Westerbeke M3-20 User manual

PARTS

LIST

Unlvarsal

MARINE

DIESEL

ENGINE

M3-20B

PUBLICATION

NO.

201009

1ST

Edition

June

2001

WESTERBEKE

CORPORATION'

MYLES

STANDISH

INDUSTRIAL

PARK

150 JOHN HANCOCK ROAD, TAUNTON,

MA

02780-7319 U.S.A.

WEBSITE: www.WESTERBEKE.COM

nrnr

NMUA

Member

National

Marine

Manufacturus

Association

s.as

.

IMPORTANT

PRODUCT SOFTWARE DISCLAIMER

Product software

of

all kinds, such as brochures, drawings, technical data, operator's and workshop manuals,

parts lists and price

lists,

and other information, instructions and specifications provided from sources other

than Westerbeke, is not within W esterbeke' s control and; according, is provided to Westerbeke customers

only as a courtesy and service. Westerbeke cannot be responsible for the content

of

snch software,

makes no warranties or respresentations with respect thereto, including the accuracy, timeliness or

completeness thereof, and will iu no event be liable 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 in Westerbeke's products and supplies

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

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of

Westerbeke's own product software. Such software may be

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by

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It

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43

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47

WESTERBEKE UNIVERSAL

M3·20B Marine Diesel Engine

TABLE OF CONTENTS

DESCRIPTION

Cylinder

Block

Assembly

Oil Pan

Assembly,

Lube

Oil

Switch

and

Sender

Cylinder

Head

Assembly

Gear Case

Assembly

Piston,

Crankshaft

and Main

Bearings

Cylinder

Head

Cover

and

Air

Intake

Exhaust

Manifold

and

Heat

Exchanger

Fuel

Injection

Pump

and

Fuel

Camshaft

Valve

Rocker

Arm

Assembly

Camshaft

Assembly

Governorlldler

Assembly

Hozzle

Holder

and

Injectors

Governor

Assembly

Cooling

System

Raw

Water

Pump

Fuel

Filter

and Oil Drain Hose

Systems

Flyvyheel and

Starter

Assembly

Bell

Housing

and

Transmission

Alternator

Assembly

Throttle

Assembly

Electrical System

Propulsion

Instrument

Panels

Miscellaneous

Numerical Part

Index

M3-20B

4

19

8

16

18

15

11

Cylinder Block A

ssembly

4

5

7

Page 1

1

2

5

6

M3-20B

Cylinder Block Assembly

Key

# Part #

Deseri ptio n

Qty

301201

Plug,

Expansion

2

302429 Plug, Expansion

1

3

299360 Pin, Straight

2

4

200597 Plug

5

302587 Plug

3

6

302589 Plug

5

7

302588 Plug

1

8

300716

Pin, Pipe

2

9

200589 Gasket, Oil Pump

1

10

301203

Assembly,

Oil

Pump

1

11

301545 Capscrew M12

3

12

302684 Nut, Hex

1

13 299413 Washer, Claw

1

14

301205

Gear, Oil Pump Drive

1

15

298820 Key, Feather

1

16

200596 Plug

3

17 301547

Pin, Pipe

2

18

013341

Plug, 1/4 NPT, Hex Head (Brass)

1

19 301543

Pin, Straight

2

20

301485 Pin, Pipe

1

21

299362 O-Ring

1

22

303030 Mount, Front Right

1

303031

Mount, Front Left (Not Shown)

1

23

040966 Nut, Jam, M16 Self-Locking

5

24

031828

Washer, Flat 5/8

SAE

Steel

2

25

040510 Isolator, Marine, 75-130

LB

2

26

024952

Capscrew, M10x1.25x25 DIN

961

6

27

019262 Lockwasher, M10

DIN

127

6

Page 2

M3-20B Oil Pan Assembly Lube Oil Switch and Sender

14

~

'U+--4

)

