Westerbeke 7.0KW BCGD-60Hz, 5.0KW BCGA-60Hz, 4.2KWBCGA-50Hz, 7.0KW BCGC-60Hz, 5.9KW BCGC-50Hz Operator's Manual

OPERATORS

MANUAL

5.0KW

5.0KW

7.0KW

7.0KW

GASOLINE

BCG-60Hz / 4.2KW
BCGA-60Hz / 4.2KW
BCGC-60Hz
BCGO-60Hz / 5.9KW

GENERATORS

Single

PUBLICATION NO. 46983

THIRD EDITION

JULy

BCG-50Hz
BCGA-50Hz

/5.9KW

BCGC-50Hz
BCGO-50Hz

Phase

2008

~

,tfJM,T Member

.w

WESTERBEKE

d

WESTERB

150

FAX

EKE

JOHN

[phone]· WEBSITE: WWW.WE

CORPORATION· MYLES

HANCOCK

Nai/Oiral Marin

ROAD· TAUNTON

e Manufaclurers Associfllion

STANDISH

MA

02780·7319 ·

STERBEK£.COM

INDUSTRIAL

TEL

, [phone]

PARK

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

CALIFORNIA

PROPOSITION

65

WARNING

Exhaust

gas

from

diesel

and

gasoline

engines

(and

some

of

its

constituents)

are

known

to

the

State

of

California

to

cause

cancer,

birth

defects,

and

other

reproductive

harm.

A

WARNING:

Exhaust

gasses

contain

Carbon

Monoxide,

an

odorless

and

colorless

gas.

Carbon

Monoxide

is

poisonous

and

can

cause

unconsciousness

and

death.

Symptoms

of

Carbon

Monoxide

exposure

can

include:

-Dizziness

-

Throbbing

in

Temples

-Nausea

-

Muscular

Twitching

-Headache

-

Vomiting

-

Weakness

and

Sleepiness

-Inability

to

Think

Coherently

IF

YOU

DR

ANYONE

ELSE

EXPERIENCE

ANY

OF

THESE

SYMPTOMS,

GET

DUT

INTO

THE

FRESH

AIR

IMMEDIATELY.

If

symptoms

persist,

seek

medical

attention.

Shut

down

the

unit

and

do

not

restart

until

it

has

been

inspected

and

repaired.

A

WARNING

DECAL

is

provided

by

WESTERBEKE

and

should

be

fixed

to a bulkhead

near

your

engine

or

generator.

WESTERBEKE

also

recommends

installing

CARBON

MDNOXIDE

DETECTORS

in

the

living/sleeping

quarters

of

your

vessel.

They

are

inexpensive

and

easily

obtainable

at

your

local

marine

store.

Engines

& Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety

manual

carefully.

Most

accidents

are

caused

by

failure

to

follow fundamental

rules

and

precau-

tions.

Know

when

dangerous

conditions exist and

take

the

necessary

precautions

to

protect yourself, your

personnel,

and your

machinery.

The

following

safety

instructions

are

in

compliance

with

the American

Boat

and

Yacht

Council

(ABYC)

standards.

PREVENT

ELECTRIC

SHOCK

A

WARNING:

00

not

touch

AC

electrical

connectlDRS

while

engine

is

running,

or

when

connected

to

shore

power.

Lethal

voltage

is

present

at

these

cDnnectiDns!

• 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 dry, not damp
(particularly shoes) when handling electrical equipment.

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

•

Do

not connect utility shore power

to

vessel's

AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage

to

vessel's

AC

generator may

result

if

this procedure

is

not followed.

• Electrical shock results from handling a charged capaci­tor.

Discharge capacitor

by

shorting tenninals together.

PREVENT

BURNS -HOT

ENGINE

A

WARNING:

OD

not

touch

hot

engine

parts

Of

exhaust

system

components. A running

engine

gets

very

hot!

• Always check

the

engine coolant level at the coolant

recovery tank.

A

WARNING:

Steam

can

cause

injury

Of

death!

•

In

case

of

an engine overheat, allow the engine

to

cool

before touching the engine or checking the coolant.

PREVENT

BURNS -FIRE

A

WARNING:

Fire

can

cause

injury

Df

death/

• Prevent

flash

fires.

Do

not smoke or pennit

flames

or

sparks

to

occur near

the

carburetor, fuel line,

filter,

fuel

pump, or other potential sources

of

spilled

fuel

or

fuel

vapors.

Use

a suitable container to catch

all

fuel

when

removing the fuel line, carburetor, or

fuel

filters.

• Do not operate with a Coast Guard Approved

flame
arrester removed. Backfire can cause severe injury or
death.

• Do not operate with

the

air cleaner/silencer removed.

Backfire can cause severe injury or death.

• Do not smoke or pennit flames or sparks

to

occur near

the fuel system. Keep the compartment and

the

engine/generator clean and free

of

debris

to

minimize the

chances of

fire.

Wipe up all spilled

fuel

and engine

oil.

• Be aware diesel

fuel

will bum.

PREVENT

BURNS -EXPLOSION

A

WARNING:

ExplosiDns

from

fuel

vapors

can

cause

injury

or

death/

• Follow re-fueling safety instructions. Keep

the

vesseFs
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before

run-

ning the blower. Run

the

blower for four minutes before

starting your engine.

•

All

fuel

vapors

are

highly explosive.

Use

extreme

care

when handling and storing fuels. Store fuel

in

a well-ven­tilated area away from spark-producing equipment and
out

of

the reach

of

children.

• Do not

fill

the fuel tank(s) while

the

engine

is

running.

• Shut off the

fuel

service valve

at

the engine

when

servicing

the fuel system. Take care in catching

any

fuel that might

spill.

DO

NOT allow

any

smoking, open

flames,

or other

sources of

fire

near

the

fuel

system or engine

when

servic-

ing.

Ensure proper ventilation exists when servicing the

fuel system.

• Do not alter or modify the fuel system.

• Be sure

all

fuel supplies have a positive shutoff valve.

• Be certain fuel line fittings are adequately tightened

and

free

of

leaks.

• Make sure a

fire

extinguisher is installed nearby

and

is

properly maintained. Be familiar with its proper

use.

Extinguishers rated ABC

by

the

NFPA

are appropriate

for all applications encountered in

this

environment.

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

STARTING

A

WARNING:

Accidental

starting

can

cause

injury

ordeathJ

• Disconnect

the

battery cables before servicing

the

engine!

generator.

Remove

the

negative lead

first

and

reconnect

it

last.

•

Make

certain

all

personnel

are

clear of

the

engine before

starting.

•

Make

certain

all

covers, guards,

and

hatches

are

re-

installed before starting

the

engine.

BATTERY

EXPLOSION

A

WARNING:

Battery

explosion

can

cause

injury

or

death!

•

Do

not smoke or

allow

an

open

flame

near

the

battery

being serviced. Lead

acid

batteries emit

hydrogen,

a

highly explosive

gas,

which

can

be

ignited

by

elect~ical

arcing

or

by

lit tobacco products. Shut off

all

electncal

equipment

in

the

vicinity

to

prevent electrical

arcing

dur-

ing servicing.

• Never connect

the

negative (-) battery cable

to

the

posi-

tive

(+) connection terminal of

the

starter solenoid.

Do

not

test the battery condition by shorting

the

terminals

together.

Sparks

~ould

ignite battery

gases

or

fuel

vapors.

Ventilate

any

compartment containing batteries

to

prevent

accumulation of explosive

gases.

To

avoid

sparks,

do

not

disturb the battery charg0r connections

while

the

battery

is

being

charged.

•

Avoid

contacting

the

terminals

with

tools, etc.,

to

prevent

bums

or

sparks

that

could cause

an

explosion.

Remove

wristwatch, rings, and

any

other jewelry before handling

the

battery.

•

Always

tum

the

battery charger off before disconnecting

the

battery connections. Remove the negative

lead

first

and

reconnect it last whenservicing the

battery.

BATTERY

ACID

A

WARNING:

Sulfuric

acid

in

batteries

can

cause

severe

injury

or

death!

•

When

servicing

the

battery or checking

the

electrolyte

level. wear rubber gloves. a rubber

apron,

and

eye

protec-

tion.

Batteries contain sulfuric acid

which

is

destructive.

If

it

comes

in

contact

with

your skin,

wash

it

off

at

once

with

water.

Acid

may

splash

on

the

skin or into

the

eyes

inadvertently

when

removing electrolyte caps.

TOXIC

EXHAUST

GASES

A

WARNING:

Carbon

monoxide

(CO)

Is a deadly

gas!

• Ensure that

the

exhaust system

is

adequate

to

expel

gases

discharged from

the

engine.

Check

the

exhaust

system

regularly

for

leaks

and

make

sure the exhaust

manifoldl

water-injected elbow

is

securely attached.

• Be

sure

the

unit

and

its

surroundings

are

well

ventilated.

Run blowers

when

running the generator

set

or

engine.

• Don't

run

the

generator set or engine

unless

the

bo~t

is

equipped

with

a functioning marine

carbon

monoXlde

detector that complies

with

ABYCA-24.

Consult

your

boat

builder

or

dealer

for

installation of

approved

detectors.

• For additional information refer

to

ABYC

T-22

(educational information

on

Carbon

Monoxide).

A

WARNING:

Carbon

monoxide

{CO}

is

an

invisible

odorless

gas.

Inhalation

produces

flu-like

symptoms,

nausea

or

death!

•

Do

not

use

copper

tubing

in

diesel

exhaust

systems.

Diesel

fumes

can

rapidly

destroy

copper

tubing

in

exhaust

systt:ms.

Exhaust sulfur causes rapid deterioration of copper

tubmg

resulting

in

exhaust/water leakage.

•

Do

not

install exhaust outlet

where

exhaust

can

be

drawn

through portholes,

vents,

or

air conditioners.

If

the

engine

exhaust discharge outlet

is

near the waterline,

water

could

enter

the

exhaust

discharge

outlet

and

close or

restrict

the

flow

of

exhaust.

Avoid

overloading

the

craft.

• Although diesel engine exhaust

gases

are

not

as

toxic

as

exhaust

fumes

from gasoline engines,

carbon

monoxide

gas

is

present in diesel exhaust

fumes.

Some

of the

symptoms

or signs of carbon

monoxide

inhalation or

poisoning

are:

Vomiting
Dizziness
Headache
Nausea

AVOID

MOVING

PARTS

Inability

to

think

coherently

Throbbing

in

temples
Muscular twitching
Weakness

and

sleepiness

A

WARNING:

Rotating

parts

can

cause

injury

or

death!

• Do not service the engine while

it

is

running. If a

situation

arises

in

which

it

is

absolutely necessary

to

make

operat-

ing

adjustments, use extreme care

to

avoid

touching

mov-

ing

parts

and

hot

exhaust system

components.

Engines & Generators

ii

SAFETY

INSTRUCTIONS

• Do not wear loose clothing

or

jewelry when servicing

equipment; tie back long hair and avoid wearing loose

jackets, shirts, sleeves, rings, necklaces or bracelets that

could be caught in moving parts.

• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective

places at all times.

• Do not check fluid levels or the drive belt's tension while
the engine is operating.

• Stay clear

of

the drive shaft and the transmission coupling
when the engine is ruuning; hair and clothing can easily
be caught in these rotating parts.

HAZARDOUS

NOISE

A

WARNING:

High

noise

levels

can

cause

hearing

loss!

• Never operate an engine without its muffler installed.

• Do not run an engine with the air intake (silencer)
removed.

• Do not run engines for long periods with their enclosures
open.

A

WARNING:

Do

not

work

on

machinery

when

you

are

mentally

Dr

physically

incapacitated

by

fatigue!

OPERATORS

MANUAL

Many

of

the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.

ENGINE

INSTALLATIONS

Preparations to install an engine should begin with a thor­ough examination

of

the American Boat and Yacht Council's

(ABYC) standards. These standards are a combination

of

sources including the USCG and the NFPA.
Sections

of

the ABYC standards

of

particular interest are:

H-2 Ventilation
P-l

Exhaust systems
P-4 Inboard engines
E-9

DC

Electrical systems

All installations must comply with the Federal Code

of

Regulations (FCR).

ABYC,

NFPA

AND

USCG

PUBLICATIONS

FOR

INSTALLING

DIESEL

ENGINES

Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda­tions when installing your engine.

ABYC

(American Boat and Yacht Council)

"Safety Standards for Small Craft"
Order

from:

ABYC
3069 Solomon's Island Rd.
Edgewater,

MD

21037

NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"

Order

from:

NFPA
11

Tracy Drive

Avon Industrial

Park

Avon,

MA

02322

USCG

(United States Coast Guard)

"USCG 33CFR183"
Order

from:

U.S. Govemment Printing Office
Washington, D.C.

20404

Engines & Generators

iii

INSTALLATION

When installing WES1ERBEKE engines and generators it is important that strict
attention be paid to the following information:

CODES

AND

REGULATIONS

Strict federal regulations, ABYC guidelines, and safety codes must he complied with
when installing engines and generators in a marine environment.

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow is close to

or

will

be

below

the

vessel's

waterline,

provisions

must

be

made

to

install a siphon-

break in the raw water supply hose to the exhaust elbow. This hose must he looped a
minimum

of

20" above the vessel's waterline. Failure

to

use a siphon-break when

the exhaust manifold injection

pOri

is at or

below

the load waterline

will

result in

raw

water

damage

to

the engine and possible flooding

of

the

boat.

If

you have any doubt about the position

of

the water-injected exhaust elbow relative

to the vessel's waterline under the vessel's various operating conditions,

install a

siphon-break.

NOTE:

A siphon-break requires periodic inspection

and

cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer

for

proper maintenance.

EXHAUST

SYSTEM

The exhaust hose must he certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of

the vessels hulL

Engines & Generators

iv

TABLE

OF

CONTENTS

Introduction

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

2

Fuel,

Engine

Oil

and

Engine

Coolant..

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

.4

Control

Panels

................................................................. ; ...

5

Preparations

for

Initial

Start-Up

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

6

Operating

Instructions

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

7

Remote

Panel

........

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

8

Break-in

Procedure/Daily

Operation

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

9

Safety

Shutdown

Switches

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

10

Maintenance

Schedule

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

11

Cooling

System

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

13

Changing Coolant.. .....................................................

13

Thermostat .................................................................. 14

Zinc Anode ................................................................. 14

Raw Water Strainer ....................................................

15

Raw Water Pump ........................................................

15

Fuel

System

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

16

GasolinelWater Separator ........................................... 16

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

16

Engine

Oil

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

17

Oil Change .................................................................

17

Battery

Charging

Circuit

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

18

Electronic

Governor

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

19

Troubleshooting

The

Electronic

Governor

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

20

Carburetor

Adjustments ....................................................

21

Engine

Adjustments

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

22

Timing Belt ..............................................................

,.22

Compression Test ....................................................... 22

Valve Clearance .......................................................... 26

Injection Timing ......................................................... 26

Torquing The Cylinder Head Bolts ............................ 26

Spark Plugs ................................................................. 27

Drive Belt Adjustment ............................................... 27

Choke Solenoid .......................................................... 27

Generator

Information

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

28

Generator

Wiring

Schematic

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

.29

BCGA

AC

Terminal

Connections

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

29

BCG

AC

Terminal

Connections

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

29

A

BCG

Generator

Wiring

Schematic

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

29A

Shore

Power

Transfer

SWitch

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

.30

BC

Generator

Single

Phase

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

31

Wiring

Schematic

(#46876) ............................................. .32

Wiring

Diagram

(#46876) .................................................. 33

Remote

Panel

Wiring

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

34

Engine

Troubleshooting

....

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

35

Lay-up

and

Recommissioning

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

37

Specifications

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

39

Specifications

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

39

A

Hardware

Torques

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

.40

Metric

Conversions

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

:.41

Suggested

Spare

Parts

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

.42

Engines & Generators

1

INTRODUCTION

This WESTERBEKE Generator

is

a product of

WESTERBEKE'S

long

years of experience and

advanced

technology.

We

take

great pride

in

the superior durability

and

(jependable

performance of our engines and generators.

Thank

you

for

selecting WESTERBEKE.

In

order

to

get the

full

use

and

benefit

from

your generator,

it

is

important

that

you

operate

and

maintain it

correctly.

This

manual

is

designed

to

help

you

do

this. Please read this

manual

carefully

and

observe all the safety precautions
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer

for

assistance.

This

is

your Operators Manual. A PaIts Catalog

is

also

provided

and

a Technical Manual

is

available

from

your

WESTERBEKE

dealer.

