OPERATORS MANUAL' MARINE D'IESEL ENGINES· a 12C~TWO 120-TWO, PUBLICATION NO.039717 REVISION 3 JANUARY 2011 ..~ WESTERBEKE , WESTERBEKE CORPORA TlON • 150 JOHN HANCOCK ROAD MyLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780 , W.B,SITE: WWW.WESTERBEKE.COM . .
A WARNING .. Exhaust gasses contain Carbon Monoxide, an odorless anil colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can Include: -Dizziness - Throbbing in Temples -Nausea - Muscular Twitching -Headache - Vomiting - Weakness and Sleepiness -Inability to Think Coherently IF. YOU ORANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO tHE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention.
SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to folww fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne~ and your machinery. follOWing safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. • PREVENT ELECTRIC SHOCK • A WARNING: File can cause injury 01 death!" Prevent flash fires.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES A WARNING: Accidental starting can cause injury A WARNING: Carbon monoxide (CO) is a deadly gas! or death! • • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifold! water-injected elbow is securely attached. • Be sure the unit and its surroundings are well ventilated. Run blowers when running the generator set or engine.
SAFETY INSTRUCTIONS OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical infonnation. Read your manual carefully, maintain your equipment, and follow all safety procedures. GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasoline engine or generator should begin with a thorough examination of the American Boat and Yacht Council's (ABYC) standards.
INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
TABLE OF CONTENTS Parts Identification ................................................2 Introductl"on ............................................................. 3 Warranty Procedures ......................................... 3 Serial Number Location .................................. .4 Fuel, Engine Oil and Coolant.. ............................5 Admiral Control Panel .........................................6 Captain Control Panel .........................................
PARTS IDENTIFICATION AIR INTAI!E/SIILENCIER, .••U'~'" PRESSURE CAP "iI~~:3r--- ENGINE SERIAL ~ OIL DRAIN HOSE i NUMBER MOTOR FRONT DC ALTE~NATOR FILL CAP COOLANT PRESSURE INTAKEJSILENCE~ ___-.LIJ"~ UHIUN PLUG OIL FILL FUEL PUNIP-,lbi~f: .
INTRODUCTION This WESTERBEKE Diesel Engine is a product of WESTERBEKE's long years of experience and advanced technology. We take great pride in the superior durability and dependable performance of our engines and generators. Thank you for selecting WESTERBEKE. In order to get the full use and benefit from your generator it is important that you operate and maintain it correctly. This manual is designed to help you do this.
INTRODUCTION SERIAL NUMBER LOCATION ORDERING PARTS The engine's model and serial number are located on a nameplate mounted on the side of the engine's water jacketed exhaust manifold. The engine serial number is also stamped into the engine block on the flat surface out board of the injection pump. Take time to enter this important information on the illustration of the namplate below, as this will provide a quick reference when seeking technical infOrmation and/or ordering parts.
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER. (No. 2·D (SAE J313) diesel fuel according to ASTM D975}. WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces. The antifreeze performs double duty.
ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off. the water temperature gauge will continue to register the last temperature reading indicated by the gauge before electrical .power was turned off. 'The oil pressure gauge will fali to zero when the key switch is turned off. 'The temperature gauge . will once again register the engine's Ime temperature when electrical power is restored to the gauge.
CAPTAIN CONTROL PANEL DESCRIPTION· The panel also includes an alann buzzer for low OIL PRESSURE or high COOLANT 1EMPERATURE. The RPM gauge is illuminated when the KEY switch js turned on and reniains illuminated while the engine is in openition. This manually-operated control panel is equipped with a KEY switch, an RPM gauge, PREHEKf and START buttons, an INSTRUMENT TEST button and three indicator lamps, one for AL1ERNATOR DISCHARGE, one for low OIL PRESSURE, and one for high ENGINE COOLANT TEMPERATURE.
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION NOTE: If the engine has not yet been filled with coolant, Before starting your engine for the first time or after a prolonged layoff, check the following items: o Check the engine oilleve!. Add oil to maintain the level at the high mark on the dipstick. OThman the fuel supply, then check the fuel supply and examine the fuel filter/water separator bowl for contaminants. Check the transmission fluid leve!. o Check the DC electrical system.
STARTING/STOPPING PROCEDURE CHECKLIST FAILURE TO START Follow this check list each day before starting your engine. If the engine fails to start when the start button is pressed for D Visually inspect the engine for fuel, oil, or water leaks. 5 seconds, wait for at least 30 seconds and repeat the starting procedure. Make certain the transmission control is in the neutral position .. Never run the starter motor for more than 30 seconds. If the engine fails to start.
