cutaway View of the 30B THREE's Fuel Injection Pump


                                           "WIV'   WESTERBEKE
                                                   Engines & Generators

                                                       54
         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 & Generators



\.                                                           55
                                       LAY-UP & RECOMMISSIONING
                                                                       Fuel System [Gasoline]
Many owners rely on their boatyards to prepare their craft,             Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the off-            of higher. A fuel conditioner such as STABIL gasoline
season or for long periods of inactivity. Others prefer to              stabilizer should be added. Change the element in your
accomplish lay-up preparation themselves.                               gasoline/water separator and clean the metal bowl.
The procedures which follow will allow you to perform your              Re-install and make certain there are no leaks. Clean
own lay-up and recommissioning, or you may use them as a                up any spilled fuel.
check list if others do the procedures.                                 Fuel System [Diesel]
These procedures should afford your engine protection                   Top off your fuel tanks with No.2 diesel fuel. Fuel additives
during a lay-up and also help familiarize you with the                  such as BIOBOR and STABIL should be added at this time to
maintenance needs of your engine.                                       control algae and condition the fuel. Care should be taken
If you have any questions regarding lay-up procedures, call             that the additives used are compatible with the primary fuel
your local servicing dealer; he will be more than willing to            tilter/water separator used in the system. Change the element
provide assistance.                                                     in your primary fuel tilter/water separator, if the fuel system
                                                                        has one, and clean the separator sediment bowl.
Propeller 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 injection
shaft 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 Circuit
period of time.                                                         Close the through-hull 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 50-50 solution of antifreeze and distilled water is                   check the zinc anode found in the primary heat exchanger on
recommended 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 the
antifreeze, depending on the area's winter climate. Check the           zinc anode is located. Clean the raw water strainer.
solution 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 antifreeze
mixture. 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 solution's strength.
                                                                        Start the engine and allow all of this mixture to be drawn
Lubrication 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 lay-up, as well
with new oil. Use the correct grade of oil. Refer to the                as providing corrosion protection.
ENGINE 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 recommissioning, but replace the cover and gasket.
  A CAUTION: 011 nllt leave the engine's old engine                     Cylinder Lubrication [Gasoline]
  III/In the SII1IIP llvel the lay-up period. Engine oil and
  tIIIIIIbusIlon 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 engine's
                                                                        out the engine as it coats the valves, cylinders and spark
  internal paris.                                                       plugs for winter protection.




                                                    ~          WESTl:RBEKE
                                                               Engines & Generators

                                                                   56
                                                LAY-UP & RECOMMISSIONING
        Starter Motor                                                         SPARE PARTS
        Lubrication and cleaning of the starter drive pinion is advis-        Lay-up time provides a good opportunity to inspect your
        able, if access to the starter permits its easy removal. Make         WESTERBEKE engine to see if external items such as drive
        sure the battery connections are shut off before attempting to        belts or coolant hoses need replacement. 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 lay-up, such as filters and zinc anodes. Refer
                                                                              to the SPARE PARTS section of tltis manual.
        Cylinder Lubrication [Diesel]
        If you anticipate a long lay-up period (12 months or more)            RECOMMISSIONING
        WESTERBEKE recommends removing the glow plugs or                      The recomntissioning of your WESTERBEKE engine after a
        fuel injectors for access to the cylinders. Squirt light              seasonal lay-up 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 lay-up 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 i'!iec-              the old gasket. Install the raw water pump impeller
        tion pump components to move. This will help prevent their                removed during lay-up (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 Thru-Hull Exhaust[Diesel]                             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, re-gap, and install
        recommissioning, 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 start-up. The through-hull              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 antifreeze/fresh water
        Intake Manifold [Gasoline]                                                solution from the raw water coolant system. When the
                                                                                  engine is put into operation, the system will self-flush 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 oil-soaked cloth in the                  debris.
        through-hull exhaust port, Make a note to remove cloths prior
        to start-up!                                                          6. Check the transntission fluid, if it had been topped off
                                                                                  during the lay-up, 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 no-loads on the
        sion to the very top to prevent corrosion. Lower the fluid to             generator at start up. [Generator]
        its normal at recommissioning. 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 lay-up 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.
    )

