Westerbeke 120D-TWO Operator'S Manual Download Page 1

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Summary of Contents for 120D-TWO

Page 1: ...120 TWO PUBLICATION NO 055411 REVISION 1 JUNE 2012 J rWESTERBEKE J WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD J M LES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEB SITE WWW WESTERBEKE COM NMMA Memb...

Page 2: ...ELY Ifsymptoms persist seek medical attention Shut down the unit and do not restart until it has been inspected and repaired A WARNING DECAL is provided by WESTERBEKE andshould be fixed to a bulkheadn...

Page 3: ...line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel lines fuel filters or other fuel system components Do...

Page 4: ...contain sulfuric acid which is destructive If it comes in contact with your skin wash it off at once with water Acid may splash on the skin or into the eyes inadvertently when removing electrolyte cap...

Page 5: ...otes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasolin...

Page 6: ...he Camshaft Installing the Camshaft Gears Piston and Connecting Rod Disassembly PISTON AND CONNECTING ROD 17 18 Inspection Piston Ring End Gap Piston Ring Side Clearance Installation Installing the Pi...

Page 7: ...ons as original equipment 2 RAW WATER COOLING CIRCUIT Siphon Break For installations where the water injected exhaust elbow is close to or will be below the vessels waterline provisions must be made t...

Page 8: ...in the engines valve clearances are properly adjusted An incorrect valve clearance can cause symptons that might incorrectly suggest an engine overhaul cylinder misfire white smoke noise etc OVERHAUL...

Page 9: ...4 Clean terminals and correct cables 5 Repair or replace starter 1 Bleed air from fuel system 2 Clean or replace filter 3 Adjust injection pressure 4 Clean or replace noule 5 Repair or replace injecti...

Page 10: ...linder 4 Replace piston and rebore cylinder OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 4 Replace avalve and valve guide EXCESSIVE FUEL ENGINE BODY TROUBLE...

Page 11: ...tem CONNECTING ROD AND CONNECTING ROD BEARING 1 Worn connecting rod big end bearing 1 Replace bearing 2 Worn crankpin 2 Grind crankshaft 3 Bent connecting rod 3 Correct bend or replace PISTON PISTON P...

Page 12: ...k of coolant 4 Low oil level or poor oil quality 5 Knocking 6 Moving parts seized or damaged 7 Defective thermostat LOW OIL PRESSURE 1 Worn Bearings 2 Relief valve malfunction 3 Clogged oil cooler 4 D...

Page 13: ...Remove the engine heat exchanger If possible leave one end of each hose connected to the part being removed LABa THE WIRES The engine should be securely mounted on a suitable engine stand TRANSMISSION...

Page 14: ...pipe assembly plug the nozzle holders and delivery valve holders to prevent intrusion of dust 2 Disconnect the glow plug lead wire 3 Loosen the fresh water pump drive belt and dismount the belt idler...

Page 15: ...ant and carbon deposits If a valve guide is found defective replace it 1 Remove the valve guide by pressing at its upper end and pull it out to the valve seat side 2 Install the valve guide by press f...

Page 16: ...andard 13 0951bs 1 398in 5 94 kg 35 5 mm limit 15 NOTE Measure the fitting pressure after compressing the spring several times Valve Spring Free Length Check Measure the free length of the valve sprin...

Page 17: ...g m ROCKER SHAFT HOLD DOWN BOLTS All main bolts are 14mm across the bolt head flats All sub bolts are 12mm across the bolt head flats Rocker shaft hold down bolts are 12mm across the bolt head flats R...

Page 18: ...e delivery holder Attach it so that the end that would connect to the fuel injector is pointing away from the engine fuel will flow from this line during the timirig check Rotate the engine s cranksha...

Page 19: ...int for wear and damage Governor Shaft Disassembly Inspection NOTE For additional information refer to the GOVERNOR SYSTEM section 1 Taking care to not scratch the gear case remove the expansion plug...

