Westerbeke W-70GA User manual

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OPERATORS MANUAL
W-70GA MARINE
GASOLINE INE
FIRST EDITION
MARCH 2004
~r~ rWESTERBEKE
J WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
• MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEB SITE: WWW.WESTERBEKE.COM
A'A'A'A'
NMMA Member National Marine Manufacturers Association
- .......

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
-Nausea
-Headache
- Throbbing in Temples
- Muscular Twitching
- 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.
WARNING
Generators Produce CARBON MONOXIDE
Regular Maintenance Required
l5i5fJWESTERBEKE
Engl"...a...ttn
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
Marine diesel and gasoline 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 by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
toke the necessary precautions to protectyourself, your
personne~ andyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connectiollS
while engine is running, Dr 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 vessels AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessels AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Dr
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 Dr 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 Dr 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/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury Dr death!
• Follow re-fueling safety instructions. Keep the vessels
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 starting 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 offthe 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 servic-
ing. 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 ofleaks.
• 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-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow 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 off all 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
accumulation 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
bums
or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric 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
protection. 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/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.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation
of approved
detectors.
• For additional infonpation refer to ABYC T-22
(educational 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
systems. Exhaust sulfur causes rapid deterioration
of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners.
If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close orrestrict 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
symptoms
or signs of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
U

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back
long hair and 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 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 an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do 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 an engine should begin with a
thorough examination of
the American Boat and Yacht
Council's (ABYC) standards. These standards are a
combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
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 DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes
and standards. Follow their
recommendations
when installing your engine.
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
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
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
Strict 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 when the vessel is static or under various
operating conditions, 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 of24"
above the vessel's waterline. Failure to use a siphon-break when the exhaust mani-
fold injection port is at or below the load waterline will result in raw water damage
to the engine andpossibleflooding 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, install 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
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2 Engine Adjustments .... ....................................... 29
Introduction ......................................................... 3 Spark Plugs.....................................................29
Fuel, Engine Oil, and Engine Coolant...~ ............. 5
Instrument Panel ................................................. 6
Drive Belt Adjustment....................................29
Electric Choke ................................................30
I .. T .
gnltIon Imlng...............................................30
Preparations for Initial Start-Up ......................... 7 Valve Clearance Adjustment ..........................30
Starting/Stopping Procedure ............................... 8 Ignition Wires .................................................
31
Engine Break-in Procedure ................................. 9
The Daily Operation ......................................... .. 10
Alarms and Circuit Breaker ............................... 10
Engine Compression Test.............................. .31
Torquing the Cylinder Head Bolts ................. 31
Engine Troubleshooting .................................... 32
Troubleshooting Gauges.................................
35
Maintenance Schedule ...................................... ll
Transmission (ZF) ............................................. 36
Cooling System ............. ..................................... 13
Initial Operation..............................................36
Raw Water Intake Strainer..............................14 . Oil Cooler.......................................................36
Raw Water Pump............................................14 Control Cables ................................................37
Heat Exchanger ..............................................
15
Shaft Couplings ..............................................38
Thermostat......................................................
15
Specifications..................................................39
Fuel System ....................................................... 16
Fuel Lift Pump................................................16
Gasdenser........................................................
16
Changing Fluid...............................................40
Maintenance....................................................
40
Troubleshooting............................................. .41
Fuel Filter ....................................................... 16
Transmission (Borg Warner) ............................ .43
Engine Lubricating Oil ...................................... . 17
Changing the Engine Oil................................ 17
Oil Pressure .................................................... 18
Remote Oil Filter ......................... ...................... 19
Carburetor Adjustments ...... ............................. .20
Water Heater ..................................................... 21
DC Electrical System ........................ ................. 22
Alternator Troubleshooting ............................22
Dual Output Alternators ................................... .24
Troubleshooting..............................................25
Transmission Fluid .........................................43
Changing Fluid...............................................44
Maintenance....................................................45
Troubleshooting..............................................46
La dR """
y-up an ecommlsslonmg .......................... .48
E " S "f t"
ngme peci Ica Ions ........................... ............ 50
Tor S "f r que peci Ica Ions ....................................... 51
Standard Hardware ............................................ 52
Sealants and Lubricants..................................52
Standard and Metric Conversion Data ............. 53
W"" S h t"
iring c ema IC .............................................. 26
Suggested Spare Parts ...................................... 55
W"" D"
Iring lag ram .................................................. 27
Tachometers . ..................................................... 28
Idle Speed Adjustment....................................28
Engines & Generators
1

