Westerbeke W-70GA Operator'S Manual Download

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Summary of Contents for W-70GA

Page 1: ... GASOLINE INE FIRST EDITION MARCH 2004 r rWESTERBEKE J WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEB SITE WWW WESTERBEKE COM A A A A NMMA Member National Marine Manufacturers Association ...

Page 2: ...hut down the unitand do notrestart until it has been inspectedandrepaired WARNING Generators Produce CARBON MONOXIDE Regular Maintenance Required l5i5fJWESTERBEKE Engl a ttn A WARNING DECAL is providedby WESTERBEKE andshouldbe fixed to a bulkheadnearyour engine orgenerator WESTERBEKE also recommends installing CARBONMONOXIDE DETECTORS in the living sleeping quarters ofyour vessel They are inexpens...

Page 3: ...carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death Do not operate with the air cleaner silencer removed Backfire can cause severe injury or death Do ...

Page 4: ...e skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is a deadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds water injected elbow is securely attached Be sure the unit and its surroundings are well ventilated R...

Page 5: ... with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install an engine should begin with a thorough examination of the American Boat and Yacht Council s ABYC standards These standards are a combination of sources including the USCG and the NFPA...

Page 6: ...njection port is at or below the load waterline will result in raw water damage to the engine andpossibleflooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under the vessel s various operating conditions install a siphon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper operation Fai...

Page 7: ...ter Pump 14 Control Cables 37 Heat Exchanger 15 Shaft Couplings 38 Thermostat 15 Specifications 39 Fuel System 16 Fuel Lift Pump 16 Gasdenser 16 Changing Fluid 40 Maintenance 40 Troubleshooting 41 Fuel Filter 16 Transmission Borg Warner 43 Engine Lubricating Oil 17 Changing the Engine Oil 17 Oil Pressure 18 Remote Oil Filter 19 Carburetor Adjustments 20 Water Heater 21 DC Electrical System 22 Alte...

Page 8: ...FILTER COOLANT PRESSURE CAP HEAT EXCHANGER k p J 20A CIRCUIT BREAKER TRANSMISSION TRANSMISS ON _ COUPLING SHIFT LEVER REAR DISTRIBUTER OIL DRAIN HOSE FUEL FILTER EXHAUST ELBOW WATER INJECTED STARTER MOTOR DC ALTERNATOR LEFT SIDE FILL PCV VALVE FILTER BURETOR THERMOSTAT HOUSING FRONT RAW WATER PUMP FILTER GASDENSER RIGHT SIDE Engines Generators 2 REAR ...

Page 9: ...hin WESTERBEKE S CONTROL WESTERBEKE CANNOTBERESPONSIBLE FOR THE CONTENT OFSUCHSOFTWARE MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO INCLUDING ACCURACY TIMEUNESS OR COMPLETENESS THEREOFAND WIU IN NO EVENTBEUABLE FOR ANY TYPE OF DAMAGE OR INJURYINCURRED IN CONNECTION WITH OR ARISING OUTOF THE FURNISHING OR USE OFSUCHSOFTWARE WESTERBEKE customers should also keep in mind the time span ...

Page 10: ...ESTMENT Care at the factory during assembly and thorough testing have resulted in a WESTERBEKE engine capable of many thousands of hours of dependable service However the manufacturer cannot control how or where the engine is installed in the vessel or the manner in which the unit is operated and serviced in the field This is up to the buyer owner operator NOTE Six important steps to ensure long e...

Page 11: ...f engine oil to mix Each brandcontains its own additives additives ofdifferent brands couldreact in the mixture to produceproperties harmful to your engine NOTE The engine compartment should have a gasoline fume detector alarm properly installed and working ENGINE COOLANT WESTERBEKE recommends a mixture of 50 antifreeze and 50 distilled water Distilled water is free from the chemicals that can cor...

Page 12: ...ngines total elapsed time in hours and 1110 hours Refer to TACHOMETER for calibration Key switch Turned to the 2 o clock position on the key switch energizes the panel Illuminates the gauges and activates the start button Prestart Button A push to start rubber booted pushbutton that is energized by the key switch Pressing this button activates the fuel lift pump Start Button Identical to the prest...

