Westerbeke 12C-TWO Operator's Manual
Marine diesel engines
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- Page 1 SERVICE MANUAL MARINE DIESEL ENGINES 12C-TWO 120-TWO PUBLICATION NO. 055411 REVISION 1 JUNE 2012 rWESTERBEKE WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD M'(LES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780 WEB SITE: WWW. WESTERBEKE.COM NMMA Member National Marine Manufacturers Association...
- Page 2 Shut down the unit and do not restart until it has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator. WESTERBEKE also recommends installing ~~~~~\ ..
- Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precau- WARNING: Fire can cause injury or death! tions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, •...
- Page 4 SAFETY INSTRUCTIONS ACCIDENTAL STARTING WARNING: Carbon monoxide (CO) is a deadly gas! WARNING: Accidental starting can cause injury or death! • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system • To prevent accidental starting when servicing the regularly for leaks and make sure the exhaust manifolds generator, remove the 8 amp fuse from the control panel.
- Page 5 SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.
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Page 6: Table Of Contents
TABLE OF CONTENTS INTRODUCTION CRANKSHAFT ............19 Removal/Inspection Serial Number ............Rear Oil Seal Replacement Siphon Break Inspecting the Oil Clearance TESTING FOR OVERHAUL ........... Installing the Crankshaft Disassembly Assembly CYLINDER BLOCK ............. ENGINE TROUBLESHOOTING Inspection (Charts) ....A-7 Bore Dimensions Cylinder Reboring ENGINE DISASSEMBLY, INSPECTION AND ASSEMBLY... -
Page 7: Introduction
Parts List). Also insist upon generator, alternator, starter motor, engine adjustments, WESTERBEKE packaged parts because will fit or generic cooling pumps, etc. parts are frequently not made to the same specifications... -
Page 8: Testing For Overhaul
TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL CONDITIONS Cause of Low Compression Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in. Generally, the time at which an engine should be overhauled Thereafter, it decreases gradually with the progress of wear of is determined by various conditions such as lowered engine these parts. -
Page 9: Engine Troubleshooting (Charts
ENGINE TROUBLESHOOTING NOTE: engine~ The following troubleshooting chart describes certain electrical system is protected by a 20- ampere manual reset circuit breaker. The preheat solenoid is problems relating to engine service, the probable causes of these problems, and the recommendations to overcome mounted on the same bracket. - Page 10 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERI Fl CAT I 0 N/REM EDY LOW OUTPUT (cont .. ) OVERHEATING Low coolant level. Add coolant. 2. Loose V-belt. 2. Adjust or replace V-belt. 3. Incorrect injection timing. 3. Adjust injection timing. Low engine oil level. 6.
- Page 11 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY (cont. (cont. SMOKY EXHAUST WHITISH OR PURPLISH d. Worn valve stem and valve guide. d. Replace. Low engine oil viscosity. Replace. f. Excessive oil pressure. f. Correct. 3. Injection timing is too late. 3. Adjust. 4.
- Page 12 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1. Main engine troubles. Overheated cylinder. See OVERHEATING; LOW OUTPUT. Carbon deposits in cylinder. Clean. 2. Too early injection timing. 2. Correct. 3. Too high injection pressure. 3. Correct. 4.
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Page 13: Disassembly Procedures
DISASSEMBLY PROCEDURES REMOVE EXTERIOR COMPONENTS Unplug the instrument panel wiring harness. Drain the trans- 9. Remove the exhaust components from the exhaust mission fluid and unbolt the transmission. manifold a) Remove the exhaust elbow (if applicable) from the NOTE: Label any lines, hoses or cables as you separate them. lower surface of the manifold. -
Page 14: Cylinder Head Removal
CYLINDER HEAD REMOVAL SEQUENCE FOR LOOSENING CYUNDER HEAD BOLTS 1. Remove the engine heat exchanger. If possible, leave one end of each hose connection attached to the part being removed. For maintenance, see HEAT EXCHANGER. 2. Remove the starter motor. For starter motor repair, see SUB !JOLTS FRONT~ STARTER MOTOR... -
Page 15: Cylinder Head
CYLINDER HEAD Cylinder Head Inspection Valve Seat Repair If a valve seat is found defective, reface it or have a machine Clean the cylinder and the cylinder block surface from which the gasket has been removed. Carefully check the cylinder shop install a new seat. -
Page 16: Valve And Valve Spring Inspection