w- 70GA PARTS IDENTIFICATION
COOLANT FILLER PRESSURE CAP
FLAME ARRESTER/AIR FILTER
OIL FILL
RAW WATER PUMP
VACUUM ADVANCE UNIT
FRONT
OIL SUMP-------4- ... "ii;
FUEL
FILTER
COOLANT
PRESSURE CAP
HEAT EXCHANGER--k--...p!!J~ ....
20A CIRCUIT
BREAKER
TRANSMISSION·
TRANSMISS{ON - ..... "~. _
COUPLING
SHIFT LEVER
REAR
DISTRIBUTER
OIL DRAIN HOSE
FUEL FILTER
EXHAUST ELBOW
WATER INJECTED
STARTER MOTOR
DC ALTERNATOR
LEFT SIDE
FILL
PCV VALVE
FILTER
BURETOR
THERMOSTAT
HOUSING
FRONT
RAW WATER PUMP
FILTER
GAS DENSER
RIGHT SIDE
Engines & Generators
2
REAR

INTRODUCTION
This WESTERBEKE marine engine is a product of
WESTERBEKE'S long years ofexperience and advanced
technology. We take great pride in the superior durability
and dependable performance ofour engines.Thank
you for
selecting WESTERBEKE.
In order to get the full use and benefit from your engine,
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. Also, if you are planning to install
this equipment yourself, contact your WESTERBEKE dealer
for WES~RBEKE' S Installation Manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If you have not received a customer identification card
registering your warranty
60 days after submitting the warranty
registration
form, please contact the factory in writing with
model information, including the unit's serial number and
commission date.
I "WV'IWESTERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
Ser. #
PRODUCT SOFTWARE
Product software (tech 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 WARRANTIES OR
REPRESENTATIONS WITH RESPECT THERETO, INCLUDING
ACCURACY, TIMEUNESS OR COMPLETENESS THEREOF AND
WIU IN NO EVENT BE UABLE 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 also keep in mind the time
span between printings ofWESTERBEKE product software
and the unavoidable existence ofearlier WESTERBEKE
manuals. In summation, 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 ofWESTERBEKE or the supplier
in question
be consulted to determine the accuracy and currentness ofthe
product software being consulted
by the cUSlomer.
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 can also be found etched into the
engine near the top ofthe engine back plate.
The generator serial number is stamped on the left side of the
generator housing and on the flat surface above the rotary
carrier bearings.
Take the time to enter this information on the illustration of
the nameplate shown
below, as this will provide a quick
reference
when seeking technical information and/or
ordering repair
parts.
~2¥fii4;l:143=t
o 0
• MODEL SPEC AYO, ". ",A SER.NO..
Fill in the infomzation for your reference. ~
Engines & Generators
3