Page 13: ...ive cable is connected to the engine ground stud this location is tagged D Check the coolant level in both the plastic recovery tank and at the manifold NOTE Ifthe engine has not yet beenfilled with coolant refer to the COOliNG SYSTEM section ofthis manual OIL FILL EXHAUST MANIFOLD D Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Check the threa...

Page 14: ...r more then 30 seconds Ifthe engine fails to start refer to the TROUBLESHOOTING CHART in this manual A CAUTION Prolonged cranking intervals without the engine starling can result in the engine exhaust system filling with raw water This mayhappen because the pump is pumping raw water through the raw water cooling system during cranking This raw water can enter the engine s cylinders by way of the e...

Page 15: ...cking that all systems raw water pump oil pressure battery charging are functioning 2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves into the 130 1400 P 55 60 C range 3 While using the vessel run the engine at various engine speeds for the fIrst 25 hours Avoid prolonged periods of idling 4 Avoid rapid acceleration especially with a cold engin...

Page 16: ...ntil the thermostat opens NOTE Never attempt to engage the starter while the engine is running Stopping Procedure To stop the engine bring the throttle to an idle position and place the transmission in neutral Allow the engine to idle for a few moments to stabilize temperatures Then shut the engine down by turning off the key switch at the same time put the throttle at full open NOTE Make certain ...

Page 17: ... electrical connections Keep bolts nuts tight remain cool Check for loose belt tension Spark Plugs 0 0 0 0 0 0 Check gap inspect for burning and corrosion Generator if applicable 0 0 0 0 0 0 0 Check that AC connections are clean and secure with no chafing see GENERATOR INFORMATION if applicable for addition information Fuel Filter Lift Pump 0 0 0 0 0 0 Inspect for fuel leaks Check wire connections...

Page 18: ... cap and rotor Engine Cylinder D D Incorrect valve clearance will result in poor engine Compression and performance Check compression pressure and Valve Clearance timing and adjust valve clearances Exhaust Elbow D Test exhaust elbow for casting integrity Replace if casting is corroded or deteriorated WARNING Adefective exhaust elbow can cause carbon monoxide leakage Lubricate Panel Key D At first ...

Page 19: ...tion of the cooling system oolant Recovery Tank A coolant recovery tank allows for engine coolant expansion and contraction during engine operation without any signifi cant loss of coolant and without introducing air into the cool ing system TIris tank should be located at or above the engine manifold level and should be easily accessible NOTE Periodically check the condition ofthe manifold pres s...

Page 20: ...t should this p ump be run dry There should always be a spare impeller and impeller cover gasket aboard an impeller kit Raw water pump impeller failures occur when lubricant raw water is not present during engine operation Such failures are not warrantable and operators are cautioned to make sure raw water flow is present at start up The raw water pump should be inspected periodically for broken o...

Page 21: ...m possibly tearing off the exchanger shelL After removing the zinc note the condition If the zinc is in poor condition there are probably a lot of zinc flakes within the exchanger Remove the end cap of the heat exchanger and clean the inside of all zinc debris Always have a spare heat exchanger end gasket in case the present one becomes damaged when removing the end cover Replace the sealing gaske...

Page 22: ... to and out of the pump and make sure that no leakeage is present and that the fittings are tight and secure The DC ground connection at one of the pump s mounting bolts should be clean and well secured by the mounting bolt to ensure proper pump operation The engine mounted fuel lift pump is maintenance free INLET FUEL FILTER To ensure clean fuel enters the fuel lift pump there is an in line filte...

Page 23: ...n the mixture to produceproperties harmful to your engine CHANGING THE ENGINE OIL The engine oil should be wann Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil to drain or attach a pump to the end of the drain hose and pump the old oil out Make sure the oil drain hose is properly secured in its holder after all of the old oil has been drained A...

Page 24: ...hecking 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 of oil with the lube oil dipstick Fill to but not over the FULL mark 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 wil...

Page 25: ...UT MARKINGS ON THE ADAPTER WHEN THE HOSES ARE REMOVED FOR INSTALLATIONS SO THEY Will BE RECONNECTED CORRECTLY To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filter kit as shown Always install this kit with the oil filter facing down as illustrated Contact your WESTERBEKE dealer for more information NOTE Westerbeke is not responsiblefor enginefailure due to inc...

