Westerbeke W-70GA Operator's Manual

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OPERATORS

W-70GA

MARINE

MANUAL

GASOLINE

INE

~r~

FIRST EDITION

MARCH 2004

rWESTERBEKE

J

WESTERBEKE

•

MYLES

WEB

SITE:

A'A'A'A'

NMMA

-

.......

CORPORATION • 150

STANDISH

INDUSTRIAL

WWW.WESTERBEKE.COM

Member

National

PARK·

Marine

JOHN

HANCOCK

TAUNTON

Manufacturers

ROAD

MA

02780

Association

A

WARNING

Exhaust
colorless
unconsciousness
exposure

-Dizziness

-Nausea

-Headache

-

IF
GET
seek
until

WARNING

Generators

Regular

gasses

gas.
can

Weakness

YOU

OR

ANYONE

OUT

INTO
medical
it

has

been

Produce

CARBON

Maintenance

l5i5fJWESTERBEKE

Engl"...a...ttn

contain

Carbon

and

include:

and

Sleepiness

ELSE

THE

FRESH

attention.

inspected

MONOXIDE

Required

Carbon

Monoxide

death.

EXPERIENCE

Shut

Monoxide,

is

poisonous

Symptoms

-

-

-

-Inability

AIR

IMMEDIATELY.
down

and

repaired.

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE
CARBON
living/sleeping

They
obtainable

of

Throbbing

Muscular

Vomiting

ANY

the

unit

DECAL

near

MONOXIDE

are

inexpensive

at

an

odorless

and

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

symptoms

and

do

is

provided

and

should

your

engine

also

recommends

DETECTORS

quarters

and

your

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

by

be

fixed

to

or

generator.

installing
in

the

of

your

vessel.

easily

marine

store.

a

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

65

and

of

State

WARNING

gasoline

its

birth

engine

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety manual
caused

by

failure

precautions.

toke the

personne~

The

following safety instructions

Know

necessary

and your

the American Boat

PREVENT

A

while

power.

• Do not operate this machinery without electrical
enclosures and covers in place.

• Shut off electrical power before accessing electrical
equipment.

• Use insulated mats whenever working on electrical
equipment.

• Make sure your clothing and skin are
(particularly shoes) when handling electrical equipment.

• Remove wristwatch and all jewelry when working on
electrical equipment.

• Do not connect utility shore power to vessels
circuits, except through a ship-to-shore double throw
transfer switch. Damage
result

• Electrical shock results from handling a charged capaci­tor.

PREVENT

A

exhaust

very

• Always check the engine coolant level at the coolant

recovery tank.

A

• In case
before touching the engine or checking the coolant.

ELECTRIC

WARNING:

engine

is

Lethal

voltage

if

this procedure

Discharge capacitor by shorting terminals together.

BURNS -HOT

WARNING:

system

hot!

WARNING:

of

an engine overheat, allow the engine

carefully.

to

follow fundamental rules

when

dangerous

precautions

Most

accidents

conditions exist and

to

protect yourself, your

machinery.

are

in

compliance

and

Yacht

Council

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

Dr

when

is

present

to

vessels

is

not followed.

connected

at

these

dry,

AC

ENGINE

Do

not

touch

hot

engine

components. A running

Steam

can

cause

injury

are

and

with

standards.

connectiollS

to

shore

connections!

not damp

AC

generator may

parts

Dr

engine

gets

Dr

death!

to

cool

PREVENT

A

• Prevent flash
sparks to occur near
pump, or other potential sources
vapors. Use a suitable container
removing the fuel line, carburetor, or fuel

• Do not operate with a Coast Guard Approved
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
the fuel system. Keep the compartment and the
engine/generator clean and free
chances of

• Be aware - diesel fuel will burn.

PREVENT

A

injury

• 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
when
ventilated area away from spark-producing equipment
and out

• Do not

• Shut off the
the fuel system.
spill.
sources
ing.
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

properly maintained. Be familiar with its proper
Extinguishers rated ABC by the
for all applications encountered in this environment.

BURNS -FIRE

WARNING:

Fire.can

fires.

fire.

Wipe up all spilled fuel and engine

cause

injury

Dr

Do not smoke or permit

the.

carburetor, fuel line,

of

spilled

to

catch

of

debris to minimize the

death!

flames

filter,

fuel

all

fuel when

filters.

flame

to

occur near

or fuel

BURNS -EXPLOSION

WARNING:

Dr

death!

fuel

handling and storing fuels. Store

fill

DO

Ensure proper ventilation exists when servicing the

Explosions

vapors

are

highly explosive. Use extreme

of

the reach
the fuel tank(s) while the engine

fuel

service valve

Take

NOT allow any smoking, open

of

fire

near

the

fire

extinguisher

from

fuel

of

children.

at

the engine

care in catching any fuel that might

fuel

system

or engine

is

installed nearby and is

NFPA

vapors

can

fuel

in a well-

is

running.

when

flames,

when

are appropriate

cause

care

servicing
or other

servic-

use.

or
fuel

oil.

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

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
starting.

• Make certain all covers, guards, and hatches are
re-installed before starting the engine.

BATTERY

A

WARNING:

or

death!

•

Do

not smoke

being serviced. Lead acid batteries emit hydrogen, a

highly explosive gas, which can be ignited by electrical
arcing
equipment in the vicinity to prevent electrical arcing
during servicing.

• Never connect the negative
positive (+) connection terminal
Do

not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases
Ventilate any compartment containing batteries to prevent
accumulation
disturb the battery charger connections while the battery
is being charged.

• Avoid contacting the terminals with tools, etc., to prevent
bums
wristwatch, rings, and any other jewelry before handling
the battery.

• Always turn the battery charger
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.

BATTERY

A

WARNING:

severe

STARTING

Accidental

starting

can

cause

of

the engine before

EXPLOSION

Battery

or

or

by lit tobacco products. Shut

of

or

sparks that could cause an explosion. Remove

explosion

allow an open flame near the battery

explosive gases.

can

cause

off

(-)

battery cable to the

of

the starter solenoid.

To

avoid sparks, do not

off

before disconnecting

injury

all electrical

or

fuel vapors.

ACID

injury

Sulfuric

or

death!

acid

in

batteries

can

injury

cause

TOXIC

• Ensure that the exhaust system is adequate to expel gases

• Be sure the unit and its surroundings are well ventilated.

• Do not run the generator set or engine unless the boat is

• For additional infonpation refer to ABYC T-22

•

•

• Although diesel engine exhaust gases are not as toxic as

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust
manifolds/water-injected elbow is securely attached.

Run blowers when running the generator set

equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation
detectors.

(educational information

A

WARNING:

odorless
nausea

AVOID

gas.

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
copper tubing resulting in exhaust/water leakage.

Do

not install exhaust outlet where exhaust can be drawn
through portholes, vents, or
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the

of

flow

exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some
symptoms
poisoning are:

Vomiting Inability to think coherently
Dizziness

Nausea

exhaust. Avoid overloading the craft.

Headache

MOVING

GASES

Carbon

monoxide

on

Carbon Monoxide).

Carbon

Inhalation

or

signs

Throbbing in temples
Muscular twitching
Weakness and sleepiness

monoxide

produces

air conditioners.

of

carbon monoxide inhalation or

PARTS

(CO)

is a deadly

of

(CO)

is

flu-like

or

engine.

approved

an

invisible

symptoms,

If

the engine

of

the

gas!

of

• When servicing the battery
level, wear rubber gloves, a rubber apron, and eye

protection. Batteries contain sulfuric acid which is

destructive.
off at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.

If

it comes in contact with your skin, wash it

or

checking the electrolyte

A

WARNING:

or

death!

•

Do

not service the engine while it is running.
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

Rotating

parts

can

cause

injury

If

a

SAFETY

•

Do

not wear loose clothing or jewelry
equipment; tie back
jackets, shirts, sleeves, rings, necklaces or bracelets that

be caught

could

•

Make

sure all attaching hardware

Keep

protective shields and guards

places at

•

Do
the

•

Stay
when
be

HAZARDOUS

A

all

times.

not check

engine

is

clear of

the

engine

caught

in

NOISE

WARNING:

long

hair

and

in

moving

fluid

levels or

operating.
the

drive shaft and

is

running; hair

these rotating parts.

High

noise

parts.

the

levels

loss!

• Never operate

•

Do

not

removed.

•

Do

not

open.

A

WARNING:

mentally

an

run

an

engine

run

engines for

Do

or

physically

engine without

with

the

air intake (silencer)

long

periods with their enclosures

not

work

on

incapacitated

when

servicing

avoid wearing loose

is

properly

in

drive belts tension

the

transmission coupling

and

clothing

can

its

muffler

machinery

by

tightened.

their respective

can

cause

hearing

installed.

when

fatigue!

INSTRUCTIONS

while

easily

you

ABYC,

INSTALLING

Read
for safety codes
recommendations

ABYC (American Boat

"Safety Standards for Small Craft"
Order

NFPA

"Fire Protection Standard for Motor Craft"
Order

USCG

"USCG 33CFR183"
Order

are

NFPA

the

following

from:

ABYC

3069

Solomon's Island

Edgewater,

(National Fire Protection Association)

from:

NFPA

11

Tracy

Avon

Industrial Park

Avon,

MA

(United States Coast

from:

U.S.

Government Printing

Washington,

AND

DIESEL

ABYC,

and

when

MD

21037

Drive

02322

D.C.

USCG

PUBLICATIONS

ENGINES

NFPA

and

USCG

standards. Follow their

installing your
and

Yacht

Rd.

Guard)

Office

20404

engine.

Council)

FOR

publications

OPERATORS

Many

of

in

your

notes

to
carefully,
procedures.

GASOLINE

Preparations
thorough examination of

Council's
combination of

Sections of

H-2
P-l Exhaust Systems
P-4 Inboard Engines

E-9

All

installations must comply

Regulations

MANUAL

the

preceding safety

Operators

highlight critical information. Read

maintain your equipment,

(ABYC)

Manual

ENGINE

to

the

Ventilation

DC

(FCR).

AND

install

an

standards. These standards

sources

ABYC

standards of particular interest

Electrical Systems

tips

and

warnings

along with other cautions

your

and

follow

GENERATOR

engine should begin

the

American Boat

including the

with

the

INSTALLATIONS

and

USCG

and

Federal

are

all

with

are

Code

repeated

and

manual

safety

a

Yacht

a

the

NFPA.

are:

of

Engines & Generators

iii

INSTALLATION

When installing WESTERBEKE engines
attention

CODES

Strict federal regulations,
when

be paid

AND

installing engines and generators

to

the following information:

REGULATIONS

ABYC

guidelines, and safety codes must be complied

and

generators it

in

a marine environment.

is

important that strict

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow
or

will

be

below the vessel's waterline
operating conditions, provisions must
water supply hose
above the vessel's waterline. Failure

fold injection port

to

the engine and possible flooding

If

you

have

to

the vessel's waterline under

to

the exhaust

is

at or

below

any

doubt about the position of

the

siphon-break.

NOTE:

A siphon-break
operation.
engine

EXHAUST

The
prevent water
of

the

Failure

damage.

SYSTEM

exhaust hose must

vessels hull.

from

requires

to

properly maintain a siphon-break

Consult

be

entering

periodic inspection and cleaning

the

siphon-break manufacturer for proper maintenance.

certified

the

when

the

vessel

is

static or under various

be

made

to

install a siphon-break

elbow.

This hose must be looped a minimum of 24"

to

use

a siphon-break

the load

exhaust under

waterline

of

the

boat.

the

water-injected exhaust elbow relative

vessel's various operating conditions, install a

for

marine

use.

The

any

sea conditions

when

will

result

can

result

system must

the exhaust mani-

in

raw

water

to

ensure

in

catastrophic

be

designed

and

at

is

in

the raw

proper

any

with

close

to

damage

to

angle

AVAILABLE
YOUR

WESTERBEKE

DEALER

FROM

A

detailed
diesel,
dealer.

40

page

engines

Marine

and

generators,

Installation

is

available

Engines & Generators

Manual

from

iv

covering

your

WESTERBEKE

gasoline

and

TABLE

Parts

Identification
Introduction
Fuel,

Engine
Instrument
Preparations

.........................................................

Oil,

Panel

for
Starting/Stopping
Engine
The
Alarms

Break-in

Daily

and

Operation

Circuit
Maintenance
Cooling

Raw Water Intake Strainer.. ............................ 14

Raw Water

Heat Exchanger ..............................................

Thermostat ......................................................

Fuel

Fuel Lift

Gasdenser ........................................................

Fuel Filter .......................................................

Engine

Changing the Engine Oil ................................

Oil Pressure ....................................................

Remote
Carburetor
Water
DC

Alternator Troubleshooting ............................ 22

Dual

Troubleshooting .............................................. 25

W""

W""

System

Pump ............................................ 14

System

.......................................................

Pump ................................................ 16

Lubricating

Oil

Filter

Adjustments

Heater

Electrical

Output

iring c ema
Iring

Alternators

S h

D"

lag

ram

Tachometers ......................................................

Idle Speed Adjustment.. .................................. 28

.............................................

and

Engine

Coolant...~

.............

.................................................

Initial

Procedure

Schedule

.............

Start-Up

Procedure

.........................

...............................

.................................

.........................................

Breaker

...............................

......................................

.....................................

Oil

......................................

.........................

......

......................

.............................

..

.....................................................

System

........................

.................

...................................

t"

IC

..............................................

..................................................

OF

CONTENTS

2

3

5
6

7

8

9

10
10

ll

13

15
15

16

16
16

.

17
17
18

19

.20

21
22

Engine

Spark Plugs ..................................................... 29

Drive Belt Adjustment. ................................... 29

Electric Choke ................................................

I

..

gnltIon Imlng ............................................... 30

Valve Clearance Adjustment ..........................

Ignition Wires .................................................

Engine Compression Test ..............................

Torquing the Cylinder Head Bolts .................

Engine

Troubleshooting Gauges .................................

Transmission

Initial Operation .............................................. 36

Cooler ....................................................... 36

Oil

.

Control Cables ................................................ 37

Shaft Couplings .............................................. 38

Specifications .................................................. 39

Changing Fluid ............................................. ..40

Maintenance ....................................................

Troubleshooting .............................................

Transmission

Transmission Fluid ........................................ .43

Changing Fluid .............................................. .44

Maintenance .................................................... 45

Troubleshooting ............................................. .46

La

y-up

E " S

ngme

Tor

que

Standard

. 24

Sealants and Lubricants .................................. 52

Standard

26

Suggested

27

28

Adjustments

T .

Troubleshooting

d R

an

ecommlsslonmg

"f

peci

S

"f

peci

Hardware
and

Spare

....

.......................................

....................................

(ZF)

.............................................

(Borg

Warner)

"""

t"

Ica

Ions

...........................

r

Ica

Ions

.......................................

............................................

Metric

Conversion

Parts

......................................

............................

..........................

............

Data

.............

29

30

30
31

.31

31
32
35

36

40

.41
.43

.48

50

51
52

53

55

Engines & Generators

1

w-

70GA

PARTS

IDENTIFICATION

FLAME

RAW

WATER

VACUUM

ARRESTER/AIR

PUMP

ADVANCE

UNIT

FRONT

FILTER

OIL

FILL

OIL

SUMP-------4-

COOLANT

...

FILLER

"ii;

PRESSURE

CAP

FUEL

FILTER

DC

ALTERNATOR

STARTER

EXHAUST
WATER

MOTOR

LEFT

ELBOW

INJECTED

REAR

SIDE

COOLANT

FUEL
FILTER

HEAT

EXCHANGER--k--...p!!J~

20A

CIRCUIT

BREAKER

TRANSMISSION·

TRANSMISS{ON -.....

COUPLING

PRESSURE

"~.

_

CAP

....

DISTRIBUTER

FILL

PCV

FILTER

VALVE

GAS

DENSER

BURETOR

THERMOSTAT
HOUSING

FRONT

RAW

WATER

FILTER

PUMP

SHIFT

LEVER

REAR

OIL

DRAIN

HOSE

Engines & Generators

2

RIGHT

SIDE

INTRODUCTION

This WESTERBEKE marine engine
WESTERBEKE'S long years of experience and advanced
technology.
and dependable performance of our engines.Thank
selecting WESTERBEKE.

In

order

is

it
This
manual carefully and observe
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer for assistance.

This
provided and a Technical Manual
WESTERBEKE
this

equipment yourself, contact your WESTERBEKE dealer

for

WES~RBEKE'

WARRANTY

Your
folder.

registering your warranty

registration
model information, including
commission

I

We

take

great pride

to

get

the

full

use and benefit from your engine,

important that

manual

is

your Operators Manual. A

you

operate and maintain it

is

designed

dealer.

to

Also,

S Installation Manual.

help

PROCEDURES

WESTERBEKE

If

you

have

form,

date.

Warranty

not

received a customer identification card

60

days

please contact

"WV'IWESTERBEKE

is

a product of

in

the

superior durability

you

do

this. Please read this

all

the safety precautions

Parts

Catalog

is

available

if

you

are

is

included

after submitting

the

factory

the

unit's serial number

from

planning

in

in

you

correctly.

is

also

your

to

install

a separate

the

warranty

writing

with

and

for

I Engines & Generators

Customer Identification

WESTERBEKE OWNER

MAIN STREET
HOMETOWN, USA

Model
Expires

Ser.

#

WESTERBEKE
OF

SUCH
REPRESENTATIONS
ACCURACY,
WIU

IN

INJURY

THE

FURNISHING

WESTERBEKE

span

between printings of WESTERBEKE product software

and

the
manuals.
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must
sively

as

not

only
representatives of WESTERBEKE or the supplier
be

consulted

product software being consulted

SERIAL

The engine's model number and serial number
on

a nameplate mounted

The

engine's serial number

engine near
The

generator serial number
generator housing and
carrier bearings.

Take

the
the nameplate shown
reference
ordering repair

CANNOT

SOFTWARE,

TIMEUNESS

NO

EVENT

INCURRED

unavoidable existence of earlier WESTERBEKE

In

summation, product software provided

the

definitive authority

makes

to

NUMBER

the

time

to

when

BE

RESPONSIBLE

MAKES

WITH

BE
IN

CONNECTION

OR

USE

customers

not

good sense but

determine the accuracy

NO

RESPECT

OR

COMPLETENESS

UABLE

FOR

OF

SUCH

should

and cannot

on

is

FOR

THE

WARRANTIES

THERETO,

ANY

WITH

SOFTWARE.

also

keep

be

the

imperative that appropriate

by

the

OR

INCLUDING

THEREOF

TYPE

OF

DAMAGE

OR

ARISING

in

mind

relied

upon

respective product.

and

currentness of the

cUSlomer.

LOCATION

are

on

the side of

can

top

of the engine back

is

stamped

on

the

flat surface above

enter this information

below,

as

this

seeking technical information and/or

parts.

also

the

engine's

be

found

plate.

on

the

on

the

will

provide a quick

etched

left side of

the

illustration of

CONTENT

AND

OUT

the

with
exclu-

in

question

located

manifold.

into

rotary

OR
OF

time

It

the

the

~2¥fii4;l:143=t

o 0

• MODEL

SPEC

AYO,

".

",A

SER.NO..

PRODUCT

Product software
catalogs) provided
are

not

SOFTWARE

(tech

from

within

WESTERBEKE'S

data,

parts

sources other

lists, manuals, brochures
CONTROL.

than

WESTERBEKE

Fill

in

the

and

Engines & Generators

3

infomzation for your

reference.

~

INTRODUCTION

ORDERING

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
or generic parts are frequently not made to the same
specifications as original equipment.

NOTES,

As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
critical information will be highlighted by
CAUTIONS,

NOTE:

A

observed,

the

A

followed,

NOTE:

by WESTERBEKE. Affix this decal in a visable location in
the engine

SPARES

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

PARTS

will

fit

CAUTIONS

and WARNINGS. An explanation follows:

An operating procedure essential

CAUTION:

can

AND

Procedures,

result

in

the

WARNINGS

NOTES,

to

note.

which

if

not

damage

or

destruction

of

your engine,

strictly

of

engine.

WARNING:

can

A carbon monoxide warning decal has been provided

room.

AND

Procedures,

result

in

personal

which

injury

if

ACCESSORIES

of

the proper WESTERBEKE parts.

not

or

loss

properly

of

life.

PROTECTING

Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE engine capable

thousands
manufacturer cannot control how
installed in the vessel
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

•

An

efficient well-designed

an

anti-siphon break to

engine.

• Changing the engine

operating hours.

• Proper maintenance

to the maintenance schedule in this manuaL

• Use clean,jiltered unleadedfueL

• Winterize

Recommissioning" section in this manual.

UNDERSTANDING

The. gasoline marine engine is in many ways similar to a
gasoline automobile engine.
in-line, and the engine's cylinder head has an overhead
camshaft which is chain-driven. The engine utilizes a solid­state distributor which is horizontally mounted and camshaft­driven. 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
important factors to the engine's longevity are proper
ventilation, maintenance

cooling system and the lubrication system.

YOUR

INVESTMENT

of

hours

of

dependable service. However the

or

where the engine is

or

the manner in which the unit is

and

alignment.

exhaust

prevent

oil

and

of

all engine components according

your

engine according to the "lo.y-up

THE

GASOLINE

The

of

a gasoline automobile engine. The most

of

the fuel system, ignition system,

system that includes

water

from

oil

jilters every 100

ENGINE

cylinders are vertical

of

many

entering the

and

Engines & Generators

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

rating

of

harm

to

your

Care

Of

The

Use

only clean

your

fuel

injection pump
particles
these
and
unsatisfactory
facilities.
engine's
advisable:

Purchase a well-known brand of
Install

metal
and

ENGINE

Use a heavy
Change
break-in operation, and every
thereafter.An
for

which

finely

keep

it

To

daily

and

bowl type filterlwater separator between

the

engine.

OIL

the

this

engine

Only

use

unleaded

89

or

higher.

Leaded

engine

and

violate

Fuel

Supply

fuel!

The clearance of

is

very

might pass through

finished

clean.

regularly service a good, Coast Guard approved

engine

parts.

It

is

important

The best

by

careless handling or improper storage

assure

use

is

duty

engine oil with

oil

oil

viscosity of

in

all

fuel

that

the

fuel

clean

and

and

filter

conditions.

can

pure,

100

SAE

fuel

with

an

octane

fuel

will

cause

serious

your

warranty.

the

components

critical; invisible dirt

the

filter

can

damage

to

buy clean

be

rendered

going into

fuel.

an

after

hours of operation

15W-40

the

tank for

the following practice

the

fuel

API

classification of

an

initial

50

hours

is

recommended

in

fuel,

your

tank

of

SJ.

is

ENGINE

WESTERBEKE
50%
that can corrode internal engine surfaces.