Also,

if

you

are planning

to

install

this

equipment yourself, contact your WESTERBEKE dealer

for

WESTERBEKE'S Installation

ManuaL

WARRANTY

PROCEDURES

Your

WESTERBEKE

Warranty

is included

in

a separate

folder.

If

you

have

not

received a customer identification

caI·d

registering your

WaITanty

60

days

after submitting

the

WaITanty

registration

form,

please contact

the

factory

in

writing

with

model infonnation, including

the

unit's serial

number

and

commission date.

,.."."WESTERBEKE

, Engines & Generators

Customer Identification

WESTERBEKE OWNER
MAIN

STREET

HOMETOWN, USA

Model
Expires

Ser. #

Customer

Identification

Card

(Typical)

The

WESTERBEKE serial number

is

an

alphanumeric

number

that

can

assist

in

determining

the

date of

manufacture of

your

WESTERBEKE engine/generator.

The

first

character indicates the decade (A=1960s, B=1970s,

C=1980s,

D=1990s E=2000s), the

first

number represents

the

year

in

the

decade,

and

the

second

and

third

numbers

represent

the

month of manufacture.

PRODUCT

SOFTWARE

Product software, (tech data, parts lists, manuals, brochures
and

catalogs), provided

from

sources other

than

WESTER-

BEKE

are

not

within WESTERBEKE'S CONTROL.

WESTERBEKE

CANNOT

BE

RESPONSIBLE

FOR

THE

CONTENT

OF

SUCH

SOFTWARE,

MAKES

NO

WARRANTIES

OR

REPRE-

SENTATIONS

WITH

RESPECT

THERETO,

INCLUDING

ACCU-

RACY,

TIMEUNESS

OR

COMPLETENESS

THEREDF

AND

WIU

IN

NO

EVENT

BE

UABLE

FOR

ANY

TYPE

OF

DAMAGE

OR

INJURY

INCURRED

IN

CONNECTION

WITH

OR

ARISING

OUT

OF

THE

FURNISHING

OR

USE

OF

SUCH

SOFTWARE.

WESTERBEKE

customers

should

also

keep

in

mind

the

time

span

between

printings of WESTERBEKE product software

and

the unavoidable existence of earlier

WESTERBEKE

manuals.

In

summation, product software provided

with

WESTERBEKE products, whether

from

WESTERBEKE

or

other

suppliers,

must

not

and

cannot

be

relied

upon

exclu-

sively

as

the

definitive authority

on

the

respective

product.

It

not

only

makes

good sense but

is

imperative that appropriate

representatives of WESTERBEKE or

the

supplier

in

question

be

consulted

to

determine the aceuracy

and

currentness of

the

product software being consulted by

the

customer.

SERIAL

NUMBER

LOCATION~~

The

engine

serial

Fill in the information

~h:;olQ'f,..~·

ryumber

is

s~am[Jed

below

for

reference.

/;::/:v

~

j'

rnto

the

engrne

block.

lY

/..:/"~'

ibli

~

f'"

"%;11L

The

engine

model

number

and

serial

number

are

printed

on a decal

on

the

engine

manifold.

The

generator serial

number

is

stamped

on

the

top

of

the

generator

HIII,'_YI.rLfJ

are

on

a decal

on

the

side

of

the

generator.

.,

Engines & Generators

2

INTRODUCTION

ORDERING

PARTS

Whenever replacement parts are needed, always provide the
generator

and

engine

model

and serial numbers.

In

addition,

include a complete part description

and

p(Ut

number for each

part needed (see the separately furnished

Parts Catalog). Also

insist

upon

WESTERBEKE packaged parts because will fit

or generic parts are frequently not

made

to

the same specifi-

cations

as

original equipment.

NOTES,

CAUTIONS

AND

WARNINGS

As

this

manual takes

you

through the operating procedures,

maintenance schedules,

and

troubleshooting of your genera-

tor, critical information

will

be highlighted

by

NOTES,

CAUTIONS,

and

WARNINGS.

An

explanation follows:

NOTE:

An operating procedure essential

to

note.

A

CAUTION:

Procedures,

which

if

not

strictly

observed,

can

result

in

the

damage

or

destruction

of

the

engine

or

generator.

A

WARNING:

Procedures,

which

if

not

properly

followed.

can

result

in

personal

injury

or

loss

of

life.

NOTE:

A carbon monoxide warning

decal

has been provided

by

WESTERBEKE.

Affix this decal

in

a visable location

in

the

engine

room.

SPARES

AND

ACCESSORIES

Certain spare parts will be needed

to

support

and

maintain

your WESTERBEKE generator or engine when cruising (see

SUGGESTED

SPARE

PARTS).

Often

even

simple items such

as

proper fuel

and

oil filter can be difficult

to

obtain along

the

way.

WESTERBEKE

will

provide

you

with a suggested

spares

and

accessories brochure

to

assist

you

in

preparing

an

on-board inventory of the proper WESTERBEKE parts.

PROTECTING

YOUR

INVESTMENT

Care

at

the

factory during assembly

and

thorough testing

have resulted

in

a WESTERBEKE generator capable of

many thousands

of

hours

of

dependable service. However the

manufacturer cannot control

how

or where

the

generator 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

generator

life:

•

Proper

engine and generator

installation

and

alignment.

• An efficient

well-designed

exhaust

system

that

includes

an anti-siphon break

to

prevent

water

from entering the

engine.

• Changing the engine oil and oil filters

every

100

operat-

ing

hours.

•

Proper

maintenance

of

aIL

engine

and

generator

compo-

nents

according

to

the maintenance

schedule

in

this

manual.

•

Use

clean,

filtered

UIlleaded

fueL

•

'Winterize

your engine

according

to

the "lAy-up

and

Recommissioning"

section

in

this

manual.

UNDERSTANDING

THE

GASOLINE

GENERATOR

The gasoline engine driving

an

AC

generator is

in

many

ways similar

to

a gasoline automobile engine. The cylinders

are verticle in-line, and

the

engine's cylinder head

has

an

overhead camshaft which

is

chain-driven. The engine utilizes

a solid-state distributor which is horizontally mounted

and

camshaft-driven. The engine incorporates a pressure

type
lubrication system, and a fresh water-cooled engine block
which is thermostatically-controlled.

To

a large degree, the
generator's engine requires the same preventive maintenance
that is required of a gasoline automobile engine. The most
important factors

to

the generator's longevity

are

proper

ventilation, maintenance

of

the fuel

system,

ignition

system,

cooling system and

the

generator backend.

Engines & Generators

3

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

CARE

OF

THE

FUEL

SUPPLY

A

CAUTION:

Only

use

unleaded

fuel

with

an

octane

rating

of 89

or

higher.

Leaded

fuel

will

cause

serious

harm

to

your

engine

and

riolate

your

warranty.

Use

only

clean

fuel!

It

is

important

to

buy

clean

fuel,

and

keep

it

clean. The best

fuel

can

be

rendered unsatisfactory

by

careless

handling

or

improper

storage

facilities.

To

assure

that

the

fuel

going into

the

tank

for

your engine's daily

use

is

clean

and

pure,

the

following

practice

is

advisable:

Purchase a

well-known

brand of

fuel.

Install

and

regularly service a

good,

Coast Guard approved

metal

bowl

type

filter/water separator between

the

fuel

tank

and

the

engine.

ENGINE

OIL

Use a good well known brand

of

oil and try to stay with

the brand you select.

Use

"ONLY" SAE 40W oil with

an

API code

of

SJ

or

better

in

this engine. Do Not use any multi grade oils.

Change the engine's lube oil and oil filter after the initial
50

hours

of

break-in operation and then every

100

hours

of

operation there after.

A

CAUTION:

Do

not

allow

two

or

more

brands

of

engine

oil

to

mix.

Each

brand

contains

its

own

addi-

tires;

additives

of

different

brands

could

react

in

the

mixture

to

produce

properties

harmful

to

your

engine.

ENGINE

COOLANT

Westerbeke recommends a mixture of

50%

antifreeze

and

50%

distilled

water,

when

possible. Distilled water

is

free

from

the chemicals that

can

corrode

internal

engine

surfaces.

The

antifreeze performs double

duty,

as

it

allows

the

engine

to

run

at

proper temperatures

by

transferring heat

away

from

the

engine

to

the

coolant. It also

lubriciltes

and protects

the

cooling circuit

from

rust

and

corrosion.

Use

a good

quality
antifreeze that contains supplemental cooling additives
(SeAs)

that

keep

the

antifreeze chemically balanced, crucial

to

long tenn protection.

The water

and

antifreeze should be pre-mixed before being

poured into

the

cooling circuit.

NOTE:

Use the new environmentally{riendly long lasting

antifreeze that is now available.

ANTIFREEZE

PROTECTION

CHART

Antifreeze

concentration

23%

30%

35%

50%

Freezing

Temperature

14°

F

8°

F

-4°F

-40°

F

(-10oG)

(-13°C)

(·20oG)

(-40°C)

COOLANT

RECOVERY

TANK

A coolant recovery tank kit

is

supplied

with

each

generator.

The

purpose

of

this

recovery tank

is

to

allow

for

engine

coolant expansion and contraction

during

engine operation,

without

the

loss of coolant

and

without introducing air into

the cooling system.

Engines & Generators

4,

CONTROL

PANELS

GENERATOR

CONTROL

PANEL

The ON and START/STOP switches are the only functional
components to operate the generator at the engine. Both
switches are used to start the generator - see

Starting the

Generator under OPERATING INSTRUCTIONS.

The

ON

switch is a two-position switch with momentary

contacts in the up

(on) position and a stationary contact

function in the center position. This switch energizes the
fuel pump.

The

START/STOP switch is a three-position switch with

momentary contacts in the up

(start) position and a stationary

contact function in the center and down

(stop) positions. The

center

(normal) position allows the generator

to

be run, once
started, and also enables the remote panel(s) to control the
start/stop functions. The up (start) position starts the generator
and once released, reverts to the center position. The down

(stop) position stops the engine in nonnal operation as well

as in an emergency situation, as it opens the K2 relay which
de-energizes the run circuit and shuts down the engine
(unlike the remote panel stop switch) controls power to the
starter, fuel pump, and ignition relay coils, thus stopping the
engine should a malfunction occur. During times when
maintenance is being performed on the generator, the
START/OFF switch should

be

placed in the stationary (off)
position. This will disable the remote control panel(s), pre­venting attempts to start the generator from their locations.

However, it is always best to remove the

Fl

fuse to prevent

accidental starting .

REMOTE

PANEL

There are three functional components on the remote panel
for generator operation:

1.

ON

switch

1.

START/STOP switch

2. Green LED indicator light
The

ON

switch is a two-position switch with momentary

contacts in the up

(on) position and a stationary contact

function in the center

PQsition. This switch energizes the

fuel pump.
The

START/STOP switch is a three-position switch with

momentary contact functions in the up

(start) and down

(stop) positions, and a stationary contact function in the

center position The center position

i~

a dual OFFIRUN mode

position and is nonnally in the

off

mode. When in the start
(up) position, this switch starts the generator (together with
the

ON

switch in the up position) and once released, reverts

to the center position,

run mode. When in the stop (down)

position, this switch stops the generator, and once released,
reverts to the center position,

off

mode.

The Green

LED

indicator light indicates the engine running

condition.

It

lights when the

ON

switch is moved to the start
position, dims when the engine is cranking, and brightens
when the engine starts, notifying the operator to release the
START switch.

~+--IHOUR

METER

RESET

BUTTON

ON

SWITCH

----IL.lo..J

START/STOP

SWITCH:

CENTERED,

THIS

SWITCH

IS

IN

THE

OFF

POSITION.

ONCE

THE

GENERATOR

IS

STARTED,

THE

CENTER

POSITION

BECOMES

THE

RUN

POSITION.

"",=--~--

F1

FUSE

REMOTE

PANEL

CONNECTION

I

REMOTE

PANEL

NOTE:

Refer to OPERATING INSTRUCTIONS
in the following pages for the operation
of

these panels.

Engines & Generators

:5

PREPARATIONS

FOR

INITIAL

START-UP

PREST

ART

INSPECTION

Before starting

your

generator

for

the

first

time

or after a

prolonged

layoff,

check

the

following

items:

• Check

the

engine

oil

level:

add

oil

to

maintain

the

level

at

the

full

mark

on

the

dipstick.

• Check

the

fuel

supply

and

examine

the

fuel

filter/separator

bowls

for

contaminants.

• Check

the

DC

electrical

system.

Inspect

wire

connections

and

battery cable connections.

•

Check

the

coolant

level

in

both

the

plastic

recovery

tank

and

at

the

manifold.

NOTE:

During the initial filling

of

the cooling system,

the

air bleed petcock on

the

manifold should

be

opened

to

purge air from

the

engine block. Once coolant, free

of

air

bubbles, flows from the petcock close

the

petcock.

After

shutdown and after the engine has cooled, the

coolant from

the

recovery tank will be drawn

into

the

engine's cooling system

to

replace the purged

air.

Before subsequent operation

of

the

generator,

the

engine's

manifold should

be

topped

off,

and the coolant recovery

tank may need to be filled to the MAX

level;

AIR

BLEED

PETCOCK

THERMOSTAT
HOUSING

ZINC

ANODE

\ I

HEAT

EXCHANGER

•

Visually

examine

the

unit.

Look

for

loose

or

missing

parts,

disconnected

wires,

unattached

hoses,

and

check

threaded connections. Search for

any

gasoline

leaks.

• Check

load

leads for correct connections

as

specified

in

the

wiring

diagrams.

•

Examine

the

air inlet

and

outlet

for

air

flow

obstructions.

•

Be

sure

no

other generator or utility

power

is

connected

to

the

load

lines.

•

Be

sure

that

in

power systems

with

a neutral

line

that

the

neutral

is

properly

grounded

(or

ungrounded)

as

the

system

requires,

and

that

generator neutral

is

properly connected

to

the

load

neutral.

In

single phase

systems

an

incomplete

or

open

neutral

can

supply

the

wrong

line-to-neutral

voltage

on

unbalanced

loads.

•

Make

certain

the

raw

water

thru-hull

is

open.

A

CAUTION:

When

starling

the

generator,

it

is

recommended

that

all

AC

loads.

especially

large

motors,

be

switched

OFF

until

the

engine

has

come

up

to

speed

and.

in

cold

climates,

starts

to

warm

up_

This

precaution

will

prevent

damage

caused

by

unanticipated

operation

of

the

AC

machinery

and

will

prevent a cold

engine

from

stalling.

ROCKER

COVER

MAX.

FULL

-MINIMUM

Engines & Generators

6

OPERATING

INSTRUCTIONS

GENERATOR

CONTROL

PANEL

Starting

the

Generator

To

start

the

generator,

hold

the

momentary

ON

switch

in

the

up

(on)

position,

then

hold

the

momentary

START/STOP

switch

in

the

up

(start)

position

(both

switches

are

held

up

together).

After

approximately

one

second,

the

starter

will

engage

and

the

engine

will

crank . Once

the

engine

is

running,

the

starter

will

disengage,

and

the

START/STOP

switch

may

then

be

released

to

return

to

its

center

(run

mode)

position.

Continue

holding

the

ON

switch

until

the

engine

has

sufficient

oil

pressure,

then

release

it

10 its center

position.

NOTE:

Should

the

engine

fail

to

start,

release

both

switches.

'Wail

20

seconds.

and

try

again.

Never

run

the

starter

more

than

20 seconds

at a rime.

ON

SWITCH

START/STOP

SWITCH

START

OFF/RUN

Starting

Under

Cold

Conditions

Make

certain

the

lubricating

oil

is

conforms

with

the

ratings

for

the

prevailing

temperature.

Check

the

table

under

ENGINE

LUBRICATING

OIL

The

battery

should

be

fully

charged

to

minimize

voltage

drop.

Stopping

the

Generator

To

stop

the

generator,

move

the

momentary

START/STOP

switch

to

the

down

(stop)

position

then

release

it

to

the

center

(ojJlrun

mode)

position.

This

will

de-energize

the

K2

run

relay

in

the

generators

control

panel

and

stop

the

generator.

EMERGENCY

STOPPING

If

the

generator

does

not

stop

using

the

START/STOP

switch,

remove

the

FI

fuse

or

disconnect

the

bartery.

A

CAUTION:

Prolonged

cranking

intervals

without

the

engine

starting

can

result

in

the

engine

exhaust

system

filling

with

raw

water.

