Westerbeke 120D-TWO Installationshandbuch Seite 1

OPERATORS MANUAL' MARINE D'IESEL ENGINES· 12C~TWO a 120-TWO, PUBLICATION NO.039717 REVISION 3 JANUARY 2011 .. ~ WESTERBEKE WESTERBEKE CORPOR

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

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER. (No. 2·D (SAE J313) diesel fuel accord

ADMIRAL CONTROL PANEL DESCRIPTION This manually-operated control panel is equipped with a KEY switch and RPM gauge with an ELAPSED TIME meter which me

CAPTAIN CONTROL PANEL DESCRIPTION· This manually-operated control panel is equipped with a KEY switch, an RPM gauge, PREHEKf and START but-tons, an IN

PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION Before starting your engine for the first time or after a prolonged layoff, check the following

STARTING/STOPPING PROCEDURE CHECKLIST Follow this check list each day before starting your engine. D Visually inspect the engine for fuel, oil, or wat

ENGINE BREAK-IN PROCEDURE DESCRIPTION Altliough your engine has experienced a minimum of one hour of test operations at the factory to make sure accur

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER ALTERNATOR WARNINGS The Captain Control Panel indicates alternator low discharge with a red warning light

MAINTENANCE SCHEDULE In order to use this Maintenance Schedule, it will be necessary to log your engine hours. Use your engine hourmeter or record you

MAINTENANCE SCHEDULE NOTE: Use the engine hourmeter gauge to log your engine hours of record your engine hours by running time. SCHEDULED CHECK HOURS

A WARNING .. Exhaust gasses contain Carbon Monoxide, an odorless anil colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and de

'FUEL SYSTEM DIESEL FUEL USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER. (No. 2-D (SAE J313) diesel fuel according to AStM D975}. FUEL F

ENGINE COOLING CIRCUIT OEseRIPTION Weslerbeke marine diesel generators are designed and ¢quipped for fresh water cooling. Heal produced in the ¢ngine

COOLING SYSTEM FRESH WATER COOLlN.G I;I{lCUIT Ftesh w:at~r coolant is pumped through the engine by a 'circulating pump, absorbing heat from the e

COOLING SYSTEM THERMOSTAT A thennosta~ located near the manifold at the' front of the engine, controls the coolant temperature as the coolant con

COOLING SYSTEM RAW WATER PUMp· The raw water pump is a.,self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller has

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. COOLING SYSTEM Zinc Anode #011885 A zinc anode, or pencil, is located in the raw water cooling circuit within the heat exchanger. The purpose of hav

ENGINE LUBRICATING OIL TYPI.CAL LUBRICATION .O!A_GRAM OIL PRESSURE' . OIL PRESSURE -~41 SWITCH OIL FILTER,...---OIL PRESS~RE'-...fi~~ RELI

REMOTE OIL FILTER (OPTIONAL) . PN# 040078 . INSTALLATION This popular accessory ·is used to reloc~te the engine's oil fil-ter from the engine to

DOMESTIC HOT WATER TANK CONNECTIONS DESCRIPTION Bothihe two mid three cylinder models are equipped with connections to send engine coolant to a domest

SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to folww fundamental rules and precautions. K

DOMESTIC HOT WATER TANK CONNECTIONS HOT WATER HEATER ABOVE THE ENGINE If any portion of the heating circuit rises above the engine's own pressure

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

ALTERNATORS-TESTINGJTROUBLESHOOTING TYPICAL 50 AMP ALTERNATOR #10 ORANGE BB!" :~ TO STARTER 81 "'...,.,.."''' VOLTA

ALTERNATORS TESTING/TROUBLESHOOTING TESTING THE ALTERNATOR A CAUTION: Before starting the engine make certain that everyone Is clear of moving parts!

ALTERNATORS TESTING/TROUBLESHOOTING TESTING THE EXCITATION CIRCUIT 1. Connect the positive (+) multimeter probe to the excit~tion terminal R on the a

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

STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight and is called a high-speed internal-reduction starter. The pinion shafris sep

STARTER MOTOR , A WARNING: When performIng these procedures, position yourself safely away from the moving parts of the engine in case the engine star

ENGINE WIRING DIAGRAM (#39144) r----I :~ : It:: I I ~ . -12 VDC =->AIill:( " ,,~ "~ ,,"U,, IUZIU r-=-:~::::-:-=-'J ___ '-

ENGINE WIRING SCHEMATIC (#39144) • I~ yO(; s,,'l n"nu -$Q~. r -, M , , , , ... _-----------------, -':"-PUH[AT r--.SOl n, --?J&apo

SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury or death! • Disconnect the battery cables before servicing th