---'~ SQUARENESS GAUGE Squareness Check Standard 2• Limit 3• Valve Spring Squareness Check. Check the squareness of ·---:r-- the valve spring and, if it is more than the limit, replace the }/C:::::;:::::=:::::=::::::l:=l=-= spring .. INSPECTING VALVES WESTERBEKE Engines & Generators... -
Page 17: Valve Installationnalve Clearance
VALVE INSTALLATION /VALVE ADJUSTMENT /INJECTION TIMING Installation CYUNDER HEAD BOLT TIGHTENING SEQUENCE Install the valve and valve springs. Refer to the illustrations and callouts shown below. NOTE: Be careful not to damage the spring and stem seal by FRONT~. excessively compressing the spring when installing the valve spring. -
Page 18: Valve Adjustment/Injection Timing
VALVE ADJUSTMENT /INJECTION TIMING 19° CRANKSHAFT PUllEY TIMING MARKS TIMING POINTER Injection Pump Timing Adjustment (Spill Timing) your engine's fuel injection timing is not properly adjusted, the engine will not operate properly, and may be difficult to start. Have the injection pump delivery rate checked by a well-established fuel injection shop. -
Page 19: Gear Case/Governor
GEAR CASE GOVERNOR Check springs GEAR CASE ASSEMBLY tor fatigue. 1. Remove the drive belt and the crankshaft pulley. 2. Remove the alternator. 3. Remove the water pump assembly. GASKET Check BRACKETS WATER PUMP For pump breakdown, for bends and ASSEMBLY see COOLANT twists. -
Page 20: Timing Gear/Camshaft
TIMING GEAR CAMSHAFT REMOVING THE TIMING GEARS Installation 1. Remove the snap ring and disassemble the idler gear. Press-fit the crankshaft gear onto the crankshaft. Remove the valve camshaft and the injection pump Press-fit the valve camshaft gear and the ignition pump camshaft on which the gears are press-fitted, remove the camshaft gear onto their respective shafts. -
Page 21: And Connecting Rods
CAMSHAFT PISTONS AND CONNECTING RODS Inspecting The Camshaft Remove the rings from each pistorr with the piston ring pliers. Using the piston setting tool, pull out the piston pin from each Make a thorough inspection of the injection pump and the piston. -
Page 22: Piston And Connecting Rod
PISTON AND CONNECTING ROD INSPECTION INSTALLATION PUSH ROD FRONT MARK (ARROW) Put each piston ring into the cylinder bore and push the ring with the piston to position the ring on square with the cylin- der wall. Measure the ring gap with a feeler gauge. If the PISTON measurement exceeds the service limit, replace that piston ring. -
Page 23: Rear Oil Seal Replacement
PISTON AND CONNECTING ROD Place a heavy hammer as shown. Coat the bearing surface of the connecting rod caps with Gently press down with the Ioree of your engine oil. Fit each cap to the connecting rod using the match hand. -
Page 24: Crankshaft
CRANKSHAFT ®[] INSPECTING THE CRANKSHAFT To check the crankpins and main journals for tapering and out-of-round wear, the diameter of each crankpin or main journal should be measured at two places along the crankpin or main journal, in two directions "A" and "B" each place. If MEASURING MAIN BEARING J.D. -
Page 25: Cylinder Block
CYLINDER BLOCK STARTER BRACKET rt-----lf-'---,.. BEARING ~-----k~ BEARING CYLINDER BLOCK INSPECTION Check the cylinder block for cracks and damage. If neces- 2.1c-·~o~-.-· sary, repair or replace it entirely. Check to see that oil or cooling water passages are not clogged and, if clogged, remove with compressed air or a wire. -
Page 26: Engine Assembly
ENGINE ASSEMBLY Install the Thermostat and Thermostat Housing Install the fuel injection nozzles. Install the fuel overflow pipe. Use new sealing washers throughout, in the same order 1. Inspect the thermostat housing and the housing gasket. as were the old washers. Apply some sealant to the gasket when reassembling. -
Page 27: Engine Assembly
Refer to the following pages for details of sub-assemblies. CAUTION: Check all AC and DC wiring connections These sections also include: Wiring Diagrams, Engine to WESTERBEKE's wiring schematics and diagrams. Specifications, Torque Diagrams, Starter Motor, Alternator and Raw Water Pump. ENGINE TUNING OPERATION After re-assembly, the unit must be test run. -
Page 28: Torque Specifications
TORQUE SPECIFICATIONS . . COMPONENT FHB(M-KG) COMPONENT FT-LB (M-KG) Alternator Bracket ......27 - 38 (3.8 - 5.3) Injection Pump Hollow Screw M10 (14) ........7.2- 10.8 (1.0- 1.5) Back Plate ........24 - 35 (3.3 - 4.8) Injectors .......... 36 - 38 (5.0 - 6.0) Connecting Rod Cap M8 (14) .. -
Page 29: Governor System
GOVERNOR SYSTEM INSPECTING THE GOVERNOR COMPONENTS Check levers for smooth movement. Check springs INSTAWNG THE SPEED CONTROL LEVER for fatigue. TORQUE SPRING SET ASSEMBLY When the torque spring set has been disassembled and inspected and defective parts replaced, reassemble and adjust Check sliding sleeve the torque spring set using the following procedure: for wear. -
Page 30: Governor System