                                                        ,,,,,,iWESTERBEKE
                                                               I Engines & Generators

\                                                                        57
                         W 20B TWO MARINE DIESEL ENGINE

                               GENERAL SPECIFICATIONS

Engine Type                                Diesel, four-cycle, two-cylinder, fresh water-cooled,
                                           vertical, in-line (18 hp at 3600 rpm maximum)

Governor                                   Mechanical, centrifugal weight'type

Valve Mechanism                            Overhead

Combustion Chamber                         Swirl chamber type

Bore & Stroke                              2.99 x 2.76 inches (76 x 70 mm)

Piston Displacement                        38.75 cubic inches (0.635 liters)

Firing Order                               1-2

Direction of Rotation                       Clockwise, when viewed from the front

Maximum Torque (at 2200 rpm)                30 Ib-ft (4.15 kg-m)

Compression Ratio                           23:1

Compression Pressure                        398 psi (28 kg/cm2) at 280 rpm

Valve Seat Angle                            Intake 45·
                                            Exhaust 45·

Valve Clearance                             Intake 0.010 inches (0.25 mm)
(engine cold)                               Exhaust 0.010 inches (0.25 mm)

Dimensions                                  Height: 19.75 inches (501.65 mm)
                                            Width: 16.00 inches (406.40 mm)
                                            Length: 25.87 inches (657.10 mm)

Inclination                                 Continuous 14·
                                            Temporary 25· (not to exceed 30 min.)

Dry Weight                                  228lbs (103.4 kgs)

Fuel Consumption                            0.7 U.S. gph (2.65Iph) running at
(propeller allowing                         2500 rpm (approximate)
rated RPM)

Idle Speed                                  1000 -1200 rpm

Cruise RPM                                  2500 - 3000 rpm




                                    Engines & Generators

                                        58
                               20B TWO MARINE DIESEL SYSTEM SPECIFICATIONS


        FUEL SYSTEM

           General                                      Open flow - totally self-bleeding, manual priming.

           Fuel                                         No.2 Diesel (cetane # 45 or better).

           Injector Pump                                In-Ilne plunger type (Bosch type).

           Engine Timing                                19" :t: 1° BlDC
           (spUi timing)                                Static

           Injector Pressure                            1991 psi (140 kg/cm2)

           Nozzle                                       Throttle type.

           U1tPump                                      12-volt DC; lift capacity 5 ft (1.5 m)
           PN 037818

           Air cleaner                                  Plastic screen type - cleanable.

           Air Row (engine combustion)                  40.6 cfm (1.1 cmm)


    )   COOUNG SYSTEM

           General                                      Fresh water-cooled block,
                                                        thennostatically-controlled
                                                        with heat exchanger.

           Operating Temperature                        170 -1900 F (77 - 88" C)

           Fresh Water Pump                             Centrifugal type, metal impeller, belt-driven.
           PN 037015

           Raw Water Pump                               Positive displacement, rubber impeller,
           PN033636                                     mechanically-driven.

           Raw Water Row, at 3600 rpm                   11.1 U.S. gpm (42Ipm) approximate.
           (measured before discharging
           into exhaust elbow)

           System Capacity (fresh water)                2.9 qts (2.7 liters)


        LUBRICATION SYSTEM

           General                                      Pressure type by TrOChoid pump,
                                                        gear-driven, with external pressure relief valve.
    )

                                           I~/WESTERBEKE
                                             I Engines & Generators
\       Westerbeke Engines
                                                   59
                              W 208 TWO SYSTEM SPECIFICATIONS

  Operating OD Pressure                         15.0 - 45.0 psi (1.0 - 3.1 kg/cm2)
  (engine hot)

  CD Grade                                      API specification of CF or CG-4
  Sump Capacity (including fmer)                3.0 U.S. qts. (2.8 liters)
ELECTRICAL SYSTEM

  StartIng Battery                              12-VoIt; 35 A-H, (-) negative ground
                                                (recommended) (45 A-H cold areas)

  Battery Capacity                              90 - 125 (Ampere-Hours)

  StartIng Aid                                  Glow plug, sheathed type

  Starter Motor                                 12-VoIt; 1.2KW, solenoid, actuated shift

  DC No-Load Current                            100 Amps at 11.5 Volts (3000 rpm, min.)

