Westerbeke 3.0BCG, 4.5BCG, 5.0BCG, 7.0BCG, 7.0BTG Operator's Manual

OPERATOR'S MANUAL

&

INSTALLATION GUIDE

WESTERBEKE CORPORATION

GASOLINE GENERATORS

7.0KW BCG

/-...v-

& 7.0KW BCGA - 60 HERTZ

5.0 KW BCG - 50 HERTZ

Publication # 038310

Edition Two

May 1993

'WESTERBEKE

• 150

J WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK

JOHN

HANCOCK AOAD,

TAUNTON"

MA 02780·7319 U.S.A.

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

Declaration of Conformity

Application

of

Council Directive(s)

Standard(s) to Which Conformity is

declared

Manufacturers Name

Manufacturers Address

of

Type

Equipment

Product Name

Model(s)

EMC

89/3361EEC

ISO 8846 1990(E)

ENS0081-1 ENS0082-2 ENSS020 ISO-8846-1990(E),

Numbers,

IWESOOI

Certification

& IWES002

Westerbeke Corporation

41

Ledin Drive

Avon Industrial

Park

Avon, Ma. 02322, USA

Marine Gasoline Generator

Westerbeke Marine

Gasoline Generator

3.0/4.5BCG, S.0/7.0BCG

7.0/9.0BTG

Product

Options

All

Supplementary Information

1.) The equipment listed

is

only for use in

Marine

Applications

aboard

2.) The equipment listed must be located below decks on the vessel and permanently instaUed in

3.) The equipment listed must be wired to the grounding system

I the undersigned, hereby declare the above Directive(s)

Place

Avon, Massachusetts,

Date: September

1,

and

1996

it's

location.

that

Standard(s).

U.

S.

A.

of

the vessel.

the equipment specified above conforms to

Carleton

F.

Bryant

(Full Name)

Chief Operating Officer

042022

(Title)

boats.

WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON, MA 02322 U,S.A

.•

TEL. (508)

588-7700.

FAX:

(508)

559-9323.

CABLE: WESTCORP

INTERNATIONAL

CERTIFICATION

TREVES

104.0

CENTRE·

BRUSSELS·

ruo de TR!::VES

BELGIUM FAX:

~

CERTIFICATE

We hereby certify the with

ISO 8846

and

MANUFACTURER:

ADDRESS:

MODEL NAME .OBCG

component

stated below is in accordance

has the following characteristics:

MARINE

INSTI'rUTE

TEL:

Int

+ (32) 2 238 78 92

Int

+(32)

2238 n 00

Certification number Signed Name Title Managing Director

Date

IWESOO1

WA'*e~

Lars

E.

<3tanholm

27-Aua-96

J~

...

~_

IMPORTANT

Product software of parts lists other than customers only

and

parts

Westerbeke,

as

all

kinds,

such

price

lists.

is

not within Westerbeke's control

a courtesy

PRODUCT

as

brochures,

and

other information, instructions

and

service.

SOFTWARE

drawings,

Westerbeke cannot be responsible for the content software, makes no warranties or representations timeliness incurred in connection with,

Forexample, components (such other products) must be

outdated rarely take

Westerbeke customers should also software, Additionally, most

or

as

engine blocks,

depend

and

has

notice

place.

and

completeness thereof, and will in no event be liable for any type of damages

or

arising out of, the furnishing or use

and

subassemblies

fuel

systems

are

generally supported by their

on

such

software for the design of

no

longer accurate.

in

advance,

the unavoidable

Westerbeke

are

frequently not

existence

products include customer-requested

and

Routine

keep

incorporated

components, transmissions, electrical components, pumps

manufacturers

Westerbeke's

changes

made

reflected

in

mind

the time

of

earlier,

non-current

indude complete documentation.

DISCLAIMER

technical

and

and,

accordingly,

data,

operator's

and

workshop

manuals,

specifications provided from sources

is

provided to

Westerbeke

of

such

with respect thereto, including the accuracy,

or

injury

of

such software.

in

Westerbeke's products

and

supplied by others

and

with their

own

by Westerbeke's suppliers, of which

in

the supplier's software until after such

span

between

Westerbeke

own

software,

product software.

printings of

software editions

special

features that frequently do

and

Westerbeke

Such

software

Westerbeke

in

may

changes

product

the

field.

not

In

summation, product software provided with suppliers, It

not

in

question

by the customer.

only

must

not

and

cannot

makes

good

sense

be

consulted to determine the accuracy

be

relied

upon exclusively

but

is

imperative that appropriate

Westerbeke

as

and

currency of the product software being consulted

products. whether from

the definitive authority

representatives

of

Westerbeke

on

the respective prod

Westerbeke

or the supplier

or other

uct.

1

Westerbeke Generators

FOREWORD

Thank

you for selecting a

you

as

a customer.

Read

this

manual periodic preventive maintenance procedures, installation ment

procedures

equipment

at

a high

carefully

are

Westerbeke

included

level

of efficiency.

and

observe

herein

marine

so you

and

product for your

all

safety

precautions included throughout. Operating procedures,

can

operate your equipment safely

expect dependable performance

use.

checks,

We

at Westerbeke

system descriptions

and

properly, maintain the

and

long

service

are

and

pleased

to

have

minor adjust-

life

in

return.

Should Service mance.

If, Identification

information, including the unit's

within

your unit

Organization

60

require

days of submitting the Warranty Registration

Card

fram:

special attention, contact your Westerbeke dealer for

is

trained to provide the support necessary to ensure long-term dependable

(see

below)

WESTERBEKE

AVON

INDUSTRIAL

AVON,

IU

Mall

To:

Form

for your unit. you

registering your warranty,

serial

number

CORPORA

PARK

02322

""VtT

liON

and

commission date.

I

please

WESTERBEKE

-,-_._

CUSTOMER IDENTIFICATION

Adam

S.ith

8S

"'_ple

Alden,

Model

Expires

Street

IN

12234

BeG

7.8

11/15/89

KW

Ser.

~

assistance.

have

contact the factory

..........

11234(986

'

._-

not

received

in

The

Westerbeke

a Customer

writing with

perfor-

Model

Westerbeke Generators

2

TABLE

OF

CONTENTS

Section GENERAL

7.0 GENERAL

7.0 SYSTEM

INSTALLATION DESCRIPTION

CONTROL

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

........................................................................... 5

KW

BeG & BCGA

SPECIFICATIONS

KW

BCG & BCGA

SPECiFiCATIONS

CHECKS

OF

PANEL PREPARATIONS STARTING STOPPING CARBURETOR ELECTRICAL

PROCEDURE

AND

SySTEM

............................................ 8

............................................... 9

................................................. 12

ENGINE

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

FOR

STARTING

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

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

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

FUEL

SYSTEM

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

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

Page

25 27 28

31

32 35

DC

CONTROL

WIRING OPTIONAL

WIRING COOUNG

LUBRICATION Be

GENERATOR

SCA

GENERATOR

GENERAL

OF

THE

ENGINE

CIRCUIT

DIAGRAM # 38028

REMOTE

DIAGRAM # 38024

REMOTE

DIAGRAM # 38025

SySTEM

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

SYSTEM

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

START

PANEL

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

INSTRUMENT

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

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

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

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

INFORMATION

GENERATOR

AND

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

TROUBLESHOOTING

CARE

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

MAINTENANCE & ADJUSTMENTS

38 & 39

PANEL

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

40

41

42 48 51 52

57 59 63

3

Westerbeke Generators

TABLE

OF

(CONTINUED)

CONTENTS

LAY-UP & RECOMMISSIONING SPARE TABLE

TIGHTENING TABLE

INDEX

PARTS

OF

UST

.......................................................... 74

STANDARD

TORQUES

TIGHTENING

HARDWARE

.................................................. 75

TORQUES

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

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

............................... 76

71

77

Westerbeke

Generators

4

GENERAL

Introduction

This

manual contains the equipment operating procedures as well the operator keep the marine equipment in proper working order. A planned maintenance program is included equipment performance and longer equipment to

satisfactory repair; therefore, a troubleshooting table

in

this manual; adhering to the program will result

life.

Proper diagnosis of a problem

is

included.

as

additional information

Study

and

follow the instructions carefully.

needed

is

the most important step

to help

in

better

Understanding

The

gasoline engine driving

cylinders are vertical in-line.

The

engine utilizes conventional points camshaft-driven. The engine incorporates a engine block which same

preventive maintenance that

to

the generators longevity are proper ventilation, maintenance of the

system, lubrication system

Ordering Parts

the

Gasoline Engine-Driven Generator

an

AC

generator

and

the engine's cylinder

is

thermostatically-controlled. To a large degree, the generator's engine requires the

is

required of a gasoline automobile engine.

and

the

AC

is

in

many ways similar

head

and

a

condenser~type

pressur~type

alternator.

to

has

an

overhead camshaft which

distributor which

lubrication

Whenever replacement parts are needed, always provide the generator KW

BeG). engine serial number, and generator serial number

the generator

identify your generator needed

parts, because "will

end

and on the exhaust manifold. You

set. In addition, include a complete part description and part number for

(see

the separately fumished Parts List). Also,

fit"

or

generic parts are frequently

CI11.lS.

be

as

they appear

provide us with this information so we may properly

sure

to

insist upon Westerbeke factory packaged

not

made

to

equipment. Note that component

pulley/drive belt the engine; imagine straddling the engine and facing in the side

is at your left, the right side at your right.

locations in the manual are referenced from the front of the engine which

end.

(The

flywheel/generator

end

is

the rear

end.)

same

Left

direction

a gasoline automobile

is

horizontally mounted

system,

fuel

model

the

and

and a fresh

The

most important factors

system. ignition

system,

number deSignation

on

the data plates located

same

specifications

right sides are determined

as

the front of the engine: the left

engine.

is

belt-driven.

The and

water~cooled

cooling

(Le.

7.0

on

each

part

as

original

is

the

by

Westerbeke generator sets

are

leaving the factory. Test running the generator ensures dependable operation, long service, and a satisfied

owner.

Care

at the factory during assembly driven generator capable of many thousands of hours of dependable turer cannot always control

in

which the unit

is

operated

thoroughly checked and given a final

and

thorough testing

have

run

under various load conditions before

resulted

in

service.

is

the manner or location the generator is installed

and

serviced

in

the field. That part

is

up to the buyer/owner-operator.

5

a Westerbeke gasoline engine-

However, what the manufac-

in

the

vessel

Westerbeke Generators

or the manner

Fresh

Water

7.0 KW BCG & BCGA Marine Gasoline Generator

Coolant Fill

Lube

Oil

Ffll

20

Amp

DC

Circuit

Breaker

HeatExChanger~

Exhaust

Temperature

Distributor

45°

Exhaust

DC

Battery

Connection

.Starter with

Switch

Elbow

Ground

Solenoid

Westerbeke Generators

6

Control

Panel

~

7.0

KW

Fuel

BCG &

Shut· off

BCGA

Solenoid

Marine

Gasoline

Generator

Air Intake

Flame

Arrester

Governor

AC

Connections

---

Outlet

Gasdenser

Lube

Oil

Drain

Hose

----

Water Switch

Sea

Temperature

Water

Pump

7

Westerbeke

Generators

7.0

KW

BCG & BCGA MARINE GASOLINE

GENERAL

SPECIFICATIONS

GENERATOR

SET

Engine

Type

Governor Combustion Chamber Bore

& Stroke

Piston

Displacement

Firing

Order Direction of Rotation Maximum Compression

Torque (at

Ratio

1800

Compression Pressure (Limit

Valve

of difference

Timing

between

rpm)

cylinders)

Gasoline, four-cycle, three-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism

(8

bhp at Hoof, Multi-sphere

2.62 x 3.19

51.6

1800

rpm,

maximum).

flyball type,

5%

speed

type.

inches (66.6 x

81

cubic inches (.846 liter)

regulation.

mm)

1-2-3

Clockwise,

when

viewed from the front.

13.5Ibf-ft

9.5:1

213.3

psi

(15.0

(28

psi

[2.0

kg/cm

Intake Opens Intake Closes

2SO

62°

kglcm

2

])

BTDC ABDC

2

at

400

)

rpm

Valve

Seat

Valve

Clearance

(engine Engine

warm)

Speed

Dimensions

Dry

Weight

Fuel

Consumption

Inclination

Angle

Exhaust Opens Exhaust

Intake Exhaust

1800 1500

Length:

Width:

Height: Approx.

0.8

Continuous

Temporary

rpm rpm

U.S.

Closes

45°

0.0098

0.0118 60

50

26.50

18.34

23.44 3091bs

gph

20°

hertz. hertz.

(3.02

14°

6z:'

BBDC

28°

ATDC

inches

(140.1

Iph)

(0.25

(0.30

(673.1

(465.8

(595.4mm)

kgs)

at full

(not to exceed

mm)

rated

output (approximate).

20

min.)

Westerbeke Generators

8

INTAKE SYSTEM

7.0 KW

BeG

& BCGA SYSTEM SPECIFICATIONS

Carburetor

(STD

IGNITION SYSTEM

General

Distributor Spark Plug Thread Size

Plug Type

Spark

SYSTEM

FUEL

General Fuel

type)

Manual with butterfly shaped

valve,

single barrel

with U.S.C.G. approved flame arrester.

Battery ignition, 12-volts (negative ground),

distributor with points, ignition coil and spark

plugs. Conventional, contact -point type. 14

x 1.25 mm pitch (0.55 x 0.05

in.)

Westerbeke part number 33805

(Always identify the generator model

when ordering parts.)

Conventional carburetor type with fuel pump. Regular

or

unleaded gasoline with

an

octane rating

of 89 or higher.

Fuel

Pump

Fuel

Screens

(on

Air cleaner

Row (engine combustion)

Air

COOUNG SYSTEM

General

Operating Temperature Fresh Water Pump

Raw

Water Pump

engine)

12.volt

Reusable screen type Metal

26.8

Fresh

DC;

lift capacity 5 ft

Oocated

screen type -cleanable.

cfm

(0.758 cmm) at 1800

water-cooled block,

(1.5

m)

at inlet

rpm.

thermostatically-controlled

with a heat exchanger.

130

-150°F

Centrifugal type, belt-driven,

(55

-

We)

1.13:1

to crankshaft.

Positive displacement, rubber impeller,

to

carburetor).

belt..(jriven.

9

Westerbeke Generators

Raw

Water Flow. at

1800 (measured before discharging into exhaust elbow)

System Capacity (fresh water)

LUBRICATION SYSTEM

7.0 KW BCG & BCGA SYSTEM SPECIFICATIONS

3.75

-4.0

U.S.

rpm

4.2

U.S.

gpm (14.19 -15.14Ipm)

qts (3.9 liters)

General

Oil Filter

Sump capacity (not including filter)

Oil

Operating

Pressure (engine hot)

Oil Grade

ELECTRICAL

Starting

SYSTEM

Battery

Battery Capacity

DC

Battery Charger

Starter

Fully - Force fed crankshaft

Full

flow, paper element, spin-on type.

type by Trochoid pump,

--driven.

P.N.036918

3.0

qts

(2.8

liters)

SE,

A-H

2

)

SF

or

in

cold areas).

10

50·70

API

12-volt. 24 (recommended)

24 - 28 (ampere-hours)

psi

(3.5

- 4.9 kg/cm

specification of

A-H,

(-)

(28

negative ground

Integral controller 13-volt.

in

the

AC

(located 12-volt,

1.2

alternator).

t<NV,

Magneto engaging type.

SG.

amp

No-Load Current

DC DC

Cranking Current

Westerbeke Generators

90 amp (max) at 11.5 volts.

100

-125

amps (engine cold).

10

AC

GENERATOR

7.0

KW

BeG & BCGA

SYSTEM

SPECIFICATIONS

General

Voltage

NOTE:

Rating

60

50

AC

BCGA

(volts

Hertz (1800

Hertz (1500 rpm)

Circuit Breaker

AC)

rpm)

models

are

60 hertz only. This

Brushless, Self

four-pole, revolving

field.

exciting. Capacitor saturated field excitation. Pre-lubricated, single-bearing design. Reconnectable

120 volts or 120/240 volts,

single-phase.

120 or 120/240 volts -

220

volts - 50

hertz.

Voltage regulation:

60

±S%

hertz no-load to

full-load.

Frequency regulation:

::t

3 hertz

(5%)

no-load to full-load.

model

cannot

120 volts

120/240 volts

220 volts

To

be

amperage

be

converted to 50

58

amps

58/29 amps

23

amps

rated

at 120% of the generator's

and

voltage output.

hertz.

rated

Generator Cooling

Requirements,

Air

at 1800 rpm

NOTE:

Increase air supply 15% for

Engine Combustion Requirements,

at 1800 rpm

TUNE-UP

SPECIFICATIONS

Spark

Plug Gap

Contact Point

Timing

Dwell

Angle

(60

hertz),

Air

(60

hertz),

Clearance

50

250 cfm (7.0

hertz

operation (1500

26.8 cfrn (0.758

0.028 - 0.031 inches (0.70 - 0.80

0.017 ~ 0.018 inches (0.4 - 0.5 mm)

10

58

0

::t

-

sse

.5°

cmm)

rpm).