The antifreeze performs double
to
the
cooling circuit
antifreeze that contains supplemental cooling additives
that
term

The water
poured

NOTE:

antifreeze that

A proper
engine coolant

COOLANT

A coolant recovery tank kit

The purpose of

coolant expansion
without
the

COOLANT

recommends a mixture of

distilled

run

engine

keep

protection.

water.

at proper temperatures

to

the

coolant. It

from

the

antifreeze chemically balanced, crucial

and

antifreeze should be premixed before being

into

the

cooling circuit.

Use

the

new environmentally-friendly,
is

now available.

50150

mixture

to

temperatures of

RECOVERY

this

and

the

loss of coolant and without introducing air

cooling

system.

Distilled water

also

rust and corrosion.

as

recommended

is

duty.

by

transferring heat
lubricates

-4O"F

TANK

is

supplied

recovery tank

contraction

is

during

50%

free

from

It allows

to

the

and

Use

a good quality

long

will

protect

with

each

allow

for

engine operation,

antifreeze

the

chemicals

engine

away

protects

lasting,

generator.

engine

from
the

(SCAs)

to

long

the

into

and

A

CAUTION:

engine

oil
additives
to

produce

NOTE:

The

detector/alarm properly installed and

00

not

allow

two

to

mix.

Each

brand

contains

of

different

properties

engine

brands

could

harmful

compartment should have a gasoline fume

to

your

or

more

its

react

engine.

working.

brands

own

additives;

in

the

mixture

of

Engines & Generators

5

NOTE:

Be

that

is

accessible

monitored

certain

by

the

to

install

and

where

helmsman.

GASOLINE

the

instrument panel

the

gauges

can

ENGINE

in

a location

be

continually

DESCRIPTION

The

marine gasoline engine is equipped with an [optional]

key start instrument panel. This panel connects to the engine
wiring harness thru a

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
operator with the engine running.

NOTE:

It

is

the
the alann wiring
connections

on

15

foot plug-in harness.

it

will

responsibility

is

properly routed and supported

the

engine.

of

the

installer

be

audible to the

to

make certain

to

its

INSTRUMENT

The following is a description
Tachometer -

and measures the engines total elapsed time in hours and
hours. Refer to

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

that is energized by the key switch. Pressing this button
activates the fuel lift pump.

Start

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
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

amount the battery is being charges

Water Temperature Gauge - Indicates the temperature

the engine coolant.
[99°C], the alarm buzzer will sound a continuous signal.

NOTE:

register
temperatures will register when

Button - A "push-to-start" rubber booted pushbutton

Button - Identical to the prestart button, the start button,

The

water temperature gauge

the

last

PANEL

of

the panel components.

Registers revolutions per minute

TACHOMETER

If

the coolant temperature reaches 210"F

reading

when

for calibration.

13V to 14V].

and

oil

the

engine

is

the

power

DC

temperature

shut

is

turned back

of

the engine

circuit [the

down.

if

the oil

The

111

of

will

on.

0

true

GASOLINE
INSTRUMENT

ENGINE

PANEL

Engines & Generators

6

PREST

Before starting your engine for
longed

D Check the engine
D

D Check

D

D Check the coolant level

ART

INSPECTION

layoff,

check

the

following

oil

level.

at

the

high mark

Turn

on

the
examine
nants.

NOTE:

fuel,

Check
and

(+) battery cable

the

stud

and

NOTE:

refer

the

the

Refer

oil

and

the

battery cable connections. Make certain

negative (-) cable

(this

at

the

If

the

to

the

on

the

dipstick.

fuel

supply,

then

fuel

fIlter/water separator

transmission fluid level.

to

the

specifications pages

transmission fluid types and quantities.

DC

electrical system. Inspect wire connections

is

connected to

is

connected

location

manifold.

is

tagged).

in

engine has not yet been filled with

COOliNG SYSTEM section

PREPARATIONS

the

first time or after a pro-

items:

Add

oil

to

maintain

check

the

fuel

bowl

in

the

starter solenoid

to

the

both

the plastic recovery tank

the

supply

for contami-

this manual for

the

engine ground

coolant,

of

this manual

FOR

level

and

positive

and

INITIAL

D

Visually

parts, disconnected

the

D Examine

Good
for proper engine performance.

D

Make

D Ensure

transmission.

D

Open
strainer.

A

engine

START-UP

examine

threaded connections

the

ventilation

sure

the

the

through-hull

Inspect

CAUTION:

is

running.

the

wires,

air

inlet

and

the

mounting

propeller shaft

the

raw

Do

not

engine.

and
an

Look

and

and

engine

outlet

ample

installation

is

securely attached

and

prime

water

pull

the

for

loose

unattached

attachments.

for

air

flow

air

supply

is

secure.

the

raw

supply.

dipstick

or

missing

hoses.

Check

obstructions.

are

necessary

to

the

water

intake

when

the

OIL

FILL

EXHAUST

MANIFOLD

DIPSTIC

-----

-

-

/IOILLEVEL

Engines & Generators

7

STARTING • STOPPING

PROCEDURE

STARTING

1.

Place
control

2.

Tum the

(If the panel

3. Press
(The

4.

Release
BUTTON.

5.

Release

6.

With
proper oil pressure

water temperature will rise slowly
when

NOTE:

engine is running.

It
Become
immediate

FAILURE

If

the

5

seconds,
procedure.
neutral
to

prevent starting in

Never
fails
this

manual.

PROCEDURE

the

transmission

to

slightly open.

KEY

SWITCH

is

energized,

the

PREHEAT

fuel

lift pump

the

PRESTART

(The

the

START

the

engine running, check

the

thermostat opens.

Never attempt to engage the starter while the

is

important

aware

action

TO

START

engine

fails

to

wait

for

Make certain

position

run

to

start,

the

starter for

refer

as

some

to

in

BUTTON,

is

priming

starter motor

BUTTON

and

battery charging voltage. The

to

closely

of

the normal engine

if

these

start

when

at

least

30

the

engines have a

gear.

more

the

TROUBLESHOOTING CHART

neutral

and

advance

to

the ON

the

BUTTON

position

gauges are

and

the

is

cranking the engine).

as

the

on.)

hold for 5 seconds.

engine

fuel

and

press

the

engine starts.

instruments for

and

then stabilize

monitor the panel

readings

readings

the

seconds

transmission control

then

start

start button

and

repeat

neutral

30

seconds.

to

is

the

(2

o'clock).

system.)

the

gauges.

and take

vary.

pressed

the

is

in

safety

If

the

throttle

START

for

starting

the
switch

engine

in

STOPPING

To

stop the engine, bring the throttle
place the transmission in neutral. Allow the engine
a

few

engine

NOTE:

(12

o'clock).

instrument panel will

will pulsate warning that the key is still in the

Starting

Make certain
prevailing temperature.
of

SJ

PROCEDURE

to

an

moments

down

Make certain this key switch is in the

or

better,

to

stabilize temperatures, then shut

by

turning off the key switch.

If

the key switch is left

put

a drain

Under

the

lubricating

SAE

Cold

Conditions

Use

30,

lOW-30,

oil

oil

ON,

on

the battery. The alarm

is

appropriate

with

an

API

or

15W-40.

idle position

OFF

the energized

ON

for

the

Specification

and

to

idle for

the

position

position.

A

CAUTION:

the

engine
system
the

pump
cooling
enter
manifold
from
through-hull
correcting
Engine

warrantable

in

mind.

starling

filling

is

pumping

system

the

engine's

once

happening

shutoff,

the

damage

issue;

Prolonged

can

with

raw

raw

during

cranking.

cylinders

the

exhaust

by

closing

draining

cause

of

resulting

the

owner/operator

cranking

result

water.

water

by
system
the

the

excessive

from

intervals

in

the

This

may

through

This

way

of

fills.

raw

water

the

exhaust

raw

water

engine

happen

the

raw

water

the

exhaust

Prevent

supply

muffler,

engine

entry

should

without

exhaust

because

raw

water

can

this

and

cranking.

is

not

keep

this

a

Engines & Generators

8

ENGINE

BREAK-IN

DESCRIPTION

Although your engine
hour of test operations at the factory
assembly procedures were followed
operated
life of
operated

Breaking-in a
piston
and
scored,
break-in

Your
conditioning operation
to
Perform
following:

1.

2.

properly,

your

engine

and

serviced during

new

rings

to

the cylinder walls. Excessive

smoky

operation indicate that the cylinder

which

is

period.

new

engine requires approximately 50

maximize the performance and service life of the engine.

this

conditioning carefully, keeping

Start

the

engine according
PROCEDURE section.
checking that
battery

charging) are functioning.

Allow

the

engine

fast

idle)

until the water temperature gauge moves into

the

130 -1400P

has

experienced a minimum of

to

make sure accurate

and

that the engine

a break-in time

is

dependent

engine basically involves seating the

caused

by

to

break

all

systems (raw water

to

warm

(55

- 60°C) range.

is

required. The service

upon

how

the engine

its

initial 50 hours of

oil

consumption

walls

overloading the engine during

hours

in

each moving part

in

mind the

to

the

STARTING

Run

the engine at fast idle

pump,

oil pressure,

up

(preferably

by

running at

use.

of

one

is

are

initial

in

order

while

the

PROCEDURE

3.

While

using

the

vessel,

speeds

for

the

fIrst

25

idling.

4.

Avoid

rapid acceleration, especially

5.

Use

caution

grey

a

reach

6.

During

varying engine speeds,

Avoid

CHECK

o Monitor
o Check
o Check

vibration

o

ConfIrm
When
When the engine
When

NOTE:

See

break-in information

not

to

overload the engine.

or black exhaust

its

full

rated speed

the

next

25

hours,

prolonged idling during this break-in

LIST

the

control

panel

for

leaks

of

fuel

for

abnormal

and

exhaust

the

engine

the

engine

the

TRANSMISSION section

noise

blow-back sounds.

smoke:
is

cold -white

is

warm

is

overloaded -some

on

your transmission.

run

the

engine at

hours.

Avoid

prolonged periods of

with

and

the inability of

are

signs

of

the

engine

with

short runs

gauges.

and

engine

oil.

such

as

knocking,

smoke.

- almost smokeless.

of

various

engine

a cold

engine.

The

presence of

the

engine

an

overload.

may

be

operated

at

full

rated

period.

friction,

black

smoke

this manualfor

rpm.

and

to

at

soot

Engines &

9

Generators

THE

DAILY

OPERATION

CHECK

Follow this check list each day before starting your engine.

LIST

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

NOTE:

manual

1.

Put the transmission in neutral, throttle advanced.

NOTE:

neutral safety switch through which the starter solenoid
energizing circuit passes. This switch is open when the
transmission is
energize.

THE

ENGINE

See STARTING/STOPPING PROCEDURE in this

for

more detailed instructions.

Hydraulically operated transmissions have a

in

gear so the starter solenoid will not

2. Tum the KEY SWITCH to the

[The panel is energized, gauges are lit}.

3. Depress the PREST ART 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

is

engine

Stopping

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 at the same time
put the throttle at full open

NOTE:

position( 120 'clock).

energized instrument panel will
The engine pulse alarm will sound as a reminder that the key
switch has been left

running.

Procedure

..

Make certain this key switch

If

the key switch is left

on.

ON

position

is

in the OFF

put

a drain on the battery.

(2

ON,

o'clock).

the

ALARMS

ENGINE

The DC harness on the engine is protected by
mounted manual reset circuit breaker
Excessive current draw or electrical overload anywhere in
the instrument panel wiring
breaker to trip. In this event most engines will shut down
because the open breaker disconnects the fuel supply.
this should occur, check and repair the source
After repairing the fault, reset the breaker and restart the
engine.

LOW

Allow oil pressure alarm switch
gallery. This switch's sensor monitors the engine's oil pres­sure. Should the engine's oil pressure fall to 5 -10 psi
(0.4 - 0.7

CIRCUIT

OIL

PRESSURE

kg!cm2),

BREAKER

(20 amps DC).

or

engine wiring will cause the

ALARM

this switch will activate a pulsating alarm.

SWITCH

is

located off the engine's oil

AND

an

engine-

If

of

the problem.

'1////"

CIRCUIT

COOLANT

A coolant temperature switch
housing. This switch will activate a continuous alarm if the

coolant's operating temperature reaches approximately
210°F (99°C).

BREAKER

TEMPERATURE

is

COOLANT
TEMPERATURE
SWITCH

SWITCH

located on the thermostat

~

/"

;".

AIR

~

PETCOCK

BLEED

Engines & Generators

10

MAINTENANCE

A

WARNING:

running.
use
servicing

NOTE:

more difficult and may require the expert knowledge

the

Many

Wear

correct

Never

the

proper

tools

for

any

of

the

engine's

o/the/ollowing

attempt

to

perform

safety

equipment

each

job.

Disconnect

DC

electrical

maintenance jobs are simple but others are

SCHEDULE

any

service

such

the

equipment.

while

the

as

goggles

battery

0/

a service mechanic.

and

terminals

engine

gloves,

when

is

and

SCHEDULED
MAINTENANCE

Fuel

Supply

FueljWater

Engine

Coolant

Drive

Visual

Spark
Generator

Fuel
Starting

(and

Engine

Re-torque

*

Adjust

Clearances

Air

Exhaust

Engine

Inlet

Oil

Level

Belts

Inspection

Plugs

Filter

Batteries

House

Oil

the

Screen

System

Hoses

Fuel

Filter

Separator

Level

(if

applicable)

(Lift

Pump)

Batteries)

Cylinder

Valve

(Flame

of

Engine

Head

Arrester)

CHECK

EACH

DAY

0

0

0

0

0

weekly

0

0 0

weekly

HOURS

OF

OPERATION

100

Please

will

inhibit

cool.

250

keep

500

engine

the

engine's

750

surface

ability

1000

clean.

to

50

NOTE:

and

oil

remain

0 0 0 0 0 0
0 0 0 0 0 0 0

0 0 0 0 0 0

0 0 0 0 0 0 0

0

0

0

0 0 0

0
0 0 0 0

0 0 0 0 0 0

0 0 0

0 0

1250

Dirt

0

Unleaded
higher.

Check

for

if

necessary).

Oil

level

should

dipstick.
Check

at

recovery

Add

coolant

Inspect

for

and

adjust

Check

for

and

electrical

Check

for

Check

gap;

Check

that

with

no

chafing -see

(if

applicable)

Inspect

for

Every

50

operating

and

make

excessive
Initial

engine

change

both
Retorque
Initial

adjustment

Clean

at

50

Initial

check

for

leaks.

exhaust

elbow

on

inside

Check

that

Hose

should

spongy.

Check

Replace

every

EXPLANATION

gasoline

water

and

indicate

if

needed.

proper

if

needed.

fuel,

oil

connections.

loose

belt

inspect

AC

connections

for

fuel

leaks.

sure

connections

corrosion.

oil & filter

every

at

50

hrs.,

at

hours,

at

50

Check

siphon

for

passages;

all

connections

be

hard & tight.

and

200

OF

MAINTENANCE

with

octane

dirt

in

between

tank;

if

empty,

tension

(3/8'

Check

and

water

tension.

for

burning

GENERATOR

addition

information.

Check

hours

check

change

100

hours.

them

every

50

hrs.,

then

every

hrs.,

then

brake

carbon

and/or

clean

and

tighten

operating

SCHEDULED

rating

of

89

fuel

(drain/replace

FULL

and

check

at

to

1/2"

deflection)

belt

edges

for

leaks.

Inspect

Keep

bolts & nuts

and

corrosion.

are

clean

and

INFORMATION

wire

connections.

electrolyte

are

very

tight.

at

50

hrs.,

500

hours.

then

every

500

100

hours.

every

250

hrs.

operation.

corrosion

replace

as

are

tight.

Replace

if

all

hose

clamps.

hours.

or

filter

LOW

on

manifold.

wear.

wiring

tight.

secure

levels

Clean

off

then

hrs.

Inspect

Check

the

buildup

necessary.

soft

or

continued

Engines & Generators

11

NOTE:

Use

engine

hours

MAINTENANCE

the

engine hourmeter gauge

by running

time.

SCHEDULE

to

log

your engine hours or

record

your

SCHEDULED

MAINTENANCE
Heat

Exchanger

Raw

Water

Pump

Coolant

System

*Starter

Distributor

*Engine

*Exhaust

Lubricate

Carburetor
Screen

Transmission
Transmission

Transmission

Engine

Motor

Cylinder
Compression
Valve

Clearance

Elbow

Panel

Switch

with

"Lockeze"

Filter

Mounts/lsolators

and

Key

Fluid
Damper

Cooler

Plate

CHECK

EACH

DAY

HOURS

OF

OPERATION

50

100

250

500

750

1000 1250

D D D D D D D

D

D

D

D

D D

D D

D D

D

D

D

D D D D

D

D

D

D

EXPLANATION

Clean

or

replace

cap

and

clean

for

professional

Remove
for

appropriate
Check

and

the

pump

wear,

replace

Lubricate
Drain,

pinion
Check

distributor
Incorrect

performance.
timing

Test
casting
WARNING:

carbon

At

once a season.
Clean

Refer
Seperate

inspect
springs,

Inspect
replace

Inspect
contacting

flush,

solenoid

lubricate.

drive.
ignition

valve

and

exhaust

is

monoxide

first

100

at

first

to

the

the

the

replace

for
if

engine

both

and

antifreeze

cap

adjust

elbow

corroded

A

hours.

50

TRANSMISSION

transmission

damper

leaks

needed.

the

OF

MAINTENANCE

anode.

out

debris.

cleaning

cover

if

needed.

when

refill

and

motor

Clean

and

timing.

and

rotor.

clearance

Check

valve

for

or

defective

leakage.

Then

hours

plate,

if

necessary.

and

mountinglisolators.

base

SCHEDULED

Open

heat

remove

and

pressure

and

inspect

Also

re-assembling.

cooling

system

mix.

for

corrosion.

lubricate

Check

condition

will

result

compression

clearances.

casting

integrity.

deteriorated.

exhaust

elbow

each

year

and

every

section.

from

the

look

for

condition

replace

the

of

mount.

exchanger

every

1000

testing.

the

impeller

replace

the

with

Remove

the

starter

of

in

poor

engine

pressure

Replace

can

at

winterizing

250

hours.

engine

wear

or

the

casting,

If

upper

end
hours

gasket.

motor

and

cause

or

and

broken

cap

is

if

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

Engines & Generators

12

mechanic.

COOLING

SYSTEM

DESCRIPTION

Westerbeke
fresh water
tion
circulates throughout the engine.
coolant cools
the engine
fresh
exchanger,
water
fresh water coolant
ferred
tube
exhaust system
other
coolant
transferred heat overboard through
fresh
each
allows

harmful

FRESH

NOTE:

recommended antifreeze

fresh water

Fresh water coolant
lating
then
heat exchanger
block
engine
the closed thermostat (although some coolant
bypassed
fold

gradually

stat
coolant
cooling

~oolant

A coolant
and

contraction during engine operation, without

cant

system.

ing
engine manifold

NOTE:

sure
good condition and check that

closes

marine engines are designed

cooling.

and

friction

oil.

water

coolant

similar

flows

through

to

the

walls

to

words,

is

cooled

water

coolant

other.

Using

the

cooling water passages

deposits.

WATER

Refer

to

coolant.

pump,

passes

through the thermostat into the manifold,

via

the

is

started cold, external coolant
around

from

overheating). As the engine

to

flow

system.

Recovery

recovery

loss

of coolant

TIris

Periodically check the condition

cap.

Ensure

tightly.

Heat produced

is

transferred

the

engine

block,

The heat

fresh

the

where

the

is

transferred externally

to

raw

water

in

function

the

tubes

flows

around the

water coolant

raw

water which

finally

engine

is

cooled

by

raw

water,

and

raw

only fresh water coolant within

COOLING

the ENGINE COOlANT section for the

and

is

pumped through

absorbing heat from

where

it

is

cooled,

suction side of the circulating

the

thermostat

opens, allowing full

unrestricted

to

in

to

fresh

TIris

its

internal moving parts,

by

means of a heat

to

an

automotive radiator.

of the heat exchanger

tubes;

is

conducted through the

is

then

it is discharged overboard.

by

fresh water coolant,

and

the

the

water circuits are independent of

to

stay clean and

CIRCUIT

water mixture

the

and

to

prevent the exhaust mani-

flow

the

external portion of

Tank

tank

allows

for engine coolant expansion

and

without introducing air into the cool-

tank should be located at or above the

level

and

should be easily accessible.

that the upper

Carry a spare

and

lower rubber seals

the

vacuum valve opens

cap.

and

the

engine

water coolant

circulating

pumped into

raw

exhaust system. The .

the

engine. The coolant

returned

flow

warms

of the engine's

of

the manifold pres-

equipped

engine heat

water carries the

to

be used as the

engine

pump.

is

prevented

flow

up,

for

by

combus-

which

fresh

water

from

the

while

trans-

the

the

engine

free

by

a circu-

to

to

the engine

When

is

the thermo-

the

any

signifi-

are

and

and

Raw

In

this

from

the

the

by

in

CHANGING

The

engine's coolant must

MAINTENANCE

become

A

critical; a substantial
traced

Drain

engine block

the

system

NOTE:

be

used

A

Wear

Refilling

After replacing the engine block drain plug,
exchanger's coolant
slowly

NOTE:

When
the

petcock and fill

Monitor
the

manifold

sure

cap.

Remove
coolant
the

cap.

flow

into

After checking for
Coolant should
engine
needed.

COOLANT

SCHEDULE.

contaminated, it

CAUTION:

back

the

engine coolant

The

drain

to

help drain engine

WARNING:

protective

the

pour

Open

a steady flow

the

the

mix

Run

the

cools

Clean

Proper

to

cooling

and

opening

with

fresh

petcock

Beware

gloves.

Coolant

petcock.

clean,

premixed

the

air-bleed petcock on

of

the

coolant

cap
to

to

the

filler

on

the

halfWay

the

engine

recovery

leaks,

draw

down.