This

may

happen

because

the

pump

is

pumping

raw

water

through

the

raw

water

cooling

system

during

cranking.

This

raw

water

can

enter

the

engine's

cylinders

by

way

of

the

exhaust

manifold

once

the

exhaust

system

fills.

Prevent

this

from

happening

by

closing

the

raw

water

supply

through.hull

shutoff,

draining

the

exhaust

muffler,

and

correcting

the

cause

of

the

excessive

engine

cranking.

Engine

damage

resulting

from

raw

water

entry

is

not

a

warrantable

issue;

the

owner/operator

should

keep

this

in

mind.

Abnormal

Stop

/START/STOP

/"':.

.......

SWITCH

.......

I

NOTE:

A

CIRCUIT

BREAKER

IS

LOCATED

ON

THE

510£

Of

TH£

PANfLSHUTS

DOWN

THE

AC

GENERATOR

CIRCUIT.

-HOUR

METER

RESET

BunON

Fl

FUSE

REMOTE

PANEL

CONNECTION

An

abnormal

stop

is

one

in

which

the

generator

ceases

to

run

and

comes

to a stop

as

a result of

ah

operating

fault

which

may

cause

damage

to

the

engine,

the

generator, or

create

an

unsafe

operating

condition.

The

fault

stop conditions

are:

1.

Over

speed

condition.

2.

High

engine

temperature.

3.

Low

oil

pressure.

4.

High

exhaust

temperature.

Should a fault

condition

occur,

the

engine

will

shutdown.

On

the

remote

panel,

the

green

LED

light

will

tum off

indicating

an

engine

shutdown.

Once

detected,

the

fault

should

be

located

and

corrected

(see

ENGINE

TROUBLESHOOTING).

NOTE:

A

30

amp

fuse

is

locared

at

(he

rear

of

the

control

box.

This

fuse

prOVides

protection

for

the

battery

chargmg

circuit.

Engines

& Generators

7

OPERATING

INSTRUCTIONS

REMOTE

PANEL

Starting

the

Generator

To

start the generator, hold the momentary ON switch

in

the

up

(on) position (the green light will come on), then hold the

momentary

START/STOP switch in the up (start) position

(both switches are held up together). After approximately one
second, the starter will engage and the engine will crank (the
green light will dim).

Once the engine is running (the green

light

will brighten», the stalter will disengage, and the
START/STOP switch may then be released to return to its
center

(run mode) position. Continue holding the ON switch

until the engine has sufficient oil pressure, then release it

to

its

center position.

NOTE:

Sfwuld the engine fail to start, release both switches,

wait

20 seconds, and try again. Never

run

the starter more

than

20 seconds

at

a time.

~~

__

OFF/RUN

STOP

OFF

START/STOP

SWITCH

Stopping

the

Generator

11-1.....::_--

OFF/RUN

ON

SWITCH

To

stop the generator, move the momentary START/STOP

switch to the down (stop) position then release

it

to the center

(off/run mode) position. This will de-energize the K2 run

relay

in

the generator's control panel and stop the generator.

Engines

&:

Generators

8

REMOTE

PANEL

BREAK-IN

PROCEDURE/DAILY

OPERATION

BREAK-IN

PROCEDURE

After

the

generator

has

been started, check

for

proper

opera-

tion

and

then

encourage a fast

warm-up.

Run

the

generator

between

20%

to

60%

of

full

load

for

the

first

10

hours.

A

CAUTION:

Do

not

attempt

to

break-in

your

genera-

tor

by

running

without a load.

After

the

first

10

hours

of the generators' operation,

the

load

can

be

increased

to

the

full-load rated output; then periodi-

cally

vary

the

load.

Avoid

overload at

all

times.

An

overload

is

signaled

by

a

smoky

exhaust

with

reduced output voltage

and

frequency.

Monitor

the

current

being

drawn

from

the

generator

and

keep

it

within

the

generators' rating. Since

the

generator operates

at

1800

rpm

to

produce 60 hertz, or

at

1500

rpm

to

produce

50 hertz, control of

the

generator's engine break-in

is

gov-

erned

by

the current drawn

from

the

generator.

To

protect against unintentional overloading of

the

generator,

the generator's output leads should

be

routed

through

a cir-

cuit breaker

that

is

rated at

the

rated output of

the

generator.

NOTE:

Be

aware

of

motor starting loads and the

high

current

drawn

required

for starting

motors.

This

starting

amperage drawn

can

be 3

to 5 times

normal

running

amper-

age.

See

GENERATOR

INFORMATION

in

this

manual.

CHECK

LIST

Follow this checklist each day before starting your

generator.

•

Record

the hourmeter reading

in

your log (engine hours

relate

to

the maintenance schedule).

•

Visually

inspect the engine

for

fuel,

oil,

or water

leaks.

• Check

the

oil level (dipstick).

• Check

the

coolant level in the coolant recovery

tank.

• Check your

fuel

supply.

• Check the starting batteries (weekly).

• Check

the

drive belt

for

wear and proper tension (weekly).

• Check for abnormal noise

such

as

knocking, vibration and

blow-back

sounds.

• Confirm exhaust

smoke:

When

the

engine

is

cold - White

Smoke.

When

the

engine

is

warm

almost Smokeless.

When

the engine

is

overloaded - some Black

Smoke.

NOTE:

Some

unstable

running

may occur

in

a cold

engine.

This

condition should abate

as

normal operating

temperature

is

reached and loads

are

applied.

A

CAUTION:

Do

not

operate

the

generator

for

long

periods

of

time

without a load

being

placed

on

the

generator.

STOPPING

THE

GENERATOR

Remove

the

major

AC

loads

from

the

generator

one

at a time.

Allow

the generator

to

run

for a few

minutes

to

stabilize the

operating temperature

and

press the

STOP

switch

down,

(see

CONTROL

PANELS).

NOTE:

After

the

first 50

hours

of

generator operation check

the

maintenance schedule for the 50 hour service

check.

GENERATOR

ADJUSTMENTS

Once

the generator has been placed

in

operation, there

may

be

governor adjustments required for engine speed

(hertz)

during

the engine's break-in period (first

50

hours) or after

this

period (see ENGINE SPEED (HER1Z) ADJUSTMENT

under ENGINE ADJUSTMENTS. A no-load voltage

adjust-

ment

may

also

be

required

in

conjunction with

the

engine's

speed adjustment

(see

GENERATOR

INFORMATION).

Engines & Generators

9

SAFETY

SHUTDOWN

SWITCHES

SAFETY

SHUTDOWN

SWITCHES

The

engine

is

protected

by a variety

of

shutdown

switches.

Should a shutdown

occur.

do

not attempt

to

restart

withqut

finding and correcting the cause.

Refer

to

the

heading

Engine

slarts,

runs

and

then

shuts

down

in

the

ENGINE

TROUBLESHOOTING

section

of

this

manual.

The

following

is

a description of

these

automatic

shutdown

switches:

Exhaust

Temperature

Switch

An

exhaust

temperature

switch

is

located

on

the

exhaust

elbow.

Nonnally

closed,

this

switch

will

open

and

interrupt

the

DC

voltage

to

the

K2-run

relay

(shutting

off

the

engine)

should

the

switch's sensor

indicate

an

excessive

exhaust

tem-

perature

(an

inadequate

supply

of

raw

water

causes

high

exhaust

temperatures).

This

switch

opens

at

260-270"F

(127-

132°C).

This

switch

resets

at

approximately

225"F

(I07"C).

EXHAUST

TEMPERATURE

SWITCH

Waler

Temperature

Switch

EXHAUST

ELBOW

A

high

water

temperature

switch

is

located

at

the

thennostat

housing.

Nonnally

closed,

this

switch,

should

the

fresh

water

coolant's

operating

temperature

reach

approximately

210°F

(99°C),

will

open

and

interrupt

the

DC

voltage

to

the

K2

run

relay

therebyshutting off

the

engine.

This

switch

resets

at

195"F

(107"C).

WATER

(COOLANT)

TEMPERATURE

SWITCH

OIL

FILTER

ASSEMBLY

low

Oil

Pressure

Switch

Oil

PRESSURE

SWITCHES

Dual

low

oil

pressure

switches

are

located off

the

engine's

oil

gallery

manifold.

One

is

nonnally

open

when

the

engine

is

in

a

static

stale.

This

switch

functions

in

the

automatic

shutdown

circuit

when

the

unit

is

operating (5

psi

rating).

The

second

oil

pressure

switch

is

installed only

on

SEA

RAY

spec.

generators.

This

switch

is

nonnally closed

and

functions

in

their

low

oil

pressure

alarm

system (10

psi

rating).

Should

the

oil

pressure

drop

to

10

psi

while

the

generator

is

operating, the

SEA

RAY

spec.

switch

will

close

activating

their

low

oil

pressure

alarm.

Should

the

oil

pressure

drop

further

to 5 psi,

the

automatic

shutdown circuit

switch

will

open

interupting

DC

voltage

to

the

K2

run

relay

thereby

shutting off

the

generator.

High

RPM

Shutdown

Switch

An

overspeed

switch

in

the

DC

circuit shuts off

the

generators engine

by

interupting

DC

voltage

to

the

K2

run

relay

if

the

engine's

speed

runs

to

high.

After

correcting

the

problem,

this

switch

can

be

reset

by

momentarily

depressing

the

stop

switch.

Refer

to

the

WIRING

DIAGRAMS

in

this

manual.

OVERSPEED
CIRCUIT

BOARD

Engine

Circuit

Breaker

The

generator's

engine

is

protected by

an

engine

mounted

manual

reset

circuit

breaker

(20

amps

DC).

Excessive

current

draw

or electrical

overload

anywhere

in

the

instrument

panel

wiring

or

engine

wiring

will

cause

the

breaker

to

trip.

In

this

event

the

generator

will

shut

down

because

the

opened

breaker

interrupts

the

DC

circuit

to

the

K2-run

relay.

If

this

should

occur,

check

and

repair

the

source

of

the

problem.

After

repruring

the

fault.

reset

the

breaker

and

restart

the

generator.

Engines & Generators

10

SCHEDULED
MAINTENANCE

Fuel

Supply

Fuel/Water

Separator

Engine

Oil

level

Coolant

Level

Drive

Belt

MAINTENANCE

SCHEDULE

A

WARNING:

Neller

attempt

to

perform

any

scfllice

while

the

engine

is

running.

Wear

the

proper

safety

equipment

such

as

goggles

and

gloves,

and

use

the

correct

tools

for

each

job.

Disconnect

the

battery

terminals

when

sefllicing

any

of

the

engine's

DC

electrical

equipment.

NOTE:

Many

of

the

following maintenance procedures

are

simple but others

are

more

difficult and

may

require

the

expert

knowledge

of

a service

mechanic.

CHECK

HOURS

OF

OPERATION

EACH

EXPLANATION

OF

SCHEDULED

DAY

50

100

250

500

750

1000 1250

MAINTENANCE

0

Unleaded

gasoline

with

octane

rating

of

89

or

higher.

0

Check

for

water

and

dirt

in

fuel

(drain/replace

filter

if

necessary).

0

Oil

level

should

indicate

between

FULL

and

LOW

on

dipstick.

0

Check

at

recovery

tank;

if

empty,

check

at

manifold.

Add

coolant

if

needed.

0

Inspect

for

proper

tension

(3/8"

to

1/2"

deflection)

weekly

and

adjust

if

needed.

Check

belt

edges

for

wear.

Visual

Inspection

01

Engine

0

NOTE:

Keep

engine surface clean. Dirt and

Check

for

fuel,

oil

and

water

leaks.

Inspect

wiring

oil will inhibit

the

engine s ability to remain

and

electrical

connections.

Keep

bolts & nuts

tight.

cool.

Check

for

loose

belt

tension.

Spark

Plugs

[j

0

0 0

0

0

Check

gap;

inspect

for

burning

and

corrosion.

Generator

0

0

0 0

0

0

0

Check

that

AC

connections

are

clean

and

secure

with

no

chafing -see

GENERATOR

INFORMATION

for

additional

information.

Fuel

Filter

::::J

0 0 0 0 0

Initial

change

at

50

hrs,

then

change

every

250

hrs.

Starting

Batteries

0 0

Every

50

operating

hours

check

electrolyte

levels

(and

House

Batteries)

weekly

and

make

sure

connections

are

very

tight.

Clean

off

excessive

corrosion.

Engine

Oil

0

0 0 0

0

0

Initial

engine

oil & filter

change

at

50

hrs.,

then

change

both

every

100

hours.

*Adjust

the

Valve

0 0

0

Initial

adjustment

at

50

hrs.,

then

every

500

hrs.

Clearances
Air

Screen

(Flame

Arrester)

0

Clean

at

50

hours,

then

every

100

hours.

Exhaust

System

::::J

0

c:::

0

Initial

check

at

50

hrs.,

then

every

250

hrs.

Inspect

for

leaks.

Check

siphon

brake

operation.

Check

the

exhaust

elbow

for

carbon

and/or

corrosion

buildup

on

inside

passages;

clean

and

replace

as

necessary.

Check

that

all

connections

are

tight.

Engine

Hoses

0

~D

0

0 0

Hose

should

be

hard & tight.

Replace

if

soft

or

spongy.

Check

and

tighten

all

hose

clamps.

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

mechanic.

(continued)

Engines & Generators

11

SCHEDULED

MAINTENANCE

Heat

Exchanger

Raw

Water

Pump

Coolant

System

*

Starter

Motor

Distributor

*Engine

Cylinder

Compression

and

Valve

Clearance

*Engine

Timing

Belt

*Exhaust

Elbow

Carburetor

Drip

Tray

MAINTENANCE

SCHEDULE

NOTE:

Use

the

engine hounneter

gauge

to

log

your

engine

hours

or

record

your

engine

hours

by running

time.

CHECK

HOURS

OF

OPERATION

EACH

EXPLANATION

OF

SCHEDULED

DAY

50

100

250

500

750

1000

1250

MAINTENANCE

:::J

0 0 0 0 0 0

Clean

or

replace

anode.

Open

heat

exchanger

end

cap

and

clean

out

debris.

Remove

every

1000

hours

for

professional

cleaning

and

pressure

testing.

0

:::J

0

Remove

pump

cover

and

inspect

impeller

for

wear;

replace

if

needed.

Also

replace

gasket.

Lubricate

both

when

reassembling.

0

Drain,

flush,

and

refill

cooling

system

with

appropriate

antifreeze

mix.

0

D

Check

solenoid

and

motor

for

corrosion.

Remove

and

lubrica,te.

Clean

and

lubricate

the

start

motor

pinion

drive.

D D

Check

ignition

timing.

Check

condition

of

distributor

cap

and

rotor.

D D

Incorrect

valve

clearance

will

result

in

poor

engine

performance;

check

compression

pressure

and

timing,

and

adjust

valve

clearances.

[]

Remove

and

replace

every

1000

hours.

Note:

Failure

to

replace

the

timing

belt

at

the

recommended

interval

could

result

in

timing

chain

failure

resulting

in

major

damage

to

the

engine.

D

Test

exhaust

elbow

for

casting

integrity.

Replace

if

casting

is

corroded

or

deteriorated.

WARNING:

A

defective

exhaust

elbow

can

cause

carbon

monoxide

leakagel

Inspect

and

drain

at

regUlar

intervals.

Do

not

allow

fuel

to

collect

in

drain.

*WESTERBEKE

recommends

this

service

be

performed

by

an

authorized

mechanic.

Engines & Generators

12

COOLING

SYSTEM

FRESH

WATER

COOLING

CIRCUIT

NOTE:

Refer

to

the

ENGINE COOLANT section for

the

recommended antifreeze and water mixture

to

be

used as

the

fresh water

coolant.

Fresh water coolant is pumped through the engine by a

circulating pump, absorbing heat from the engine. The
coolant then passes through the thermostat into the manifold,
to

the heat exchanger where

it

is cooled, and returned to the

engine block via the suction side

of

the circulating
pump.When the engine is started cold, external coolant flow
is prevented by the closed thermostat (although some coolant
flow is bypassed around the thermostat to prevent the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow

of

the engine's

coolant to flow unrestricted to the external portion

of

the

cooling system.

Coolant

Recovery

Tank

A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any
significant loss

of

coolant and without introducing air into
the cooling system. This tank should be located at or above
the engine manifold level and should

be

ea~ily

accessible.

COOLANT

RECOVERY

TANK

NOTE:

Periodically

check

the

condition

of

the manifold pres-

sure

cap.