BTDC

cmm)

at 1800

mm)

rpm

11

Westerbeke Generators

INSTALLATION CHECKS

General Since

the crafts according to your craft's specific on

procedures

are

details of the installation which require periodic checks to ensure the best operating conditions for the equipment gasoline

Factors

in provide air for engine combustion system,

to properly discharge

the cooling water supply; the electrical connections, both

unrestricted

in

which

Westerbeke

al

ready

well..cJevel

and

safe

operating conditions for the personnel

generator in the

vessel

the installation that

fuel

supply

and

generators

design.

oped

are

lIJ.US1.

and

raw

cooling water

The

and

well-understood.

of prime importance.

be

considered

to

remove

properly filtered

are

installed vary in design, installation procedures will

intent of this section is not to advise boatyards or installers

fuel

However,

on

board. Proper location

are

ventilation, to aid

heat

produced by the engine while operating; the

(sea

water); to quiet the exhaust

AC

and

to the

fuel

pump on the

the owner/operator must

in

cooling the generator

and

DC.

and a fuel

system that will provide

engine.

and

installation of

to

expel

realize

exhaust

CAUTION

vary

there

the

end;

to

exhaust

gas;

an

For safety leaving the factory,

This

as

a preservative, providing

generator

Inspection

The

generator

shipped

Before

and

require

in

accepting shipment of the generator

the contents inspected for concealed

the delivery agent sign

reasons,

the generator's engine

however,

each

generator set

testing, among other things, provides

reliable

is

properly stored.

of

Equipment

is

shipped from the factory securely mounted

a separate

small

box,

usually packed within the generator's

protection against corrosion for

set

from the transportation company, the crate

damage.

"Received

in

damaged

is

not filled with lubricating

all

the contents of the shipment against the packing list discrepancies

concerning loss or damage

exist.

These

noted

lllJJ.SI.

discrepancies

be

made

to the carrier. not to Westerbeke Corporation.

oil

for shipment.

is

thoroughly tested with

oil

in

internal parts with a coating of oil.

at

least one

and

properly crated. Accessory equipment

crate.

If either visible or concealed damage

condition"

and

make sure that the proper notation

are

your protection against loss or

on

the proper delivery receipt

its

engine.

This

oil

year

should

is

noted,

damage.

Before

acts

if the

be

you

Also,

is

made

is

opened

should

check

if

any

Claims

Westerbeke Generators

12

Rigging and Lifting

The generator is fitted with lifting eyes. Rope should lifting eyes have been designed required

be attached

or

desired.

must

Slings

to

the eyes and the generator lifted

to

carry the full weight

not

be

so

short as to place significant stress on the generator's lifting eyes. Strain

placed on the generator's lifting eyes

by

vertical plain.

or

chain slings capable

by

means

of

the generator; therefore, auxiliary slings are not

CAUTION

the lifting sling must

SLING LIFTING

ANGLE

MUSl

EXCEED

LIFT

EYE

10·

IIIG

of

supporting the generator's weight

of

tackle attached

not

be in excess

IIOT

to

these slings. The

of

10° from the

[.SIIIE

The general rule in moving generators

place. Move the engine a little by

avoiding haste.

to

lift the engine in positions other than the horizontal position. Certain situations exist

must

be

lowered endwise through a small hatchway which cannot be made larger. Under these conditions,

if the opening

Do

of

the hatchway is extremely small, it is possible

dimensions of the generator

at

a time and see that it is firmly supported. Eliminate the possibility

not

lift the generator

by

removing external components such as the cooling system's piping, the heat

is

to

see that all equipment used is

by

its crankshaft pulley. I n certain situations it may be necessary

to

reduce,

amply

strong and firmly fixed

by

which the engine

to

some extent, the outside

of

accidents

in

exchanger, certain filters, the mounting rails and other obstructive equipment. This accessory equipment should exposed parts. the removal position as soon as the generator has cleared the obstruction and is ready platform. Be sure

In case it becomes necessary attachment of lifting slings must be done the weight in handling

be removed

by

a competent mechanic and

In addition, be careful not

to

allow

special

dirt

care should

and foreign matter

of engine components. Removed parts/components should

to

use new gaskets where and when needed.

to

hoist the generator front-end upwards

of

the slings

heavy

may

bear. Special rigging

machinery.

carefully

to

avoid the possibility

work

is best done by someone experienced and competent

be

taken

to

avoid damage

to

enter any opening created by

be

returned

to

be positioned on its mounting

or

generator-end upwards, the

of

damaging the parts on which

to

their respective

to

any

13 Westerbeke Generators

Generator Mounting - Location

The complete generator unit is mounted on lightweight rails help prevent the transfer

1/2 inch bolt holes

These holes are on 13.5

of

vibration from the generator

so

bolts can be employed

or

14.5 inch mounting centers. Consult the sales brochure for exact mounting

to

the rails. Each generator mounting rail has several

to

properly secure the generator

specifications.

by

means

of

four flexible isolator mounts that

to

its mounting platform.

The mounting location from above cannot splash

lIJ.J.ml

be dry, above low-lying vapor areas, and in an area where bilge water and water

or

drip be accessible for minor servicing and repairs. Access for major repairs should well. The generator set

aJ1J.S1.

be properly ventilated engine combustion needs, and needs fresh cool air in whatever location in the vessel removed from the generator area. The platform on which the generator and its mounting rails are located

~

be

strong enough

Westerbeke

Generators

to

support the generator during all angles

(1/2-

on the generator

to

remove heat produced

~OUNTING

or

drive engine. The drive engine and generator

to

provide fresh cooling air

by

it is installed.

HOLES)

be

given consideration as

for

the generator end, for

the engine while operating. The generator set

Hot

generator discharge air

of

vessel operation.

14

lr!!.lSI.

!IJ.J.!.S1

be

Exhaust System

IWARNINGI

Carbon monoxide gas is deadlyl Carbon monoxide is a dangerous gas that can

unconsciousness and is potentially lethal. inhalation

or

poisoning

are

a Dizziness

o

Intense Headache

o Weakness and Sleepiness

The generator should exhaust manifold and cylinders or power in which conditions.

Special attention

case

have

the

its

own

is

vessel

lI1..U.S1:

listed below.

separate exhaust installed

prevented while the engine

may experience

be

taken to

Some

ofthe symptoms or signs of carbon monoxide

o Vomiting

a Muscular Twitching

o Throbbing in Temples

so

that the entry of raw water into the engine's

is

not running, or while the

heeling,

make

backing down from following

certain the exhaust system

leaks. The

raw

water supply through-hull

or

weedless scoop types must not

When used, as haust

a water lift type exhaust system is

the exhaust muffler should be mounted

close

to

the engine

discharge

as

practical.

should

downward into the exhaust muffler. Loops

sea

be

The

always

cock fittings

used,

as

they

ex-

drop

in

m.uM.

be

of

the flush-hull type. High-speed scoop types

tend

to encourage siphoning.

the exhaust hose between the water-injected exhaust elbow and the water should

be avoided,

as

these will trap

lift muffler

and

hold

water.

vessel

seas,

is

secure, tight

cause

is

or

and

under

sail

any other

free

of

For

installations

where

the

exhaust

manifold/water-injected exhaust elbow is

to

or

close

provisions

break

or

below the vessel's water

CIJJmI.

be

made

to

install

a vent in the

raw

water supply hose

line,

a siphon-

to the water-injected exhaust elbow. This

stops the flow of raw water that runs through

the raw water cooling system from filling the

when

always

all

angles of

vent

the en-

in

the

line.

be

The

hose

or

exhaust and engine cylinders gine

is

shut down. This raw water supply

hose

CllJml.

be

looped above the water line and the siphon-break or vent installed high point of the

This siphon-break or vent

loop above the water

aJ.lJS.

above the water line during

vessel vent, when tube routed

operation to prevent siphoning.

used,

l11.U.Sl

have

its

so

it can remain above the water line and empty of water when the engine is shut down. This allows air

to

this vent

prevent Siphoning.

to enter through

muml

5UEUlat

'UIV

U.IIE

IlAlEI

WUER

WE

LIU

15

Westerbeke Generators

Excessive back-pressure can be caused hose, a

in the exhaust hose, improper tings, water pockets, and a high volume tem discharge hose. The use and hose's routing should since these will create tions back-pressure. The generator's haust from system. Dry portions system between

haust manifold and jected

insulated

by

a small diameter exhaust

small muffler, sharp bends

of

water in

due

to

the length

fittings in

the

exhaust sys-

of

the exhaust

of

the

exhaust discharge

be

flow

and

contribute

system

any

exhaust

cmmt.

other engine's exhaust

to

hold in

to

be

of

the

engine's ex-

the

elbow

the

heat.

mIJ.S1.

fit·

elbows

limited restric-

exhaust

ex·

separate

exhaust

water in-

be

DRY

STACK

EXHAUST

Dry stack·type exhaust systems (shown above)

by

means water from entering cooling water.

of

a flexible connector pipe. This system

into

the

engine's cylinders. Provisions

tr.I.I.m1.

Exhaust Back-Pressure

The exhaust discharge hose

to

minimal run Exhaust back-pressure should be checked before a ator is

put

back-pressure will affect

affects generator

To

measure

a pressure gauge. mechanic should have a manometer If

the generator set

exhaust elbow,

fitting in

NPT

Measure the engine's back-pressure

while the generator is under a

prevent excessive exhaust back-pressure.

into service. (Refer

AC

power

for

back-pressure, use a mercury manometer,

or

a water column. A boatyard

does

one

must.

the

dry

area

~

be

of

adequate size and

to

the illustration.) Excessive

the

engine's performance which

output.

or

a pressure gauge.

not

have a tapped hole in its

be

drilled and tapped

of

the

elbow.

at

full-load.

for

the exhaust elbow

or

a 1/8 inch

be

attached

~be

gener-

marine

to

the

generator engine's exhaust manifold

property supported and insulated

CIJ.USt.

be

made

for

discharging

to

the

engine's raw

Exhaust Elbow

Exhaust

prevent

Refer

to

the pressure specifications listed on

page.

Westerbeke

Generators

the

following

16

A water column and the Tap)

taping

other

one

end

of

pipe fitting.

can

be

made

by taking a clear plastic tube

end

of the tube along a yardstick

the tube with a

1/8

inch

NPT

and

(National

fitting

Pipe

Measure

while the generator

Dimension Back

not

Exhaust System Failures

When erosion

orwater injected

so

entering

in

the

engine's

A cannot

pressure,

exceed

3 inches of mercury (0.104 kg/cm

as

the following specifications:

39 inches of water

22 ounces 1 1/2 psi

psi

the engine's

takes

place.

that the

diameter

entering

raw

as

water

possible.

back-pressure

is

under a full..foad.

exceed

measured

in

a water column

(.099 kg/cm

raw

water is

This

erosion

''Wef'

exhaust

stream

should

39

by a

fed

of

raw

at

the

inches

2

may

system

of

gauge

instrument,

2

)

at 40 C)

into

an

exhaust

cause

to prevent this problem requires that the

water does not

be

as

low

exhaust

water.

system

premature

as

possible.

elbow

should

so that the full

failures.

directJy

which

The

strike a

can

stream

of this water strikes a

proper design of either a

raw

water inlet be

surface.

be

achieved

In

addition, the velocity

by

having

surface.

water

jacketed

positioned

inlet fittings

of as

the

big

The

best protection against carbon monoxide poisoning Check areas

the

inspected Make

installed weight could insulated

for

leaks

around

excessively.

sound

or appearance

and

sure

there

off

the

repaired

are

exhaust

cause

portions

Prolonged exhaust pumping can Prevent exhaust

start. Engine

system

raw

enter the engine's cylinders by way

this

muffler,

the owner/operator

manifolds,

If

excessive

of

the

at

once

no

unnecessary

manifold

deflection or distortion of the manifold resulting

of

the

exhaust

cranking

with

intervals

raw

water through

from

happening by closing the

and

correct the

damage

resulting

should

gaskets,

heat

exhaust

is

present.

and

system,

by a qualified

objects

should

water

not

system

without

coolant. This

the

raw

to

the

water cooling

cause

from this type

keep

this

in

suspended

exceed

ensure

for the

is

a daily inspection of the complete

welds.

Make

sure

correct the situation

shut

down the unit immediately

mechanic.

from any portion of the exhaust

Ilbs

in

total weight

there

is

no

CAUTION

engine

starting

may

happen

can

system

of

the exhaust manifold

raw

water

supply through-hull shut-off, drain

excessive

of

raw

water entry is

mind.

exhaust

lines

are not

immediately.

If

heating

you

and

notice a

have

lines.

when

rigidly constructed.

in

damage

and/or intemalleaks.

deterioration of the insulation.

result in filling the engine-mounted

because

during cranking.

engine cranking

once

not

the

raw

water

This

the exhaust

needed

a warrantable

pump

raw

system

to obtain a

system.

surrounding

change

the

system

Exhaust

risers

Excessive

Inspect

is

water

fills.

the

issue;

in

17

Westerbeke Generators

Exhaust

Elbow

Installation

The Westerbeke Corporation offers a 45°and

900exhaust

elbow as well as an exhaust riser you can install on your

to

generator. Refer the exhaust elbow purchased

NOTE: Fabricated exhaust elbows tached

Ibs

when

1.

Coat

only one side

Tack"

adhesive sealant. Place this coated surface

the instructions below when installing

for

your generator.

to

the exhaust manifold shall

unsupported.

of

the exhaust gasket with *"High

or

not

exceed 8

risers at-

against the exhaust manifold's exhaust port flange (the gasket should stick

to

the

flange without falling off).

2. Place the clamp over the elbow's flange. Place your

exhaust

elbow against

the

exhaust manifold's flange so

the exhaust manifold's flange rests snug against the

exhaust elbow's flange with the gasket centered

tween the two.

Now

slip the exhaust clamp over both

be-

flanges.

3.

A.

Tighten the clamp just enough so the exhaust elbow

to

can remain attached

the manifold and still be

rotated.

EXHAUST

CLAMP

MANIFOLD

FLANGE

451>

ELBOW

Kit * 037402

B.

The exhaust elbow discharge

downward

gases

which There should

connected between

so

the mixture of raw water and exhaust

will flow/fall downward into the exhaust muffler

~

be

positioned below the exhaust elbow.

be

no

loops

or

the

exhaust elbow and the muf-

lIlLI.St.

be

rises in the exhaust hose

fler, as these would trap water and possibly allow water

to

flow back into the engine during starting or

at shut down.

4.

Adjust the elbow ment

with

the exhaust piping is acquired.

5. Carefully tighten the clamp between 2

to 35 Ib-in,

or

0.27

by

rotating it until the desired align-

to

3 Ib-ft, or 24

to

0.41 kg-m.

CAUTION

Approach the 3 Ib-ft torque limit with caution. The

clamp's threads will break if more than applied

If a leak exists, correct it immediately.

to

the clamp.

directed

3 Ib-ft

is

EXHAUST

CLAMP

90°

ELBOW

Kit*037401

by

* Manufactured

Permatex Company, Brooklyn,

Westerbeke Generators

N.Y.

18

Fuel System

The generator and primary fiJter/Water separator. tank(s) are level

of

engine is through the supply line into the engine through the carburetor, should the carburetor float needle valve stick in the open position

This (anti-siphon) shut-off valve can be e1ectrically-operatecf (with a manual override) generator's engine is started, and valve can also deck. supply

(anti·siphon) shut-off pickup at the tank and the service shut-off valve located

The Guideline. These Hlustrations show basic fuel system layouts that incorporate anti-siphon protection.

All

be supported every 12 - 14 inches. Use as few connections

The fuel tank's vent should fuel tank(s). Moisture must

Installations where the generator is located above the fuel tank(s), whereby the routing of the fuel

line

two

fuel

lines should be routed and supported

l1lU.S1.

have its own fuel supply line; in other words, it

Do

not

tee off another engine's fuel supply. Installations where the fuel

at

or

above the generator, with the fuel supply lines

the fuel tank's top,

not

running. This installation procedure helps guard against the possibility

or

be

installed and should

to

the generator's carburetor remains above

illustrations that follow were taken from the Coast Guard publication Fuel System Compliance

011J.S1.

have a means

not seat propeny,

to

valve. A manually-operated service shut·off valve should be located between the fuel

be

located

not

be allowed

or

close when the generator's engine is shut down. A manually-operated

be

operational from the generator's start/stop panel

so

that its discharge route

of

shutting off the fuel

should the fuel line rupture between the engine and fuel tank.

the

at

the fuel connection

to

prevent leaks from vibration and chafing. The line should

to

accumulate in the vent's line.

~

have its own fuel tank pickup tube

to

the engine's carburetor routed below the

to

the generator's engine when the

of

gasoline Siphoning

to

open when the

or

from the vessel's

top

level of the

as

possible in the plumbing of these lines.

cannot

fuel

tank,

to

the generator.

allow water

do

not require this

to

enter through to the

fUEL

TOP

FUEl

LINE

LEVEL

TANI

ALWAYS

TOP

lEYEL

ABOYE

10

ANTI-SIPHON

"'-

_FUEL

fUEL

TANK

TOP

LEVEL

DEVICE

OPERATED

NOT

ACCEPTABLE

OR

VALVE

NEEDED

~=UEL

ELECTRICALLY

TANI

19 Westerbeke Generators

-..r-

___

~

ANTI-SIPHON

_

OPERATED

DEVICE

FUEL

STOP

OR

ELECTRICALLY

UALVE

FUEL

LINE

BELOW

FUEL

TANK

ANTI-SIPHON VALUE

FUEL

TAN[

TOP

FUEL

LINE

TOP

L

!