Add

up

any

in

be

changed according

-If

the

coolant

can

lead

to

overheating

cooling

number

system

by

the

water,

on

coolant appears at

system until the manifold

the manifold

neck

coolant recovery tank

between

and

tank.

stop

back into the cooling

coolant

spilled coolant.

system

of

engine

corrosion.

loosening

manifold pressure

then

the heat exchanger should also

coolant.

of

the

Then

coolant

and

observe

the engine

the

start

the

hot

engine

run

the

into

the

and add

install the

LOW

and

the

coolant

to

the

recovery

COOLANT

the

heat

the

and

EXPANSION

to

the

is

allowed

problems.

maintenance

failures

drain

plug

refill

process.

cap.

can

on
Flush

is

be

the

coolant.

close

the

heat

engine

at

idle

manifold.

exchanger.

petcock,

as
manifold

and

MAX

allow

system

close

remains

needed.

pres-

fill

with

and

replace

expansion

it

to

as

the

tank

if

Fill

cool.

to

and

full.

Engines & Generators

13

COOLANT

RETRACTION

COOLING

RAW

WATER

NOTE:

Always install

the

strainer will always be self-priming.

A clean raw water intake strainer is a vital component
engine's cooling system. Include a visual inspection
strainer when making your periodic engine check. The water
in the glass should be clear.

Perform the following maintenance after every 100 hours
operation:

1.

Close the raw water seacock.

2. Remove and clean the strainer filter.

3. Clean the glass.

4. Replace the sealing washer

5. Reassemble and install the strainer.

6.

Open the seacock.

7. Run the engine and check for leaks.

NOTE:

Also follow the above procedure after having

aground.

If

the engine temperature gauge ever shows a higher than
normal reading, the cause may
may have been caught up in the strainer, slowing the flow
raw water through the cooling system

INTAKE

STRAINER

the

strainer at

or

below

the

waterline

if

necessary.

be

that silt, leaves or grass

of

run

of

this

the

of

hard

of

SYSTEM

RAW

so

The raw water pump
non-ferrous housing and a Neoprene impeller. The impeller
has flexible blades which wipe against a curved cam plate
within the impeller housing, producing the pumping action.

On no account should this

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 start­up. The raw water pump should be inspected periodically for
broken or tom impeller blades. See

SCHEDULE.

NOTE:

(seals and bearings), it may be more cost efficient
chase a new pump and rebuild

Changing

Close the raw water intake valve. Remove the pump cover
and, with the aid
impeller out
Move the blades to conform to the curved cam plate and
push the impeller into the pump's housing. When assem­bling, apply a thin coating oflubricant to the impeller and
gasket.

Run the engine and check for leaks around the pump. Also
check for water discharge at the stem tube. Absence
flow indicates the pump has not primed itself properly.

WATER

Should a failure occur with

Open the

PUMP

is

a self-priming, rotary pump with a

p"ump"

the

the

Raw

Water

of

two small screwdrivers, carefully pry the

of

the pump. Install the new impeller and gasket.

raw

water intake valve.

Pump

be run dry. There should

MAINTENANCE

the

pump s internal parts

to

pur-

original pump as a

spare.

Impeller

of

water

RAW

WATER

TYPICAL

INTAKE

[OWNER

INSTALLED]

STRAINER

RAW

A

CAUTION:

impeller,
the

they

cooling

exchanger

WATER

PUMP

INCOMING
RAW

If

any

must

circuit.

WATER

of

be

located

They

the

often

vanes

to

prevent

can

have

be

found

broken

off

blockage

in

the

the

in

heat

Engines & Generators

14

COOLING

THERMOSTAT

A thennostat controls the coolant temperature as the coolant
continuously flows through the closed
the engine is first started the closed thennostat prevents
coolant from flowing (some coolant is by-passed through
thennostat to prevent the exhaust manifold from over­heating). As the engine
opens. The thennostat is accessible and can be checked
cleaned, or replaced easily.
gasket.

wanns

up, the thennostat gradually

Cany

THERMOSTAT

cooling circuit. When

tile

a spare thennostat and.

SYSTEM

If

the zinc pencil needs replacement, hold the hex boss into
which the zinc pencil is threaded with a wrench while
loosening the anode with another wrench. This prevents the
hex boss from possibly tearing off the exchanger shelL After
removing the zinc, note the condition.
condition, there are probably a lot
exchanger. Remove the end cap
clean the inside
exchanger end gasket in case the present one becomes
damaged when removing the end cover. Replace the sealing
gasket (refer to your engine model's heat exchanger end gasket
part number), O-ring and cover, and install a new zinc anode.

NOTE:

The

not

require

insulate

threads

sealant.

the

zinc from

of

all zinc debris. Always have a spare heat

of

the

zinc anodes

Sealant should not

the

metal

housing preventing electrolysis action

If

the zinc is in poor

of

zinc flakes within the

of

the heat exchanger and

are

pipe

threads

be

used

as

of

the

heat exchanger
on

the

zinc.

it

and

may

do

THERMOSTAT

If

you suspect a faulty thennostat, place it

bring to a

ZINC

ANODE

A zinc anode (or pencil) is located in the raw water cooling
circuit within the heat exchanger. The purpose

~node

is to sacrifice itself to electrolysis action taking place
m the raw water cooling circuit, thereby reducing the effects
of

electrolysis on other components

dition

of

the zinc anode should be checked monthly and the
anode cleaned
be carried onboard.

NOTE:

Electrolysis

and

vessel

TEST

in

a pan

boiL

A working thennostat should open about

of

the system. The con-

or

replaced, as required. Spare anodes should

NEW

location,

REPLACE

is

the result

not that

of

CLEAN & REUSE

of

each particular installation

the

engine.

of

of

the zinc

water and

112".

HEAT

EXCHANGER

Cool raw water flows through the inner tubes
exchanger. As the engine coolant passes around these tubes
the heat
which is then pumped into the exhaust system and discharged.
The engine coolant (now cooled) flows back though the
engine and the circuit repeats itself.

The engine coolant and raw water are independent
other;
hannful deposits found in raw water.

Heat

After approximately 1000 hours
and pressure test the engine's heat exchanger. (A local auto­motive radiator shop should be able to clean and test the heat

. exchanger).

NOTE:

that a heat exchanger cleaning
every 1000

of

the internal engine is conducted to the raw water

tins keeps the engine's water passages clean from the

Exchanger

Operating

Service

in

silty

a1ld/or

of

operation, remove, clean

tropical waters

be

peifol71zed

hours.

of

the heat

may

nwre

of

each

require

often

then

Engines & Generators

15

GASOLINE

Use unleaded
follow
companionways
ventilate after

NOTE:

The

fume detectorlalann properly installed

89

octane or higher

U.s. Coast Guard regulations, close off

to

prevent

fueling.

generator compartment should have a

fumes

gasoline.

from

When

entering

and

working.

all

hatches

the

gasoline

FUEL

fueling,

and

boat,

and

SYSTEM

AWARNING:

when

servicing

ing

any

fuel

ing,

open

fuel

system

tion

exists

GASOLINElWATER

A primary
installed between the fuel tank

water

be carried
Most installers include a type of filter/water separator

the generator installation package
the problems that contaminants in

These gasoline filters must have
through")
bowls
impurities.

fuel

and

other contaminants
to

to

have

drain valves

FUEL
WATER

Owner

Shut

off

the

fuel

valve

at

the

tank

the

fuel

system.

that

may

spill.

flames

or

other

when

servicing.

when

servicing

SEPARATOR

filter of the water separating type must be

the

fuel

system

meet U.s. Coast Guard requirements. The metal

to

use

FILTER

SEPE~TOR

Installed

Take

care

DO

NOT

allow

any

sources

the

on

of

fire

near

Ensure

proper

fuel

system.

AND

FILTER

and

the

engine

from

the

fuel

before they

the

engine.

as

they

are well aware of

the

fuel

can cause. .

metal bowls (not "see-

when

checking for water

,.

RACOR
MODEL
ILLUSmATED

in

catch-

smok-

the

ventila-

to

remove

110A

can

with

and

GASDENSER

The gasdenier
around
between
denser

ENGINE

Periodically
leakage.

MAINTENACE

Changing

1. Shut off

2. Unscrew

housing

3. Remove

4. Replace the sealing

the housing. Thread the retainer ring
to

cross thread. When retainer contacts the
tighten
run

A

WARNING:

Use

extreme

consists

the

raw

the

raw

cools

the

FUEL

check

Change

the

fuel

the

and

and

114 -1/2

the engine

care

of a portion of

water

intake

line

water intake

fuel

to

prevent

and

vapor

FILTER

the

fuel

connections

the

filter

element after

SCHEDULE.

Filter

Element

supply.

retainer ring that holds the filter

allow

bowl

to

come

replace

the

filter element

"0"

ring

turnes

by

hand.

to

inspect for leaks.

Fuel

is

present

to

prevent

spillage.

and

the

and

insulated.

Open

in

the

fuel

raw

water

lock.

and

the

the

first

away

from

and

reassemble

on

carefully

the

the

housing

line

It

is

pump.

filter

50

bowl

the

clean

the

"0"

fuel

that

is

located

The

bowl

hours.

to

housing.

the

bowl

so

ring,

supply

and

coiled

gas-

for

See

the

bowl.

to

as

not

and

lines.

.

FUEL

LIFT

PUMP

Periodically check

and make sure that

are tight
pump's mounting bolts should
the mounting bolt

The engine mounted

INLET

To

in-line filter at the incoming fuel line. This filter should be

replaced every

and

FUEL

ensure clean fuel enters the fuel lift pump, there

the

fuel

connections

no

leakeage

secure. The

DC

ground connection at one of the

to

ensure proper pump operation.

fuel

lift

pump

FILTER

200 operating hours.

is

present

be

clean and

is

maintenance

to

and out

and

that

well

of

the pump

the

fittings

secured

by

free.

is

an

Engines & GEmerators

16

HOUSING

,Ik---FILTER

----O-RING

I~~~mk-_-RETAINING

'II

'ELEMENT

RING

ENGINE

LUBRICATING

OIL

DESCRIPTION

The lubricating

oil

pump.

oil

pump,

oil

filter,
engine.
continuous
specified pressure,

oil
within

The

pump

its

system
The engine
which

drives

oil

cooler
oil

then

cycle.

Wbyn

and

returns

specified

and

the

range.

is

a pressure feeding system

oil

is

drawn

from

the

the

oil,

under pressure, through

various lubricating points

returns

to

the

oil

sump

the

oil

pressure exceeds the

oil

to

pushes

the

oil

open

sump,

the

keeping

LUBRICATION
DIAGRAM

oil

to

repeat

relief

the

sump

in

valve

oil

using

by

the

the

the

the

in

the

pressure

an

CHANGING

The

engine

from

its
allow
hose

and

is

properly

been

drained.

Always

emulsion

this

condition

prevent

is

present

be

the

engine and/or a siphoning through

circuit

THE

ENGINE

oil

should

attachment bracket

the

oil

to

drain,

pump

the

old

secured

observe

indicates

serious

in

result of a
into

the

in

the

old

the

is

rare,

damage.

the

oil.

Raw

fault

exhaust, filling into

OIL

be

wann.

and

or attach a

oil

out.

Make sure

its

holder

oil

as

it

presence of

it

does

·require

Call a competent

water present

in

the

exhaust

Remove

lower it into a container

pump

after

is

the

oil

drain

hose

to

the

end

of

the

the

oil

drain

all

of

the

old

oil

has

removed. A yellow/gray

water

in

the

oil.

Although

prompt

the

the

in

the

system

raw

engine.

attention

mechanic

oil

can

attached

water

cooling

to

if

to

and

drain

hose

water

the

ENGINE

Use a

Change the engine oil and filter after
break-in operation, and every
thereafter.An oil viscosity of SAE
for this engine

A

engine
additives

to

OIL

heavy

duty

in

CAUTION:

oil

to

mix.

of

different

produce

properties

engine oil with

100

all conditions.

Do

not

allow

Each

brand

brands

harmful

an

hours
15W-40

two

contains

could

to

API

classification of

an

initial 50

of operation

is recommended

or

more

its

react

in

your

engine.

hours

brands

own

additives;

the

mixture

SJ.

of

of

Engines & Generators

17

TIGHTEN

BY

MOISTEN

THE

FILTER

GASKET

CLEAN

OIL

INSTALLING

A

WARNING:

contaminants.
and

nails
discard
used

oil

Avoid

thoroughly

clothing

properly.

HAND

NEW

WITH

WHEN

Used

or

rags

engine

oil

prolonged

using

soap

containing

contains

skin

contact.

and

water.

used

harmful

Clean

Launder

oil.

Discard

skin

or

ENGINE

LUBRICATING

OIL

REPLACING

When removing the used oil filter, you may find
punch a hole in the upper and lower portion
to drain the oil into a container before removing it. This helps
to lessen spillage.
helpful in removing the old filter.
and a plastic bag around the filter when unscrewing
any oil that's in the filter. Inspect the old oil filter as it is
removed to make sure that the rubber sealing gasket comes
off

with the filter.
against the oil filter adapter, gently remove it. When
installing the new filter element, wipe the filter gasket's
sealing surface on the filter adapter free
thin coat
Screw on the filter and tighten the filter firmly by hand.

NOTE:

are

not

REFILLING

Add fresh oil through the valve cover. After refilling the oil,
run the engine for a few moments while checking the engine's
oil pressure. Make sure there is no leakage around the new
oil filter or from the oil drain system, and then stop the
engine. Then check the quantity
dipstick. Fill to,

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
75 psi (2.8 and 5.2 kglcm2).

THE

OIL

FILTER

it

of

the old filter

An

automotive filter wrench should be

Place some paper towels

If

this rubber sealing gasket remains sealed

of

oil and apply a

of

clean engine oil to the rubber sealing gasket.

Use

genuine WESTERBEKE oil filters. Genericfilters

recommended.

THE

OIL

SUMP

of

oil with the lube oil

but

not over, the FULL mark.

helpful to

it

to catch

40 and

LOW

OIL

PRESSURE

The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3

+ 0.1 kglcm2). A gradual loss

worn bearings. For additional information on low oil pressure
readings, see the

TESTING

To test the oil pressure, remove the oil pressure sender, then
install a mechanical oil pressure gauge in its place. After
warming up the engine, set the engine speed at
and read the oil pressure gauge.

OIL

PRESSURE

SENDER

AND

ENGINE

\

OIL

PRESSURE

35.0

SWITCH

TORQUE

of

oil pressure usually indicates

TROUBLESHOOTING

Ib/in'

(3.8

kg/em')

or

higher

9 -13

ft-Ib

(1.2

3000 rpm

at

3000

-1.8 m -

chart.

rpm.

kg).

NOTE:

A newly

reading

an

oil pressure

readings
engine

up

will

and

to

the

started,

80

psi (5.6

reading

vary

rpms.

cold

kg!cm

as

low

depending

engine

can

2

).

A warmed engine

as

35 psi (2.5

upon

the

have

an

oil pressure

kg!cm

temperature

2

).

of

can

have

These

the

Engines & Generators

18

REMOTE

OIL

INSTALLATION

This popular accessory is used to relocate the engine's oil fil-

ter from the engine to a more convenient location such as an

engine room bulkhead.

NOTE:

Refer

to

instructions

ENGINE

on

changing

OIL

the

CHANGE

oil

filter.

in

this

manualfor

FILTER

(OPTIONAL)

To

install, simply remove the engine oil filter and thread on
WESTERBEKE's remote oil filter
install this

Contact your WESTERBEKE dealer for more information.

NOTE:

Westerbeke

incorrect installation

kit as shown. Always

kit with the oil filter facing down as illustrated.

is

not

responsible

of

the

Remote Oil

for

engine

Filter.

failure

due

to

APPLY A THIN
INSTAlliNG
TIGHTEN

AN

CONTACTS

THE

COAT

OF

KIT.

BASE.

CLEAN

THREAD

THIS

ADDITIONAL

3/4

OIL
THE

TURN

TO

THE

KIT

ON.

AFTER

O-RING

THEN

THE

O-RING

WHEN

HAND

FASTEN

(SCREWS

SECURELY

TO A BULKHEAD

ARE

OWNER

SUPPLIED)

NOTE:

THE

ON

THE

ADAPTER

REMOVED

Will

BE

RECONNECTED

"IN"

AND

"OUT"

WHEN

FOR

INSTALLATIONS

MARKINGS

THE

HOSES

ARE

SO

CORRECTLY.

THEY

Engines & Generators

19

APPLY A THIN

FILTER

GASKET

FILTER

CONTACTS

ADDITIONAL

COAT

WHEN

3{4

OF

INSTALLING.

THE

BASE.

TURN.

CLEAN

OIL

TO

THE

AFTER

TIGHTEN

THE

IT

AN

CARBURETOR

NOTE:

WESTERBEKE
adjustments
The

information below

be

recommends

performed

is

by

provided

ADJUSTMENTS

that

the

a competent

to

assist

following

engine

the

engine

mechanic.

mechanic.

.

CARBURETOR

The carburetor
cleanable metal screen air intake.

The choke is operated by a 12V
starts (cold start), the choke circuit is kept activated opening
the choke. This helps prevent stalling on a cold start. The
circuit remains active until shutdown.

Air

Screen/Flame

The air screen/flame arrester can easily be removed by
releasing the hold-down clamp. Clean after the first
of

operation, every 100 hours from then on. Clean the air

screen in kerosene and blow dry with

is

a single barrel, down-draft type with a

DC

current. After the engine

Arrester

air.

TO

ROCKER

COVER

50 hours

Carburetor

Clean this filter element after the first 50 hours

then clean and inspect every
the screen
there are no leaks.

Idle

Mixture

Adjustment is performed with the engine operating. Screw
the

jet

turns.

Note:

An

induce

Filter

Screen

250 operating hours. Replace

if

necessary. Tighten the plug and make certain

Jet

slowly in until it seats, then back it out

idle

mixture

a sooty exhaust

jet adjusted

discharge

too

at

far off

engine

start-up

1-112

its

of

seat

operation,

to 2

can

and

shut-down.

AIR

SCREEN

FLAME

ARRESTER

FROM

SEE
IN

ENGINE

FUEL

FILTER

ELECTRIC

THIS

MANUAL
ADJUSTMENTS

CHOKE

UNDER

IDLE

MIXTURE

JET

Engines & Generators

FILTER

ACCELLERTAOR
PUMP

COVER

SCREEN

20

WATER

HEATER

CONNECTIONS

WESTERBEKE

on-board hot water

provides easy access for connecting

system.

engines hot water (coolant)

tank, heating

the

fresh

water

engine.
The water heater should

in

either
that
run
trap

Hoses
heater
heater
then
fitting

a high or

the

connecting

in

a reasonably direct line without

air.

should rise continuously

to

the

engine

to

the

engine.

an

air bleed petcock must be installed at

on

the

heater for bleeding air

TO

CONNECT

SIMPLY

BY-PASS
HEATER

ANOTHER

PASS

FROM

ENGINE

be

low

position

hoses

so

that air will rise naturally

If

trapped air

TO

CUT

AND

HOSE

CHOICE

HOSE

AND

HEATER

FITTINGS.

These connections

to

flow

to

the

and

then

cycling back

mounted

from

in

relation

the

in

a convenient location

heater

any

from

their

is

able

while

THE

WATER

HEATER

TAP

INTO

WITH

IS

ATTACH

HOSES

THE

THE

TWO

TO

REMOVE

THE

TO

DIRECTLY

WATER

allow

ships

to

the

to

the

loops

low

point at

to

rise

the

filling

ENGINE

THE

BY­AND
TO

THE

to

an

for

hot water

to

the

engine,

engine can

which

might

the

from

the

to

the

heater,

higher

the

system.

the

so

WESTERBEKE
ADAPTER

PN#302391

NOTE:

An air bleed petcock is located on

exchanger

petcocks when filling

to

escape.

NOTE:

and on the thermostat housing.

the

engine's coolant system

Close both tightly after all

If

any portion

of

the

heating circuit rises above

engine's closed cooling system pressure

the

the

air

cap,

engine's heat

Open

these

to

allow air

is

removed.

then a

the

pressurized (aluminum) remote expansion tank (Kit #024177)

in

must be installed

Tee

the

remote

ing

the

higher

the

heater,

and plumb a single line

and

the

other back to the engine's

expansion tank

the circuit to become

expansion tank into

of

the

two connections for

in

a convenient location so

coolant level can easily

be

checked.

the

heater

up

to

return.

The

the

highest point.

circuit,

the

return.

the

tanks location

Install

the

the

fresh water

remote

expansion

choos-

Tee

at

remote

tank will now serve as a check and system fill point. The

plastic coolant recovery tank is not used when the remote

expansion tank

i~taUed,

since this tank serves the

kit is

same function.

MANIFOLD

COOLANT
BY-PASS

HOSE

WESTERBEKE
ADAPTER

PN#302391

THERMOSTAT
HOUSING

OWNER
INSTALLED
HEATER

HOSE

Engines & Generators

21

ALTERNATOR

DESCRIPTION

The

charging system consists

regulator,

cuit

the use
regulator is very compact and is mounted internally
back

an engine

breaker and a battery with connecting cables. Because

of

integrated circuits (IC's), the electronic voltage

of

the alternator.

DC

of

an alternator with a voltage

wiring harness, a mounted

DC

or

cir-

on

of

the

TESTING

1.

Start

the Engine.

2. After a few minutes
tery voltage
set on
The voltage should be

the

alternator

at

the battery terminals using a multi-meter

DC

volts. .

is working. Turn to Step 4

of

running measure the starting bat-

inc~easing

MULTIMETER

toward 14 volts.

( 14.0)

o

COM

,

If

it is,

#14

TO

~iS===:::

VIOLET

CHOKE

.

#10

TO

I·

TROUBLESHOOTING

A

WARNING:

hot.

Do

not

This

troubleshooting section is to determine
exists with the charging circuit
determined that the alternator
best to have a qualified technician check it

The alternator charging circuit charges the starting battery and
the service battery.
battery selector switch is usually mounted in the circuit to iso­late the batteries so the service battery is not discharged along
with the service battery.

ing

battery but not the service battery,. the problem is in the

service battery charging circuit and not with the alternator.

Testing

A

that

sheaves

the

WARNING:

everyone

and

A failed

touch

until

An isolator with a diode, a solenoid,

alternator

the

alternator

or

If

the alternator is charging the start-

can

has

or

with the alternator.

voltage regulator is bad,

Alternator

Before

is clear of

belts

during

starting

moving

test

procedures.

the

engine

parts!

Keep

become

cooled

if

a problem

out

make

away

very
down.

If

it

or

certain

from

it

is

is

a

RED

STARTER

SOLENOID

3.