ENGINE BREAK-IN PROCEDURE DESCRIPTION Altliough your engine has experienced a minimum of one hour of test operations at the factory to make sure accurate assembly procedures were followed and that the engine operated properly, a break-in time is required. The service life of your engine is dependent upon how the engine is operated . and serviced during its initial 50 hours of use. Breaking-in a new engine basically involves seating the piston rings to the cylinder walls.
WARNING LIGHTS, ALARMS & CIRCUIT BREAKER ALTERNATOR WARNINGS COOLANT TEMPERATURE SWITCH The Captain Control Panel indicates alternator low discharge with a red warning light. The Admiral Control Panel uses a voltmeter to monitor the performance of the alternator. A coolant temperature switch is located on the thermostat housing; This switch will activate a continuous alarm if the coolant's operating temperature reaches approximately ~J!Ff (99'Cl.
MAINTENANCE SCHEDULE In order to use this Maintenance Schedule, it will be necessary A WARNING: Never attempt to perform any service to log your engine hours. Use your engine hourmeter or record your engine hours by running time. NOTE: Many of the following maintenance procedures are simple but others are more difficult and may require the expert knowledge of a service mechanic. SCHEDULED MAINTENANCE CHECK EACH DAY while the engine is running.
MAINTENANCE SCHEDULE NOTE: Use the engine hourmeter gauge to log your engine hours of record your engine hours by running time. SCHEDULED MAINTENANCE CHECK EACH DAY HOURS OF OPERATION 50 MAINTENANCE DESCRIPTION 100 250 500 750 1000 1250 Raw Water Pump Remove the pump from the engine. Disassemble and inspect all components, replacing all worn components as needed. Inspect the drive gear slot for wear. Replace drive gear as needed. D At 750 operating hours, disassemble and inspect for overhaul.
'FUEL SYSTEM ENGINE FUEL FILTER DIESEL FUEL Periodically check the fuel connections and the bowl for leakage. Replace the filter element after the first 50 hours then follow the MAINTENANCE SCHEDULE. USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER. (No. 2-D (SAE J313) diesel fuel according to AStM D975}. -Changing/cleaning the filter element FUEL FItTERS 1. Shut off the fuel supply. 2.
ENGINE COOLING CIRCUIT 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 water, and the raw water carries the transferred heat overboard through the exhaust system. The . fresh water coolant and raw water circuits are independent of each other. Using only fresh water coolant wilhin the engine allows the cooling water passages 10 slay Clean and free from harmful deposits.
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 engine. The coolant then passes through the .thermostat into the manifold, to the heat exchanger where it is cooled and returned to the engine block via the suction side of the circulating pump.
COOLING SYSTEM THERMOSTAT A thennosta~ located near the manifold at the' front of the engine, controls the coolant temperature as the coolant continuously flows through the closed cooling circirit. When the engine is first started, the closed thennostat prevents coolant from flowing (some coolant is by-passed t)rrough a hole in the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thennostat gradilally opens.
COOLING SYSTEM .. ·RAW-wATERJ'llMP(wu,Y"MODELsj 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 flexible blades which wipe against a curved cam plate . within the impeller housing, producing the pumping action. On no account should this pump be run dry.
REPAIR PARTS ARE AVAILABLE FROM YOUR WESTERBEKE DEALER KEY NO. NOTE THE PUMP-REPAIR KIT (49000) INCLUDES ALL THE USTED CDMPQNENTS EXCEPT ITEMS 1 AND 7., THE KiT ALSO INCLUDES' A PUMP MOUNTING GASKET. ASSEMBLED VIEW !l' ·a~"',.' ...• . • ' "~_c'-"l~". .' til ........
.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 having the . zinc anode is to sacrifice them to electrolysis action takjng place in the raw water cooling circuit, thereby reducing the effects of electrolysis on other components of the system. The condition of the zinc anode shonld be checked monthly and the anode cleaned or replaced as required: Spare anodes should be carried on board. .
ENGINE LUBRICATING OIL 2. Replacing the Oil Filter. When removing the used oil filter; you may find it helpful and cleaner to punch a hole • in the upper and lower portion of the old filter to ~ain the "il from it into a container before removing it. This helps to lessen spillage. A small style automotive filter wrench should be helpfijl in removing the old oil filter. • TYPI.CAL LUBRICATION .O!A_GRAM OIL PRESSURE' .
