Westerbeke 80N4 User manual

OPERATORS MANUAL
80N4/11 OT 4-120N6/170T6
MARINE 01 L ENGINES
PUBLICATION NO. 045139
FIRST EDITION
JULY 2000
WESTERBEKE CORPORATION
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCKROAD, TAUNTON, MA 02780-7319
AIIT'-AIITAIIT
NMMA Member National Marine Manufacturers Association
.. UWW

A WARNING
Exhaust gasses contain Carbon Monoxide. an odorless and
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 OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS.
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms 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 and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Most accidents are caused
byfailure
to follow fundamental rules and precautions.
Know when dangerous conditions exist
and talre the
necessary precautions to protectyourself,
your personnel,
and your machinery.
Thefollowing safety instructions are in compliance with the
American Boat
and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers
in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel's AC generator may
result
if this procedure is not followed.
• Electrical shock results from handling a charged capacitor.
Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine
or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel 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 line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near the
fuel system. Keep the compartment and the engine/gener-
ator clean and free
of debris to minimize the chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before running
the blower. Run the blower for four minutes before start-
ing your engine.
• All fuel vapors are highly explosive. Use extreme care when
handling and storing fuels. Store fuel
in a well-ventilated
area away from spark-producing equipment and out
of the
reach
of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care
in catching any fuel that might
spill. DO NOT allow any smoking, open flames.
or other
sources of
fire near the fuel system or engine when servicing.
Ensure proper ventilation exists when servicing the
fuel
system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered
in this environment.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
instaIled before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or aIlow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or
by lit tobacco products. Shut offall electrical
equipment in the vicinity to prevent electrical arcing during
servicing.
• Never connect the negative (-) battery cable to the positive
(+) connection terminal of the starter solenoid. Do not test
the battery condition
by shorting the terminals together.
Sparks could ignite battery gases or fuel vapors. Ventilate
any compartment containing batteries to prevent accumu-
lation
of explosive gases. To avoid sparks, do not disturb
the battery charger connections while the battery
is being
charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and
any other jewelry before handling
the battery.
• Always turn the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
A WARNING: Sulphuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which
is destructive. If
it comes in contact with your skin, wash it offat once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• 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 manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are weIl ventilated.
.• In addition to routine inspection of the exhaust system,
instaIl a carbon monoxide detector. Consult your boat
builder or dealer for instaIlation
of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing
in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration of copper
tubing resulting in exhaust/water leakage.
• Do not instaIl exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. Ifthe engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow
of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas
is present in diesel exhaust fumes. Some of the symp-
toms or signs
of carbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing
in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine/generator while it is running. If a
situation arises
in which it is absolutely necessary to make
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; avoid wearing loose jackets. shirts, sleeves.
rings. necklaces or bracelets that could be caught
in
moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belts' tension while
the engine/generator
is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine
is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate a generator without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines or generators for long periods with
their enclosures open.
A WARNING: 00 not work on machinery when you
are mentally or physically incapaCitated by fatigue!
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 information. 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. These standards are from
a combination
of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest 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 USCG PUBLICATIONS FOR
INSTALLING GASOLINE AND DIESEL ENGINES AND
GENERATORS
Read the following ABYC. NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your WESTERBEKE engine/generator.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1 Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"USCG 33CFR183"
Order From:
U.S. Government Printing Office
. Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Federal regulations, ABYC guidelines, and safety codes must be complied with when
installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine
and possibleflooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, instaU a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation.
Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult
the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ................................................ 2 W
"" 0"
IFing lagrams ................ ; ............................... 27
Introduction . ............................................................ 3
Engine Troubleshooting ... .................................. 29
Warranty Procedures........................................