GOVERNOR SYSTEM Leaving the dial gauge set, its condition unvaried, depress the TORQUE SPRING SET INSTALLATION spring stopper and slide over the torque spring set support NOTE: This adjustment is done at engine overhaul with no spring case. Read the deflection of the dial gauge which cor- generator installed or with the leads removed from the responds to the projection of the spring stopper from the generator capacitor. -
Page 31: Exhaust Manifold/Heat Exchanger
They also service transmission and engine oil coolers. 6. Repaint the assembled heat exchanger with WESTERBEKE's heat resistant spray enamel. CLEAN OR REPLACE THE MANIFOLD EXHAUST MANIFOLD ASSEMBLY 1. If the manifold was removed as an assembly and left intact, it can be replaced on the cylinder head in the reverse order of removal. -
Page 32: Fuel Injection Pump
FUEL INJECTION PUMP REMOVING THE INJECTION PUMP NOTE: Do not disassemble the injection pump unless absolutely necessary. Injection pump service should be per- DELIVERY VALVE-- formed by a qualified technician in an extremely clean envi- HOLDER ronment. 1. Disconnect the fuel injection pipes. 2. -
Page 33: Fuel Injectors
FUEL INJECTORS DISASSEMBLING AND INSPECTING INSTALLING Oamp the nozzle holder in a vise, then remove the Install the nozzle and nozzle holder assembly in the reverse cap nut. order of removal. When installing the nozzle and nozzle holder assembly, use a new copper washer. 2. -
Page 34: Fuel Injectors
TESTING FUEL INJECTORS REMOVING THE INJECTORS Inspecting Spray Pattern 1. Operate the hand lever of the nozzle tester at intervals of NOTE: Injector must be serviced in a "clean room" environment. one stroke per second to check if the fuel is injected cor- 1. -
Page 35: Glow Plugs
GLOW PLUGS DESCRIPTION Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 10 to The glow plugs are wired through the preheat solenoid. 15 seconds. If the plugs don't heat up quickly, check for a When PREHEAT is pressed at the control panel this solenoid short circuit. -
Page 36: Tachometer
TACHOMETER TACHOMETER/HOUR METER NOTE: Current model tachometers use a coarse adjustment· · dial to set the tachometer to the crankshaft pulley rprils. The The tachometer/hour meter used in propulsion engine instru- calibrating screw is then used for fine tuning. ment panels contains two separate electrical circuits with a common ground. -
Page 37: Engine Adjustments
ENGINE ADJUSTMENTS ENGINE COMPRESSION DRIVE BELT ADJUSTMENT Check the engine's compression pressure at 500 and 1250 Excessive drive belt tension can cause rapid wear of the belt operating hours or whenever engine performance is reduced. and reduce the service life of the fresh water pump's bearing. Remove each glow plug and check each cylinder's A slack belt or the presence of oil on the belt can cause belt compression pressure. -
Page 38: Testing Oil Pressure
ENGINE ADJUSTMENTS TESTING OIL PRESSURE OIL PRESSURE RELIEF VALVE To test oil pressure, remove the hex head plug from the oil The oil pressure relief valve is located in the front gear case gallery and install a mechanical oil pressure gauge in its cover just below the oil pressure senders location. -
Page 39: Adjusting Idle Speed
ENGINE ADJUSTMENTS ENGINE IDLING SPEED THROTILE CONTROL The engine idling speed is pre-set at the factory but once the lEVER boat is operating in the water other variables such as pro- peller size, shaft length, ahd the transmission can affect the idle speed. -
Page 40: Raw Water Pumps
RAW WATER PUMP (PN. 033636) EARLY MODELS Disassembly 3. Support the pump housing at the impeller side. Apply a small amount of glycerin to the seals (#7) inner lips and The pump, as removed from the engine, will have hose to the impeller shaft (#8). -
Page 41: Raw Water Pumps
RETAINING EXTERNAL RING recommended that 0-rings, -gaskets, and seals be replaced. WHEN ASSEMBLING: APPLY A THIN COAT OF GLYCERIN TO THE INSIDE OF THE COVER, THE COVER 0-RING, AND THE IMPELLER EXPLODED VIEW REPAIR PARTS ARE AVAILABLE FROM YOUR WESTERBEKE DEALER... -
Page 42: Atlernator Testing
ALTERNATOR TESTING DESCRIPTION Testing the Alternator 1. Start the Engine. The charging system consists of an alternator with a voltage 2. After a few minutes of running measure the starting bat- regulator, an engine DC wiring harness, a mounted DC cir- tery voltage at the battery terminals using a multi-meter cuit breaker and a battery with connecting cables. - Page 43 ALTERNATOR TESTING e. Now check the voltage between the alternator output Alternator is Working terminal (B+) and ground. If the circuit is good, the 4. Check the voltage of the service battery. This battery voltage at the alternator should be the same as the bat- should have a voltage between 13 and 14 volts when the tery, or if an isolator is in the circuit the alternator volt- engine is running.