TESTING
BATTERY·
(ENGINE

If

the starting battery voltage remains around
after the engine is started and
problem exists with the alternator

Thrn

off the engine. Inspect all wiring and connections.

a.

Ensure that the battery terminals and the engine ground
connections are tight and clean.

A

CAUTION:

charging

switch

when

b.

If

a battery selector switch is in the charging circuit,

ensure that

c.

Turn

on the ignition switch, but do not start the engine.

d. Check the battery voltage.

condition the reading should be 12 to

circuit,

the

it

is

THE

STARTING

ALTERNATOR

RUNNING)

To

avoid

damage

never

shut

engine

is

running!

on

the correct setting.

If

(g])

_

GROUND

12

volts

run

for a few' minutes, a

or

the charging circuit.

to

the

battery.

off

the

engine

battery

your battery is in good

13

volts.

A

WARNING:

DC

and

AC
applications.
isolate
before
made

DC

pedorming

without

MULT/METERS

circuits

are

Always

and

AC

converters
DC

proper

often

mixed

disconnect

and

testing.

No

knowledge

AND

together

shore

shut

AC

of

AC

DC

CIRCUITS:

in

power

down

generators

tests

should

circuits.

marine

cords,

be

Engines & Generators

TESTING

ALTERNATOR
(IGNITION

22

THE

VOLTAGE·

ON -ENGINE

OFF)

0~_-.MULTIMETER

COM

+

;a

-=-

GROUND

ALTERNATOR

TESTING

e. Now check the voltage between the alternator output

If

terminal (B+) and ground.
voltage at the alternator should be the same as the
tery, or
age will be zero.
between the alternator and the battery. Check all the
connections - look for an opening
circuit.

TESTING

BATTERY -ALTERNATOR
(ENGINE

f. Start the engine again. Check the voltage between the

alternator output and ground.
The voltage reading for a properly operating alternator
should be between 13.5 and 14.5 volts.
alternator is over­a reliable service shop.

NOTE:

voltmeter to ensure that
sent at the
only battery voltage

If

the wiring looking

Jump

source
is
12

if

an isolator is in the circuit the alternator volt-

If

not, a problem exists in the circuit

THE

STARTING

RUNNING)

or

under-charging, have it repaired at

Before removing the alternator

EXC

terminal

at

12 volts are not present

for

12 V to the Exc. tenninal from a known

and

operate the alternator.

13-14 volts, the alternator

volts not being present

the circuit is good, the

in

the charging

,.¢::=-

If

for

12 volts

the B output terminal.

breaks and poor connections.

DC

excitation is pre-

if

the previous test showed

at

the

EXC

terminal, trace

If

the voltage output

is

o.k. Trace the cause

at

the Exc. terminal.

ENGINE

.......

GROUND

your

repair, use a

12V

bat-

for

Alternator

4. Check the voltage
should have a voltage between
engine is running.

battery charging circuit. Troubleshoot the service battery

charging circuit by checking the wiring and connections,

the solenoid, isolator, battery switch and the battery itself.

is

Working

of

the service battery. This battery

13

and 14 volts when the

If

not, there is a problem in the service

CHID

.

MUlTIMETER

A

CAUTION:

tor

charging

(i.e.

Megger).

ALTERNATOR

When rebuilding the engine, the alternator should be cleaned
and inspected. The housing can be wiped off with a solvent
and the alternator tenninal studs should be cleaned with a
wire brush. Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness.

Tum the rotor pulley by hand. It should tum smoothly.
Depending on when the alternator was last serviced, the

brushes may need replacing.
send it to a service shop for testing and overhaul.

G

COM

TESTING
BATTERY

When

performing

circuit

do

not

use a high

You

can

damage

INSPECTION

If

the alternator

SERVICE

BATTERY

THE

tests

voltage

the

alternator

SERVICE

(ENGINE

on

the

alterna­tester
diodes

is

at all suspect,

RUNNING)

Engines & Generators

23

DUAL

OUTPUT

DESCRIPTION

Dual output and high output alternators are available as

optional equipment on most
alternators can
add-on equipment at anytime.

Dual alternators
batteries at the
charge each set

be

installed during factory assembly or

can

be configured to charge

same

of

batteries separately.

WESTERBEKE engines. These

as

two

banks

of

time or, using a battery selector switch,

INSTALLATION

If

an optional dual alternator has already been factory installed,
simply follow the
engine installation instructions.

If

the new dual alternator is being added to an existing "in­the-boat"

instructions below:

1.

2. Remove the alternator and disconnect or tape

3. Install the new alternator.

4. Attach a new heavy gauge output cable[s] from the

engine, carefully follow the alternator installation

Disconnect the alternators negative cable from the
battery.

output [positive] cable. Do not reuse.

alternator's output terminal [s]. Using the cable sizes
indicated.

LENGTH

----

{ALWAYS

WESTERBEKE

REQUIRED

USE

FINE

UP

TO.~6='

UP

TO

12'

UP

TO

20'

STRAND

wiring diagram and the

_#~4

WIRE

#2

WIRE

#0

WIRE

CABLE]

off

the

TO

ALTERNATORS

SPACER
BRACKET

DUAL

OUTPUT

[CHARGING

ONE

TO

MOUNTING

ALTERNATOR

BATTERY]

5. Make certain that the batteries negative post ground
cable to the engine block is the same heavy gauge as
the positive cable.

6. Mount the regulator to a flat surface in a cool dry
location.

a. Connect the black wire to the ground terminal on the

alternator.

A

CAUTION:

out

first

grounding

b. Plug the 2-pin connector into the alternator, make

certain it is firmly seated.

c.

TIle red "battery sense" wire should
the batteries positive

d. The brown wire

which actuates the regulator, this wire must connect
to a switched

Do

not

connect

the

regulator.

[+]

"keyed ignition" is the key circuit

[+]

12 volt source. Refer to the

any

power

source

be

connected to

post [or the positive cable].

WESTERBEKE WIRING DIAGRAM for the proper

connection.

Dual

Pulleys

A variety
charging alternators are available from your
dealer.

of

accessory pulleys for high powered and dual

with-

TO

BATTERY

1

-------

"BATIERY

TO

~ONNECTS

.

DUAL
[CHARGING

SENSE"

BAmRY

BLUE

LEADS.
CONNECTS

BUZZER.

WIRE

CONNECTS

OIL

PRESSURE

OUTPUT

POSITIVE

TWO

POST

TO

PINK

AND

THE

PINK

TO

THE

THE

BLUE

TO

THE

SWITCH.

ALTERNATOR

BATTERIES]

Engines

24

& Generators

DUAL

OUTPUT

ALTERNATORS

TROUBLESHOOTING

NOTE:

Before

troubleshooting, make certain that

belts

are

tight

and

the

batteries

.

Regulator

The red "battery sensing"
must always read battery voltage.
present, trace the wire for a bad connection.

The orange wire
volts [approximately] with the key on.
incorrect, trace the wire for a

The blue
voltaae will vary depending
loadl;m.
key on,

KEY

ON -NO

KEY

OFF -BAmRY

REGULATOR
TerminalIColor

I

Brown

A

Red

S

Orange

F

Blue

All.

Output

Testing

S should read 0 volts with the key off, 12

wire F supplies current to the alternator fields, its

The readings can vary from 4 to 12 volts with the

0 volts with the key off.

VOLTAGE

TEST

POINTS

Ignition

o

12.6

o
o

12.6

REGULATOR

VOLTAGE

AND
Off

volts

volts

volts

volts

volts

are

in

good

wire

A connects to the battery, it

If

battery voltage is not

If

the readings are

bad

connection.

on

the battery charge or actual

IS

DEFECTIVE

REGULATDR

PROPER

Ignition

2

-12

12

o

volts
10
12

VOLTAGE

On

volts

volts

-11

volts

volts

IS

DEFECTIVE

Engine

14.2

14.2
6 - 8
4 -12

14.2

the

condition.

Running
volts
volts

volts

volts

volts

drive

Alternator

The

regulator

are

in

1.

Test the voltage at the alternator plug with the engine
off-key on. The voltage at the alternator terminal F and
the voltage in the plug [blue wire
should read the same.

2. Hold a screw driver close

If

.not, the problem may be the brushes [worn] or the rotor

[open circuit].

3. Start the engine, at fast idle the output terminals should
indicate 14.2 volts [no load]. A reading

indic~te

Apply a load such as an electric bilge pump, the voltage
should maintain at least 13.8 volts.
indicates the alternator is faulty.

Testing

is

functioning

good

condition.

voltage is present you should feel the magnetic field.

the alternator is not performing properly.

properly

[112"]

and

F]

from the regulator

to the alternator pulley.

of

13

volts or less

the

batteries

12.6 would

NOTES:

o

When

the

engine

is

first started, it takes a few moments

to

for the alternator

is a noticeable change

RPM gauge will

o A slight

on

the

alternator.

whine

"kick in" and take

in

the

excite.

is

normal when

sound

running

the

load.

of

the

engine

with a full load

There

and

the

If

o

When

become very

o

When

purchase

the

alternator

hot.

replacing

and

is

the

alternator drive

replace

dual belts

producing high

in

matched

amperage,

belts,

always

it will

pairs.

Engines

25

.x

Generators

WATER

TEMP

AI

ARM.

SWITCH

'I

1

W ALARM

011

ALARM

SWITCH

PRESS

W-70GA

"4

WIRING

V 10

DIAGRAM

AL

TERNA

TOR

PRESS

SWITCH

Q.lL

PRESS

SENDER

I
1

1_

- - -

ill.L

Dr

T

f------,

+

ULlL

"4

WHT

tt

4 V

SPARK PLUGS

DISTRIBUTOR

10

III

1111

III

'III

III

'III

'"

'III

;

/-,-----~~

I

BATTERY

+tly

t

SEE

1

NOTE

----

" 0

-=-

3 J

WHT

'0'

4 } SAFETY

\0....

TO

61..OCK

NEUTRAL
SW

ITCH

WAH

R

TEMP

SENDER

r

~========t===========~'~"~O~R~"==~~~========================t====================t==~~

I NSTRUMENT PANEl

Oil

PRESSURE

:\4

Y

WATER

T€MP

II

t1

R[O/':'iHT

TACH-HOUR

METER

=-Q

~

~JI-----_

Engines & Generators

26

W·70GA

WIRING

SCHEMATIC

F.(SP(iN$lerLH

J.

THE

wESTERB(KI:':

THE

rACTOR'

r.OAST

GUARD

Hor N(C(SS4RILY

AIIO

ISOLATED

2.

IT

IS

THE:

INSTALLATION

).

AN

OH-OH

(IRCUn

TwELVE

OUR,uIOIi
SWITCH
SERvE

THESE

START(R

<4.

THIS

PRODuCT

THE

STARTER
CuRRENT
CAUSE

THE

DOWN

BECAUSE

THE

BUILDER

ARE

INSTALLED

+-

FOP.

ANO

REGULATrON

FRON

RESPONSIBILITY

OF

SWITCH

rROM

THE

vOLT

STARTERS

OF

INDIVIDuAL

WITH A

COI~TlNUOUS

rUNCTIONS BuT

CIRCUIT.

IS

AND

DRAIN

ANTWHERE

BREAKER

THE

OWNER

TO

____

+-

SAFETY

REGULATICllS

1!'1GI.

GASOlllI(

"'ARINE

eXClUSivE

l3

so

CQNPLY

GA.SOllNE

OF

THIS

ENGINE

MUST

BE

IItSTALlED

BArTERl

IN

TYPICALLY

CRANKING

RATING Of' 175

PROHeTE'O

AS

CLOSE

TO

IN

TO

TRIP. IN THIS (VENT

OPENED

BREAKER

MUST

8~

PREVENT

CONTACT

STARr

SOL.

i-~'-~:------~~r-------------~

I I

ALTERNATOR

__

~OU~T~

EXC

PRCPIJLSrON

or

ITS

IflsrRUI~ErlT

CfR-r8~.

THE

ANO

IS

INTENDED

SOuRCES

1M

THE

BOAT

AND

ITS ,"STRUMEliT

IN

AN

EMERGENCY

DRAW

lao

CYCLES

SUCH A SWITCH

8Y

A

MANUAL

THE

SOURcE

THE

INSTRUMENT

D I

SCaNNEC

SURE

THAT

THE

BEiY/EEW

eA

TTEI{, I (

rG~N~O

________________ ~ ____________

TACH

DIODE

eALLAST

RESISTOR

C.P.

SWI

TCH

EHGUlE

PANEL

COr.cFL1(S

STAIUiARD

lIiSTRUN(NT

TO

BE

INSTAL-lEO

ACCORDANCE

MAHuFAcruREp.

THIS

RESEr

WITH

TO

It/SuAE

PANEL

COIltPt.,Y

liNE

TO

DISCONNECT

AND

WHEH

LEAVING

TO

!OO

AMPS

NOT

AT

NEVER

CIRCUIT

CURRENT
MOST

ENGINE

THE

VUC

WHEN

£.XC£EO

12

VOLTS

BE

BAEAKER

AS

POSSIBLE. ExCESSIVE

WIRING

I R

ruEI.

SHOULD

AMPS

NUST

or

PANEL.
T5

INSTRUMENT PANEL WIRING

ELE(TRICAL DEVICES

STAIHER

COl L

AS

SHlfPEI'J

33t;F'A

CRANKIfIG.

jO

WILL

uSED

OR

MODELS

SUPPL

WITH

PANEL

ABOvE

163.410

THAT

WIYH

THE

SECONDS.

NORMALLY

TO

LOCATED

ENGINE

WilL

T •

·AND

FRvM

u.s.

DOES

DECK

THE

J3CFR-r83,

THE

STARTER

BOAT,

·NA~E"

Will

SHuT
THEREFORE
AND
SALT

Ibl,

THE

A

THE

HEAR

ENGIHE

WATER.

~

PRESTART

SWI

reM

'-

___________

__

f-

____

TACHOMETER

-"{s

GliO

VOL

TNETER

GNO

'-+

GND

\ S

--------

....

~_'_{I

GOA'ciG'E

GHD

Engines & Generators

27

TACHOMETER

TACHOMETER/HOUR

The tachometerlhour meter used in propulsion engine instru­ment panels contains two separate electrical circuits with a
common ground.

other the tachometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to the

on the back
The tachometer circuit operates on AC voltage 6-8 volts, fed

fTom
tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8

volts DC.

The following are procedures to follow when troubleshooting
a fault
meter.

Hour

Check for the proper
terminals.

1.

Voltage present - meter is defective - repair or replace.

2. Voltage not present - trace
nections for fault. (Jump 12 volts DC to meter
terminal to

Tachometer

Check for the proper
terminal and

1.

Voltage present - attempt adjusting meter through calibra­tion access hole. No results, repair or replace meter.

2.

AC voltage not present - check for proper alternator DC
output voltage.

3. Check for

ground.

4. Check electrical connections from tachometer input ter­minal

Tachometer

1.

Check for proper
nal and

2.

Check for good ground connection between meter (-)
minal and alternator.

3. Check that alternator is well grounded to engine block at
alternator pivot bolt.

of

the instrument.

one

of

the diodes in the alternator and supplied to the

in

either

of

meter

Inoperative

verifY

Inoperative

(-)

terminal with the engine running.

AC

to

alternator connection.

Sticking

(-)

terminal.

METER

One circuit operates the hour meter and the

(+) terminal

the two circuits in a tachometerlhour

DC

voltage between (+) and

(+) and (-) electrical con-

the operation.)

AC

voltage between tachometer input

voltage at tach terminal on alternator

AC

voltage between "tach inp." termi-

(-)

(+)

to

NOTE:

Current model tachometers use a coarse adjustmei1t
dial to set the tachometer to the crankshaft pulley rpms. The
calibrating screw is then used

COARSE

ADJUSTMENT

TACHOMETER
IDLE

SPEED

NOTE:

In a new installation (commissioning) the tachometer
in the instrument panel will not always be correctly
calibrated to the engine's RPM. The tachometers calibration

must be checked in a new installation (commissioning)

1.

Place a piece
front crankshaft pulley.

Start the engine and allow the engine

2.
then set the engine speed at a high idle
a strobe type tachometer shooting the front crankshaft
pulleys reflective tape for an accurate engine rpm reading.

3. Positive
selections.
closest

4. Using a small phillips screw driver, adjust the calibration

to

pod

S.

Check the tachometer readings at idle and at high rpm.

6. Adjust the idle speed at a comfortable rpm, but not at too
Iowa
the transmission.

CALIBRATION

ADJUSTMENT

of

reflective tape on the outer edge

the"coarse" adjustment at each

Select the one that sets the tachometer reading

to

the 1500 rpm.

set the tachometer exactly on 1500 rpm.

speed to induce vibration and stalling when shifting

for

fine tuning.

CALIBRATION

&

(New

WIRE

TERMINAL

INP

AC

VOLTAGE

Installation)

of

to

warm up and

1500 rpm, using

of

the six

..

the

Tachometer

a. With a hand-held tach on the front

pulley retaining nut or with a strobe-type tach, read the

front crankshaft pulley rpm at idle.

h. Adjust the tachometer with a small Phillips type screw-

driver through the calibration access hole in the rear

the tachometer. Zero the tach and bling it
indicated
idle and at high speed.

Inaccurate

by

the strobe or hand tach.

of

the crankshaft

to

the rpm

VerifY

the rpm at

of

Engines & Generators

28

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should be cleaned and regapped after the
first 50 hour break-in period, then inspected every 250 hours

thereafter and replaced

SPARK
SPARK

NOTE:

the
of

PLUGS

A

WARNING:

the

engine

removing

PLUG

GAP:

PLUG

TORQUE:

Loctite Anti-Seize applied

spark plugs will retard

the

spark plugs

Do

is

hot.

Allow

them.

0.031-0.028 ± 0.0002
10

easier.

as

needed.

not

remove

the

-15Ib-H

corrosion,

the

spark

engine

to

cool

in.

(0.8-0.7mm)

(1.5 -2.31

kg-m)

to

the

threadedportion

making fuiure removal

plugs

before

while

of

INSPECTING
THE

SPARK

PLUGS

DRIVE

The drive belts must be properly tensioned. Excessive drive
belt tension can cause rapid wear
service life
and engine coolant
on
temperatures and the failure

1.

2.

NOTE:

3. The drive belts are properly adjusted

4.

NOTE:

BELT

ADJUSTMENT

of

the belts

of

the bearing and the alternator,

pump.

A slack belt or the presence of

the belt can cause belt slipping, resulting

of

the same components.

To

adjust the alternator and the engine coolant belts,
loosen the alternator mounting bolts and pivot the
alternator

To
bolts and slide the pump
Retighten the bolts.

frayed

no
(12mm)
midpoint between
the belt.

Operate the engine for about 5 minutes, then shut down
the engine and recheck the belts tension.

proper belt

ried

as

needed. Retighten the bolts.

adjust the raw water pump belt, loosen the mounting

up

and down

When

the

belts

are

loose,

inspect for

edges,

and

replace

less than 3/8 inch (lOmm) and

as

the belt

the

Maintain a

on

operation.

board

22

lb

if

necessary.

no

is

depressed with the thumb

two

pulleys

pressure

Spare

on

to

the

belts should

and

reduce the

raw

water pump,

in

high operating

as

needed.

wear,

cracks

if

it

can

be

deflected

more

than

112

inch

at

the

the longest span of

belt's outer face for

always

be

car-

oil

and

CHECK

FOR

CARBON

AND

BURNING

\\.

..... _-'L._--INSPECT

DAMAGE

FOR

A

WARNING:

drive

belt's

Never

tension

attempt

while

the

to

check

engine

is

or

in

adjust

a

operation.

Engines & Generators

29

ENGINE

NOTE:

WESTERBEKE recommends that the following engine
adjustments be peiformed by a competent engine mechanic.
The infonnation below is provided to assist the mechanic.

ADJUSTMENTS

VALVE

NOTE:

engine's valves (see TORQUING THE CYLINDER HEAD
BOLTS).

1.

2. Position the No.1 piston at Top Dead Center

CLEARANCE

Retorque the cylinder head bolts before adjusting the

Remove the rocker cover and

compression stroke and adjust the

No.1 and No.2 valves on the intake side
head and the No.1 and No.3 on the exhaust side. Rotate
the crankshaft
the remaining four valves.

ADJUSTMENT

gaske~.

(IDC)

of

#1

and #3 exhaust

of

the cylinder

360° in a clockwise direction and adjust

#1

INTAKE

#4

EXHAUST

its

IGNITION

1.

Attach a timing light
front crankshaft timing
scale embossed on the engine's front cover.

Each timing mark represents

TIMING

to

the

#1

spark plug and mark the

groove and the timing mark

2°.

/

/

/'

CRANKSHAFT'

PULLEY

2. Start the engine and warm the engine to its nonnal
operating temperature.

Using the timing light, align the timing groove in the front

3.
crankshaft pulley with the proper timing mark
tion timing scale embossed on the engine's front cover.

tillS

Do
body. Refer to the timing specifications:

TIMING

by loosening and slowly rotating the distributor

SPECIFICATIONS

0°

TOC

AT

625

RPM

on

the igni-

on

the

3. Replace the rocker cover and the rocker cover gasket..

Rocker cover torque: 2.9-S.1Ih-ft (0.4-0.7 kg-m)

4. Adjust all values to 0.012 (0.30mm) with the engine hot.

~'.D121'."mm)

Engines & Generators

.

ELECTRIC

The electric choke uses a 12 volt heating element which
opens the choke automatically when the engine starts.

The choke
the choke by loosening the three cover-securing screws and
rotating the cover clockwise to
counterclockwise to
set at the factory for an average
temperature. The choke may need readjustment at engine
commissioning for the ambient temperature of the area the
engine

on the underside

SEE

CHOKE

is

adjusted with the engine off and cooled. Adjust

LEAN

RICH

the choke. The .choke

is

operating in. The choke reference mark is located

of

the choke cover.

CARBURETOR

of

700P

the choke and

(21°C) room

30

is

initially

ENGINE

NOTE:

WESTERBEKE recommends that the following engine adjust­ments be performed by a competent engine mechanic. The information
below is provided

to

ADJUSTMENTS

assist the mechanic.

TORQUING

After the initial break-in period (approximately 50 hours), the
cylinder head bolts should be re-torqued.

Tighten the cylinder head bolts according to the sequence
shown. Make sure the engine
loosen one head bolt one-half turn and then tighten it
between 55 - 59 lb-ft (8.2 - 8.8 Kg-rn). Then proceed to the
next head bolt in the sequence. Tighten the RS (rocker cover
stud) securely.