.3
Tachometer ........................................................ 31
Serial Number Location ...................................4
Admiral Control Panel ........................................ .5
Engine Adjustments ... .......................................... 32
Drive Belt Adjustment....................................32
Fuel, Engine Oil and Coolant .............................. 6 Fuel Injectors .................................................32
Oil Pressure ......................................................6 Testing Engine Compression..........................33
Preparations for Initial Start-Up ......................... 7
Starting/Stopping Procedure ............................... 8
Warning Lights, Alarms and Circuit Breaker ...... 9
Testing Oil Pressure........................................33
Valve Clearance Adjustment ..........................34
Injection Timing ............................................34
Hurth Transmissions .......................................... 36
Engine Break-In Procedure ...................... ......... 10 Changing Fluid...............................................37
The Daily Routine ............................................. . 11
Maintenance ..................................................37
Starting the Engine .........................................
11
Cable Connections..........................................38
Maintenance Schedule .. ................................... 12
Shaft Couplings ..............................................38
Cooling System ................................................. .14
Thermostat......................................................
15
Borg Warner Transmission ..... ........................... 39
Changing Fluid...............................................40
Raw Water Pump............................................16
Heat Exchanger ..............................................
17
Maintenance .................................................. 41
Transmission Troubleshooting ......................... .42
Air Intake Filter.............................................. 18
Lay-up and Recommissioning .......................... .44
Fuel System ...................................................... . 19
Metric Conversions ......................................... .46
Fuel Lift Pump................................................19
Fuel Filters......................................................
19
Fuel PumplFuel Bleeding...............................20
Engine Lubricating Oil ....................................... 21
Oil Change....................:................................. 21
Specifications 80N4 ........................................ ..48
Specifications 11 OT4 ........................................ .49
Specifications 120N6 ........................................ 50
Specifications 170T6 ......................................... 51
Remote Oil Filter............................................22
Suggested Spares ............................................. 52
Water Heater ..................................................... 23
DC Electrical System .......................................... .24
Alternator Troubleshooting ............................24
Battery ............................................................25
Glow Plugs .....................................................26
Engines & Generators
1

PARTS IDENTIFICATION
MODEL 110T4
ILLUSTRATED
COVER
FRONT
RAW WATER
DC ALTERNATOR
OIL DRAIN HOSE
LEFT SIDE
CONNECTION
SIPHON BREAK
TURBOCHARGER
AIR INTAKE/"
& FILTER
TRANSMISSION
OIL COOLER
REAR
MANIFOLD PRESSURE CAP
COOLANT FILL
//.
OIL GALLERY
OIL FILTER
Engines & Generators
2
OIL FILL
ID NAME PLATE
EXHAUST ELBOW
MANIFOLD
HEAT
-~----;;I--'--- EXCHANGER
STARTER MOTOR
THERMOSTAT
ASSEMBLY
TRANSMISSION
FLUID DIPSTICK
FUEL FILTER
INJECTION
PUMP
FUEL PRIMING PUMP
BLE
MOUNT
OIL DIPSTICK
RIGHT SIDE

INTRODUCTION
These high perfonnance marine engines are products of
WESTERBEKE's long years of experience and advanced
technology.
We take great pride in the superior durability and
dependable perfonnance
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. Please read this
manual carefully and observe all the safety precautions
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This
is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer.
If you are planning to install this
equipment, contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If. after 60 days of submitting the Warranty Registry
fonn you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model infonnation, including the unit's
serial number and commission date.
Customer Identification Card
l"WV"JWESTERBEKE
I
Customer Identification
MR. WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model80N4
Expires
2151200 I
Ser.
#UOOOO-E702
The WESTERBEKE serial number is an alphanumeric
number that can assist in detennining the date
of manufacture
of your WESTERBEKE engine or generator. The manufac-
turer's date code is placed
at the end of the engine serial
number and consists
of a character followed by three num-
bers. The character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s E=2000s), the first number represents the
year
in the decade: and the second and third numbers repre-
sent the month
of manufacture.
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT
OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS
THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should keep in mind the time
span between printings
of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
product software. The product software provided with .
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense but
is imperative that appropriate
representatives
of WESTERBEKE or the supplier in question
be consulted to detennine the accuracy and currentness
of the
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures.
maintenance schedules, and troubleshooting
of your marine
engine, critical infonnation will be highlighted
by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, if not strictly
observed, can result in the damage or destruction of
your engine.
A WARNING: Procedures which, if not properly
followed, can result in personal injury or loss of life.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
a nameplate mounted on the side
of the engine's manifold.