Page 26: ...clamp Clean after the first 50 hours of operation every 100 hours from then on Clean the air screen in kerosene and blow dry with air TO ROCKER COVER FROM FUEL FILTER SEE ELECTRIC CHOKE IN THIS MANUAL UNDER ENGINE ADJUSTMENTS IDLE MIXTURE JET Carburetor Filter Screen Clean this filter element after the first 50 hours of operation then clean and inspect every 250 operating hours Replace the screen ...

Page 27: ... escape Close both tightly after all the air is removed NOTE Ifany portion ofthe heating circuit rises above the engine s closed cooling system pressure cap then a pressurized aluminum remote expansion tank Kit 024177 must be installed in the circuit to become the highest point Tee the remote expansion tank into the heater circuit choos ing the higher ofthe two connectionsfor the return Tee at the...

Page 28: ...he service battery Ifthe alternator is charging the start ing battery but not the service battery the problem is in the service battery charging circuit and not with the alternator Testing the Alternator A WARNING Before starting the engine make certain that everyone is clear ofmovingparts Keep away from sheavesandbelts during testprocedures A WARNING MULT METERSAND DC CIRCUITS DCandAC circuits ar...

Page 29: ... and operate the alternator Ifthe voltage output is 13 14 volts the alternator is o k Trace the cause for 12 volts not being present at the Exc terminal Alternator is Working 4 Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery charging circuit Troubleshoot the service batte...

Page 30: ...TO 6 _ 4 WIRE UP TO 12 2 WIRE UP TO 20 0 WIRE ALWAYS USE FINE STRAND CABLE 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 TO A CAUTION Do not connect anypower source with out first grounding ...

Page 31: ...lts 14 2 volts Alternator Testing The regulator is functioning properly and the batteries are in good condition 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 F from the regulator should read the same 2 Hold a screw driver close 112 to the alternator pulley If voltage is present you should feel the...

Page 32: ...AGRAM AL TERNA TOR 4 V10 SPARK PLUGS III 1111 III III III III III ULlL DISTRIBUTOR 4 WHT tt 4 V 10 BATTERY tly t SEE 1 TO 61 OCK NOTE 3 J I 0 WHT 0 NEUTRAL 4 SAFETY 0 SW ITCH SENDER T t O R t t r 4 Y II t1 R O iHT WAH R TEMP SENDER I NSTRUMENT PANEl Oil PRESSURE WATER T MP TACH HOUR METER JI _ Engines Generators 26 Q ...

Page 33: ...F INDIVIDuAL CRANKING CYCLES SHOULD NOT XC EO jO SECONDS A SWITCH WITH A COI TlNUOUS RATING Of 175 AMPS AT 12 VOLTS WILL NORMALLY SERvE THESE rUNCTIONS BuT SUCH A SWITCH NUST NEVER BE uSED TO NA E THE START R CIRCUIT 4 THIS PRODuCT IS PROHeTE O 8Y A MANUAL RESEr CIRCUIT BAEAKER LOCATED HEAR THE STARTER AND AS CLOSE TO THE SOURcE or CURRENT AS POSSIBLE ExCESSIVE CuRRENT DRAIN ANTWHERE IN THE INSTRU...

Page 34: ... minal and alternator 3 Check that alternator is well grounded to engine block at alternator pivot bolt Tachometer Inaccurate a With a hand held tach on the front of the crankshaft 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 of the tachome...

Page 35: ...f oil on the belt can cause belt slipping resulting in high operating temperatures and the failure of the same components 1 To adjust the alternator and the engine coolant belts loosen the alternator mounting bolts and pivot the alternator as needed Retighten the bolts 2 To adjust the raw water pump belt loosen the mounting bolts and slide the pump up and down as needed Retighten the bolts NOTE Wh...

Page 36: ...d the timing mark on the scale embossed on the engine s front cover Each timing mark represents 2 CRANKSHAFT PULLEY 2 Start the engine and warm the engine to its nonnal operating temperature 3 Using the timing light align the timing groove in the front crankshaft pulley with the proper timing mark on the igni tion timing scale embossed on the engine s front cover Do tillS by loosening and slowly r...