REMOTE OIL FILTER (OPTIONAL) . PN# 040078 INSTALLATION This popular accessory ·is used to reloc~te the engine's oil fil- NOTE: Westerbeke is not responsiblefor engine failure due to incorrect installation of the Remote ail Filter. . , ter from the engine to a more convenient location such as an engine room bulkhead. . NOTE: Refer to ENGINE OIL CHANGE in this manual for instructions on removing the oil jilter.
DOMESTIC HOT WATER TANK CONNECTIONS PREVIOUS MODEL ENGINES DESCRIPTION Bothihe two mid three cylinder models are equipped with connections to send engine coolant to a domestic water heater. [fthe owner/operator wishes to connect a water heater, remove the bypass hose and connect a water heater as described in . the instructions presented below. REMOVE THE BY-PASS HOSE' , ,HEATER BELOW ENGINE • CURRENT MODEt.
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 cap, the a pressurized (aluruinum) remote expansion tank must be installed in the circuit to become the highest point. The remote expansion tanks part number is 24177. Tee the remote expansion tank into the heater circuit . at the heater connection, choosing the higher of the two for the retum.
TACHOMETER TACHOMETER/HOUR METER The tachometerlhour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and the other the tachometer. The hour meter circuit operates on 12 volts alternator charging voltage supplied to the (+) terminal on the back of the instrument.
ALTERNATORS- TESTINGJTROUBLESHOOTING TYPICAL 50 AMP ALTERNATOR #10 ORANGE BB!":~ TO STARTER 81 VOLTAGE REGULATOR The integra! voltage regulator is an electronic switching device which senses the system voltage level and switches the voltage applied to the field in order to maintain it proper . system voltage. The regulator design utilizes all-silicon semi conductors and . thick~film assembly techniques. After the voltage has been '~..
ALTERNATORS TESTING/TROUBLESHOOTING TESTING THE ALTERNATOR A CAUTION: Before starting the engine make certain that everyone Is clear of moving parts! Keep away from sheaves and belts during test procedures. 'li~~~~ 6 .",...~ . 1. Start the engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery tenninals using a multimeter set on DC volts. a.
ALTERNATORS TESTING/TROUBLESHOOTING TESTING THE EXCITATION CIRCUIT CHECKING THE SERVICE BATTERY Check the voltage of the service battery. lhis battery shOuld have .voltage between 13 and 14 volts when the engine is running. If not, there is a pro.b1em in the service battery charging circuit. Troubleshoot.the service 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 .
GLOW PLUGS Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 20. to 25 seconds. If the plugs don't heat up quiCkly, check for a short circuit. When reinstalling the glow plugs, use anti-seize compound on the tlrreads. DESCRIPTION The glow plugs are wired through the preheat solenoid. When PREHEAT is pressed at the control panel this solenoid should "click" on and the glow plug should begin to get hot.
STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight and is called a high-speed internal-reduction starter. The pinion shafris separate from the motor shaft; the pinion ~lides only on the pinion shaft. A rednction gear is installed between the motor shaft and a pinion shaft. The pinion sliding part is not exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease. The motor shaft is supported at both ends on ball bearings.
STARTER MOTOR EMERGENCY START ,A WARNING: When performIng these procedures, Corrosion to the starter brushes and/or the solenoid contacts can cause the spcradic problem of the engine starting one time bul'not another. If corrosion is the problem, the starter will Iieed to be rebuilt. ' It is however, sometimes possible to get started by taping the starter ligbtly with a small hammer. With the battery switch off and no ignition,.
ENGINE WIRING DIAGRAM (#39144) r---I :~ : It:: I . I - ~ 12 VDC =- >AIill:( ,,~ "~ " ADMIRAL PANEL ,,"U,, IUZIU r-=-:~::::-:-=-'J ___'-==, ___ '___ _ I '- - - - - - - -- '-'="----'-----'--'-'_ - - " f' \ "\ ~ I _I " LU1l ; CAPTAIN PANEL ~~ ,IH ---.J I r - - ; "'- I ,4~J --c...s= &T-'9 .- 0 ur= .'" ,,/..'~ r ""'"") ( J I -~ - " . .u ~~~ I --- -- ;, ir.", \ ~~L ~ -- ~~ II", ... I ... 'u .I - - -- - • • 31 - - -- _.