NOTE: is

not recommended since these may

valve.

In

addition, if a check valve's cracking pressure

EUEl:.-_

ANTI-SIPHON STOP

VALVE

60ES

BELOW

The

use of mechanical spring-type check

A check valve

AT

FUEL

LEVEL

ABOUE

DEVICE

.....

DEVICE

AT

FUEL

OR

TANE

WITHDRAWAL

FUEL

TANK

~-==-:..

______

FUEL

OR

POINT

WHERE

TANK

TOP

can

trap debris under its

ELECTRICALLY

-----'\",....,j'

LINE

BELOW

TOP

ELECTRICALLY

FUEL

lEVEL

tax

;;; L -;;;;-

TOP

lEVEL OPERATED

FITTING

ANTI-SIPHON

J'

OPERATED

FUEL

LEVEl

OPERATED

DISTRIBUTION

valves

the

fuel

pump's ability

seat

which inhibits the valve's ability to close.

is

too

T;;

high,

LEY

FUEL

LINE

instead

this

El

:;::;r

STOP

DEYICE

FUEL

STOP

OR

ELECTRICALLY

VALVE

of a solenoid shut-off valve

to

draw

fuel

through a check

can

contribute

to

vapor lock.

Should a mechanical type, spring-loaded check

as

such

a Weatherhead #43 x

cracking pressure

as

to

excessive

prevent the

that will prevent siphoning

6.

This adjustable type valve should

fuel

pump from drawing

The installer should install an approved fuel finer/water separator

to

tank and the generator's engine

help remove contaminants in the fuel before the fuel reaches the

engine-mounted fuel pump and carburetor.

valve

be

used,

when

the generator

fuel

through the

it should

in

be

an

adjustable type,

be

adjusted to

is

not operating but not so

valve.

the fuel supply between the fuel

Such contaminants can cause the failure components and such failures are not warrantable. Owner/operators are advised sibility

to

maintain finer/separators so that contaminants

do

not reach the engine's fuel system.

IWARNINGI

Fuel

leakage

explosion. Repair leaks

in

or around the generator compartment

promptJy

and

make

sure

the compartment

is

a potential

cause

is

properly ventilated.

of fire and/or

have

a

of

these system

it

is

their

respon-

Westerbeke Generators

20

Oil Drain Hose

An

oil sump drain hose is installed on the engine with the discharge

the engine.

Oil may

be

drained from this hose by removing the cap and the discharge

end

secured by a bracket at the front of

the support bracket and lowering the hose into a container. The hose cap fitting Pipe

Tap) and can be extended or

have

a pump added, by the operator, for easier removal of the old

desired.

end

is

1/4 inch

of the hose from

NPT

(National

oil,

if

Connecting Pressure Sensing Devices

Oil

pressure sensing devices, such

use

with the of the

of extended nipples or

fittings used

to

make such a connection. If these fittings fail, the engine loses its oil pressure

as

tees.

to

senders

The

Oil

Galleries

and

switches, must

reason

is

not

be

connected to

simply that continued engine Vibration causes fatigue quickly seizes. When

additional sensing devices such as switches or sensors need to

oil

pressure, these devices grade of lubricating oil iron composition. Brass must

Raw Water Intake System

Make

sure the intake system (raw water cooling cock and strainer are unobstructed. inlet thread of the raw water pump.

while the vessel is at

raw

water lines to make sure there are no collapsed sections, which would restrict water flow.

m.u.s1.

hose.

sea

and should

be

bulkhead-mounted

Any fittings

not

be

used

Sea

The

be

and

connected to the oil gallery using

used

to connect the hose

for this application.

system)

is

in proper order. Check that the

cocks and strainers should be at least one size greater than the

strainer should

be

of the type that may be withd

mounted below the water line to ensure self-priming. Inspect the

be

installed that function

to

the gallery must

be

there are no air leaks at any of the connections.

Cooling System

an

engine's

of

steel

rawn

oil

gallery

on

engine

an

appropriate

or malleable

hull

inlet,

for cleaning

Make

and

sea

sure

The

generator's engine

is

fresh water-cooled by mounted heat exchanger. exchanger's cooling medium. exchanger

by a raw water pump and

exhaust for discharge, carrying with it the the engine's fresh water cooling system.

Raw

water should

a

flUSh-type between the through-hull raw

water pump. This raw water should

be

supplied to the

through-hull fitting using a wire-reinforced hose

fitting

visual-type raw water strainer for delivery to the pump. Hoses routed from the through-hull fitting to the raw water system on the engine should

prevent the hose from collapsing during the generator's opera-

tion (suction from the pump may collapse a non·reinforced

hose).

water line

Raw

water strainers should be mounted at or below the

to

make sure the strainer

shutdown.

Raw

water

to

and

an

is

used

as

water

is

pumped into the

is

then injected into the

heat

removed

raw

water

pump

the gasdenser

be

directed through a

be

wire-reinforced

line

remain

and

primed after

engine-

the heat

from

through

to the

raw

water

21

to

Raw

water

Pump

Westerbeke Generators

Belt

tension

318-V2

deflection

inch

at

CAUTION

Do

not

use a

scoop

to

water

can push

filling it and the engine's cylinders as well. Aush-type, clear, through-hull fittings are recom-

mended and should be located on the hull so as of boat operation.

the generator. Water pressure against this type fitting, while the vessel is under way,

raw

or

weedless scoop-type through-hull fitting as a means

water past the raw water pump's impeller into the generator's exhaust system,

to

be

below the waterline during all angles

of

supplying raw

NOTE:

Westerbeke Corporation

The use generally have

Raw water entry into the engine cylinders is a warranty issue with

of

common-type street elbows is not recommended

very

restrictive inside diameters. Machined fittings

for

plumbing

with

true inside diameters are preferred.

Electrical System

The electrical system should be checked clamps from vibration. appropriate terminals. Also, ensure that these terminals are not the recipients leaky hatch covers

DC Electrical

A tagged common ground stud

generator, next connected at this stud.

Connect the

or

plastic ties and that all wiring harnesses are supported at intervals close enough

Check

Connections

battery's positive ( + ) connection

to

make sure all engine harness connections are tight and that they are made

or

corrosion will result.

for

to

the starter, in the form

to

make sure all wires and harnesses are properly tied down with

the negative

of

a threaded grounding stud. The

(-)

DC terminal connection is found at the bell housing

to

the starter solenoid tagged

for

the

installer,

the

raw water circuit. These

of

bilge water

DC

battery ground should be

this connection.

not

the

to

prevent chafing

or

water from

to

of

the

To

avoid an overcharging condition and a possible equipment failure,

DC battery source while the engine is running.

Grounding

The generator set specifies that a propulsion engine's grounded starter motor circuit. This tal passage of cranking current through fuel systems and smaller electrical conductors common engines. This conductor

must.

be grounded

common

conductor

CD1.lSt

be the same size

Westerbeke Generators

CAUTION

do

not

disconnect the

to

comply

be

with United States Coast Guard regulation 33 CFR-183 which

connected between the generator set and the vessel's main

conductor

as

the largest battery cable.

(the

common

ground) prevents acciden-

22

to

the

Automatic

High

An

exhaust

voltage to the ignition

exhaust switch opens at 260 -2700 F (127

High

A

high

the

DC

temperature

Low Oil Pressure Shutdown Switch (normally open)

A low

engine DC

voltage to the ignition coil

High

Shutdown

Exhaust

Water

oil

RPM

Temperature

temperature switch

temperature

Temperature Shutdown Switch (normally closed)

water temperature switch

voltage to the ignition coil

reach

approximately 2050 F

pressure

oil

pressure.

Shutdown Switch

shutdown

Shutdown Switch (normally closed)

is

located

coil

(which turns

(an

inadequate

-13T

is

(which

switch

Should the engine's oil

(which

on

the

OFF

the

supply of

located

C)

raw

and

on

turns

(gao

C).

is

located off the engine's

pressure

turns

OFF

exhaust

engine),

resets

the thermostat housing. OFF

This

the

elbow.

This switch will open

should the switch's sensor indicate

water coolant

at approximately 2250 F

the

engine),

switch

fall to 10 - 15

causes

should

resets

oil

high

This

the

fresh water coolant's

0

at 195

F

gallery. psi,

the switch will

exhaust temperatures).

(lOr

switch

(lor

The

engine).

and

C).

will

C).

switch's

open

interrupt

an

open

and interrupt

is

kept

interrupting

the

DC

excessive

This

operating

closed

by

the

An

overspeed engine's switch.

Generator

Make

sure

with the specific

section of this

Batteries

Make

sure

The

negative

Do not smoke or allow

shutdown switch

speed

(Make

sure

(Ae

Output)

that the

manual.)

the positive ( + ) battery connection

(-)

highly.-explosive

shuts

OFF the generator

reach

approximately 2175

the

cause

of

the

engine

AC

output connections within the generator's distribution box

AC

Load

Connections diagram

battery connection should

rpm.

overspeed

is

connected to the battery connection

be

connected to the

set

by grounding out the ignition

Reset

this switch by momentarily depressing

found

shutdown

later

in

is

this

system

IWARNINGI

an

open

flame

near

batteries.

Lead

gas.

system

should

the

corrected.)

are

tight

and

in

accordance

manual.

ground

(See

the

of

(the

engine block).

"BC

GENERATOR"

the starting

acid batteries emit hydrogen, a

the

STOP

solenoid.

23

Westerbeke Generators

IWARNINGI

When servicing the battery apron, and eye protection. Battery acid may splash on the skin when removing the electrolyte caps.

the

Check sure the battery's terminals are clean and tight.

battery's electrolyte level and specific gravity

or

checking the electrolyte level, wear rubber gloves, a rubber

to

ensure maximum engine starting efficiency. Make

Ventilation

The ventilation requirements

engine the generator's engine during operation; and ventilating air is required as well as the compartment in vapors.

Keep in mind that

compartment and cool fresh air should be directed

cylinders; cooling air is required for the generator end and also

hot

be accomplished with the aid

SPECIFICATIONS"

section

of

air rises,

of

this manual

the

generator sets include the following: combustion air is required for the

which

the generator is located,

so

heated air should be removed from the upper area

to

the lower areas

blowers especially when the vessel is not underway. Refer

for

the airflow requirements of the generator set.

of

potentially toxic and flammable gasoline

or

into the eyes inadvertently

for

removing the heat produced

to

clear the bilges below the generator,

of

the generator

ofthe

compartment. Ventilation should

to

the "SYSTEM

by

Westerbeke Generators

24

General

DESCRIPnON

OF ENGINE CONTROL PANEL

The engine-mounted control panel is equipped with an ON switch, a panel also has

1.

ON Swjtcb< The ON switch provides power

protective oil pressure shutdown switch until the engine's oil pressure reaches

two

fuses

to

protect the DC circuit. The three switches serve the following functions:

to

the

START

circuit. This switch also bypasses the

switch, and a STOP switch. The

10 -

15

psi once it is

started.

2.

START: The START switch energizes the starter's solenoid which cranks the engine. This switch will not

operate unless the ON switch is depressed and held

3.

SIQe.;.

depressed until the generator comes

The engine mounted control panel has two protective fuses incorporated in it. A 15 amp fuse protects the

start circuit and an 8

or

instrument panel installed.

The STOP switch is used

amp

fuse protects the operating circuitry on the engine and any remote start/stop panel

to

stop the generator. This switch must be depressed and held

to

a complete stop.

at

the same time.

25

Westerbeke Generators

Optional Remote

An

optional

a water

tem

remote

perature

switches.

Instrument

instrument

gauge,

oil

and

Remote Start Panels

panel

is

available,

pressure

gauge,

which

includes starting controls. This

battery voltmeter, operating hourmeter

panel

also includes

and

start-stop control

REMOTE START PANEL

The

remote temperature sender The

water temperature sender

adjacent to the oil

Electrical connections for

instrument

NOTE:

The

connection

When

installing

panel

has

with

and

the

other,

an

is

installed

pressure

blue

is for the water temperature

switch.

each

sender

colored connection

the

optional

remote

the installer's responsibility to comply with

An

optional

Remote purpose

that the generator

remote

start

ofthe

panels

LED

set

start

panel

is

available

include a

is

to alert the operator to

is

green

running.

it

two

oil

Use

are

sending

pressure

in

the thermostat housing

sealing

tied off adjacent to

is

units to

sender.

compound

for the

oil

be

Plugged

on

the

each

pressure

sender.

IWARNINGI

start

panel

or the optional remote instrument

U.S.

Coast

Guard

for controlling the generator from a

LED

which lights

release

when

the

engine

the

starter toggle switch

REMOTE

installed

ports for

and

I

NSTRUMENT

on

the

each

the

threads of both

sender's location.

sender

Standards

runs

at approximately

in

PANEL

engine

oil

pressure

and

33 remote

are

located

senders

the

CFR

block.

on

sender

when

tan

colored

panel,

PART

183.

location.

600

One,

the

is

installed

installing.

it

is

rpm.

a water engine.

The

addition to continue indicating

Westerbeke Generators

26

PREPARATIONS

This

section of the warm), and stopping procedures. your Westerbeke generator

Take

the steps described below

manual

provides the operator with preparation, initial starting, break-in, starting

Follow

set

will give you reliable performance and long service

in

starting your engine for the first time or after a prolonged shutdown or

the

lay-up.

Fill

your engine with

on

the dipstick (the installation angle of your generator

may

have

an readily available lubricating SE,

SF

or

SG

and

ture in your operating

in your generator's engine, refer

SPECIFICATION"

oil

up

to but not over

effect

on

the dipstick reading). Select a

oil

with

an

SAE

number suitable for the tempera-

area.

For the quantity of oil needed

section of this manual.

an

the

upper limit

API

specification of

to

the "SYSTEM

FOR

procedures

set

STARTING

as

presented, for the conditions indicated,

life.

UPPER

(NORMAL

(cold

lIMIT

LEUEL)

or

and

Each

unit

is

supplied with a coolant recovery kit (part

#249n)

and

Fill

as staooard equipment which

~

be installed

the following applies:

A.

Remove

with a mixture of water

section of this manual.)

B.

Make

location where it

be

below the manifold

C.

Coolant should be added to the plastic recovery tank after the engine

its operating temperature and the engine's cooling the

the

the pressure cap from the engine's exhaust manifold and slowly fill the engine's cooling

and

antifreeze suitable for your temperature zone.

Replace

sure the plastic recovery tank

can

be

monitored and filled easily

mounted at manifold

level

is

permitted.

has

system.

J:Mastic

fuel

recovery tank half full. Monitor this recovery tank daily and add coolant

tank with unleaded or leaded gasoline that

the pressure cap on the manifold.

is

properly mounted near the unit (with the bracket provided)

(see

"COOLING

or above, however, if the installation does not permit

been

reached,

With

make sure

all

the manifold filled completely and the pressure

has

an

octane rating of

LOWER

(See

the

"COOLING

SYSTEM").

The

recovery tank

this,

has

been

filled and started. After

air

is

expelled out of the engine's manifold

cap

as

needed.

89

or higher.

LIMIT

system

SYSTEM'I

should

mounting

installed,

in

a

it

fill

27

Westerbeke Generators

STARnNG

IWARNINGI

PROCEDURE

1.

Ventilate

Carbon

the generator compartment for a

monoxide

minimum

exhaust

of 5 ventilating blowers remove potentially explosive gasoline bilge.

2.

Depress

the ON switch

and

hold it depressed for 5 to 15 seconds to

engine is primed to the carburetor. Continuing to depress the

3.

Depress switch shutdown circuit until the

the

START

depressed

switch.

When

the generator

for a few seconds longer.

oil

pressure

rises

starts,

(Keeping

the ON switch

enough to close the switch internally

circuit.)

4.

Release

the ON switch.

NOTE: switch

The

is

carburetor

has

an

electric choke solenoid that

depressed, applying positive choke function during starting.

CAUTION

When

starting the generator,

until

the engine

will

prevent damage caused by the unanticipated operation of

has

come up to

all

AC

loads, especially large

speed

and,

in

cold climates,

a cold engine from stalling.

gas

is

minutes

fumes

ON

release

motors,

starts

deadly!

prior to starting the generator.

from

the generator compartment

make

sure

the

fuel

switch,

only the

closes

AC

proceed to step #3.

START

depressed

bypasses

and

the

choke

should

to

warm

machinery

be

up.

and

switch.

the

maintain the ignition

when

the start

switched OFF

This

precaution

will

prevent

system

Keep

oil

pressure

on

the

The and

the

ON

Prolonged cranking intervals without the mounted exhaust system with raw water coolant. This pump is pumping raw water through the water

can

enter the engine's cylinders by way ofthe exhaust

fills.

