Westerbeke 12C- TWO Operator'S Manual Download Page 45 | Manualshive

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Summary of Contents for 12C- TWO

Page 1: ...TWO a 120 TWO PUBLICATION NO 039717 REVISION 3 JANUARY 2011 WESTERBEKE WESTERBEKE CORPORATlON 150 JOHN HANCOCK ROAD MyLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 W B SITE WWW WESTERBEKE COM L rMemb...

Page 2: ...ersist seekmedicalattention Shut down the unit anddo notrestart until it hasbelln inspected andrepaired AWARNING DECAL isprovidedby WESTERBEKE andshould be fixed to a bulkheadnear your engine orgenera...

Page 3: ...r fuel line filter fuel punlp or other poten ial sources ofspilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate...

Page 4: ...into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadly gas Ensure that the exhaust system is adequate to expel gases discharged from th...

Page 5: ...are H 2 Ventilation H 24 Gasoline Fuel Systems P l Exhaust Systems P 4 Inboard Engines E 9 DC Electrical Systems All installations must comply with the Federal Code of Regulations FCR ABYC NFPA AND US...

Page 6: ...e will result in raw water damage to the engine andpossibleflooding ofthe boat Ifyou have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under the...

Page 7: ...le Speed d 3 38 8 S FuellRun Shut Off Solenol Fuel ystem 14 D Belt AdJ ustment 39 nve FueI Water Filter 14 E Co pressl on 39 ngme m Fuel Filters 14 l ti 0 1 Pressure 40 es ng 1 Cooling System 15 Oil P...

Page 8: ...SERIAL NUMBER OIL DRAIN HOSE MOTOR i FRONT DC ALTE NATOR FILL CAP COOLANT PRESSURE INTAKEJSILENCE ___ LIJ UHIUN PLUG FUEL PUNIP lbi f OIL FILL J ___ RAW WATER PUMP INLET FUEL FILTER OIL DIPSTICK DRAIN...

Page 9: ...nuals brochures and catalogs provided from sources other than WESTERBEKE are not within WESTERBEKE s control WESTERBEKE CANNOTBE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WAR RANTIES OR RE...

Page 10: ...Iii DIIESI L FUEL SPRAY PRE COMBUSTION CHJI MBI R ORDERING PARTS Whenever replacement parts are needed always provide the engine model number and serial number as they appear on the silver and black...

Page 11: ...ne can have an oil pressure reading upwards of60 psi 4 2 kg cm A warmed engine can have an oil pressure reading as lowas 25 psi 1 8 kg cm These readings will vary depending upon the temperature of the...

Page 12: ...very Admiral Panel The installer is responsibla for electrically con necting the buzzer to the four pin connection on the engine s electrical harness The installer is also responsible for installing t...

Page 13: ...IFTHE ENGINE S OIL PRESSURE FALLS BELOW 5 10 psi 0 4 0 7 kg em IN THIS EVENT THEALliRM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRC...

Page 14: ...und stud this location is tagged o Check the coolant level in both the plastic recovery tank and at the manifold NOTE Ifthe engine has not yet beenfilled with coolant refer to the COOLING SYSTEM secti...

Page 15: ...r the RPM gauge to activate NOTE When starting AVQltage drop will occur when thepreheat switch is depressed FAILURE TO START Ifthe engine fails to start when the start button is pressed for 5 seconds...

Page 16: ...checking that all systems raw water pump oil pressure battery charging are functioning 2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves into the...

Page 17: ...ut the engine will slow and stop Ifthis breaker should trip check for the cause of high current draw and repair the problem Reset the breaker and re start the engine COOLANT TEMPERATURE SWITCH Acoolan...

Page 18: ...pect wiring oil will inhibit the engine s ability to remain and electrical connections Keep bolts nuts tight cool Check for loose belt tension Fuel Filter 0 D D D D D Change at 50 hours then every 250...

Page 19: ...sion Remove and lubricate Clean and lubricate the starter motor pinion drive 1 Preheat Circuit D D Check operation of preheat solenoid Remove and clean glow plugs check resistance 4 6 ohms Reinstall w...

Page 20: ...OWl to the housing Thread the retainer ring on carefully SO as not to cross 1bread When retainer contacts the 0 ring tighten 1 4 112 turns by hand Open the fuel ID PPlY and run the engine to inspect f...

Page 21: ...walls to the raw water which is then pump d into the exhaust system where finally it is discharged overboard In other words the engine is cooled by fresh water coolant this coolant is cooled by raw wa...

Page 22: ...gine operation with outintroducing air into the system This recovery tarik is provided with fresh water cooled models and with the fresh water coolant conversion kit and must be installed before opera...

Page 23: ...ithout any signifi cant loss of coolant and without introducing air into the cool ing system This tank should be located at or above the engine manifold level and should be easily accessible TO COOLAN...