The engine's serial number
is stamped into the engine block
(left side) behind the alternator, below the manifold Take the
time
to enter this information on the illustration of the name-
plate shown below, as this will provide a quick reference when
seeking technical information and/or ordering repair parts.
~~~~~~~~~
~1¥fii4il:1B3=t
o 0
• MODEL SPEC AVO_ MA USA SER.NO..
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism
is essentially the same. The cylinders
are arranged above a closed crankcase. The crankshaft
is the
same general type as a gasoline engine, and the diesel engine
has the same type
of valves, camshaft, pistons, connecting
rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the same
preventive maintenance as a gasoline engine. The most
important factors are proper ventilation and proper mamte-
nance of the fuel, lubricating and cooling systems. Fuel and
lubricating filter elements must be replaced
at the time peri-
ods specified, and frequent checking for contaminants (water,
sediment, etc.)
in the fuel system is also essential. Another
important factor
is the consistent use of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines.
The diesel engine' does differ from the gasoline engine,
however,
in its method of handling and firing of fuel. The
carburetor and ignition systems are replaced
by a single
component -the fuel injection pump -which performs the
function
of both.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine model number and serial number as they appear on
the silver and black nameplate located on the manifold.
You
must provide us with this information so we may properly
identify your engine. In addition, include a complete part
description and part number for each part needed (see the
separately furnished Parts List). Insist upon WESTERBEKE
packaged parts because willfit or generic parts are frequently
not made to the same specifications
as original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE engine. Your local WESTE.RBEKE dealer
will
a'ssist you in preparing an inventory of spare parts. See
the SPARE PARTS page in this manual. For engine acces-
sories, see WESTERBEKE's ACCESSORIES brochure.
Engines & Generators
4

ADMIRAL CONTROL PANEL
DESCRIPTION
This manually-operated control panel is equipped with a
KEY switch and RPM gauge with an ELAPSED TIME
meter which measures the engine's running time in hours and
in III 0 hours. The panel also includes a WATER TEMPER-
ATURE gauge which indicates water temperature in degrees
Fahrenheit, an OIL PRESSURE gauge which measures the
engine's oil pressure
in pounds per square inch, and a DC
control circuit VOLTAGE gauge which measures the sys-
tem's voltage. All gauges are illuminated when the key
switch is turned on and remain illuminated while the engine
is
in operation. The panel also contains two rubber-booted
pushbuttons, one for PREHEAT and
on,? for START.
RPM GAUGE: REGIS-
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATED FOR
ACCURACY FROM THE
REAR OF THE PANEL.
HOURMETER:
REGISTERS ELAPSED
TIME, AND SHOULD BE
USED AS A GUIDE FOR
THE MAINTENANCE
SCHEDULE.
WATER TEMPERATURE GAUGE: THIS GAUGE IS
GRADUATED IN DEGREES FAHRENHEIT AND IS
ILLUMINATED WHILE THE KEY SWITCH IS
TURNED ON. THE ENGINE'S NORMAL OPERATING
TEMPERATURE IS 170· -190· F(n·- SS·C).
PREHEAT PRESSED, ENERGIZES THE
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 fall to zero
when the key switch is turned
off The temperature gauge
will once again register the engine's true temperature when
electrical power is restored to the gauge.
A separate alarm buzzer with harness is supplied with every
Admiral Panel. The installer
is responsible for electrically con-
necting the buzzer to the four-pin connection on the engine's
electrical harness. The installer
is also responsib,le for installing
the buzzer
in a location where it will be dry and where it will
be audible to the operator should it sound while the engine is
running. The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engine's oil pressure rises above
15 psi (1.1 kg/cm2).
,
OIL PRESSURE GAUGE: THIS GAUGE IS GRADUATED
IN POUNDS PER SQUARE INCH (PSI) AND IS
ILLUMINATED WHILE THE KEY SWITCH IS TURNED
ON. THE ENGINE'S NORMAL OPERATING OIL
PRESSURE RANGES BETWEEN 40 - 85 pSi.
SWITCH: PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER.