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Page 44: Starter Motor Testing
STARTER MOTOR TESTING DESCRIPTION No-Load Test The starter can be roughly divided into the following sections: Connect the ammeter, voltmeter, and battery to the starter • A motor section which generates a drive power. as illustrated. • An overrunning clutch section which transmits an arma- 2. - Page 45 STARTER MOTOR REPAIR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and between tenninals S and body. No continuity should be found between S and M. Continuity should be found between S and the body and M and the body. "- Brush and Brush Holder Inspection limit,...
- Page 46 STARTER MOTOR TESTING Return test: With a battery connected to the solenoid ter- minal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position AITRACTION TEST when released from holding by hand. Holding test.
- Page 47 STARTER MOTOR REPAIR Field Coil Inspection Greasing. Whenever the starter has been overhauled, apply grease to the following parts: 1. Check for insulation between one end (brush) of the a. Armature shaft gear and reduction gear. coil and yoke. b. All bearings. 2.
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Page 48: Transmission
150 John Hancock Road Taunton, MA 02780 Tel: 508-823-7677 Website: www. westerbeke.com NOTE: If the transmission is not being re-built, it should be visually inspected. Flush out and pressure test the oil cooler and replace the coolant hoses. Inspect and lubricate the gear shift linkage and the propeller shaft coupling. -
Page 49: Engine Specifications
12C AND 120 TWO ENGINE SPECIFICATIONS SPECIFICATIONS LUBRICATION SYSTEM Engine Type Diesel, four-cycle, two-cylinder, fresh water- General Pressure type by Trochoid pump, gear-driven, cooled, vertical in-line. with external pressure valve relie·f 12 Hp 3000 rpm maximum Operating Oil Pressure 15-45 psi (1.0-3.1 kg/em') Governor Mechanical, centrifugal weight type (engine hot) -
Page 50: Wiring Diagrams
WIRING DIAGRAM #39144 114 f'NK ,------ 1 SEE NOTE +iu:D_ ~-==- ll.A.I.I.EJl..l ADMIRAL PANEL •10 RED 1--------------------------------J CAPTAIN PANEL < KEYSWJTCH - - ------------- L--------++--:=:==.-':~{~~~ B B L I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ --_I... - Page 51 WIRING SCHEMATIC #39144 START IZ VOC STARHR ~~LT- PREHEAT I . : : . r- - ~ -R~ 1 SOL =P~~ T[RM. :~·~ ~cCiu:iiniiiRTENNTTl-------, "No~ Al T[RNATOR TIMER zoe -· ' " ONLY m ~~·: ( Jl" rwHEN usEbl FUEl SOL c.
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Page 52: Service Data/Standards Limits
12C/12D TWO SERVICE DATA STANDARDS AND LIMITS Component Specified Value Standard Repair Limit Component Specified Value Standard Repair limit inches(mm) inches(mm) lnches(mm) inches(mm) - - - COMPRESSION TIMING ROCKER ARM Cylinder Compression ... 398.16 psi at 280 rpm ....355.5 psi Interior Diameter ....... - Page 53 12C/12D TWO SERVICE DATA STANDARDS AND LIMITS Component Specified Value Standard Repair limit inches(mm) inches(mm) Component Specified Value Standard Repair limit inches(mm) inches(mm) INJECTION PUMP CAMSHAFT -------------------------- ----~ CONNECTING ROD BEARING Driving Method ......... Gear Drive Type ........Aluminum with Black Metal Front Journai.
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Page 54: Standard Hardware Torques
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Grade 7T, 8T and 8.8 Pitch I b-It kg-m Pilch I b-It kg-m Grade 4 6mm bolt head/nut 5.8-8.7 0.8-1.2 2.9-5.1 0.4-0.7 6mm bolt head/nut... -
Page 55: Remote Oil Filter
Contact your WESTERBEKE dealer for more information an engine room bulkhead. NOTE: Westerbeke is not responsible for engine failure due to NOTE: Refer to ENGINE OIL CHANGE in this manual for incorrect installation of the Remote Oil Filter. -
Page 56: Metric Conversion Data
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 Miles x 1.609 = Kilometers (km) x .0621 = Miles VOLUME = Cubic Centim~ters Cubic Inches (in x 16.387 x .061... - Page 59 i·ii#;l =1#.1Si 6/2012-1164...