12

Page 3

M3-20B

Oil

Pan Assembly, Lube Oil Switch and Sender

Key#

Part #

Description Qty

1

039385

Hose,

Oil

1

2

024844 Adapter, 1/8 BSPT

to

1/8

NPT 1

3

013340

Elbow,

1/8 NPT

90

Street (Brass) 2

4

032480

Bracket, Oil Pressure Sender 1

5

037323 Switch, Oil Pressure

#5

- 1/8 2T 1

6

019369

Plug,

Hex Head, 1/8 NPT (Brass) 1

7

301212 Dipstick

1

8 299967

O-Ring 1

9

200588

Strainer, Oil Pickup 1

10

016789 Capscrew,

M8

x 16

DIN

933

11

302762

Gasket, Sump

1

12

035785 Capscrew, M6 x 12 JIS 6 w/Lockwasher 18

13

302761 Sump, Oil

1

14

024132

Sender, Oil Pressure (Optional with Admiral Panel) 1

Page 4

M3-20B Cylinder Head Assembly

1

Page 5

M3-20B Cylinder Head Assembly

Key #

Part # Description

Qty

1 301549

Eye,

Lifting

2

200615

Assembly, Cylinder

Head (Includes Key Nos. 4 thru

8,

11

& 12)

3

301217 Bolt, Cylinder Head

14

4

301214 Guide, Intake Valve

3

5

301215 Guide, Exhaust Valve

3

6

301550 Plug

1

7

302690 Plug, Expansion

2

8

299906

Plug,

Expansion, 30MM DIN 443 (Brass) 1

9

016789 Capscrew, M8 x 16 DIN 933

2

10

200613

Gasket, Cylinder Head

11

302593 Plug

12

299362

O-Ring

Page 6

M3-20B Gear Case Assembly

21

2

1

13

A~15

-\

~6

18 17

13

11

Page 7

7

8

M3-20B

Gear

Case Assembly

Key

# Part #

Description

illY

1

302692

Assembly, Gear Case (Includes Key Nos.4,

11

& 20)

2 299365 Capscrew, M6 x 18 JIS

1

3 302693

Gasket, Timing Case

1

4

300160 O-Ring

3

5 301554

Spring, Oil Relief Valve

1

6 301556

Ball, Oil Relief Valve

1

7 301555

Seat, Valve Cap, Oil Relief Valve

8 302625

Filter,

Oil

1

9

301490 Adapter,

Oil

Filter

1

10 301222

Washer,

Oil Adapter Nipple

1

11

302593 Plug

12

12-1

034212

Capscrew, M6 x 75

DIN

931

1

12-2

031783

Lockwasher,

M6

DIN 127

1

13

301552 Bolt

3

14

302697

Seal, Oil

1

15 302679

Clamp, Sea Water Pump Mount

2

16

031783

Lockwasher,

M6

DIN 127

2

17

020628

Capscrew, M6 x 25 DIN 933

2

18 042175

Pump, Raw Water

1

19

302678

Gasket,

Sea Water Pump Mount

1

20

301551 Pin, Start Spring

21-1

039248

Capscrew, M6 x

70

DIN

931

21-2 031783

Lockwasher,

M6

DIN 127

Page 8

2

M3-20B Piston, Crankshaft and Main Bearings

,//

: 1-1

\..

""~~;;;)

1-,

/1-2

1_-

(~

1

5

•

1

5---;

5-2

5-3

5-4

2

6

______

1

_______

,

/ \

6-1

Page 9

17

1-1

1-2

2

3

3-1

3-2

4

5

5-1

5-2

5-3

5-4

5-5

6

6-1

6-2

200598

200581

299490

200582

200584

200583

200586

200585

200587

301639

301640

302726

200610

200563

300813

M3-20B Piston, Crankshaft and Main Bearings

Description

Piston Ring Set (Includes

1-1

or 1-2)

Assembly,

Piston Ring, Standard

Assembly,

Piston Ring,

25

Cir-clip, Piston

Piston (Includes

Key

No.

3-1

or

3-2)

Piston, Standard

Piston, .25

Pin,

Piston

Assembly, Connecting

Rod

(Includes Key No.

5-1

or 5-2)

Bushing, Connecting

Rod

Bearing, Connecting

Rod

Set, Standard

Bearing, Connecting

Rod

Set,

.2

MM

Bearing, Connecting

Rod

Set, A

MM

Bolt, Connecting

Rod

Assembly, Crankshaft (Includes

Key

Nos.

6-1

& 6-2)

Ball

Bushing, Crankshaft

7 299549

Key,

Feather

8 Bearing, Crankshaft

(Includes Key

No.