DC VOLTMETER:
INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED.
SHOULb SHOW 13V TO 14V.
AUTOMATIC ALARM SYSTEM
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE
FUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS. IT BYPASSES THE ENGINE'S
OIL PRESSURE ALARM SWITCH. IN ADDITION, THIS
BUTTON ENERGIZES THE START BUTTON.
I/<' : SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
~...: REACHES 210· F (99·C), THIS SWITCH WILL CLOSE SOUNDING THE
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.
THIS BUTTON WILL NOT OPERATE ELECTRICALLY
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD
AT THE SAME TIME.
--- ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
OIL PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
FALL TO 5 -10 psi (0.4 - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND-
ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
SIGNAL.
Engines & Generators
5

DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL
Use fuel that meets the requirements or specification of Class
2-D (ASTM), and has a cetane rating
of #45 or better.
Care Of The Fuel Supply
Use only clean diesel fuel! The clearance of the components
in your fuel injection pump
is very critical; invisible dirt
particles which might pass through the filter can damage
these finely finished parts. It
is important to buy clean fuel,
and keep it clean. The best fuel can be rendered unsatisfac-
tory by careless handling or improper storage facilities.
To
assure that the fuel going into the tank for your engine's daily
use
is clean and pure, the following practice is advisable:
Purchase a well-known brand
of fuel.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.
The Raycor445 or larger
is a good example of such a filter.
ENGINE OIL
80N41120N6
l1OT41170T6
API Grade CF or CG-4
API Grade CG-4
Use the heavy duty engine oils as specified above. Change
the engine oil after
an initial 50 hour break-in period and
every 100 hours
of operation thereafter.
Engine oil viscosity largely affects engine startability, perfor-
mance, oil consumption, speed
of wearing and occurrence of
seizure, etc. Using lubricants whose viscosity is selected
according to the atmospheric temperature
is important.
ENGINE OIL VISCOSITY CHART
ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE
I
SAE 2020W
_SA. 40.501
.I
I .1
SAE lOW SAE 30
I
A CAUTION: Do not allow two or more brands of
engine oil to mix. Each brand contains its own additives;
additives of different brands could react in the mixture
to produce properties harmful to your engine.
OIL PRESSURE
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 25 and
85 psi.
NOTE: A newly staned, cold engine can have an oil pressure
reading up to
85 psi. A warmed engine can have an oil pres-
sure reading as low as
25 psi. These readings will vary
depending upon the temperature
of the engine, the load
placedon the engine,
and the RPM's.
ENGINE COOLANT
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. It allows the engine to
run at proper temperatures by transferring heat away from the
engine to the coolant, and lubricates and protects the cooling
circuit from rust and corrosion. Look for a good quality
antifreeze that contains Supplemental Cooling Additives
(SCAs) that keep the antifreeze chemically balanced, crucial
to long term protection.
The distilled water and antifreeze should be premixed before
being poured into the cooling circuit.
NOTE: Look for the new environmentally-friendly long lasting
antifreeze that is now available.
Antifreeze mixtures will protect against an unexpected freeze
and they are beneficial to the engine's cooling system. They
retard rust and add to the life
of the circulating pump seal.
ANTIFREEZE PROTECTION
Antifreeze Concentration
23% 30% 35% 50%
Freezing Temperature
14°F 8°F
(-10°C) (-13°C)
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine. The purpose
of this recovery
tank is to allow for engine coolant expansion and contraction
during engine operation, without the loss
of coolant and
without introducing air into the cooling system. This kit
is
provided and must be installed before operating the engine.
NOTE: This tank, with its short run of plastic hose, must be
located above the level
of the engine's manifold.
\\
"
,
Engines & Generators
6

PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff, check the following items:
D Check the engine oil level. Add oil to maintain the level
at the high mark on the dipstick.
D Turn on the fuel supply, then check the fuel supply and
examine the fuel filter/water separator bowl for contami-
nants.
D Check the transmission fluid leveL
NOTE: Refer to the previous page for fuel, oil and
transmission fluid.