Page 24: ...rs or pli ers Carefully pry pull the impeller out of the pump Lightly coat the inside of the pump housing with glycerine InstaU the new impeller aod cover with gasket open the raw water intake valve N...

Page 25: ...0 IMPELLER COVER 1 4 48500 IMPELLER KIT O RING GLYCERIN I 5 34458 CAM 1 6 49171 WEAR PLATE 1 7 302575 DOWEL 8 48253 SPRING SEAL WASHER 1 9 34463 IMPELLER COVER SCREW 6 10 48359 IMPELLER COVER O RING 1...

Page 26: ...e inside ofall zinc debris Always have a spare heat exchanger end gasket in case the present one becomes dam aged when emoving e end cover Replace the gasket refer to your engIne model s heat exchange...

Page 27: ...ilter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Please keep your engine clean Inspect the old oil filter as it is...

Page 28: ...DDITIONAL 3 4TURN AFTER THE O RING CONTACTS THE BASE NOTE Westerbeke is not responsiblefor engine failure due to incorrect installation ofthe Remote ail Filter A CAUTION It Is vital to install the oil...

Page 29: ...line without any loops which might trap air PREVIOUS MODEL ENGINES REMOVE THE BY PASS HOSE HEATER BELOW ENGINE HEATER COILS BELOW PRESSURE CAP ON ENGINE MANIFOLD With the bypass hose re11 ved there r...

Page 30: ...now serve as a check and system fill point The plastic coolant recovery tank is not used when the remote expansion tank kit is installed since this tank serves the same function The pressure cap on th...

Page 31: ...ngine block at alternator pivot bolt Tachometer Inaccurate ca With a hand held tach on the frollt of the crankshaft pulley retaining nut or with a strobe type tach read the front crankshaft pulley rpm...

Page 32: ...the alternator These alternators produce a rated output of50 or 51 amps rated output is achieved at approxiroately 6000 alternator rpm at an ambient temperatnre of 75 P 23 S C The alternators are desi...

Page 33: ...to 13 volts MEASURING q BAITelIY VOLTAGE ENGINERUNNING li MEASURiNG 6 BATIERY VOLTAGE lGN ITION ON TESTING THE OUTPUT CIRCUIT 1 Connect the positive probe to the output terminal Band connect the negat...

Page 34: ...vice battery eharging circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself When the problem has been solved and before the alternator is back in o...

Page 35: ...connection and the other to the body of the glow plug as shown Agood glow plug will have a 1 0 to 1 5 ohm resistance This method can be usedwith the plug in or out of the engine You can also use an a...

Page 36: ...few seconds never more than 10 seconds at a time then run your hand along the wires and terminals looking for warm spots that indicate resistance Repair or replace any trouble spots Using a multimete...

Page 37: ...use the spcradic problem of the engine starting one time bul not another Ifcorrosion is the problem the starter will Iieed to be rebuilt It is however sometimes possible to get started by taping the s...

Page 38: ...ENGINE WIRING DIAGRAM 39144 r I It I I 12 VDC AIill U IUZIU r J___ ___ ___ _ r I I I _ _I f LU1l IH J I 4 J I 0 T 9 J I c s ur u L r I I u 31 ADMIRAL PANEL CAPTAIN PANEL ir II _...

Page 39: ...MEVILLE 10 AMP ALT UIIIH I G P UHIAT SIITCH PH l lrl f n STAU i 1 1 1 1 1 ALT 0 LAW 1 1 LA O DZ UCHOIItTU n U 1 CAPTAIN PANEL SI AMP ALTERNATOR STANOARD ALTERNATOR ON TII 110 RED 11 1 114 LT 8tU II PI...

Page 40: ...Z z 1 i I l 5 a l 3 m 0 j 19 Q S1 16 S216 0 6 i 61 P20 I I 1 _ 0 I 1 4GRlI I c 2 4 L_ __ lLI I TACHOMETER I J I START PREHEAT 1 KEY SWITCH VOL TMETER TCH S CH I I OIlLK I o e l _____________ ____ J W...

Page 41: ...T SOI EN IO o AGIIOiDTO MG ll CCM Y i f r _ WATER TEM SWITCH I fG T II U f 4 1 I I I I I I I I T ll IIE 1 OIL _ q PRESSURE ___ J SWITCH I Jr _ mL U f E t _____ 1__ IUSED c E WE S I C V 0 0 PRESSURE SE...

Page 42: ...r solenoid OK Check that 12 volts are present althe connection on the fuel solenoid n t functioning 2 Defective fuel solenoid 2 fuel run solenoid Engine cranks but does not 1 Faulty fueling system 1 C...

Page 43: ...e thermostat 2b Loss of coolant check hoses hose clamps drain plug etc for leaks 2c Broken or ioose belts tighten replace 2d Air leak in system run engine and open the pressure cap to bleed air Add co...