Page 37: ...ist the molded cap then pull the cap off the spark plug THE RESISTANCE VALUE IS 410 OHM PER INCH TESTING RESISTANCE 4 ENGINE COMPRESSION If it becomes necessary to check the engines cylinder 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 ...

Page 38: ...e NEUTRAL SWITCH under HURTH HSW TRANSMISSIONS 3 Check switch with ohmmeter 4 Check that 12 volts are present at the solenoid connection 5 Check battery connections 6 Check battery charge state 1 Check that fuel valves are open Check fuel supply 1a Check for air in fuel system Bleed air from fuel system 1b Fuel filters clogged Replace filters and bleed air from fuel system 2 Pump should be ticking...

Page 39: ...vated when engine i not running Test the oil pressure switch 2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 amp meter in battery lines Do not start engine Remove connections and replace after short is located 3 Low resistance leak 3 Check all wires for temperature rise to locate the fault 4 Poor battery connections 4 Check cable connections at battery for loose connections c...

Page 40: ...4 Change filter 5 Relief valve is stuck 5 Service engine 6 Faulty oil pump strainer 6 Service engine 7 Faulty engine bearings 7 Service engine 8 Faulty oil filter 8 Change filter 9 Oil is sump is slugged 9 Service engine Flush Sump High oil pressure 1 Dirty oil or wrong SAE type oil in 1 Change oil the engine 2 Relief valve is stuck 2 Service engine No DC charge to the 1 Faulty connections to 1 Ti...

Page 41: ...old 3 Black smoke 3 Improper grade of fuel 3a Fuel burn incomplete due to high back pressure in exhaust or insufficient air for proper combustion check for restrictions in exhaust system check air intake 3b Dirty flame arrester 3c Faulty carburetor Choke is stuck 3d Lack of air check air intake and air filter Check for proper ventilation 3e Idle mixture jet too rich 3f Overload TROUBLESHOOTING COO...

Page 42: ...nough in idle to fill the cooler and hoses with transmission fluid Shift into gear forward and reverse shifting should be smooth and positive Direct changes from forward to reverse are permissible since the multiple disc clutch permits changing at high rpm including sudden reversing at high speeds in the event of danger After initial operation make a visual inspection of the output coupling oil co...

Page 43: ...he transmission is suitable for single lever remote control Upon loosening the retaining screw the actuating lever can be moved to any position required for the control elements cable or rod linkage Make certain that the shift lever does not contact the actuating lever cover plate the minimum distanc between lever and cover should be O 5mm The control cable or rod should be arranged at right angle...

Page 44: ...lposition to AandB If this mechanism is in any way tampered with the transmission warranty will be void SHAFT COUPLINGS WESTERBEKE recommends a flexible connection between the transmission and the propeller shaft if the engine is flexi bly mounted in order to compensate for angular deflections The installation of a special propeller thrust bearing is not required since the propeller thrust will be...

Page 45: ...he dipstick hole This could cause severe burns OPERATING TEMPERATURE The maximum permissible ATF temperature should not exceed 230 1l00 This temperature can only be reached for a short time A CAUTION If the transmission fluid temperature is too high stop the engine immediately and check the transmission fluid LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not requir...

Page 46: ... the fluid level A WARNING Neverpullout the dipstick while the engine is running Hot fluid willsplash from the dipstick hole This couldcause severe burns MAINTENANCE Transmission maintenance is minimal Keep the exterior housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hours Periodically inspect the transmission and the cooler for leaks an...

Page 47: ...nto gear 1 Output coupling is not turning 1 Transmission needs professional attention but fails to propel the boat 2 Propeller shaft is not tuming 2 The coupling bolts are sheared or the coupling is Slipping Output coupling is turning on the propeller shaft Tighten or replace set screws keys pins and coupling bolts as necessary 3 Output coupling and 3 Inspect the propeller It may be missing or dam...

Page 48: ...sion and the cooler for leaks and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawbeny cream Lay up Winlerize Storage requires special care Follow these procedures o Drain water from the transmission oil cooler and replace with a proper mixture of antifreeze coolant NOTE This operation will normally occu...