Ensure

that

the

upper and lower rubber seals

are

in

good condition and check that

the

vacuum

valve

opens and

closes

tightly.

Carry a spare

cap.

CHANGING

COOLANT

The engine's coolant must

be

changed according to the

MAINTENANCE

SCHEDULE.

If

the coolant is allowed to

become contaminated, it can lead to overheating problems.

A

CAUTION:

Proper

cooling

system

maintenance

is

critical; a substantial

number

of

engine

fai/ures

can

be

traced

back

to

cooling

system

co"osion.

Drain the engine coolant

by

removing the drain plug and
opening the manifold pressure cap. Flush the system with
fresh water, then reinstall the drain and start the refill process.

A

WARNING:

Beware

of

the

hot

engine

coolant.

Wear

protective

gloves.

Refilling

the

Coolant

After replacing the engine drain plug, open the air bleed
petcock

on

the exhaust manifold and slowly pour clean,

premixed coolant into the manifold.
Monitor the coolant in the manifold and add as needed. Fill

the manifold neck.

Once coolant begins flowing from the air

bleed petcock free

of

air bubbles, close the petcock and

install the manifold pressure cap.
Remove the cap on the coolant recovery tank and fill with

coolant mix to halfway between

LOW and

MAX

and replace
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank.

Mter

checking for leaks, stop the engine and allow

it

to cool.
Coolant should draw back into the cooling system as the
engine cools down. Add coolant to the recovery tank

if
needed and check the coolant in the manifold. Clean up any
spilled

coolant.

,-

COOLANT

DRAIN

SEALS

LOCATED

JUST

BELOW

THE

INTAKE

MANIFOLD

CHECKING

THE

PRESSURE

CAP

FROM

COOLANT

RECOVERY

TANK

MAKE

CERTAIN

THESE

PASSAGES

ARE

KEPT

CLEAR

TO

COOLANT

RECOVERY

TANK

COOLANT

RETRACTION

Engines & Generators

13

COOLANT

EXPANSION

COOLING

SYSTEM

THERMOSTAT

A thermostat controls

the

coolant temperature

as

the

coolant
continuously flows through the closed cooling circuit. When
the

engine is first started

the

closed thermostat prevents

coolant from flowing (some coolant

is

by-passed around

the

thermostat

to

prevent

the

exhaust manifold

from

over-

heating).

As

the engine

warms

up,

the

thermostat gradually

opens.

The thermostat is accessible and can

be

checked,

cleaned, or replaced

easily.

Carry a spare thermostat and

gasket.
If

you

suspect a faulty thermostat, place

it

in

a pan

of

water and

bring

to

a

boiL

A working thermostat should open about

112"

MANIFOLD
PRESSURE

CAP

CHANGING

THE

THERMOSTAT

GASKET

APPLY

SEALANT

TO

GASKET

WHEN-----?1

INSTALLING

THERMOSTAT

Cool

raw

water

flows

through the inner tubes of

the

heat

exchanger.

As

the

engine coolant passes around these

tubes

the

heat of the internal engine

is

conducted

to

the

raw

water

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 of each

other;

this

keeps the engine's water passages clean

from

the

harmful deposits

found

in

raw

water.

Heal

Exchanger

Service

After approximately 1000 hours of operation, remove, clean
and

pressure test the engine's heat

exchanger.

(A

local automo-

tive radiator shop should be able

to

clean

and

test

the

heat

exchanger).

WARNING:

DO

ALl:.OW

WATER

TO

INTO

THE

GENERATOR

HOUSING

...

COVER

THE

AIR

FAN

INLET

WITH

FOIL

WHEN

REMOVING

THE

END

CAP

-

GASKET

O-RING

NOTE:

Operating

in

silty and/or tropical waters

requlre

that a heat exchanger cleaning be peifonned

more

often then

every 1000 hours.

ZINC

ANODE

A

zinc

anode

(or pencil)

is

located

in

the

raw

water cooling

circuit within

the

heat exchanger. The purpose of the

zinc

anode is

to

sacrifice itself

to

electrolysis action taking place

in

the

raw

water

cooling circuit, thereby reducing

the

effects

of electrolysis on other components of

the

system. The

con-

dition

of

the

zinc anode should be checked monthly

and

the

anode cleaned or replaced,

as

required. Spare anodes should

be carried onboard.

NOTE:

Electrolysis

is

the result

of

each particular installation

and vessel location, not that

of

the

engine.

If

the

zinc

anodes need replacement,

hold

the

hex

boss into

which

the

zinc

anode is'threaded

with

a wrench while

loosening

the

anode with another wrench. This

prevent~

the

hex boss

from

possibly tearing off the exchanger

shell.

After

removing

the

zinc,

note

the

condition

of

it.

If

the

zinc

is

in

poor condition, there are probably alot of

zinc

flakes within

the

exchanger.

Remove

the

end 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

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

threads

of

the zinc anodes

are

pipe threads

and

do

not

require

sealant. Sealant should not

be

used as it may

insulate

the

zinc from the metal

of

the

heat exchanger

housing preventing electrolysis action

on

the

zinc.

ZINC

ANODES

NEW

THROW

OUT

THROW

OUT

CLEAN

AND

REUSE

Engines & Generators

14

COOLING

SYSTEM

RAW

WATER

INTAKE

STRAINER

NOTE:

Always install

the

strainer at or below

the

waterline

so

the

strainer will always be self-priming.

A clean raw water intake strainer is a vital component

of

the

engine's cooling system. Include a visual inspection

of

this

strainer when making your periodic engine check. The water

in the glass should be clear.

Perform the following maintenance after every

100

hours of

operation:

1.

Close

the

raw water seacock.

2.

Remove and clean the strainer filter.

3. Clean the glass.

4. Replace the washer

if

necessary.

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

run

hard

aground.

If

the engine temperature gauge ever shows a higher than

normal reading, the cause may be that silt, leaves or grass

may have been caught up in the strainer, slowing

the

flow

of

raw water through

tt,le

cooling system

STRAINER

~

RAW

WATER

INTAKE

STRAJNER

OWNER

INSTAlLED

(TYPICAL)

RAW

WATER

COOLING

CIRCUIT

The

raw

water

flow

is

created

by

a positive displacement

impeller pump. This pump draws water directly from

the

raw

water source (ocean, lake,

or

river) through a hose

to

the
water strainer. The raw water passes from the strainer
through the

raw

water pump

to

the heat exchanger (through

the

heat exchanger tubes) where it cools the engine drculat-

ing

fresh water coolant. The raw water

is

then discharged

into

the

water-injected exhaust

elbow,

mixing with and cool-

ing

the exhaust gasses. This mixture of exhaust

gas

and

raw

water

is

discharged overboard

by

the engine's exhaust

gas

discharge pressure.

RAW

WATER

PUMP

The raw water pump

is

a self-priming, rotary pump with a
non-ferrous housing and a Neoprene impeller. The impeller
has flexible blades which wipe against a curved cam plate
within the impeller housing, producing

the

pumping action.

On

no

account should this

pump

be run dry. There should

always be a spare impeller and impeller cover gasket aboard
(an impeller

kit). Raw water pump impeller failures occur

when lubricant (raw water) is not present during engine
operation.

Such failures

are

not warrantable, and operators

are cautioned

to

make sure raw water flow is present at start-

up. The raw water pump should be inspected periodically for

broken or tom impeller blades.

See MAINTENANCE

SCHEDULE.

NOTE:

Should a failure occur

with

the

pump s internal parts

(seals and bearings),

it

may

be

more

cost efficient to pur-

chase a new pump and rebuild

the

original pump as a

spare.

Changing

the

Raw

Water

Pump

Impeller

Close the

raw

water intake valve. Remove the pump cover

and, with the aid

of

two small screwdrivers, carefully

pry

the

impeller out

of

the pump. Install the new impeller and gasket.

Move the blades to conform

to

the curved cam plate

and

push the impeller into the pump's housing. When assem-

bling, apply a thin coating

of

lubricant

to

the impeller

and

gasket. Open the raw water intake valve.

RAW

WATER

PUMP

CAM

PLATE

APPLY

LUBRICANT

OR

LIQUID

SOAP

AT

ASSEMBLY

A

CAUTION:

If

any

of

the

vanes

have

broken

off

the

impeller,

they

must

be

located

to

prevent

blOCkage

in

the

cooling

circuit.

They

often

can

be

found

in

the

heat

exchanger.

Engines & Generators

15

FUELSVSTEM

GASOLINE

Use

unleaded

89

octane or higher

gasoline.

When

fueling,

follow

U.S.

Coast Guard regulations, close off

all

hatches

and

companionways

to

prevent

fumes

from

entering

the

boat,

and

ventilate

after

fueling.

NOTE:

The

generator compartment should have a gasoline

fume detector/alarm properly installed

and

working.

AWARNING:

Shut off

the

fuel

valve

at

the

tank

when

servicing

the

fuel

system.

Take

care

in

catching

any

fuel

that

may

spill.

DO

NOT

allow

any

smoking,

open

Hames

or

other

sources

of

fire

near

the

fuel

system

when

servicing.

Ensure

proper

ventilation

exists

when

servicing

the

fuel

system.

GASOLlNEIWATER

SEPARATOR

AND

FILTER

A primary

fuel

filter of the water separating type must be

installed between the

fuel

tank and the engine

to

remove

water

and

other contaminant's

from

the

fuel

before

they

can

be carried

to

the

fuel system on the engine.

Most installers include a type of filter/water separator with
the generator installation package

as

they are well aware of

the

problems that contaminant's

in

the

fuel

can

cause.

These gasoline fliters must have metal bowls (not "see­through")

to

meet

U.S.

Coast Guard requirements. The metal

bowls have drain valves

to

use

when checking for water

and

impurities.

GASOLlNEjWATER
SEPERATDR & FILTER

OWNER

INSTALLED

ENGINE

FUEL

FILTER

Periodically check

the

fuel

connections

and

the

bowl

for

leakage. Replace

the

fliter element after the first

50

hours

then

follow

the

MAINTENANCE SCHEDULE.

Changinglcleaning

the

filter

element.

1.

Shut the fuel supply

off.

2.

Unscrew

the

filter bowl from the housing.

3. Pull the

fuel

element down and

off.

4.

Inspect

the

sealing O-ring

and

replace if

necessary.

5. Install a

new

fliter element and reassemble the

bowl.

6.

Screw

the

bowl

on

tightly

by

hand. Open the fuel supply

and

run

the engine

to

inspect for leaks.

FILTER

HOUSING

~

FILTER

ELEMENT--

FUEL

IN

A

WARNING:

Fuel

is

present

in

the

hDusing

and

lines.

Use

extreme

care

to

prevent

spillage.

Engines & Generators

16

ENGINE

OIL

ENGINE

OIL

CHANGE

1.

Draining the Oil Sump. Discharge the used

oil

through

the

sump

drain

hose

(attached

to

the front of

the

engine)

while

the

engine

is

warm.

Drain

the

used

oil

completely,

replace

the

hose

in

its bracket,

and

replace the end

cap

securely.

NOTE:

Thread

size for

the

lube

oil drain

Iwse

capped

end

is

1/4

NPT.

Always

observe

the

used oil

as

it

is removed. A

yellow/gray emulsion indicates

the

presence of water

in

the

oil.

Although this condition

is

rare, it

does

require

prompt attention

to

prevent serious

damage.

Call

a

qualified mechanic should water

be

present in

the

oiL

Raw

water present

in

the

oil

can

be

the

result of a fault

in

the exhaust system attached

to

the

engine andlor a

siphoning of

raw

water through

the

raw

water cooling

circuit into

the

exhaust,

filling

the

engine.

This problem

is

often caused

by

the absence of

an

anti-siphon

valve,

its

poor location

or

lack of maintenance.

((

.)~

.........

--:;r---·

REMOVE

USING

AN

8MM

(11116"0

SOCKET

OIL

DRAIN

HOSE

TO

DRAIN

THE

OIL

OR

PUMP

THE

WARMED

OIL

UP

THRU

THE

HOSE

.,

DI~~TICK~

TU~OllPAN

-~

2.

Replacing the Oil

Filter.

When removing

the

used

oil

filter,

you

may

find it helpful

and

cleaner

to

punch

a hole

in the upper

and

lower portion of the old filter

to

drain

the oil from

it

into a container before removing

it.

This

helps

to

lessen spillage. A small automotive filter wrench

should

be

helpful in removing

the

old oil

filter.

NOTE:

Do

nol

punch this hole without first loosening

the

filter

to

make

certain

it

can

be

removed.

Place

some

paper

towels

and a plastic bag

around

the

filter

when

unscrewing it

to

catch

any

oil

left

in

the

filter.

(Oil

or

any

other

fluid

on

the

engine reduces the engine's

cooling

ability.

Keep

your engine clean.) Inspect the old

oil filter

as

it

is

removed

to

make

sure

that

the

rubber

sealing gasket

comes

off with the old oil

filter.

If

this

rubber sealing gasket remains sealed against

the

filter

bracket,

gently

remove

it.

When

installing the

new

oil

filter element,

wipe

the

filter

gasket's sealing surface

on

the bracket

free

of oil

and

apply a

thin

coat of clean engine oil

to

the rubber gasket

on

the

new

oil

filter.

Screw the filter onto

the

threaded

oil

filter

nipple

on

the

oil filter bracket,

and

then

tighten

the

filter

firmly

by

hand.

FILTER

GASKET

APPLY

CLEAN

OIL

OIL

FILTER

ASSEMBLY

WHEN

ASSEMBLING

NEW

FILTER

~

NOTE:

Generic filters

are

not

recommended,

as

the

material standards or diameters

of

important

items

on

generic parts might

be

entirely different

from

genuine

parts.

Immediately after

an

oil filter change and oil fill,

run

the

engine

to

make sure the oil pressure

is

nonnal

and that

there

are

no oil leaks around

the

new

oil

filter.

3. Filling the

Oil

Sump. After refilling,

run

the

engine for a

few

moments

while checking

the

oil pressure. Make sure

there

is

no

leakage around the

new

oil

filter or

from

the

oil drain system.

and

stop

the

engine.

Then check

the

quantity of oil with the lube oil dipstick. Fill to, but

not

over

the

high mark

on

the dipstick, should

the

engine

require additional

oil.

A

CAUTION:

Used

engine

oil

contains

harmful

contaminates.

Avoid

prolonged

skin

contact.

Clean

skin

and

nails

thoroughly

using

soap

and

water.

Launder

or

discard

clothing

or

rags

containing

used

oil.

Discard

used

oil

properly.

Engines & Generators

17

THE

BATTERY

CHARGING

CIRCUIT

The

DC

Circuit

on

the

BCGB

functions

to

start, operate

and

stop the generator's engine. The circuit

is

best understood

by

reviewing the DC Wiring Diagram

and

Wiring Schematic.

The engine's

DC

wiring is designed with three simple basic

, circuits:

start,

run

and

stop.

The engine

has a 12

volt

DC

electrical control circuit that

is

shown

on

the

WIring

Diagrams. Refer

to

these diagrams

when

troubleshooting or when

serviQing

the DC electdcaI

system

or

the engine.

BATTERIES

A

CAUTION:

To

avoid

damage

to

the

battery

charg-

Ing

clrcut,

never

shut

off

the

engine

battery

switch

while

the

engine

is

running.

Shut

off

the

engine

battery

switch,

however,

to

avoid

electrical

shorts

when

work-

ing

on

the

englne~

electrical circuit.

Specifications

The recommended capacity

of

the "dedicated" starting battery

used for the engine's 12VDC circuit

is

600-800 C.C.A.

BATTERY

CHARGER

The generator supplies a continuous

17

amp charge from

its battery charger

to

the starting battery.

To

test the battery

charger, put a multimeter between the positive

(+)

and

negative H leads

to

the battery. It should indicate l3.0V to

i3AV with the engine running.

If

only the battery voltage

is

indicated, check that the battery charger terminal

connections are tight With the unit

runiling, test between

the

(+) and (-) terminals for 13.0V

to

13AV.

If

no

charge

is

indicated, replace the charger.

RED

TO

CIRCUIT

BREAKER

GREEN

H

BRIDGE

RECTIFIER

TO

GROUND

Battery

Maintenance

Review

the manufacturer's recommendations

and

then

estab-

lish

a systematic maintenance schedule

for

your

engine's

starting

batteries

and

house

batteries.

• Monitor

your

voltmeter

for

proper charging

during

engine

operation.