  Cold Cranking Current                         125 Amps at 10 Volts (805 rpm, min.)

  Alternator                                    12-Volt DC, 50 Amps

  Regulator                                     Internal regulator, built into altemator


TRANSMISSION

  General (JS Transmission)                     Case-hardened helical gears, with an intermediate
                                                reverse gear. Reversing carried out by a servo
                                                double disc system.

  Standard Gear Ratio                           2.47:1

  Propeller Shaft,
  Direction of Rotation                         Right handed - standard transmission

  Propeller Recommendations                     140 X 11 P - 2 blade or 14 D x 9 P - 3 blade
  (USing JS transmission                        Propeller should allow the engine to reach
  2.47:1 reduction)                             its full rated RPM (3600 + 000 - 100) at full open
                                                throttle while underway.

  Lubricating on Grade                          API specification of CF or CG-4

  SAE Grade                                     SAE 20W/20 or SAE 30 exclusively
                                                (DO NOT mix grades of on!)
                                                (DO NOT use multigrade OilS!)

  Transmission Sump
  Capacity                                      1 qt (1 liter)




                                      Engines & Generators

                                          60
                        W 30B Tl-IREE MARINE DIESEL ENGINE

                               GENERAL SPECIFICATIONS

Engine Type·                                  Diesel, four-cycle, three-cylinder, fresh water-cooled,
                                              vertical, in-line (27 hp at 3600 rpm maximum)

Govemor                                       Mechanical, centrifugal weight type

Valve Mechanism                               Overhead

Combustion Chamber                            SwIrl chamber type

Bore & Stroke                                 2.99 x 2.76 inches (76 x 70 mm)

Piston Displacement                         59.09 cubic inches (0.952 Itters)

Firing Order                                  1-3-2

Direction of Rotation                         Clockwise, when viewed from the front

Maximum Torque (at 2200 rpm)                  43 Ib-ft (5.9 kg-m)

Compression Ratio                           23:1

Compression Pressure                          398 psi (28 kglcm 2 ) at 280 rpm

Valve Seat Angle                              Intake 45°
                                              Exhaust 45°

Valve Clearance                               Intake 0.0098 inches (0.25 mm)
(engine cold)                                 Exhaust 0.0098 inches (0.25 mm)

Dimensions                                  Height: 19.75 inches (501.65 mm)
                                            WKlth: 16.00 inches (406.40 mm)
                                              Length: 28.81 inches (731.77 mm)

Inclination                                 Continuous 14°
                                            Temporary 25° (not to exceed 30 min.)

Dry Weight                                    272 Ibs (123.3 kgs)

Fuel Consumption                            1.19 U.S. gph (4.5 Iph) running at
(Propeller allowing                         2500 rpm (approximate)
rated RPM)

Idle Speed                                  1000 - 1200 rpm

Cruise RPM                                  2500 - 3000 rpm




                               l"'fN'IWESTERBEKE
                                   I Engines & Generators
                                         61
                      30B THREE MARINE DIESEL SYSTEM SPECIFICATIONS


FUEL SYSTEM

  General                                       Open flow - totally self-bleeding, manual priming.

  Fuel                                           No.2 Diesel (cetane # 45 or better).

  Injector Pump                                 In-Ilne plunger type (Bosch type).

  Engine Timing                                 19' ±1°BTDC
  (spDI timing)                                 Static

  Injector Pressure                              1991 psi (140 kgtcm2)

  Nozzle                                        ThrotUe type.

  Lift Pump                                     12-volt DC; lift capacity 5 ft (1.5 m)
  PN037818

  Air cleaner                                   Plastic screen type - cleanable.

  Air Flow (engine combustion)                  60.4 cfm (1.7 cmm)


COOUNG SYSTEM

  General                                       Fresh water-cooled block,
                                                thennostatlcally-controlled
                                                with heat exchanger.

  Operating Temperature                         170 - 190° F (77 - 88" C)

  Fresh Water Pump                              Centrifugal type, metal impeller, belt.;,                   ."'" ,
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                                                                    Ulrich Heinemann
                                                                    Managing Director
                                                                           0609
                                                                       011 12000
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