Westerbeke 120D-TWO Service Manual

SERVICE MANUAL MARINE DIESEL ENGINES 12C-TWO 120-TWO PUBLICATION NO. 055411 REVISION 1 JUNE 2012 J'~ rWESTERBEKE J WESTERBEKE CORPORATION • 150 J

ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERI Fl CAT I 0 N/REM EDY LOW OUTPUT (cont .. ) OVERHEATING 1. Low coolant level. 1. Add coolant. 2. Loo

ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY SMOKY EXHAUST (cont. 1 WHITISH OR PURPLISH (cont. d. Worn valve stem and valve guide

ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE ! 1. Main engine troubles. a. Overheated cylinder. ' b. C

DISASSEMBLY PROCEDURES REMOVE EXTERIOR COMPONENTS Unplug the instrument panel wiring harness. Drain the trans-mission fluid and unbolt the transmissio

CYLINDER HEAD REMOVAL 1. Remove the engine heat exchanger. If possible, leave one end of each hose connection attached to the part being removed. For

CYLINDER HEAD Cylinder Head Inspection Clean the cylinder and the cylinder block surface from which the gasket has been removed. Carefully check the c

VALVE AND VALVE SPRING INSPECTION VALVE REMOVAL 1. Dismount the cylinder head assembly. 2. Depress the valve retainer (to compress the valve spring) a

VALVE INSTALLATION /VALVE ADJUSTMENT /INJECTION TIMING Installation Install the valve and valve springs. Refer to the illustrations and callouts shown

VALVE ADJUSTMENT /INJECTION TIMING 19° CRANKSHAFT PUllEY TIMING MARKS TIMING POINTER Injection Pump Timing Adjustment (Spill Timing) If your engine&ap

GEAR CASE I GOVERNOR GEAR CASE ASSEMBLY 1. Remove the drive belt and the crankshaft pulley. 2. Remove the alternator. 3. Remove the water pump assemb

A wARNING Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.

TIMING GEAR I CAMSHAFT REMOVING THE TIMING GEARS 1. Remove the snap ring and disassemble the idler gear. 2. Remove the valve camshaft and the injectio

CAMSHAFT I PISTONS AND CONNECTING RODS Inspecting The Camshaft Make a thorough inspection of the injection pump and the valve camshafts. Check the Old

PISTON AND CONNECTING ROD INSPECTION Put each piston ring into the cylinder bore and push the ring with the piston to position the ring on square with

PISTON AND CONNECTING ROD Place a heavy hammer as shown. Gently press down with the Ioree of your hand. The entire surface should be coated with fresh

CRANKSHAFT INSPECTING THE CRANKSHAFT To check the crankpins and main journals for tapering and out-of-round wear, the diameter of each crankpin or mai

CYLINDER BLOCK BEARING ~-----k~ CAP CYLINDER BLOCK INSPECTION Check the cylinder block for cracks and damage. If neces-sary, repair or replace it enti

ENGINE ASSEMBLY Install the Thermostat and Thermostat Housing 1. Inspect the thermostat housing and the housing gasket. Apply some sealant to the gas

ENGINE ASSEMBLY Install the raw water pump and drive belt. Insure it is in proper alignment with the crankshaft pulley. Check tension. Refer to RAW WA

TORQUE SPECIFICATIONS .. COMPONENT FHB(M-KG) Alternator Bracket ... 27 -38 (3.8 -5.3) Back Plate ...

GOVERNOR SYSTEM INSPECTING THE GOVERNOR COMPONENTS Check levers for smooth movement. Check springs for fatigue. Check sliding sleeve for wear. damage,

SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precau-tions.