• Check the electrolyte

level

and specific

gravity

with

a

hydrometer.

• Use

only

distilled

water

to

bring electrolytes

to

a proper

level.

• Make certain that

battery

cable connections

are

clean

and

tight

to

the

battery

posts

(and

to

your engine).

•

Keep

your batteries

clean

and

free of corrosion.

A

WARNING:

Sulfuric

acid

in

lead

batteries

can

cause

severe

burns

on

skin

and

damage

clothing.

Wear

protective

gear.

GENERATOR

CONTROL

PANEL

r - - - -

--

- - - -- - -------- --------- - - -- - - - - - - -- - -- --- -

--,

J

IDC

I

DEVOLTAGE

OUTPUT";:\;'

10.,

'

ADJUSTMENT

POT

:i;';:~)f,

.

:I".l.·n~

...

"~'.'I'

. "

1'\C':'tF'<I

"~

C.WTO

INCREAS.~

..

J'i'/;)""';~J

C.C.W

TO

DECREASE

L~,i~'S

TESTING

THE

BATTERY

CHARGER

I

30A

'

AC

iCHARGE

I

I At

-J>I-

-

I.e.

i

I I

I

INTEGRAL

CONTROLLER

:

I I

I

Hz,

1

l

___________________________

....J

Engines & Generators

18

ELECTRONIC

GOVERNOR

Electronic

Governor

System

The system

is

composed

of

three basic components:

1.

Controller. Mounted

in

the instrument panel.

Z.

Sensor. Installed on the bellhousing over the flywheel

ring

gear.

3.

Actuator. Mounted at the front

of

the engine and

attached with linkage to the throttle arm of

the

injection

pump.

Controller

Adjustment

1. Speed. This adjustment

is

used to raise or lower the

engine's speed

to

the desired hertz.

2.

Gain. This adjustment affects the reaction time

of

the

actuator to the generator/engine load changes.

NOTE:

A high gain adjustment

can

induce

an

oscillating

of

the actuator producing a hunting mode. In such cases,

lessen

the

gain adjustment.

SENSOR

LINEAR
ACTUATOR

CONTROLLER

Calibration

1.

With

no

power to the governor, adjust

the

GAIN

to

9:00

o'clock.

2.

Start the engine and adjust the speed

by

turning

lhe

speed

pot clockwise

to

desired speed.

NOTE:

Controllers

are

factory adjusted

to

minimum

rpm.

However.

for

safety,

one

should

be

capable

of

disabling

.the

engine

if

an

overspeed should

exist.

3.

At no-load. turn the GAIN potentiometer clockwise

until

the

engine begins

to

hunt.

if

the engine does

not

hunt,

physically upset the governor linkage.

4. Turn the GAIN potentiometer counterclockwise
until stable.

FLYWHEEL

HOUSING

LINEAR

ACTUATOR

KEEP

ACTUATOR

LINKAGE

WELL

LUBRICATED

TO

ELECTRONIC

CONTROLLER

Engines & Generators

19

TROUBLESHOOTING

THE

ELECTRONIC

GOVERNOR

PROBLEM

TEST/CHECK

CDRRECnDN

Unit

starts,

then

overspeeds

1.

Check

DC

voltage

between

terminal

1.

Charge

starting

battery.

Start

unit,

troubleshoot

and

shuts

down.

#12

and + connection

on

hourmeter

battery,

charge

circuit.

when

ON

switch

is

depressed.

NOTE:

When

troubleshooting,

manually

operate

the

throttle

to

prevent

an

overspeed

or

disconnect

the

throttle

from

the

actuator

and

operate

manually.

2.

Check

the

AC

signal

from

the

MPU

2.

Check

the

MPU

resistance

value

and

positioning.

while

cranking,

voltage

should

be

Adjust

and

replace

as

needed.

1.5 • 2.5

VAC.

3.

Check

the

actuator.

3.

Check

the

resistance

value.

Apply

12VOC

across

leds.

Should

fully

retract.

Replace

as

needed.

4.

Check

the

controller.

4.

Manually

control

unit.

Start

and

check

DC

voltage

between

#9

and

#8,

between

'11

and

110.

Replace

controller

or

OS

board

as

needed.

Unit

starts,

runs

at

idle.

1.

Incorrect

speed

adjustments

..

1.

Check

and

adjust

speed

adjustment.

NOTE:

Less

than

one

volt

DC

2.

Faulty

governor

controller..

2.

Check

DC

voltages

from

controller

to

OIS

board

found

between

terminals

19

and

and

OIS

board

to

actuator.

18

and

high

DC

voltage-10

volts

or

higher

between

terminals

111

and

110

indicated a faulty

controller.

Actuator

hunts

during

operation.

1.

Improper

controller

adjustment.

1.

Lessen

GAIN

adjustment.

NOTE:

Check

carburetor

adjustments

before

proceeding.

2.

Linkage

or

rod

end

bearings

are

2.

lubricate

and

replace

as

needed.

sticking

or

binding.

3.

Inadequate

DC

supply

voltage.

3.

Manually

stabilize

the

unit.

Check

the

DC

voltage

to

the

controller.

Correct

as

needed.

4.

MPU

positioned

marginally

4.

Check

the

MPU

signal.

Adjust

pOSitioning

too

far

away

from

the

flywheel

as

needed.

teeth,

giving

an

erratic

AC

input

signal

to

the

controller.

Engines & Generators

20

CARBURETOR

ADJUSTMENTS

CARBURETOR

The carburetor is a single barrel, side-draft type with a
cleanable metal screen air intake filter/spark arrester.

The choke is operated by a

12

VDC solenoid. This choke

solenoid is activated when the

ON switch

is

depressed and

stays activated so long as the

ON switch is held depressed.

Once the

ON switch is released the choke solenoid deactivates.

Air

Screen/Flame

Arrester

The air screen can easily be removed. Clean after

the

first

50

hours of operation, every

100

hours

from

then

on.

Clean

the

air screen

in

a water soluble cleaner such

as

GUNK.

Drip

Tray

Do not allow fuel to build up in the drip tray. Use the allen / /

screw

drain

to

remove

any

fuel

build

up.

AIR

SCREEN

SIDE DRAFT CARBURETOR

SPARK

ARRESTER

SILENCER

FUEL

SHUT

OFF

SOLENOID

CARBURETOR CHECKS

FOR

PROPER OPERATION

DRIPTRAV

ELECTRIC

SPEED

"''''''Tn,,,,./

ACTUATOR

1.

The idle mixture screw adjustment. Remove the plastic limiter. Turn the mixture

screw in

till

it seats. Then back it out 3

yz

turns. Once running adjust the screw

no more

than

yz

turn in or out to further stabilize engine operation.

2.

Verify that the choke mechanism flutters when the engine is cranking on a start.
The choke return spring should rest against the actuator mounting bracket.

3. The throttle linkage's eye bolts need to be

25/8"

apart (center to center). This

should place the throttle full open when the unit

is

shut down.

4. Throttle actuator should move freely. Lubricate with Teflon or Gmphite lubricant

"only".

5.

Carburetor inlet screen must

be

clean for good air flow into the engine.

Engines & Generators

21

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends

that

the

following

engine

adjustments

be

performed

by

a competent

engine

mechanic.

The

information below

is

provided

to

assist

the

mechanic.

TIMING

BELT

INSPECTION

AND

REPLACEMENT

Timing

Belt

Removal

A

CAUTION:

Water

or

oil

on

the

timing

belt

severely

reduces

the

service

lite

of

the

belt.

Keep

the

timing

belt

sprocket

and

tensioner

free

of

oil

and

grease.

These

pans

should

never

be

cleaned.

Replace

if

seri-

ously

contaminated

with

dirt

or

oil.

If

oil

is

evident

on

these

pans,

check

the

front

case~

oil

pump

oil

seals,

and

camshaft

oil

seals

for a possible

oi/leak.

1.

Turn the crankshaft clockwise

to

align·the timing mark on

the camshaft sprocket and timing belt rear cover.

NOTE:

always

turn

the

crankshaft

clockwise.

TIMING

MARK

2. Remove the plug on the left surface

of

the cylinder block

and insert a rod with a diameter

of

8mm (O.3fin.) to lock

the counterbalance shaft.

NOTE:

Be

sure

to

use

an

inserting

rod

with a diameter

of

8m111

(0.31

in.).

2.6

IN

(65MM)

----1'......--~1O-i

ROD

3. Loosen the timing belt tensioner nut.

CYLINDER

BLOCK

4. Move the timing belt tensioner toward the water pump,
and temporarily tighten the nut to hold the tensioner in
that position.

TIMING

BElT

TENSIONER

5. Remove the timing bell.

NOTE:

lfthe

timing

belt

is

to

be

reused,

draw

an

arrow

on

the

belt back

to

indicate

the

direction

of

rotation

(clock·

wise).

Camshaft

Sprocket

Removal

1. Remove the bolt without tuming the camshaft.

Oil

Pump

Sprocket

Flange

Nut

Removal.

1.

Remove the plug from the left side of the cylinder block.

2. Insert an 8

mm

(0.31

in.) diameter round bar to lock the

counterbalance shaft.

3. Remove the nut.

Engines

& Generators

22

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends

that

the

following

engine

adjustments

be

peiformed

by

a competent

engine

mechanic.

The

information below

is

provided

to

assist

the

mechanic.

Crankshaft

Bolt

Removal

i.

Lock the crankshaft in position.

NOTE:

Do

not turn

the

crankshaft.

2. Remove the crankshaft bolt.

Timing

Belt

Inspection

Replace the belt

if

any

of

the following conditions exist:

I. Hardening

of

back rubber-back side is glossy, without

resilience, and leaves no indent when pressed with

fin-

gernail.

2. Cracks on rubber back.

3.

Cracks or peeling

of

canvas.

4. Cracks on tooth bottom.

5. Cracks on belt.

6.

AbnOlmal wear

of

belt sides. The sides are normal

if

they are sharp as

if

cut by a knife.

7. Abnormal wear

on

teeth.

8.

Tooth missing and canvas fiber exposed.

CRACKS

OR

PEELING

RUBBER
EXPOSEO-,

----ho

,

3.

5.

7.

Tensioner

Inspection

6.

8.

ABNORMAL

WEAR

(FLUFFY

STRANO)

TOOTH

MISSING

AND

CANVAS

FIBER

EXPOSED

1.

Replace the tensioner

if

the pulley binds, rattles or is noisy

when turned.

Flange

Installation

1. Mount the flange so that

its

side shown by the heavy

anow

in

the illustTation faces toward the sprocket.

FLANGE

rfWASHER

-~--=W

Crankshaft

Bolt

Installation

1.

Lock

the crankShaft.

NOTE:

Do

not

turn

the

crankshaft.

2.

Tighten the crankshaft bolt to the specified torque.

Oil

Pump

Sprocket

Flange

Nut

Installation

1. Insert a round bar into the plug hole in the left side

of

the

cylinder block to keep the counterbalance shaft

fTom

turn-

ing.

2. Install the oil pump sprocket.

3. Tighten the nut to the specified torque.

Camshaft

Sprocket

Bolt

Installation

1. Tighten the bolt to the specified torque.

Bearing

Cap

Bolt

Torque

36

40

fUbs

(50

-55

Nm)

lOll

PUMP

SPROCKET

BOLT

Engines & Generators

23

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends

that

the

following

engine

adjustments

be

peiformed by a competent

engine

mechanic.

The

information below is provided

to

assist

the

mechanic.

Tensioner

Spring/Timing

Tensioner

Installation

1. Install the tensioner spring

and

timing belt tensioner.

2.

Hook

the tensioner spring onto the bend

of

the timing belt
tensioner bracket and the stopper pin on the cylinder
block.

3.

Move

the timing belt tensioner as close as possible to the

water pump; temporarily tighten the tensioner nut.

TIMING

BELT

TENSIONER

Timing

Belt

Insiallation

1. Align the trlangular marking on

,the

camshaft sprocket

with a marking

on

the timing belt rear cover.

2. Align the notch in the crankshaft sprocket flange with

the marking

on

the front case.

3.

Align the triangular marking on the oil pump sprocket
with the marking

on

the front case, and then insert a 65

mm

(2.56 in.) or longer, 8

mm

(0.31 in.) diameter

round bar into the plug hole in the left side

of

the

cylinder block.

MARKING

ON

TIMING

BELT

REAR

COVER

TRIANGULAR'
MARKING

ON

CAMSHAFT
SPROCKET

TIMING

BELT

TENSIONER,

MARKING

ON

FRONT

At

this time, check that the moveable range

of

teeth on

the oil pump sprocket is according to specifications.

Standard

value: 4 to 5 teeth

in

forward

direction.

1

to 2 teeth

in

reverse

direction.

REVERSE

OIL

PUMP

SPROCKET

4.

If

the movable range

of

the oil pump sprocket exceeds

the specified range, correct as follows:
a. Pull out the round bar from the plug hole in the left

side

of

the cylinder block.

b. Turn the oil pump sprocket one turn at a time until
the round bar can again

be

inserted.

c. Check that the movable range

of

the oil pump

sprocket is in the specified value.

S. Set the timing belt over the crankshaft sprocket and

then over the oil pump sprocket and camshaft sprocket,
in that order.

NOTE:

Ensure

that

the

tension

side

of

the

timing

belt

is

not

slack.

Keep

the

round bar inserted

until

the

timing

belt

has

been

placed.

After this

step,

be

sure

to

remove

the

round

bar.

6. Apply counterclockwise force to the camshaft sprocket
to make the belt taut on the tension side, and make
sure that ail timing marks are lined up.

CAMSHAFT

SPROCKET

TENSION

SIDE

7. Loosen the temperorarily tightened tensioner nut on
the water pump side 1

or

2 turns, and tension the belt

making use

of

spring force.

NOTCH

IN
CRANKSHAFT
SPROCKET

flANGE

CASE

-~----'WESTERBEKE

Engines & Generators

24

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends

that

the

following

engine

adjustments

be

peiformed by a competent

engine

mechanic.

The

information below

is

provided

to

assist

the

mechanic.

8. Turn the crankshaft clockwise by nine camshaft sprocket

teeth

(817) to align the timing mark on the camshaft

sprocket with the tensioner

set

mark

on

the timing belt

rear cover.

A

CAUTION:

This

operation

is

performed

to

give

a

proper

tension

to

the

timing

belt,

so

do

not

tum

the

crankshaft

counterclockwise

and

push

the

belt

to

check

the

tension.

TENSIONER

"';::::""'"h.,_-,SET

MARK

9. Make sure that the timing belt teeth are engaged with
the camshaft sprocket teeth along the portion

of

the
sprocket shown by the curved arrow in the illustration
below. Then tighten the tensioner nut.

10. Pull the timing belt in the center

of

the tension side
toward the sealing gasket line for the belt cover, as
illustrated.

Make

sure that the clearance between the

back

of

the belt and the sealing line is the standard

value.

Standard

Value:

12mm

(0.47in.)

SEALING
GASKET

LINE

11. Pull out a rod from the plug hole on the left surface

of
the cylinder block and apply the specified sealant.
Then tighten the plug

to

the specified torque.

Specified sealant value;

3M

AID

Part No. 8660

or

equivalent
Tightening torque: 15-22

Nm

(11-16 ft.lbs.)

ENGINE

COMPRESSION

TEST

1.

To

check the engine's compression pressure, warm

up

the

engine then shut

it down.

2. Remove the three spark plug caps and remove the three
spark plugs.

3. InstaIJ a compression adapter and gauge in the spark plug
hole.

4. Close off the raw water intake seacock.

5. Crank the engine with the start motor and unplug the
ignition

coil and allow the compression gauge to reach a

maximum reading and record.

6. Measure the compression pressure for all the cylinders.
Ensure that compression pressure differential for each

cylinder

is

within

the

specified

unit.

Compression

pressure

should

not

differ

by

more

Ihan

14

psi

(100

Kpa).

7.

If

a cylinder's compression or pressure differential is

below the limit, add a small amount

of

engine oil through

the spark plug hole and repeat steps 4 and

5.

(a)

If

additional

of

oil causes an increase

of

pressure, the

piston

ling and/or cylinder wall may be worn or damaged.

(b)

If

additional oil does not increase compression pres­sure suspect poor valve contact, valve seizure, or valve
wear.

8. Reinstall three plugs and ignition wires.

9.

Open the raw water

thru

seacock.

ADAPTER

COMPRESSION
GAUGE
(TYPICAL)

~~j

~~I

Engines & Generators

25

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends

that

the

following

engine

adjustments be performed

by

a competent

engine

mechanic.

