Westerbeke 20B TWO/30B THREE Wartungshandbuch

TECHNICAL MANUAL WESTERBEKE 20B TWO 30B THREE MARINE DIESEL PROPULSION ENGINE Publication #037600 Edition One April 1990 j r~ 'WESTERBEKE J

UNIT 1.0. PLATES • MODEL SPEC . AVO .. MA USA SER.NO.. 20B TWO UNIT 1.0. PLATE • MODEL SPEC AVO" MA USA SER.NO.. 30B THREE UNIT 1.0. PLATE The un

Engine Type Governor Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation 20B TWO MARINE DIESEL ENGINE GENERAL

20B TWO MARINE DIESEL SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Engine Timing (spill timing) Injector Pressure Nozzle Lift Pump PN

208 TWO MARINE DIESEL SYSTEM SPECIFICATIONS Oil Filter PN 036918 Sump Capacity (including filter) Operating Oil Pressure (engine hot) Oil Grade ELECTR

30B THREE MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direc

30B THREE MARINE DIESEL SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Engine Timing (spill timing) Injector Pressure Nozzle Lift Pump P

30B THREE MARINE DIESEL SYSTEM SPECIFICATIONS Oil Filter PN 036920 Sump Capacity (including filter) Operating Oil Pressure (engine hot) Oil Grade ELEC

20B TWO AND 30B THREE ENGINE SERVICE SPECIFICATIONS NOTE: All dimensions and specifications contained in this section are given in inches then millim

Valves Valve clearance (IN & EX) Valve head dia. (IN) (EX) Overall length StemO.D. Stem to guide clearance (IN) (EX) Valve face angle Valve head t

Specified Value/Standard Repair Limit Rocker Arm Rocker arm 1.0. 0.472 (12 mm) Rocker arm to shaft clearance -0.008 (Service limit) (-0.2 mm) Cylinder

SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the opera

Piston (continued) Oversize Protrusion from cylinder block top surface Piston Pin Type 0.0. Piston pin to piston clearance Piston pin to connecting ro

Specified Value/Standard Repair Limit Connecting Rod Type Forged I-beam Bend and twist Within 0.002 (0.05 mm) Big end thrust clearance 0.004 - 0.014 (

Specified Value/Standard RepairUmit Main Bearing Type Aluminum metal with back metal Oil clearance (No.2: Flanged metal) Under size 0.01,0.02 (0.25, 0

Oil Specification TEMPERATURE ENGINE OIL [SRE I) c" F" -30 -20 -20 -10 o 10 20 30 40 50 o 20 40 GO 80 100 120 _un Dii' mmmwn NBI"

NOTES Westerbeke Engines 22

ENGINE OVERHAUL Section ... Page PREPARATIONS FOR OVERHAUL ...

PREPARATIONS FOR OVERHAUL 1. Shut off and disconnect all fuel lines, raw water and exhaust connections. 2. Unbolt the engine and carefully move it to

ENGINE DISASSEMBLY This section describes the disassembly of the engine when performing a complete overhaul of the unit. The procedures which follow i

CYLINDER HEAD CONSTRUCTION AND SERVICING ~ ~~~ @ .• ~~ -=---ej) Cylinder head a cross section ~--I' • .F----J. CYLINDER HEAD COMPONENT PARTS 1.

Cylinder Head Removal 1. Remove the high pressure injection line assembly. CAUTION When disconnecting each injection line from the injection pump side

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and worksho

Cylinder Head Inspection and Repair Check guide for ware and damage. Check for valve contact, wear, damage, and sink of seat face. Valve Guide Repl

Valve Seat Repair If a valve seat is found defective, reface it or replace the cylinder head. Sinkage of valve Standard Service limit 0.5 mm 1.5 mm CA

VALVES AND VALVE SPRINGS ~=---':~' ~--(2) ..----@ VALVE SYSTEM COMPONENT PARTS 1. Valve stem cap. 4. Valve stem seal. 2. Retainer lock. 5. V

Valve Removal 1. Dismount the cylinder head assembly. 2. Depress the valve retainer (to compress the valve spring) and remove the retainer lock. 3. Re

1. If the valve face is found worn down, resurface it with a valve refacer. If the margin of the resur-faced valve exceeds the service limit, replace

VALVE CLEARANCE ADJUSTMENT Valve Clearance Adjustment Cylinder head bolts lIl.USt. be retightened before adjust-ing the valve clearance. When retighte

GEAR CASE AND OIL PUMP (Ii) '!}) GEAR CASE COMPONENT PARTS 1. Bushings. 5. Relief plunger. 9. Oil pump housing. 2. Plug. 6. Relief spring. 10. Ge

Gear Case and Oil Pump Removal and Inspection 1. Remove the crankshaft pulley. 2. Remove the fan and fan belt. 3. Remove the tie-rod cover from the si

Front Oil Seal Replacement 1. Remove the front oil seal. 2. Press-fit the new front oil seal. CAUTION Apply a thin coat of engine oil to the circumfer

Governor Levers' Disassembly and Reassembly 1. Removal of the shaft. a. Remove the expansion plug, taking care not to scratch the gear case. b.