Prevent

this from happening by closing the

the exhaust muffler, and correct the

a start.

the owner/operator should

Once

the engine starts, ensure raw water flow instruments starter while the engine

temperature to come

NOTE:

out

Engine

are

Some

as

the operating temperature

damage resulting from this type

installed, for proper

is

running. Apply a light

up

to

130

- 150° F (55 -

unstable running may occur

keep

this

oil

pressure and battery charging

cause

in

is

reached

raw

mind.

5SO

applied to the generator.

CAUTION

engine

starting

may

water cooling

raw

water supply through-hull shut-otf, drain

for the excessive

of

raw

water entry

is

discharged with the

load

to the generator

C)

before applying

in a cold

(130

engine,

- 150° F

can

result

happen system manifold

engine

cranking

is

exhaust

vottage.

any

but

this

[55 -SSO

in

filling the engine-

because

during cranking. This

once

not a warrantable

the

raw

the

exhaust

needed

and

to obtain

check instruments,

water

raw

system

issue;

Never attempt to engage the

and

allow the engine's operating

heavy

loads.

condition should smooth

C])

and

when

a load

if

is

Westerbeke Generators

28

Break-In Precautions

Because control attempt

Upon starting

first

After the first

Pericxiically vary

Avoid over1oad at frequency. Monitor the current being drawn from the generator and keep

Be aware

3 - 5 times the amperage draw during normal running (see the

INFORMATION

the

generator set operates at 1800 rpm

of

the generator's engine break-in

to

break-in

10 hours

of

your

generator set

the

generator set, check

of

the generator's operation, run the generator set between 20 and 60 percent

10 hours

motor

of

the generator's operation, the load may be increased

the

load.

all times.

starting loads and the high current draw required for starting motors. This is upward of

AND CARE OF THE GENERATOR" section).

An

to

is

governed

by

running it without a load.

for

proper AC output and engine operation; both are related. For the

overload is signalled

produce

by

60

hertz,

or

by

the current drawn from the generator.

a smoky exhaust with reduced output voltage and

"Amps

for

Starting Under Normal Conditions

Follow the procedure below

Check the engine's lubricating oilleveJ prior at

the high mark on the dipstick.

for

routine starting

of

the generator:

to

each day's use. Add oil as needed and maintain the oil level

at

1500 rpm

to

produce 50 hertz,

Do

not

of

full-load.

the rated full-load output.

it within the generator's rating.

Startingll chart in the "GENERAL

Check the coolant level in the plastic recovery tank.

NOTE: Excessive loss system leak. pressurize the system

Check the entire cooling system, as well as the coolant recovery system, and

of

fresh water coolant from the plastic recovery tank indicates a cooling

to

locate the leak. In cases

be refilled as outlined under the IIPREPARATIONS

Visually examine the unit;

to

Check contaminants.

Start the generator, following the procedure engine's operating temperature

make sure there is sufficient fuel in the tank and examine the filter/water separator bowl for

Oean

look

for

any

abnormalities and correct them as needed.

and drain the bowl as needed.

outlined in the "STARTING PROCEDURE" section, and allow the

to

reach 130 -150° F

load.

Starting Under Cold Conditions

Under extremely cold temperatures, when operating

Lubricating

prevailing atmospheric temperature. Refer atmospheric/oil viscosity specification table.

your

generator set in cold weather.

oil

turns viscous - Make certain that the lubricating oil used conforms with the ratings for the

the

following conditions can occur. Follow the instructions listed below

to

the "LUBRICATION SYSTEM" section of this manual for an

(55

of

excessive

FOR

STARTINGII

-W

C)

codant

before placing the generator under a heavy

Joss,

section

the system

of

this manual.

must

29

Westerbeke Generators

Voltage across battery terminal drops -

drop across the battery

terminals.

Remote Starting Procedure The

remote start

When

starting at a remote location, the

rpm.

This indicates

panel

when

is the

the

same

START

as

switch

audible.

A.

When

starting the generator

set

at a remote location,

lights but continue depressing the

ON

switch

B +

B.

After the generator

ON

switch first.

untO

path

to the ignition

the oil

pressure

is

system.

is

started, the generator's starter

Make

certain that the battery

the engine-mounted start

green

LED

lights

when

the generator

can

be

released

since the starting of the generator

release

ON

switch. After

sufficient

to

close the

releasing

oil

will

is

fully charged to minimize voltage

panel

except that it

is

the

START

the

START

pressure

not

safety

crank until someone

has a green

running at approximately

switch

when

LED

may

not be

the green

light.

600

LED switch, continue holding the switch, providing the normal

again

operates the

Westerbeke Generators

30

1.

Remove

the

AC

electrical

load

stabilize its operating temperatures.

2.

Depress

3.

Now

the

release

STOP

the

STOP

switch

switch.

and

from

hold it

STOPPING

the

generator

until

the generator

PROCEDURE

and

allow the generator to

is

completely stopped.

run

for 3 to 5

minutes

to

Remote

To the engine's ignition circuit. stop.

between in

Stopping Procedure

STOP

the generator, depress the

Remote

the

IIELECTRICAL

the

start

T·1

panels

and

T-2

SYSTEMn

STOP

The

STOP

switch which

switch

lllIm1.

be

opens

held

open until the generator comes to a complete

may be connected to the generator set

connections at the

section of this

panel

connection terminal board.

manual.)

the normally closed B + path for voltage to

as

indicated. A jumper

(Refer

Overspeed Shutdown Should the generator

attempting

to

restart the

switch momentarily If the

overspeed

lift the T

-1

coil connection from the switch

the generator with the

Replace

the

overspeed

shut

gene~tor.

and

then

switch itself

overspeed

switch

down from

an

overspeed

Resetting

the

condition, the overspeed circuit must

overs

peed

switch

is

done by simply depressing the

proceeding with the normal starting procedure.

is

faulty

and

switch

to

maintain

resetting and

bypassed.

this

it

tape the

safety

by depressing the

end

of the T

Bypass

-1

wire with electrical

this circuit only

circuit's integrity.

STOP

switch will not

to

test the overspeed circuit.

IWARNINGI

The overspeed shutdown must always be installed and functioning. Any tampering with the overspeed shutdown injury should the generator's belt-driven governor

module,

which would

cause

fail

it

to

malfunction, could

and

cause

the generator drive engine to

be a cause

overspeecl.

has

to

be

to the wiring

be

reset

the circuit,

tape.

Do not

removed

diagram

before

STOP

operate

of

31 Westerbeke Generators

Gasoline

CARBURETOR AND FUEL SYSTEM

Use unleaded

or

leaded gasoline with an octane rating

In cold weather particularly, water vapor is produced Keep

fuel tank(s) full and completely free

The carburetor is a single barrel,

down--draft

of

dirt and water.

type

arrester.

of

89 or better.

by

condensation when air is present in the fuel tank.

with a cleanable metal screened air intake filter/spark

.:

Choke

.

(Enla.rced.

Solenoid-Remo

View)

....

ed

Westerbeke Generators

32

Optional Fuel Filter/Water Separator

A primary fuel fitter of

separating type

tween

the

fuel tank

This

is

to remove water

taminants from the

be carried

gine engine fuel

where

stoppage

system

to

the

they

equipment

~

fuel

can

and

the

water

be

installed

and

the

engine.

and

other con-

fuel

before they can

system

cause

unwanted

damage

on

the

Most installers do include with erator installation

ter/Water

separator for they

package

a type of fil-

are of the problems contaminants fuel

can

cause -

wa.rrantable A typical

fuef

lustrated at the right.

Raycor use

with

Modef

marine filter/water separator should fuel

be

system.

all

of which

through

Westerbeke.

fitter/Water

110

and

are

separator is il-

This

is

approved for

gasoline products. A

of

this type

part of your installation's

on

the

to the

engine.

the

aware

in

the

not

the

be-

en-

gen-

Replacing Filter Elements

The

generator manual to

as

the

To

remove

has

modef

one

fuef

inlet filter

the filter

covered

filter

screen

screen.

screen,

unscrew

filter plug and remove the

screen Clean

new

behind the

the filter

one.

plug.

screen

or

replace

Periodically check this filter

by this

referred

the

fuel filter

it with a

screen.

33

Westerbeke Generators

The

is

engine

free

mounted

of water or other types of

Periodically check the

and

that the fittings

DC

to the pump

should

be

clean

is

clean.

and

are

fuel

pump

fuel

connections to

tight

well

secured

requires

contaminants

and

secure.

and

secure.

by

the

little or

no

maintenance.

that will hinder the

and

out of

the

Also,

check that

The

DC

ground

mounting bolt to

Ensure

pumps

pump

and

make

the

DC

electrical connection supplying

connection at

ensure

proper

fuel

being supplied to this pump

operation.

sure

that

no

leakage

one

of the pumps mounting bolts

pump

operation.

is

present

12

volts

12 Volt DC

Male

Bayonet

DC

(Installers

(+)

Fuel

Compression

Ground

Connection)

Connection

Connector

Connection

Wire

Supply

Fuel

Fuel Pump

(In)

Fitting

Connection

Outlet

(To Carburetor)

Fuel

Connection

Fuel

leakage

Make

sure

Westerbeke

at the

proper ventilation

Generators

fuel

pump

exists

or

its

whenever

IWARNINGI

connections

servicing

34

is

Pump

a fire

fuel

Mounting

hazard

system

Bolt

and

should be corrected.

components.

ELECTRICAL

SYSTEM

Engine

The

diagram which components

12

...

Volt

DC

Control Circuit

engine that drives the generator

follows

on

the

in

this section.

engine.

end

Refer

has

a 12-volt DC electrical control circuit,

to

these

diagrams

CAUTION

To

avoid damage to the battery's charging circuit, never shut

while the engine is running.

However,

engine's electrical circuit with the

An

overspeed shutdown switch shuts off the generator

set

should the engine's

rpm. This shutdown circuit consumes

or 1/4th of connected to its battery. 18

amp-hours cerned with this slight discharge during normal operation. If the generator set were

shut off the engine's battery switch to avoid electrical shorts when working

an

amp)

in

speed

at

all

times once the generator

As

a month, it

engine

reach approximately

25

this only amounts to about

is

unnecessary to

stopped.

milliamps

be

2175

(.25

con-

seasonal

to

be

unattended for many months, the two easiest ways to stop this slight drain

is to first tum off the

12

volts to the generator

this slight drain

is

generator-mounted control

to

main

set.

remove

panel.

battery switch providing

The

second way to stop

the ignition fuse

on

the

is

as

shown

when

troubleshooting or servicing electrical

off

the engine's battery switch

on

the wiring

the

a

IGNITION

AMP

FUSE

Should the generator shutdown from

restart the generator. If the overspeed switch itself

to

will not

tape.

for testing purposes.

reset

Do

it, lift the T

not

operate the generator with the

Replace

Battery Specification

The

minimum recommended capacity of the battery

ampere-hours (minimum) for the generator

When

quick·charging the battery with cables from damage

the

diodes

an

overspeed condition, the overspeed circuit

is

faulty

and

-1

coil connection from the overspeed switch

overspeed

switch

the overs peed switch to maintain this safety circuit's integrity.

used

in

the engine's 12·volt DC control circuit

set

covered by this

CAUTION

an

battery.

in

the

Leaving

integral

external

the charging circuit connected while quick-charging will

controller's circuitry.

charger,

35

fI'!.IJ.St.

resetting it by depressing the

and

tape the terminal

bypassed.

manual.

be

Bypass the

sure

to

overspeed

disconnect the battery

Westerbeke Generators

be

end

reset

in

STOP

switch

with

electrical

switch only

is

24 -28

order

Testing

1.

2.

the

Battery Charging Circuit

AC

Stator Winding:

Lift

the two two leads which should ground.

Bridge Rectifier

AC

leads off the bridge rectifier

O.

14

Ohm

measure

0.14

ohm.

and

measure

No

continuity should exist between these two leads and the

with

an

ohmmeter the resistance between these

Normal

the two

AC

Normal of the bridge rectifier; that

AC

voltage running to the rectifier (while the engine

AC

connections

voltage running to the bridge rectifier (approximate):

No-load off the generator Full-load off the generator

DC

voltage running out of the rectifier

on

the bridge rectifier.

16.0

volts

17.5

volts

is.

+ and

__

-----1A~C_r---,~+~----------__I.----.CHARG

At

~

.

-t>I-

(See

AC AC

(in

BRIDGE

RECTIFIER

DC

voltage running from the bridge rectifier (approximate):

No-load off the generator Full-load off the generator

17.0

18.5

volts volts

DC DC

is

operating at

the illustration below.)

volts

DC)

is

measured across the two

1800

rpm)

DC

I.C.

INTEGRAL

CONTROLLER

is measured across

DC

connections

-

"=-

3.

Testing the Bridge Rectifier

A.

Set

your ohmmeters

set

the needle to zero.

a.Connect

ohmmeter negative #2, no

deflection for any of the points touched.

C.

Remove connectthe negative

points #1, #2, and #3.

deflect, indicating a

the diodes located internally at these points.

Westerbeke Generators

the

to

point #4. Taking the ohmmeter's

(-)

lead, momentarily touch points #1,

#3,

and #5.

the positive ( + )

scale

(+)

positive lead from the

The

ohmmeter should register

lead

(-)

lead

passage

on

RX1

(+

DC)

and

from point

to point #4. Touch

The

needle

of current through

#4

and

should

36

Point

(Reclit1er

15

)[ountl;oz

Point

Hole)

13

D.

With the

E.

Place the

should not register

(-)

negative lead still connected

(+)

positive lead on point

any

deflection (no deflection indicated infinite resistance). Reverse these connec-

#1

tions and the ohmmeter should again register (A

-

E),

replace the rectifier because it is defective.

to

point

and the

no

#4~

touch

point

#5.

The needle should not deflect

(M)

negative lead on point

#3.

deflection. If the rectifier fails any

The ohmmeter again

of

the previous tests

NOTE:

Various style/model meters may produce test results directly opposite

from

tests

B-E.

In such tests, the results are as above.

4. Integral Controller (I.e.)

The integral controller (I.C.) is an encapsulated, solid·state unit that supplies a DC charging voltage

generator's starting battery

Charging Voltage: Charging Amperage:

A separate group of stator windings supplies AC voltage into

DC current

to

supply the I.C. unit. The

DC charge when one is needed. If you suspect that the I.C. unit is faulty (that low), check the charging circuit's components and performance connections

for

cleanliness and tightness including the ground before replacing the I.C. unit.

NOTE:

When the generator is first started, the I.C. unit will produce a

charging rate

will

while the generator

is

operating.

13.0 - 14.0 volts DC

0-10

amps DC

I.e.

unit senses the needs

rise as the generator is operated

to

a bridge rectifier which converts

of

the starting battery and supplies a

is,

if the battery's charge is

by

following steps

low

charging rate. This

for

awhile.

White

I Yellow

(

... ) Positi

Terminal

ve

of

rectifier

#1

the

AC current

-

3.

Check all

to

the

White/Green

(-

) Negative

VOLTAGE

OUTP..=.U.:.-T_---

Terminal

of

rectifier

ADJUSTMENT POTENTIOMETER

Hnfll

NOTE:White/Green

White I

Black

Ground

(-)

Negative

are

interchangeable.

and

37

Westerbeke Generators

DC

CONTROL

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Description

COOUNG SYSTEM

Westerbeke

the

engine

This

circulating extemallyfrom the radiator. engine into the

fresh

water

exhaust

water within the two independent circuits

Fresh Water

Fresh engine.

it

is

cooled, pump. (although overheating).

marine gasoline

by combustion

Raw

water flows through the tubes

heat

transferred to

exhaust

is

cooled by

system.

Circuit

NOTE: mixture

water

It

then

Refer

used

is

and

When

the

some

As the

engines

and

friction

fresh

water cools the

fresh

water to

fresh

water

system

engine

and

discharged

raw

The

fresh

water

allows the cooling

and

water,

their components

to paragraphs A as

the

fresh

water

circulated through

passes

through the thermostat into the exhaust

then

is

returned

engine

fresh

is

started

water flow

engine

warms

coolant to flow unrestricted to the

are is

raw

water by

and

and B in

the

to

the

cold,

is

bypassed

up,

external

designed

transferred

engine

is

conducted through the tube

overboard.

the

raw

water

coolant,

engine

external

the

portion of

and

equipped for

to the fresh water which circulates throughout

block

and

its

internal

means

of

the

of a heat

heat

In

exchanger,

exchanger while fresh water flows around

basic

terms,

water carries the transferred

circuits

passages

are

this section

and

by

a belt-driven circulating

are

independent of

to

stay

discussed

on

the recommended

for information

block through the suction

fresh

water flow

around

the

thermostat to prevent the

thermostat gradually

the

cooling

fresh moving

walls

the

engine

clean

and

in

the following

on

filling

manifold,

is

prevented

opens,

system.

water cooling.

parts.

similar

to the

heat

in

function to

raw

is

cooled by

over the side through the

each

free

from

Heat

The

heat

water which

fresh

other.

Using

harmful

paragraphs.

antifreeze

the

fresh

pump,

then to the

side

of the

by

and

water

system.

absorbing

heat

exchanger

fresh

water circulating

the

closed thermostat

exhaust

allowing the engine's

produced

the

engine.

is

transferred

an

automotive

the

is

pumped

water, only

deposits.

water

heat

from the

manifold

fresh

in

tubes;

the

fresh

The

where

from

water

A.