INTRODUCTION
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine model and serial numbers. In addition, include a
complete part description and part number for each part
needed (see the separately furnished Parts Catalog). Also
insist upon WESTERBEKE packaged parts because will
fit
or generic parts are frequently not made to the same
specifications as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of your engine,
critical information 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
the engine.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine
room.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain
your WESTERBEKE engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filter can be difficult to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
on-board inventory
of the proper WESTERBEKE parts.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE engine capable
of many
thousands
of hours of dependable service. However the
manufacturer cannot control how
or where the engine is
installed in the vessel
or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps to ensure long engine life:
• Proper engine installation and alignment.
• An efficient well-designed exhaust system thatincludes
an anti-siphon break to prevent water from entering the
engine.
• Changing the engine oil and oil jilters every 100
operating hours.
• Proper maintenance of all engine components according
to the maintenance schedule in this manuaL
• Use clean,jilteredunleadedfueL
• Winterize your engine according to the "lo.y-up and
Recommissioning" section in this manual.
UNDERSTANDING THE GASOLINE ENGINE
The. gasoline marine engine is in many ways similar to a
gasoline automobile engine.
The cylinders are vertical
in-line, and the engine's cylinder head has an overhead
camshaft which is chain-driven. The engine utilizes a solid-
state distributor which is horizontally mounted and camshaft-
driven. The engine incorporates a pressure type lubrication
system, and a fresh water-cooled engine block which is
thermostatically-controlled. To a large degree, the marine
engine requires the same preventive maintenance that is
required
of a gasoline automobile engine. The most
important factors to the engine's longevity are proper
ventilation, maintenance
of the fuel system, ignition system,
cooling system and the lubrication system.
Engines &Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Only use unleaded fuel with an octane
rating of 89 or higher. Leaded fuel will cause serious
harm to your engine and violate your warranty.
Care Of The Fuel Supply
Use only clean 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
unsatisfactory
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, Coast Guard approved
metal bowl type filterlwater separator between the fuel tank
and the engine.
ENGINE OIL
Use a heavy duty engine oil with an API classification of SJ.
Change the engine oil and filter after an initial 50 hours of
break-in operation, and every
100 hours ofoperation
thereafter.An
oil viscosity of SAE 15W-40 is recommended
for
this engine in all conditions.
A CAUTION: 00 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.
NOTE: The engine compartment should have a gasoline fume
detector/alarm properly installed and working.
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. It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antifreeze that contains supplemental cooling additives
(SCAs)
that keep the antifreeze chemically balanced, crucial to long
term protection.
The water
and antifreeze should be premixed before being
poured
into the cooling circuit.
NOTE: Use the new environmentally-friendly, long lasting,
antifreeze that is now available.
Aproper 50150 mixture as recommended will protect the
engine coolant to temperatures of -4O"F
COOLANT RECOVERY TANK
Acoolant recovery tank kit is supplied with each generator.
The purpose of this recovery tank is to allow for engine
coolant expansion and contraction during engine operation,
without
the loss ofcoolant and without introducing air into
the cooling system.
Engines & Generators
5

GASOLINE ENGINE INSTRUMENT PANEL
NOTE: Be certain to install the instrument panel in a location
that
is accessible and where the gauges can be continually
monitored
by the helmsman.
DESCRIPTION
The marine gasoline engine is equipped with an [optional]
key start instrument panel. This panel connects to the engine
wiring harness thru a 15 foot plug-in harness.
Included with the panel is an alarm buzzer. This alarm buzzer
will sound when the ignition key is turned on and should
silence when the engine has started and the oil pressure rises
above 5 psi. The installer is responsible for installing this
alarm buzzer in a dry location where
it will be audible to the
operator with the engine running.
NOTE: It is the responsibility of the installer to make certain
the alann wiring
is properly routed and supported to its
connections
on the engine.
GASOLINE ENGINE
INSTRUMENT PANEL
The following is a description of the panel components.
Tachometer -Registers revolutions per minute
of the engine
and measures the engines total elapsed time in hours and
111 0
hours. Refer to TACHOMETER for calibration.
Key switch -Turned to the 2 o'clock position [on], the key
switch energizes the panel. {Illuminates the gauges and
activates the start button.]
Prestart Button - A "push-to-start" rubber booted pushbutton
that is energized by the key switch. Pressing this button
activates the fuel lift pump.
Start Button -Identical to the prestart button, the start button,
when pressed, energizes the starter which cranks the engine.
Oil Pressure Gauge -Measures the engines oil pressure in
pounds per square inch. The alarm buzzer will sound
if the oil
pressure falls below 10 psi. This alarm will briefly sound when
the engine is first started prior to oil pressure being produced.
Voltage Gauge -Measures the voltage in the DC circuit [the
amount the battery is being charges 13V to 14V].
WaterTemperature Gauge -Indicates the temperature of
the engine coolant. If the coolant temperature reaches 210"F
[99°C], the alarm buzzer will sound a continuous signal.
NOTE: The water temperature gauge and oil temperature will
register
the last reading when the engine is shut down. The true
temperatures will register when the power is turned back on.
Engines &Generators
6

PREPARATIONS FOR INITIAL START-UP
PREST ART 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 specifications pages in this manualfor
fuel, oil and transmission fluid types and quantities.
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 notyet beenfilled with coolant,
refer to the COOliNG SYSTEM section of this manual
OIL FILL
EXHAUST MANIFOLD
D Visually examine the engine. Look for loose or missing
parts, disconnected wires, and unattached hoses. Check
the threaded connections and engine attachments.
D Examine the air inlet and outlet for air flow obstructions.
Good ventilation and an ample air supply are 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 prime the raw water intake
strainer. Inspect the raw water supply.
A CAUTION: Do not pull the dipstick when the
engine is running.
DIPSTIC
/IOILLEVEL
-----
-
-
Engines & Generators
7