THE

CYLINDER

10

HEAD

BOLTS

is

cold when this

7 3

is

done, and

4

ENGINE

If

compression, warm the engine and shut it down.
Remove the spark plugs and install a compression adapter

(screws into a plug hole) with a gauge.
Crank the engine (close off the raw water) and unplug the

ignition coil. Allow the compression gauge to reach a
maximum reading and record.

Measure the compression pressure for each cylinder. Ensure
that the pressure differential for each cylinder is within the
specifications.

COMPRESSION
LIMIT

If

the limit, add a small
plug hole and repeat the test.
pressure, the piston ring andlor cylinder wall may be worn or
damaged.
pressure suspect poor valve contact, valve seizure, or valve
wear. Reinstall the plugs, ignition wires, and coil.
raw

COMPRESSION

it becomes necessary to check the engines cylinder

PRESSURE

OF

DIFFERENCE

a cylinder's compression or pressure differential

If

the added oil does not increase compression

water

tbru

AT

BETWEEN

an10unt

seacock.

1400

RPM

CYLINDERS

of

engine oil through the spark

If

the oil causes

198.1

28.0

psi

psi

an

increase

(14

(2.0

is

Open

kg/em')
kg/em')

below

of

the

HIGH

TENSION

Check the ignition wires every 500 operating hours as engine
compartment heat can deteriorate the wires.

Check the resistance
because the wire connection inside the cap may become
separated or the insulator may be damaged. When removing
the wires from the spark plugs, grasp and twist the molded
cap, then pull the cap off the spark plug.

THE

RESISTANCE

CORDS

VALUE

IS

(IGNITION

of

each wire. Do not pull on the wire

410

OHM

PER

WIRES)

INCH.

TESTING
RESISTANCE

Engines & Generators

31

The

following
relating
and

the

When
the

ELECTRICAL SYSTEM

troubleshooting

to

engine

service,

recommendations

troubleshooting indicates

table

the

probable

to

overcome

WIRING

describes

causes

an

electrical

DIAGRAMS.

ENGINE

certain

problems

of

these

these

problems.

problem,

TROUBLESHOOTING

NOTE:

The

problems,

refer

to

ampere
the
the

engine s electrical system is protected

manual
back
same

of

the

bracket.

reset

circuit breaker located

engine.

The

preheat solenoid is mounted

by a 20

on

a bracket at

on

No

panel

indications;

or

fuel

pump

is

on

START
engagement.

Engine

Poor

is

and

PRESTART

button

cranks,

running

Problem

fuel

not

is

but

performance.

solenoid

working

button

depressed,

does

not

(key

switch

is

depressed)

no

starter

start.

1.

Battery
20-amp

2.

3.

Loose

1.

Connection

2.

Gear

Faulty

3.
Faulty

4.

5.

Loose
Low

6.

1.

Faulty

2.

Fuel

3.

Choke.

4.

Low

5.

Carburetor

6.

Engine

Worn

7.

High

8.

Faulty

9.

10.

Faulty

11.

Faulty

12.

No

13.

Faulty

1.

Carburetor

Probable

switch

circuit

battery

to

shift

not

switch.
starter
battery

battery.

fueling

lift

pump

battery

power.

filter

is

flooded.

or

faulty

tension

ignition
distributor.
wire

connection.

engine

compression.

idle

adjustment.

inlet

Cause

not

on.

breaker

tripped.

connections.

solenoid

faulty.

in

neutral.

solenoid.

connections.

system.

failure.

screen

is

spark

plugs.

wires

grounding.

coil.

clogged.

clogged.

1.

Check

2.

Reset
circuit

3.

Check
engine

1.

Check

2.

Gear

HURTH

3.

Check

4.

Check

5.

Check
Check

6.

1.

Check

1a.

Check

1

b.

Fuel
fuel

2.

Pump

volts.

Check

3.

4.

Switch

5.

Clear

6a.

Carburetor
replace

6b.

Float

6c.

Float
Replace

7.

Replace.
Inspect

8.

9.

Test

10.

Test

11.

Inspect

12.

test

13.

Adjust

1.

Remove

VerificationJRemedy

switch

and/or

breaker;

and

check

(+)

connection

ground

connection.

shift

must

HSW

switch

with

that

12
battery
battery

that

fuel

for

air

in

filters

clogged.

system.

should

Replace

pump.

choke

operation.

to

combine

with

compressed

float

the

needle

in

carburetor

chamber

gasket

wires

coil.

distributor,

wires.

compression,

idle,

see

and

clean.

battery

connections.

if

breaker

trips

for

shorts

to

starter

Check

battery

neutral

present

state.

are

open.

system.
Replace

Check

Adjust

and

air

or

valve

leaking.

damaged

tighten

manual.

manual.

again,

to

solenoid

cable

(see

NEUTRAL

at

the

Check

Bleed

air

filters

and

connections,

tension.

start

clean

open

or

Repair

or

securing

screws.

circuit

stud.

be

in

TRANSMISSIONS).

ohmmeter.

volts

are
connections.
charge

valves

fuel

be

"ticking".

house

needle

valve.

is

gasket

and/or

and

test.

see

see

manual.

check

preheat

ground.

and

connections.

solenoid

fuel

supply.

from

fuel

bleed

batteries.

with

kerosene.

damaged.

or

replace

solenoid

(-)

connection

SWITCH

connection.

system.

air

from

check

Replace

Clean

float.

screws

are

to

under

for

12

batteries.

or

loose.

2.

3.

4.

5.

Main

jet

clogged.

Air

intake,

carburetor
Carburetor
Fuel

lines

clogged.

screen

dirty.

inlet

filter

clogged.

Engines & Generators

32

2.

3.

4.

5.

Remove
Remove
Remove

Inspect

and
and
and

lines.

clean.
clean.
clean.

replace

inlet

fuel

filter.

(continued)

ENGINE

TROUBLESHOOTING

Engine
and

then

Engine
does

not

Engine

Battery

Battery

Engine

Problem

starts,

runs

shuts

starts,

runs

throttle

hunts

runs

down.

not

charging

misfires.

down.

but

up.

1.

Dirty

2.

Faulty

Fuel

1.

2.

Throttle
Faulty

3.

Air

4.

5.

High

Low

1.
Cracked

2.

Faulty

3.

4.

Faulty
High

5.

Valves

6.

7.

Dirty
Oil

1.

High

2.

3.

Low
Poor

4.

DC

5.

(tachometer

1.

DC

Alternator

2.

1.

Poor

1a.

Fuel
Incorrect

2.

3.

Dirty

4.

Cracked

5.

Faulty

Spark

6.

High

7.

Valve

8.

Probable

fueVwater

fuel

lift

line

restriction.

plate

fuel

lift

intake

restriction.

exhaust

battery

voltage.

distributor

high

tension

fuel

lift

exhaust

are

out

fuel

filters.

pressure

resistance

resistance

battery

altemator

charge

circuit

drive.

quality

blockage.

timing.

flame

arrester.

distributor
ignition
plugs

exhaust

clearances

Cause

separator

filter.

pump.

binding.

pump.

back

pressure.

cap.

wires.

pump.

back

pressure.

of

adjustment.

switch.

leak

to

ground.

leak.

connections.

not

charging

not

operating).

faulty.

fuel.

cap.

wires.

are

worn.

back-pressure.

are

incorrect.

Change

1.

2.

Pump

should

1.

Inspect

Adjust

2.

3.

4.

5.

1.

2.

3.

4.

5.

6.

7.

1.

2.

3.

4.

5.

1.

2.

1.
1a.

2.

3.

4.

5.

6.

7.

8.

linkage.

Lift

pump

Check

air

I

nspect

hose.

Test

Check

batteries.
Replace
Test

wires.

Lift

pump

Inspect

hose.

Test

Adjust

valves.

Change

Observe
not

running.

Check

wiring.

lines.

(Do

after

short

Check

all

Check

cable

corrosion
Check

connections,

ALTERNATOR

Perform

Testing

Check

drive

for

loose

volts

are

Check

filters
Replace
Adjust

timing.
Clean

with
Replace
Test,

replace.
Replace
Test

back

Check

clearances.

Verification/Remedy

filters.

be

"ticking".

Check

all

fuel

lines.

should

"tick".

Check

intake.

Clean/replace

exhaust

elbow

for

back

pressure.

distributor

should

exhaust

elbow

back

pressure.

filters.

if

gauges

Test

Insert

not

start

is

located.

wires

for

connections

TESTING.

DC

voltage

the

Battery

belt

connections.

present

for

inlet

fuel

compressed

distributor.

spark

plugs.

pressure.

corrosion.

cap.

"tick".

Check

for

corrosion.

and

panel

the

oil

pressure

sensitive

engine.)

temperature

at

check

check

Charging

tension;

alternator

Check

at

the

Exc.

water.

Change

filter,

check

air

lights

Remove

battery

belt

of

generator

Circuit.

output

terminal.

fuel

or

connections,test

connections,

filter

screen.

Check

connections,

Check

are

activated

switch.

(0 -.25

amp)

connections

rise

to

locate

for

loose

tension,

test

charging

should

turn

with

voltmeter.

fuel.

lines.

kerosene.

for

12

test

for

12

volts.

exhaust

elbow

test

for

12

volts.

exhaust

elbow

when

engine

meter

in

battery

and

replace

the

fault.

connections,

alternator.

circuit.

freely.

Ensure

See

Check

volts.

i

See

12

Engines & Generators

33

ENGINE

TROUBLESHOOTING

Problem

Engine

backfires.

Engfne

overheats.

Low

oil

pressure.

High

oil

pressure.

No

DC

charge

starting

battery.

Oil

leak.

Engine

alarm

Engine

alarm

to

the

sound

sounds

pulsates.

continuously.

1.

Spark
wrong.

2.

Incorrect

3.

Engine

flooded
to

start.

4.

Dirty
Cracked

5.

6.

High

7.

Choke

1.

Coolant

2.

Faulty

3.

Belts

4.

Faulty
Heat

5.

6.

Collapsed
Faulty

7.

8.

Coolant

1.

Low

2.

Faulty
Wrong

3.

4.

Wrong
Relief

5.

Faulty

6.

7.

Faulty
Faulty

8.

Oil

is

9.

Dirty

1.

the

engine.

Relief

2.

Faulty

1.

battery.

2.

Connections
loose

Faulty

3.

1.

Oil

drain

2.

Damaged
cover

Loose

3.

switch

4.

Loose
Oil

pan

5.

1.

Loss

2.

Oil

pressure

Engine

1.

2.

High

too

Probable

plug

wires

tlming.

is

flooded.

under

Engine

flame

arrester.

distributor

exhaust

back-pressure.

is

stuck

closed.

loss.

raw

water

are

loose

or

thermostat.

exchanger

hose.

coolant

pump.

tank

or

oil

level.

oil

pressure

SAE

type

type

oil

filter

valve

is

stuck.

oil

pump/strainer.

engine

bearings.

oil

filter.

sump

is

slugged.

oil

or

wrong

valve

is

stuck.

connections

to

or

faulty.

alternator.

hose

loose.

or

loose

or

rocker

or

damaged

or

sender.

or

damaged

leaking.

of

oil.

switch.

coolant.

temperature

Iowa

temperature.

Cause

are

connected

See

Engine

cranks

cap.

pump

impeller.

broken.

is

clogged.

pressure

switch,

oil

in

the

..

SAE

type

to

the

alternator

timing

arm.

oil

pressure

oil

filter.

switch

is

but

cap

faulty.

sender,
engine.

oil

are

chain

opens

.

fails

in

at

gauge.

.

1.

Reconnect

2.

Adjust

3.

See

4.

Clean

5.

Replace

6.

Test

7.

Inspect

1.

Check

2.

Replace

3.

Tighten,

4.

Replace.

5.

Service

6.

Replace.

7.

Remove

8.

Inspect,

1.

Add

2.

Test
Change

3.

4.

Change

5.

Service

6.

Service

7.

Service

8.

Change

9.

Service
Change

1.

2.

Service

1.

Tighten

Tighten

2.

3.

Test

1.

Tighten,
Tighten,

2.

Tighten,

3.

Tighten,

4.

5.

Tighten

1.

Check
oil

2.

Replace

1.

Check

2.

Check
check

Verification/Remedy

correctly.

engine

timing.

Engine

cranks

but

with

compressed

distributor.

back-pressure.

carburetor.

for

leaks,

pressure
impeller.
check

belts.

heat

exchanger.

and

replace.

replace.

oil.
and

replace.

oil.

filter

..
engine.
engine.
engine.

filter.
engine.

Flush

oil.

engine.
and

clean

connections

and

clean

connections.

alternator.

replace.
replace.

replace.

replace.

bolts,

replace

dipstick,

hose

oil

pressure
engine
for

satisfactory

with

ohmmeter,

look

connection.

coolant

drain

See

manual.

fails

air

or

test

Sump.

pan

gasket.

for

oil

leaks

switch.

level.

operation

replace

to

start

column.

kerosene.

system.

..

at

oil

with

if

faulty.

filter

switch

and

at

bypassed,

Engines & Generators

34

ENGINE

TROUBLESHOOTING

Problem

Engine

slows

Engine

overheats/shuts

Exhaust

smoke

and

stops.

problems

down.

1.

Fuel

2.

Switches
or

disconnected.

3.

Fuel

4.

20

5.

Exhaust

6.

Water

7.

Air

1.

Raw

2.

Coolant

1.

Blue

2.

White

3.

Black

Probable

lift

pump

and/or

starvation.

Amp

circuit

system

in

fuel.

intake

obstruction.

water

not

not

smoke.

smoke.

smoke.

Cause

failure.

wiring

breaker

is

restricted.

circulating.

circulating.

loose

tripping.

1.

Fuel

lift

pump

pump

with

spare.

2.

Inspect

wiring

Inspect

switches

3.

Check

fuel

supply,

4.

Check

for
Ensure
cause

Check

5.

exhaust

6.

Pump
bleed

7.

Check

1.

Raw

2.

Obstruction

2a.

Thermostat -remove

Replace

2b.

Loss

for

2c.

Broken

2d.

Air

bleed

1.

Incorrect

1a.

Crankcase
through

1

b.

Crankcase

1c.

Valves

2.

Engine

3.

Improper

3a.

Fuel
insufficient
exhaust

3b.

Dirty

3c.

Faulty

3d.

Lack
ventilation.

3e.

Idle

3f.

Overload.

high

breaker

tripping.

for

blockage,

elbow.

water

fuel

system.

air

intake.

water

pump

at

thermostat.

of

coolant -check

leaks.

or

loose

leak

in

system;

air.

Add
grade

is

the

exhaust).

breather
and/or
is

running
grade

burn

incomplete

air

system;

flame

arrester.

carburetor.

of

air-check

mixture

jet

Verification/Remedy

should

make a distinct

for

short

circuits

for

proper

fuel

valves,

DC

amperage

is

not

overly

collapsed

from

fuel

tank(s);

failure.

Check

raw

water

intake

and

test

hoses,

belts -tighten/replace.

run

engine

coolant

as

needed.

of

engine

oil.

overfilled

with

hose

is

clogged.

piston

rings

are

cold.

of

fuel.

due

proper

check

Choke

air

intake

rich.

to

combustion

air

intake).

is

stuck.
and

for

too

ticking

and

loose

operation.

fuel

lift

pump.

draw

during

sensitive

to

hose,

carbon

change

impeller -replace.
or

raw

in

hot

water.

hose

clamps,

and

open

Oil

is

diluted.

engine

oil

(oil

worn.

high

back-pressure

(check

air

filter.

sound.

connections.

operation.

heat

which

buildup

filters

and

water

filter.

drain

the

pressure

is

blowing

for

Check

for

Replace

would

at

plug,

etc.

cap

to

out

in

exhaust

restrictions

proper

or

in

TROUBLESHOOTING

If

the gauge reading
by the gauge when the instrument panel is energized, the
step is to check for 12 volts
and the Negative (B-) terminals

Assuming that there
instrument panel energized and perfonn the following steps:

1.

Disconnect the sender wire at the gauge and see
gauge reads zero, which is the nonnal reading for this
situation.

2.

Remove the wire attached to the sender terminal at the
sender and connect it to ground. See
full scale, which

is

other than what is nonnally indicated

DC

between the ignition (B+)

of

the gauge.

is

12 volts as required, leave the

is

the nonnal reading for this situation.

COOLANT

if

the gauge reads

TEMPERATURE

fIrst

if

the

Engines & Generators

35

AND

OIL

If

both

of

the above gauge tests are positive, the gauge

undoubtedly

PRESSURE

OK

and the problem lies either with the

GAUGES

is

conductor from the sender to the gauge or with the sender.

If

either

of

the above gauge tests are negative, the gauge

probably defective and should be replaced.

is

Assuming the gauge

OK, check the conductor from the

sender to the sender tenninal at the gauge for continuity.
Check that the engine block

is

connected to the ground.
Some starters have isolated ground terminals and if the
battery is connected to the starter (both plus and minus
tenninals), the ground side will not

necessmily be connected

to the block.

is

ZF

TRANSMISSIONS

SHIPMENT

Por safety reasons, the transmission
transmission
temporarily attached

Before leaving the WESTERBEKE plant,
undergoes a test
The residual

draining

against corrosion for at least one year if properly stored.

SELECTION
LEVER

OUTPUT
COUPLING,

OIL

COOLER

The oil
continuous cooling
passes through the tubes of the cooler
overboard. The transmission

the tubes and back into the transmission.

WESTERBEKE

HAVING A SPARE

ABOARD

fluid

during shipment

to

the actuating

run,

with Dextron III ATF transmission

fluid

remaining

acts

as

a preservative and provides protection

DIPSTICK

cooler,

mounted above the transmission, provides

for

the transmission

RECOMMENDS

COOLER

is

not

filled

with

and

the selector lever

shaft.