ENGINE WIRING SCHEMATIC (#39144) s,,'l I~ yO(; • - n"nu M $Q~. r -, ,, ,, ... _----------- -':"- ------, PUH[AT r--., n, SOl --?J' , - -- '~CI'IIHVU Al~UOI ;r I[ .. ~~~~: , e.~. r-:'--~---·-..'.'·.!:.I I .!~ m",1 LifT 'UN' ., , •~ ~. '1 ~ , ~ fUll SMh...-7\ =1 J 'Pile ~liRN'ln,,9NI r L '-----------, F-P t ~- ~:•'".. HII~UB!SHI 50 AHP ALI ADM I RAL PANEL U;~!!~ ~ 114 1.11 ,T ~ o~ .o[ S""T ~!:o ......... AUU -- UV5( I PRESTOLIT(\LEECEwMEVILLE 10 AMP. ALT.
ADMIRALS PANELW.IRING DIAGRAM (#36844) ~ W' JtJ::;Z o:'!Z' ~a:l%:3: I§.::l ~5 ~ ~~j; S1 ~ ;[;19; \'; ~ z ;!! ,~ ~ ~ ;; ~16 ~ S216 '," ~ ~ 0 ~ .~ ; ", 0 iQ " 1; m 6 i 61 P20 ~ I --.--.~-! 1 :..;,•.)@~'"_ •• ~ ~~ I ! I \ ~\~ I 0 1·,4GRlI ;:.' L_~_ _':-',,~~ '---'-----"'4:.--. I 1 I I ~ ~ KEY SWITCH ~ ~\ c.;2 ....; .,.. \~!lLI': J I~TCH ~ .: TACHOMETER I START PREHEAT S~CH VOL.TMETER "'OIlLK.
CAPTAINS PANEL WIRING DIAGRAM (#36467) .---f-"~---..., 1 I I I WATER TEM". G!.OwPLuGS I SWITCH 11",4,Q011;. I otllf.II!)IIIG 011 IlUNalA 01 Cll.llIOEIiSl ~ 4 I I "'fG T.II.U( I ,.NEHEt.T ;1-\ SOI..EN')IO .,. T. !ll.IIE " ___ I SWITCH _ --mL !U.f.~E'tIUSED c< , ': J I PRESSURE SENDEP. ,. fO""'ON"I. ,..ITM ·"STAU"E"! o;AGIIOiDTO ""'NELl [MG"ll ~CCM \ I "WE.S' 0" 1 1 ~E _____ -1__ ,,-.J I ~ 'I' : -Jr, _-=q OIL PRESSURE' ... '" I FUEL 501.
ENGINE TROUBLESHOOTING The following troubleshooting table describes certain problems relating to engine service, the probable causes of these problems, and the recommendations to overcome these problems, NOTE: Fuel run/shut off solenoid (Optional). Problem No pan,1 indications; fu,lsol,nold or fuel pump Is not working (key switch is on and PREHEAT button Is depressed).
ENGINE JROQBLESHOOTING Problem Engine slows and stops. Probable Cause VerilicationJRemedy 1. Fuel lift pump failure. 2. Switches and/or wiring loose or disconnected, 3. Fuel starvation. 4. 20 Amp circuit breaker tripping. 5. Exhaust system Is restricted. Engine overheats/shuts down. 1. Fuellift pump should make a distinct ticking sound. Replace pump with spare. 2. Inspect wiring for short circuits and loose connections. Inspect switches for proper operation. 3.
CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine contro(system is protected by a 20 amp manual reset circuit breaker located on the engine as close as possible to the power source. Probable Cause Problem Verilication/Remedy PREHEAT depressed, no panel Indications fuel solenoid, electric fuel pump and preheat solenoid not energized. 1. Oil Pressure switch. 1. Check switches andlor battery connections. 2. 20 amp circuit breaker tripped. 2. Reset breaker.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below is provided to assist the ENGINE IDLING SPEED The engine idling speed is pre-set at the factory but once the boat is operating in the water other variables such as propeller size, shaft length, and the transmission can affect the idle speed. The normal idle speed for these engine models is 1000-1200 rpm at normal engine operating temperatures.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE ':;'commends that the/allowing engin~ adjust. ments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. ENGINE COMPRESSION DRIVE BELT ADJUSTMENT Check; the engine's compression pressure at 500 and 1250 openiting'houis or whenever engine perfonnance is reduced. Remove each glow plug and check each cylinder's compression pressure. The engine's cranking speed is at 280 rpm.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peTjonned by a competent engine T(lechanic. The infonnation below is provided to assist the mechanic. TESTING OIL PRESSURE OIL PRESSURE RELIEF VALVE The all pressuterelief valve is located. in the front gear case To test oil pressure, remove the hex head plug from the oil gallery and install a mechanical oil pressure gauge in its place. After warming up the engine, read the oil pressure gauge.