Fresh

Water Coolant

A freshwater to split the

and

heat

antifreeze

exchanger

will prevent freezing

Use

soft water with

water. heat

Antifreeze use

reliable

use Make

Use

of

~rd

exchanger which will

of poor quality or without

antifreeze

which

manufacturer. Never

is

ZEREX

sure

or

PRESTONE

that the cooling

water or water containing impurities will

(Antifreeze)

mixture

and

promote better

few

impurities,

reduce

is

compatible with

mix

with

system

I n order to control the concentration of the adding it to the cooling

Westerbeke Generators

system.

Mixture.

should

crack the

be

engine

heat

such

as

tap

the

cooling

rust

inhibitors will

aluminum different brands rust

inhibitors.

of the

engine

mixture,

used

year-round.

Water,

when

it

freezes,

expands sufficiently

block. A water/antifreeze mixture of proper concentration

transfer

system's

(see

lead

efficiency.

cause

is

of

well

cooling

mix

42

system

antifreeze.

cleaned

the

page

for

an

antifreeze/water mixture

water)

to

the

or

rainwater.

collection of

Never

scale

corrosion within the cooling

components

Recommended

before

adding

antifreeze

and

which

antifreeze

antifreeze.

fresh

water thoroughly

use

in

the

system.

is

for

hard

engine

made

year

chart). or

foul and

AJways

by

a

round

before

Antifreeze Concentration %

ANTIFREEZE

13 23 30 35 45

CONCENTRATION

50

DATA

60

Freezing Temperature

NOTE:

is about

B.

Filling the

An

100 F

A coolant recovery tank of

this recovery tank is to allow for

without the loss of coolant

This

coolant recovery tank should be

it

can

be

easDy

monitored

steel

mounting bracket

to connect the

hose

e

antifreeze

(50

Fresh

between

0 F

C)

concentration should

C)

lower

Water

System

kit:,

PN

and

is

supplied with

Coolant

23

(-5)

14

(~10)

than

the

0249n,

engine

5 -4

(-15)

(-20)

be

actual

atmospheric temperature

is

supplied with

coolant expansion

-22

(-30)

selected

each

-40

(-40)

on

the

Westerbeke

and

without introducing air into the cooling

where

installed

coolant

each

at,

or

can

be

kit along

above,

the engine's

easDyadded,

with

a

30

if

needed

inch length of

the engine's manifold fitting to the hose

Recovery

Tank,

Recommended

~58

(-58)

basis

of a temperature which

expected.

gasoline

generator.

contraction, during

system.

spud

manifold

(see

on

the clear the

level,

figure

plastic

base

Installation

The

purpose

engine

in

operation,

a location

where

below). A stainless

hose

and

clamps

of the

recovery

tank.

NOTE: fitting, manifold for coolant

Coolant loss

and

the

tank

and

evaporates.

loss.

can

occur at the connection points of the plastic

spud

and

go undetected

Check these connections

43

when

this coolant leaks onto

when

troubleshooting

hose,

at

the

manifold

the

hot

exhaust

the

cooling

Westerbeke Generators

system

FUNCTION

OF

MANIFOLD

PRESSURE CAP

From Coohint Tent

10

Coolant Tank

Coolant from the engine, manifold pressure When

the engine is

cap and enter the recovery tank

shut

of the engine's coolant cooling system, free of air on

the manifold and the filler neck

Fill

the

fresh water system

when

down

allowing some of the coolant in

and

as

COOLANT

RETRACTION

EXPANSION

heated during the engine's operation, will

via

the

hose connecting the recovery tank

and

cools, a

without

in

small

checkvaJve

loss.

PericxJically

the manifold

in the pressure cap is opened by the contraction

the

recovery tank to

check that the

is

clear so coolant

follows:

passage

can

flow

expand,

be

drawn

(A)

in

either direction.

lift

the spring·loaded

to

the manifold.

back into the engine's

between the

90°

fitting

1.

Remove

2. Pour a

fill

3. Replace the pressure cap

4.

Remove between the

5.

Start and

coolant mixture to flow through the

6.

Add

(Periodically check that the manifold

the pressure

clean,

water/antifreeze mixture into the manifold and allow enough time for the coolant mixture to

the

fresh water cooling system and

cap

from the manifold.

on

the manifold.

expel

the plastic cap from the coolant recovery tank

ADD

mark

and

the

MAX

mark.

run

the engine long enough for the engine to warm

engine

coolant mixture

to

the

recovery

is completely

tank,

block

Thermostat The

thermostat used

block to rise

in

is

simply a choke device that

temperature. This temperature

coolant mixture to circulate through the cooling

all

air.

and

fill the tank with coolant mixture halfway

Replace

as

rise

the cap

and

to the

required,

full

and

remains

effects the thermostat causing it to open; thus, allowing

on

the manifold.

up

so the thermostat will open, allowing the

rest

of the fresh water cooling system.

to top

no

off

the

fresh

water cooling system.

air pocket is present.)

closed causing the coolant mixture

in

the engine

system.

Westerbeke Generators

44

Raw Water Circuit

The raw water flow draws

raw

water directly from the

to

the heat exchanger's around which the fresh water coolant mixture circulates. then is discharged from

Raw Water Pump

The

raw

water pump is a self-priming, belt-driven rotary pump with a non-ferrous housing impeller. producing the pumping action. spare impeller

The

NOTE:

Self priming occurs vessel.

Zinc Anodes

A zinc anode, or pencil,

of the zinc reducing the effects of electrolysis should on board.

anooe

be checked monthly

is

created by a

raw

the

cooling system overboard through the water-injected wet

impeller

and

Impeller failures resulting from a

has

flexible

impeller cover gasket

when

is

located

is

to sacrifice itself to electrolysis action taking place in the

and

water

On

the

belt-driven,

ocean

inlet.

vanes

no account should this pump be run dry. There

engine

in

the

on

other components

anode

positive displacement. neoprene impeller pump.

through the

The

which wipe against a curved cam plate within the impeller

on

board

loss

mounted

raw

water cooling circuit within the heat exchanger.

cleaned

raw

water

(an

of

or replaced,

sea

raw

pump

cock and

passes

Heat

impeller kit).

water coolant are not warrantable failures.

is

of

raw

water strainer and

through the heat exchanger's tubes, from

from the fresh water system

close to or below the water line of the

raw

water cooling circuit, thereby

the

system.

as

required. Spare anodes

The condition of

passes

is

absorbed

exhaust

and a neoprene

should

the

should

The

pump

the water

system.

housing,

always

The

purpose

zinc anode

be

carried

and

be

a

NOTE:

not

If the zinc pencil needs hold the hex boss into which the zinc

pencil wrench while loosening the anode with another wrench.

the hex the exchanger the zinc, note the condition

zinc

is probably a lot of zinc exchanger. heat exchanger and of

all zinc debris. Always have a spare heat exchanger end gasket in case

the damaged when removing the end cover. your engine model's heat exchanger end gasket part number), install a

Electrolysis action

that of the generator. Generators do not produce electrolysis.

replacement,

is

threaded

This

boss from possibly tearing off

shell.

After removing

in

poor condition, there

flakes

Remove

present

Replace

new

zinc pencil.

the

end

clean

one

the gasket (refer to

cover,

is

with

prevents

of

it.

If the

are

within the

of the

the inside

becomes

and

the result

a

NEW

ANODE

of

each

particular installation and/or

REPLACE

vessel

location;

REPLACE

CLEAH

OR

REPLACE

45

Westerbeke Generators

Govemor/Fresh Water!Raw Water Pump Belt Tension

IWARNINGI

Never attempt to adjust the drive belt's tension while

Excessive reduce or

temperatures,

The

governor

inch

and between be

carried

the

no

the two pulleys

govemor

the service

presence

and

more

on

board.

and

water

pump

life

of

the

fresh

of

oil

on

the

belt

as

well

as

poor

regulation

water pump drive belt than

1/2 inch (10

on

the longest

Governor

mm,

drive

water pump

can

is

properly adjusted if the belt

12

mm)

span

Belt

3/8-1/2

the

engine

CAUTION

belt tension

and

cause

during generator load

as

the

of the belt.

tension

inch

can

governor shaft

belt $lipping, resulting

belt

is

depressed with the thumb at the midpoint

(See

the figure

is

cause

changes.

in operation.

rapid wear of

bearings.

can

Excessive

in

high

be

deflected no

below.) A spare

Fresh Water

Pump

the

belt

operating

drive belt

Pulley

and

slack

less

than 3/8

should

Govemor/Fresh

Westerbeke Generators

Water/Raw

46

Water

Pump

Front

Pulley

Belt

Crankshaft

Tension

Engine Oil

For

the

engine's lubrication.

having

Engine Oil Viscosity (SAE Number)

Use

an

API

specification of

oil

having a viscosity best suited to the atmospheric

TEMPERATURE

C

F*

use

a lubricating oil designated for gasoline

SEt

SF

LUBRICATION

or

SG.

Do

not

SYSTEM

use

oils designated

temperature.

q

1.0

2.0

service.

DS.

Refer

30

to the

40

Use

a good grade of oil

oil

viscosity chart below.

120

ENGINE

Oil Pressure

The

engine's

by

the

standard oil pressure switch.

During

normal operation. the engine's

NOTE: psi.

A warmed engine

OIL

(SAE

I)

oil

pressure is indicated by the

A newty started, cold engine

can

also vary depending upon the load that

fitted

with

safe

an

operating

Your generator set is oil

pressure

damage

drop below a

to your generator's engine from occurring by interrupting the

have

oil

pressure

can

an

oil

pressure

pressure,

oil

pressure

have

is

placed

sensing

the sensor

will

range

an

reading

switch

gauge

(when

between

oil

pressure

as

low

on

the generator.

as

standard equipment. Should your engine's

will

shut the engine

equipped with

35

and

55

psi

(engine

reading upwards of

as

35

psi.

These

readings

OFF

to prevent any internal

DC

voltage

to

the ignition coil.

one)

or

hot).

60

is

monitored

to

80

may

Westerbeke Generators

48

Engine

Oil

Change

(to

include

filter)

1. Draining the

Discharge the (attached at the front of is

still

warm.

the hose

in

Oil

old

Drain

its

bracket,

Sump oil

through the sump

the

engine)

the

old

oil completely,

and

replace

while

the

drain

the

securely.

Always yellow/gray emulsion indicates the water in

observe the

the

oil.

Although this condition

old

oil

as

it

is

removed.

presence

does require prompt attention to prevent damage.

be

can attached to the through the haust,

2.

Replacement

When helpful lower portion of the old filter to container before spillage. A should be helpful

some

when unscrewing

(Oft engine's cooling

ator's engine

removed came gasket gently

filter requires no cleaning inside,

proper1y

Call

a competent mechanic

present in the

be the result

oil.

of

engine,

raw

water cooling circuit into

filling it up into

of

removing the

and

cleaner to

removing

small

in

paper towels

it

or any other fluid

abnity.

clean.)

to

make

sure

off

with the old

remains

remove

sealed

it.

The

disposed

Raw

water

a fault

in

and/or water

the

engine.

the

Oil

Filter

used

oil

punch a hole

it.

style

automotive filter

removing

and

a plastic

to catch any

on

the

Please

Inspect the

thatthe rubber

oil

filter.

against the

replaceable

of.

should

present

the

exhaust

filter,

you

in

the upper

drain

the

This

helps

the

old

oil

filter.

bag

around

oil

left

engine

keep

old

reduces

your oil filter sealing

If this rubber

engine

cartridge-type

so

siphoning

may

in

it

hose

engine

replace

end

is

rare,

serious

water

in

the

system the

find

oil

into

to

lessen

wrench

Place

the

generas

gasket

sealing

block,

may

cap

A

of

it

oil

ex-

and

a

filter

filter.

the

it

is

oil

be

it

When

installing the

oil

and apply a thin coat of

the threaded oil filter

NOTE: important items

after

an

that there

new

stub,

Generic filters

on

oil filter

are

change

no

oil

filter

element,

clean

engine

and

then tighten the filter firmly by

are

wipe

oil

not

recommended,

generic parts might be

and

oil fill,

run

oil

leaks

around

the

to

the

new

the

engine

oil

49

filter gasket's

rubber gasket

as

the

entirely

different from

to

make

filter.

sealing

on

hand.

material

sure

the

surface

new

on

the engine block

oil

filter. Screw the filter

standards or diameters

genuine

the

parts.

Immediately

oil

pressure

Westerbeke Generators

is

normal

of

and

free

onto

of

3.

Filling

the

Add

fresh

After

refilling

while

checking

there

is

no

oil

drain

system, quantity of high

mark

additional

Oil

Sump

oil through the

the

oil,

run

the

engine's

leakage oil

on

around the

and

stop the

with the dipstick.

the dipstick, should

oil.

oil

filler cap

engine

oU

pressure.

new

engine.

Fill

to,

on

the

valve

for a few

oil

filter or from Then, but not

the

engine

cover.

moments

Make

sure

check

over,

require

the the the

Top

Oil

Fill

Side

Oil

Fill--~""'"

Oil

Dipstick

Westerbeke Generators

50

The

BC

generator to produce exciter windings. current build point this

generator's

an

in

the

up

of

the

regulated field produces a steady voltage

is

a brushless, self-excited generator which requires only the driving force

AC

output.

When

the generator is started, residual magnetism

stator which

current

AC

in

the four rotating poles

capacitor(s)

terminals to operate

and

The

stator houses two sets

then

generates

a regulated energy field is then maintained

BC

GENERATOR (60-50 HERTZ)

of

windings; the

an

even larger current in

and

in

the exciter windings quickly reaches

in

the stator windings which can then

AC

equipment.

of

main

stator windings

in

the

four rotating poles induces a

the

exciter windings. This mutual

in

the stator. At

be

and

the

drawn

saturation

same time,

off

the

engine

Governor Internal Wiring Schematic

Battery Charging Circuit

A. Rotating Field! Auxiliary Windings with Diodes

C.

Single Exciter Winding and Capacitors

with

DC

B.

Main

Stataor Windings

D. Bridge Rectifier Controller

E. Dual Exiter Windings

and

Integral

and

D

r

..

----------------------------------------,

I J

I I

~

I I

I'

r---------.,

I I I I

I I I

I I I CONTROLLER

I

IDIODE

A

, I I

I I l

I....

_________

Generator Frequency

I I

~

I T I

I E I

I It I

: 2

r 3 II I

I II I

,I

I

r L I

I

:

I 5 I I

J-

----1-------

1 I

~

4

II

11

0 I

c::

r:

I>

_...J I

l

B

r

I I

r--

----------"

. 1

o

s

o

fie TERMINAL

- - - - - - - - - - -

I I

..J

I

HZ

I

so

I

: I

I

tfAI"ACITO~~

L-

____________

:

II

fl

c

I

..J

!

L_!-:-i~

DC

:)

4

o

2

6

o

BLOtt

__

~_J

Capacitors.

~

I

"::;::'

:

...,.

- - -

--,

I

so' E

Hzl

Frequency is a direct result change manual.

the

generator's frequency, refer to the

of

engine/generator

speed:

"MAINlENANCE

1800 rpm-60 hertz, 1500

51

rpm

- 50 hertz.

AND ADJUSTIvlENTS" section

Westerbeke Generators

To

of

this

seA

GENERATOR

(60

HERTZ

ONLy)

o

r----------------------oc------·

J

I I

J I

r--------,

r I I I

I I I J

I

:

DIODE

I I I

I I

I I 2 A I

A I I L J B

I I 4 B I

I I 5 J

I I C I I K

JOIODE

I

I I I

J I

1......-------'/

J

I

I~

__ -__

: : 1

I 5 I

1----------

I I

I r

I J

'--

________

BRIDGE

RECTIFIER

- I

------T---------------~

~

I .

~

:

~

I

T

--..J

ACTERMINAL

Ie

...1

o

CHARGE

1

4

o

5

o

BLOCK

2

I

A.

Rotating Field/Auxiliary

'Nindings with Diodes

C.

Exciter Windings and Capacitor

Westerbeke Generators

Generator Internal Wiring Schematic with

DC

Battery

Charging

Circuit

B. Main Stator Windings

D.

Bridge

Rectifier

52

and

Integral

Controller

No-Load

1.

2.

:Make

is, governor as needed

3. and and the is

4. #5)

5. plugs grouped then disconnect the generator's no-load voltage the three plugs

Voltage

Remove

the

louvered

Adjustment

metal

Start the generator and allow it

sure the generator

shut

OFF

all electrical appliances).

Refering to the

BCA

models,

hote

lead with a volt

115-128 volts at 60.5-61.5 hertz.

Shut

off the generator.

is

operating without

to

obtain the correct engine

AC

load connections,

check the generator's no-load

Make

is plugged into the capacitor.

Do capacitor can shock.

operating

Refer

to

not attempt

lin addition, attempting

the illustrations

for

to

make

hold a 450-500

can

cause

on

the right capacitor terminal, #7, #8 and #9.

lower

numbered

is

number.

Note

available.

plate covering the tenninal connections and the capacitor.

to

run

for

approximatley

any

equipment drawing

Make

sure the engine's

speed

as

illustrated under the

voltage

emter.