STARTING • STOPPING PROCEDURE
STARTING PROCEDURE
1. Place the transmission in neutral and advance the throttle
control
to slightly open.
2. Tum the KEY SWITCH to the ON position (2 o'clock).
(If the panel
is energized, the gauges are on.)
3. Press the PREHEAT BUTTON, and hold for 5 seconds.
(The fuel lift pump is priming the engine fuel system.)
4. Release the PRESTART BUTTON and press the START
BUTTON. (The starter motor is cranking the engine).
5. Release the START BUTTON as the engine starts.
6. With the engine running, check the instruments for
proper oil pressure
and battery charging voltage. The
water temperature will rise slowly
and then stabilize
when the thermostat opens.
NOTE: Never attempt to engage the starter while the
engine is running.
It is important to closely monitorthe panel gauges.
Become aware of the normal engine readings andtake
immediate
action if these readings start to vary.
FAILURE TO START
If the engine fails to start when the start button is pressed for
5 seconds, wait for at least 30 seconds and repeat the starting
procedure. Make certain the transmission control is in the
neutral position as some engines have a neutral safety switch
to prevent starting in gear.
Never run the starter for more then 30 seconds. If the engine
fails to start, refer to the TROUBLESHOOTING CHART in
this manual.
A CAUTION: Prolonged cranking intervals without
the engine starling can result in the engine exhaust
system filling with 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 not a
warrantable issue; the owner/operator should keep this
in mind.
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, then shut the
engine down by turning off the key switch.
NOTE: Make certain this key switch is in the OFF position
(12 o'clock). If the key switch is left ON, the energized
instrumentpanel will
put a drain on the battery. The alarm
will pulsate warning that the key is still in the
ON position.
Starting Under Cold Conditions
Make certain the lubricating oil is appropriate for the
prevailing temperature. Use oil with an API Specification
of SJ or better, SAE 30, lOW-30, or 15W-40.
Engines & Generators
8

ENGINE BREAK-IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum of one
hour oftest 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. 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 ofthe engine.
Perform this conditioning carefully, keeping in mind the
following:
1. Start the engine according to the STARTING
PROCEDURE 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
0P
(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 acold 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
9

THE DAILY OPERATION
CHECK LIST
Follow this check list each day before starting your engine.
D Visually inspect the engine for fuel, oil, or water leaks.
D Check the oil level (dipstick).
D Check the coolant level in the coolant recovery tank.
Periodically check the manifold coolant level.
D Check the transmission fluid level.
D Check your fuel supply.
D Look for clean fuel in the fuel filter/water separator
transparent bowl.
D Check for loose wires at the alternator and make sure its
mounting is secure.
D Check the starting batteries (weekly).
D Check drive belts for wear and proper tension (weekly).
D Visually inspect the raw water pump for leakage.
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 SWITCH to the ON position (2 o'clock).
[The panel is energized, gauges are lit}.
3. Depress the PRESTART BUTTON, hold for 5 seconds.
[The fuel lift pump is priming the engine).
4. Release the PRESTART BUTTON and press the START
BUTTON. [The start motor is cranking the engine}.
5. Release the START BUTTON as the engine starts.
6. With the engine running, check the instruments for
proper oil pressure and battery charging voltage. The
water temperature will rise slowly until the thermostat
opens.
NOTE: Never attempt to engage the starter while the
engine
is running.
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. Then shut the
engine down by turning offthe key switch at the same time
put the throttle at full open
..
NOTE: Make certain this key switch is in the OFF
position(120'clock). If the key switch is left ON, the
energized instrument panel will
put a drain on the battery.
The engine pulse alarm will sound as a reminder that the key
switch has been left
on.
ALARMS AND CIRCUIT BREAKER
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 open 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.
LOW OIL PRESSURE ALARM SWITCH
Allow oil pressure alarm switch is located offthe engine's oil
gallery. This switch's sensor monitors the engine's oil pres-
sure. Should the engine's oil pressure fall to 5 -10 psi
(0.4 -0.7 kg!cm2), this switch will activate a pulsating alarm.
'1////"
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
210°F (99°C).
COOLANT
TEMPERATURE
SWITCH
;". AIR BLEED
~ ~ PETCOCK
/"
Engines & Generators
10