D Check the DC electrical system. Inspect wire connections
and battery cable connections. Make certain the positive
(+) battery cable is connected to the starter solenoid and
the negative
(-) cable is connected to the engine ground
stud (this location
is tagged).
D Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: If the engine has not yet been filled with coolant,
refer to the COOLING SYSTEM section
of this manual.
D Visually examine the engine. Look for loose or missing
parts, disconnected wires, and unattached hoses. Check
the threaded connections and engine attachments.
D Make certain there is proper ventilation around the
engine. An ample supply
is necessary for proper engine
performance.
D Make sure the mounting installation is secure.
D Ensure the propeller shaft is securely attached to the
transmission.
~
D Open the through-hull and make certain raw water is ~ ~ ""-..',
primed to the raw water strainer ~ ~
~ ~,-~ .. '" ,,\)1 I
DIPSTICK
PUSH IN TIGHT
'" I
'I
\~
~/" ~ "/',,---- .,,,1:' ;,\\1''-- '~I
",'\l'l/ . i/
j ?CcC"r~ COOLANT PRESSURE CAP
Engines & Generators
7
MANIFOLD
.'"
)

STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
These marine diesel engine have l2V DC electric starters. The
start circuitry
is designed so that the PREHEAT button must
be depressed for the time specified in the preheat chart. Then,
while keeping the PREHEAT button engaged, the START
button
is depressed to crank the engine.
Starting Procedure
1. Place the transmission in neutral and advance the throttle
control to slightly open.
A CAUTION: Make certain the transmission is
in neutral. Starting in gear could result in serious
damage to your transmission, your boat, and
vessels nearby.
2. Turn the KEY SWITCH to the ON position (2 o'clock).
3. Depress the PREHEAT switch. The voltmeter, panel
lights, gauges, meters and fuel solenoid will be activated.
The PREHEAT switch should be depressed
in accordance
with the following chart:
TemperatureJPreheat
Atmospheric Temperature Preheating TIme
41°F(5°C) or higher
Approx. 5 seconds
41°F(5°C) to 23°F (-5°C) Approx. 10 seconds
23°F(-5°C) or lower Approx. 15 seconds
NOTE: The STARTbutton will not energize unless the PRE-
HEAT button is depressed. Depressing the PREHEATbutton
activates the glow plugs in the cylinder headso use the PRE-
HEAT intem!ittently to avoid overheating the glow plugs.
4. While still depressing the PREHEAT switch, depress the
START switch. This will engage the starter solenoid.
Upon engine starting, release the START switch and
release the PREHEAT switch.
NOTE: When starting:
A voltage drop will occur
when the preheat button
is depressed.
12 I 14
~6
\
",
~ 'I,
L....J \:i VOLTS
5. Should the engine not start when the START button is
depressed for 10 to 20 seconds, release both buttons and
wait 30 seconds; repeat the procedure above and preheat
longer. Never
run the starter for more than 30 seconds.
A CAUTION: Prolonged cranking Intervals wfthout
the engine starting can result in the engine exhaust
system filling wfth raw water. This may happen because
the pump Is pumping raw water through the raw water
cooling system during cranking. This raw water can
enter the engine's cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this
from happening by closing the raw water supply
through-hull shutoff, draining the exhaust muffler, and
correcting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry is nota
warrantable issue; the owner/operator should keep this
in mind.
6. Once the engine starts, check the instruments for proper
oil pressure and battery charging voltage.
NOTE: Never attempt to engage the starter while the
engine is running.
Starting Under Cold Conditions
Make sure the lubricating oil is appropriate for the prevailing
temperature. Use oil with an API Specification of CF or CG-4,
SAE 30. lOW-30, or 15W-40, or 20W-40.
The battery should be fully charged to minimize voltage drop.
Use a sufficient amount of preheat to aid in starting. See the
Temperature/Preheat chart elsewhere in this section.
Stopping Procedure
To stop the engine, bring the throttle to an idle position and
place the transmission
in neutral. Allow the engine to idle for
a
few moments to stabilize temperatures. Turn the engine off
using the stop control cable.
NOTE: Make certain this key switch is in the OFF position
(12 o'clock). If the key switch is left ON, the battery will
discharge.