Make

sure

If

the voltage

you

record

output

sure the correct hertz

Refer

to

the

illustration on the

WARNING

a no-load voltage adjustment while the generator

five

minutes

speed

before

proceeding.

"Load

by

measuring the voltage across the neutral

so

the engine

AC

current

(hertz)

is

correct.

from

Connnections" heading

this reading. The generator's no-load voltage

is

higher

lead

for

the

top

or

BC

lower

than

model

of the next

specified,

(60

hertz

page.

is

volt charge. Touching any wiring can result in a

to

make a no-load

fingers

to

be

cause

the next page

plug and

in

before

connect high, then disconnect that the plug presently

the

voltage adjustment while the generator is

generator's

making

rotor.

any

adjustments.

If

the generator's no-load voltage

Note

the plug with the next higher

the

higher numbered plug and connect the plug

connected

to this tenninal

may

can

warm

up.

the generator (that

Adjust

the

for

the

lead

proceed.

#6,

or

50

hertz

operating. The

severe

electrical

that there are three

is

low,

number.

If

the

with

be

anyone of the

BC

6.

If

the generator's

no-load

voltage cannot highest numbered plug is already the

lowest

numbered plug is connected, then local listed

Westerbeke

at

the bottom of the

NOTE: with each other

NOTE:

dealer

for a Be

Make

sure

the

or

in contact with the generator's

Dual Exciter Circuit

plugged into each capacitor

connected

GENERAL

insulating

Models

for

the hertz the generator

be

adjusted

to

the right terminal, or the voltage

follow

TROUBLESHOOTING

covers

the

because

steps

the voltage

at the bottom of hhe

GUIDE

on

the

unused leads are in place and are not in contact

housing.

ensure that the correct hertz

is

operating

53

needs

to

be

increased and

needs

to

be

lowered

before perfonning the

led8,

60

HZ

or

50

at.

Westerbeke

Ask

your

HZ

is

Generators

the

and

steps

7.9

KW

BeG A BCGA

GENERATOR

THE

.,

SHOW"

TO

THE

ONLY

fOR

STRATIOM

PlU6

COHNECTED

CAPACITOR

DEMON-

PURPOSES.

AC

load

ler.inal

IS

Connection

Block

SO

Herh

Plug

(PHIXP":

A~~O.

~~ucs

se.eRATD.·C

wI.DIMes

l'

TH(

_lilies;.

AMv TO

TMcet

MDuCIMC

DO

_aT

D~

TDUCH

HOUCX.C.

.IL~

~LVCC

DR

THtec

.VA"

THe

DTHC.

A. Check the resistance

Single Exciter Circuit

KW

BCG

7.0

Dual

KW BCG: 2.5 ohm

7.0

C.

Check the engine's speed.

& BCGA:

Exciter Circuit

TOUCH

of

the exciter windings

1.9ohm

B. Check the capacitor.

Single Exciter Circuit

7.0

KW

BCG

&

BCGA:

Dual

Exciter Circuit

7.0KWBCG:

18.0uF±5°

31.5

6eneriltor

uF

± 5°

End

Plah

60

hertz: 60.5 - 61.5

50 hertz: 50.5 - 51.5

Adjust the engine's speed

NOTE: Refer

to

the

by

"NOTE"

use

at the bottom

of

the governor speed adjustment

of

the next page.

54

to

obtain the correct hertz.

Westerbeke Generators

Load

Connections

The

generator's data plate

decal

is

affIXed

connections is provided The

generator

hertz;

or

the

"SYSTEM

to the inside of the

is a single-phase,

110

volts

AC

two-wire,

SPECIFICATIONS"

on

gives

the

louvered

the

decal.

reconnectable

110/220

section of

voltage,

cover

volts

current

AC

this

and

on

the

120

volts

three-wire,

manual

frequency

generator

AC

two-wire or

or

220

for

the

7.0

rating

of the generator. An

end.

A diagram of the various

120/240

volts

AC

KVV

BeG generator

volts

two-wire,

AC

three-wire,

at

50

rating.

AC

hertz.

AC

wiring

voltage

Refer

at

60

to

NOTE: volts,

A circuit breaker should

rated

at

considerations.

The

frame ground

50

hertz.

120%

of the generator's

be

installed

wire

AC

cnu.st.

between

output

BC

be

moved

the generator

and

be

able

Generator

L,

4e3

4 3

5.

110V

For

making multi-strand wire and

amperage that will be drawn through the conductor(s).

generator's amperage

l1J1.!§1.

connections to the

sized

NOTE: governor!!1l.!§!.

changed for

When

be

selected for the voltage

50

changing

be

(#5) or

6

-2

50Hz

for the number of conductors

and

voltage

hertz

made.

The

60

1

5

L

120V

AC

terminal

ratings.)

produced by AC

output

and

(#6)

hertz

2e6

60Hz

block,

the

connections

hertz

to

use.

when

changing from

and

the

to

react

quickly to

(60 -50

240V

use

in

generator,

be

hertz)

1 4

36e

5 2

L, N

60Hz

terminal

the

bundle,

(Refer

an

on

the

produced. A plug

110

volts,

50

hertz

to

AC

load.

This

circuit breaker

overloads,

220V

ends

for #10 studs which will . accept

the

rating

to

the

engine

above

speed

illustrated terminal blocks

at

subject to motor starting

1

4-==-3

5e2e6

50Hz

of

the conductor's

generator's data

adjustment at the

the

capacitor must

/22.0

should

insulation.

plate

be

for the

SCA

Generator

~

120VAC

55

(60

hertz

only)

4 -

•

5

•

CID:J

L1

120/240VAC

L2

:2

N

Westerbeke Generators

Shore Power Connections If the installer connects shore power to the vessel's

POWER/OFF/SHIPS

GEN.,

center position-off transfer switch shown below.

AC

circuit, this must

simultaneous connection of shore power to generator output.

CAUTION

Damage to the generator

same

at the

time. This type of generator damage

installer's responsibility to

Genero1l1tor

{ N

can

G1

'<32

• \

..

.;:.

I

I I I /

L-----f-<JJ

r-----~

I '

I

~

•

~

1

~

Shore

result if utility shore power

is

not

make

sure

all

AC

connections are correct.

HOTE: Diagram W'ire.120·

use

dotted

... --....

\

..... _ ....

l

/--"~

Yolt

~\

4--

J

shows

connections

system.

linn

For a three·

for

the

other

hot

--I

I

I I I

N"-._~--"'I-~}

Ship's

,--.,.../

-;;;;

G::.:..,o:::.;;u:.;.;.:nd~-4-

__

-III'

f?

Powe,

NOTE: Diagram shows wire,

12O·Yolt

with

three-wire.120-Yolt

system

connections from

the

generator.

boat

system.

be

done by means

Use

of

and

generator output are connected

of

the

this switch prevents

covered under the warranty; it is the

for

a

two-

Wire

system

leg.

Ship-to·

Shore

Switch

(3

Pole)

PoIto)

Load

for a two-

PH

32008

(40

Ampal

PM

32009

(SOAmpal

PN

32010

(125

Ampel

PH

32133

(200

"",",Pole)

Pole)

SHORE

'-----1---11----+(9)

~

Shore Power

Operators loads the

vessel

are

cautioned when switching from shore power

should be shut off before switching as voltage surges induced by switching with heavy

being operated can/may cause damage to the exciter circuit components in the generator.

Westerbeke Generators

Ship·to·

PH

32008

(40

Ampal

/--

.....

,

\ :E-+-+-;;';';(W;;';;KT':::':':').-...N Ships

"!r;

.....

_

1

Z

...

Ground

(GRN)

'Neutral

J

'---"'L1

L2}

:~~~-YOlt

II'

Equipment

r'::'i~~~Po'e)

PH

32010

(125

Load

Ampa'

PH

32133

(200AmpaJ'PoIe)

Shore Power Switch Connection Diagrams

to

generator power or vice-versa, heavy motor

56

Shore

SWitch

Pole)

(3

Pole)

AC

loads

on

GENERAL INFORMATION

Use

of

Electric Motors

The

power required

is

started.

Some

more current to

to

start

motors require much more current

start,

under similar circumstances, than other easy-starting loads, such as

small

be

avoided,

power tools.

whenever possible, if the electric motor

Because

an

electric motor

as

washing

they require 5

machines,

AND

is

considerably

or

to

7 times

repulsion-induction motors require from 2 to 4 times to start any motor varies with the load connected to

example,

for In

general,

approximately

will require more current than a motor to which no load

the current required to start 120-volt motors connected to medium starting loads will

as

follows:

CARE

OF

more

to

start

than

types.

where

loads

as

much current to start

is

to be driven by a

as

much current

it.

An

electric motor connected

THE

GENERATOR

than

is

required to keep it running after it

others. Split-phase

These

motors

are

applied after the motor

as

small

generator. Capacitor

to

start

as

to

run.

is

connected.

(AC)

are

commonly

to

run, The

to

an

motors

is

their

require

used

started,

use

on

such

should

and

current

required

air compressor,

be

* Note that

than for larger made

Because

wli not be damaged if it

starting motors, tum off

Required Operating Speed

Although individual units driven

the

generators described

in

larger

heavy

in

the above table the maximum

ones.

The

sizes.

surge of current

can

all

other electrical loads

may

MOTOR

AMPS

SIZE

(HP)

1/6 1/4 1/3 1/2 3/4 1

reason

for this

needed

is

for starting motors

bring the motor up to

vary slightly, the

in

this

manual

are

normal

shown

FOR RUNNING (Amperes)

3.2

4.6

5.2

7.2

10.2 13

"Amps

for Starting"

AMPS

FOR

STARTING

(Amperes)

6.4

to 22.4*

9.2

to 32.2*

10.4

to 72.8*

14.4

to

29.2

20.4

to 40.8

26

to

52

is

more for some

small

that the hardest starting types (split-phase)

is

required for only

speed

and,

in

a few seconds. If difficulty

if possible, reduce the load on the electric motor.

voltage on

and

the chart

frequency of typical

on

the next page.

an

instant, the generator

is

6O(50)hertz

motors

are

not

experienced

engine-

in

Run

the generator at first with no-load applied, then

full capacity See

the rpmlhertz/frequency chart

as

indicated

on

the generator's data

on

the next

page.

at

half the generator's capacity, and finally loaded to

plate.

57

Westerbeke Generators

its

Load

Applied

4-Pole

Speed Frequency

(rpm)

(Hertz)

Generator

120V

(110)

Plants

Voltage

240V

Plants

(220)

None

1830 62

(1530)

Half

Full

The

output voltage should be checked periodically

1800

(1500)

1755

(1455)

the appliances it supplies. If

an

AC

vottmeter or ampmeter

is

not installed to monitor voltage

and amp-probe.

Preventive

Maintenance

1.

Keep

2.

Make and

Maintenance (Generator)

on

the generator is minimal.

the generator clean,

sure

all

connections

dry

are

protected against chafing.

and

well-ventilated.

clean and tight

(52)

60

(SO)

59

(49)

to

ensure

and

that cables carrying

proper operation of the generating plant

122 240

(112)

120

(110)

110

(100)

and

load

I check it with a portable meter

AC

voltage are properiy supported

(224)

240

(220)

220

(200)

and

3.

The

rear armature bearing

becomes rough or noisy, replace

Generator Troubleshooting

A complete and

incorporated

and

illustrated text on troubleshooting the

in

the Technical

is

lubricated and

it.

Manual

sealed;

which

therefore,

BC

is

available through your local dealer.

no

maintenance

series of generators

is

required. If the bearing

furnished

in

booklet form

Westerbeke Generators

58

ENGINE

TROUBLESHOOTING

Introduction

The tables which follow indicate troubleshooting procedures based upon certain problem indicators. the

probable causes

Note that the engine's control system (electrical system) breaker located next beginning

of

this manual

the problems, and the recommendations

is

to

the starter

for

motor

and the

a photograph showing the exact position

(-)

ground terminal. Refer

to

overcome these problems.

protected

by

a 20-Ampere manual reset circuit

to

the model photographs at the

of

this reset circuit breaker.

Trouble

Engine cranks

to

start.

but

fails

eossjble Cause

1.

Out

of

fuel.

2. Engine is flooded.

3.

Filters are clogged by contaminated fuel.

4. Voltage

5.

Worn

drop

at ( + ) at overspeed switch.

or

faulty spark plugs.

6. Bad ignition coil.

7.

High-tension leads grounding (wet system).

8.

Automatic shutdown switch is faulty.

9.

Fuel

pump inoperative.

10.

Filter in carburetor is clogged.

11.

Tripped overspeed switch (reset and start).

Engine does

not

crank.

59

12.

Faulty choke solenoid.

13.

Faulty fuel solenoid

1.

Battery is

2. Engine's

3.

Raw

4.

Loose battery connections.

5.

Voltage

low

or

dead.

DC 20-Amp breaker has tripped.

water filled cylinders. (Remove spark plugs.)

drop

at starter solenoid terminal.

Westerbeke Generators

on

carburetor.

Trouble

possible Cause

6. Bad starter solenoid.

7. Faulty START switch.

Engine starts, runs and then shuts down.

firing through carburetor.

Back

1. Faulty automatic shutdown switch

(oil, water,

2. Faulty overspeed switch (reset and start; bypass

3. Faulty fuel pump.

or

switch

eXhaust).

to

test).

4. Faulty STOP switch.

5. Engine circuit breaker is tripping.

6.

Dirty fuel filters.

7. Low oil level in sump.

8.

Mechanical pump creating fuel starvation.

1.

Ignition timing is wrong.

check

is unable

valve

at

the fuel supply fuel

to

draw fuel through this valve

Engine overheats.

Westerbeke Generators

2. Engine is flooded.

3.

Choke is stuck closed.

4.

Spark plug wires are connected wrongcheck firing order.

5. Distributor cap is cracked.

6.

Dirty air cleaner.

1. Coolant loss (pressure test the cooling system).

2. Belts are loose

3. Raw water pump's impeller is faulty.

4. Raw water

or

pump

broken.

is worn.

60

Trouble

Possible

5.

Faulty

Cause hose.

Engine

hunts.

6. Thermostat

7. Heat exchanger

8. Faulty

gauge

is

stuck closed.

(check coolant temperature

with a thermometer).

1. Throttle linkage

2.

Fuel

starvation.

fuel

3. Dirty

4. Defective

5.

Governor

6.

Valves

7. Generator

8.

Cracked distributor.

filters.

fuel

pump.

is

out of adjustment.

are

out of adjustment.

is

overloaded.

is

clogged.

is

binding.

Engine

High

oil

misfires.

pressure.

9. Faulty high-tension leads.

1.

Ignition timing

2. Spark plugs

3.

Valve

clearances

4.

Dirty

carburetor.

5. Dirty air

6.

Poor quality

1.

Faulty

gauge.

2.

Relief

valve

3.

Dirty

oil

is

are

cleaner.

fuel.

is

stuck.

or wrong

wrong.

worn.

are

incorrect.

SAE

type

oil

in

the

engine.

61

Westerbeke Generators

Low

oil

pressure.

Trouble

Possible

1.

Low

oil

Cause

level.

No

DC

starting

Black

from

the

charge to the

battery.

exhaust

smoke

engine.

is

discharged

2. Faulty

3. Wrong

4. Wrong type

5.

6. Faulty

1.

gauge.

SAE

Relief

valve

oil

pump.

DC

connections to

type oil

is

stuck.

oil

filter.

in

the

controller

engine.

loose or faulty.

2.

Faulty controller circuit component

1. Dirty air

2.

Choke

3.

Carburetor

intake.

is

stuck

closed.

is

flooding.

are

Blue

exhaust

from

the exhaust

smoke

is

discharged

1.

Valves

2.

Piston

3.

Lubrication

4. Crankcase breather

are

worn or adjusted incorrectly.

rings

are

worn

oil

is

diluted.

or

hose

unseated.

is

clogged.

Westerbeke Generators

62

Introduction

MAINTENANCE

AND

ADJUSTMENTS

This section contains a scheduled preventive maintenance program

can

owner/operator

Preventive Maintenance (Engine)

Perform the preventive maintenance

Adherence

to

perform without the benefit of sophisticated

in

accordance with the schedules

these schedules

will

make

sure the equipment

that it will perform to expectations. Those items

by

an

authorized dealer or distributor.

Daily (before each use)

Check the

1.

2.

Check the coolant

MAX

3.

Visually inspect the

damaged

4. Check the

octane rating of

and

oil

sump

ADD

hoses,

fuel

leVel.

level

marks.

unit;

loose

supply.

89

or

Maintain the oil

in

the plastic recovery tank. Maintain the coolant

check for loose belts,

clamps.

RII

and other equipment not properly

the tank(s) with a good grade of

higher.

marked

level

by

at or near the upper

chafed

is

maintained

an

asterisk

or

and

broken

and

several

expensive

listed

in

(*)

are

level

wires,

secured.

unleaded

adjustment procedures the

tools and instruments.

in the following paragraphs.

the

best

possible condition

recommended to

mark

on

level

halfway

loose brackets

be

dipstick.

performed

between

and

fittings,

or leaded gasoline that

has

and

the

an

5.

Check the primary

separator-

6.