Page 20: ...llation Press fit the crankshaft gear onto the crankshaft Press fit the valve camshaft gear and the ignition pump camshaft gear onto their respective shafts Install the gear assemblies in the followin...

Page 21: ...heated pistons While the piston is still warm check for bore integrity Insert the pin from each side If the pin binds at the center the bore might be tapered if the bore is misaligned the pin will cli...

Page 22: ...de Clearance Measure the side clearance for each piston ring set in the ring groove in the piston If the service limit is exceeded replace the ring ith a new one Ring Side Clearance No 1 Limit 0 012in...

Page 23: ...rom rotating on the same side CAP Torque 23 35 ft lb 3 2 3 5 m kg CRANKSHAFT REMOVAL AND INSPECTION OF THE CRANKSHAFT ASSEMBLY 1 Loosen the flywheel bolts and remove the flywheel 2 Loosen the cranksha...

Page 24: ...rance still exceeds the service limit regrind the crankshaft to the next undersize and replace the bearing with one of the corresponding undersize Direction of installation ofcap Bearing tightening to...

Page 25: ...rebored to the next oversize the remaining cylinders must also be rebored to the same oversize Cylinder Reboring Use the following procedure when reboring a cylinder a Select a piston size 0 25mm Ove...

Page 26: ...sealing washers throughout in the same order as were the old washers Injector Tightening Torque 43 51 ft lb 5 0 6 0 m kg See FUEL INJECTORS Install the glow plugs and connectors Use anti seize com pou...

Page 27: ...cylinder head If there is no oil circulation or if the oil circulation is sluggish stop the engine and make the appropriate repairs or adjustment Re install the cylinder head cover 22 9 Mount the eng...

Page 28: ...ardware listed is metric with values given asfollows Flywheel Bolt M1 0 17 M1 0 indicates Metric 1Omm thread diameter 17 indicates 17mm across the flats ofthe bolt head wet indicates that the bolts if...

Page 29: ...Coat the o rings with oil before installing them Deflection must not exceed 0 787in 20mm with the governor spring installed Install the governor spring lever and the speed control lever so that the pl...

Page 30: ...ng Set The current version is a solid unit 25 TORQUE SPRING SET INSTALLATION NOTE This adjustment is done at engine overhaul with no generator installed or with the leads removedfrom the generator cap...

Page 31: ...ylinder head and the manifold using new gaskets Do not use any gasket sealant b Gradually tighten each fitting to make sure of proper alignment of all the parts This should be done in three steps Mani...

Page 32: ...ester and cam box All pans that are removedfrom the pump should be kept classified by cylinders and immersed in clean fuel Check the Control Rack movement It should be smooth no catching NJECTIIJII PU...

Page 33: ...reverse order of removal When installing the nozzle and nozzle holder assembly use a new copper washer ASSEMBLING Assemble in the reverse order of disassembly noting the fol lowing points 1 To assemb...

Page 34: ...nozzle tester d Use the fuel at the approximate temperature of 68 F 200 C e Operate the hand lever of nozzle tester several times to bleed the air in the nozzle line then move the hand lever at inter...

Page 35: ...touch Be carefulnot to burn your fingers when testing the plugs _GLOW PLUG FUEL LIFT PUMP Periodically check the fuel connections to and out of the pump and make sure that no leakage is present and t...

Page 36: ...ernator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurate a With a hand held tach on the front of the crankshaft pulley retaining nut or with a st...

Page 37: ...PTABLE DIFFERENCE BETWEEN 35 5 PSI 2 5 Kg em 32 DRIVE BELT ADJUSTMENT Excessive drive belt tension can cause rapid wear of the belt and reduce the service life of the fresh water pump s bearing A slac...

Page 38: ...ssure read ings see the ENGINE TROUBLESHOOTING chart 33 OIL PRESSURE RELIEF VALVE The oil pressure relief valve is located in the front gear case cover just below the oil pressure senders location It...

Page 39: ...njection pump s fuel rack is needed To obtain this remove the shut offlever and gasketjust below the fuel injection pump 2 Thread the locknut onto the solenoid and then apply a small amount ofTeflon s...