ENGINE ADJUSTMENTS NOTE: WEST.ERBEKE recommends that the fallowing engine adjustments be performed by a competimt engine mechanic. TIW information below is provided to assist the mechanic. CYLINDER HEAD BD,LT TIGHTENING SEQUENCE 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 done when the engfue is cold. Cold engine valve clearance is O.OIOin (O.25mriJ.). ~~~=O.lnOiin(0.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments .be petformed by a competent engine mechanic. The information below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT (CDNT.) 5. When setting IDe for the No.2 cylinder proceed as follows: a. For the two engine (2 cylinder) from IDC for the No.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peifonned by a competent engine mechanic. The infonnatlon below is provided to assist the mechanic. FUEL INJECTORS INSPECTING THE SPRAY PATTERN NOTE: WESTERBEKE recommends that the following engine 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.
JS AND BW TRANSMISSION DESCRIPTION If the throw distance (or travel) of the remote cable is too The transmission's gear ratio is 2.47 to I. This manual transmission rotates opposite to the engine when in forward gear. The JS transmits its power with case-hardenedheli,al gears and, in reverse, an intennediate gear. The revei.'~i.ng·piocess IS cllITied out by a servo double disc system. For safety reasons, the transmission is NOT filled with lubricating for shipment.
JS AND BW TRANSMISSION SAILING OPERATION SERVICE The JS transmission'should be left in i~, NEUTRAL position while sailing, Leaving the transmission in NEUTRAL while sailing alleviates unnecessary drag on the vessel because the propeller is able to freewheel (spin). However, if the transmission is left in its FORWARD gear while sailing, the transmission will not be daruaged. (Leaving the transmission in NEUTRAL is just good sailing practice).
HURTH ifBWJZF TRANSMISSIONS NOTE: When installing the transmission, make certain that DESCRIPTION shifting is not impeded by restricted movability of the· cable or rod linkage, by unsuitably positioned guide sheaves, too small a bending radius or other restrictions. In order to mount a support for shift control cable connections, use the two threaded holes located above the cable bracket mounted on the gear housing. Refer to the WESTERBEKE parts list.
HURTH HBWJZF TRANSMISSIONS INITIAL OPERATION LOCKING THE PROPELLER All HBWIZF marine transmissions are test-run on a test stand with the engine at the factory prior to delivery. For safety reasons the fluid is drained before shipment. Fill the gearbox with Automatic Transmission Fluid (DEXRON II or DEXTRON ill). The fluid level should be up to the index mark on the dipstick. To check the fluid level, just insert the dipstick, do not screw it in.
HURTH HBWJZF TRANSMISSIONS MAINTENANCE OPERATING TEMPERATURE. 1bmsinission maintenance is ininimal. Keep the exterior housing clean, check the fluid level as patt of your regular routine, and change the fluid every 300 operating hours. Periodicruly inspect the transinission and the cooler for leaks and corrosion. Lubricate the cable connections. . A WARNING: If the transmiSsion fluid temperature is· too high, stop the engine immediately and r:hlir:kthe transmission fluid.
HURTH HBW/ZF TRANSMISSION TROUBLESHOOTING CONTROL CABLES The majority of transmission difficulties arise as a result of improper clutch adjustments (manual transmissions) or 'problems with control cables (hydraulic transmissions) rather than from problems with the ·transmission itself. HURTHIZF clutches, in particular, are very sensitive to improper cable adjustments. If you experience operating problems with the transmission, shut the engine down. First check the transmission.
HURTH HBWJZF TRANSMISSION TROUBLESHOOTING Probable ~ause Problem Verllicalion/Remedy High fluid temperature. 1. Fluid level high during operation. 2. Fluid level low. 3. Plugged or restricted fluid coole, 4. No walerJn 'cooling system. 5. Filter cill\lged (If applicable). Fluid on transmission housing. 1. 2. 3. 4. 5. Fluid and water mixed; shifts hard., Loose screws. Loose screw connections. Loose dipstick. Loose fluid filter. Fluid level high during operation. 1. Damage to fluid cooler•. ·2.
PRM HEWAGE TRANSMISSIONS 120HASABREATHEti,~ MODELS aD-AND 120 . . THE MODEL FITTING ON THE TOP OF THE CASEr:::::::!!!!:I NOTE: When changing the'fluid, take care not to lose the drain plug sealing washer. The drain plug will leak without this sealing washer. A WARNING: Never pull (lut the dipstick while the -':'DII'$m:K 112" HEX PLUG .' MOPEL 80'(MODEL 120 USES A8MMHEX PLUG) inglne is running. Hot fluid will splash from the dipstick hole. This t;(luld cause severe burns.