TABLE OF CONTENTS Section ... Page 20B TWO GENERAL SPECIFICATIONS ...

TIMING GEARS "'4 Cj) TIMING GEAR COMPONENT PARTS 1. Crankshaft gear. 3. Camshaft gear. 2. Idle gear. 4. Injection pump camshaft gear. Wester

Timing Gears' Removal 1. Pry the snap ring out and remove the idle gear. 2. Remove the valve camshaft and injection pump cam-shaft on which the r

Timing Gears' Installation 1. Press-fit the crankshaft gear onto the shaft. 2. Press-fit the valve camshaft gear and injection pump camshaft gear

CAMSHAFTS (Valve and Pump) @ @ I @ ~~ rID @ (1) CAMSHAFT COMPONENT PARTS 1. Camshaft (valve). 8. Tappet. 2. Camshaft gear. 9. Push rod. 3. Ball beari

Valve Camshaft Removal 1. When it is necessary to remove only the valve camshaft, use the following procedure. a. Dismount the cylinder head assembly.

Camshafts' Inspection Each ball bearing-Wear and noise Inspection of Camshafts Cam lobe-Wear and damage Oldham's coupling-Wear Major diame

Camshafts' Installation When installing the camshafts, give care to the fol-lowing. 1. Coat the bearings and cam lobes with oil. 2. Install the

PISTON AND CONNECTING ROD Os-=--: ---(J) (~)~ €31_'!l1 €!---I ~" (8)--IQ' PISTON AND CONNECTING ROD COMPONENT PARTS 1. Piston ring No.1

Piston and Connecting Rod Removal 1. Remove the cylinder head assembly. 2. Remove the oil pan. 3. Remove the oil screen. 4. Chalk the cylinder number

Inspection of piston ring gaps. Put each piston ring into the cylinder bore and push the ring with the piston to position the ring on square with th

TABLE OF CONTENTS (CONTINUED) STARTER ... 71 ALTERNATOR ...

FRONT mark (arrow) 2. Installation of piston rings. FRONT mark ---... Rod front --.------~ mark Align notches -accurately with each other. Tighteni

3. Set the piston ring gaps to the proper positions as shown in the figure at right. Coat the rings and cylinder wall with oil. Ol'ri"if

CRANKSHAFT ® CRANKSHAFT COMPONENT PARTS 1. Key. 6. Washer. 11. Rear oil seal case. 2. Crankshaft. 7. Spring washer. 12. Gasket. 3. Crankshaft gear. 8.

Crankshaft Removal 1. Loosen the flywheel bolts and remove the flywheel. 2. Loosen the crankshaft pulley nut and remove the pulley. 3. Remove the rear

Checking the crankshaft for wear. To check the crankpins and main journals for tapering wear and out-of-round wear, the diameter of each crankpin o

Crankshaft Rear Oil Seal Replacement 1. Pry the oil seal out with a screwdriver. 2. Drive in a new oil seal to the oil seal case. When installing the

CYLINDER BLOCK CYUNDER BLOCK COMPONENT PARTS 1. Cylinder block. 5. Main bearing. 9. Idler gear shaft. 2. Front plate. 6. Starter bracket. 10. Oil filt

Cylinder Block Inspection Inspect the cylinder block. If it is found defective, repair or replace the block. Cylinder Bore (mm): Mgdel 20B 30B Standa

FUEL INJECTION PUMP INJECTION PUMP COMPONENT PARTS 1. Union collar. 8. Delivery valve. 15. Plunger. 9. Gasket. 16. Lower seat. 3. Delivery valve holde

Injection Pump Inspection while on the Engine Never attempt to disassemble the pump unless it is necessary. If the pump is assumed defective,

... T9PEngine Oil 50 Amp DC Alternator Adjustable Engine Isolator Westerbeke Diesel Engines ·4 45° Exhaust Elbow G:ear Shift Lever Gea~ As~~mbly Batte

Injection Pump Assembly 1. I nsert the plunger barrel into the housing. 2. Install the delivery valve and valve spring. Temporarily tighten the holde

INJECTION NOZZLE @:_--I ::g <9 @ @ @ NOZZLE HOLDER ASSEMBLY COMPONENT PARTS 1. Body subassembly. 5. Distance piece. 2. Shim washer. 6. Nozzle assem

Injection Nozzle Removal 1. Disconnect the injection pipe and fuel return pipe. 2. Remove the injection nozzle assembly from the cylinder head. CAUTIO

Injection Nozzle Adjustment Adjust injection start pressure by increasing or decreasing the thickness of the shim washer to be inserted. Vary

GOVERNOR SYSTEM I---@ ® GOVERNOR SYSTEM COMPONENT PARTS 1. Sealing metal. 11. Tie-rod clip. 21. Stop lever assembly. 2. Sealing wire. 12. Tie-rod cove