An engine alarm buzzer is provided to warn the
operator
of this condition (key switch ON). The best method
of preventing the batteryfrom discharging is to remove the
keyfrom the key switch after stopping the engine.
ALTERNATOR WARNINGS
The Admiral Control Panel uses a voltmeter to monitor the
performance
of the alternator.
COOLANT TEMPERATURE SWITCH
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 210°F
(99°C).
Engines & Generators
8

WARNING LIGHTS, ALARMS & CIRCUIT BREAKER
ALTERNATOR WARNINGS
The Admiral Control Panel uses a voltmeter to monitor the
performance of the alternator.
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing. This switch will activate a continuous alarm ifthe
coolant's operating temperature reaches approximately 2IOOF
(99°C).
COOLANT TEMPERATURE
SENDOR
THERMOSTAT
HOUSING
AIR BLEED
PETCOCK
LOW OIL PRESSURE ALARM SWITCH
A low oil pressure alarm switch is located off the engine's
oil gallery. This switch's sensor monitors the engine's oil
pressure. Should the engine's oil pressure fall to 5 -
IO psi
(0.4 -0.7 kg/cm2), this switch will activate a pulsating alarm.
ENGINE CIRCUIT BREAKER
The DC harness on the engine is protected by an engine-
mounted manual reset circuit breaker (20 amps DC).
Excessive current draw or electrical overload anywhere
in the
instrument panel wiring or engine wiring will cause the
breaker to trip.
In this event most engines will shut down
because the opened breaker disconnects the fuel supply.
If
this should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the
engine.
OIL PRESSURE
SEND OR
OIL PRESSURE SWITCH
(NORMALLY OPEN)
I
FROM ENGINE
BLOCK
Engines &Generators
9

ENGINE BREAK-IN PROCEDURE
DESCRIPTION
Although 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 oper-
ated 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 pis-
ton rings to the cylinder walls. Excessive oil consumption
and smoky operation indicate that the cylinder walls are
scored, which is caused by overloading the engine during the
break-in period.
Your new engine requires approximately
50 hours of initial
conditioning operation to break in each moving part in
order
to maximize the performance and service life of the engine.
Perform this conditioning carefully, keeping in mind the fol-
lowing:
1. Start the engine according to the STARTING PROCE-
DURE section. Run the engine at fast idle while 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 130 -140°F (55 -60°C) range.
3. While using the vessel, run the engine at various engine
speeds for the first 25 hours. Avoid prolonged periods
of
idling.
4. Avoid rapid acceleration, especially with a
cold engine.
5. Use caution not to overload the engine. The presence
of a
grey
or black exhaust and the inability of the engine to
reach its full rated
speed are signs of an overload.
6. During the next 25 hours, the engine may be operated at
varying engine speeds, with short runs at full rated rpm.
Avoid prolonged idling during this break-in period.
CHECK LIST
o Monitor the control panel gauges.
o Check for leaks of fuel and engine oil.
o Check for abnormal noise such as knocking, friction.
vibration and blow-back sounds.
o Confirm exhaust smoke:
When the engine is
cold -white smoke.
When the engine is
warm -almost smokeless.
When the engine
is overloaded -some black smoke and soot.
NOTE: See the TRANSMISSION section of this manualfor
break-in information on your transmission.
Engines & Generators
10

THE DAILY ROUTINE
CHECK LIST
Each day before starting your engine, take a few moments to
run this check list:
o Visually inspect the engine for fuel, oil, or water leaks.
o Check the oil level.
o Check the transmission fluid level.
o Check for loose wires at the alternator.
o Check the starting batteries (weekly).
o Check drive belts for wear and proper tension (weekly).
o Log your engine running time. These hours relate to
scheduled maintenance.
o Check fuel supply; always keep fuel tank(s) as full as
possible.
o Look for clean fuel in the fueVwater separator bowl.
o Check the coolant level in the plastic recovery tank.
NOTE: Excessive loss of coolant indicates a cooling system
leak. Check the entire system.