Page 49: ...nsmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi tion may be made at any time below 1000 rpm and in any order Shifts should be made at the lowest practical engine speed Start...

Page 50: ...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 D Clean off the transmission and properly dispose of the used fluid Refill the transmission with DEXTRONIII ATF The quantity will vary depending on the transmission model and the installation angle Pill through the dipstick hole Check the dipstick for the prop...

Page 51: ...ct the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate all moving parts NOTE Ifthe transmission is to be storedfor a long time twelve months or more it should be topped offwith fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into service WARRANTY NOTES ...

Page 52: ... cooler causing cross leaks to occur These internal cooler leaks will cause one of the fol lowing two problems 1 Transmission fluid will leak into the flow of raw water and be discharged overboard through the engine exhaust A loss oftransmissionfluid will cause the transmission to fail 2 The raw water will leak into the transmission fluid caus ing an increase in transmission fluid This contaminate...

Page 53: ...spect a majorproblem in your transmission immediately contact your WESTERBEKE dealer or an autho rized marine transmission acility 1 1 2 3 Engines Generators 47 VerificationJRemedy Mount aflexible coupling with another stiffness factor between the engine and transmission acoupling with ahigher stiffness factor might be sufficient Transmission needs professional attention The coupling bolts are she...

Page 54: ...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 Diesel Top off your fuel tanks with No 2 diesel fuel Fuel additives such as BioBor and Sta Bil should be added at this time to control algae and condition the fuel Care shoul...

Page 55: ...coating Check that the transmission vent is open For additional information refer to the TRANSMISSION SECTION Spare Parts Lay up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand orreplace those items used during the lay up such as filters and zinc...

Page 56: ...th ignitor module and ignitor ignition coil and spark plugs Solid state type with signal generator and ignitor 14mm X1 25 pitch Down draft type single barrel USCG approved flame arrester General Fuel Fuel Lift Pump Fuel Consumption Fuel Filter on engine Air cleaner Flame Arrester AirFlow engine combustion General Operating Temperature Fresh Water Pump Raw Water Pump System Capacity coolant FUEL SY...

Page 57: ...y 12 17 1 6 2 4 MB 10 7 15 4 1 6 2 3 Coolant Temperature Sender 9 13 1 2 1 B Rear Cover Assembly 5 3 B O 8 0 12 0 Coolant Temperature Switch 9 13 1 2 1 B Rocker Shaft Assembly 12 0 1B 1 1 B 2 7 Crank Shaft Pulley 22 1 25 5 3 3 3 B Spark Plug 10 0 15 4 1 5 2 3 Cylinder Head Timing Belt Crank Pulley Bolt 120 9 134 4 1B 0 20 0 Cold 55 59 B 2 B B Timing Belt Cover Hot 63 67 9 5 10 0 Upper 4 7 6 7 7 0 ...

Page 58: ...6 440 597 605 820 14 435 590 675 915 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 M36 55mm 700 950 992 1345 1925 2610 2744 3720 NOTE Fonnu a to convert Ft Lhs to Nm Newton Meters multiply Ft Lbs by 1 356 SEALANTS LUBRICANTS GASKETS SEALANTS Oil based PERMATEX...

Page 59: ...Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x3 377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x13 783 H20 Inches of Water H20 x 03613 psi x 27 684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4 026 H20 TORQUE Pounds Force Inches in Ib x 113 Newton ...

Page 60: ... 56168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHER VALUES e g 6 000 METERS 6 561 68 YARDS POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0 454 6 2 722 1 2 205 6 13 228 2 0 907 7 3 175 2 4 409 7 15 432 3 1 361 8 3 629 3 6 614 8 17 63...

Page 61: ... DTS AND A GALLON OFPREMIXED COOLANT CARR NGBAG SPARE PARTS KITS WESTERBEKE also offers two Spare Pmts Kits each packaged in a rugged rust free toolb x KIT A includes the basic spares KIT B is for more extensive off shore cruising KIT A Impeller Kit Heat Exchanger Gasket Oil Filter Drive Belt Zinc Anodes Spark Plugs Engines Generators 55 KIT B Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc...

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