Page 40: ...the bearings pushing at the impeller drive slot end using the base of the drive slot Push the shaft through both of the bearings flush against each other so that the flat sided end of the shaft exten...

Page 41: ...ace if worn INSPECTION REASSEMBLY Reassemble the pump in the reverse order Apply a small amount of petroleum jelly on the lip of the shaft seal and on the shaft itself when installing the shaft bearin...

Page 42: ...d in the circuit to isolate the batteries so the service battery is not discharged along with the service battery Ifthe alternator is charging the starting battery but not the service battery the prob...

Page 43: ...ent at the EXC terminal trace the wiring looking for breaks and poor connections Alternator is Working 4 Check the voltage of the service battery This battery should have a voltage between 13 and 14 v...

Page 44: ...ack and measure the return stroke called pinion gap 3 If the pinion gap is not within the standard range 0 5 to 2 0 mm adjust it by increasing or decreasing the number of shims on the solenoid The gap...

Page 45: ...lace it if the service limit is exceeded Also check the commutator outside surface for dirtiness and roughness If rough polish the commutator with fine crocus cloth Commutator Outside Diameter Standar...

Page 46: ...her 6 Unsc w the bolts and remove the center bracket At the same time the washers for the pinion shaft end play adjustment will come off STARTER MOTOR PINION 4 Return test With a battery connected to...

Page 47: ...nd play adjustment Set the end play thrust gap to between 0 5 to 2 mrn by inserting an adjusting washer between the center bracket and the reduction gear a Fit the pinion shaft reduction gear washer a...

Page 48: ...rine Transmissions Westerbeke Corporation 150 John Hancock Road Taunton MA 02780 Tel 508 823 7677 Website www westerbeke com PRM Marine Transmissions Newage Transmission Limited Barlow Road Coventry C...

Page 49: ...805 rpm min 12 Volt DC 50 Amps Internal regulator built into alternator 44 LUBRICATION SYSTEM General Operating Oil Pressure engine hot Oil Grade Oil Filter Pn 036920 Sump Capacity including filter Ge...

Page 50: ...1SEE 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 KEYSWJTCH I L 1 I I B BL I ___________________ __ BL 45 ADMIRAL PANEL 114 f NK CAPTAIN PANEL 18 _I...

Page 51: ...ATTERY IN AN EMERGENCY AND WHEN LEAVING THE BO t T A SWITCH WITH A CONTINUOUS RATING OF 115 AMPS AT IZ VDC WILL SERVE THIS F UNCTION THIS SWITCH SHOULD NOT BE USED TO MAK OR BREAK TH CIRCUIT J THE PIN...

Page 52: ...28mm Squareness 2 3 TIMING GEARS Backlash between gears in Mesh 0 0003 0 0005 0 01 0 14 0 012 0 3 Idler Gear Bushing Clearance between Bushing and Shaft 0 001 001 0 0 03 0 07 0 0078 0 2 Component Spec...

Page 53: ...No 2 Flanged Metal Under Size 0 01 0 02 0 25 0 50 VAlVE CAMSHAFT Driving Method Gear Drive Front Journal Ball Bearing Journal to Cylinder 0 006 0 15 Block Hole Clearance Lobe Height 1 078 27 37 0 039...

Page 54: ...lt head nut 2 101 3 159 1 14 0 22 0 Grade 6T Grade 5Cap Screw 6mm bolt head nut 1 4 3 6 5 0 6 0 9 1 4 UNC 9 11 1 2 1 5 8mm bolt head nut 1 25 10 8 15 9 1 5 2 2 1 4 UNF 11 13 1 5 1 8 1Omm bolt head nut...

Page 55: ...ATTACH TO THE IN CONNECTION AT THE REMOTE OIL FILTER 50 To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filter kit as shown Always install this kit with the oil f...

Page 56: ...28 35 Grams g x 035 Ounces Pounds lb x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x...

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