If necessary, use a cooling sys-
tem pres'sure tester to pressurize the cooling system to locate
the area
of leakage. III cases of excessive coolant loss, refill
the svstem as outlined
in the ENGINE COOLANT CIRCUIT
secti~n of this manual.
STARTING THE ENGINE
NOTE: See STARTING/STOPPING PROCEDURE in this
manual
for more detailed instructions.
1. Put the transmission in neutral, throttle advanced.
NOTE: Hydraulically operated transmissions have a
neutral safety switch through which the starter solenoid
energizing circuit passes. This switch
is open when the
transmission
is in gear so the starter solenoid will not
energize.
2. Tum the KEY to the ON position (2 o'clock).
3. Depress PREHEAT
(5 seconds).
4. While pressing PREHEAT, push
START. As the engine
fires, release START and PREHEAT.
NOTE: Some unstable running may occur in a cold
engine. This condition should abate
as normal operating
temperature
is reached and loads are applied.
NOTE: Should the engine fail to start, wait 30 seconds,
then repeat the above procedure, and PREHEAT
longer.
5. Allow a few minutes for the engine to warm at a com-
fortable rpm (approximately 1200 rpm), then reduce the
rpm, and get underway.
A CAUTION: When shifting the transmission, always
reduce the engine rpm to idle, then shift the transmis-
sion firmly from one direction to another. A slight pauSe
in neutral will allow the propeller to slow. Shifting at
high rpm will damage the transmission/damper plate.
Engines & Generators
11

MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary
to log your engine hours. Use your engine hounneter or
record your engine hours
by running time.
NOTE: Many a/the/allowing maintenance procedures are
simple but others are more difficult
and may require the
expert knowledge 0/a service mechanic.
A WARNING: Never attempt to perform any service
while the engine is running. Wear the proper safety
equipment such as goggles and gloves, and use the
correct tools for each job. Disconnect the battery
terminals when servicing any of the engine's DC
electrical equipment.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE DESCRIPTION
MAINTENANCE
EACH
DAY
50 100 250 500 750 1000 1250
Fuel Supply
0
Fuel/Water Separator
0
Engine Oil Level
0
Coolant Level
0
Transmission Fluid Level
0
Drive Belts
0
weekly
Visual Inspection of Engine
0
NOTE: Keep engine surface clean. Dirt and'
oil will inhibit the engine's ability to remain
cool.
Fuel Filter
0 0 0 0 0 0
Starting Batteries
0
(and House Batteries) weekly
Engine Oil and Filter
0 0 0 0 0 0 0
Heat Exchanger Zinc Anode
0 0 0 0 0 0 0
,
Fuel/Water Separator
0 0 0 0 0 0
Exhaust System
0 0 0 0
Engine Hoses
0 0 0 0 0 0
Throttle and Transmission
0 0 0 0
Control Cable
Raw Water Pump
0 0 0
Engines & Generators
12
Diesel No.2 rating of 45 cetane or higher.
Check for water and dirt in fuel (drain/replace filter
if necessary).
Oil level should indicate between MAX. and LOW on
dipstick.
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Fluid level should indicate between MAX and LOW
on dipstick.
Inspect for proper tension (3/8" to 1/2" deflection)
and adjust if needed. Check belt edges for wear.
Check for fuel, oil and water leaks. Inspect wiring
and electrical connections. Keep bolts & nuts tight.
Check for loose belt tension.
Change at 50 hours then every 250 hours.
Check electrolyte levels every 50 operating hours
and make sure connections are very tight. Clean off
excessive corrosion.
Initial engine oil & filter change at 50 hours, then
change both every 100 hours.
Inspect zinc anode, replace if needed. Clear the heat
exchanger end of zinc anode debris.
Change filter every 200 hours.
Initial check at 50 hours, then every 250 hours.
Inspect for leaks. Check anti-siphon valve opera-
tion. Check the exhaust elbow for carbon and/or
corrosion buildup on inside passages; clean and
replace as necessary. Check that all connections are
tight. Check casting integrity.
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Check for loose fittings, cotter pins, etc.
Lubricate with WD-40 or equivalent.
Remove the pump cover and inspect the impeller,
gasket, cam and cover for wear. Check the bearings
and seals (the shaft can turn, but not wobble).