MAINTENANCE SCHEDULE
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.
NOTE: Many o/the/ollowing maintenancejobs are simple but others are
more difficult andmay require the expert knowledge
0/ a service mechanic.
CHECK
HOURS OF OPERATION
SCHEDULED
EACH EXPLANATION OF SCHEDULED
MAINTENANCE DAY
50
100 250
500 750 1000 1250 MAINTENANCE
Fuel Supply
0
Unleaded gasoline with octane rating of 89 or
higher.
FueljWater Separator
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
Engine Oil Level
0
Oil level should indicate between FULL and LOW on
dipstick.
Coolant Level
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Drive Belts
0
Inspect for proper tension (3/8' to 1/2" deflection)
weekly
and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
0
NOTE: Please keep engine surface clean. Dirt
Check for fuel, oil and water leaks. Inspect wiring
and oil will inhibit the engine's ability to
and electrical connections. Keep bolts & nuts tight.
remain cool.
Check for loose belt tension.
Spark Plugs
0 0 0 0 0 0
Check gap; inspect for burning and corrosion.
Generator (if applicable)
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing - see GENERATOR INFORMATION
(if applicable) for addition information.
Fuel Filter (Lift Pump)
0 0 0 0 0 0
Inspect for fuel leaks. Check wire connections.
Starting Batteries
0 0
Every 50 operating hours check electrolyte levels
(and House Batteries) weekly
and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil
0 0 0 0 0 0 0
Initial engine oil & filter change at 50 hrs., then
change both every 100 hours.
Re-torque Cylinder Head
0 0 0
Retorque at 50 hrs., them every 500 hours.
* Adjust the Valve
0 0 0
Initial adjustment at 50 hrs., then every 500 hrs.
Clearances
Air Screen (Flame Arrester)
0
Clean at 50 hours, then every 100 hours.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check siphon brake operation. Check the
exhaust elbow for carbon and/or corrosion buildup
on inside passages; clean and replace as necessary.
Check that all connections are tight.
Engine Hoses
0 0 0 0 0 0
Hose should be hard & tight. Replace if soft or
spongy. Check and tighten all hose clamps.
Inlet Fuel Filter
0 0 0 0 0 0
Replace every 200 operating hours.
continued
Engines & Generators
11

MAINTENANCE SCHEDULE
NOTE: Use the engine hourmeter gauge to log your engine hours or record your
engine
hours by running time.
CHECK
HOURS OF OPERATION
SCHEDULED
EACH
EXPLANATION OF SCHEDULED
MAINTENANCE
DAY 50 100
250
500 750
1000 1250
MAINTENANCE
Heat Exchanger
D D D D D D D
Clean or replace anode. Open heat exchanger end
cap and clean out debris. remove every 1000 hours
for professional cleaning and pressure testing.
Raw Water Pump
D D D
Remove the pump cover and inspect the impeller
for wear, replace if needed. Also replace the gasket.
Lubricate both when re-assembling.
Coolant System
D
Drain, flush, and refill cooling system with
appropriate antifreeze mix.
*Starter Motor
D D
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the starter motor
pinion drive.
Distributor
D D
Check ignition timing. Check condition of
distributor cap and rotor.
*Engine Cylinder
D D
Incorrect valve clearance will result in poor engine
Compression and
performance. Check compression pressure and
Valve Clearance
timing and adjust valve clearances.
*Exhaust Elbow
D
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteriorated.
WARNING: A defective exhaust elbow can cause
carbon monoxide leakage.
Lubricate Panel Key
D
At first 100 hours. Then each year at winterizing or
Switch with "Lockeze"
once a season.
Carburetor Filter
D D D D D
Clean at first 50 hours and every 250 hours.
Screen
Transmission Fluid
Refer to the TRANSMISSION section.
Transmission Damper Plate
D
Seperate the transmission from the engine and
inspect the damper plate, look for wear or broken
springs, replace if necessary.
Transmission Cooler
D D
Inspect for leaks and condition of the casting,
replace if needed.
Engine Mounts/lsolators
D
Inspect engine mountinglisolators. If upper cap is
contacting the base replace the mount.
*WESTERBEKE recommends this service be performed by an authorized mechanic.
Engines & Generators
12