If

an

is

optional instrument

filter/Water

optional, but strongly recommended.)

temperature, and starting battery charging voltage once the engine

7.

If

AC

gauges are installed, check the generators output meters for proper

frequency.

Monthly

. Check the

as

required.

Servicing After Initial 50 Hours

1.

2.

conc.jition

Keep

ofthe zinc anode

the

area

Change the engine's lubrication Oean or replace the

panel

separator.

is

installed, check the engine's

in

Drain

the heat exchangers raw water circuit. Oean or replace the

inside the heat exchanger

of

Operation

oil

and

oil filter.

fuel

filter screen

in

the carburetor and

and

servide this filter

clean

of zinc

as

required.

gauges

in

the primary fuel filter/Water separator.

for proper oil pressure, operating

is

operating.

ancx:te

debris.

(A

primary filter/water

AC

voltage

and

output

anode,

63

Westerbeke Generators

*3. Retorque the cylinder head bolts.

*4.

Adjust valve clearances.

5.

Adjust the GovemorlFresh water pump and Raw Water Pump drive belt tension,

if

required.

*6. Adjust the engine's no-speed, ifrequired (Hertz).

warrantable adjustment during or after the unit's break-in.

*7. Check ignition point gap and engine timing. (Check condition

Please note that these adjustments are not a

Servicing After Every 100 Hours of Operation

1.

Change the engine's lubrication oil and oil filter.

2.

Adjust the water

3. Check syphon break for proper operation. (when installed)

pwnp

drive belt tension,

if

required.

Servicing After Every 250 Hours of Operation

Clean

or

replace the fuel filter element

in

the carburetor.

Servicing After Every 500 Hours of Operation

*

1.

Adjust the valve clearances.

and

*2. Drain, flush

*3.

Check the condition

refill the fresh water cooling system

of

the starter motor drive pinion; lubricate pinion.

of

distributor cap rotor.)

*4. Check the raw water pump for internal wear. Examine the pump's cover, cam, and internal housing. Replace worn parts as needed. Check for leaks and repair them as needed.

5.

Check the outside

oil

on

the engine inhibits the engine's ability to remain cool. Please keep the engine clean.

6.

Check spark plug gap, ignition point gap and ignition timing.

7.

Inspect plug wires, distributor cap and rotor.

8.

Check water injected exhaust elbow for carbon and/or corrosion build-up on inside passages.

Clean/replace as needed.

9.

Change governor lube oil.

Servicing

After

* Check the tightness

of

the engine. Make sure that any oil

Every 800

of

bolts, nuts, clamps.

Bours

of Operation

on

the engine's surface is cleaned. Any dirt or

Westerbeke Generators

64

Servicing After

Every

1000

Hours

of

Operation

Remove,

be able to

clean,

clean

NOTE:

be

performed

and

pressure

and

test the

Operating

more

test

heat

in

silty and/or tropical

often

than

Generator Frequency Adjustment

is

Frequency When

the generator

run

at 1500

Therefore, the frequency

a direct

rpm,

to change the generators

change,

Voltage Connections"

section of this

manual.

the

result

of

engine/generator

is

run

at

1800

AC

voltage output frequency

connect

diagram

the

specified

the

primary

exchanger.)

every

1000

rpm,

the

AC

frequency,

AC

output

for your generator

heat

exchanger.

waters

may

(A

local automotive radiator shop should

require

that a

hours.

speed,

as

indicated by the following:

voltage output frequency

is

50

hertz.

the

leads

generator's

to the

speed

AC

terminal block

set,

which

heat

exchanger cleaning

is

60

hertz.

must.

be

changed.

in

accordance with the

appears

in

the

When

the generator

"BC

is

To accomplish

"AC

GENERATORu

65

Westerbeke Generators

Ignition Timing

1.

Attach a timing light to the #1 spark plug and mark the front timing pointer to indicate

on

timing mark

2.

Start

the engine and warm

without

a load on

the crankshaft pulley and mark it with white chalk or crayon.

it

up

to

its normal operating temperature.

Make

sure

it.

the generator

10°.

is

Locate the

operating

3. Using the timing light, align the timing mark

mark of the timing pointer. Do this by loosening timing specifications below.

Timing Specifications:

7.0

in

KW

the front crankshaft pulley

and

slowly rotating the distributor

BCG & BCGA

so

it

is

just slightly before the 10°

body_

10° ± .5°

BTDC

at 1800 rpm

Refer

to the

Choke Solenoid

The

choke solenoid tions to close the choke plate in the carburetor START

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

be out

Keep

between

Westerbeke Generators

switch

START

present

as

switch

when

the engine reaches operating temperature.

this solenoid dry

the solenoid

is

a 12 volt

is

depressed during engine start

is

released.

the engine starts cold but should smooth

and

Some unstable running may

periodically lubricate the linkage

the choke

DC

operated unit that func-

up.

lever.

when

66

the

Governor

Adjustments

Operate the generator set

NOTE: If the governor is severely out of adjustment, manually adjust the linkage without any load on the generator

Three adjusting points are on the governor. (Refer

1.

Bumper Screw This screw

remove a no-load surge only. Never tum the bumper screw into the governor far enough so that it increases the no-

load speed. Toadjustthegovemor, tum the bumper screw

stops

crease/Decrease Speed Screw (on the

governor) up until the generator runs

'between 60.5

Apply a 1/4, a 1/2 and a 3/4 load

generator and ensure the generator

does not surge under these three load

intervals.

surging.

to

bring the unit up

to

obtain a safe output voltage before proceeding with the adjustment.

is

used

to

in

until the engine

Now

bring

the

In-

61.5 cycles no-load.

to

the

to

its operating temperature before attempting an adjustment.

to

the illustration below.)

7.0

KW

BeG & BCGA Governor

Increase/Decrease Speed

Carburetor

Throttle

Lever

NOTE:

and

2.

locreaseIPecrease Speed This adjusting bolt

between the governor arm and throttle lever should be adjusted

engine is not running.)

lubricated.

lubricant

Only If the generator surges at any of these load intervals are you

#3

below.

sets

the no-load speed of the engine. (The linkage arm

to

hold the throttle full open when the

Make

sure this linkage moves freely and that the

Use

graphite lubricant at this connection. Disconnect the

to

the inside of the

jOint.

3. l::IumingtRegulatjon If the variation in engine speed between no-load and

eye bolt

adjusted as

If the governor surges (Check the speed adjustment.)

Governor

1.

Periodically lubricate the attaching points at both ends of the linkage

equivalent.

to

draw the spring closer to the lever hub. The increase/decrease speed bolt may

Maintenance

NOTE:

Free movement of this linkage arm is important for proper govemor/throttJe operation.

Well.

whDe

under a load, adjust this eye bolt

to

move the spring away from the lever

arm.

to

follow steps

ball

joint connectors are properly

ball

joint and apply a graphite

full..Joad

Use a graphite lubricant or

is

too

#2

great, adjust this

need

to

hub.

be

an

67

Westerbeke Generators

2.

Governor oil capacity:

7.0

KW

BCG & BCGA

is

1.5

ounces

of

SAE

#10/30 motor

oil.

NOTE:

3.

Change

4.

The

drive belt should be

of cracking.

To

change

oil

from

engine

Carburetor Adjustment

1.

Idle Mixture Jet

Do

not overfill the governor.

the governor's

(Keep

the

oil.

remove

the governor.

oil,

and

replace the

a spare

Reinstall

Disconnect the throttle idle

stop

screw.

(counterclockwise)

to

1/2

of a tum.

2.

Run

Mixture Jet

Tum the

slowly until the

The

idle mixture

oil

every

maintained

on

the governor

the

plugs.

linkage

arm

idle

500

hours of operation.

in

good

hand

for unexpected

from

governor on the

from

the

mixture

should

engine

screw

smooths

be

satisfactory

condition.

Replace

needs.)

engine

and

remove

engine

and

governor control

clockwise

then

(in)

skips

at

this setting.

the belt if it

the

oil

fill

it with the proper quantity of

arm

and

until the engine

again;

then

becomes

fill

and

fill

level

reduce the engine's

skips;

tum the

screw

worn or shows signs

plug

and

drain

all

the

SAE

10/30

speed

with the

back the screw out

clockwise

(in)

1/4

This

mixture jet

the

unit

is

operating at

Adjustments"

is

pre-sized

1800

section of this

at

the

rpm,

manuaf

factory

will

and

have

an

for instructions

is not adjustable.

affect

on

the unit's performance.

on

how to adjust the engine's

An

adjustment to

the

idle jet

Refer

speed.

screw.

to the

while

IIGovernor

Westerbeke Generators 68

Torquing Cylinder Head

BoHs

Tighten the cylinder head bolts according

to

the sequence shown in the illustration below. Make sure the

engine is cold when this is done. Loosen one head bold one-half

torque. Then proceed

to

the next head bolt in the sequence numbering shown.

7.8

KW

8e6

,

BCGA

TIGHTENING

tum

and then tighten

SEQUENCE

it

to

the specified

Torque Specifications:

7.0

KVV

BeG &

BCGA

36.2 -43.4 Ib-ft (5.0 - 6.0 kg-m)

69

Westerbeke Generators

Valve

Clearance

Adjustment

NOTE: Retorque the cylinder head bolts before adjusting the engine's valves.

1.

Remove the rocker cover and the gasket.

2. Carry out the check and adjustment

with the piston

of

its compression stroke and the exhaust and intake

valves

completely closed.

below

for

3. Rotate

the cated

top

the

of

in

of

the No.1 cylinder positioned at the top

See

the values

crankshaft 180°

its

exhaust stroke. Adjust the values as

#3

of

to

the table

be adjusted

to

the right

of

valve clearances,

#2

of

the table

in

this position.

to

the right

position the No.1 piston at

indi-

below.

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

gasket.

2.9 -

5.1

Itrft

Rocker cover torque:

(0.4 ~ 0.7 kg-m)

Spark Plugs

#2

#3

CiAII(

ANGLE

~

Mo.

1M

Dr

COIIIpr

~ju.t

t .... ",iIlw

'hn

Mo.I

at

the

top of

adjust

tM

1

pi.tGfl

pilt.on

...

ion .t,..«.

uhaust

..,:alw..

i

...

•.

i.

t

..

t

positiOMd

stroke.

IN

EX

IN

EX

•

2

•

3 1

•

To service the spark plugs. clean,

needed.

IWARNINGI

Do

not

remove the spark plugs while the engine is hot. Allow the engine plugs.

Spark

plug gap: 0.028 -

Spark plug torque:

7.0 KW

Check each plug

BeG

& BCGA 10.8 -15.21b-ft

for

NOTE: Loc-tite

portion

of

the spark plugs

future removal of the spark

to

cool before removing the spark

0.031

(0.7 - 0.8 mm)

(1.5 - 2.1

damage and/or wear.

"Anti~Seizeu

gap

or

replace the plugs as

inches

kg-m)

applied

wDl

retard corrosion, making

to

the threaded

plugs easier.

PLUS

SAP

WEAR

AND

ADHESION

OF

CARBON

BURNT

CONDITION

DAMAGE

AHD

DETERIORATION

DAMAGE

Westerbeke Generators

70

General

LAY-UP

AND

RECOMMISSIONING

Many owners rely during the off-season or for long periods of inactivity. Others prefer

on

their boatyards to prepare their craft, including engines and generators, for lay-up

to

accomplish lay-up preparation

themselves.

The procedures which follow

a check list if others lay-up and

also help

do

the procedures.

famUiarize

regarding lay-up procedures,

will allow you to perform your own lay·up and recommissioning, or to

These

you with the maintenance needs of your engine. If you

call

your local servicing dealer;

procedures should afford your engine protection during a

have

any questions

he

will

be

more than willing

to

provide

use

as

assistance.

Fresh Water Cooling System

A

SO-50

solution of antifreeze and

all times. This solution may require a higher concentration of antifreeze, depending on the area;s winter

climate. Check the solution Should more antifreeze

be

concentrated mixture. Operate the engine to ensure a complete circulation

fresh

in

the manifold

needed.

water

drain

is

recommended for

to

make

sure the antifreeze protection

an

appropriate amount from the engine block

use

in

the fresh water cooling system at

and

is

adequate.

and

add a more

mixture of the antifreeze concentration throughout the cooling system. Now recheck the antifreeze solution's strength in the manifold.

Lubrication System

With the engine some paper towels and a plastic

When

installing the

base of the filter.

specification of

no

leaks.

Do

oj

life of your engine's

Fuel

System

Top

off

your fuel tanks with regular or unleaded gasoline with

should

used

be

are compatible with the primary filter/Water separator

primary fuel filter/Water separator, the

bowl.

Oean the filter screen at the inlet

warm,

drain

all

the lubricating oil from the

bag

around the filter

new

oil filter,

FDI

the sump with the correct amount

SE,

SF

or

not

leave the engine's old lubricating oil

SG.

be

sure

to apply a

Run

the engine and check for proper oil pressure

and combustion deposits combine to produce harmful chemicals which

internal parts.

added at this time to control algae and condition the fuel. Care should be taken that the additives

fuel

system should contain one, and clean the separator sediment

to

the carburetor.

oil

sump.

to

catch the

small

amount of oil on the rubber sealing gasket at the

of

oil

Remove

oil

and replace the

during its removal.)

for your engine model.

and

Use

make

CAUTION

in

the sump over the lay-up period. Lubricating

can

reduce the

an

octane rating

used

in

the system. Change the element in your

of

89 or higher.

oil

filter.

an

oil with sure there

Fuel

(Place

an

API

are

additives

71

Westerbeke Generators

Raw

Water Circuit

Oose the through-hull this

hose

into a 5-gallon bucket of

in

the primary

if

one

is

Start

the

is

empty,

winter

freeze

Start

the

is

empty,

the winter Remove

bucket).

heat

installed,

engine

stop the

protection

engine

stop the

lay-up, as

the impeller from your

Examine impeller (into the Lubrication

ll

section

sea

exchanger

in

the inside of

and

allow the

engine

and

allow

engine.

well

in

as

cock.

and

your

all

This

Remove

clean

on

the

engine

the

hull.

raw

water pump to draw

refill

the bucket

area.

of

this mixture to

antifreeze

prOviding

raw

water pump

the

fresh

and

mixture

corrosion protection.

the impeller. Acquire a replacement,·if pump)

until

recommiSSioning,

below.

Intake Manifold and Througf1..Hull Exhaust The

flame

sprayed

the

same

arrester

with fogging

manner.

on

the carburetor oil

into the intake of the carburetor. Oose off the exhaust outlet of the transom

Be

sure

to

remove

is

removed

both cloths

raw

water intake hose from the

water.

Before

clean

starting the

or replace it

fresh

with

an

antifreeze solution slightly stronger than

be

drawn through the

should

(some

protect the

antifreeze mixture will accompany

water through the

needed,

but replace the cover

to fog the

and

engine.

reinstall

the flame arrester prior to

as

required.

raw

and

Do not

sea

engine,

check the zinc anode found

aean

water

water circuit

a cover

and

gasket. gasket.

reinstall

cock.

the

system.

from

it.

Place

the

raw

water

When

the

needed

Once

the

freezing during

it,

so

catch

Do not

See

replace

the

"Cylinder

a cloth

start-up.

end

of

strainer,

bucket

for

bucket

it

in

the

in

a

Starter

Lubrication removal. in

Cylinder Lubrication

Fogging the engine Remove

Motor

and

Make

proper1y

replacing

the air intake screen

cleaning of the starter drive

sure

the battery connections

any

electrical connections

should

be done

(the

air filter)

as

fogging oil into the carburetor while the

coat

the

walls

and

spray a

small revolutions by gapped

prior to recommissioning. Oose off the carburetor's air filter with

of the cylinders,

amount of this

hand.

Reinstall,

pistons,

oil

into

but do not tighten, the spark

Spares

Lay-up

belts or coolant replace section of this

time provides a good opportunity to inspect the equipment to

hoses

need

replacement.

those items

used

during the

lay-up,

manual.

pinion

are

the last

and

of spray

engine

and

valve

each

spark plug hole

Check

such

is

advisable,

shut

off before attempting to

removed

the

is

running.

surfaces

from the starter.

antifreeze mixture

Marvel

Mystery

Spray enough

with this protective oil.

and

tum the

plugs,

your basic spares kit

as

filters and zinc

if access to the starter permits its

remove

is

drawn into the

Oil

or another commercially

oil

engine

as

these

an

oily

see

if external

and

anodes.

Refer

the

starter.

raw

Take

water circuit.

available

to

stall

the

Remove

engine.

the

This

spark

over two or three complete

will

need

to

be

cleaned

rag.

items

such

as

order items not

to the

on

IISPARE

hand,

PARTS

easy

care

will

plugs

and

drive

or

II

Westerbeke Generators

72

Batteries

If batteries are to that

way,

to prevent them from freezing. If there exists any doubt that the batteries will

or

that they will be subjected to

warmer,

Recommissioning

The as

more compatible environment.

recommissioning of your

those presented

normal starts.

be

left on board during the lay-up period,

severe

environmental conditions,

Westerbeke

in

the

"PREPARATIONS

However,

some

of the lay-up procedures will

engine.

1.

Remove

2.