GOVERNOR SYSTEM Leaving the dial gauge set, its condition unvaried, depress the spring stopper and slide over the torque spring set support spring cas

EXHAUST MANIFOLD I HEAT EXCHANGER EXHAUST MANIFOLD The exhaust manifold, which was disassembled from the cylinder head, should be inspected before rea

FUEL INJECTION PUMP REMOVING THE INJECTION PUMP NOTE: Do not disassemble the injection pump unless absolutely necessary. Injection pump service shoul

FUEL INJECTORS DISASSEMBLING AND INSPECTING 1. Oamp the nozzle holder in a vise, then remove the cap nut. 2. Remove the pressure adjusting screw, the

TESTING FUEL INJECTORS REMOVING THE INJECTORS NOTE: Injector must be serviced in a "clean room" environment. 1. Disconnect the high pressure

GLOW PLUGS DESCRIPTION The glow plugs are wired through the preheat solenoid. When PREHEAT is pressed at the control panel this solenoid should "

TACHOMETER TACHOMETER/HOUR METER The tachometer/hour meter used in propulsion engine instru-ment panels contains two separate electrical circuits with

ENGINE ADJUSTMENTS ENGINE COMPRESSION Check the engine's compression pressure at 500 and 1250 operating hours or whenever engine performance is r

ENGINE ADJUSTMENTS TESTING OIL PRESSURE To test oil pressure, remove the hex head plug from the oil gallery and install a mechanical oil pressure gaug

ENGINE ADJUSTMENTS ENGINE IDLING SPEED The engine idling speed is pre-set at the factory but once the boat is operating in the water other variables s

SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury or death! • To prevent accidental starting when servicing the

RAW WATER PUMP (PN. 033636) EARLY MODELS Disassembly The pump, as removed from the engine, will have hose attachment nipples threaded into its inlet a

RAW WATER PUMP (PN.48080) (FROM MARCH 2004 PRODUCTION AND ON) Disassembly 1. Remove the six screws and lock washers, and the sealing 0-ring. Inspect

ALTERNATOR TESTING DESCRIPTION The charging system consists of an alternator with a voltage regulator, an engine DC wiring harness, a mounted DC cir-c

ALTERNATOR TESTING e. Now check the voltage between the alternator output terminal (B+) and ground. If the circuit is good, the voltage at the altern

STARTER MOTOR TESTING DESCRIPTION The starter can be roughly divided into the following sections: • A motor section which generates a drive power. •

STARTER MOTOR REPAIR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and between tenninals S and body. No c

STARTER MOTOR TESTING AITRACTION TEST 3. Holding test. With a battery connected to the solenoid terminal S ( +) and to the starter body, manually pull

STARTER MOTOR REPAIR Field Coil Inspection 1. Check for insulation between one end (brush) of the coil and yoke. 2. Check for continuity between both

TRANSMISSION For Transmission Service and Maintenance, refer to your Transmission manual or WESTERBEKES 12C/12D Operators Manual. To re-build a transm

12C AND 120 TWO ENGINE SPECIFICATIONS Engine Type Governor Valve Mechanism Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direc

SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sle

,------1 SEE NOTE 2 1~1 I I I I .J +iu:D_ ~-==-ll.A.I.I.EJl..l 5I WIRING DIAGRAM #39144 I •10 RED I 1--------------------------------J < ~ ~ - ---

WIRING SCHEMATIC #39144 + IZ VOC START -SOL STARHR r---~ M I I I I ---- ----r-l PREHEAT r--1 SOL =P~~ s -Al T[RNATOR ~~LT-~ -R~ T[RM. I .::. I I ~

12C/12D TWO SERVICE DATA I STANDARDS AND LIMITS Component Specified Value I Standard Repair Limit inches(mm) inches(mm) ---COMPRESSION I TIMING Cylin

12C/12D TWO SERVICE DATA I STANDARDS AND LIMITS Component Specified Value I Standard Repair limit inches(mm) inches(mm) -----------------------------

STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. G

REMOTE OIL FILTER (OPTIONAL) PN:040078 REMOTE OIL FILTER SET INSTALLATION This popular accessory is used to relocate the engine's oil filter from

STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 =Millimeters (mm) x .0394 = Inches Feet (ft) x .305 = Meters (m) x 3.281 = Feet

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TABLE OF CONTENTS INTRODUCTION Serial Number ... 2 Siphon Break TESTING FOR OVERHAUL ...

INTRODUCTION SERIAL NUMBER LOCATION The engine's model number and serial number are located on a nameplate mounted on the side of the engine&apos

TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression Generally, the time at which an engine should be overhauled is d

ENGINE TROUBLESHOOTING The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problem