Page 44: ...sensitive 0 25 amp meter In battery lines Do NOT start engine Remove connections and replace after short is located 3 Low resistance leakto ground 3 Check all wires for temperature rise to locate the...

Page 45: ...replacement or new fuel run solenoid 1 Visual access to the fuel injection pump s fuel rack is needed To obtain this remove the shut off lever and gasketjust below the fuel injection pump 2 Threed th...

Page 46: ...aulty Abnormally high readings on all cylillders indicates heavy carbon accumulations a condition that might be accompanied by high pressures and noise NOTE In case ofsevere vibrations and detonation...

Page 47: ...from rotating parts such as the cooling fan v belt pulleys and flywheel Keep long hairaway from rotating parts and do not wearmusic earphones LOW OIL PRESSURE A gradual loss of oil pressure usually i...

Page 48: ...ap Nuts IOmm socket snug 41 W LVE CLEARANCE ADJUSTMENT The valve clearance must be adjusted every 500 operating hours or whenever the valve rocker is abnormally noisy Valve adjustment should only be d...

Page 49: ...older 3 Reinstall only the delivery valve holder and re attach the high pressure fuel line to the delivery holder Attach it so that the end that would connect to the fuel injector is pointing away fro...

Page 50: ...ING THE SPRAY PATTERN 1 Operate the hand lever of the nozzle tester at intervals of one stroke per second to check if the fuel is injected correctly in its axial direction Anozzle is defective if it i...

Page 51: ...hetransmissibil hous f I ing Make sure that the two a ring gaskets on the dipstick are in good shape These a rings will keep the dip tic ic in I I z place EVER E 1112 FORWARD 1 Change the transmission...

Page 52: ...pling and the propeller shaft s coupling Disassembly of the transmission in the field is not recom mended If an overhaul or repair is needed the work should be done by an authorized WESTERBEKE service...

Page 53: ...ge by unsuitably positioned guide sheaves too small a bending radius orother restrictions In order to mount a supportfor shift control cable connections use the two threaded holes located above the ca...

Page 54: ...ling washer A WARNING Never pull out the dipstick while the engine is running Hot fluid will splash from the dipstick hole This could cause severe burns LOCKING THE PROPELLER Locking of the propeller...

Page 55: ...he fluid every 300 operating hours Periodicruly inspect the transinission and the cooler for leaks and corrosion Lubricate the cable connections Lay up Winterize Storage requires special care Follow t...

Page 56: ...or replace unattached Cable radius is too severe 3 Shift lever Is binding against cover plate 3 Detaoh the shiftcable and operate the lever by hand Clearance should be 0 02 in 0 5mm 1 Output coupling...

Page 57: ...ion 5 Pump outfluid to the maximum and mark on dipstick Fluid and water mixed shifts hard 1 Damage to fluid cooler 1 Replace cooler and flush transmission and hoses 2 Selector coritrollinkage 2 Refer...

Page 58: ...ipe down the transmission and properly dispose of the used fluid After running the engine shut down and recheck the fluid leveL NOTE When changing the fluid take care not to lose the drain plug sealin...

Page 59: ...ssion 1402 West marineview Drive Everett WA 98021 Tel 425 259 3285 Transmission Marine 223 Southwest 33 Court P O Box 21086 Ft Lauderdale FL 33335 1086 Tel 954 467 1540 Fax 954 467 1525 Newage Transmi...

Page 60: ...correct distaQoe Remove cable and operate lever by hand to check movement Adjust cableif necessary Propeller speed does not increase 1_ Cone clutch cable Slippage Damaged 1 Remove and ex mlne clutch...

Page 61: ...nal pressure valve relief 15 45 psi 1 0 3 1 kg cm API Specification CF CF 4 CG 4 CH 4 or CI 4 SAE 15W 40 all season Full flow paper element spin on 3 0 U S q s 2 B liters FUEL SYSTEM Open flow self bl...

Page 62: ...n the sump over the lay up period ubricating oiland combustion depOSits combine to produce harmful chemicals which can reduce the life ofyour engine s internalparis FUEL SYSTEM Top off your fuel tanks...

Page 63: ...p any unpainted areas Protect the coupling and the output flange with an anti corrosion coating Check that the transmission vent is open For Spare Parts Lay up time provides a good opportunity to insp...

Page 64: ...is metric with values given asfollows Flywheel Bolt M1 0 17 M10 indicates Metric 10mm thread diameter 17 indicates 17mm across the flats ofthe bolt head wet indicates that the bolts if removed are to...

Page 65: ...125 17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125...

Page 66: ...5 Ounces Pounds Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kllopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals...

Page 67: ...ch packaged in arugged hinged toolbox Kit An includes the basic spares Kit B is for more extensive off shore cruising AKit Impeller Kit lIeat Exchanger Gasket Fuel Filter with Gasket Oil Filter DrlveB...

Page 68: ...WESTERBEKE Engines Generators 1158 2 2011...

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