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 with the lever in the neutral position. The neutral position of the operating lever in the cockpit must coincide with the neutral position of this lever. The shift level travel must be such that the lever just strikes the internal stops for the lever when shifted into forward or reverse.
. PRM NEWAGE TRANSMISSIONS TROUBLESHOOTING . Problem· Excessive noise at low speeds. Excessive noise at all speeds. Fluid needs constant topping off. Difficulty in moving lever control. VerlllcationJReme~y Probable CaUse 1. 1. 2. 3. 1. Engine idle speed too low. Defective coupling. Prop out of balance. 2. Check alignment with feeler gauge. 3. Remove, check pitch, balance and weight. Power too high. 1. Compare engine and transmission data. Shaft misalignment. 2.
12C AND 120 TWO ENGINE SPECIFICATIONS LUBRICATION SYSTEM SPECIFICATIONS General Pressure type by Trochoid pump, gear-driven, with external pressure valve relief Operating Oil Pressure (engine hot) 15-45 psi (1.0-3.1 kg/cm') Mechanical, centrifugal weight type Valve Mechanism Overhead Oil Grade Combustion Chamber Swirl chamber type API Specification CF. CF-4, CG-4, CH-4 or CI-4 SAE 15W-40 (all season) Bore & Stroke 2.99 x 2.76 inches (76 x 70 mm) Oil Filter (Pn.
LAY-UP &RECOMMISSIONING GENERAL FUEL SYSTEM Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the off-season or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves. The procedures which follow will allow you to perform your own lay-up and recorrunissioning, or you may use them as a check list if others do the procedures.
LAY-UP &RECOMMISSIONING Starter Motor Spare Parts -, Lubrication and cleaaing of the starter drive pinion is advisable, if access to the starter permits its easy removal. Make sure the battery connections are shut off before attempting to remove the starter. Take care in properly replacing aay electrical connections removed from the starter. Lay-up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement.
TORQUE SPECIFICATIONS COMPONENT FHB (M-KG) COMPONENT Alternator Bracket ..........................27 - 38 (3.8 - 5.3) Back Plate ......................................24 - 35 (3.3 - 4.8) Connecting Rod Cap M8 (14) ...... 23 - 28.2 (3.2 - 3.5) Coolant Pump ................................12 - 17 (1.6 - 2.4) Coolant Pump Pulley ...................... 12 - 17 (1.6 - 2.4) . CoolantTemperature Sender ........ 9 - 13 (1.2 - 1.8) CoolantTemperature Switch .......... 9 - 13 (1.2 - 1.
DECIMAL TO METRIC EQUIVALENT CHART Fractions of an inch Decimal (in.) 1/64 0.015625 0.39688 1/32 0.03125 3/64 0.046875 1/16 5/64 0.0625 0.078125 Fractions of Decimal (in.) Metric (mm) 33/64 0.515625 13.09687 0.79375 17/32 0.53125 1.19062 1.58750 35/64 0.546875 13.49375 13.89062 9/16 37/64 0.5625 0.578125 .14.28750 Metric (mm) . 1.98437 an inch 14.68437 3/32 0.09375 2.38125 19/32 0.59375 15.08125 7/64 0.109375 2.77812 39/64 0.609375 15.47812 1/8 0.125 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 = Feet Miles x 1.609 = Kilometers (km) x .0621 = Miles VOLUME . Cubic Inches (in') x 16.387 = Cubic Centim~ters x .061 =in' Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt Imperial Galions (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal Imperial Quarts (IMP qt) x1.201 = US Quarts (US qt).x .
SUGGESTED SPARE PARTS Carry Only Genuine Westerbeke Spare Parts . .' 0 '"' • Jr;~ {:: 0, . '. HARDWARE KIT WESTERI3EKE CARRYING ENOUGH SPARE . . ENGINE OIL (YOUR BRAND) FOR Alii OIL CHANGE (5 OTS.) AND A GALLON OF PREMIXED COOLANT. . SP.ARE PARTS .•.."'~...... WESTERBEKE also offers two Spare Pints Kits, each packaged in a rugged hinged toolbox. Kit "An includes the basic spares. Kit "B" is 'for more. extensive off-shore cruising. .
~ WESTERBEKE Engines & Generators 1158·2/2011