each

transmission

in

the transmission after

~~~~'!.fJ-

ZF-63

fluid.

Raw

and

discharges

fluid

is

cooled

as

it

flows

FILTER

ASSEMBLY

water

RAW

CONNECTION

is

fluid.

around

WATER

INITIAL

Set the shifting lever
and
with

shifting should be smooth
forward
clutch permits changing at high
reversing at high speeds

After initial operation,
coupling,
the transmission.

LOCKING

Locking of
required: use
direction of travel
the position corresponding
boat.

WHEN.

Rotation of
boat
well

(for charging the battery),
the transmission.

NOTE:

gear shift must be
idle and

DAILY

D Check the transmission

D

D Start
D Shift into

OPERATION

to

neutral position

let it run long enough

transmission

to

oil

UNDER

is

being sailed, being towed or anchored

as

operation of the engine with

VVhen

can

fluid.

reverse

cooler

THE

PROPELLER

the

propeller shaft

the

gear shift lever position opposite your

for

SAIL

the

propeller without a load,

the

boat

in

free-wheel.

in

idle

Shift into

and

are

permissible since the multiple

in

the event of

make

a visual inspection of

and

hoses,

this

purpose. Never put

to

OR

BEING

will

is

being sailed (engine

the

neutral position.

OPERATION

fluid.

Visually

to

check the gear shift linkage and transmission.

the

engine in neutral, allowing a

warm

the

fluid.

gear.

(N).

Start the engine

to

fill

the

cooler

and

gear,

forward

positive. Direct

rpm

including

danger.

and the cable connections

by

an

additional brake

the direction of

and

reverse;

changes
sudden

the

the

gear shift in

travel

of

TOWED

such

as

when

in a river,

the

propeller stopped

have

no

detrimental effects

stopped),

The

propeller

few

minutes

hoses

from

disc

output

is

not

the

the

as

the

is

at

to

on

at

idle

'Mi7J---

ZF

TRANSMISSION

Pill the transmission with

the

up

first

should be
level, press the dipstick into the case
During
output shaft
should be changed after the
hours thereafter.

NEUTRAL

These transmissions
switch. This
Unless the transmission selector lever
neutral, the engine starter

FLUID

De),:tron

to

the mark
25

and

transmission cooler

on

operating hours, inspect

SWITCH

are

equipped with a neutral safety

is

to

prevent the engine

will

TRANSMISSION

FLUID

COOLER

III

the dipstick. After checking the

first

25

hours

not activate.

CONNECTIONS

ATF.

The

fluid

and

tum it

to

tighten.

the

bell housing,

for

leakage.

from

is

perfectly aligned in

and

every 300

starting

The

in

NOTE:

from

the

Operating

The operating temperature of the transmission should not

level

fluid

exceed
is

provided.

reach 2200P

A

too
transmission

gear.

Engines & Generators

36

Too

low

an idle speed will produce a chattering noise

the

transmission gear and damper

idle speed should be

increased.

Temperature

176°P

(80°C).

At

(104°C).

CAUTION:

high,

stop

A connection for a temperature probe

maximum output of

If

the

transmission

the

engine

fluid.

plate.

the

engine,

fluid

immediately

and

In

such cases

the

fluid

may

temperature

check

is

the

ZF

DESCRIPTION

The

information below is specific to the

the

TRANSMISSION TROUBLESHOOTING SECTION

applies to all models.

CONNECTION

HBW

recommend a flexible connection between the
transmission gearbox and the propeller shaft
flexibly mounted, in order to compensate for angular
deflections. The installation
bearing is not required, since the propeller thrust will
taken

by

specified under

However, the output shaft should

additional loads.

torsional vibration.

certain to observe the manufacturers instructions.

Even

with the engine solidly mounted, the use
coupling
gearbox bearings caused
wooden boats
output flange and stern gland is less than about

OF

GEAR

BOX

of

a special propeller thrust

the transmission bearing, provided the value

SPECIFICATIONS is not exceeded.

Special care should

When

using a universal

or

*"DRlVESAVER" will reduce stress in the

by

hull distortions, especially in

or

where the distance between transmission

ZF

Transmissions,

WITH

PROPELLER

be

protected from

be

taken to prevent

joint

if

the engine is

shaft, make

of

flexible

800mm.

TRANSMISSIONS

NOTE:

"When

installing

be

shifting
Bowden
sheaves,
support for shift control
threaded holes located
gear

CONTROL

The transmission is suitable for single lever remote control.
Upon loosening the retaining screw, the actuating lever can
be
(cable or rod linkage). Make certain that the shift lever does
not contact the actuating lever cover plate: the minimum

distanc~

The control cable
the actuating shift lever when in
neutral position
should coincide with the neutral position

The shifting travel, as measured at the pivot point
actuating lever, between the neutral position and end
positions

30mm

A greater amount
detrimental and is recommended. However,
travel is shorter, proper clutch engagement might
which, in
generation and clutch plate failure. This would be indicated

by slow clutch engagement or no engagement at all.

NOTE

is

not impeded by restricted movability

cable

or

rod

linkage,

too

small a bending

housing.

Refer

to

CABLES

moved to any position required for the control elements

between lever and cover should

or

rod should

of

the operating lever on the control console

A and B should be at least

for the inner pivot point.

of

shift lever travel is in no way

turn, would mean premature wear, excessive heat

Checkfor proper lever travel at least

the

transmission,

by unsuitably positioned

radius,

etc.

cable

connections,

above

the

shift cover

the

WESTERBEKE

be

arranged at right angle to

the neutral position. The

35mm

make

certain

of

the

In

order

to

mount a

use

the

two

on

top

of

parts

list.

be

O.5mm.

of

this lever.

of

the

for the outer and

if

the lever

be

impeded

each

season.

that

guide

the

IF

TRANSMISSION

A

CAUTION:

the

actuating

shift

(ever

this

mechanism

transmission

* DRlVESAVER is a product

The

lever

travel

is

warranty

position

is

factory-adjusted

from

neutral

in

any

way

will

of

the

mechanism

to

position A and

tampered

be

void.

of

Globe Marine, Rockland, MA.

with,

behind

ensure

B.

If

the

equal

SHIFT

LEVER

CHECK
FROM
FORWARD

FORWARDS

FOR

EQUAL

NEUTRAL

AND

REVERSE

TRAVEL

THRU

N _

NEUTRAL

DRAIN

A

COVER

MAKE

CERTAIN

LEVER

IS

TIGHTLY

FASTENED

TO

SHAFT.

REVERSE

PLATE

THIS

THE

Engines & Generators

37

ZF

TRANSMISSIONS

CABLE

The
Upon
illustration)
control
actuating lever
distance
(O.5mm).

The
to
neutral

should coincide

transmission.
The

actuating lever between the neutral position
A and

I-3116in

CONNECTIONS

transmission

loosening

elements

between

control

the

actuating

position

shifting

B,

should

(30mm)

is suitable for a

the retaining

can

be moved

(cable or rod

does

the lever

cable or rod should be

lever when

of

with

travel,

be at least I-3/8in

for the inner pivot

single

screw,

to

any

position

linkage).

not contact

the gear shift lever

the neutral

as

measured

and

in

the

the

the

neutral

position

at

lever

hub

arranged

the

(35mm)

lever gear

the

actuating lever (see

Make

hub:

should be

position. The

on

the
of

pivot point of the

point.

shift.

required for

certain that

the

minimum

O.02in

at

a ught

control console

the

lever

on

and

end positions

for

the outer

N

the

angle

the

and

the

SHAFT

WESTERBEKE
the
bly

The installation of a

required, since the propeller

transmission

SPECIFICATIONS

shaft
should be
universal joint
turer's

Even
coupling or "DRIVESAVER"
box
boats or
coupling

NOTE:

shifting
or rod
small a bending
111OUl2t
two
the gear

For additional

COUPLINGS

recommends a flexible

transmission

mounted,

should

instructions.

with

bearings

where

and

When

is

linkage,

a support for shift control cable

threaded lwles located

lwusing.

and

the

propeller shaft

in

order

to

compensate

special

bearing,

be

taken

the

caused
stem

installing

110t

impeded by restricted movability

provided

is

not

exceeded.

protected

to

shaft,

engine

the

by unsuitably positioned guide

radius

Refer

information

prevent

make

solidly

by

hull
distance
gland

is

the

or other

to

from

transmission,

the

connection

if

the

for

angular

propeller thrust

thrust

will

be

absorbed

the

value

specified

However,

additional
torsional
certain

mounted
will

reduce

distortions,

between

less

than

r€<5trictions.

on

the

WESTERBEKE parts

contact

loads.

vibration.

to

observe

the

use

stress

especially

the

transmission

about

800mm.

make

connections,

cable

bracket mounted

engine

deflections.

bearing

the

Special

When

the

manufac-

of a

in

the

certain

of

the

sheaves,

In

order

between

is

flexi-

is

not

by

the
under
output

care

using

flexible

gear-

in

wooden

output

that

cable

too

to

use

the

list.

a

on

A greater
detrimental
is

shorter,
which,
generation
by

CONTROL CABLES under TRANSMISSION
TROUBLESHOOTING)

NOTE:

season.

A

the

shift

this
transmission

amount

proper clutch engagement might be impeded

in

tum, would mean premature

slow

clutch

Checkfor proper actuating lever travel

CAUTION:

actuating

lever

mechanism

of actuating lever

and

is recommended.

and

clutch plate failure.

engagement or

The

position

lever

is

factory-adjusted

travel

from

neutral

is

in

any

warranty

will

travel

However,

wear,

This

no

engagement at all (see

of

the

mechanism

position

way

tampered

be

void.

is

would

to

to A and

with,

,ACTUATING

LEVER

in

no

way

if

the lever travel

excessive heat

be indicated

at

least each

behind

ensure

equal

B.

If

the

ZF

Industries
Marine
3131
Fort
Tel.:
Fax:

FOR

US

Headquarters

SW

42nd

Street

Lauderdale,

(954)
[phone]

ADDITIONAL

WWW.zF-MARINE.COM

FL

581-4040

INFORMATION

TYPICAL

STEERING

33312

",..t---GEAR

SHIFT

STATION

Engines & Generators

38

ZF

TRANSMISSIONS

INITIAL

All

the engine

sons

Fill the gearbox with Automatic Transmission Fluid

(DEXRON

up

just insert

into the case after the
not forget the sealing ring under the hexhead of the dipstick.
Check
also

hoses,

FLUID

Change
operation, then every 250 operating
year or

Removing

Push a suction pump hose down through the dipstick hole
the bottom of the housing and suck out the
allows, use the transmission
from
drain
washer.
the
recheck

Drain

NOTE

drain plug sealing
this sealing

OPERATION

ZF marine transmissions are test-run

at

the

factory prior

the

fluid

is

drained before shipment.

II

or DEXTRON ill).

to

the

index mark

the

for

leaks

make

a visual inspection of the coupling, oil cooler and

and

shift cables.

ZF

TRANSMISSION

dipstick,

and

change the

on

fluid

to

the dipstick.

do

not screw it

level

CHECKING

FLUID

delivery.

is

fluid

on

For safety

The

fluid

To

check the

in.

Screw

checked and

after

the

FULL

CHANGE

the

fluid

for

the

first

time after about

hours

'or

when

you

change engine

the

fluid

the

into

used

plug

:

bottom

Wipe

fluid.

the

torque

When

of

the transmission

a container, then reinstall the plug with

down

the transmission

After running the engine, shut down

fluid

level.

20 -25

ft/Ibs

changing

washel:

the

washer.

oil.

fluid.

drain). Remove the drain plug

and

allow the

and

properly dispose of

fluid,

take

care

not

The

drain plug will leak without

a test stand

rea-

level should

fluid

the

dipstick

tighten.

first

25

hours,

OPERATING

25

hours of

at least once a

(If space

fluid

its

sealing

and

to

lose

the

with

be

level,

Do

to

to

OPERATING

The

maximum permissible
exceed
a short

A

CAUTION:

too

high;

transmission

LOCKING

Locking of the propeller shaft
required:
direction of
in

the position corresponding

boat.

WHEN

Rotation of
is

being
operation of
charging the battery),

transmission

DAILY

o Check

o Visually check

TEMPERATURE

ATF

temperature should

230°

(1l00).

This temperature

time.

If

the

transmission

stop

the

engine

immediately

fluid.

THE

use

the gear shift lever position opposite

travel

UNDER

the

propeller without

sailed,

being towed,

the

.

PROPELLER

by

for

this

purpose.

to

the direction of

SAIL

OR

BEING

or

anchored

engine

with

the propeller stopped (for

will

have

no

an

TOWED

load,

detrimental

OPERATION

the

transmission

the

fluid.

gear shift linkage

can

only

fluid

and

additional brake

Never put

such

in a river,

and

o Start the engine in neutral, allowing a

idle

to

warm the

o Shift into

NOTE:

from

the

For additional information refer

Transmission

MAINTENANCE AND TRANSMISSION

TROUBLESHOOTING.

Too

Iowan

the

transmission gear and damper

idle

speed should

Section:

ZF

TRANSMISSIONS

General

Gear

ratio

(optional)

Lubricating
Transmission

Capacity
Propeller

Direction

Fluid

Sump

Shaft
of

Rotation

gear.

fluid.

idle

speed will produce a chattering noise

plate.

be

increased

to

the

following

SHAFT

COUPLINGS,

SPECIFICATIONS

Case-hardened

servo-operated

2.63: 1 (ZF

2.99: 1 (ZF

2.74: 1 (ZF

ATF -type A or

ZF

15

ZF

15

ZF

25

M

Rig

ht

hand-

TransmissiOn

MA
MIV

helical

multiple

15

MA -3R)

15

MIV -3R)

25

M -

Dextran

0.59

U.S.

1.11

U.S.

0.75

U.S.

Standard

not

be

reached

temperature

check

your

the

gear shift

travel

as

when

as

effects

transmission.

few

minutes at

In

such

text

gears,

with

disc

clutch.

3R)

-1/

or

11/

qts

(0.561

qts

(1.05

qts

(0.79

the

is

not

of

the

well

on

cases

in

this

a

liters)
liters)
liters)

for

is

the

boat

as

the

A

WARNING:

engine

is

dipstick

hole.

Never

running.

This

pull

out

flot fluid will

could

cause

the
splash
severe

dipstick

from
burns.

while
the

the

Engines & Generators

39

ZF

TRANSMISSIONS

CHANGING

16MM

(8")

SCREW

THE

TRANSMISSION

FLUID

ZF·45

Replacing

Pour

with

the

Transmission
ers,

length of

Reinsert the

and

tighten

NOTE:

screw

After

A

engine
hole.

the

Fluid

in

new

Dextron

dipstick.

fluid

quantities

hoses

and·the angle of

Approximate Quantities

ZF

45

- 2.12 quarts

ZF

63

- 3.2 quarts

ZF

63V

filter

assembly into

the

Allen

Some

ZF transmissions

on

their filter

running

WARNING:

is

running.

This

could

the

assemblies.

engine,

Never

cause

III ATF

- 4.2

screw.

shut

pullout

Hot

fluid

severe

fluid

will

(3.0

quarts

the

use a itT"

down

will

burns.

vary

(2.0

(4.0

the

splash

MAINTENANCE

Transmission
housing
routine,

Periodically inspect the transmission
and

corrosion.

checking

(fluid

will

maintenance

clean,

and

change

the

fluid

appear

check the

the

Make

certain the air

level look for

as

strawberry

is

minimal.

fluid

level

fluid

every 300 operating

signs

cream).

and

check

with

the

transmission.

Liters)

Liters)

Liters)

housing.

and

recheck

dipstick

Keep

as

part of

and

vent

is

of water

the

quantity

the

use

Press

handle

in

the

while

from

the

the

exterior

your

hours.

the cooler

clear

and

contamination

of

cool-

it

in

place

place

of

fluid

level.

the

dipstick

regular

for

leaks

when

a

Filter

Element

The ZF transmission

This

dipstick.
changed.

Remove
a 6mm Allen

Twist

and

the

new
it clockwise. Check
necessary.
local

WESTERBEKE

Removing

Push a suction
the

filter)
Remove

to

drain into a

Wipe

down

fluid.

filter must

the

filter

by

wrench.

pull out

filter

Replacement

to

the

the

onto

the

the

Fluid

pump

the

bottom of the housing

oil return line

container,

the

transmission

has

a filter element'Iocated opposite the

be

replaced whenever the

loosening

filter and remove

cover and lock it into place

the

dealer or ZF

hose

the

screw

on

the

O-rings for damage

filters

can be obtained from your

dealer.

down

through

from

the cooler

then reconnect

and

properly dispose of

the

and

the

the

cover using

element. Place

and

replace if

pipe hole (under

suck out the

and

allow

oil return

fluid

by

is

turning

fluid.

the

oil

line.

the

used

Lay-up/Winterize

Storage

o Drain water

o
o Fill

o

o Inspect

requires

with

a proper mixture of antifreeze coolant

NOTE:

engine

Clean

(use

heat resistant paint).

the
prevent internal corrosion (extended storage
months

Loosen

flange

removing

and

spray

Look
the

conduit,

all

moving

NOTE:

(twelve

to

fluid

before

special

care.

from

the transmission

This

operation

raw

water cooling system

up

the

transmission

transmission

or

more).

attaching hardware

and

propeller shaft

the

with

the

gear shift

for

corrosion of

and

parts.

If

the

transmission

l1wnths

prevent internal

putting

boat

from

lubricant.

bending of

or

more),

the

engine back

with

Follow these

will

normally occur

and

touch

Dextron

from

coupling

the

water.

cable,

linkage,

the

end

fittings,

the

is

to

be

it slwuld

corrosion.

is

the

actuator

storedfor a

into

procedures:

oil

cooler

when

properly

up

unpainted

III ATF

Separate

be
Reduce

fluid

only,

transmission

flange

before

the

and

attachments.

cracks

rods.

topped offwith

the

service.

and

replace

the

winterized.

areas

to

twelve

output

.

flanges

or

cuts

in

Lubricate

long

time

fluid level

Engines & Generators

40

TRANSMISSION

TROUBLESHOOTING

[ZF]

CONTROL

The majority of transmission
improper
problems
rather

ZF

clutches,

cable

CABLES

clutch

adjustments

with

control

than

from

in

particular,

adjustments.

cables (hydraulic

problems

are

difficulties

(manual

with

the

very

transmission

sensitive

If you experience operating problems

shut the engine

level,

then

the

fuII

range -from
neutral,
observe
is

stiff

to

and

try

again.

excessively

Transmission
Fails

to

move

Transmission
but

fails

Delay

of

only

after

Transmission

Chattering
mainly

at

Boat

fails

Oil

Leakage.

down.

have

a helper

into

fuIl

reverse,

the

actuating lever

operate,

If it

tight

bends,

Problem

gears

cannot

into

gear.

shifts

to

gear

an

low

to

into

propel

the

engagement

increase

noise

becomes

transmission

engine

attain

specified

First check

move

the

neutral

to

and

back

on

the

break the cable

is

still stiff, check

and

check

be

shifted.

gear,

boat.

or

engages

in

speed.

louder.

noise,

speed.

max.

speed.

the

cockpit

full

to

transmission.

loose

any

arise

as

a result of

transmissions)

transmissions)

itself.

to

improper

with

the

transmission,

transmission-fluid

shift

lever

forward,

back

to

neutral -while

If

the

at

the

transmission

the

cable

for

kinks

linkage

1.

2.

3.

1.

2.

3.

1.

2.

3.

1.

2.

1.

1.

2.

1.

2.

for

binding.

Probable

Actuating
Shifting

Actuating

Propeller
Output

Output
propeller

Actuating
equal

Actuating

Actuating

to
transmission.

transmission
alignment

The

lever

cable

unattached.

Output

Damage
misalignment

Beginning
running
engine

vibrations
a

"chattering"

Operating
Operating
Corrosion

Damaged
Misalignment

coupling

coupling

coupling

to N to

wear

output.

engine

Cable

lever

shaft

shaft

lever

A.

level

lever

starting

or

fatigue,

damage

without

of

transmission,

or

in

the

temperature
without

at

radial

sealing

is

between

due

of

or

through

you

remote

or

Cause

is

loose.

broken,

bent

radius

is

too

is

binding

against

is

not

turning.

is

not

tuming.

is

turning.

and

are

turning.

travel N to B not

travel

in

insufficient.

is

binding

against

on

flexible

possibly

engine

of

bearings

to

torsional

fluid,

overload,

or

propeller

generates

drive

unit

in

cooling.

sealing

ring.

output

which

the

transmission.

is

high.

ring

flanges.

noise

A

new

cable

and
needed.
out
make

If

have
the
needs
thrust,
the

it isn't

NOTE:

While

of gear

sure

there's

the

transmission

a helper put it

propeIIer

professional

check

shaft

or,

stuck

If

you

using

shaft;
to

if

in

suspect a major
immediately contact your
authorized

or

severe.

the

cover

coupling
due

to

and

in

vibrations,

wrong

excessive

torsional

produces

and

shaft.

due

plate.

marine

1.

Tighten

2.

Check

Detach

3.

hand.
Transmission

1.

The

2.

on
pins

Inspect

3.

A

propeller

1.

Adjust

See

2.

Check

DIAGRAM.

3.

Check
Check

1.

inspect
engine.

Transmission

2.

Mount a flexible

1.

between
a

Inspect

2.

transmission.
Wrong

1.

Check

2.

Transmission

1.

Check

2.

perhaps a new

the

cable

is

loose,

the

lever

on

no

binding

passes

these

in

forward

if

the

shaft isn't

attention.

see

you

still

you

have a folding

the

"no

pitch"

WESTERBEKE

transmission

Verification/Remedy

damping

bolt

the

cable,

reattach

the

shift

Clearance

coupling

the

and

folding

ACTUATING

higher

cable

should

needs

bolts

propeller

shaft.

coupling

the

propeller.
propeller
may

be

cover

plate

LEVER

shift

lever

cable

clearance,
alignment,

the

damper

Replace

if

needs

coupling

the

engine

stiffness

the

damper

Replace

type

of

fluid.

cooler.

Inspect

needs

alignment.

bolts

in

until

adjust

inspect

necessary.

factor

Must

linkage

the

inside

tests,

and

shift

side

the

reverse

mechanism

the

transmission

of

the

case.

crank

turning,

If it

does

tum

have

a propeller
or

feathering

position.

problem

in

your

dealer

facility.

on

shifting

lever.

or

replace.

and

operate

be

professional

are

sheared
Tighten

as

It

may

may

be

"no

pitch"

the

length.

if

plate

professional

and

transmission; a coupling
might

plate

if

Use

coolant

professional

be

the

0.02

in

(0.5mm).

attention.

or

the

or

replace

necessary.

be

missing

jammed. A variable

position.

lever

is

TEXT

necessary.

exact

AND

DIAGRAM.

See

ACTUATING

necessary.

flexible

coupling.

between

the

attention.

with

another
be

sufficient.

between

the

Dextron

III,

hoses

attention.

within

0.003

check

and

may

transmission

the

engine

while

you

the

transmission

but

there's

on

the

end

propeller,

transmission,

or

an

actuating

lever

coupling

is

Slipping

set

screws,

or

damaged.

pitch

mid-position.

LEVER

If

noise

transmission

stiffness

engine

coolant

in

perSists,

factor

with

and

the

fluid

level.
flow.

(0.08mm).

be

in

and
to

and

observe

no

of

that

by

keys,

and

the