ADMIRALS PANELW.IRING DIAGRAM (#36844) JtJ::;Z W' ~ o:'!Z' z ~ 1; " i '" I§.::l ~5 ~a:l%:3: ;!! m ~ ~ ,~ 0 ~ ~~j; ;[;19;

CAPTAINS PANEL WIRING DIAGRAM (#36467) : 1 'I' ': J I \ I ",:-:'OID TO 1 (II6'1I( BUltK G!.OwPLuGS 11",4,Q011;. o

ENGINE TROUBLESHOOTING The following troubleshooting table describes certain problems relating to engine service, the probable causes of these prob-le

ENGINE JROQBLESHOOTING Problem Probable Cause VerilicationJRemedy Engine slows and stops. 1. Fuel lift pump failure. 1. Fuellift pump should make a di

CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine contro(system is protected by a 20 amp manual reset circuit

ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information belo

ENGINE ADJUSTMENTS NOTE: WESTERBEKE ':;'commends that the/allowing engin~ adjust-. ments be peiformed by a competent engine mechanic. The in

ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust-ments be peTjonned by a competent engine T(lechanic. The infonnation b

ENGINE ADJUSTMENTS NOTE: WEST.ERBEKE recommends that the fallowing engine adjustments be performed by a competimt engine mechanic. TIW information bel

ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments .be petformed by a competent engine mechanic. The information bel

SAFETY INSTRUCTIONS OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions an

ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peifonned by a competent engine mechanic. The infonnatlon belo

JS AND BW TRANSMISSION DESCRIPTION The transmission's gear ratio is 2.47 to I. This manual trans-mission rotates opposite to the engine when in f

JS AND BW TRANSMISSION SAILING OPERATION The JS transmission'should be left in i~, NEUTRAL position while sailing, Leaving the transmission in NE

HURTH ifBWJZF TRANSMISSIONS DESCRIPTION The infonnation below is specific to the Haw Transmissions, the TRANSMISSION TROUBLESHOOTING SECTION applies t

HURTH HBWJZF TRANSMISSIONS INITIAL OPERATION All HBWIZF marine transmissions are test-run on a test stand with the engine at the factory prior to deli

HURTH HBWJZF TRANSMISSIONS OPERATING TEMPERATURE. A WARNING: If the transmiSsion fluid temperature is· too high, stop the engine immediately and r:hli

HURTH HBW/ZF TRANSMISSION TROUBLESHOOTING CONTROL CABLES The majority of transmission difficulties arise as a result of improper clutch adjustments (m

HURTH HBWJZF TRANSMISSION TROUBLESHOOTING Problem Probable ~ause Verllicalion/Remedy High fluid temperature. 1. Fluid level high during operation. 1;

PRM HEWAGE TRANSMISSIONS MODELS aD-AND 120 . . THE MODEL 120HASABREATHEti,~ FITTING ON THE TOP OF THE CASEr:::::::!!!!:I -':'DII'$m:K 1

PRM NEWAGE TRANSMISSIONS MODELS 80 AND 120 CONTROL CABLES The control cable or rod should be arranged at a right angle to the actuating shift lever wi

INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND R

. PRM NEWAGE TRANSMISSIONS TROUBLESHOOTING . Problem· Probable CaUse VerlllcationJReme~y .. Excessive noise at low speeds. 1. Engine idle speed too lo

Engine Type Governor Valve Mechanism Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Maximum Torque Compre

LAY-UP & RECOMMISSIONING GENERAL Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during t

LAY-UP & RECOMMISSIONING Starter Motor -, Lubrication and cleaaing of the starter drive pinion is advisable, if access to the starter permits its

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

DECIMAL TO METRIC EQUIVALENT CHART Fractions of Decimal (in.) Metric (mm) Fractions of Decimal (in.) Metric (mm) an inch . an inch 1/64 0.015625 0.3

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

SUGGESTED SPARE PARTS Carry Only Genuine Westerbeke Spare Parts WESTERI3EKE CARRYING ENOUGH SPARE . . ENGINE OIL (YOUR BRAND) FOR Alii OIL CHANGE (5 O

~ WESTERBEKE Engines & Generators 1158·2/2011

TABLE OF CONTENTS Parts Identification ... .2 Alternator Testing/Troubleshooting ... 25 Int

PARTS IDENTIFICATION AIR INTAI!E/SIILENCIER, .•• U'~'" PRESSURE CAP "iI~~:3r---ENGINE SERIAL ~ NUMBER OIL DRAIN HOSE MOTOR i FRONT

INTRODUCTION This WESTERBEKE Diesel Engine is a product of WESTERBEKE's long years of experience and advanced technology. We take great pride in