8-1, 8-2 or 8-3

8-1

301282 Bearing, Main Standard

8-2

301641

Bearing, Main, 0.2MM

8-3 301642 Bearing, Main,

Oo4MM

9

301281

Gear, Crankshaft

10

302731

Slinger, Oil

11

301289 O-Ring

12 301287 Collar, Crankshaft

13

13-1

13-2

13-3

14

14-1

14-2

14-3

15

15-1

15-2

15-3

16

16-1

16-2

16-3

17

18

19

Bearing, Crankshaft (Includes Key

No.

13-1, 13-2 or 13-3)

200605 Bearing, Crankshaft, Standard

301645 Bearing, Crankshaft,

.2MM

301646 Bearing, Crankshaft,

o4MM

Thrustwasher (Includes Key No. 14-1,14-2 or 14-3)

299503 Thrustwasher, Standard

301649 Thrustwasher, .2MM

301650 Thrustwasher,

o4MM

Bearing, Crankshaft (Includes

Key

No. 15-1, 15-2 or 15-3)

200604 Bearing, Crankshaft, Standard

300754 Bearing, Crankshaft,

.2

300755 Bearing, Crankshaft, A

Thrustwasher (Includes

Key

No. 16-1,16-2 or 16-3)

299502 Thrustwasher, Standard

301647 Thrustwasher, .2MM

301648 Thrustwasher,

o4MM

018804 Capscrew,

M6

x

20

DIN

933

301231

Seal, Oil

Bolt

20

301228 Cover, Bearing Case

21

22

23

24

25

26

27

302698 Bolt, Bearing Case

301229 Gasket,

Oil

Seal Flange Rear

200578 Assembly, Main Bearing Case

301227 Gasket, Oil Seal Flange Rear

200600 Assembly, Main Bearing Case

200577 Assembly, Main Bearing Case

301235 Bolt, Bearing Case

Page

10

3

6

3

6

1

3

1

2

1

2

8

1

8

6

1

2

M3-20B Cylinder Head Cover and Air Intake

Page

11

M3-20B Cylinder Head Cover and Air Intake

Key#

Part

# Description Qty

1 302707 Cap, Oil Filler

1

2

298740 O-Ring

1

3 200566 Nut, Cap

3

4

301241 Gasket, Rocker Cover Stud

1

5

200601 Cover, Rocker

1

6

200602 Gasket, Rocker Cover

7

300977

Elbow, Male 1/8 NPT x 1/4 Tube

8

024906 Clamp, Hose

2

9

301560 Hose, Breather

1

10 301558 Plate, Breather Element

1

11

301237 Element, Breather

1

12

301557 Plate, Breather Element

1

13

301559 Oil Shield, Breather

1

14

301399

Screw, M5 x 10 w/lockwasher

2

15

200694

Assembly, Inlet Manifold (Includes Key Nos. 16 & 17)

1

16

302770 Gasket, Inlet Manifold

1

17

302769 Manifold, Inlet

1

18

035789 Capscrew, M6 x 45 JIS w/Lockwasher

1

19

021878 Clamp, Hose 20

1

20 300429 Element, Air Filter

1

21

301926 Silencer, Intake

1

22 300983

Clip, Spring-Breather Hose

1

23

299365 Capscrew, M6 x 18

JIS

2

Page 12

M3-20B Exhaust Manifold and Heat Exchanger

4

21

Page

13

12

M3-20B Exhaust Manifold and Heat Exchanger

Key # Part #

Description

Qty

1 302400 Manifold,Exhaust

2

024306 Cap, Pressure 15 PSI

3 299823

Hose, 5/8"

(4

Inches Required)

4

301061 Nipple, 3/8 NPT x 5/8 Hose

5

011341 Clamp, Hose 08

1

6 302785 Gasket, Exhaust Manifold

1

7

036838 Nipple, 3/4 NPT x 7/8 Hose

1

8 011386 Clamp, Hose 12

6

9

019059 Hose, 7/8" Wire Inserted (

26

Inches Required)

1

10

022851

Gasket, Exchanger 2-3/4"