Engines & Generators

41

ZF

TRANSMISSIONS

OPERATING

A

CAUTION:

too

high,

transmission

Normal operating temperature of the
should be
A

maximum

reached
Make certain there is enough space

to

provide

TRANSMISSION

Coolers

15

M,

for the ZF 5
The cooler

vents

any

fluid.

However,

in

will,

leaks.

A transmission cooler
some circumstances, depending on operating
waters, maintemance,

TEMPERATURE

If

the

transmission

stop

the

engine

immediately

fluid.

0

in

the

range

temperature of

for

a short

good

ventilation

of

time.

122

266

and

F

0

cooling.

COOLER

are

standard equipment

15

MA,

15

MIv,

and

M).

is

a seperate part of the

possibilities of coolant diluting

the continued

time,

erode the inside of

may
etc.

for

the

25 M (no

flow

last ten

it might

fluid

and

transmission

(500

C)

to

0

(130

F

the

C)

around

the

ZF

cooler

transmission

the

of coolant thru the cooler

cooler

causing

years

or

only

last half

temperature

check

the

fluid

0

212

may

the

transmission

10

M,

transmission

more

hours,

F

(100

be

only

12

M,

is

necessary

which

external

but,

tropical

that

time.

0

pre-

in

is

C).

MAINTENANCE

Transmission maintenance
housing
routine,

Periodically inspect the transmission
and
checking the
(fluid

clean,

and

change

corrosion.

will

appear

check

Make

fluid

level look

as

is

the

fluid

the

fluid

every

certain

the

for

strawbeny

minimal.

level

air vent

signs

cream).

Lay-up/Winlerize

Storage

o Drain water

o Clean

o Fill the
o Loosen attaching hardware

o Inspect the gear shift cable,

requires

with

a proper mixture of antifreeze

NOTE:

engine

(use

heat resistant

prevent internal corrosion
months

flange
removing
and

spray

Look
the

conduit,

all

moving

special,

care.

from

the

transmission

This

operation will normally occur

raw

water cooling system

up

the

transmission

paint).

transmission

or

more).

and

propeller shaft
the
with

for

corrosion of

and

parts.

boat

from

lubricant.

bending of

with

the

Follow

and

Dextron

(extended

from

coupling

the

water.

linkage,

end

fittings,

the

Keep

as

part of

300

operating

and

of water

these

oil

coolant.

is

properly

touch

III ATF

the

flange

Separate

and

actuator

.

the

exterior

your

regular

hours.

the

cooler

is

clear

and

contamination

procedures:

cooler

and

when

winterized.

up

unpainted

fluid

storage

only,

transmission

before

the

attachments.

cracks

or

rods.

Lubricate

for

leaks

when

replace

the

areas

to

twelve

output

flanges

cuts

in

,

OIL

"UUILcn

IUU"""LLl

LEAKAGE

INSPECT

AND

CORROSION

FOR

NOTE:

If

the

(twelve

fluid

before

For additional

months or

to

prevent internal

putting

information

ZF Industries
Marine
3131
Fort
Tel.:
Fax:

FOR
WWW.ZF-MARINE.COM

US

SW

Lauderdale,

(954)
[phone]

ADDITIONAL

transmission

more),

the

engine

contact:

Headquarters

42nd Street

FL

581-4040

INFORMATION

is

to

be

it should

corrosion.

back

into

33312

stored for a

be

topped offwith

Reduce

the

service.

long

fluid

time

level

Engines & Generators

42

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

OIL

COOLER

BORG

WARNER

VELVET

DRIVE

SHIPMENT

For safety reasons, the transmission
transmission fluid during shipment and the selector lever
is

temporarily attached to the actuating shaft.

Before leaving the WESTERBEKE plant, each transmission

undergoes a test run, with

fluid. The residual fluid remaining in the transmission after
draining acts as a preservative and provides protection
against corrosion for at least one year

TRANSMISSION

Check the transmission fluid level on the dipstick.
transmission has not been filled, fill with
continue to use this fluid. During the first 25 hours
operation, keep a lookout for any leakage at the bell housing,
output shaft and transmission cooler. This fluid should be
changed after the first 25 hours and approximately every
300 operating hours thereafter and/or at winter lay-up.

A

CAUTION:

and

the

correct

starting

the

Be

size

engine.

Dextron III

FLUID

certain

cooler

is

not filled with

ATF

if

the

transmission

is

properly

transmission

properly stored.

If

the

Dextron III and

of

is

filled

installed

before

SHIFT

The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
(F), Neutral
ball located behind the transmission lever must work freely
to center the lever
the helm must be coordinated with those
actuating lever through shift mechanism adjustments. An
improperly adjusted shift mechanism can cause damage
the transmission. The shifting mechanism and transmission
actuating lever should be free
ensure proper operation.

Shifting

Place the gear shift in Neutral before starting the engine.
Shifting from one selector position to another selector posi­tion may be made at any time below
order. Shifts should be made at the lowest
speed. Start the engine and set the throttle at idle speed;
allow the transmission fluid to warm up for a few minutes.

LEVER

POSITION

(N), and Reverse (R) shifting positions. A detent

in

each position. The gear shift positions at

of

the Velvet Drive

of

dirt and well lubricated

Into

Gear

1000 rpm and in any

practical engine

to

to

Neutral

Move the gear shift lever to the middle position.
feel the detent. This centers the actuating lever on the trans­mission. With the control in this position, hydraulic power
completely interrupted and the output shaft
sion does not turn.

NOTE:

Some transmissions are equipped with a neutral safety
switch.
aligned in neutral, the engine starter will not activate.

Unless the transmission actuating lever is perfectly

You

of

the transmis-

should

Forward

Move the gear shift lever to the forward position.
feel the detent. The actuating lever on the transmission

the forward position. The output shaft and the propeller shaft
move the boat in a forward direction.

You

should

is

in

Reverse

Move the gear shift lever to the reverse position.

feel the detent. The actuating lever on the transmission

the reverse position. The output shaft and the propeller
should move the boat in a reverse direction (astern).

NOTE:

Moving the transmission actuating lever from Neutral

Position to Forward is always toward the engine. Reverse is
always away from the engine.
the gear shift control in the forward position, shut
engine! This problem may be a result
of

the actuating lever by the gear shift

If

boat moves backwards with

of

incorrect movement

lever.

You

off

should

is

in

the

is

Engines & Generators

43

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

F

FORWARD

DAILY

OPERATION

N

NEUTRAL

N

REVERSE

D Check the transmission fluid.

D Visually check the gear shift linkage and transmission.

P Start the engine in neutral. Allow a few minutes at idle

for the fluid to warm.

NOTE:

Too

low

an

idle

speed will produce a chattering

the

noise from
such

cases

transmission gear and damper

the

idle

speed slwuld

be

increased.

D Shift into gear.

A

CAUTION:

cause

damage

throttle

on

back

the

transmission

Shifting

to

the

to

idle

gears

engine

when

and

the

above

damper

shifting

damper

1000

plate.

gears

plate.

INSPECTION

D Visually check for oil leaks at the hydraulic connections.

Check for wear on the hydraulic lines and replace
worn.

D Lubricate the detent ball and shift cable attachments.
D Inspect the shift linkage.
D Inspect the transmission bolts; retorque

rpm

Pulling

will

save

if

necessary.

plate.

can

wear

In

the

if

D Clean off the transmission and properly dispose

used fluid.
Refill the transmission with

quantity will vary depending on the transmission model
and the installation angle. Pill through the dipstick hole.

Check the dipstick for the proper fluid level.
Replace the oil filler cap and dipstick. (press the dipstick

into place and turn clockwise until finger-tight.)
Run the engine, shutdown and recheck the fluid level.

A

WARNING:

engine

is

hole.

This

Oil

Capacity

Approximately 2.5 quarts (2.36 liters) will fill most transmis­sions to the oil level fill mark on the dipstick. Many variables

have a direct relationship to the oil capacity. Additional oil

will

be

required to fill the oil cooler and the cooler lines. The

of

angle
oil required to fill the transmission.

installation will make a difference in the quantity

MAKE
RUBBER
SCREWED
TIGHTTOTHE
HANDLE

Never

running.

could

cause

CERTAIN

SEAL

IS

Hot

THE -.........

pull

out

fluid

will

severe

"',

DEXTRON

the

dipstick

splash

from

burns.

III

ATF.

while

the

dipstick

MAX

of

The

the

the

of

A

CAUTION:

transmission

detent

ball

CHANGING

After the initial
be changed
ter haul-out. However, the fluid must be changed whenever it
becomes contaminated, changes color, or smells rancid.

Clutch

failure

will

occur

shift

lever

does

not

fully

positions.

THE

TRANSMISSION

50

hour change, the transmission fluid should

at

every 300 operating hours thereafter or at win-

FLUID

D Remove the oil filler cap and dipstick.
D Remove the oil cooler return line and allow the oil to

drain into a container.

D Reconnect the oil cooler return line.
D Use a suction pump to remove the transmission oil

through the filler cap/dipstick hole.

if

the

engage

the

Engines & Generators

44

Oil

Temperature

A maximum oil temperature
mended. Discontinue
ture exceeds

PRESSURE

An

optional mechanical pressure gauge can

the control panel to constantly monitor the pressure

transmission fluid. A normal reading at
gear should indicate 95 - 120 Ib-in
constant.

2300P

(1

GAUGE

of

1900P (88°C) is recom-

operation anytime sump oil tempera-

lO°C).

be

installed at

2000 rpm in forward

2

(6.7 - 8.4 kg-cm

of

2

)

the

and be

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

Transmission maintenance
housing clean, check
routine, and change the

Periodically inspect the transmission and the cooler for leaks
and corrosion. Make certain the air vent
checking the

(fluid

will

fluid

appear

level look for signs of water contamination

as

Lay-up/Winterize

Storage requires special care. Follow these procedures:

o Drain the water from the transmission

replace it with a proper mixture of antifreeze coolant.

NOTE:

This operation will usually occur when the engine

raw water cooling system is properly winterized.

o Clean

up

the transmission

(use

heat resistant paint).

o Fill the transmission with Dextron III

mark.

is

minimal. Keep the exterior

the

fluid

level

as

fluid

every 300 operating hours.

strawberry cream).

and

touch-up unpainted areas

part of your regular

is

clear and when

oil

cooler

and

ATF

fluid

to

the

fill

o Loosen attaching hardware from the transmission

output

flange

and propeller shaft coupling
removing the boat from the
and spray with lubricant.

water.

Separate the

flange

before

flanges

o Inspect the gear shift cable, linkage, and attachments.

Look for corrosion of
the conduit, and bending of the actuator
all

moving parts.

the

end fittings, cracks or cuts

rods.

in

Lubricate

WARRANTY

Service manuals
dealer.

For assistance, contact:

BORG WARNER

1208
Liberty,
Tel.:

BORG WARNER

placed
operation
shifting. Therefore torque loads and directional changes
should
failure
be

denied.

A

CAUTION:

occur
resulting
BORG
related

If

any

problems occur with the transmission,

TRANSMISSION TROUBLESHOOTING

NOTES

are

available from your BORG WARNER

Old Norris Blvd.

SC

29657

800-583-4327 ext.l29

is

aware of the shock loads that can

on

its

gears

as

the result of mechanical propeller

or

fully reversing of the propeller blades while

be

made

at

was

caused

at

low

engine

in

damage

WARNER

torsional

low engine speeds.

by

a shock load,

System-related

speeds
to

is

not

vibration

which

the

engine

responsible

of

noises

this

If

it

is

any

warranty claim

or

can

cause

and/or

for

total

type.

in

found that a

vibrations

gear

rattle

transmission.

system-

see

this

manual.

be

will

can

NOTE:

If

the transmission

(twelve months

fluid to prevent internal corrosion. Reduce the fluid level

before putting the engine back into service.

or

is

to be stored

more), it should be topped

for

a long time

offwith

Engines & Generators

45

TRANSMISSION

TROUBLESHOOTING

CONTROL

The majority

CABLES

of

transmission difficulties arise

as

a result

of
improper clutch adjustments (manual transmissions) or prob­lems with control cables (hydraulic transmissions) rather than
from

problems with the transmission itself.

HURTH clutches,

in

particular, are

very

sensitive

to

improper

cable adjustments.
If

you experience operating problems with the transmission,
shut the engine down. First check the transmission-oil level,
then have a helper move the cockpit shift lever through the
full range - from neutral to full forward, back
into full reverse, and back
the actuating lever on the transmission.

to

neutral-

while you observe

If

to

neutral,

the remote is stiff
to operate, break the cable loose at the transmission and try
again.

If

it

is

still stiff, check the cable for kinks or exces­sively tight bends, and check any linkage for binding. A new
cable and perhaps a new linkage mechanism may be needed.
While the cable
gear using the lever on the side
sure there's

is

loose, shift the transmission in and out of

of

the transmission

no

binding inside the case.

to

make

If the transmission passes these tests, crank the engine and
have a helper put it in forward and reverse while you observe
the propeller shaft;
needs professional attention.
thrust, check
the shaft

or,

if

the shaft isn't turning, the transmission

If

it does turn but there's

to

see you still have a propeller

if

you have a folding or feathering propeller, that

on

no

the end

of

it isn't stuck in the "no pitch" position.

OIL

COOLERS

The continued flow of raw water through the cooler will,
time, erode the inside of the cooler causing cross
occur.

These internal cooler leaks will cause

one

leaks

of the

in
to
fol-

lowing two problems:

1. Transmission fluid
and

be

discharged overboard through the engine exhaust.

A

loss

of

transmission fluid will

will

leak into the

cause

flow

the

of

raw

water

transmission

fail.

2.

The raw water
ing

an

increase

fluid

will

will eventually

Either case requires

1. Install a

2.

Refill the transmission with DEXTRON III

If

water has contaminated the fluid, the transmission fluid
needs to be cleaned out and replaced
take several fluid changes
Check your dipstick each time until it appears
mission fluid. Change the transmission filter
the fluid lines that connect

If

the transmission fails to shift properly, it
need the attention

A transmission cooler may last ten years or more
some circumstances, depending
waters, maintenance, etc. it might only last half that

appear

new

will

leak into the transmission

in

transmission fluid. This contaminated

as

strawberry cream.

The

transmission

fail.

an

immediate response:

oil

cooler.

ATF.

with

fresh

to

get rid of the contamination.

as

and

to

the cooler.

will

of

a qualified transmission service

on

operating

hours,

fluid

caus-

fluid.

It

will

pure trans-

clean out

most likely

facility.

but,

in
tropical
time.

WESTERBEKE recommends having a spare cooler aboard

to

Problem

Transmission

Shifting

pressure

Transmission

gears

too

noise

cannot

be

low.

becomes

shifted.

loude'r.

Probable

1.

Shifting

2.

Shifting
unattached.

3.

Loss

of

4.

Water

1.

Improper

2.

Filter

is

3.

Water

4.

Transmission

5.

Air

vent

1.

Fluid

level

so

that

2.

Damage

to

wear

ment

3.

Beginning
mission

without

transmission,

lever

is

loose.

cable

is

broken,

transmission

in

transmission

fluid.

dirty

(if

applicable).

in

transmission

fluid

is

clogged.

too

low,

pump

sucks

starting

or

fatigue,

between

engine

damage

due

to

torsional

fluid,

overload,

or

Cause

bent

fluid.

fluid.

fluid.

too

low.

in

air.

on

flexible

possibly

and

transmission.

of

bearings

vibrations,

wrong

excessive

or

coupling
due

to

in

trans-

alignment

engine

due

misalign-

running

of

output.

1.

Tighten

2.

Check

3.

Check
Tighten
Oil

cooler

4.

Replace
compartment,
item

2.

1.

Replace

2.

Replace

3.

Replace

4.

Add

fluid.

5.

Remove

1.

Top

up

2.

Replace

and

transmission.

3.

Transmission

VerificationJRemedy

damping

bolt

on

shifting

the

cable,

reattach

or

replace.

for

leaks

at

gear

with

transmission

case

bolts.

leak -see

oil

cooler

(see

remedy

with

DEXTRON

filter.
oil

cooler -see

paint/dirt

from

fluid

to

flexible

coupling.

needs

Check

OIL

COOLER.

OIL

COOLEFf).

cause.

11/

ATF.

OIL

vent.

marking

on

Check

professional

lever.

seal

and

all

oil

hoses

High

Shifting

pressure

COOLER.

dipstick.

alignment

attention.

output

for

water

between

shaft.

leaks.

in

engine

too

low,

see

engine

Engines & Generators

46

TRANSMISSION

TROUBLESHOOTING

Chattering

mainly

Transmission
fails

NOTE:

transmission

at

low

to

propel

If

you
immediately
rized

marine

1.

The
vibrations
a

Output

1.

2.

Propeller
Output

3.

Output
propeller

in

your

Probable

engine

in

"chattering"

coupling

shaft

coupling

coupling

shaft

transmission,

Problem

speed.

into

boat.

noise,

gear,

but

engine

shifts

the

suspect a major problem
contact your WESTERBEKE dealer or

transmission/acility.

Cause

or

propeller

the

drive

noise

is

is

is

and

are

an

unit

in

the

not

turning.

not

turning.

turning.

turning.

autho-

generates

torsional

which

produces

transmission.

Mount a flexible

1.

between

a

higher

Transmission

1.

The

coupling

2.

on

the

pins

and

3.

Inspect
A

folding

Variable

VerificationJRemedy

coupling

the

engine

stiffness

needs

bolts

propeller

coupling

the

propeller;

propeller

pitch

propeller

with

and

transmission; a coupling

factor

might

professional

are

sheared

shaft.

Tighten

bolts

as

necessary.

it

may

be

may

be

jammed.

may

be

another
be

sufficient.

attention.

or

the

or

replace

misSing
in

"no

stiffness

coupling

set

screws,

or

damaged.

pitch:'

factor

with

is

slipping

keys,

Engines & Generators

47

LAY-UP

&

RECOMMISSIONING

GENERAL

Many owners rely
including engines and generators, for lay-up during the
off-season or for long periods
to accomplish lay-up preparation themselves.

The procedures which follow will allow you to perform your

own lay-up and recommissioning, or you may use them as a

check list
These procedures should afford your engine protection

during a lay-up and also help familiarize you with the
maintenance needs

If

you have any questions regarding lay-up procedures, call

your local servicing dealer; he will be more than willing to

provide assistance.

if

Propeller

The transmission and propeller half couplings should always
be opened up and the bolts removed when the boat is hauled
out

of

the water or moved from land to water, and during
storage in the cradle. The flexibility
severe strain on the propeller shaft
the boat is taken out
shaft has actually been bent by these strains. This does not
apply to small boats that are hauled out
not in use, unless they have been dry for a considerable

of

period

Fresh

A 50-50 solution
recommended for use in the coolant system at all times.
This solution may require a higher concentration
antifreeze, depending
solution to make sure the antifreeze protection is adequate.

Should more antifreeze
amount from the engine block and add a more concentrated
mixture. Operate the engine to ensure a complete circulation
and mixture
cooling system. Now recheck the antifreeze solution's strength.

time.

Water

Lubrication

With the engine warm, drain all the engine oil from the oil
sump. Remove and replace the oil filter and fill the sump
with new oil. Use the correct grade

ENGINE LUBRICATING OIL pages in this manual for the

oil changing procedure. Run the engine and check for proper
oil pressure and make sure there are no leaks.

A

CAUTION:

in

the

sump
combustion
chemicals
internal

parts.

on

their boatyards to prepare their craft,

of

inactivity. Others prefer

others do the procedures.

of

your engine.

Shaft

Coupling

or

Cooling

of

antifreeze and distilled water is

on

of

the antifreeze concentration throughout the

[Propulsion

of

or

coupling

put in the water. In some cases, the

Circuit

the area's winter climate. Check the

be

needed, drain an appropriate

[Propulsion

Engine]

the boat often puts a

or

of

the water when

System

of

oil. Refer to the

00

not

leave

the

over

the

deposits

which

can

lay-up

period.

combine

reduce

the

engine's

to

produce

life

old

Lubricating

harmful

of

your

engine's

both, while

Engine]

of

engine

oil

oil

and

Fuel

System

Top off your fuel tanks with unleaded gasoline
or

higher. A fuel conditioner such as Sta-Bil gasoline

stabilizer should be added. Change. the element in your
gasoline/water separator and clean the metal bowl. Re-install
and make certain there are no leaks. Clean up any spilled
fuel.

Fuel

System

Top off your fuel tanks .with

such as
control algae and condition the fuel. Care should be taken
that the additives used are compatible with the primary fuel
filter/water separator used in the system. Change the element
in your primary fuel filter/water separator,
has one, and clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the
fuel system, as needed. Start the engine and allow it to run
for 5 - 10 minutes to make sure no
system. Check for any leaks that may have been created in
the fuel system during this servicing, correcting them as
needed. Operating the engine for 5 - 10 minutes will help
allow movement
equipment on the engine.

Raw

Close the through-hull seacock. Remove the raw water intake
hose from the seacock. Place the end
gallon bucket
check the zinc anode found in the primary heat exchanger on
the engine and clean
any zinc debris from inside the heat exchanger where the
zinc anode is located. Clean the raw water strainer.

Start the engine and allow the raw water pump to draw the
fresh water through the
stop the engine and refill the bucket with an antifreeze
solution slightly stronger than needed for winter freeze
protection in your area.

Start the engine and allow all
through the raw water system.
the engine. This antifreeze mixture should protect the raw