Lubricate when reassembling.
(continued)
--*

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log yourengine hours or record your
engine hours
by running time.
SCHEDULED
CHECK
HOURS OF OPERATION
MAINTENANCE
EACH
MAINTENANCE DESCRIPTION
DAY 50
100 250 500 750 1000
1250
Coolant System
0 0
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
DC Alternator
0 0 0
Check DC charge from alternator. Check mounting
bracket; tighten electrical connections.
Transmission Oil Cooler
0
Remove; have professionally cleaned and pressure
tested.
Engine Transmission
0
Chattering at idle and low rpms is an indication
Damper Plate
of damper plate wear. Remove and replace.
*Fuellnjectors
0
Check and adjust injection opening pressure and
spray condition (Refer to your service manual).
*Starter Motor
0 0
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
*Preheat Circuit
0 0
Check operation of preheat solenoid. Remove and
clean glow plugs. Reinstall with anti-seize
compound on threads.
*Engine Cylinder
0 0
Check compression pressure and timing,
Compression
(see ENGINE ADJUSTMENTS).
* Adjust the Valve Clearances
0 0 0
Adjust Valve Clearances, (see ENGINE
ADJUSTMENTS).
*Heat Exchanger
0
Remove, have professionally cleaned and pressure
tested.
Lubricate Panel Key Switch
0 0 0 0 0 0
At first 100 hours, then each year at winterizing.
with "Lockeze"
Transmission
0 0 0 0 0 0
Initial fluid change at 25 hours, then every
Fluid and Filter
300 hours or at winterizing. Replace the filter at each
fluid change.
Feed Pump Strainer
0 0 0 0 0
Clean every 250 operating hours.
Turbocharger
0 0
Initial 50 hour check, inspect all connections for oil
and exhaust leaks. Check mounting bolts for
tightness. Check for air leakage. Inspect the radial
and axil play of the rotor shaft. Lubricate the shaft
bearings.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
13

COOLING SYSTEM
DESCRIPTION
Westerbeke marine diesel engines are designed and equipped
for fresh water cooling. Heat produced in the engine by
combustion and friction is transferred to fresh water coolant
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block, its internal moving
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means
of a heat
exchanger, similar
in function to an automotive radiator. Raw
water flows through the tubes
of the heat exchanger while
fresh water coolant flows around the tubes; engine heat
transferred to the fresh water coolant is conducted through
the tube walls to the raw water which
is then pumped 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 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 within the engine
.allows the cooling water passages to stay clean and free from
harmful deposits.
FRESH WATER COOLING CIRCUIT
NOTE: Referto the ENGINE COOLANTsection for the rec-
ommended antifreeze and water mixture to be used as the
fresh water coolant.
Fresh water 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.
When the engine is started cold, external coolant flow
is
prevented by the closed thermostat (although some coolant
flow
is bypassed around the thermostat to prevent,.the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow of the engine's
coolant
to flow unrestricted to the external portion of the
cooling system.
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any
significant loss
of coolant and without introducing air into
the cooling system. This tank should be located at
or above
the engine manifold level and should be easily accessible.
~
TO COOLANT RECOVERY
TANK
)I-
COOLANT EXPANSION
COOLANT RETRACTION
NOTE: Periodically check the condition of the manifold pres-
sure cap. Ensure that the upper and lower rubber seals are
ill
good condition and check that the vacuum valve opens and
closes tightly. Carry a spare cap.
CHANGING COOLANT
The engine's coolant must be changed according to the
MAINTENANCE SCHEDULE. If the coolant is allowed to
become contaminated, it can lead to overheating problems.
A CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine fai/ures can be
traced back to cooling system corrosion.
Drain the engine coolant by loosening the drain plug on the
engine block and opening the manifold pressure cap. Flush
the system with fresh water, then start the refill process.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
DRAIN PLUG
DRAIN PETCOCK
........... '\- ... ,
I
Engines & Generators
SOME ENGINE MODELS ARE EQUIPPED
WITH A PETCOCK THAT ALLOWS FOR
A HOSE TO BE ATTACHED
14