The

information below

is

provided

to

assist

the

mechanic.

VALVE

CLEARANCE

ADJUSTMENT

NOTE:

Retorque

the

cylinder head bolts before adjusting

the

engine's valves

(see

TORQUING

THE

CYLINDER

HEAD

BOLTS).

1.

Remove

the

rocker cover

and

gasket.

2. Rotate the crankshaft

in

the normal direction of rotation,

placing

the

No.1 piston at the

top

of

its

compression

stroke

with

the exhaust and intake valves completely

closed. Adjust the intake and exhaust valves

for

No.1

cylinder,

the

exhaust valve for No.2 cylinder,

and

the

intake valve for No.3 cylinder (see chart).

3. Rotate the crankshaft 180

0

in

its

nOlmal

direction of

rotation. Locate

the

piston

in

No.1 cylinder at

the

top

of

its exhaust stroke. Adjust the intake valve for

No.2

cylinder

and

the

exhaust valve for No.3 cylinder (see

chart).

CYLINDER

#

CRANK

ANGLE

1 2 3

When

No. 1 piston

is

set

at

top

of

IN

•

I

•

compression

stroke

• •

EX

When

No. 1 piston

is

positioned

at

top

of

exhaust

stroke

IN

•

EX

•

4

•.

Replace the rocker cover along with a new rocker cover
gasket..

Rocker

cover

torque:

2.9-5.1

(b-n

(4

• 7

Nm)

VALVE
CLEARANCE

Valve

Clearance:

Inlake

O.20mm

(.008

inches)

Exhaust

0.30mm

(.0:12

inches)

IGNITION

TIMING

1.

Attach a timing light

to

the

#1

spark plug

and

mark

the

front timing pointer

to

indicate

15°.

Locate

the

timing

mark

on

the

crankshaft pulley

and

mark it

with

white

chalk

or a crayon.

2. Start

the

engine

and

warm

it

up

to

its

normal

operating

temperature. Make sure the generator

is

operating without

a load on

it.

3. Using

the

timing light, align

the

timing

mark

in

the

front

crankshaft

puI1ey

so

it

is

just slightly before the

first

tim-

ing

pointer.

Do

this

by

loosening

and

slowly rotating

the

distributor

body.

Use

the following timing specifications:

Timing

Specifications:

15" ± .50 BTDe

at

1800

rpm

(no

load

on

generator)

,

IGNITION

TIMING

TORQUING

THE

CYLINDER

HEAD

BOLTS

After

the

initial break-in peliod (approximately

50

hours),

the

cylinder

head

bolts

should be re-torqued.

Tighten

the

cylind~r

head

bolts

according

to

the

sequence

shown.

Make sure

the

engine

is

cold

when

this

is

done,

and

loosen one head bolt one-half

turn

and

then

tighten

it

between

43

51lb-ft

(60

70

Nm).

Then

proceed

to

the

next

head

bolt

in

the

sequence. Tighten

the

RS

(rocker cover

stud)

securely.

FRONTO~

ENGINE

~

6

4

2

Engines & Generators

26

7

ENGINE

ADJUSTMENTS

SPARK

PLUGS

The spark plugs should

be

cleaned and regapped after the

first

50

hour break-in period, then inspected every 250 hours

thereafter and replaced as needed.

A

WARNING:

Do

not

remove

the

spark

plugs

while

the

engine

is

hot.

Allow

the

engine

to

cool

before

removing

them.

Spark

plug

gap:

0.031

- ±

0.0002

in.

(0.8 -0.05

mm).

Spark

plug

torque:

10

-15Ib·ft

(1.5 -2.31

kg.m).

NOTE:

Loctite Anti-Seize applied to the threaded portion

of
the spark plugs will retard corrosion, making future removal
of

the spark plugs easiel:

GAP

INSPECT

FOR

WEAR & CARBON

INSPECTING

THE

SPARK

PLUGS

CHOK~

SOLENOID

/'

INSPECT

FOR

DAMAGE

--CHECK

FOR

DETERIORATION

AND

DAMAGE

The choke solenoid is a

12

volt

DC

operated unit that func-

tions to close the choke plate in the carburetor when

the

ON

switch

is

depressed during engine start-up.

The choke solenoid de-energises once the engine starts and
the

ON

switch

is

released. Some unstable running may be

present when the engine starts cold,

but

should smooth out as
the engine reaches normal operating temperature.
Keep this solenoid dry and periodically lubricate the linkage,
plunger and choke

shaft with graphite lube.

__

CHOKE

SOLENOID

"

it

CARBURETOR

DRIVE

BELT

ADJUSTMENT

The drive belt must

be

properly tensioned. Excessive drive

belt tension can cause rapid wear

of

the belt and reduce the

service life

of

the fresh water pumps bearing. A slack belt

or

the presence

of

oil on the belt can cause belt slipping.

1. Remove the belt guard.

2. To release the belt, back off the pivot bolt and loosen the
bracket bolt.

3. Swing the bracket to loosen for removal.

4. Inspect the belt for frayed edges and excessive wear.

S. Re-install

or

replace the belt and re-tighten the bolts.

The drive belts are properly adjusted

if

it can be deflected

no

less than

3/8

inch (lOmm) and no more than

112

inch

(12mm) as the belt is depressed with the thumb at the

midpoint between the two pulleys on the longest span

of

the belt.

NOTE:

Maintain a 22

Ib

pressure to the belts outer face

for
proper belt operation. Spare belts should always be carried
on board.

A

WARNING:

Never

attempt

to

check

01

adjust

a

drive

belt's

tension

while

the

engine

is

in

operation.

6. Operate the generator for about 5 minutes, then shut down

the generator and recheck the belt(s) tension.

7. Replace the belt guard.

RAW

WATER

PUMP

BRACKET

Engines & Generators

27

GENERATOR

INFORMATION

USE

OF

ELECTRIC

MOTORS

The

power

required

to

start

an

electric

motor

is

considerably

more

than

is

required

to

keep

it

running

after

it

is

started.

Some

motors

require

much

more

current

to

start

them

than

others.

Split-phase

(AC)

motors

require

more

current

to

start,

under

similar

circumstances,

than

other

types.

They

are

commonly

used

on

easy-starting

loads,

such

as

washing

machines,

or

where

loads

are

applied

after

the

motor

is

started,

such

as

small

power

tools.

Because

they

require 5 to 7 times

as

much

current

to

start

as

to

run,

their

use

should

be

avoided,

whenever

possible,

if

the

electric

motor

is

to

be

driven

by a small

generator.

Capacitor

and

repulsion-induction

motors

require

from 2 to 4 times

as

much

current

to

start

as

to

run.

The

current

required

to

start

any

motor

varies

with

the

load

connected

to

it

An

electric

motor

connected

to

an

air

compressor,

for

example,

will

require

more

current

than

a

motor

to

which

no

load

is

connected.

In

general,

the

current

required

to

start

115-

Volt

motors

connected

to

medium

starting

loads

will

be

approximately

as

follows:

MOTOR

SIZE

AMPS

FOR

AMPS

FOR

(HP)

RUNNING

STARTING

(AMPERES)

(AMPERES)

1/6

3.2

6.4

to

22.4*

1/4

4.6

9.2

to

32.2*

1/3

5.2

In

d

1/2

7.2

14.4

to

29.2*

3/4

10.2

20.4

to

40.8"

1

13

26

to

52

*NOTE:

In

the

above

table

the

maximum

Ampsfor

Starting

is

more

for

some

small

motors

than

for

larger

ones.

The

reason

for

this

is

that

the

hardest

starting

types

(split-phase)

are

not

made

in

larger

sizes.

Because

the

heavy

surge

of

current

needed.

for

starting

motors

is

required

for

only

an

instant,

the

generator

will

not

be

damaged

if

it

can

bring

the

motor

up

to

speed

in a few

seconds.

If

difficulty

is

experienced

in

starting

motors,

tum off

all

other

electrical

loads

and,

if

possible,

reduce

the

load

on

the

electric

motor.

REQUIRED

OPERATING

SPEED

Run

the

generator

first

with

no

load

applied,

then

at

half

the

gener-

ator's

capacity,

and

finally

loaded

to

its

full

capacity

as

indicated

on

the

generator's

data

plate.

The

output

voltage

should

be

cheeked

periodically

to

ensure

proper

operation

of

the

generating

plant

and

the

appliances

it

supplies.

If

an

AC

voltmeter

or

amp-

meter

is

not

installed

to

monitor

voltage

and

load,

check

it

with

a

portable

meter

and

amprobe.

NOTE:

When

the

vessel

in

which

the

generator

is

installed

con-

tains

AC

equipment

of J 20

volts

only,

it

is

recommended

that

the

generator s AC

temlinal

block

be

configured

to

provide

one J 20

volt

AC

hot

legfor

the

vessel's

distribution

panel.

This

will

ensure

good

motor

starting

response

from

the

generator.

GENERATOR

FREQUENCY

ADJUSTMENT

Frequency

is

a direct result

of

engine/generator speed,

as

indicated

by

the

following:

•

When

the

generator

is

run

at 1800

RPM,

the

AC

voltage

output frequency

is

60

Hertz.

•

When

the

generator

is

run at 1500

RPM,

the

AC

voltage

output frequency

is

50 Hertz.

Therefore,

to

change

the

generator's

frequeney,

the

generator's

drive

engine's

speed

must

be

changed

along

with a reconfiguring

of

the

AC

output

connections

at

the

generator.

GENERATOR

MAINTENANCE

•

Maintaining

reasonable

cleanliness

is

important.

Connections

of

terminal

boards

and

rectifiers

may

become

corroded,

and

insulation

surfaces

may

start

conducting

if

salts,

dust,

engine

exhaust,

carbon,

etc.

are

allowed

to

build

up.

Clogged

ventilation

openings

may

canse

excessive

heating

and

reduce

life

of

windings.

•

For

unusually

severe

conditions,

thin

rust-inhibiting

petroleum

based

coatings

should

be

sprayed

or

brushed

over

all

surfaces

to

reduce

rusting

and

corrosion.

•

In

addition

to

periodic

cleaning,

the

generator

should

be

inspected

for

tightness

of

all

connections,

evidence

of

overheated

terminals

and

loose

or

damaged

wires.

•

The

drive

discs

on

single

bearing

generator's

should

be

checked

periodically

if

possible

for

tightness

of

screws

and

for

any

evidence

of

incipient

cracking

failure.

Discs

should

not

be

allowed

to

become

rusty

because

rust

may

accelerate

cracking.

The

bolts

which

fasten

the

drive

disc

to

the

generator

shaft

must

be

hardened

steel

SAE

grade

8,

identified

by 6 radial

marks,

one

at

each

of

the 6 comers

of

the

head.

•

The

rear

armature

bearing

is

lubricated

and

sealed;

no

maintenance

is

required.

However,

if

the

bearing

becomes

noisy

or

rough-sounding,

have

it

replaced.

•

Examine

the

bearing

at

periodic

intervals.

No

side

movement

of

the

shaft

should

be

detected

when

force

is

applied.

If

side

motion

is

detectable,

inspect

the

bearing

and

shaft

for

wear.

Repair

must

be

made

quickly

or

major

components

will

rub

and

cause

major

damage

to

the

generator.

Carbon

Monoxide

Detector---------,

WESTERBEKE

recommends

mounting a carbon

monoxide

detector

in

the

vessel's

living

quarters.

Carbon

monoxide,

even

in

smaU

amounts,

is

deadly.

TIle

presence

of

carbon

monoxide

indicates

an

exhaust

leak

from

the

engine

or

generator

or

from

the

exhaust

elbow!

exhaust

hose,

or

that

fumes

from a nearby

vessel

are

entering

your

boat.

If

carbon

monoxide

is

present,

ventilate

the

area

with

clean

air

and

correct

the

problem

immediately!

Engines & Generators

28

120Vl60Hz

#31

#11

CIRCUIT
BREAKER

L1

BCGA & C

AC

TERMINAL

CONNECTIONS

240V/60Hz

230Vl50HZ

115V150HZ

#11

#41

#42<

#11

#22

#42

#31

#21

#41

#31

#21

CIRCUIT

CIRCUIT

BREAKER

BREAKER

ISOLATED

ISOLATED

ISOLATED

POST

POST

POST

(NEUTRAL)

(NEUTRAL)

I

~.

N

L1

L2.

-

N

N

L1

BCGA & C

GENERATOR

WINDINGS

SCHEMATIC

El1~

~1

•

L..*:JE22

,.----------T11

t--------

T3

1

-----I

EWl

'"-------T41

L..--------T42

'-----------T21

L..-------------T22

~-Vl

'------V2

N

L1

EW1

EXCITER

WINDING

1

EW2 -EXCITER

WINDING

2

60Hz

OPERATION:

CONNECT

CAPACITORS

TO

E3'·E41/E1,·E21

50Hz

OPERATION:

CONNECT

CAPACITORS

TO

E31-E421E1'-E22

BCW -BATTERY

CHARGER

WINDING

RW -ROTOR

WINDING

W1 -STATOR

WINDING

1

W2 -STATOR

WINDING

2

C,

CAPACITOR

D1/D2-DlODES

Engines & Generators

29

ISOLATED

POST

120V/60Hz

1 +

CIRCUIT
BREAKER

L1

BeG

& 0

AC

TERMINAL

CONNECTIONS

240V/60Hz

230Vl50HZ

115V1'50HZ

1 5

CIRCUIT
BREAKER

l1

L2.

4 2

1 6

CIRCUIT
BREAKER

ISOLATED

POST

N

BeG

& 0

GENERATOR

WINDINGS

SCHEMATIC

r

-------

---I

I I

I I

I I

ROTOR

WINDINP

!

~

;:[*1:·

Ef

~~

-

~.

BATIERY

CHARGING

CIRCUIT

50

Hz

I I

I I

I I

STATOR

WINDING

I I

I I

I I

~----o2

I ,

I I

I I

I I

. I I

ROTOR

WINDING

j

I I

L -

-:C~~R

w,:Ji

g

.-rn

7

--,---06

6t,'F

STATOR

WINDING

CAPACITOR.

Engines & Generators

29A

l1

ISOLATED

POST

SHORE

POWER

TRANSFER

SWITCH

120

VOLT/GO

HERTZ

TWO

WIRE

CONFIGURATION

Generator

~

NOTE: Diagram shows connections for a

two-

wire, 120wVoit system from the

generator,

with

three-wire.

120-Voll

boat

system.

230

VOLT/50

HERTZ

TWO

WIRE

CONFIGURATION

Generator

~

Ll

:N

-

Q

Ship·to·

Shore

Switch

(3

Pole)

PN

32008

z

w
w

a:

GENERATOR

GROUND

w

!::

:<:

I'

o GENERATOR/SHORE

PN

32133

.J

III

L2

/...--

.......

,

L1

'---t--t----f-@9\Neutral

iiif?!

~

./Je/+,

-+--(W-H-T-)-"N

~

--",~~ro~un~d~~

__

~

w·

ii'

Z (GRN)

~

Shore Power

(40Amps!Pole)
PN

32009

(60Amps!

Pole)

PN

32010

(125

Amps!

Pole)

Ships

Load

PN

32133

NOTE:

(200

Amps!

Pole)

No

240-Voll

Equipment

If

the installer connects shore power to the vessel's AC

circuit, this must be done by means

of

the Shore Power

Transfer Switch

..

Set the transfer switch shown in the

diagrams to the

OFF

position. This switch prevents

simultaneous connection

of

shore power to generator output.

A

CAUTION:

Damage

to

the

generator

can

result

if

utility

shore

power

and

generator

output

are

connected

at

the

same

time.

This

type

of

generator

damage

is

not

covered

under

the

warranty;

it

is

the

installer's

responsi-

bility

to

make

sure

all

AC

connections

are

correct.

"

::i

SWITCH

r:D:

....... -.......

;;:

/

'\

! !

1

~L1

,--~'---~~3

2 I

" /

'-_.-'

/

......

-

........

,

L---~~:5

~N

(NEUTRAL)! !

,....-'-----'-'rf7

6 I

'-

/

'-_/

SHIP'S

LOAD

-=

SHORE

GROUND

_

SHIP'S

- GROUND

~

SHORE

POWER

230V

50HZ

Switching

Shore

Power

to

Generator

Power

A

CAUTION:

Heavy

motor

leads

should

be

shut

off

before

switching

shore

power

to

generator

power

or

vice-versa

because

voltage

surges

induced

by

switching

with

heavy

AC

loads

on

the

vessel

being

operated

may

cause

damage

to

the

exciter

circuit

components

in

the

generator.