water circuit from freezing during the winter lay-up, as well

Remove the impeller from your raw water pump (some

Examine the impeller. Acquire a replacement,

BioBor and Sta-Bil should

Water

as providing corrosion protection.

antifreeze mixture will accompany it, so catch it in a bucket).

a cover gasket.
until recommissioning,

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the
opening
shove the cloth out
recommissioning, and an attempt is made to start the engine,
you may need assistance
note to remove the cloth prior to start-up. The thru-hull
exhaust port can be blocked in the same manner.

[Gasoline]

of

89 octane

[Diesel]

No.2

diesel fuel. Fuel additives

be

added at this time to

if

the fuel system

air is left in the fuel

of

the treated fuel through the injection

Cooling

of

Do

Manifold

of

the intake manifold to block the opening. Do not

Circuit

of

this hose into a five

clean fresh water. Before starting the engine,

or

replace it as required, and also clean

·system. When the bucket is empty,

of

this mixture to be drawn

Once the bucket is empty, stop

if

needed, and

not replace the impeller (into the pump)

but

replace the cover and gasket.

and

Thru-Hull

of

sight.

of

(If

the servicing dealer. Make a

Exhaust

it is not visible at

Engines & Generators

48

LAY-UP

&

RECOMMISSIONING

Starter

Lubrication and cleaning
if
battery connections are shut off before attempting to remove
the starter. Take care in properly replacing any electrical
connections removed from the starter.

Cylinder

If

WESTERBEKE recommends removing the fuel injectors for
access to the cylinders. Squirt light lubricating oil into the
cylinders to prevent the piston rings from sticking to the
cylinder walls.

Make sure you have a replacements for the injector and return

line sealing washers.

Intake

Clean the filter screen in the flame arrester, and place a clean
cloth lightly soaked in lube oil around the flame arrester to

block any opening. Also place an oil-soaked cloth in the

through-hull exhaust port, Make a note to remove cloths prior
to start-up!

Cylinder

Spray fogging oil into the open air intake, with the flame
arrester removed, while the engine is running. The fogging oil

will stall out the engine and coat the valves, cylinders and spark

plugs for winter protection.

NOTE:

and re-gapping at spring commissioning.

Motor

of

the starter drive pinion is advisable,

access to the starter permits its easy removal. Make sure the

Lubrication

you anticipate a long lay-up period (12 months or more)

Manifold

Lubrication

The

spark plugs will need

[Diesel]

[Gasoline]

[Gasoline]

to

be removed for cleaning

Batteries

If

batteries are to be left on board during the lay-up period,
make sure that they are fully charged, and will remain that way,
to prevent them from freezing.
batteries will not remain fully charged, or that they will be
subjected to severe environmental conditions, remove the
batteries and store them in a warmer, more compatible
environment.

A

WARNING:

highly-explosive

arcing

or a lighted

smoke

or
serviced.
to

prevent

Transmission

Check

or

change the fluid in the transmission as required Wipe

off

grime and grease and touch up any unpainted areas. Protect
the coupling and the output flange with an anti-corrosion
coating. Check that the transmission vent is open. For
additional information, refer to the

Lead

gas,

allow

an

Shut

off

all

electrical

[Propulsion

Cigarette,

open

If

acid

batteries

which

can

name

electrical

arcing

during

Engine]

there is any doubt that the

emit

be

ignited

cigar,

or

pipe.

near

the

equipment

hydrogen,

by

Do

battery

in

a

electrical

not

being

the

vicinity

servicing.

TRANSMISSION SECTION.

Spare

Lay-up time provides a good opportunity to inspect your
Westerbeke engine to see
or
kit and order items not
during the lay-up, such as filters and zinc anodes. Refer to the

SPARE

Parts

if

external items such as drive belts

coolant hoses need replacement. Check your basic spares

on

hand,

or

replace those items used

PARTS

section

of

this manual.

Recommissioning

The recommissioning

seasonal lay-up generally follows the same procedures as
those described in the
tion regarding preparation for starting and normal starts.
However, some
counteracted before starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold.

2. Remove the raw water pump cover and gasket and
discard the old gasket. Install the raw water pump impeller
removed during lay-up (or a replacement,
Install the raw water pump cover with a new cover gasket.

3. Reinstall the batteries that were removed during the
lay-up, and reconnect the battery cables, making sure the
terminals are clean and that the connections are tight.
Check to make sure that the batteries are fully charged.

A

CAUTION:

and

eye

protection
batteries
can
cigarette,
name
electrical
arcing

4. Remove the spark plugs, wipe clean, re-gap, and install to

S. Check the condition

6.

emit

be

ignited

Cigar,

near

the

equipment

during

proper tightness

circuit and clean
that it is not necessary to flush the antifreeze/fresh water
solution from the raw water coolant system. When the
engine is put into operation, the system will self-flush in a
short period
advisable, as either an end
service, to inspect the area where the zinc is located in the
heat exchanger and clear any and all zinc debris from that
area.

Start the engine in accordance with procedures described
in the

PREPARATIONS FOR STARTING section

manual.

of

your Westerbeke engine after a

PREPARATIONS

of

the lay-up procedures will need to be

Wear

rubber

gloves, a rubber

when

serviCing

hydrogen, a highly

by

electrical

or

pipe.

battery

being

in

the

arcing

Do

not

serviced.

vicinity

FOR

batteries.

explosive

or a lighted

smoke

or

Shut

to

prevent

STARTING sec-

if

required).

apron,

Lead

gas,

allow

off

servicing.

[gasoline}.

of

the zinc anode in the raw water

or

replace the anode as needed. Note

of

time with no adverse affects. It is

of

season

or

recommissioning

acid

which

an

open

all

electrical

of

this

Engines & Generators

49

W-70GA

GASOLINE

ENGINE

Engine

Type

Combustion
Bore & Stroke
Piston
Firing
Direction
Compression
Dimensions

Weight
Maximum

Installation
Maximum

Operation

Compression
(Limit
between

Valve

Valve

Valve
(engine

Engine

Chamber

Displacement

Order

of

Rotation

angle

angle

of

difference

cylinders)

Timing

Seat

Angle

Clearance

warm)

Timing

EXHAUST

Emission

Control

Systems

eneral

tributor

-k

Plug

Thread

uretor

(STD

SPECIFICATIONS

Ratio

of

of

TUNE-UP

Pressure

IGNITION

Size

Type)

Gasoline,

four-cycle,
water-cooled,
mechanism

Multi-sphere

3.38 x 3.70

133.3

cubic
1-3-4-2
Clockwise,
8:6:1
Height:

Width:
Length:

421
Not

Not

Ibs

(190.9

to

exceed

to

exceed

25.0

21.2

35.1

Vertical,

66

hp@3600

type

inches

inches

when

inches
inches
inches

kgs)

14°

20°

four-cylinder,

in-line

rpm

(86.0 x 94.0

(2.2

liters)

viewed

from

SPECIFICATIONS

198.1

psi

(14

kg/cm')

at

400

28.0

psi

(2.0

kg/cm')

Intake

Opens

2°

Intake

Closes

Exhaust
Exhaust

Intake

45°

Exhaust
Intake

0.012

Exhaust
0°

TDC

EMISSIONS

Meets

53°

Opens
Closes

45°

inches

0.012

inches

at

625

rpm

U.S.C.G.

BTDC

ABDC

57°

BBDC

2°

ATDC

(0.3

mm)

(0.3

mm)

SYSTEMS

Regulation

33

SYSTEMS

Battery

ignition

12V
Distributor
ignition

coil,

Solid

state

ignitor
14mm X 1.25
Down

draft

USCG

approved

with

and

type

type,

ignitor

spark

with

pitch

single

flame

negative

module

plugs.

signal

barrel,

arrester

fresh

overhead

mm)

the

front

(634

mm)

(538

mm)

(893

mm)

rpm

CFR

183

ground.

and

ignitor,

generator

valve

and

General

Fuel

Lift

Pump

Fuel
Fuel

Consumption

Fuel

Filter

(on

engine)

Air

cleaner

(Flame

Arrester)

AirFlow
(engine

combustion)

General

Operating
Fresh

Water

Raw

Water

System

Capacity

(coolant)

General
Oil

Filter

Sump

Capacity

(not

including

Operating
(engine

hot)

Oil

Grade

Starting

Battery

Battery

Capacity
Starter
DC

Charging

DC

Amperage

Draw

Cranking

Temperature

Pump

Pump

LUBRICATION

filter)

Oil

Pressure

ELECTRICAL

FUEL

SYSTEM

Conventional
pump

Regular

or

rating

of

89

Electric-lift

6,0

U,S,

GPH

Replaceable

Metal

screen

140.0

cfm

COOLING

controlled

Centrifugal

9,0

4,0

55-75

API

300 -600

SYSTEM

Fresh

water-cooled

with

130

-150° F

Positive

displacement,

belt

driven

qts

(8.5

Pressure

fed

Full

flow,

paper

U,S.

qts

psi

(3,8 -5,2

Specification

12-Volt,

(-)

Cold

12-Volt,

reduction-solenoid

12

VDC

belt

175-200

arnps

carburetor

unleaded

or

capacity

at

cartridge-screw

type-cleanable

(3,9

(55

type,

liters)

better

3600

cmm)

block,

heat

-

66°

metal

type

gasoline

of

6ft

rpm

exchanger

C)
impeller,
rubber

SYSTEM

system

element,

spin-on

(3.7

liters)

kg/cm')

of

SJ

SYSTEM

negative

ground

Cranking

driven

alternator

(cold

engine)

with

electric

with

an

octane

(18mm)

on

thermostatically-

belt-driven

impeller,

type

Amps

(CCA)

mounted

fuel

Engines & Generators

50

TORQUE

SPECIFICATIONS

COMPONENT

Air

Cleaner

Bracket...
Alternator
Alternator
Alternator
Camshaft
Carburetor

Connecting
Coolant
Coolant
Coolant
Coolant
Crank
Cylinder

Cylinder
Drive
Exhaust
Front

Intake

Bracket...
Flange
Strap
Pully

...............................................

Rod
Pump
Pump

Temperature
Temperature

Shaft

Pulley

Head

Cold

....................................................

Hot

.....................................................

Head

Plate

...............................................

Manifold

Housing

Manifold

...............................

.................................

Bolt...

...........................

.......................................

Lock

Bolt...

Cap

..............................

..........................................

Pulley

...............................

Sender.
Switch

...................................

Cover.

...............................

.....................................

Assembly

........................................

.........................

.....................

.44.3 -47.0

..................

...................

MAJOR

FHB

(M-KG)

12.7

-17.4

25.5 -35.6

12.7 -20.B

12.7 -17.4

32.2 -44.3
B.O -11.4

12

-17

(1.6 -2.4)

12 -17

(1.6 -2.4)

9 -

13

(1.2 -1.B)

9 -

13

(1.2 -1.B)

22.1 -25.5

55 -59

(B.2 -B.B)

63 -67

(9.5 -10.0)

2.6 -4.0

16.1 -1B.1
12

12.7
12

-17

-17-4

-17

(4.0 -6.0)

(1.6 -2.4)

(1.6 -2.4)

(1.9 -2.6)
(3.B -5.3)
(1.9 -3.1)
(1.9 -2.6)
(4.B -6.6)

(1.2 -1.7)

(6.6 -7.0)

(3.3 -3.B)

(2.4 -2.7)

(1.9 -2.6)

BOLTS

AND

NUTS

COMPONENT

Main

Bearing

Cap

....................................

Oil

Pan

....................................................

Oil

Pressure

Oil

Pressure

Oil

Pump
MB
M10

Oil

Strainer
M6

MB
Rear
Rocker

Spark
Timing
Timing

Upper

Lower

Timing
Thermostat
Water

Sender

................................

Switch

.................................

......................................................

....................................................

......................................................

......................................................

Cover

Assembly

Shaft

Plug

............................................... 1 0.0 -15.4

Belt

Crank

Belt

Cover

................................................

...............................................

Tension

Cover.

Pump

..............................

Assembly

............................................

...........................

Pulley

Bolt...

Lock

Bolt

.......................

...................................

...............

..4.7 -6.7

FHB

(M-KG)

56.4 -60.4

.4.7 -B.O

9 -

13

(1.2 -1.B)

9 -

13

(1.2 -1.B)

12.7

-17.4

25.5 -35.6

5.3 -B.O

10.7 -15.4

5.3 -B.O

12.0 -1B.1

120.9

.4.7 -6.7

25.5 -35.6

12.7 -20.8
12

(8.0

-134.4

(7.0
(7.0 -10.0)

7 -17.4

(B.4 -9.0)

(7.0 -12.0)

(1.9 -2.6)
(3.B -5.3)

(B.O

-12.0)

(1.6

-2.3)

-12.0)

(1.B

-2.7)

(1.5 -2.3)

(1B.0 -20.0)

-10.0)

(3.8 -5.3)
(1.9 -3.1)
(1.9 -2.6)

NOTE:

Formula

to

convert

Ft-Lbs

to

Nm

(Newton

Meters)

multiply

Ft-Lb x 1.356.

Engines & Generators

51

BOLT

HEAD

Bolt

strength

Customary
(strongest).
i.e.; a grade

MARKINGS

classes

are

(inch)

bolts

are

The

marks

correspond

seven

bolt

will

embossed

identifed

to

display

five

on

the

head

by

markings

two

marks

embossed

STANDARD

of

each

bolt.

two

to

grade

eight

less

than

the

actual

grade,

marks.

HARDWARE

Metric

bolt

class

strongest.

numbers

identify

bolts

by

their

strength

with

10.9

the

NOTES:

Capsrew
(Inches) • (Thread)

NOTE:

1.

Use

the

torque

values

listed

below

when

specific

torque

values

2.

These

torques

are

based

on

clean,

dry

3.

Reduce

torques

STANDARD

Body

114 -20

-

5116·18

-

3/8-16

-

7/16·14

-

1/2

-13

-

9/16

-12

-18

5/8

·11

·18

3/4·10

·16

7/8· 9

-14

1·

·14

BOLT & NUT

SAE

Size

Ft·Lb

28

24

24

20

20

8

Grade

Torque

(Nm)

8

(11)

10

(14)

17

(23)

19

(26)

31

(42)

35

(47)

49

(66)

55

(75)

75

(102)

85

(115)

11'0

(149)

120

(163)

150

(203)

170

(231)

270

(366)

295

(400)

395

(536)

435

(590)

590

(800)

660

(895)

by

30%

or

TORQUE

5

SAE

threads.

more,

when

SPECIFICATIONS

Grade

6-7

Torque

Ft-Lb

(Nm)

10

(14)

19

(26)

34

(46)

55

(75)

85

(115)

120(163)

167

(226)

280

(380)

440

(597)

660

(895)

Reduce

threading

SAE

Grade

Torque

Ft·Lb

(Nm)

12

(16)

14

(19)

24

(33)

27

(37)

44

(60)

49

(66)

70

(95)

78

(106)

105

(142)

120

(163)

155

(210)

170

(231)

210

(285)

240

(325)

375

(508)

420

(569)

605

(820)

675

(915)

910

(1234)

990

(1342)

torque

capscrews

8

•

Fonnu/a to convert Ft-Lhs to Nm (Newton Meters) multiply Ft-Lbs by 1.356.

are

not

by

10%

into

aluminum.

METRIC

Bolt

Dia.

M3
M4
M5

M8
M9

M10

M12
M14
M16

M18
M20
M22

M24
M27
M30

M33
M36

available.

when

Wrench

5.5mm
7mm
8mm

10mm
13mm
16

mm

1Bmm
21

mm

24mm

27mm
30mm
33mm

36mm

41

mm

46mm

51

mm

55mm

engine

oil

is

BOLT & NUT

Grade

Size

4.6

Ft-Lb

(Nm)

0.3

(0.5)

O.B

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(80)

81

(110)

118

(160)

159(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

used.

TORQUE

Grade

Ft·Lb

(Nm)

0.5

(0.7)

1

(1.5)

2

(3)

4

(5.5)

10

(13)

18

(25)

33

(45)

55

(75)

85

(115)

118

(160)

166

(225)

225

(305)

288

(390)

417

(565)

568

(770)

774

(1050)

992

(1345)

SPECIFICATIONS

Grade

8.B • 9.B

4.8
Ft·Lb

1

2

4.5

7.5
18

37

63

103
159

225
321
435

553

811

1103

1500
1925

(1.3)

(Nm)

(3)

(6)

(10)

(25)

(50)

(85)

(140)

(215)

(305)
(435)

(590)

(750)

(1100)

(1495)

(2035)
(2610)

Grade

Ft-Lb

1.5
3

(4.5)

6.5

11
35
55

97
151
232

321
457
620

789
1154
1571

2139
2744

10.9

(Nm)

(2)
(9)

(15)
(26)
(75)

(130)

(205)
(315)

(435)
(620)
(840)

(1070)

(1565)
(2130)

(2900)
(3720)

GASKETS/SEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

O-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper
ing

assembly.

Specialized
ing
copper

gasket

non-hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

LIQUID

red

sealant

of

the

gaskets

that

SILICONE

ADHESIVE

SPRAYS

sealers
properties.

gaskets

and

it's

effective

fuel.

should

oil

pan

seal

grease.

such

as

HYLOMAR

as

HIGH

TACK

in

just

TEFLON

can

be

used

gasket

with

around

water

are

useful

HYLOMAR

it

resists

equivalent

about

be

on

high

for

work

is

particlarly

fuel,

oil

SEALANTS & LUBRICANTS

Use

LIQUID

TEFLON

for

are

any

joint

used

on

oil

adapter

temp

(coolant)

holding

gaskets

well

effective

and

water.

excellent

in

contact

rubber

gaskets

hoses

RED

SILICONE

passages,

in

in

applications

on

all

with

passages.

BOLTS & FASTENERS/ASSEMBLIES

.

and

the

sealer.

coat

both

position

requir-

Engines & Generators

oil

dur-

Lightly
plugs
HIGH

When
Anti-seize

threaded
LOCTITE

LITHIUM

ing

boxes.

Heavily

use

Do

not

oil

head

that

penetrate

TACK.

assembling

compounds
components
offers

based

oil

all

sliding

clean

engine

use

bolts

and

the

the

levels

grease

and

oil!

sealing

tape

other

water

flywheel,

and

yet

allows

of

locking

is

waterproof,

reciprocating

52

pipe

sealants!

fasteners

jacket

coat

thread

locking

them

according

plugs

and

as

you

should

be

the

bolt

threads

adhesives

to

came

to

the

ideal

for

water

components

fillings

that

assemble

sealed

with

with

such

apart

when

job.

pump

when

connect

coolant

them.

Bolts

PERMATEX

LOCTITE

blue.

as

LOCTITE

necessary.

bearings'and

assembling.

and

#2

or

protect

stuff-

Always

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x

1.609

=

Kilometers

METRIC

(mm)

x

.0394

(m)

x

3.281

=

Feet

(km)

x

.0621

CONVERSION

=

Inches

=

Miles

DATA

DISTANCE

EQUIVALENTS

1

Degree

of

1

Minute

of

Latitude

Latitude

VOLUME

Cubic

Inches

(in3)
Imperial
Imperial
Imperial
Imperial
Imperial
Fluid
US
US
US

Pints
Quarts
Gallons

Quarts

Gallons

Ounces

Pints

(US
Quarts
Gallons

x

(US

(US

(IMP

(IMP

29.573

pt)

qt)

MASS-WEIGHT

Ounces

(oz)

x

28.35

Pounds

(Ib)

x

.454

PRESSURE

Pounds

Per

Sq

In

Inches

of

Mercury

Inches

of

Mercury

Inches

of

Water

Inches

of

Water

Inches

of

Water

=
= 1

x

16.387

pt)

(IMP

(IMP

(IMP

x

.473

x

.946

gal)

x

=

=

(psi)

(Hg)

(Hg)
(H20)
(H20)

(H20)

60

Nm

=

Nm

=

1.852

=

Cubic

x

.568

=

qt)

x

1.137

gal)

x

4.546

qt)

x

1.201

gal)

x

1.201

=

Milliliters

=

Liters(L)

=

Liters

3.785

=

Liters

Grams

(g)

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

111.120

Liters

(kg)

=

=

=
=
=

Kilopascals

km

km

Centimeters

(L)

x

=

Liters

(L)

=

Liters

=

US

Quarts

=

US

Gallons

x

.034

=

x

2.113

(L)

x

1.057

(L)

x

x

.035

=

x

2.205

Kilopascals

psi

x

2.036

Kilopascals
Inches

of

psi

x

27.684

x

1.76

=

x.88

=

(L)

x

.22

(US

(US

Ounces

=

Pints
=

Quarts

.264

=

Gallons

Ounces

=

Pounds

(kPa)
=

Hg

(kPa)

Mercury

=

H20

(kPa)

x

.061

IMP

IMP

=

qt)

gal)

x

.145

x

x

4.026

3

=in

pt

qt

IMP

x

.833

x

=

.2961

13.783

=

gal

=

.833

psi

=

H20

IMP

=

Hg
=

H20

qt

IMP

gal

TORQUE

Pounds-Force
Pounds-Force

Inches
Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles
Kilometers
Miles
Kilometers

TEMPERATURE

Degree
Degree

LIQUID

Diesel
Fresh
Gasoline

Salt

Water

(Hp)

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Liter

.

Fahrenheit
Celsius

(DC) = (OF

WEIGHTS

Oil

= 1

US

Water

= 1

US

= 1

US

gallon

= 1

US

(in-Ib)

(ft-Ib)

x

1.609

x

.745

=

(MPG)

(Km/L)

US

(MPG)

(Km/L)

(OF) = (DC

gallon

=

gallon

=

6.1

gallon

=

x

.113

x

1.356

=

Kilometers

Kilowatts

x

.354

x

2.352

x

.425

x

2.352

X

1.8) + 32

-

32) x .56

7.13

Ibs

=

8.33

Ibs

8.56

Ibs

=

Newton

=

Newton

(Kw)

=

Kilometers

=

IMP

=

Kilometers

=

US

Ibs

Meters

Meters

Per

x

1.34

MPG

MPG

Hour

=

MPH

Per

Per

(Nm)

(Nm)

(KPH)

Liter

Liter

x

8.85

x

.738

x

.621

(Km/L)

(Km/L)

=in-Ib

=

ft-Ib

=

MPH

Engines. & Generators

53

METRIC

CONVERSIONS

INCHES TO MILLIMETERS

Inches

1
2 50.80 20
3
4 101.60
5

10

10

mm

25.40

76.20 25

127.00

254.00 40

MILLIMETERS

= 1

INCHES TO METERS

Inches

1
2
3
4
5
6

Meters

0.0254 7 0.1778

0.0508

0.0762

0.1016

0.1270

0.1524 12

TO

CONVERT

METERS

YARDS TO METERS

Yards

1
2
3
4
5

Meters

0.91440

1.82880 7 6.40080 2 2.18723

2.74320 8

3.65760 9

4.57200

MOVE

DECIMAL

POINT

Inches

15

30
35

CENTIMETER,

Inches

8

9
10
11

TO

CENTIMETERS,

Yards Meters

6

10

FOR

mm mm

381.00 1 0.0394

508.00

635.00

762.00 4 0.1575 30 1.1811

889.00

1016.00
100

Meters

0.2032 0.2 7.874 0.8

0.2286 0.3

0.2540

0.2794 0.5 19.685

0.3048 0.6 23.622 1.2 47.244

5.48640 1

7.31520

8.22960 4 4.37445 9 9.84252

9.14400

HIGHER

2
3

5

10

CENTIMETERS

MOVE

VALUES

= 1

Meters

0.1

0.4

DECIMAL

Meters

3

5

-

e.g.

MILLIMETERS TO INCHES

Inches

0.0787

0.1181

0.1969 35 1.3780

0.3937 40 1.5748

METER = 39.37

mm

15
20 0.7874
25 0.9843

INCHES

(3.3

FEET)

METERS TO INCHES

Inches

3.937

11.811

15.748 1.0 39.370

POINT

TWO

Meters

PLACES

0.7 27.559

0.9

1.1

TO

THE

RIGHT

METERS TO YARDS

Yards

1.09361

3.28084 8 8.74891

5.46807

6,000

METERS = 6,561.68

Meters

6
7 7.65529

10

YARDS

Inches

0.5906

Inches

31.496

35.433

43.307

Yards

6.56168

10.93614

POUNDS TO KILOGRAMS

Ib

1
2
3
4 1.814 9
5

kg

0.454

0.907 7 3.175 2

1.361

2.268

GALLONS

Gallons

1 3.79
2 7.57
3
4
5

Liters

11.36

15.14

18.93

PINTS TO LITERS

Pints

1 0.47 6
2
3
4

5

32

Liters

0.95 7 3.31 2

1.42

1.89

2.37

40

50

I I I I I
I I I I

5 10

0

KILOGRAMS TO POUNDS

Ib

6

8

10

kg kg

2.722 1

3.629

4.082 4 8.818 9 19.842

4.536

3

5

2.205 6

4.409 7 15.432

6.614 8

11.023

TO LITERS LITERS TO

Gallons

10
20
30
40 151.42
50

113.57

189.28 20 5.28 180

Liters

37.86 1 0.26 60 15.66

75.71

Liters

2
5

10

Gallons

0.53

1.32 120 31.32

2.64 150

LITERS TO PINTS

Pints

8
9

10

Liters

2.84 1 2.11 6

3.79 3

4.26

4.73

Liters

4
5

Pints

4.23 7 14.79

6.34 8 16.91

8.45 9

10.57

TEMPERATURE

70

60

75

85

95

105

I I I I I I I

I I I I I I I I

15

20 25

30 35

40

Ib

140

60

kg

10

GALLONS

Liters

90

Liters

10

175

212

80

100

Ib

13.228

17.637

22.046

Gallons

23.77

39.62

47.54

Pints

12.68

19.02

21.13

of

°C

Engines & Generators

54

CONTACT

WESTERBEKE

YOUR

WESTERBEKE DEALER

SUGGESTED

SPARE

MARINE

FOR

GASOLINE

SUGGESTIONS AND ADDITIONAL INFORMATION

PARTS

ENGINES

DISTRIBUTER

AND

WIRES

WESTERBEKE also offers two Spare Pmts Kits,
each packaged in a rugged, rust free

KIT

A includes the basic spares.

KIT B is

CAP

MOLDED
HOSE

KIT

INA

CANVAS

~--------.CARR~NGBAG-----------------------------------------------

toolb()x.

for more extensive off-shore cruising.

KIT

A

Impeller Kit

Heat Exchanger Gasket

Oil Filter

Drive Belt

Zinc Anodes

Spark

Plugs

.

SPARE

PARTS

KITS

WESTERBEKE
ENGINE
AND A GALLON

RECOMMENDS

OIL

(YOUR

CARRYING

BRAND)

OF

PREMIXED

FOR

AN

COOLANT.

KIT

B

Impeller Kit
Water

Pump Repair Kit

Thermostat Kit

Zinc Anodes
Complete Gasket Kit .

Heat Exchanger Gasket
Oil Filter
Drive Belt
Spark

Plugs

HARDWARE

ENOUGH

OIL

CHANGE

KIT

SPARE

(5

DTS.)

Engines & Generators

55

Engines & Generators

WM/DW1081-5/04