COOLING SYSTEM
DESCRIPTION
Westerbeke marine engines are designed and equipped for
fresh water cooling. Heat produced in the engine by combus-
tion and friction is transferred to fresh water coolant which
circulates throughout the engine. TIris 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 ofa heat
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes ofthe heat exchanger while
fresh water coolant flows around the tubes; engine heat trans-
ferred 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: Refer to the ENGINE COOlANTsectionfor the
recommended antifreeze
and watermixture to be used as the
fresh water
coolant.
Fresh water coolant is pumped through the engine by a circu-
lating
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 ofthe 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 mani-
fold from overheating). As the engine warms up, the thermo-
stat
gradually opens, allowing full flow ofthe engine's
coolant
to flow unrestricted to the external portion of the
cooling system.
~oolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-
cant
loss ofcoolant and without introducing air into the cool-
ing
system. TIris tank should be located at or above the
engine manifold
level and should be easily accessible.
NOTE: Periodically check the condition of the manifoldpres-
sure
cap. Ensure that the upper and lower rubber seals are in
good condition andcheck 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 failures 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.
NOTE: The drain petcock on the heat exchanger should also
be used to help drain engine coolant.
A WARNING: Beware of the hot engine coolant.
Wear protective gloves.
Refilling the Coolant
After replacing the engine block drain plug, close the heat
exchanger's coolant petcock. Then run the engine at idle and
slowly pour clean, premixed coolant into the manifold.
NOTE: Open the air-bleedpetcock on the heat exchanger.
When a steadyflow of coolantappears at the petcock, close
the petcock andfill the system until the manifold remains full.
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the manifold pres-
sure cap.
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfWay between LOW and MAX and replace
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank.
After checking for leaks, stop the engine and allow it to cool.
Coolant should draw back into the cooling system as the
engine cools down. Add coolant to the recovery tank if
needed. Clean up any spilled coolant.
COOLANT EXPANSION
COOLANT RETRACTION
Engines &Generators
13

COOLING SYSTEM
RAW WATER INTAKE STRAINER
NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.
A clean raw water intake strainer is a vital component of the
engine's cooling system. Include a visual inspection
of this
strainer when making your periodic engine check. The water
in the glass should be clear.
Perform the following maintenance after every 100 hours of
operation:
1. Close the raw water seacock.
2. Remove and clean the strainer filter.
3. Clean the glass.
4. Replace the sealing washer
if necessary.
5. Reassemble and install the strainer.
6. Open the seacock.
7. Run the engine and check for leaks.
NOTE: Alsofollow the above procedure after having run hard
aground.
If the engine temperature gauge ever shows a higher than
normal reading, the cause may
be that silt, leaves or grass
may have been caught up in the strainer, slowing the flow
of
raw water through the cooling system
RAW WATER INTAKE STRAINER
TYPICAL [OWNER INSTALLED]
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 shouldthis p"ump" be run dry. There should
always be a spare impeller and impeller cover gasket aboard
(an impeller kit). Raw water pump impeller failures occur
when lubricant (raw water) is not present during engine
operation. Such failures are not warrantable, and operators
are cautioned to make sure raw water flow is present at start-
up. The raw water pump should be inspected periodically for
broken or tom impeller blades. See MAINTENANCE
SCHEDULE.
NOTE: Should afailure occur with the pumpsinternal parts
(seals and bearings), it may be more cost efficient
to pur-
chase a new pump and rebuild
the original pump as a spare.
Changing the Raw Water Pump Impeller
Close the raw water intake valve. Remove the pump cover
and, with the aid
of two small screwdrivers, carefully pry the
impeller out
of the pump. Install the new impeller and gasket.
Move the blades to conform to the curved cam plate and
push the impeller into the pump's housing. When assem-
bling, apply a thin coating oflubricant to the impeller and
gasket. Open the
raw waterintake valve.
Run the engine and check for leaks around the pump. Also
check for water discharge at the stem tube. Absence
of water
flow indicates the pump has not primed itselfproperly.
RAW WATER PUMP
INCOMING
RAW WATER
A CAUTION: If any of the vanes have broken off the
impeller, they must be located to prevent blockage in
the cooling circuit. They often can be found in the heat
exchanger
Engines & Generators
14