Engines & Generators

30

o

~

:z:

[;)

m

BC

GENERATOR

SINGLE

PHASE

INTEGRAL

CONTROLLER

(I.C.)

The Integral Controller (I.C.) is an encapsulated, solid-state
unit that supplies a DC charging voltage to the generator's
starting battery while the generator is opening.

Charging Voltage:

13.1

• 13.4 volts DC

Charging Amperage: 0 • 17.0

amps

DC

A separate group

of

stator windings supplies

AC

voltage to a

bridge rectifier which converts the

AC

current

to

supply the

I.e.

unit. The

I.e.

unit senses the needs

of

the starting battery

and supplies a

DC

charge when one is needed.

If

you

susp~ct

that the I.C. unit is faulty (that is,

if

the battery's charge is
low), check the charging circuit and it's components as
described in the following steps. Check all connections for
cleanliness and tightness including the ground before replacing
the I.C. unit.

NOTE:

When

the

generator

is

first started,

the

L

C.

unit will

produce a

low

charging

rate.

This

charging

rate

will

rise

as

the

generator

is

operated.

The

Integral Controller is mounted inside the generator hous-

ing in the

12:00 position. There is a voltage output adjustment

on

the controller that

wi1I

allow a DC voltage output adjust-

ment

of

± 2 volts.

NOTE:

New

four

wire

controllers eliminate

the

ballast resistor

circuit since

the

ballast resistor's junction

is

now handled

internally.

Whenever replacing

an

early stylr controller with

the

newer four

wire

model,

remove

the ballast resistor and

its

wiring.

VOLT

~

+

-

GND

GREEN

RED

GROUND

TO

GENERATOR

CASE

VOLTAGE

OUTPUT

AOJUSTME.NT

AC

BRIDGE
RECTIFIER'

Testing

the

Battery

Charging

Circuit

1.

Bridge

Rectifier

Normal

AC

voltage running to the rectifier (while the

engine is operating at

1800 rpm) is measured across the

two AC connections on the bridge rectifier. (As

illustrated).

AC

voltage running to the bridge rectifier (approximate):

No-load

off

the

generator

16.0

volts A C

Full-load

off

the

generator

17.5 volts

AC

Normal DC voltage running out

of

the rectifier (in volts

DC) is measured across the two DC connections

of

the

bridge rectifier; that is

+ and

-.

DC

voltage running from the bridge rectifier

(approximate):

No-load

off

the

generator

Full-load

off

the

generator

2.

AC winding: O.lOohm

17.0 volts

DC

18.5 volts

DC

Lift the two

AC

wire leads off the bridge rectifier and

measure, the resistance between these two leads with an

ohmmeter. It should measure 0.10 ohm. No continuity

should exist between these two leads and the ground or

the main AC stator windings.

3. Testing

the

Bridge

Rectifier (meter used - Simpson 260)

a.

Set your ohmmeter's scale on

RXI

(+ DC) and set the

needle to zero.

b. Connect the

(+ ) positive lead from the ohmmeter to

point #4. Taking the ohmmeter's negative

H lead,

momentarily touch points

#1, #2, #3, and #5. The ohm-

meter should register no deflection for any

of

the

points touched.

c.

Remove the positive (+) lead from point

#4

and

connect the negative

(-)

lead; momentarily touch

points #1, #2, and

#3.

The

ohmmeter's needle should

deflect when each point is touched.

d.

Leaving the negative ohmmeter

(-)

lead on point #4,

. touch point

#5

with the positive lead. No deflection

should take place.

e. Place the positive (+) lead on point

#1

and the negative

(-)

lead on point #3. The ohmmeter again should not
register any deflection (no deflection indicated infinite
resistance). Reverse these connections and the

ohmme-

ter should again register no deflection.

If

the rectifier

fails any

of

the previous tests (A-E), replace the recti-

fier because it is

defective,

NOTE:

Different

types

and/or brands

of

test meters

may

produce opposite test

results.

POINT

1/1

POINT

14

.

BRIDGE-

RECTIFIER

POINT

#5

MOUNTING

HOLE

Engines & Generators

Revised August 2003

31

NOTE:

An

on-off

switch

should

be

Installed

in

this

circuit

to

disconnect

the

starter

from

the

battery

in

an

emergency

and

when

leaving

the

boat.

Twelve

volt

engine

starters

typically

draw

200

to

300

amps

when

crankiflg.

A

switch

with a continuous

rating

of

175

amps

at

12

VDCwill

normally

serve

this

function,

but a switch

must

never

be

used

to

"make"

the

starter

circuit

+ 12

vee

WIRING

SCHEMATIC

#46876

BATTERY

DISCONNECT

SWITCH

BATTERY

!2VDC

BATTERY

CHARGER

'2

HOUR

METER

D I STi I

SUTOR

rUEL

PUMP

FUEl SOL.

'2,

RUN

RE

LAY

~

____

-+

_________

8~'

}8r5

______________

--1

CHOKE

SOl.