Torque Spring Set Installation Install and adjust the torque spring set using the follow-ing procedure: 1. Set the speed control lever to the high idl

3. Leaving the dial gauge set condition unvaried, depress the spring stopper (1) and slide the torque spring set support spring case (2). Read the de

GOVERNOR Check springs ~GJ for fatigue. ~~\d)./ 7 ~\,i) Check springs for fatigue. ~~ Check shaft for flaws. Check sliding sleeve joint for wear and

GLOW PLUG Glow Plug Inspection Check for conduction between the glow plug terminal and body. Ifthe plug is not conductive at all or shows a large resi

COOLING SYSTEM Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw waterflow through their independent cooling c

,FreSh W_ Fill CaP~ !VI ll'ilake Silenger ~ Zinc I'\mJUt:i~ -Gear Dipstick and Oil Filler _~~~~e Engine Isolator 5 Fuellnjeciion~. Pump - .

Fresh Water Pump Drive BeH Tension Generator models come equipped with belt guards that cover over the belt(s) on the front of the engine. ("Out

Raw Water Pump Overhaul Raw water pump #033636 repair instructions are as follows: Disassembly The pump, as removed from the engine, will have hose at

Assembly a. Install the seals (ref 7) and spacer (ref 14) in the pump housing. Push the impeller side seal into the housing. Rotate the pump and insta

STARTER (,!l) I}) lID .~~ STARTER COMPONENT PARTS 1. Front bracket assembly. 6. Through bolt. 11. Gear. 2. Lever assembly. 7. Armature. 12. Yoke assem

Starter Adjustment and Repair If any abnormality is assumed by the following tests, adjust the starter or disassemble and repair it. 1. Pinion gap ins

3. Magnetic switch. Perform the following tests. If any test result is not satisfactory, replace the magnetic switch assembly. a. Disconnect the wire

Starter Disassembly 1. Disconnect the wire from the magnetic switch terminaIIM." 2. Loosen the two screws fastening the magnetic switch. Remove t

Starter Inspection Wear and chipping Bearing: Play. noise. and rough rotation Bearing: Play. noise. and rough rotation Break and short circuit Insp

2. Inspecting the armature. a. Check the armature with a growler tester. If it's short circuited, replace the armature. Also, check for insulati

b. Measure end play by moving the pinion shaft in the axial direction. If the end play exceeds 0.5 mm, increase the number of adjusting washers inser

:50 Amp ~t~rnator AdJU;;'LQU',\;; :Engine Isolator Starter with Solenoid' . -Westerbeke Engines . .. fresh Water Fill Cap Ge~r Shift

ALTERNATOR CD @ @ @ @ I @ ALTERNATOR COMPONENT PARTS 1. Pulley. 5. Rear bearing. 9. Rectifier assembly. 2. Front bracket assembly. 6. Stator. 10. Rear

Alternator On-Engine Inspection 1. Erroneous handling can cause damage to the charging circuit and other troubles so avoid the following: a. Never con

e. Apply all load Including the lamps. f. Increase engine speed until normal alternator speed is attained. Read the maximum indication of the ammeter

5. Unsolder the stator coil lead wires. Remove the stator assembly. CAUTION Never heat the lead wires long to prevent damage to diodes. 6. Disconnect

2. Inspecting the field coil. a. Check for conduction between slip rings. If there is no conduction, the field coil is suspected to be broken. Replac

AHernator Assembly Reassemble the alternator assembly in the reverse order of disassembly giving care to the following: 1. The rear bearing has an ecc

NOTES Westerbeke Engines 84

Preheat is depressed: no preheat. Preheat is depressed: fuel pump does not operate. Start is depressed: no fuel delivery to injectors. ENGINE TROUBLES

.E.auI1 Possjble Cause Yerifjcatjon/Correctjon START switch is de-1. Connection to starter 1. Check connection S at the pressed: no starter solenoid f

Engine Stops. Battery runs down. Black exhaust smoke. possjble Cause 1. Fuel starvation. Fuel shut-off is turned off. 2. Fuel pump is inoperative. 3.

20 Amp DC Circuit Zinc Anode Gear Dipstick and Oil Filler ... Adjustable Engine Isolator . Air Intake Silel'!cer Fuel Injection Pump Fresh Water

MARINE TRANSMISSIONS JSGear The standard transmission on the 20B Two and 30B Three is the JS Gear. Contact Westerbeke Corpora-tion factory for overhau

TABLE OFSTANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standard

Socket Size .Lb:ft. &l:m Cylinder head bolt M 10 (14 mm) 54 -61 7.5 - 8.5 M 8 (12 mm) 14 -22 2.0 - 3.0 Rocker shaft hold down bolts M 8 (12 mm) 11

SPARE PARTS Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than your home port, certain spare

NOTES Westerbeke Engines 92

INDEX A ALTERNATOR ...

Cylinder Bore ...

INJECTION NOZZLE ... 59

S SPARE PARTS .........

NOTES 97 Westerbeke Engines