11

022850 Cap, Exchanger 2-3/4"

in

1 Hole 1

12

022852 Capscrew, 3/8 NC x 3/4 (Brass)

1

13

019321 O-Ring, Exchanger End Cover 1

14

031552 Capscrew, 5/16 NC x 5/8

2

15

031758 Lockwasher, 5/16 Split

Med

(Steel)

2

16

031759 Washer, Flat 5/16 SAE (Steel) 2

17

303145 Exchanger, Heat

1

18

303146

Pad,

Exchanger Mount

1

19

298974 Stud, Manifold End

1

20 011885 Zinc

1

21

031766 Nut, Hex 3/8-24 NF (Steel)

3

22

031764

Lockwasher, 3/8

Split Med (Steel)

3

23

298599 Flange, Exhaust 1.25

NPT 1

24

298600 Gasket, Exhaust Flange

1

25 287077

Plug,

Sq

Head 3/8 NPT (Brass)

1

26

012506 Stud, 3/8 NC x 3/8 NF x 1-5/8

2

27

302083 Stud, M6 x 85

6

28 031783 Lockwasher, M6

DIN

127

6

29

015812

Nut, Hex M6 DIN 934

6

30

024977 Kit, Coolant Recovery Tank

1

31

024786 Strap, Coolant Recovery Tank

32

024704 Tank, Coolant Recovery

1

33

024858 Cap, Coolant Recovery Tank

1

34

024637 Tubing, Manifold to Recovery Tank

35

024906

Clamp, Hose 1

36-1

036660 Bushing, Exhaust Elbow

to

Manifold (45 Deg. or

90

Deg. Elbow)

1

36-2

021876

Bushing, Exhaust Elbow

to

Manifold, 1.5 to 1.25

NP

-Exh Riser

1

37-1

302207 Elbow, Water Injected Exhaust-45 Deg, 1.25 NPT

1

37-2

200385 Elbow, Water Injected Exhaust-90 Deg, 1.5 NPT

1

37-3

200266 Riser, Exhaust, 1.25 NPT

1

38-1

302217

Elbow, 1/2 NPT x 5/8 Hose

90

(w/ 302207 or 200385-Exh Riser 1

38-2

302258 Elbow, 3/4 NPT x 5/8 Hose (w/ 200266 Exhaust Elbow)

39-1

035747

Plug,

1/2 NPT Elbow (with 036547 Elbow)

39-2

013341 Plug, Hex-Head Brass, 1/4 NPT (w/200266 Exh Riser)

Page 14

M3-20B Fuel Injection Pump and Fuel Camshaft

10~

7---E!:I'

/

12

22

23

\

17

1a

20

Page 15

6P

7~

Va

M3-20B Fuel Injection Pump and Fuel Camshaft

Key # Part #

Description Qty

1 301749

Screw, Bleed

2 301750 Washer, Bleed

Screw

3

301751 Bolt, Banjo

1

4 301752 Washer, Banjo 2

5 301314 Banjo, Injection Pump

6

039874 Capscrew, M6 x

20 DIN 912 2

7

031783 Lockwasher, M6 DIN 127 4

8

200695 Gasket, Injector 1

10

301313

Nut, Cap

2

11

200572 Assembly, Injection Pump

12

200574 Shim, Injection Pump .25MM

200573 Shim, Injection Pump .20MM (Not shown)

1

13

200575 Shim, Injection Pump .30MM 1

14 301312

Stud

2

200603 Assembly, Fuel Camshaft (Includes Key No.'s 15 thru 27)

1

15

301320 Ring, Retaining (External) 1

16

301319 Ball Bearing 1

17

302782 Camshaft, Fuel 1

18 299549 Key, Feather 1

19

301317 Ball Bearing 1

20 301574 Stopper, Fuel Cam 1

21

035785 Capscrew, M6 x

12

J

IS

w/Lockwasher 2

22 300198 Cir -Clip, Governor Sleeve 1

23

301572 Case, Governor Ball Bearing 1

24 301573 Ball, Governor 32

25

301571 Sleeve, Governor 1

26 299534 Ball

8

27

200590 Gear, Injection Pump 1

Page 16

M3-20B Valve Rocker Arm Assemly

17

11

__

....

10~~~

10

11

16

1

Page 17

8

7

6

3

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