K

I-STA.RT

RElAY

~~~oL-~~~,~~------_+----~------_+---------8ri6

}8i5

______________

--1

I

I

I

rrl

..

~f8J

_ITl .

!!IIMUE

COM!ECIl!R

SHORT I

NG

PLUG ~ JUMPER

PINS 2 TO

5:

TROUBLL';;OOOTING -

WHEN

TROUBLESHOOTING

THE

DC

CIRCUIT:

TO

BY

PASS

THE

OVERSPEED

TO

DETERIME

IF

IT

IS

FAULTY.

MOVE

CONNECTION

#3

TO

CONNECTION

#5.

NOTE -

DO

NOT

OPERATE

TIlE

UNIT

WI11l

THE

OVERSPEED

BYPASSED.

Engines & Generators

32

AUX.

Oil

PRESS.

SWITC1-I

elK

Fffi-IIRE

II

SAW(;

II

GSDEG

C

600V·AlPNU

IBSSII&·MII+16818D

TYPE

81

UNlESS

SPECIFIED

OTHERWISI.

l.

,AJUil1CG

RElAYS

Kl.

K2

HAVE

INfERNAL

DIODES

ACROSS

THEIR

COilS. POUlilT"

AS

INDICATED

MUST

BE

MAlHTAINU

TO

AVOID

DAIIAGE

TO

THE

RHAYS.

WIRING

DIAGRAM

#46876

A.UX.

OL

PRESS

SWITCH

INICI

OL

PRESS

SWITCH

WOl

~

o~

«

'"
'"

-

'"

~

c

~

'"

.

+

116

V10fW r

w

~

tl4

RED/VIO

'"

.

112 YEL/RED

""

w

«

~

Ii

!:

t'2

RED

tl&

RED/WHT

'16

ORG

tl6

WHT

"116

elK

116

RED/VIO

Engines & Generators

33

AC

GEN.

""

«

""

.,

FIJSE

8A

ON

SWITCH

START/STOP

SWITCH

rus£

30A

;;

REMOTE

PANEL

WIRING

SCHEMATIC

REMOTE

PANEL

#043912 WITH 1 FOOT HARNESS

START/STOP

SW

RED

EXTENSION

HARNESS

15 Feet PN# 043914

30

Feet PN# 043860

Engines & Generators

34

#14

5LK

#14

WHT/RED

#14

YELIRED

#14

WHT

#14 RED/VIO

VIEWED

FROM

MATING

END

ENGINE

TROUBLESHOOTING

The following troubleshooting

tables

are

based

upon

eertain

engine

problem

indicators and the most likely causes of the

problems.
When troubleshooting indicates

an

electrical problem,

see

the

ELECTRICAL

SYSTEM

WIRING

DIAGRAM,

as

these

may

reveal

other possible causes

of

the problem

which

are

not

listed

below.

PROBLEM

PROBABLE

CAUSE

Engine

does

not

1.

Voltage

drop

at

starter

solenoid

crank.

terminal.

2.

Engine

circuit

breaker

has

tripped.

3. 8

amp

fuse/holder

is

faulty.

4.

Battery

is

low

or

dead.

5.

Loose

battery

connections.

6.

Faulty

wire

connection.

7.

Faulty

start

switch.

8.

Faulty

start

relay

(Kl).

9.

Faulty

starter

solenoid

10.

Raw

water

filled

cylinders.

Engine

starts,

runs

1.

Faulty

shutdown

switch,

and

then

shuts

(oil

pressure,

water

or

exhaust

down.

temperature).

2.

Faulty

overspeed

switch

(See

note

below).

3.

Dirty

fuel/water

separator

filter.

4.

Mechanical

check

valve

at

the

fuel

supply

faulty

(if

installed).

5.

Low

oil

level

in

sump.

6.

Faulty

fuel

pump.

7.

High

engine

water

or

exhaust

temperature.

Engine

starts.

runs

1.

Faulty

mag-pickup

sensor.

but

does

not

come

2.

Electronic

governor

controller

faulty,

up

to

speed.

3.

Fuel

pump.

4.

Fuel

supply

to

engine

restricted.

5.

Throttle

linkage

binding.

6.

Actuator

or

electrical

connections

faulty.

7.

AC

generator

overload.lshort.

8.

Air

intake

restricted.

9.

Exhaust

restricted.

NOTE:

171e

engines control system (electrical

system)

is

protected

by

a

20

Ampere manual

reset

circuit breaker

located

on

the

control

panel.

PROBLEM

PROBABLE

CAUSE

Engine

cranks

but

1.

Out

of

fuel.

fails

to

start.

2.

Engine

is

flooded.

3.

Faulty

carburetor.

4.

Faulty

choke

solenoid.

Engine

hunts.

1.

Controller

gain

adjustment

needed.

2.

Faulty

fuel

pump.

3.

Mag

pick-up

sensor

needs

adjustment.

4.

Low

DC

battery

voltage.

5.

Generator

overload.

6.

Valves

need

adjustment.

Engine

misfires.

1.

Poor

quality

fuel.

2.

Incorrect

timing.

3.

Dirty

flame

arrester.

4.

Cracked

distributor

cap.

5.

Faulty

ignition

wires.

6.

Spark

plugs

are

worn.

7.

High

exhaust

back-pressure.

S.

Valve

clearances

are

incorrect.

Engine

backfires.

1,.

Spark

plug

wires

are

connected

wrong.

2.

Incorrect

timing.

3.

Engine

is

flooded.

See

Engine

is

flooded

under

Engine

cranks

but

fails

to

start.

4.

Dirty

flame

arrester.

5.

Cracked

distributor

cap.

6.

High

exhaust

back-pressure.

Engine

overheats,

1.

Coolant

loss.

Pressure

test

cooling

system.

2.

Faulty

raw

water

pump

impeller.

3.

Belts

are

loose

or

broken.

4.

Raw

water

pump

worn.

5.

Faulty

thermostat.

NOTE:

OVERSPEED

SWITCH:

TO

BY-PASS

THE

OVERS

PEED

SWITCH

WHEN

TROUBLESHOOTING

MOVE

CONNECTION

#3

AND

CONNECT

IT

ONTO

AND

WITH #5.

REFER

TO

WIRING

DIAGRAM

#46876.

Engines

& Generators

35

ENGINE

TROUBLESHOOTING

PROBLEM

PROBABLE

CAUSE

PROBLEM

PROBABLE

CAUSE

Low

oil

pressure,

1.

Low

oil

level.

Black

exhaust

smoke

1.

Dirty

flame

arrester.

2.

Wrong

SAE

type

oil

in

the

engine,

discharge

from

the

2.

Faulty

carburetor.

3.

Faulty

or

wrong

type

oil

filter,

engine.

3.

Idle

mixture

jet

too

rich.

4.

Relief

valve

is

stuck,

4.

Faulty

choke/solenoid,

5.

Faulty

oil

pump.

6.

Faulty

engine

bearings.

5.

Valves

are

worn

or

incorrectly

adjusted.

7.

Faulty

oil

filter,

6.

Piston

rings

are

worn

or

unseated,

High

oil

pressure.

1.

Dirty

oil

or

wrong

SAE

type

oil

in

the

engine.

2.

Relief

valve

is

stuck,

Poor

performance

1.

Contaminates

in

carburetor.

at

generator

speed,

2.

Faulty

fuel

pump/contaminated.

3.

Electronic

governor

controller

needs

No

DC

charge

to

the

1.

Faulty

connections

to

adjustment.

starting

battery.

battery

charging

control.

2.

30

amp

fuse

blown/faulty,

3.

Faulty

battery

charging

control.

4.

Faulty

bridge

rectifier,

5.

Faulty

generator

charger

windings,

Blue

exhaust

smoke

1.

Lube

oil

is

diluted.

discharge

from

the

2.

High

lube

oil

level.

engine,

3.

Crankcase

breather

hose

is

clogged,

4.

Valves

are

worn

or

adjusted

incorrectly,

5.

Piston

rings

are

worn

or

unseated.

. Engines & Generators

36

LAY-UP & RECOMMISSIONING

G~NERAL

Many owners rely on their boatyards to prepare their craft,
including engines and generators, for lay-up during the off­season or for long periods

of

inactivity. Others prefer to

accomplish lay-up preparation themselves.
The procedures which follow will allow you to perform your

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

if

others do the procedures.

These procedures should afford your engine protection
during a lay-up and also help familiarize you with the
maintenance needs

of

your engine.

If

you have any questions regarding lay-up procedures, call
your local servicing dealer; he will be more than willing to
provide assistance.

Propeller

Shaft

Coupling

[Propulsion

Engine]

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

of

the boat often puts a
severe strain on the propeller shaft or coupling or both, while
the boat is taken out or put in the water. In some cases, the
shaft has actually been bent by these strains. This does not
apply

to

small boats that are hauled out

of

the water when
not in use, unless they have been dry for a considerable
period

of

time.

Fresh

Water

Cooling

Circuit

A 50-50 solution

of

antifreeze and distilled water is
recommended for use in the coolant system at all times.
This solution may require a higher concentration

of
antifreeze, depending on the area's winter climate. Check the
solution to make sure the antifreeze protection is adequate.

Should more antifreeze be needed, drain an appropriate
amount from the engine block and add a more concentrated
mixture.

Operate the engine to ensure a complete circulation

and mixture

of

the antifreeze concentration throughout the

cooling system. Now recheck the antifreeze solution's strength.

Lubrication

System

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

of

oil. Refer to the

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:

Do

not

leave

the

engine's

old

engine

oil

in

the

sump

over

the

lay-up

period.

Engine

oil

and

combustion

depOSits

combine

to

produce

harmful

chemicals

which

can

reduce

the

life

of

your

engine's

internal

parts.

Fuel

System

[Gasoline]

Top off your fuel tanks with unleaded gasoline

of

89 octane

of

higher. A fuel conditioner such as

STABIL

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

BlOB

OR

and

STABIL

should be added at this time to
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,

if

the fuel system

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 air is left

in

the fuel
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

of

the treated fuel through the injection

equipment on the engine.

Raw

Water

Cooling

Circuit

Close the through-hull seacock. Remove the raw water intake
hose from the seacock.

Place the end

of

this hose into a five

gallon bucket

of

clean fresh water. Before starting the engine,
check the zinc anode found in the primary heat exchanger on
the engine and clean or replace it as required, and also 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 system. When the bucket is empty,
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

of

this mixture to be drawn

through the raw water system.

Once the bucket is empty, stop
the engine. This antifreeze mixture should protect the raw
water circuit from freezing during the winter lay-up, as well
as providing corrosion protection.

Remove the impeller from your raw water pump (some

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

Examine the impeller. Acquire a replacement,

if

needed, and

a cover gasket.

Do

not replace the impeller (into the pump)

until recommissioning, but replace the cover and gasket.

Cylinder

Lubrication

[Gasoline]

With the engine running, remove the flame arrester and spray
fogging oil into the open

air intake. The fogging oil will stall

out the engine as it coats the valves, cylinders and spark

plugs for winter protection.

Engines & Generators

37

LAY-UP

&

RECOMMISSIONING

Starter

Motor

Lubrication and cleaning

of

the starter drive pinion is advis-

able,

if

access to the starter

penn

its

its

easy removal. Make

sure the battery connections are shut off before attempting to

remove the starter. Take care in properly replacing any electri-

cal connections removed from the starter.

Cylinder

Lubrication

[Diesel]

If

you anticipate a long lay-up period (12 months

or

more)

WESTERBEKE recommends removing the glow plugs

or
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. Rotate the engine by hand
two revolutions then replace the glow plugs or injectors.

Make sure you have a replacement

if

removing the injector

sealing washer for the injector and fuel line return.

NOTE:

If engine storage

is

going to

be

a lengthy

one,

12

months or

beyond,

it

is

wise

to

rotate

the

engine

by

hand two

complete turns every additional 4 months

to

allow

the

injec-

tion

pump components

to

move. This will help prevent their

sticking during extended storage periods.

Intake

Manifold

and

Thru-Hull

Exhaust[Diesel]

Place a clean cloth, lightly soaked

in

lubricating oil. in the

opening

of

the intake manifold to block the opening.

Do

not

shove the cloth out

of

sight.

(If

it is not visible at
recommissioning, and an attempt is made to start the engine,
you may need the assistance

of

a servicing dealer.) Make a

note to remove the cloth prior to

start-up. The through-hull

exhaust port can

be

blocked in the same manner.

Intake

Manifold

[Gasoline]

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!

Transmission

[Propulsion

Engine]

Check or change fluid in the transmission as required.

If

the

engine is to be layed up 12 months or more, fill the transmis-

sion to the very top to prevent corrosion.

Lower

the

fluid

to

its normal

at

recommissioning. Wipe off grime and grease

and touch up unpainted areas. Protect coupling and output
flange with an anticorrosion coating. Refer to the

TRANSMISSION SECTION in this manual for additional

information.

Batteries

If

batteries are to be left on board during the lay-up period,

make sure they are fully charged, and will remain that way, to

prevent them from freezing.

If

there exists any doubt that the

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.

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, or replace those items
used during the lay-up, such as filters and zinc anodes. Refer
to the

SPARE

PARTS

section

of

this manual.

RECOMMISSIONING

The recommissioning

of

your WESTERBEKE engine after a

seasonal lay-up generally follows the same procedures

as

those described in the PREPARATIONS

FOR

STARTING

sec­tion regarding preparation for starting and normal starts.
However, some

of

the lay-up procedures will need to be

counteracted before starting the engine.

1. Remove any rags that were placed in the exhaust, intake

manifold. or flame arrester.

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,

if

required).

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.

4. Remove the spark plugs, wipe clean,

ie-gap. and install

to proper tightness.

[Gasoline]

5. Check the condition

of

the zinc anode in the raw water

circuit and clean

or

replace the anode as needed. Note
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

of

time with no adverse affects. Also open up
the heat exchanger ends and clear out any accumulated
debris.

6. Check the transmission fluid,

if

it

had been topped off

during the lay-up, lower the level

of

the fluid to nonnal.

[Propulsion

Engine]

7. Make certain

an

electrical connections and switches are

in

the correct position and there are no-loads on the

generator at

start up.

[Generator]

8. Start the engine in accordance with the procedures
described in the

PREPARATIONS

FOR

STARTING

section

of

this manual.

Engines & Generators

38

5.0KW

BCG/BCGA

GENERATOR

SPECIFICATIONS

ENGINE

SPECIFICATIONS

Engine

Type

Bore & Stroke
Total

Displacement

Bearings

Compression

Chamber

Compression

Ratio

Hp@1800/1500

rpm

Firing

Order

Aspiralion

Direction

of

Rotation
Inclination
Dry

weight

Governor

Fuel

Pump

Fuel

Distributor
Spark

Plugs

Ignition

Coil

Flame

Arrester
Carburetor
Fuel

Consumption

(Full

Load)

3-cylinder,

4-cycle, , overhead

camshaft

w/counterbalance

shaft,

water

cooled

gasoline

engine

2.56 x 2.61

inches

(65.0 x 66.3

mm)

40.3

cubic

inches

(0.66

liters)

Fou r main

bearings

Semi-spherical

9.8:1

8.016.5

1 -3 -2
Naturally

aspirated

Counterclockwise

viewed

from

the

back

end

25°

continuous,

aI/

directions

3071bs

(139.3

Kg)

Electronic

FUEL

SYSTEM

Electric

fuel

pump

Unleaded

89

octane

or

higher

gasoline

Breakerless

distributor
14mm
12

volt

Metal

screen

type

Single

draft

type
.8

GPH @ 1800

rpm

ELECTRICAL

SYSTEM

Start

Motor

Starting

Battery

Battery

Capacity

Battery

Charging

12-Volt

reduction

gear

with

solenoid

12-Volt,

to)

negative

ground

600-800

Cold

Cranking

Amps

(CCA)(min))

Integral

electric,

17

amps

General

Fresh

Water

Pump

Raw

Water

Pump

Raw

Water

Flow,

Cooling

Water

Capacity

Operating

Temperature

Fresh

water-cooled

block

through

raw

water-cooled

heat

exchanger

circuit

Centrifugal

type,

metal

impeller,

belt-driven.

Positive

displacement,

rubber

impeller,

belt-driven.

4.9

US

gpm @ 1800

rpm

(439

gmp@1500rpm)

(approx.

measure

before

discharging

into

exhaust

elbow).

3

qts

(2.8

liters).

150·

-170· F

(65

-

7]0

C)

LUBRICATION

SYSTEM

Type

Oil

Fmer

Oil

Capacity

Operating

Oil

Pressure

Oil

Grade

Forced

lubrication

by

gear

pump

Full

flow,

paper

element.

spin-on

disposals

2.5

qls.

(2.4

liters).

40 -60

psi

(2.8

-

4.2

kg/em').

API

Specification

SJ

class

AC

GENERATOR

(Single

Phase)

Type
Ratings:

5.IlKW

4.2KW

Brushless,

four-pole

capacitor,

regulated.

1800

rpm/60Hz,

1500

rpml50Hz

120

volts,

41.6

amps,

60Hz

single

phase, 4 wire,

1.0

power

factor

230

volts,

18.2

amps,

50Hz

single

phase, 4 wire,

1.0

power

factor

TUNE-UP

SPECIFICATIONS

Spark

plug

Gap

Spark

Plug

Torque

Cylinder

Head

Torque

Ignition

Timing

Bolt

Torque

0.031 ± .002

inches

(0.8

:t

0.05mm)

10.8

-15.2Ib-ft

60-70

Nm

(43-51

ft-ltJs)

15°

± 5·

BTDC

at

1800

rpm

See

TORQUING

THE

CYLINDER

HEAD

Engines & Generators

39

7.0

KW

BCGC/BCGD

GENERATOR

SPECIFICATIONS

ENGINE

SPECIFICATIONS

Engine

Type

Bore & Stroke

Total

Displacement
Bearings
Compression

Chamber

Compression

Ratio

Hp@1800/1500

rpm

Firing

Order
Aspiration
Direction

of

Rotation

Inclination

Dry

weight

Governor

Fuel

Pump
Fuel
Distributor
Spark

Plugs

Ign~ion

Coil

Flame

Arrester
Carburetor
Fuel

Consumption

(Full

load)

3-cylinder.

4-cycle, , overhead

camshaft

w/counterbalance

shaft,

water

cooled

gasoline

engine

2.56 x 2.61

inches

(65.0 x 66.3

mm)

40.3

cubic

inches

(0.66

liters)

Four

main

bearings

Semi-spherical

9.8:1

8.0/6.5

1

3-2

Naturally

aspirated

Counterclockwise

viewed

from

the

back

end

25°

continuous,

all

directions

3071bs

(139.3

Kg)

Electronic

FUEL

SYSTEM

Electric

fuel

pump

Unleaded

89

octane

or

higher

gasoline

Breakerless

distributor
14mm
12

volt

Metal

screen

type

Single

draft

type

.8

GPH

@

1800

rpm

ELECTRICAL

SYSTEM

Start

Motor

Starting

Battery

Battery

Capacity

Battery

Charging

12-Volt

reduction

gear

with

solenoid

12-Volt,

(-)

negative

ground

600-BOO

Cold

Cranking

Amps

(CCA)(min))

Integral

electric,

17

amps

General

Fresh

Water

Pump

Raw

Water

Pump

Raw

Water

Flow,

COOling

Water

Capacity

Operating

Temperature

Fresh

water-cooled

block

through

raw

water-cooled

heat

exchanger

circuit

Centrifugal

type,

metal

impeller,

belt-driven.

Positive

displacement,

rubber

impeller,

belt-driven.

4.9

US

gpm @ 1800

rpm

(439

gmp@1500

rpm)

(approx.

measure

before

discharging

into

exhaust

elbow).

3

qts

(2.8

liters).

150·

-170° F (65

-

77·

C)

LUBRICATION

SYSTEM

Type
Oil

Filter

Oil

Capacity

Operating

Oil

Pressure

Oil

Grade

Forced

lubrication

by

gear

pump

Full

flow,

paper

ele:nent.

spin-on

disposals

2.5

qts.

(2.4

liters).

40 -60

psi

(2.8 -4.2

kg/em').

API

Specification

SJ

class

AC

GENERATOR

(Single

Phase)

Type
Ratings:

7.0KW

5.9KW

Brushless,

four-pole

capacitor,

regulated.

1800

rpm/60Hz,

1500

rpm/50Hz

120

volts,

58.3

amps,

60Hz

Single

phase, 4 wire.

1.0

power

factor

230

volts,

25.6

amps,

50Hz

single

phase, 4 wire,

1.0

power

factor

TUNE-UP

SPECIFICATIONS

Spark

plug

Gap

Sparlk

Plug

Torque

Cylinder

Head

Torque

Ignition

Timing

Bolt

Torque

0.031

:±:.002

inches

(O.B.:±:

0.05mm)

10.8 -15.2

Ib-ft

60-70

Nm

(43-51

ft-Ibs)

15° ± 5°

BTDC

at

1800

rpm

See

TORQUING

THE

CYLINDER

HEAD

Engines & Generators

39A

GENERATOR

HARDWARE

TORQUES

Timing

Bell

Nm

ft.lbs.

Fronl

Case,

Counterbalance

Shall

Nm

ft.lbs.

Crankshaft

bolt

135-145

98-105

Front

case

bolts

8-10

6-7

Timing

belt

cover

bolts

10-12

7-9

Oil

pump

cover

Dolts

8-10

6-7

Camshaft

sprocket

bolts

80-100

58-72

Oil

pan

bolts

10-12

7·9

Oil

pum p sprocket

nuts

50-57

36-41

Oil

drain

plug

35-45

25-33

Timing

tensioner

nuts

22-30

16-22

Oil

screen

Dolts

15-22

11-16

Timing

be~

rear

cover

bolts

10-12

7-9

Oil

pump

driven

gear

bolt

34-40

25-29

Rocker

Arms

and

Rocker

Shaft

Rear

cove r bolts

10-12

7-9

Rocker

cover

shaft

29-35

21-25

Piston

and

Connecting

Rod

Camshaft

thrust

plate

bolt

10-12

7-9

Connecting

rod

cap

nut

15 + 90"

tum

11 + 90"

tum

Rocker

amn

adjust

nut

8-10

6-7

Crankshaft,

Bearing

Cylinder

Head,

Valve

Oil

seal

case

bolts

10-12

7-9

Cylinder

head

bolt

(cold

engine)

60-70

43-51

Bearing

cap

bolts

50-55

36-40

Spark

plug

15.2

10.8

Cylinder

Block

Rocket

cove

r

12-13

9-10

Taper

plug

1/16

8-12

6-9

Miscellaneous

Taper

plug

1/8

15-22

11-16

Coolant

temperature

sender

12-18

9-13

Water

drain

plug

35-45

25-33

Coolant

temperature

switch

12-18

9-13

Taper

plug

1/4

NPT

35-45

25-33

Generator

mounts

34-47

23-34

Oil

pressure

switch

12-18

9-13

Exhaust

manifold

16-23 12-17

Oil

pressure

sender

12-18

9-13

Thermostat

housing

8-11

6-8

Water

Pump

Water

pump

8-10

6-7

Engines & Generators

40

STANDARD

AND

METRIC

CONVERSION

DATA

LENGTH-DISTANCE

Inches

(in) x 25.4 = Millimeters

(mm) x .0394 = Inches

Feet

(ft) x .305

::::

Meters

(m) x 3.281 = Feet

Miles x 1.609

Kilometers

(km) x .0621

::::

Miles

DISTANCE

EQUIVALENTS

1

Degree

of

latitude

60

Nm

::::

111.120

km

1

Minute

of

latitude 1 Nm

::::

1.852

km

VOLUME

Cubic

Inches

(in3) x 16.387 = Cubic

Centimeters x .061

::::in

3

Imperial

Pints

(IMP

pt) x .568

::::

Liters

(ll x 1.76 = IMP

pt

Imperial

Quarts

(IMP

qt) x 1.137::::

Liters

(l)

x.88

::::

IMP

qt

Imperial

Gallons

(IMP

gal) x 4.546::::

Liters

(l) x .22

::::

IMP

gal

Imperial

Quarts

(IMP

qt) x 1.201 = US

Quarts

(US

qt) x .833

::::

IMP

qt

Imperial

Gallons

(IMP

gal) x 1.201 = US

Gallons

(US

gal) x .833 = IMP

gal

Fluid

Ounces x 29.573

Milliliters x .034 = Ounces

US

Pints

(US

pt) x .473 = Liters(l) x 2.113 = Pints

US

Quarts

(US

qt) x .946 = Liters

(l) x 1.057 = Quarts

US

Gallons

(US

gal) x 3.785 = Liters

(l) x .264 = Gallons

MASS-WEIGHT

Ounces

(OZ)

x

28.35::::

Grams

(g) x .035

::::

Ounces

Pounds

(Ib) x .454

Kilograms

(kg) x 2.205 = Pounds

PRESSURE

Pounds

Per

Sq

In

(psi) x 6.895

::::

Kilopascals

(kPa) x .145

::::

psi

Inches

of

Mercury

(Hg) x .4912

::

psi x 2.036 = Hg

Inches

of

Mercury

(Hg) x 3.377

::

Kilopascals

(kPa) x .2961

::::

Hg

Inches

of

Water

(H20) x .07355

::::

Inches

of

Mercury x 13.783::::

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

Meters

(Nm) x 8.85

=in-Ib

Pounds-Force

Feet

(ft-Ib) x 1.356

::::

Newton

Meters

(Nm) x .738::::

ft-Ib

VELOCITY

Miles

Per

Hour

(MPH) x 1.609::::

Kilometers

Per

Hour

(KPH) x .621

::::

MPH

POWER

Horsepower

(Hp) x .745 = Kilowatts

(Kw) x 1.34 = MPH

FUEL

CONSUMPTION

Miles

Per

Hour

IMP

(MPG) x .354 = Kilometers

Per

Liter

(Km/l)

Kilometers

Per

Liter

(Km/L) x 2.352 = IMP

MPG

Miles

Per

Gallons

US

(MPG) x .425 = Kilometers

Per

Liter

(Km/L)

Kilometers

Per

Liter

(Km/L) x 2.352 = US

MPG

TEMPERATURE

Degree

Fahrenheit

(OF) = (OC X 1.8) + 32

Degree

Celsius

(OC) = (OF -32) x .56

LIQUID

WEIGHTS

Diesel

Oil

= 1

US

gallon = 7.131bs

Fresh

Water

= 1

US

gallon = 8.33

Ibs

Gasoline", 1 US

gallon = 6.1

Ibs

Salt

Water

= 1

US

gallon",

8.56

Ibs

Engines & Generators

41

SUGGESTED

SPARE

PARTS

WESTERBEKE

MARINE

GASOLINE

GENERATORS

CONTACT

YOUR

WESTERBEKE

DEALER

FOR

SUGGESTIONS

AND

ADDITIONAL

INFORMATION

'-'&---'1/

MANIFOLD

CAP

MOLDED

HOSE

KIT

WESTERBEKE

RECOMMENDS

CARRYING

ENOUGH

HARDWARE

KIT

SPARE

ENGINE

OIL

(YOUR

BRAND)

FOR

AN

OIL

_________________________

CHANGEANDALSOA

GALLON

OF

PREMIXED

WESTERBEKE

also

offers

two

Spare

Parts

Kits,

each packaged

in

a rugged, rust

free

toolbox.

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

SPARE

PARTS

KITS

Engines & Generators

42

COOLANT

FOR

THE

COOLING

SYSTEM.

-

KITB

Impeller

Kit

Water

Pump

Repair

Kit

...

Thermostat

Kit

Zinc

Anodes

Complete

Gasket

Kit

Heat

Excbanger

Gasket

Oil

Filter
Drive Belt
Spark

Plugs

Engines & Generators

WMDWl2102