Remove removed

the oil-soaked cloths from the intake manifold and from the

raw

water pump cover

and

during lay-up (ora replacement, if required). Install the

gasket.

Wear

rubber

gloves, a

rubber

apron,

acid batteries emit hydrogen, a highly-explosive or a lighted cigarette, cigar, or being serviced.

Shut off

pipe.

all

electrical equipment

during servicing.

unit after a

FOR

STARTING"

gasket.

IWARNINGI

and

eye

Do

not

make

sure they are fully charged,

seasonal

lay-up generally follows the

section regarding preparation for starting

need

Discard the

protection

gas,

gasket.

which

can

smoke or allow

in

the vicinity

remain

remove

when

the batteries

to

be counteracted

the

through-hull

Install the

raw

water pump cover with a

servicing

be

ignited by electrical arcing

an

open flame near the battery

to

prevent electrical arcing

and

exhaust

raw

water pump impeller

batteries.

and

fully

store them

same

before

port.

Lead

will

remain

charged

in

procedures

and

starting

new

the

cover

a

3.

Reinstall the terminals are

the batteries that were

clean

and

removed

that the connections

fully-charged.

4. Check the condition of the zinc anode

Note

that it

is

not necessary to

When

the unit is put into operation, the

flush

the antifreezelfresh water solution from the

effects.

5.

Start the unit

in

accordance with those procedures found

manual.

during the lay-up,

in

the

raw

water circuit

system

will

and

are

tight. Check

seH-flush

in

the

reconnect the battery

to

make

sure

and

clean

or replace the anode

raw

water coolant

in a short period of time

"STARTING

PROCEDURE"

cables,

making

the batteries

as

with

no

section of this

sure

are

needed.

system.

adverse

73

Westerbeke Generators

SPARE

Since

a possibDity exists

your home

port, certain spare parts should be kept

in

which the engine

may

refer to your engine's Parts List for part numbers

that should be carried

parts

1. A

Raw

Water Pump Impeller

2.

A Filter Screen for the Inlet to the Carburetor.

on

board at

Kit.

all

times.

PARTS

need

to be serviced at

on

board to

when

ordering spare

UST

help

sea

or while in a port other than

minimize delays

parts.

Listed

in

your voyage.

Please

below are those spare

3. A Raw

4.

Hose Oamps.

5.

A Spare

6.

Spark

7.

Control

8.

Zinc Anooe with

Water Pump/Fresh Water Pump/Governor -

on

Plugs,

Panel

Filter with a

Ignition

Fuses.

Heat

Spare

Wires,

Distributor

Exchanger

Quart of

End

Other parts, whose life expectancy cannot addition are

to

those listed above) especially

listed

below.

1.

Cooling System

2.

A Starter.

3. A 20

4.

An

Amp

Electric

DC

Fuel

Hoses.

Circuit

Pump.

Breaker.

Drive

Belt.

Engine

Cap,

Oil

Rotor

and a

and

Gallon

Points.

of

Gasket.

be

accurately predetermined, should

if

the

vessel

is

to

be

taken

on long ocean voyages. These parts

Premixed Antifreeze.

be

carried on board

(in

5. A Raw

6.

Battery Terminal Connectors.

7.

8.

Oil

9.

Overspeed Switch.

The

spare voyages. ocean

Water Pump

Carburetor

Fuel

or

major repair

Solenoid.

Pressure Switch/Water Temperature SwitchlExhaust Temperature Switch.

parts listed directly above

You may wish

voyages

as

to

ask other boat

to

what spare parts they carried of the voyage. From the list provided directly parts may dealer for a

Westerbeke

be needed.

In

addition,

listing of the Westerbeke dealers located

Generators

kit.

are

those

we

recommend

owners

if

you are planning a long ocean voyage, consult your local Westerbeke

above

who

on

and

on

74

have

board

from

your

be

carried

on

board during long ocean

similar crafts and who have completed long

and

what parts were needed at

these

inquiries, you

can

determine what spare

specifiC

times

route.

TABLE

Unless stated otherwise hardware.

Gmg~4I

6mm

bolt head/nut

Smm

10mm bolt head/nut 1.25 10mm bolt head/nut 12mm bolt head/nut 12mm 12mm 13mm bolt head/nut 14mm 14mm 16mm 16mm bolt head/nut 2 51.4 - 76.7

Grag~6I

10mm bolt head/nut 1.5 12mm 12mm bolt head/nut 1.5 12mm bolt head/nut

bolt head/nut

bolt head/nut 1.75 bolt head/nut 1.5 36.2 - 57.9

bolt head/nut bolt head/nut 1.5 54.2 - 79.6

6mm

bolt head/nut

8mm

bolt head/nut 1.25

10mm

bolt head/nut 1.25 bolt head/nut

OF

STANDARD

for

a specific assembly, use

Pitch

1 2.9 -

1.25

1.5

1.25

OSO)

1.5

2

1 4.3 -

1.250S0)

1.75

HARDWARE

the

following

TIGHTENING

7.2

13.7

13.0

25.3 - 39.S

25.3 - 39.8

21.7

32.5 - 50.6

34.0

10.8

21.7

19.5

36.2

34.7

TORQUES

torque

Ilrft

..

11.6

..

22.4

..

21.7

..

36.2 3.0.. 5.0

..

55.7

..

15.9

..

32.5 3.0.. 4.5

..

30.4

..

57.9

..

50.6

..

49.2

values when tightening standard

kg-m

5.1

6.5

0.4 - 0.7

1.0 - 1.6

1.9

1.8

3.5.. 5.5

3.5 - 5.5

4.5 -

5.0

4.7

7.5-11.0

7.1

0.6-

1.5 - 2.2

2.7 - 4.2

5.0 - 8.0

5.0 - 7.0

4.S-

..

3.1

..

3.0

7.0

..

8.0

..

7.7

-10.6

0.9

6.8

t1md~

7T.

aT

aDd

a·s

..

6mm

bolt head/nut bolt head/nut

Smm

10mm 10mm bolt head/nut 12mm

12mm bolt head/nut 1.5

12mm bolt head/nut 1.75 13mm 14mm 14mm bolt head/nut 16mm bolt head/nut 1.5 108.5 -166.4 15.0 -23.0

16mm

~!l1d~

bolt head/nut

5

~pscr~w

1/4

UNC

1/4

UNF 5/16UNC 5/16 UNF

UNC

3/8

UNF

7/16

UNC

7/16

UNF

1/2

UNC

1/2

UNF

1

1.25

1.5

1.250S0)

1.5

2

5.8

8.7

14.5 - 21.7 2S.9

..

39.S

26.8

..

37.6

54.2

..

75.9

SO.6 -65.1

43.4 - 61.5 ..

86.8

57.9

72.3

-10S.5 10.0 -15.0

68.7 -101.3 9.5 -14.0

101.3 -159.1 14.0 -22.0

11

9 -

11

- 13

18 - 20

23

21

-

28

..

33

30-

35

44

..

49

55

50-

68-

73

73 -

80

10.1 -11.1

0.8

..

1.2

2.0

..

3.0

5.5

4.0..

3.7

..

5.2

7.5

-10.5

7.0

..

9.0

6.0

..

8.5

8.0 -12.0

1.2 - 1.5 ..

1.8

1.5

2.5.. 2.8

2.9.. 3.2

3.7

- 4.6

4.1

- 4.8

6.1

- 6.8

6.9

..

7.6

9.4

-10.1

75

Westerbeke Generators

TABLE

OF

TIGHTENING

TORQUES

lb::ft

Cylinder Head BoIts*

(*See

the

Torquing

to

Crankshaft pulley

Rocker cover

Spark

plug

to

Timing belt cover

Timing belt tensianer

Valve adjusting screws

pan drain plug and oil pan 25.3 - 32.5

Oil

Flywheel bolts 28.9 - 36.2

crankshaft

to

cylinder block

cylinder head

#1

#2

Cylinder

36.2 - 43.4

Head

Botts

36.2

2.9 -

10.8

3.2 - 4.8

5.2

23.1

9.4

-43.4

5.1

-15.2

-7.8

- 34.7

- 13.0

section.)

.Kg;:m

5.0 - 6.0

5.0

-6.0

0.4 - 0.7

1.5 -

0.44

-0.66

0.72

-1.08

3.2

-4.8

1.3 - 1.8

3.S

-4.5

4.0

-5.0

2.1

Exhaust manifold

Intake manifold

8.4 - 12.6

7.5

- 10.8

1.16

1.04

-1.74

-1.56

Westerbeke Generators

76

INDEX

A

AC

Output.

Generator

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

Automatic Shutdown ...................................................................................................................................

B

23 23

Batteries

Battery BCA BC Break·ln

BELT CLAMP DO DO DO ENGINE NEVER

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

Specification ...................................................................................................................................

GENERATOR

Precautions

C

TENSION

THREAD

NOT

DISCONNECT

NOT

LEAVE

NOT

USE NOT

SHUT-OFF PROLONGED QUICK SUNGS WHEN UTiUTY

CHARGING

MUST

STARTING

SHORE

23 & 73

(60

HERTZ

(60 -50

ONLY)

HERTZ)

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

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

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

CAUTION

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

TORQUE

OIL

IN

SCOOP-TYPE

SHIPPED

ENGINE

CRANKING

BATTERY

NOT

BE

GENERATOR,

POWER

UMIT ...................................................................................................

DC

BA

lTERY

SUMP

OVER

THROUGH-HULL

WITH

OIL .....................................................................................................

BATTERY

INTERVALS

WITH

SHORT

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

AND

GENERATOR

SOURCE

LAY-UP

SWITCH

WITH

PERIOD

FITTING

WITH

ENGINE

ON

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

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

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

ENGINE

ON

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

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

EXTERNAL

TURN

AC

CHARGER

LOADS

OUTPUT

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

OFF

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

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

17 & 28

35

52

51

29

46

18 22 71 22

12 35

35

13

28

56

Ca.rburetor CARBURETOR Choke Connecting COOUNG Cylinder

DC

EJectrical DESCRIPTION DISCLAIMER,

Adjustment ...............................................................................................................................

AND

FUEL

SYSTEM

Solenoid ...........................................................................................................................................

Pressure

SySTEM

Sensing

....................................................................................................................... 21,

Lubrication ....................................................................................................................................

D

Connections ..........................................................................................................................

OF

ENGINE

PRODUCT

SOFTWARE

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

Devices

CONTROL

......................................................................................................... 1

to

Oil

PANEL

Galleries

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

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

n Westerbeke Generators

42

68 32 66 21

& 47

72

22 25

E

ELECTRICAL Engine ENGINE Engine Engine Engine ENGINE Exha.ust Exha.ust Exha.ust Extlaust

SYSTEM

12-Volt

CONTROL

Oil

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

Oil

Change

Oil

Viscosity

TROUBLESHOOTING Back-Pressure Elbow

System

F

FOREWORD

Fresh Fresh Fuel

System

................................................................................................................................................... 2

Water

Circuit ...................................................................................................................................... 42

Water

Cooling

........................................................................................................................................ 19 &

G

Gasoline

GENERAL

GENERAL GENERAL Generator Generator Generator Generator Generator Governor Govemor/Fresh Governor Grounding

....................................................................................................................................................... 32

....................................................................................................................................................... 5

INFORMATION SPECIACATIONS,

(AC Frequency Frequency Mounting-LClC:aIion Trout>leshooting

Adjustments ................................................................................................................................. 67

Maintel'lance

.................................................................................................................................................... 22

....................................................................................................................... 22 & 35

DC

ContrC>l

Circuit. ..............................................................................................................

PANEL,

DESCRIPTION

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

....................................................................................................................................... 49

(SAE

Number)

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

.................................................................................................................. 59

............................................................................................................................... 16

InstaJlation

.......................................................................................................................... 18

........................................................................................................................................... 15

FaHures

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

System .......................................................................................................................

AND

CARE

OF

THE

OutplJt)

GENERATOR

7.0

KW

BCG & BCGA

.................................................................................. 8

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

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

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

Adjustment ...............................................................................................................

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

....

......................................................................................................................... 58

WaterIRaw

Water!Pump

Belt

Tension

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

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

35

25

48

17

71 71

57

23

51

65

14

46

67

I

gnition

I

nspection

INSTALLATION

Intake

Timing

of

Equipment

Manifold

............................................................................................................................................. 66

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

CHECKS

and

............................................................................................................................ 12

Through-Hull

L

LAY..up

Loa.d

Westerbeke

AND

RECOMMISSIONING

Connections ........................................................................................................................................

Generators

Exhaust

................................................................................................ 72

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

78

12

71

55

LUBRICATION

M

SYSTEM

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

48 & 71

MAINTENANCE

AND

ADJUSTMENTS

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

N

Load Voltage Adjustment ...................................................................................................................... 53

No

o

Oil

Drain

Hose .............................................................................................................................................

Oil

Pressure

Optional

Ordering

Overspeed

Parts, PREPARATIONS Preventive Preventive PRODUCT

................................................................................................................................................. 48

Fuel

Filter/Water Separator .......................................................................................................... 33

Remote

Parts

Instrument

and

Remote

Start

Panels

............................................................................ 26

............................................................................................................................................... 5

Shutdown .................................................................................................................................

p

Ordering .............................................................................................................................................. 5

FOR

STARTING Maintenance, Maintenance,

SOFlWARE

Engine ................................................................................................................

Generator ........................................................................................................... 58

DiSCLAIMER

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

.......................................................................................................... 1

63

21

31

27

63

R

Raw

Water Circuit ................................................................................................................................

Raw

Water Intake

Raw

Water

System

Pump

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

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

Recommissioning ........................................................................................................................................ 73

Remote Remote Replacing Required Rigging

Starting

Pr<>eedure

........................................................................................................................ 30

Stopping Procedure ......................................................................................................................

Filter

Elements

........................................................................................................................... 33

Operating Speed ......................................................................................................................... 57

af'ld

Lifting ...................................................................................................................................... 13

s

Shore Power

SPARE Spares Spark

Plugs

SPECIFICATIONS,

Connections ..........................................................................................................................

PARTS

UST

.................................................................................................................................... 74

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

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

GENERAL,

7.0

KW

BCG & BCGA

45 & 72

................................................................................. 8

79

Westerbeke Generators

21 45

31

56 72

70

SPECIFICATIONS,

SYSTEM,

7.0

t<MI

BCG & BCGA

.............................................................•........•...........•. 9

Starter Motor ................................................................................................................................................

STARTING

Starting Under Starting

STOPPING SYSTEM

PROCEDURE

CC>Id

Under

Nortll81

PROCEDURE

SPECIFICATIONS,

AC

Generator .....................................................................................................................................

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

Conditions ..................................................................................................................

Conditions ..............................................................................................................

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

7.0

KW

BCG & BCGA

Cooling ................................................................................................................................................. 9

Electrical. ............................................................................................................................................ 1 0

Fuel ....................................................................................................................................................... 9

Ignition ................................................................................................................................................. 9

Intake

.................................................................................................................................................... 9

Lubrication ......................................................................................................................................... 10

Tune-Up

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

T

72

28

29

31

11

TABLE TABLE TABLE

Testing

OF

CONTENTS

OF

STANDARD

OF

TIGHTENING

the

Battery Charging Circuit ...........................................................................................................

.................................................................................................................................. 3

HARDWARE

TORQUES

TIGHTENING

TORQUES

................................................................ 75

.......................................................................................................... 76

36

Thermostat ................................................................................................................................................... 44

Torquing Cylinder Head Bolts ..................................................................................................................... 69

u

Understanding the Gasoline Use

of Electric Motors .................................................................................................................................

v

Valve

Oearance Adjustment .......................................................................................................................

Ventilation .....................................................................................................................................................

W

Engine-Driven

Generator ................................................................................ 5

57

70 24

IWARNINGI

CARBON DO DO

FUEL INSTAWNG

NEVER

OVERS REMOVE WEAR

MONOXIDE

NOT

ATTEMPT A NO-LOAD ADJUSTMENT

NOT

SMOKE

NEAR

GAS

BATTERIES ................................................................................................ 23

LEAKAGE ......................................................................................................................

THE

opnONAL

ADJUST DRIVE BELT TENSION WITH ENGINE ON ........................................................... 46

PEED

SHUTDOWN

SPARK PLUGS ONLY

PROTECTION

MUST

WHEN

Westerbeke Generators

IS

DEADLyl

REMOTE

BE

WHEN

SERVICING

................................................................................. 15 & 28

WITH

ENGINE ON ............................................... 53

20 & 34

PANELS

............................................................................. 26

FUNCTIONING ....................................................................

ENGINE

BA lTERIES ...........................................................

IS

COOL ............................................................. 70

24 & 73

80

31

WIRING WIRING WIRING

z

Zinc

Ancx:Jes

DIAGRAM DIAGRAM DIAGRAM

#38024, #38025, #38028,

OPTIONAL

DC

CONTROL

REMOTE

CIRCUIT

START

INSTRUMENT

PANEL

....................................................................... 38 &

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

PANEL

...........•....•...•..•.•..••.•.•..•.........

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

40

41

39

45

81

Westerbeke

Generators

NOTES

Westerbeke Generators 82

Westerbeke 3.0BCG, 4.5BCG, 5.0BCG, 7.0BCG, 7.0BTG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual