Westerbeke 4.5 KW BCGTC, 3.75KW BCGTC, 7.2 KW BCGTC, 6.0 KW BCGTC, 9.6 KW BCGTC Operator's Manual

OPERATORS

MANUAL

WESTERBEKE

•

I

GASOLINE

GENERATOR

CARBURETOR

4.5

3.

7.2

6.0

9.6

8.0

KW

75KW

KW
KW
KW
KW

Single

PUBUCATION 42832

1

st

Edition / September 1997

BCGTC -60
BCGTC -50
BCGTC -60
BCGTC -50
BCGTC -60
BCGTC -50

Phase

MODELS

Hz
Hz
Hz
Hz
Hz
Hz

~

WESJ'ERBEKE

WESTERBEKE

AVON

,

MA

~~.,"""

~M'A

CORPORATION· AVON

02322 • TEL:

M~mber

Naiio1l41

(SOB)

Morine

588-7700 ·

M

INDUSTRIAL

FAX:

(SOB)

o.twfoctu~rsASS()CiD.tion

PARK

559-9323

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this SIlfety manu4l carefully. Most accidents are caused
by faiLure
Kn
necessary precautions
and

The
the A merican

PREVENT

A

while

power.

• Do not operate this machinery without electrical

• Shut

• Use insulated mats whenever

• Make sure your clothing

• Remove wristwatch and all jewelry when working on

•

• Electrical shock results from handling a charged capacitor.

PREVENT

A

exhaust

very

• Always check the engine coolant level at the coolant

A

• In case

w follow fundamenwL

ow

when dangerous conditions exist

to protect yourse/};

your machin
following SIlfety instructUms are

WARNING:

engine

Lethal

enclosur

off

equipment.

equipment.

(particularly shoes) when handling electrical equipment.

electrical equipment.
00

not connect utility shore

circuits, except through a ship-la-shore double throw

transfer switch. Damage to

result if this procedure is not followed.

Discharge capacitor

WARNING:

hot!

recovery tank.

WARNING:

before touching the engine

ery.

Boat

and

Yacht

ELECTRIC

is

voltage

es and

electrical power before accessing electrical

SHOCK

Do

not

ronning, or

is

covers

in

by

BURNS -HOT

00

not

system

components

Steam

of

an engine overheat, allow the engine to cool

rul

es

and precautions.

and wke the

you

r personnel,

in

compliance with

Council

touch

when

present

place.

and

power

vessel's

shorting terminal s together.

(ABYC) swndards.

AC

electrical

connected

at

these

working

skin are dry, not damp

to

AC

connections

to

shore

connections!

on electrical

vessel's

AC

generator may

ENGINE

touch

hot

engine

. A

ronning

can

cause

or

checking the coolant.

injury

parts

engine

or

death!

or

gets

PREVENT

A

• Prevent flash fires.
sparks to occur near the carburetor, fuel line, filter, fuel

pump,

vapors. Use a suitable container to catch all fuel when

removing the fuel line; carburetor,

•

00
arrester removed. Backfire can cause severe injury
death.

•

Do

Bac'kfire can cause severe injury

• Do not smoke

fuel system. Keep the compartment and the engine/gener·
ator clean and free

fire. Wipe up all spilled fuel and engine oil.

•

Be aware - diesel fuel will bum.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin

af

the blower. Run the blower for four minutes before start­ing your engine.

• All fuel vapors are highly explosive. Use extreme care when
handling and storing fuels. Store fuel
area away from spark-producing equipment and o
reach

00

•

• Shut
the

spill.
sources

Ensure proper ven

system.

•

00

•

Be

Be

•
free

•

Make sure a fire extinguisher is installed nearby and is
properly maintained .
Extinguishers rated
for all applications encountered

BURNS -FIRE

WARNING:

or

not operate with a Coast Guard Approved flame

not operate with the air cleaner/silencer rem oved.

Fire

can

cause

00

not smoke or permit flames

other potential sources

or

pennit flames

of

debris to minimize the chances

injury or

of

or

or

death!

or

spilled fuel

or

fuel filters.

death.

sparks to occur ncar the

or

fuel

or

of

BURNS -EXPLOSION

WARNING:

or

death!

ter fueling. Check below for fumes/vapor before running

of

children.

not

fill

off

the fuel service valve

fuel system. Take care

DO

of

not alter
sure all fuel supplies have a positive shutoff valve.
certain fuel line fittings are adequately tightened and

of

leaks.

Explosions

the fuel tank(s) while the engine is running.

NOT

allow any smoking, ope n flames ,

fire near the

tilation exists when servicing the fuel

or

modify the fuel system.

ABC

from

fuel

vapors

in

a well·ven tilated

at

the engine when servicing

in

catching any fuel that might

fuel

sys

tem

or

engine when servicing.

Be

familiar with its proper use.

by the NFPA are appropriate

in

this environment.

can

cause

ut

or

of

the

other

Engines

& Generators

SAFETY

INS

TR

UCTIONS

ACCIDENTAL

A

WARNING:

Dr

death!

• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first

it

last.

• Make certain all personnel are clear
starting.

• Make certain all covers, guards, and hatches are

installed

BATTERY

A

WARNING:

Dr

death!

•

Do

not
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can
arcing
equipment in the vicinity to prevent electrical arcing during

servicing.

• Never connect the negative

(+) connection lenninal

tive
test the battery condition by shorting the terminals

together. Sparks could ignite battery gases
Ventilate
accumulation
disturb the battery charger connections while the battery is
being

• Avoid contacting the
burns
wristwatch, rings, and any other jewelry before handling
the battery.

• Always

the battery connections. Remove the negative lead first

and reconnect

BATTERY

A

WARNING

severe

STARTING

Accidental

before

starting the engine.

starti

ng

can

cause

and

of

the engine before

reconnect

EXPLOSION

Battery

smoke

or

allow an open flame near the battery

or

by lit

tobacco products. Shut

any

compartment containing batteries to prevent

of

explosive gases.

charged.

or

sparks that could cause an explosion. Remove

tum

the battery charger

it

last when servicing the battery.

explosion

(-)

of

leoninals

can

cause

injury

be

ignited by electrica l

off

all electrical

battery cable to the posi-

the starter solenoid.

or

fuel vapors.

To

avoid sparks, do not

with tools, etc.! to prevent

off

before disconnecting

ACID

:

injury or

Sulphuric

death!

acid in batteri

es

can

injury

re~

Do not

cause

TOXIC

• Ensure that the exhaust system is adequate to expel gases

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

•

• For addi tional information refer

• Do not use copper tubing

• Do not install exhaust outlet

EXHAUST

A

WARNING:

discharged from the engine.
regularly for leaks and make sure the exhaust manifolds
are securely attached and no
attention to the manifold,
exhaust pipe nipple .

In

addition to routine inspection

install a carbon monoxide detector. Consult your boat

or

builder

tional information on Carbon Monoxide).

A

WARNING:

odorless

nausea

• AJthough diesel engine exhaust

gas_

Dr

death!

fumes can rapidly destroy copper tubing
tems. Exhaust sulfur causes rapid deterioration
tubing resulting

through portholes, vents,
exhaust discharge outlet is near the waterline, water could

enler the exhaust discharge outlet and

of

flow

exhaust fumes from gasoline engines, carbon monoxide
gas is present
toms

exhaust. Avoid overloading the craft.

or

signs

GASES

Cari10n

dealer for installation

Cari10n

Inhalation

in

in

diesel exhaust fumes. Some

of

carbon monoxide inhalation

monoxide

Check

warping

water

monoxide

produces

in

diesel exhaust systems. Diesel

exhausVwater leakage.

where

or

air

(CO)

is a

deadly

the exhaust system

exists. Pay close

injection elbow, and

of

the exhaust system,

of

approved detectors.

to

ABYC

T-22 (educa-

(CO)

is

an

invisible

flu-like

conditione~.

gases

symptoms

in

exhaust sys-

of

exhaust can

close

are not as toxic as

be

If

the engine

or

restrict the

of

the symp-

or

poisoning

copper

gas!

,

drawn

are:

Vomiting
Dizziness

Throbbing

Muscular twitching
Intense headache
Weakness and sleepiness

AVOID

MOVING

in

temples

PARTS

•

When

servicing the battery

wear

level,

tion. Batteries contain sulfuric acid which is destructive.
it

comes

with water. Acid may splash on the skin

inadvertently when removing electrolyte caps.

rubber gloves, a rubber apron, and eye protec-

In contact with your skin, wash

or

checking the electrolyte

it

off

at once

or

into the eyes

~

A

WARNING:

If

or death!

•

Do

not service the engine/generator while

situation arises

WESTERBEKE

En

gines

& Generators

i i

Rotating

in

which

parts

can

cause

injury

it

is running.

it

is absolutely necessary to make

If

a

SAFETYINSTRUCT10NS

r

operating

moving

• Do not wear loose clothing or jewelry when servicing

equipment;

rings, necklaces
moving parts.

• Make su
Keep protective shields and guards
places at all times.

• Do not check fluid levels

the

• Stay clear

when the

be caught

HAZARDOUS

A

adjustments,

parts

and

hot

avoid

wearing

or

re

all allaching hardware

engine/generator

of

the drive shaft and the transmission coupling

engine is

in

these rotating

NOISE

WARNING:

High

use

extreme

exhaust

loose

bracelets that could be caught

or

is

operating.

running;

care

to

avoid

system

components.

jackets,

the drive belts' tension while

hair

shirts,

is

properly tightened.

in

their respective

and

clothing

can

sleeves,

parts.

noise

levels

can

cause

healing

touching

in

easily

loss!

• Never operate a generator without

• Do

not

run

an

engine

with

removed.

•

Do

not run engines

their

enclosures

or

generators for long periods with

open

.

the

its

muffler installed.

air

intake

(silencer)

ABYC, NFPA
INSTAWNG

AND

USCG

GASOUNE

AND

PUBLlCAnONS

DIESEL

FOR

ENGINES

AND

GENERATORS

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

ABYC
"Safety Standards for Small Craft"

Order From:

NFPA (National Fire Protection Association)

"Fire Protection Standard for Motor Craft"
Order From:

"USCG 33CFR183"

Order

(American Boat and Yacht Council)

ABYC
15

East 26th

New York, NY 10010

NFPA
1 Ballerymarch Park
P.O.

Box 9101

Quincy, MA 02269-9101

USCG (United

From:

U.S. Government Printing Office

Washington, D.C. 20404

~treet

States Coast Guard)

A

WARNING:

ale

mentally

OPERATORS

Many

of

the preceding safety tips and warnings are repeated

in

your

Operators

notes

to

highlight critical information. Read your manual

carefu

lly,

maintain

procedures.

GASOLINE

Do

01

physically

MANUAL

Manual

your

ENGINE

AND

not

work

on

machinery

incapacitated

along

with

equipment,

and

GENERATOR

other

follow

when

by

fatigue!

cautions

all

you

and

safety

INSTALLATIONS

Preparations
begin

Yacht Council's (ABYC) standards. These standards are
a combination

Sections

H-2 Ventilation
H-24 Gasoline fuel systems
P

-1

Exhaust systems

P4

Inboard engines

E-9 DC Electrical systems

All installations must comply with the Federal Code
Regulations (FCR).

to

install

with a thorough

of

sources including the USCG and the

of

the

ABYC

a gasoline

examination

standards

engine

or

generator

of

the

American

of

particular interest are:

should

Boat

of

and

from

NFPA.

Engines & Generators

iii

INSTALLATION

•

When installing WESTERBEKE engines and generators
attention be paid to the following infonnation:

CODES

Strict federal regulations. ABYC guidelines. and safety codes must be complied with

when installing engines

AND

REGULATIONS

and

generators

in a marine environment.

it

is impo

nant that s

tri

ct

SIPHON·BREAK

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

or

below

the

vessel's

th

e raw water supply hose to the exhaust elbow. This hose must be looped a minimum

of

IS" above the vessel's waterline. Failure to use a siphon-break when

numif

old

injection

damage

EXHAUST

Th

prevent

of the vessels hull.

to

the engine and possible flooding

SYSTEM

e exhaust hose must

water

A

detailed
diesel,
dealer.

port

from

entering

40

engines

wate

rlin

e,

provisions must

is

at

or

below the load waterline will result in

be

certified for marine use. The system must

the

page

and

exhaust

Marine

generators,

under

Installation

of

is

available

be

made

the

boaL

any

sea conditi

Manual

covering

from

to

install

a s

ons

and

gasoline

your

WESTERBEKE

iph

on-

break

th

e exhaust

raw

waLer

be

designed to

at any angle

and

in

~

WESTERBEKE

Engines & Generators

iv

-.v'

WESJERBEKE

Engines & Generators

Declaration

of

Conformity

Application

of

Council

Directive(s)

Standard(s)

to

Which

Conformity

is

declared

Manufacturers

Name

Manufacturers

Address

Type

of

Equipment

Product

Name

Model(s)

Product

Options

Supplementary

Information

EMC

89/336IEEC

ISO

8846 1990(E)

EN50081-1
EN50082-2

EN55020

ISO-8846-1990(E),

Certification

Number,

IWES003

Westerbeke

Corporation

41

Ledin

Drive

Avon

Industrial

Park

Avon,

Ma.

02322, USA

Marine

Gasoline

Generator

Westerbeke

Marine

Gasoline

Generator

3.7/4.5BCGTE,6.017.2BCGTE

8.0/9.6BCGTE,3.7/4.5BCGTC,

6.017.2BCGTC & 8.0/9.6BTGTC

All

1.)

The

equipment

listed is only for use

in

Marine

Applications

aboard

boats.

2.)

The

equipment

listed

must

be

located below decks on

the

vessel

and

permanently

installed in

it's

location.

3.)

The

equipment

listed

must

be

wired

to

the

grounding

system

of

the

vessel.

I

the

undersigned,

hereby

declare

that

the

equipment

specified above conforms to

the

above Directive(s)

and

Standard(s).

Place Avon. Massachusetts, U.S.A.

Date: September 1, 1996

Carleton

F.

Bryant

(Full Name)

Chief Operating Officer

(Title)

WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON,

MA

02322 U.S.A

.•

TEL.[phone]

.FAX:

[phone]_ WEBSITE:WWWWESTEABEKE.COM

INTERNATIONAL

MARINE

CERTIFICATION

INSTITUTE

Treves Centre, Rue de Treves 45

B-1040

8RUXELLES

BELGIQUE

tel: [phone]

fax: [phone]

eEl?

TIFICA

TE

We

hereby certify the component stated below meets the

EC

Directive 94J25/EC for

type-examination in accordance with

ISO 8846 and has following characteristics:

ITYPE

I

Gasoline Marine Generator

MANUFACTURER

Westerbeke Corp.

ADDRESS

Avon Industrial Park,

Avon, MA

02333

USA

IGROUP

OF

I

+++++

I

+++++

I

+++++

Model 1 3.7/4.5 BCGTE

+++++

+++++

Model 2 6.017.2 BCGTE

+++++

+++++

Model

3

80/96

BCGTE

+++++

+++++

Model

4 3.7/4.5 BCGTC

+++++

+++++

Model 5

60/7.2

BCGTC

+++++

+++++

Model 6

80/9.6

BCGTC

+++++

+++++

Model 7

+++++

+++++

+++++

Model 8

+++++

+++++

+++++

Model 9

+++++

+++++

+++++

Model 1 0

+++++

+++++

+++++

Model

11

+++++

+++++

+++++

Model 12

+++++

+++++

+++++

Model

13

+++++

+++++

+++++

Model 14

+++++

+++++

+++++

Model 15

+++++

+++++

+++++

Model 16

+++++

+++++

+++++

Model

17

+++++ +++++

+++++

Model 18

+++++

+++++

+++++

Model

19

+++++

+++++

+++++

Model 20

+++++

+++++

+++++

Model

21

+++++ +++++

+++++

Model 22

+++++

+++++

+++++

Model 23

+++++

+++++

+++++

Certification

number

IWES003

/

Signed

..(.c'/h

?

-,\:::://r

<'-~-,

Name Lars

E.

8r'§nholm

Title

Managing Director

EU

Notified Body No 0609

Date 02/0211998

I

I

TABLE

OF

CONTENTS

Introduction

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

.2

Engine

Lubricating

0i1

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

16

Warranty Procedures .................................................... 2

Description .................................................................

16

Customer Identification

Card

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

Changing the Engine Oil... ......................................... 16

Product Software ......................................................... .2

Replacing the Oil Filter. ............................................. 16

Serial

Number

Location ............................................... 2

Refilling the Oil Sump ............................................... 16

Ordering

Parts .............................................................

.3

Notes, Cautions

and

Warnings ..................................... 3

Remote

Oil

Filter

(Optionalj

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

17

Installation .................................................................. 17

Protecting Your Investment .........................................

.3

Spares

and

Accessories ............................................... .3

Control

Panels

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

..4

DC

Electrical

System

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

18

12-

Volt

DC

Control Circuit. ...................................... .18

Batteries ...................................................................... 18

Generator

Panel

............................................................ 4

Remote

Panel .............................................................. .4

Overspeed Circuit Board ............................................. .4

Safety

Shutdown

Switches

.......

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

.5

Specifications ...................................................... 18

Battery Maintenance ...........................................

18

Battery

Charging ........................................................

18

Component Testing ....................................................

18

Safety Shutdown Switches .......................................... .5

Wiring Diagram #42834 ............................................. 19

High Exhaust Temperature Switch ......................

.5

Wiring Schematic #42834 ......................................... .20

High

Water

Temperature Switch ..........................

.5

Wiring Diagram #42857 Remote Panel(s) ................

.21

Low

Oil Pressure Switch .....................................

.5

Engine Circuit Breaker ........................................

.5

Fuel,

Engine

Oil

and

Engine

Coolant

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

6

Engine

Adjustments

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

22

Engine Speed (Hertz) Adjustment... ........................... 22

Governor ............................................................. 22

Gasoline ........................................................................ 6 Governor Adjustments ........................................ 22

Care of the Fuel Supply ............................................... 6

Governor Maintenance ....................................... .22

Engine

Oil

.................................................................... 6

Torquing the Cylinder Head Bolts ............................. 22

Engine Coolant ............................................................. 6 Valve Clearance Adjustment ...................................... 22

Coolant Recovery Tank ................................................ 6

Choke Solenoid ..........................................................

23

Preparations

for

Initial

Start-Up

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

7

Prestart

Inspection ......................................................

_,

7

Operating

Instructions

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

8

Generator

Panel

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

Starting

the

Generator ........................................... 8

Stopping the Generator ......................................... 8

Remote Panel ............................................................... 8

Ignition Timing .......................................................... .23

Spark Plugs .................................................................

23

Carburetor Adjustment .............................................. .24

Drive Belts Adjustment ............................................. .24

Timing Belt Inspection

and

Replacement ................. .25

Engine

Troubleshooting

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

.29

Generator

Information

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

.31

Starting

the

Generator ........................................... 8 Use

of

Electric Motors ..............................................

.31

Stopping the Generator ......................................... 8 Required Operating Speed ........................................

.31

Emergency .stopping .................................................... 8

Generator Frequency Adjustment ..............................

31

Starting Under Cold Conditions ................................... 8 Generator Maintenance ..............................................

31

Abnormal Stop ............................................................. 8

Generator

Wiring

Diagrams

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

.32

Break-In

Procedure/Daily

Operation

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

9

AC

Electrical

Connections

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

33

Break-In

Procedure ...................................................... 9

Check List .................................................................... 9

Stopping the Generator ................................................ 9

Generator Adjustments ................................................. 9

Maintenance

Schedule

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

10

Engine

Cooling

Circuit..

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

12

Lay-Up

&

Recommissioning

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

.34

General ....................................................................... 34

Fresh Water Cooling System ...................................... 34

Lubrication System ................................................... .34

Fuel System ............................................................... .34

Raw

Water

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

34

Description .................................................................

12

Intake Manifold ......................................................... .35

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

13

Starter Motor ............................................................. .35

Thermostat Test ..........................................................

13

Cylinder Lubrication ................................................ .35

Draining

the

Coolant ..................................................

13

Spare Parts ................................................................. .35

Refilling the Coolant ..................................................

13

Batteries ..................................................................... .35

Raw Water

Pump ........................................................ 14 Recommissioning ....................................................... 35

Changing the Raw Water Pump Impeller .................. 14

Heat Exchanger .......................................................... 14

Drive Belt Adjustment .............................................. .14

Fuel

System

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

15

Gasoline .....................................................................

.15

Carburetor ..................................................................

.15

BCGTC

Generator

Specifications

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

36

BCGTC

Generator

Parts

Identification

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

.37

Standard

Hardware

Torques

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

.38

BCGTC

Generator

Hardware

Torques

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

.39

Metric

Conversions

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

.40

Gasoline/Water Separator and Filter ..........................

15

Suggested

Spare

Parts

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

.41

Fuel Pump .................................................................. 15

Gasdenser ................................................................... 15

Engines & Generators

1

INTRODUCTION

This

WESTERBEKE

Generator is a product

of

WESTERBEKE'S

long years

of

experience and advanced

technology. We take great pride

in

the superior durability and

dependable perfonnance

of

our engines and generators.

Thank you for selecting WESTERBEKE.

In

order to get the full use and benefit from your generator,

it

is important that you operate and maintain

it

correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer for assistance.

This is your Operators Manual. A

Parts Catalog is also
provided and a Technical Manual is available from your
WESTERBEKE

dealer. Also, if you are planning to install
this equipment yourself, contact your WESTERBEKE dealer
for

WESTERBEKE'S

Installation Manual.

WARRANTY

PROCEDURES

Your

WESTERBEKE

Warranty is included

in

a separate
folder. If you have not received a customer identification
card registering your warranty

60 days after submitting the
warranty registration form, please contact the factory in
writing with model information, including the

unit's serial

number and commission date.

I~l

WESTERBEKE

1

Marine

Engine

Pl'Oducts

Customer

Identification

WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA

Model

BCGTC

Ser.

#D703XXXX

Expires

9/20/02

CUSTOMER

IDENTIFICATION

CARD

(Typical)

The

WESTERBEKE

serial number is an alphanumeric

number that can assist in determining the date

of

manufacture

of

your WESTERBEKE engine/generator.

The

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

C=1980s, D=1990s), the second character represents the year

in the decade, and the fourth and fifth number represents the
month

of

manufacture.

PRODUCT

SOFTWARE

Product software (tech data, parts lists, manuals, brochures
and catalogs) provided from sourccs other than

WESTER-

BEKE

are not within

WESTERBEKE'S

CONTROL.

WESTERBEKE

CANNOT

BE

RESPONSIBLE

FOR

THE

CONTENT

OF

SUCH

SOFTWARE,

MAKES

NO

WARRANTIES

OR

REPRE·

SENTATIONS

WITH

RESPECT

THERETO,

INCLUDING

ACCU·

RACY,

TIMELINESS

OR

COMPLETENESS

THEREOF

AND

Will

IN

NO

EVENT

BE

LIABLE

FOR

ANY

TYPE

OF

DAMAGE

OR

INJURY

INCURRED

IN

CONNECTION

WITH

OR

ARISING

OUT

OF

THE

FURNISHING

OR

USE

OF

SUCH

SOFTWARE.

WESTERBEKE customers should also keep

in

mind the time

span between printings

of

WESTERBEKE

product software

and the unavoidable existence

of

earlier

WESTERBEKE

manuals.

In

summation, product software provided with

WESTERBEKE

products, whether from

WESTERBEKE

or
other suppliers, must not and cannot be relied upon exclu­sively as the definitive authority on the respective product.

It

not only makes good sense but is imperative that appropriate
representatives

of

WESTERBEKE

or

the supplier

in

question

be consulted to determine the accuracy and currentness

of

the

product software being consulted by the customer.

SERIAL

NUMBER

LOCATION

The

generator serial number and model

number

is located on
a decal on the the generator housing. Take the time to enter
the information on the blank decal provided. This will

pro-

vide a quick reference

when

seeking technical information

and/or ordering parts.

Engines & Generators

2

INTRODUCTION

The

engine model number and serial number are located on a

plate mounted on the

engine's valve cover.

ORDERING

PARTS

Whenever replacement parts are needed, always provide the

generator and engine model and serial numbers.

In

addition,
include a complete part description and part number for each
part needed (see the separately furnished

Parts Catalog). Also

insist upon WESTERBEKE packaged parts because

will fit

or

generic parts are frequently not made to the same specifi-

cations as original equipment.

NOTES,

CAUTIONS

AND

WARNINGS

As

this manual takes you through the operating procedures,

maintenance schedules, and troubleshooting

of

your genera-

tor, critical information will be highlighted by NOTES,

CAUTIONS, and WARNINGS.

An explanation follows:

NOTE:

An

operating procedure essential

to

note.

A

CAUTION:

Procedures,

which

if

not strictly

observed,

can

result

in

the

damage

or

destruction

of

the

engine

or

generator.

A

WARNING:

Procedures,

which

if

not

properly

followed,

can

result

in

personal

injury or

loss

of

life.

PROTECTING

YOUR

INVESTMENT

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

WESTERBEKE

generator capable

of

many thousands

of

hours

of

dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner

in

which the unit is

operated and serviced

in

the field. This is up to the

buyer/owner-operator.

NOTE:

Six important steps to ensure long generator life:

•

Proper

engine

and

generator installation

and

alignment.

•

An

efficient well-designed

exhaust

system that includes

an

anti~siphon

break to

prevent

water

from

entering

the

engine.

•

Changing

the

engine

oil

and

oil fdters every

ZOO

operat.

ing

hours.

• Proper maintenance

of

all

engine

and

generator compo-

nents

according

to

the

maintenance schedule

in

this

manual.

• Use clean, filtered unleaded fuel.

• Winterize

your

engine

according to the "Lay-up

and

Recommissioning"

section

in

this mnnual.

SPARES

AND

ACCESSORIES

Certain spare parts will be needed to support and maintain
your WESTERBEKE generator

or

engine when cruising (see

SUGGESTED SPARE PARTS). Often even simple items such

as proper

fuel and oil filter can be difficult to obtain along

the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you

in

preparing an

on-board inventory

of

the proper WESTERBEKE parts.

Engines & Generators

3

CONTROL

PANELS

GENERATOR

PANEL

The

ON

and START/OFF switches are the

only

functional

components to operate

the

generator at the engine. Both

switches are used to start

the

generator - see Starting the

Generator under

OPERATING

INSTRUCTIONS.

The

ON

switch is a two-position switch with

momentary

contacts

in

the up (on) position and a stationary contact

function

in

the center position. This switch energizes the

fuel pump.
The

START/OFF switch is a three-position

switch

with

momentary contact functions in the

up

(start)

and

down

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

center position.

When

in

the

center (normal) position, this

switch allows the

generator

to be run, once started.

When

in the up (start) position (together with the

ON

switch in

the up position), this

switch

starts the generator,

and

once

released, reverts to the

center

position. When

in,

the

down

(off) position, this switch

stops

the engine

in

nonnal

oper-

ation

as

well as in an emergency situation.

When

maintenance is

being

performed on the generator,

the 8

amp

fuse should

be

removed. This will disable the

remote control panel(s), preventing attempts

to

start the

generator from their locations. However,

it

is

always

best

to disconnect the battery

during

this time

jf

it is not

required to perfonn

the

maintenance.

START/OFF
TOGGLE

SWlTCH

8

AMP

FUSE:

THE 8 AMP

FUSE

ENERGIZES

THE

.

DC

CIRCUIT

,

HOURMffiR:

THE

HOURMETER

RECORDS

ELAPSED

TIME

OF

ENGINE

USAGE.

THE

TOTAL

NUMBER

OF

HOURS

SHOULD

BE

USED

AS A GUIDE

FOR

MAINTENANCE

SCHEDULING.

20

AMP

CIRCUIT

BREAKER:

THE

20

AMP

RESET

CIRCUIT

BREAKER

PROTECTS

THE

ENGINE'S

ELECTRICAL

SYSTEM

FROM

ELECTRICAL

OVERLOADS.

~-I+

___

ON

TOGGLE

SWITCH

CIRCUIT

BREAKER:

THE

HEAVY

DUTY

ON/OFF

CIRCUIT

BREAKER

SHUTS

DOWN

THE

GENERATOR'S

AC

POWER.

NOTE:

THIS

CIRCUIT

BREAKER

SHOULD

BE

IN

THE

OFF

POSITION

WHEN

PERFORMING

MAINTENANCE.

REMOTE

PANEL

There are three functional components on

the

remote panel

for generator operation:

LON

switch

2.

START/STOP switch

3. Green

LED

indicator light

The

ON

switch

is

a two-position switch with momentary

contact functions

in

the up

(Oil)

position and a stationary con-

tact function in the center position.

This

switch energizes the

fuel pump.

The

START/STOP switch is a three-position switch with

momentary contact functions

in

the up (start) and down

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

ter position.

The

center position is a dual

offJrun

mode posi-

tion and is normally

in

the

off

mode. When

in

the

start (up)

position, this switch starts the generator (together with the

ON

switchin

the

up position) and once released, reverts to

the center position,

run mode. When

in

the

stop

(down) posi-

tion, this switch stops the generator, and

once

released,

reverts to the center position,

off

mode.

The

Green

LED

indicator light indicates

the

engine running

condition.

It

lights when the ON switch is

moved

to the start

position,

dims

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

START/STOP
TOGGLE

SWITCH

REMOTE
PANEL

OVERSPEED

CIRCUIT

BOARD

ON

TOGGLE
SWITCH

The overspeed circuit board senses the engine speed through
pulses

off

the engine coil. If the engine speed exceeds 3800

rpm, this overspeed circuit

will

activate, and will interrupt DC

power to the K2 relay shutting the engine down.

It has an

automatic reset.

GENERATOR
PANEl

a

~

WESTERBEKE

OVERSPEED
CIRCUIT

BOARD

Engines & Generators

4

SAFETY

SHUTDOWN

SWITCHES

SAFETY

SHUTDOWN

SWITCHES

The

engine is protected by three automatic shutdown

switches. Should a shutdown

occur, do

not

attempt to restart

without

finding

and

correcting the cause. Refer to the head-

ing

Engine starts, runs and then shuts down

in

the ENGINE

TROUBLESHOOTING section

of

this manual.

The

following is a description

of

these automatic

shutdown

switches:

High

Exhaust

Temperature

Switch

An

exhaust temperature switch is located on the exhaust
elbow. Nonnally closed, this switch will open and interrupt
the

DC

voltage to the K2-run relay (shutting off the engine)

should the switch's sensor indicate an excessive exhaust tem-

perature (an inadequate supply

of

raw water causes high

exhaust temperatures).

This

switch opens at 260-270°F

(127-

132°C).

This

switch resets at approximately 225°F (107°C).

HIGH

EXHAUST
TEMPERATURE

I

High

Water

Temperature

Switch

ELBOW

A high water temperature switch is located at the thermostat
housing. Nonnally closed, this switch, should

the

fresh

water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the

DC

voltage to

the

K2-run

relay thereby shutting

off

the engine. This switch resets

at

195°F (107°C).

THERMOSTAT
HDUS!NG-

___

.1

HIGH

WATER
TEMPERATURE
SWITCH

/

Low

Oil

Pressure

Switch

A low oil pressure shutdown switch is located

off

the

engine's oil gallery. Normally open

in

a static state, this

switch's

sensor

monitors the engine's oil pressure. Should the

engine's oil pressure fall to

5-10 psi, this switch will open

interrupting the

DC

voltage to the K2-run relay thereby shut-

ting off the engine.

LOW

OIL

PRESSURE

SWITCH

Engine

Circuit

Breaker

The generator's engine is protected by an engine mounted
manual reset circuit breaker

(20 amps DC). Excessive current

draw or electrical overload anywhere

in

the instrument panel

wiring

or

engine wiring will cause the breaker to trip.

In

this
event the generator will shut down because the opened
breaker interrupts the

DC

circuit to the K2-run relay. If this

should occur,

check

and repair the source

of

the problem.

After repairing

the

fault, reset the breaker and restart the gen-

erator.

Engines & Generators

5

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

Only

use

unleaded

fuel

with

an

octane

rating

of

89

or

higher.

Leaded

fuel will

cause

serious

hann

to

your

engine

and

violate

your

warranty.

CARE

OF

THE

FUEL

SUPPLY

Use only clean fuel! The clearance

of

the components

in
your carburetor is very critical; invisible dirt particles which
might pass through the filter can damage these finely finished
parts.

It

is important

to

buy clean fuel, and keep

it

clean. The

best fuel can be rendered unsatisfactory

by careless handling

or

improper storage facilities. To assure that the fuel going
into the tank for your engine's daily use is clean and pure, the
following practice is advisable:

Purchase a well-known brand

of

fuel.

Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank

and the engine.

ENGINE

OIL

Use a heavy duty engine oil with an API classification

of

S1.

Change the engine oil after an initial

50

hours

of

break-in

operation, and every

100 hours

of

operation thereafter. For

recommended oil viscosity, see the foHowing chart:

Operating

Temperature

Oil

Viscosity

Above

68° F (20°

C)

SAE

30,

10W-30

or

15W-40

41° -68° F (5°-20°

C)

SAE

20

or

10W-30

Below

41° F (5°

C)

SAE

10W-30

A

CAUTION:

00

not

allow

two

or

more

brands

of

engine

oil

to

mix.

Each

brand

contains

its

own

addi-

tives;

additives

of different

brands

could

react

in

the

mixture

to

produce

properties

harmful

to

your

engine.

ENGINE

COOLANT

Westerbeke recommends a mixture

of

50% antifreeze and
50% distilled water, when possible. Distilled water is free
from the chemicals that can corrode internal engine

surt'aces.

The antifreeze petfonns double duty, as

it

allows the engine

to

run at proper temperatures by transferring heat away from

the engine

to

the coolant. It also lubricates and protects the

cooling circuit from rust and corrosion.

Use a good quality
antifreeze that contains supplemental cooling additives
(SeAs)

that keep the antifreeze chemically balanced, crucial

to

long term protection.

The water and antifreeze should

be

pre-mixed before being

poured into the cooling circuit.

NOTE:

Use the new environmentally-friendly long lasting

antifreeze that

is

now

available.

ANTIFREEZE

PROTECTION

CHART

Antifreeze

concentration

23%

30%

35%

50%

Freezing

Temperature

WF

8°

F

_4°

F

-40°

F

(-10°C) (-13°C)

(-20°C)

(-40°C)

COOLANT

RECOVERY

TANK

A coolant recovery tank kit is supplied with each generator.
The purpose

of

this recovery tank is to allow for engine

coolant expansion and contraction, during engine operation,

without the loss

of

coolant and without introducing air into

the cooling system.

COOLANT

RECOVERY

TANK

-..v

WESTERBEKE

Engines & Generators

6

PREPARATIONS

FOR

INITIAL

START-UP

PRESTART

INSPECTION

Before starting your generator for the first time

or

after a pro-

longed layoff, check the following items:

• Check the engine oil level: add oil

to

maintain the level at

the full mark on the dipstick.

• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.

• Check the

DC

electrical system. Inspect wire connections

and battery cable connections.

• Check the coolant level in both the plastic recovery tank
and at the manifold.

OIL

FILL

NOTE:

After

the initial running

of

the generator, the air

in

the engine's cooling system will be purged to the coolant

recovery

tank

After

shutdown

and

after the engine has
cooled, the coolant from the recovery tank will be drawn
into the engine's cooling system to replace

the

purged

air.

COOLANT
PRESSURE

----1~~~~

CAP

Before subsequent operation

a/the

generator, the engine's

manifold should be topped off, and the coolant recovery
tank may need to be filled to the

MAX

level.

• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.

• Check load leads for correct connections as specified

in

the wiring diagrams.

• Examine the air inlet and outlet for air flow obstructions.

• Be sure no other generator or utility power is connected

to

the load lines.

• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded)

as

the system
requires, and that generator neutral is properly connected
to the load neutral.

In

single phase systems

an

incomplete
or open neutral can supply the wrong line-to-neutral volt­age on unbalanced loads.

A

CAUTION:

When

starting

the

generator,

it

is

recommended

that

all

AC

loads,

especially

large

mOtolS,

be

switched

OFF

until

the

engine

has

come

up

to

speed

and,

in

cold

climates,

starts

to

warm

up.

This

precaution

will

prevent

damage

caused

by

unantici-

pated

operation

of

the

AC

machinery

and

will

prevent

a

cold

engine

from

stalling_

COOLANT
RECOVERY
TANK

Engines & Generators

7

LOW

OPERATING

INSTRUCTIONS

GENERATOR

PANEL

Starling

the

Generator

To

start the generator, hold the momentary ON switch in the

up

(on) position, then hold the momentary START/OFF

switch

in

the up (start) position (both switches are held up

together). After approximately one second the starter will

engage and the engine

will crank. Once the engine is run-

ning, the starter

will

disengage, and the START/OFF switch

may

then

be

released

to

return to its center (run mode) posi-

tion. Continue holding the

ON switch until the engine has

sufficient oil pressure, then release

it

to its center position.

NOTE:

Should the engine fail to start, release both switches,

wait

20 seconds,

and

try again. Never run the starter more

than

20

seconds

at

a time.

START

....

_?

(MOMENTARY)

</~:./'

lH':x.",----

CENTER

OFF/RUN

UHP-.--

POSITION

<,

'

--<:

..

~

OFF
(MOMENTARY)

START/OFF

SWITCH

Stopping

the

Generator

----;)

ON

(MOMENTARY)

('-

....

//

C

~~::::::>

CENTER

OFF/RUN

',,"

POSITION

ON

SWITCH

To stop the generator, move the momentary START/OFF

switch to the down (off) position then release it to the center

(normal) position.

REMOTE

PANEL

Starling

the

Generator

To start the generator, hold the momentary ON switch in the
up

(on) position (the green light will

come

on), then hold the

momentary

START/STOP switch

in

the up (start) position

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

wi1l

dim). Once the engine is running (the green

light will brighten), the starter will disengage and the
START/STOP switch may then be released to return to its
center

(run mode) position. Continue holding the

ON

switch
until the engine has sufficient oil pressure, then release it to
its center position.

NOTE:

Should the engine fail to start, release both switches,

wait

20

seconds,

and

try again. Never run the starter more

than

20

seconds

at

a time.

START

ON

/?

(MOMENTARY)

(MOMENTARY)

-,...-;.//

-?

c

,...--

/~

,

CENTER

OFF/RUN

",---

//

k

'v'

CENTER

OFF/RUN

POSITION

POSITION

<

,

,

,

,

,

,

---~

STOP
(MOMENTARY)

STARTISTOP

SWITCH

ON

SWtTCH

Stopping

the

Generator

To

stop the generator, move the momentary START/STOP

switch to the down (stop) position then release it to the center

(offlrun mode) position. This will activate the remote control

panel for START/STOP functions.

A

CAUTION:

Prolonged

cranking

intervals

without

the

engine

starting

can

result

in filling

the

engine

exhaust

system

with

raw

water.

This

may

happen

because

the

pump

is

pumping

raw

water

through

the

raw

water

cooling

system

during

cranking.

This

raw

water

can

enter

the

engine's

cylinders

by

way

of

the

exhaust

manifold

once

the

exhaust

system

fills.

Prevent

this

from

happening

by

closing

the

raw

water

supply

through-hull

shutoff,

draining

the

exhaust

muffler,

and

correcting

the

cause

of

the

excessive

engine

cranking.

Engine

damage

resulting

from

raw

water

entry

is

not

a

warrantable

issue;

the

owner/operator

should

keep

this

in

mind

•

EMERGENCY

STOPPING

If the generator does not stop using the START/OFF switch,
remove the 8

amp

fuse

or

disconnect the battery.

STARTING

UNDER

COLD

CONDITIONS

Make certain the lubricating oil

confonns

with the ratings for

the prevailing temperature. Check the table under

ENGINE

LUBRiCATING

OIL. The battery should

be

fully charged to

minimize voltage drop.

ABNORMAL

STOP

An abnormal stop is one

in

which the generator ceases to run

and

comes

to a stop as a result

of

an operating fault which

may cause

damage

to the engine, the generator,

or

create an

unsafe operating condition. The fault

stop

conditions are:

1. Overspeed condition.

2. High engine temperature.

3.

Low

oil pressure.

4. High exhaust temperature.

Should a fault condition occur, the engine

will shut down and

the green

LED

light on the remote panel will go off indicat-

ing that a fault has occurred.

Once detected, the fault should

be located (see

ENGINE

TROUBLESHOOTING).

WESTERBEKE

Engines & Generators

8

BREAK-IN

PROCEDURE/DAILY

OPERATION

BREAK-IN

PROCEDURE

Once the generator has been started, check for proper opera­tion and then encourage a fast warm-up. Run the generator
between

20%

to 60%

of

full load for the first 10 hours.

A

CAUTION:

00

not

attempt

to

break-in

your

genera-

tor

by

running

without a load.

After the first 10 hours

of

the generators' operation, the load
can be increased to the full-load rated output; then periodi­cally vary the load.

Avoid overload at all times.

An

overload is signaled by a

smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep

it

within the generators' rating. Since the generator operates

at

3600 rpm to produce 60 hertz, or at 3000 to produce

50

hertz, control

of

the generator's engine break-in is governed

by the current drawn from the generator.

To protect against unintentional overloading

of

the generator,
the generator's output leads should be routed through a cir­cuit breaker that is rated at the rated output

of

the generator.

NOTE:

Be

aware

of

motor starting loads

and

the high
current drawn required for starting motors. This starting
amperage drawn can

be

3 to 5 times normal running amper-

age (see GENERATOR

INFORMATION).

CHECK

LIST

Follow this checklist each day before starting your generator.

• Record the hourrneter reading in your log (engine hours

relate to the maintenance schedule).

• Visually inspect the engine for fuel, oil, or water leaks.

• Check the oil level (dipstick).

• Check the coolant level

in

the coolant recovery tank.

• Check your fuel supply.

• Check the starting batteries (weekly).

• Check the drive belts for wear and proper tension

(weekly).

• Monitor the control panel gauges.

• Check for abnormal noise such as knocking, friction,

vibration and blow-back sounds.

• Confinn exhaust smoke:

When the engine is cold

- White Smoke.
When the engine is warm - almost Smokeless.
When the engine is overloaded - some Black Smoke.

NOTE:

Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached

and

leads are applied.

A

CAUTION:

00

not

operate

the

generator

for

long

periods

of

time

without a load

being

placed

on

the

generator.

STOPPING

THE

GENERATOR

Remove the major

AC

loads from the generator one at a
time. Allow the generator to run for a few minutes to stabi­lize the operating temperature, (then see SlOpping the

Generator under OPERATING INSTRUCTIONS).

NOTE:

After

the first

50

hours

of

generator operation check

the maintenance schedule for the

50

hour service check.

GENERATOR

ADJUSTMENTS

Once the generator has been placed

in

operation, there may

be governor adjustments required for engine speed (hertz)

during the

engine's break-in period (first

50

hours) or after

this period (see

ENGINE

SPEED (HERTZ) ADJUSTMENT

under ENGINE ADJUSTMENTS. A no-load voltage adjust-
ment may also be required in conjunction with the engine's

speed adjustment (see GENERATOR INFORMATION).

WESTERBEKE

Engines & Generators

9

SCHEDULED
MAINTENANCE

Fuel

Supply

Fuel/Water

Separator

Engine

Oil

Level

Coolant

Level

Drive

Belts

MAINTENANCE

SCHEDULE

A

WARNING:

Never

attempt

to

perform

any

service

while

the

engine

is

running.

Wear

the

proper

safety

equipment

such

as

goggles

and

gloves,

and

use

the

correct

tools

for

each

job.

Disconnect

the

battery

terminals

when

servicing

any

of

the

engine's

DC

electrical

equipment.

NOTE:

Many

a/the

following maintenance procedures are simple but others are

more difficult

and

may require the expert knowledge

of

a service mechanic.

CHECK

HOURS

OF

OPERATION

EACH

EXPLANATION

OF

SCHEDULED

DAY

50

100

250

500

750

1000 1250

MAINTENANCE

0

Unleaded

gasoline

with

octane

rating

of

89

or

higher.

0

Check

for

water

and

dirt

in

fuel

(drain/replace

filter

if

necessary).

0

Oil

level

should

indicate

between

FULL

and

LOW

on

dipstick.

0

Check

at

recovery

tank;

if

empty,

check

at

manifold.

Add

coolant

if

needed.

0

Inspect

for

proper

tension

(3/8'

to

1/2"

deflection)

Weekly

and

adjust

if

needed.

Check

belt

edges

for

wear.

Visual

Inspection

of

Engine

0

NOTE:

Keep

engine suiface clean. Dirt arul

Check

for

fuel,

oil

and

water

leaks.

Inspect

wiring

oil

will inhibit

the

engine:s ability to remain

and

electrical

connections.

Keep

bolts & nuts

tight.

coo!.

Check

for

loose

belt

tension.

Spark

Plugs

0 0 0 0 0 0

Check

gap;

inspect

for

burning

and

corrosion.

Generator

0 0 0 0 0 0 0

Check

that

AC

connections

are

clean

and

secure

with

no

chafing -see

GENERATOR

INFORMATION

for

additional

information.

Carburetor

Filler

Screen

0 0 0 0 0 0

Initial

change

at

50

hrs,

then

change

every

250

hrs.

Starting

Batteries

0 0

Every

50

operating

hours

check

electrolyte

levels

(and

House

Batteries)

Weekly

and

make

sure

connections

are

very

tight.

Clean

off

excessive

corrosion.

Engine

Oil

0 0

0

0 0 O· 0

Initial

engine

oil & filter

change

at

50

hrs

.•

then

change

both

every

100

hours.

'Adiustthe

Valve

0 0 0

Initial

adjustment

at

50

hrs

.•

then

every

500

hrs.

Clearances

Air

Screen

(Flame

Arrester)

0

Clean

at

50

hours,

then

every

100

hours.

Exhaust

System

0 0 0 0

Initial

check

at

50

hrs.,

then

every

250

hrs.

Inspect

for

leaks.

Check

siphon

break

operation.

Check

the

exhaust

elbow

for

carbon

and/or

corrosion

buildup

on

inside

passages;

clean

and

replace

as

necessary.

Check

that

all

connections

are

tight.

Engine

Hoses

0 0 0

D

D

D

Hose

should

be

hard & tight.

Replace

if

so11

or

spongy.

Check

and

tighten

all

hose

clamps.

Governor

0 D

D

D D

Change

oil

every

250

hours.

Lubricate

linkage

arm

periodically.

'WESTERBEKE

recommends

this

service

be

periormed

by

an

authorized

mechanic.

(continued)

Engines & Generators

10

SCHEDULED
MAINTENANCE

Heal

Exchanger

Raw

Water

Pump

Coolant

System

'Starter

Motor

Distributor

'Engine

Cylinder

Compression

and

Valve

Clearance

'Engine

Timing

Belt

'Exhaust

Elbow

MAINTENANCE

SCHEDULE

NDTE:

Use

the

engine

hourmeter

gauge

10

log

your

engine

hours

or

record

your

engine

hours

by

running

lime.

CHECK

HOURS

OF

OPERATION

EACH

EXPLANATION

OF

SCHEDULED

DAY

50

100

250

500

750

1000

1250

MAINTENANCE

D D D D D D

D

Clean

or

repiace

anode.

Open

heal

exchanger

end

cap

and

clean

out

debris.

Remove

every

1000

hours

for

professional

cleaning

and

pressure

testing.

D D D

Remove

pump

cover

and

inspect

impellertor

wear;

replace 0 needed.

Also

replace

gasket

Lubricate

both

when

reassembling.

D

Drain,

flush,

and

refill

cooling

system

with

appro-

priate

antoreeze

mix.

D D

Check

solenoid

and

motor

for

corrosion.

Remove

and

lubricate.

Clean

and

lubricate

the

Start

motor

pinion

dlive.

D D

Check

ignition

timing.

Check

condition

of

distlibu-

tor

cap

and

rotor.

D

D

Incorrect

valve

clearance

will

resuft

in

poor

engine

performance;

check

compression

pressure

and

timing,

and

adjust

valve

clearances.

D

Remove

and

replace.

NOTE:

Failure

to

replace

the

timing

beft

at

the

rec-

ommended

interval

could

resuft

in

timing

beft

fail-

ure

resufting

in

major

damage

to

the

engine.

D

Test

exhaust

elbow

for

casting

integrity.

Replace

if

casting

is

corroded

or

deteliorated.

WARNING:

A

defective

exhaust

elbow

can

cause

carbon

monox-

ide

leakage!

'WESTERBEKE

recommends

thiS

service

be

performed

by

an

authonzed

mechamc.

Engines & Generators

11

ENGINE

COOLING

CIRCUIT

DESCRIPTION

The

generator's engine is fresh water cooled (engine coolant)

by an engine-mounted heat exchanger. Raw water is pumped

through the heat exchanger

by a belt-driven, positive

displacement impeller pump.

Mtcr

the raw water cools the

fuel in the gasdenser and cools the engine coolant

in

the heat

exchanger,

it

mixes with the engine's exhaust gases, cools the

exhaust hose, and discharges overboard.

The

engine's coolant is circulated by a belt-driven centrifu-

gal-type metal impeller pump mounted on the front

of

the

engine.

COOLANT

TANK

THERMOSTAT

FRESH

WATER

COOLANT

..

RAW

WATER

PRESSURE

CAP

EXCHANGER

DRAIN

ZINC
ANODE

The engine's coolant temperature is thennostatically
controlled.

The

engine's cooling system should be drained, flushed out,

and refilled with a fresh mixture

of

coolant at

750

operating

hours or every two years.

A

CAUTION:

Proper

cooling

system

maintenance

is

critical;

almost

half

of

engine

failures

can

be

traced

back

to

cooling

system

corrosion.

MANIFOLD

"

BLEED
PETCOCK

EXHAUST

FRESH

WATER

COOLANT

PUMP

~

WESTERBEKE

Engines & Generators

12

ENGINE

COOLING

CIRCUIT

THERMOSTAT

A thermostat controls the coolant temperature as the coolant
continuously flows through the closed cooling circuit. When
the engine is first started the closed thermostat prevents
coolant from flowing (some coolant is by-passed through a
hole in the thermostat to prevent the exhaust manifold from

overheating).

As

the engine warms up, the thermostat gradu-

ally opens.

The

thermostat is accessible and can be checked,

cleaned,

or

replaced easily.

CarTy

a spare thermostat and gas-

ket.

THERMOSTAT

TEST

If you suspect a faulty thermostat, place it

in

a pan

of

water and

bring to a boil. A working thermostat should open about

1/2".

DRAINING

THE

COOLANT

Remove the manifold pressure cap, loosen the water drain

located on the left side

of

the engine block just under the

manifold and loosen the heat exchanger drain plug.

REFILLING

THE

COOLANT

Slowly pour clean premixed coolant into the manifold.

NOTE:

Open the air bleed petcock on the exhaust manifold to

help remove air from the system. When a steady flow

of

coolant appears at the drain, close the water drain plug, fill

the system and close the petcock.

Start the engine and bring

it

to operating temperature.
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the pressure cap.

Remove the cap on the coolant recovery tank and fill with
coolant halfway between

LOW

and MAX, and replace the

cap.
Run the engine and observe the coolant expansion flow into

the recovery tank.

TO

COOLANT

RECOVERY

TANK

FROM

COOLANT

RECOVERY

TANK

COOLANT

RETRACTION

PRESSURE

CAP

COOLANT

EXPANSION

After checking for leaks, stop the engine and anow

it

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

if

needed. Clean up any spilled coolant.

NOTE:

Periodically check the condition

of

the pressure cap.

Ensure that the upper

and

lower rubber seals are in good
condition and check that the vacuum valve opens and closes
tightly. Carry a spare cap.

A

WARNING:

Always

check

the

coolant

level

at

the

coolant

recovery

tank.

If

the

engine

is

/Jot,

allow

it

to

cool

before

checking.

HOT

COOLANT

and

STEAM

can

cause

INJURY

or

DEATH!

00

not

check

the

coolant

at

the

manifold

unless

the

engine

is

cool!

Engines & Generators

13

ENGINE

COOLING

CIRCUIT

RAW

WATER

PUMP

The

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

On

no

account should this

pump

be

run

dry.

There should
always be a spare impeller and impeller ccver gasket aboard
(an impeller kit). Raw water pump impeller failures occur when
lubricant (raw water) is not present during engine operation.
Such failures are not warrantable, and operators are cautioned
to make sure raw water flow is present at start-up.

The

raw

water

pump

should be inspected periodically for broken or

tom impeller blades.

See MAINTENANCE SCHEDULE.

GASKET

RAW
WATER

IN

FROM

GASDENSER

t

TO

HEAT

EXCHANGER

RAW

WATER

PUMP

CHANGING

THE

RAW

WATER

PUMP

IMPELLER

NOTE:

Coat the replacement impeller blade tips with petro-

leum jelly before installing.

A

CAUTION:

The

raw

water

intake

valve

(seacock)

must

be

closed

when

servicing

any

components

of

the

raw

water

system,

and

must

be

re-opened

before

start-

ing

the

engine.

HEAT

EXCHANGER

Cool raw water flows through the inner tubes

of

the heat

exchanger.

As the engine coolant passes around these tubes

the heat

of

the internal engine is conducted to the raw water

which is then pumped into the exhaust system and discharged.
The engine coolant (now cooled) flows back though the
engine and the circuit repeats itself.

The engine coolant and raw water are independent

of

each

other; this keeps the engine's water passages clean from the

harmful deposits found

in

raw water.

TO

ENGINE

BLOCK

~t

FROM

RAW

WATER

PUMP

NEW

ANODE

ZINC

1

t

COOLANT
DRAIN

REPLACE

REPLACE

ZINC

ANODES

CLEAN

AND

REPLACE

HEAT

EXCHANGER

END

CAP

A zinc anode (or pencil) is located

in

the raw water cooling

circuit within the heat exchanger.

The

purpose

of

the zinc

anode is to sacrifice itself to electrolysis action taking place

in

the raw water cooling circuit, thereby reducing the effects

of

electrolysis on other components

of

the system.

The

con-

dition

of

the zinc anode should be checked monthly and the
anode cleaned or repJaced, as required. Spare anodes should
be carried onboard. The area in the exchanger where the
anode is located should periodically be cleaned

of

anode

debris. Take care not to lose the small O-ring that nestles

between the heat exchanger end gasket and the ccver.

DRIVE

BELT

ADJUSTMENT

A

CAUTION:

The

drive

belt

must

be

properly

tensioned

for

the

belt-driven

water

pumps

to

function

properly.

For the raw water pump/fresh water pump drive belt tension

adjustment procedure, see

DRIVE

BELTS ADJUSTMENT

under ENGINE ADJUSTMENTS.

-.y-

WESTERBEKE

Engines & Generators

14

FUEL

SYSTEM

GASOLINE

Use unleaded

89

octane

or

higher gasoline.

When

fueling,

follow

U.S. Coast Guard regulations, close

off

all hatches
and companionways to prevent fumes from entering the boat,
and ventilate after fueling.

NOTE:

The generator compartment should have a gasoline

fume detector/alarm properly installed and working.

A

WARNING:

Shut

off

the

fuel

valve

at

the

tank

when

servicing

the

fuel

system.

Take

care

in

catching

any

fuel that

may

spill.

DO

NOT

allow

any

smoking,

open

flames

or

other

sources

of

fire

near

the

fuel

sys-

tem

when

servicing.

Ensure

proper

ventilation

exists

when

servicing

the

fuel

system.

CARBURETOR

The

carburetor is a single barrel downdraft

type

with a sole-

noid-activated electric choke and electric fuel shutoff solenoid.

These gasoline filters must have metal

bowls

(not "see-

through")

to meet U.S. Coast Guard requirements.

The

metal

bowls have drain valves to use

when

checking

for water and

impurities.

Ii

, I

FUEL

PUMP

GASOLlNEJWATER
SEPARATOR

Periodically check the fuel connections to and out

of

the pump

and make sure that no leakeage is present and that the fittings

are tight and secure. The

DC

ground connection at one

of

the

pump's mounting bolts should be

dean

and well secured by the

mounting bolt to ensure proper pump operation.

A

WARNING:

Fuel

leakage

at

the

fuel

pump

or

its

connections

is a fire

hazard

and

should

be

corrected.

Make

sure

proper

ventilation

exists

whenever

servicing

fuel

system

components.

GASDENSER

The

gasdenser consists

of

a portion

of

the fuel line that

is

coiled around the raw water intake line and insulated. It is
located between the raw water intake

and

the raw water

pump.

The

gasdenser cools the fuel to prevent vapor lock.

RAW

WATER

INTAKE

CARBURETOR

GASOLINE/WATER

SEPARATOR

AND

FILTER

A primary fuel filter

of

the

water

separating type must be
installed between the fuel tank and the engine to remove
water and

other

contaminants from the fuel before they can

be

carried to the fuel system

on

the

engine.

Most installers include a type

of

filter/water separator with

the generator installation package

as

they are well aware

of

the problems that contaminants

in

the fuel can cause.

"'"""

WESTERBEKE

Engines & Generators

15

FUEL

IN

....

TO

CARBURETOR

FUEL

ENGINE

LUBRICATING

OIL

DESCRIPTION

Use a heavy duty engine oil with an API classification

of

SJ.

Change the engine oil after an initial 50 hours

of

break-in

operation and every

100 hours

of

operation thereafter. For

recommended oil viscosity see the following chart:

Operating

Temperature

Oil

Viscosity

Above

68" F (20"

C)

SAE

30,

10W-30

or

15W-40

41" -68" F (5"_20"

C)

SAE

20

or

10W-30

Below

41" F (5"

C)

SAE

10W-30

A

CAUTION:

00

not

allow

two

or

more

brands

of

engine

oil

to

mix.

Each

brand

contains

its

own

addi·

tives; additives of

different

brands

could

react

in

the

mixture to

produce

properties

harmful

to

your

engine.

CHANGING

THE

ENGINE

OIL

The

engine oil should be warm. Remove the oil drain hose

from its attachment bracket and lower

it

into a container and

allow the oil to drain, or attach a pump

to

the end

of

the drain
hose and pump the old oil out. Make sure the oil drain hose
is properly secured

in

its

holder after all

of

the old oil has

been drained.

Always observe the old oil as

it

is removed. A yellow/gray

emulsion indicates the presence

of

water

in

the oil. Although
this condition is rare, it does require prompt attention to
prevent serious damage. Call a competent mechanic if water
is present

in

the oil. Raw water present

in

the oil can

be the result

of

a fault

in

the exhaust system attached to the
engine and/or a siphoning through the raw water cooling
circuit into the exhaust, filling

it

up into the engine.

OIL

DRAIN

HOSE

OIL

CONTAINER

A

WARNING:

Used

engine

oil

contains

harmful

contaminants.

Avoid

prolonged

skin

contact.

Clean

skin

and

nails

thoroughly

using

soap

and

water.

Launder

or

discard

clothing or

rags

containing

used

oil.

Discard

used

oil

properly.

REPLACING

THE

OIL

FILTER

When removing the used oil filter, you may find

it

helpful

to

punch a hole

in

the upper and lower portion

of

the old filter

to drain the oil into a container before removing

it.

This helps

to lessen spiI1age. An automotive filter wrench should be

helpful

in

removing the old oil filter, Place some paper towels
and a plastic bag around the filter when unscrewing it to catch
any oil that's in the filter. Inspect the old oil filter as

it

is

removed

to

make sure that the rubber sealing gasket comes
off with the old oil filter. If this rubber sealing gasket remains
sealed against the oil filter adapter, gently remove

it.

When
installing the new oil filter element, wipe the filter gasket's
sealing surface on the oil filter adapter free

of

oil and apply a

thin coat

of

clean engine oil to the rubber gasket on the oil
filter. Screw the filter onto the threaded oil filter nipple, and
tighten the filter firmly by hand.

NOTE:

Use genuine WESTERBEKE oil fillers. Generic fillers

are not recommended.

REFILLING

THE

OIL

SUMP

Add fresh oil through the valve cover. After refilling the oil,
run the engine for a few moments while checking the engine's
oil pressure. Make sure there is

no

leakage around the new
oil filter or from the oil drain system, and then stop the
engine. Then check the quantity

of

oil with the lube oil dip-

stick. Fill to, but not over, the FULL mark on the dipstick.

....v-

WESTERBEKE

Engines & Generators

16

REMOTE

OIL

FILTER

(OPTIONAL)

INSTALLATION

This popular accessory is used to relocate the engine's oil fil­ter from the engine to a more convenient location such as an
engine room bulkhead.

NOTE:

Refer to REPLACING THE OIL FILTER for instruc-

tions

on

removing the oil filter.

APPLY A THIN

COAT

OF

CLEAN

OIL

TO

THE

D-RING

WHEN

INSTALLING

THIS

KIT.

THREAD

THE

KIT

ON,

THEN

TIGHTEN

(BY

HAND)

AN

ADDITIONAL

3/4

TURN

AFTER

THE

D-RING

CONTACTS

THE

BASE.

To

install, simply remove the engine oil filter and thread on
WESTERBEKE's remote oil filter kit as shown. Always
install this kit with the oil filter facing down as illustrated.

Contact your WESTERBEKE dealer for more information.

NOTE:

Westerbeke is not responsible for engine failure due to

incorrect installation

of

the

Remote

Oil

Filter.

FASTEN

SECURELY

TO A BULKHEAD

(SCREWS

ARE

OWNER

SUPPLIED).

~PPLYI'!~I~.

~OA~OF

CLEAN

Oil

TO

WHEN

INSTALLING.

WHEN

THE

F!lTER

CONTACTS

THE

BASE,

TIGHTEN

IT

(BY

HAND) A 3/4

TURN

MORE.

"SlY'

WESTERBEKE

Engines & Generators

17

DC

ELECTRICAL

SYSTEM

12-VOLT

DC

CONTROL

CIRCUIT

The

DC

Circuit

on

the BCGTC functions

to

start, operate and

stop the generator's engine. The circuit is best understood

by

reviewing the

DC

Wiring Diagram and Wiring Schematic.

The engine's

DC

wiring is designed with three simple basic

circuits: start, run and stop.
The engine has a 12 volt

DC

electrical control circuit that is
shown on the Wiring Diagrams. Refer to these diagrams
when troubleshooting

or

when servicing the

DC

electrical

system or the engine.

BAmRIES

A

CAUTION:

To

avoid

damage

to

the

banery

charg-

ing

circut,

never

shut

off

the

engine

banery

switch

while

the

engine

is

running.

Shut

off

the

engine

banery

switch,

however,

to

avoid

electrical

shorts

when

work-

ing

on

the

engine's

electrical circuit.

Specifications

The minimum recommended capacity

of

the battery used in

the engine's 12-volt

DC

control circuit is 300 CCA.

Battery

Maintenance

Review the manufacturer's recommendations and then estab­lish a systematic maintenance schedule for your engine's
starting batteries and house batteries.

• Monitor your voltmeter for proper charging during engine
operation.

• Check the electrolyte level and specific gravity with a
hydrometer.

• Use only distilled water to bring electrolytes to a proper
level.

• Make certain that battery cable connections are clean and
tight

to

the battery posts (and to your engine).

• Keep your batteries clean and free

of

corrosion.

A

WARNING:

Sulfuric

acid

in

lead

baneries

can

cause

severe

burns

on

skin

and

damage

clothing.

Wear

protective

gear.

BATTERY

CHARGING

The generator supplies a continuous 17 amp charge from its

battery charger to the starting battery.

BATIERY
CHARGER

COMPONENT

TESTING

BLACK
GREEN
YELLOW

RED

All

DC

voltage measurements are made to the engine battery

negative ground point unless specified otherwise.

In

making
test measurements, make sure that a good ground for the
meter is established, preferably the point where the negative
battery is connected

to

the engine. Battery positive voltage is

indicated as B+ and should

measure no Jess than 11.5 volts.

AC

voltage measurements should be made with a true RMS

AC

meter to insure measurement accuracy.

Relay. The relays used

in

the control system have coils

which are polarized

by

the fact that they have internal free

wheeling suppression diodes across them. Relay coil terminal

86 must be maintained

(+),

tenninaI85(-). The relay coil is
rated 12V DC, and the coil resistance is typically 85 ohms.
With B+ on terminal 86, direct grounding

of

terminal

85

is

permissible for testing purposes.

~

WESTERBEKE

Engines & Generators

18

DC

ELECTRICAL

SYSTEM

WIRING

DIAGRAM

#42834

OIL

TEMP

SWITCH

INC)

[

~

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Rev.

E 3/2S/98

19

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ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE recommends that the following engine

adjustments be performed

by

a competent engine mechanic.

The information below is provided to assist the mechanic.

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The

belt-driven, mechanically operated governor maintains the
engine's rpm under various load conditions. Engine speed
determines the hertz and voltage output

of

the generator.

Governor

Adjustments

Operate the generator to bring the unit up to operating temper­ature before adjusting the governor.

NOTE:

If

the governor is severely out

of

adjustment, manually
adjust the linkage at no-load to obtain a safe output voltage
before proceeding with the adjustment.

There are three adjusting points on the governor (see i1lustra­tion).

1.

Increase/Decrease

Speed

Adjustment. This adjusting bolt

sets the no-load speed

of

the engine. (The linkage

ann

between the governor

ann

and throttle lever should be
adjusted to hold the throttle full open when the engine is
not running.) Make sure this linkage moves freely and that
the ball joint connectors are properly lubricated.

Use
graphite lube for this purpose. Disconnect the ball joint and
apply graphite lube to the inside

of

the joint.

2. Hunting/ReguliltWnAdjustment_ If the variation in engine

speed between no-load and full-load is too great, adjust this
eye bolt to draw the spring closer to the lever hub. The
increase/decrease speed bolt may need to be adjusted as
well.

If

the governor surges under load, adjust this eye bolt to
move the spring away from the lever hub (check speed
adjustment).

3. Bumper Screw Adjustment.

This

screw is used to remove a

no-load

surge ONLY.

NEVER

turn the bumper screw into

the governor so far that it increases the no-load speed.

CARBURETOR
THROTILE

LEVER

ARM

REGULATION

ADJUSTMENT

Oil

FILL

SPEED

An.""

"'T>"Nl

FRONT

OF

ENGINE

Governor

Maintenance

1.

Periodically lubricate the linkage arm attaching points at
the governor arm and throttle lever.

Use a graphite lubri-

cant

or

equivalent.

NOTE:

Free movement

of

this linkage

arm

is important for

p"roper

governor/throttle operation.

2. Governor oil capacity - 3 ounces 10/30 engine oil.

NOTE:

Do

not overfill the governor.

3. Change the governor oil every 250 hours

of

operation.

To

change the oil, remove the governor from the engine,

remove the oil fill and the fill level plug, and drain all the

oil. Reinstall on the engine and fill with 3 ounces

of

10/30

engine oil. Replace the plugs.

4. Periodically adjust the governor belt tension (see

DRIVE

BELTS ADJUSTMENT). Since belts stretch slightly, this

stretching

wil1,

to some degree, affect the govenor's

action.

TORQUING

THE

CYLINDER

HEAD

BOLTS

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

Tighten the cylinder head bolts according to the sequence

shown. Make sure the engine is cold when this is done, and
loosen one head bolt one-half turn and then tighten it
between

43-51 lb-ft

(60-70

Nm).

Then

proceed to the next

head bolt in the sequence. Tighten the

RS

(rocker cover stud)

securely.

6 4 2

7

B

3 5

GOVERNOR

Engines & Generators

Rev.611f98

22

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE recommends that the following engine

adjustments be

performed

by

a competent engine mechanic.

The information below

is

provided to assist the mechanic.

VALVE

CLEARANCE

ADJUSTMENT

NOTE:

Retorque the cylinder head bolts before adjusting the

engine's valves (see TORQUING THE CYLINDER

HEAD

BOLTS).

1. Remove the rocker cover and gasket.

2. Adjust the intake and exhaust valves

in

the firing

order

of

the engine (1-3-2), as follows:

Rotate the crankshaft

in

its nonnaI direction

of

rotation,

placing the No. I piston at the

IDC

(Top Dead Center)

of

its compression stroke with the intake and exhaust valves

completely closed. Then adjust the intake and exhaust

valve clearances for cylinder No.

].

Valve clearances:

Intake valves -

0.20 mm (.008 in)

Exhaust valves -

0.30

mm

(.012 in)

Repeat the above procedure to adjust the intake and exhaust
valves for

No.3

cylinder, then repeat this procedure

once

more to adjust the intake and exhaust valves for

No.2

cylinder.

3. Replace the rocker cover along with a new rocker

cover

gasket.
Rocker cover torque: 2.9-5.1 Ib-ft (0.4-0.7 kg-m)

VALVE
CLEARANCE
ADJUSTMENT

CHOKE

SOLENOID

The

choke solenoid is a 12 volt

DC

operated unit that func-

tions to close the choke plate in the carburetor when the

ON

switch is depressed during engine start-up.
The

choke solenoid de-energizes once the engine starts and

the

ON switch is released. Some unstable running may

be
present when the engine starts cold but should smooth out as
the engine reaches operating temperature.

Keep this solenoid dry and periodically lubricate the linkage

between the solenoid and the choke lever.

CHOKE
SOLENOID

IGNITION

TIMING

1.

Attach a timing light

to

the

#1

spark plug and mark the

front timing pointer

to

indicate 18°. Locate the timing

mark on the crankshaft pulley and mark

it

with white

chalk

or

a crayon.

2.

Start the engine

and

warm

it

up to its normal operating

temperature. Make sure the generator is operating

without

a load

on

it.

3. Using the timing light, align the timing mark

in

the front

crankshaft pulley so

it

is just slightly before the first tim-

ing pointer.

Do

this by loosening and slowly rotating the

distributor body.

Use the following timing specifications:

Timing Specifications:

18° ±

.so

BIDC

at

3600

rpm (no

load on generator)

tGNITION

TIMING

SPARK

PLUGS

The spark plugs should

be

cleaned and rcgapped after the

first

50

hour break-in period, then inspected every 250 hours

thereafter and replaced

as

needed.

A

WARNING:

Do

not

remove

the

spark

plugs

while

the

engine

is

hot.

Allow

the

engine

to

cool

before

removing

them.

Spark plug gap: 0.028 - 0.031 in. (0.7 - 0.8 mm).
Spark plug torque: 10.8

-15.2lb-ft

(1.5 -

2.1

kg-m).

NOTE:

Loc-tite Anti-Seize applied to the threaded portion

of

the spark plugs will retard corrosion, making future removal

of

the spark plugs easier.

WEAR

AND

SPARK

PLUG

INSPECTION

CARBON

BURNT

CONDITION

I---D""GE

AND

DETERIORATION

~

WESTERBEKE

Engines

& Generators

Rev.

6(1198

23

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends that

the

following engine

adjustments be performed by a competent engine mechanic.

The information below is provided to assist the mechanic.

CARBURETOR

ADJUSTMENT

Basic

Jet

Adjustment

is

performed with the generator operat-

ing.

Screw the jet slowly in until

it

seats, then back

it

out

1-1/2 to 2 turns.

NOTE:

An

idle

mixture

jet

adjusted too

far

off

its

seat

can

induce a sooty exhaust discharge at engine start-up and shut-

down.

NOTE:

At

idle speed,

oil

pressure will

be

lower

than the rating

afthe

oil pressure switch. Jump this switch to prevent engine

shutdown

at

idle speed.

Run

Mixture

Jet. This mixture jet

is

presized at the factory

and

is

not adjustable.

The

idle mixture jet adjustment can be

made in the

3600 rpm range

to

improve engine performance.

FLAME

ARRESTER

LINKAGE

ARM

IDLE

MIXTURE

--k'<::~~

SC!iEW

CARBURETOR

FUEL

SHUT-OFF

SOLENOID

DRIVE

BELTS

ADJUSTMENT

The drive belts must be properly tensioned. Excessive drive
belt tension can cause rapid wear

of

the belt and reduce the

service life

of

the fresh water pump's bearing. A slack belt

or

the presence

of

oil

on the belt can cause belt slipping, result-

ing in high operating temperatures.
The BCGTC generator has two drive belts, one for the gover-

nor and one for the raw water pump/fresh water pump.

The

tension adjustment procedure for both belts

is

as follows:

1. Remove the belt guard.

2.

To adjust the governor drive belt, loosen the two governor
mounting bolts.

To adjust the raw water pump/fresh water pump drive
belt, loosen the two raw water pump mounting

bolts.

3. With the belt(s) loose, inspect for wear, cracks and frayed
edges, and replace

if

necessary.

4.

To loosen or tighten the governor drive belt, slide the gov­ernor in or out as required, then retighten its mounting
bolts.

To loosen or tighten the raw water pump/fresh water
pump drive belt, slide the raw water pump

in

or out as

required, then retighten its mounting bolts.

5. The drive belts are properly adjusted if they can be
deflected

no

less than 3/8 inch (10mm) and

no

more than

1/2 inch ( 12mm) as the belt

is

depressed with the thumb
at the midpoint between the two pulleys on the longest
span

of

the belt.

NOTE:

Maintain a

22

lb pressure to the belt's outer face

for

proper

belt operation. Spare belts should always

be

carried

on

board.

A

WARNING:

Never

attempt

to

check

or

adjust

a

drive

belt's

tension

while

the

engine

is

in

operation.

6.

Operate the generator for about 5 minutes, then shut down

the generator and recheck the belt(s) tension.

7.

Replace the belt guard.

Engines & Generators

24

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE

recommends that the following engine

adjustments

be

performed

by a competent engine mechanic.

The information

below

is

provided to assist the mechanic.

TIMING

BELT

INSPECTION

AND

REPLACEMENT

5. Remove the timing belt.

Timing

Belt

Removal

NOTE:

If

the timing belt is to

be

reused, draw an arrow on

the belt back to indicate the direction o/rotation (clock-

it.

CAUTION:

Water

or oil

on

the

timing

belt

severely

reduces

the

service

life

of

the

belt.

Keep

the

timing

belt

sprocket

and

tensioner

free

of oil

and

grease.

These

parts

should

never

be

cleaned.

Replace

if

serio

ously

contaminated

with dirt or oil.

If

oil is evident

on

these

parts,

check

the

front

case,

oil

pump

oil

seals,

and

camshaft

oil

seals

for a

possible

oil

leak.

1. Turn the crankshaft c10ckwise to align the timing

mark

on

the camshaft sprocket and timing belt rear cover.

NOTE:

always turn the crankshaft clockwise.

TIMING

MARK

2. Remove the plug on the left surface

of

the cylinder block

and insert a rod with a diameter

of8mm

(0.31in.) to lock

the counterbalance shaft.

NOTE:

Be sure to use an inserting rod with a diameter

of

8mm

(0.31 in.).

__

E;;;~~~~ROO

65

MM

(2.6

IN)

.

j:)

COUNTERBALANCE
SHAFT

CYLINDER
BLOCK

3.

Loosen the timing belt tensioner nut.

4.

Move the timing belt tensioner toward the water

pump,
and temporarily tighten the nut to hold the tensioner in
that position.

TIMING

BELT

TENSIONER

PUMP

wise).

(

Camshaft

Sprocket

Removal

1.

Remove the bolt without turning the camshaft.

Oil

Pump

Sprocket

Flange

Nut

Removal.

1.

Remove the plug from the left side

of

the cylinder block.

2. Insert an 8 mm

(0.31 in.) diameter round bar to lock the

counterbalance shaft.

3. Remove the nut.

"""

WESTERBEKE

Engines & Generators

25

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE recommends that the following engine

adjustments be performed by a competent engine mechanic.

The information below is provided to assist the mechanic.

Crankshaft

Bolt

Removal

1. Lock the crankshaft in position.

NOTE:

Do

not

turn the crankshaft.

2. Remove the crankshaft bolt.

Timing

Belt

Inspection

Replace the belt

if

any

of

the following conditions exist:

1.

Hardening

of

back rubber-back side is glossy, without

resilience, and leaves

no

indent when pressed with fin-

gernail.

2. Cracks on rubber back.

3. Cracks or peeling

of

canvas.

4. Cracks on tooth bottom.

5. Cracks on belt.

6. Abnormal wear

of

belt sides.

The

sides are normal if

they are sharp as

if

cut by a knife.

7. Abnormal wear on teeth.

8. Tooth missing and canvas fiber exposed.

1.

CRACKS~

OR

PEELING

3.

~,.

5.

RUBBER

---If.r!S

EXPOSED

7.

Tensioner

Inspection

2.

0

ACKS

4.

ROUNDED

EDGE

.........

~ABNORMAL

WEAR

~

(flUffY

STRAND)

6.

TOOTH

MISSING

AND

CANVAS

~BEREXPOSED

~

8.

1.

Replace the tensioner

if

the pulley binds, rattles or is noisy

when turned.

Flange

Installation

1. Mount the flange so that its side shown

by

the heavy

arrow in the illustration faces toward the sprocket.

FLANGE

BEARING

SPROCKET

Crankshaft

Bolt Installation

1. Lock the crankshaft.

NOTE:

Do

not

turn the crankshaft.

2. Tighten the crankshaft bolt to the specified torque.

Oil

Pump

Sprocket

Flange

Nut

Installation

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

of

the

cylinder block to keep the counterbalance shaft from turn-

ing.

2. Install the oil pump sprocket.

3. Tighten the nut to the specified torque.

NUT

Camshaft

Sprocket

Bolt

Installation

1. Tighten the bolt to the specified torque.

OIL

PUMP

SPROCKET

~

WESTERBEKE

Engines & Generators

26

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE recommends that the following engine

adjustments

be performed by a competent engine mechanic.

The information below is provided

to

assist the mechanic.

Tensioner

Spring/Timing

Tensioner

Installation

1. Install the tensioncr spring and timing belt tensioner.

2. Hook the tensioner spring onto the bend

of

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

3.

Move the timing belt tensioner as close

as

possible to the

water pump; temporarily tighten the tensioner nut.

TIMING

BELT

TENSIONER

Timing

Belt

Installation

1. Align the triangular marking on the camshaft sprocket
with

a marking on the timing belt rear cover.

2.

Align the notch in the crankshaft sprocket flange with
the marking on the front

casco

3. Align the triangular marking on the oil pump sprocket
with the marking on the front case, and then insert a 65
mm (2.56 in.) or longer, 8 mm

(0.31 in.) diameter

round bar into the plug hole

in

the left side

of

the

cylinder

blOC~k~.~;;;~~~_~

MARKING

ON

TIMING

BELT

~

REAR

COVER

TRIANGULAR

MARKING

ON

CAMSHAFT
SPROCKET

TIMING

BELT

TENSIONER

~b..'~'-..L--j,-TRIANGULAR

MARKING

ON

OIL

PUMP

SPROCKET

MARKING
ON

FRONT

CASE

At this time, check that the moveable range

of

teeth

On

the oil pump sprocket is according to specifications.
Standard value: 4 to 5 teeth in forward direction

1 to 2 teeth in reverse direction

REVERSE

OIL

PUMP

SPROCKET

4. If the movable range

of

the oil pump sprocket exceeds

the specified range, correct as follows:

a.

Pull out the round

bar

from the plug hole

in

the left

side

of

the cylinder block.

b. Turn the oil

pump

sprocket one turn at a time until

the round

bar

can again be inserted.

c.

Check that the movable range

of

the oil pump

sprocket is in the specified value.

S.

Set the timing belt

over

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

NOTE:

Ensure that the tension side

of

the timing belt is

not

slack.

Keep

the

round

bar

inserted until the timing

belt

has

been placed.

After

this step,

be

sure to remove

the round bar.

6. Apply counterclockwise force to the camshaft sprocket
to make the belt taut on the tension side, and

make

sure that all timing marks are lined up.

CAMSHAFT
SPROCKET

TENSION

SIDE

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

or

2 turns, and tension the belt

making use

of

spring force.

NOTCH

IN
CRANKSHAFT
SPROCKET

FLANGE

Engines & Generators

27

ENGINE

ADJUSTMENTS

NOTE:

WESTERBEKE recommends that the following engine

adjustments be performed

by a competent engine mechanic.

The information below is provided to assist the mechanic.

8.

Tum

the crankshaft clockwise by nine camshaft

sprocket teeth

(81") to align the timing mark on the

camshaft sprocket with the tcnsioner set

mark

on the

timing belt rear cover.

A

CAUTION:

This

operation

is

performed

to

give

a

proper

tension

to

the

timing

belt,

so

do

NOT

turn

the

crankshaft

counterclockwise

and

push

the

belt

to

check

the

tension.

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

of

the

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

10. Pull the timing belt

in

the center

of

the tension side

toward the sealing gasket line for the belt cover, as

i1lustrated. Make sure that the clearance between the

back

of

the belt and the sealing line is the standard

value.

Standard Value:

12mm

(0.47in.)

SEALING
GASKET

/L1NE

\\0:1

~>-

__

12

mm

(GA7IN)

11.

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

of

the cylinder block

and

apply the specified sealant.

Then tighten the plug to the specified torque.

Specified sealant value:

3M

AID

Part No.

8660

or

equivalent

Tightening torque: 15-22 Nm (11-16 ft.lbs.)

Engines & Generators

28

ENGINE

TROUBLESHOOTING

The

following troubleshooting tables

are

based

upon

certain

engine problem indicators

and

the

most likely causes

of

the

problems.

PROBLEM

PROBABLE

CAUSE

Engine

does

not

1.

Voltage

drop

at

starter

solenoid

crank.

terminal.

2.

Engine

20A

circuit

breaker

has

tripped.

3.

Battery

is

low

or

dead.

4.

Loose

battery

connections.

5.

Faulty

wire

connection.

6.

Faulty

start

switch.

7.

Faulty

start

relay

(K1).

8.

Faulty

starter

solenoid.

9.

Raw

water

filled

cylinders.

Engine

cranks

but

1.

Out

of

fuel.

fails

to

start.

2.

Engine

is

flooded.

a.

Carburetor

float

needle

valve

open

or

damaged.

Clean

or

replace

the

needle

valve.

b.

Float

in

carburetor

is

leaking.

Repair

or

replace

float.

c.

Float

chamber

gasket

damaged

or

securing

screws

are

loose.

Replace

gasket

and/or

tighten

screws.

3.

Fuel

pump

inoperative.

4.

Worn

or

faulty

spark

plugs.

5.

High

tension

wires

grounding

(wet

system).

6.

Faulty

ignition

coil.

7.

Faulty

distributor.

8.

Faulty

wire

connection.

9.

Faulty

overspeed

circuit

board.

Replace.

10.

Faulty

run

relay

(K2).

11.

Timing

belt.

12.

No

engine

compression.

13.

Faulty

idle

adjustment.

When

troubleshooting

indicates

an

electrical problem, see

the

DC Electrical System

Wiring

Diagram

and

Schematic,

as

they

may

reveal

other

possible causes

of

problems

not

listed

below.

PROBLEM

PROBABLE

CAUSE

Engine

starts,

runs

1.

Faulty

shutdown

switch,

and

then

shuts

(oil

pressure,

water

or

exhaust

down.

temperature).

2.

High

engine

water

or

exhaust

temperature.

3.

Dirty

fuel/water

separator

filter.

4.

Mechanical

check

valve

at

the

fuel

supply

faulty.

5.

Low

oil

level

in

sump.

6.

Faulty

fuel

pump.

7.

Faulty

engine

temperature

sensor.

Engine

starts,

runs

1.

Fuel

line

restriction.

but

does

not

come

2.

Mechanical

check

valve

at

the

up

to

speed.

fuel

supply

is

faulty.

3.

Throttle

plate

binding.

4.

Faulty

fuel

pump.

5.

Faulty

wire

connection.

6.

Faulty

engine

temperature

sensor.

7.

AC

generator

overload.

8.

High

exhaust

pressure.

Engine

hunts.

1.

Low

battery

voltage.

2.

Generator

is

overloaded.

3.

Cracked

distributor

cap.

4.

Faulty

high

tension

wires.

5.

Faulty

fuel

pump.

6.

High

exhaust

back-pressure.

7.

Valves

are

out

of

adjustment.

Engines & Generators

29

ENGINE

TROUBLESHOOTING

PROBLEM

PROBABLE

CAUSE

PROBLEM

PROBABLE

CAUSE

Engine

misfires.

1.

Poor

quality

fuel.

High

oil

pressure.

1.

Dirty

oil

or

wrong

SAE

type

oil

in

the

2.

Incorrect

timing.

engine.

3.

Dirty

flame

arrester.

2.

Relief

valve

is

stuck.

4.

Cracked

distributor

cap.

No

DC

charge

to

the

1.

Faulty

connections

to

5.

Faulty

ignition

wires.

starting

battery.

battery

voltage

regulator.

6.

Spark

plugs

are

worn.

2.

Faulty

battery

voltage

regulator.

7.

High

exhaust

back-pressure.

3.

Faulty

bridge

rectifier.

8.

Valve

clearances

are

incorrect.

4.

Faulty

generator

charger

Engine

backfires.

1.

Spark

plug

wires

are

connected

windings.

wrong.

Blue

exhaust

smoke

1.

Lube

oil

is

diluted.

2.

Incorrect

timing.

discharge

from

the

2.

High

lube

oil

level.

3.

Engine

is

flooded.

See

Engine

is

engine.

3.

Crankcase

breather

hose

is

clogged.

flooded

under

Engine

cranks

but

4.

Valves

are

worn

or

adjusted

fails

to

start.

incorrectly.

4.

Dirty

flame

arrester.

5.

Piston

rings

are

worn

5.

Cracked

distributor

cap.

or

unseated.

6.

High

exhaust

back·pressure.

Black

exhaust

smoke

1.

Dirty

flame

arrester.

Engine

overheats.

1.

Coolant

loss.

Pressure

test

discharge

from

the

2.

Faulty

carburetor.

cooling

system.

engine.

2.

Faulty

raw

water

pump

impeller.

3.

Belts

are

loose

or

broken.

4.

Raw

water

pump

worn.·

Poor

performance

1.

Main

jet

clogged.

Remove

and

clean.

at

generator

speed.

2.

Carburetor

inlet

filter

clogged.

Remove

and

clean.

5.

Faulty

thermostat.

3.

Fuel

pump

clogged.

Remove

and

Low

oil

pressure.

1.

Low

oil

level.

replace.

2.

Wrong

SAE

type

oil

in

the

engine.

3.

Wrong

type

oil

filter.

4.

Air

intake

filter

screen

dirty.

Remove

and

clean.

4.

Relief

valve

is

stuck.

5.

Faulty

oil

pump.

6.

Faulty

engine

bearings.

~

WESTERBEKE

Engines & Generators

30

GENERATOR

INFORMATION

USE

OF

ELECTRIC

MOTORS

The

power required to start an electric motor is considerably

more than is required to keep

it

running after

it

is

started.
Some motors require much more current to start than others.
Split-phase (AC) motors require more current

to

start, under
similar circumstances, than other types. They are commonly
used on easy-starting loads, such as washing machines,

or
where loads are applied after the motor is started, such as
small

power

tools. Because they require 5 to 7 times as much

current to start as to run, their use should

be

avoided, when-

ever possible,

if

the electric motor is to be driven by a small

generator. Capacitor and repulsion-induction motors require
from

2 to 4 times as much current to start as to run. The CUT-

rent required to start any motor varies with the load con­nected

to

it.

An

electric motor connected to an air
compressor, for example, will require more current than a
motor to which no load is connected.

In general, the current required to start 115 volt motors
connected to medium starting loads will be approximately
as follows:

AMPS

FOR

AMPS

FOR

MOTOR

SIZE

RUNNING

STARTING

(HP)

(AMPERES) (AMPERES)

1/6

3.2

6.4

TO

22.4

1/4

4.6

9.2

TO

32.2

1/3

5.2

10.4

TO

72.8

1/2

7.2

14.4

TO

29.2

3/4

10.2

20.4

TO

40.8

1

13

26

TO

52

NOTE:

In the above table the maximum

"AMPS

FOR

STARTING" is more for some small motors than for larger

ones. The reason for this is that split-phase (the hardest start­ing types) are used in the smaller motors only.

Because the heavy surge

of

current needed for starting

motors is required for only an instant, the generator will not

be

damaged

if

it can bring the motor up to speed

in

a few

seconds.

If

difficulty is experienced

in

starting motors, tum

off

all other electrical loads and, if possible, reduce the load

on the electric motor.

REAR

CAPACITOR

P

GENERATOR

COMPONENTS

REQUIREO

OPERATING

SPEED

Although individual units may vary slightly, the normal
voltage and frequency

of

typical

60

(50) hertz engine-driven

generators described in this manual are approximately as fol-

lows: run first with

no

load applied, then

at

half the generator's

capacity, and finally loaded to its full capacity as indicated on

the generator's data plate.

The

output voltage should

be

checked periodically to ensure

proper operation

of

the generating plant and the appliances it

supplies.

GENERATOR

FREQUENCY

ADJUSTMENT

• Frequency is a direct result

of

engine/generator speed, as

indicated by the following:

•

When

the generator is run at 3600 rpm, the

AC

voltage

output frequency is

60

hertz.

•

When

the generator is run at 3000 rpm, the

AC

voltage

output frequency is

50

hertz.

Therefore, to change the generator's frequency, the generator's
drive engine's speed must

be

changed. A reconfiguring

of

the

AC

output connections at the generator must also

be

made.

GENERATOR

MAINTENANCE

Maintaining cleanliness is important.

Do

not allow salt, dust,

or

carbon from engine exhaust to build up on either the gen-

erator

or

its engine.

BAND

-FLANGE

FRONT

COVER

CONTROL

BOX

Engines & Generators

31

GENERATOR

WIRING

DIAGRAMS

RED

+

;-----------,

, '

, '

, 2

,

, 3

,

Allicr:::

,

Cnm_mi

0Jll

.ll.

L,:-t

Hz

WINDING

RESISTANCE

AT

20°

C TEMPERATURE

A-A

B

C-C 0

ROTATING

BATTERY STATOR

EXC

PART

CHARGER

WINDING

WINDING

WINDING

~-2

50~!

3.058

.n..

o.i41

.n..

('.433

.n..

4-.334

.n..

---

--

'-3

,o-g

MODEL

4.5

KW

c·-S'-5A

.n.

3.

4S"~

.n

4-,

'io-1-

0·491

.!1.

4.5.34

.n.

'·6

'o-if

0·55;t

....n..

3.

;r.q

..

..n.

R[

+

,-----------1

~

,

'8

SOHI

, 2

,

, 3

,

Allicr::;

,

:

__

mmniOjjj

.It

L,:-t

Hz

MODELS

7.2

KW

AND

9.6

KW

Engines & Generators

Rev.

6/1/98

32

AC

ELECTRICAL

CONNECTIONS

r--------.,

iAR]i

I

I

I
I
I

B

UA.._...J

B'~-...J

WHITE

rv

AR]i

...,..----{)

4

I

I I

.....

_--------

C

VA----05

DITWlo

50

189HZ

HZ

666

LJ

CONNECT

fOR

REQUIRED

FREQUENCY

AND

OUTPUT

VOLTAGE

A -

ROTOR

BI-

BATTERY

CHARGE

WINDING

MODEL

4.5

KW

B2-

BATTERY

CHARGE

WINDING

MODELS

7.2

KW

AND

9.6

KW

C -

STATOR

WINDING

D -

CAPACITOR

WINDING

CIRCUIT

BREAKER

4------,

L

+

+

120

VAC

60

HZ

(CONNECT
JUMPER)

1-------,

5------~

r:___:h

240/120

VAC

60

HZ

(REMOVE

JUMPER)

6-------,

220

VAC

34 :

r±----Jh

50

HZ

_

"'"

-

(REMOVE

-0

JUMPER)

N

L

A

WARNING:

When

changing

from

60Hz

to

50Hz,

make

certain

the

ground

wire

(white & green

stripe)

is

properly

repositioned

according

to

this

diagram.

Engines & Generators

33

Rev.

6/1/98

LAY-UP

&

RECOMMISSIONING

GENERAL

Many

owners rely on their boatyards

to

prepare their craft,

including engines and generators, for Jay-up during the off-

season

or

for long periods

of

inactivity. Others prefer to

accomplish lay-up preparation themselves.
The

procedures which follow will allow you to perform your

own

lay-up and recommissioning,

or

wi1l

serve as a checklist

if others do the procedures.

These

procedures should provide protection

for

your

engine/generator during a Jay-up and also help familiarize

you with its maintenance needs.

If

you have any questions regarding lay-up procedures, caB

your local servicing dealer. He will

be

more

than willing to

provide assistance.

FRESH

WATER

CODLING

SYSTEM

A 50-50 solution

of

antifreeze and distilled water is recom-

mended for use

in

the fresh water cooling system

at

all

times.

This solution may require a higher concentration

of

antifreeze,

depending on the area's winter climate.

Check

the solution to

make sure the antifreeze protection is adequate.

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

Operate the engine to ensure a complete circulation and mix­ture

of

the antifreeze concentration throughout the cooling

system. Then recheck the antifreeze solution's strength.

LUBRICATION

SYSTEM

With the engine warm, drain all the engine oil from the oil

sump. Remove and replace the oil filter.

(Place some paper

towels and a plastic bag around the filter to catch the oil dur-

ing its removal.)
When

installing the new oil filter,

be

sure to apply a small

amount

of

oil on the rubber sealing gasket at the base

of

the

filter. Fill the

sump

with the correct amount

of

oil for your

engine model. (Refer to the

SPECIFICATIONS section

of

this manual.) Use an oil with an API specification

of

SJ.

Run the engine and check for proper oil pressure and make

sure there are no leaks

or

fuel spills.

A

CAUTION:

Do

not

leave

the

engine's

old

engine

oil

in

the

sump

over

the

lay-up

period_

Engine

oil

and

combustion

deposits

combine

to

produce

harmful

chemicals

which

can

reduce

the

life of

your

engine's

internal

parts.

FUEL

SYSTEM

Top

off

your fuel tanks with unleaded gasoline

of

89

octane

or

higher. A fuel conditioner such as STABIL gasoline stabi-

lizer should be added.

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

Start the engine and allow it to run for 5-10 minutes. Check
for any leaks that may have been created

in

the fuel system
during this servicing and correct them. Clean up any fuel
spills.

RAW

WATER

CIRCUIT

Close the through-huH fitting. Remove the raw water intake
hose from the fitting.

Place the end

of

this hose into a 5-gallon

bucket

of

clean fresh water. Before starting the engine,

check

the zinc anode

in

the heat exchanger on the engine and clean

or

replace it as required. Clean the raw water strainer,

if

one

is installed on the inside

of

the hull.

Start the engine and anow the raw water pump to draw the
fresh water through the system. When the bucket is empty,
stop the engine and refill the bucket with an antifreeze solu­tion slightly stronger than needed for winter freeze protection

10

your area.

Start the engine and allow all

of

this mixture to be drawn

through the raw water system.

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

Remove the impeller from your raw water pump (some
antifreeze mixture will accompany

it,

so catch it

in

a bucket).

Examine the impeller. Get a replacement,

if

needed, and a
cover gasket. Do not replace the impeller (into the pump)
until recommissioning, but replace the cover and gasket.

Engines & Generators

34

LAY-UP

&

RECOMMISSIONING

INTAKE

MANIFOLD

Clean the filter screen in the flame arrester, and place a clean
doth

lightly soaked

in

lube oil around the flame arrester to

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

through-hull exhaust

port.

Make a note to remove cloths prior

to

start-up!

STARTER

MOTOR

Lubrication and cleaning

of

the starter drive pinion is advisable,

if access to the starter permits its removal. Make sure the bat-

tery connections are shut

off

before attempting to remove the
starter. Take care in properly replacing any electrical connec­tions removed from the starter.

CYLINDER

LUBRICATION

Spray fogging oil into the open air intake, with the flame
arrestor removed, while the generator is running.

The

fogging

oil

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

spark plugs for winter protection.

NOTE:

The spark

plugs

will need to be removed

for

cleaning

and regapping at spring commissioning.

SPARE

PARTS

Lay-up time provides a good opportunity to inspect your
WESTERBEKE

engine to see if external items such as drive

belts

or

coolant hoses need replacement. Check your basic

spares kit and

order

items not on hand,

or

replace those items

used during the lay-up, such as filters and zinc anodes.

BATTERIES

If

batteries are to

be

left on ·board during the lay-up period,
make sure that they are fully charged, and will remain that
way, to prevent them from freezing.

If

there is any doubt that

the batteries will not remain fully charged,

or

that they will

be

subjected to severe environmental conditions, remove the
batteries and store them in a wanner, more compatible envi­ronment.

A

WARNING:

Lead

acid

batteries

emit

hydrogen,

a

highly·explosive

gas,

which

can

be

ignited

by

electri·

cal

arcing

or a lighted

cigarette,

cigar,

or

pipe.

Do

not

smoke

or allow

an

open

flame

near

the

battery

being

serviced.

Shut

off

all

electrical

equipment

in

the

vicinity

to

prevent

electrical

arcing

during

servicing.

RECOMMISSIONING

The

recommissioning

of

your

WESTERBEKE

engine after a
seasonal lay-up generally follows the same procedures as
those presented in the

PREPARATIONS

FOR

INITIAL

START-

UP section regarding preparation for starting and normal

starts. However, some

of

the lay-up procedures will need to

be

counteracted before starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold
and from the through-hull exhaust

port.

2. Remove the raw water pump

cover

and gasket. Discard the
gasket. Install the raw water pump impeller removed dur­ing lay-up

(or

a replacement,

if

required). Install the raw

water

pump

cover with a new

cover

gasket.

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

proper tightness.

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

5. Note that it

is

not necessary to flush the antifreeze/fresh
water solution from the raw water coolant system. When
the engine is put into operation, the system will self-flush
in a short period

of

time with no adverse affects.

6.

Start the engine

in

accordance with procedures

in

the

PREPARATIONS

FOR

INITIAL

SDlRT-UP section

of

this

manual.

Engines & Generators

35

BCGTC

GENERATOR

SPECIFICATIONS

ENGINE

SPECIFICATIONS

Engine

Type

3

cylinder, 4 cycle,

overhead

camshaft

wlcounterbalance

shaft,

carbureted,

water

cooled

gasoline

engine

Bore

and

Stroke

2.56 x 2.61

in.

(65.0

mm x 66.3

mm)

Total

Displacement

40.3

cu.

in.

(.66

liter)

Bearings

Four

main

bearings

Combustion

Chamber

Semi-spherical

Compression

ratio

9.8

- 1

Firing

Order

1 - 3 - 2

Direction

of

Rotation

Counterclockwise

viewed

from

the

back

end

Inclination

Governor

Fuel

Pump
Fuel
Distributor
Spark

Plugs

Ignition

Coil

Flame

Arrester

Carburetor

250 continuous,

all

directions

300 temporary,

all

directions

Mechanical

FUEL

SYSTEM

Electric

fuel

pump

Unleaded

89

octane

or

higher

gasoline

Breakerless

distributor

14

mm

12

volt

Metal

screen

type

Single-barrel

downdraft

type

ELECTRICAL

SYSTEM

-

Start

Motor

Starting

Battery

Battery

Capacity

Battery

Charging

12

volt

reduction

gear

wlsolenoid

12

volt

negative

ground

300

cold

cranking

amps

(CCA)

(min)

Integral

electriC,

17

amps

AIR

REQUIREMENTS

Generator

Cooling

Engine

Combustion

(all

models)

Engine

Cooling

225--250

CFM

(6.3-7.0

cmm)

42

CFM

(1.2

cmm)

100

CFM

(2.8

cmm)

General

Fresh

Water

Pump

Raw

Water

Pump

Raw

Water

Flow,

at

3600

RPM

Fresh

water-cooled

block

through

raw

water-cooled

heat

exchanger

circuit

Centrifugal

type,

metal

impeller,

belt-driven
Positive

displacement,

rubber

impeller,

belt-driven

7.0-7.5

gpm

(26.4-28.3

Ipm)

measured

before

discharge

into

water

injected

exhaust

elbow.

Cooling

Water

Capacity

3.5

qts.

(3.4

liters)

LUBRICATING

SYSTEM

Type
Oil

Filter

Oil

Capacity

Oil

Grade

Forced

lubrication

by

gear

pump

Fuel

flow,

paper

element

spin-on

disposals

2.7

qts.

(2.6

liters)

API

specification

SJ

class

AC

GENERATOR

SPECIFICATIONS

Type

2

pole

capacitor

regulated

50/60

hertz-1.0

power

factor

Rating

(minimum)

r~m

Model

Hz

KVA

VAC

3000

3.75

Kw

50

3.75

230

3000

6.0

Kw

50

6.0

230

3000

8.0

Kw

50

8.0

230

3600

4.5

Kw

60

4.5

120

3600

7.2

Kw

60

7.2

120

3600

9.6

Kw

60

9.6

120

Consult

factory

for

120/240

volt

application

TUNE-UP

SPECIFICATIONS

Spark

Plug

Gap

Spark

Plug

Torque

0.031 ± .002

inches

(0.8 ± 0.05

mm)

10.8 -15.2

Ib-ft

Valve

Clearances

Intake

valves:

0.20

mm

(.008

in)

Exhaust

valves:

0.30

mm

(.012

in)

Timing

Specifications

18

0

±

.50 BTDC

at

3600

rpm

(no

load

on

generator)

Cylinder

Head

60 -70

Nm

43-51

ft-Ibs

Boll

Torque

see

TORQUING

THE

CYLINDER

HEAD

BOLTS

under

ENGINE

ADJUSTMENTS

-..v-

WESTERBEKE

Engines & Generators

Rev.

6/1/98

36

BCGTC

GENERATOR

PARTS

IDENTIFICATION

WATER

FRESH

WATER

FILL

CAP

CARBURETOR

TEMPERATURE

-------1

SWITCH

Oil

PRESSURE

SWITCH

DC

BATIERY

GROUND

CONNECTION

DATA

TAG

STARTER

WITH

SOLENOID

WATER

INJECTED

EXHAUST

ELBOW

FRESH

WATER

DRAIN

PLUG

RIGHT

SIDE

Oil

FILL

CAP

LEFT

SIDE

~

WESTERBEKE

Engines & Generators

37

GOVERNOR

OIL

FILTER

::i-----

RAW

WATER

Oil

DRAIN

HOSE

DISTRIBUTOR

PUMP

ZINC

ANODE

COIL

STANDARD

HARDWARE

TORQUES

NOTE:

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.

Grade

4

Pitch

Ib-n

kg-m

Grade

7T,

8T

and

8·.8

Pitch

Ib-n

kg-m

6mm

bolt

head/nut

1

2.9-5.1

0.4-0.7

6mm

bolt

head/nut

1

5.S-S.7

0.S-I.2

Smm

bolt

head/nut

1.25

7.2-11.6

1.0-1.6

Smm

bolt

head/nut

1.25

14.5-21.7

2.0-3.0

10mm

bolt

headinut

1.25

13.7-22.4

1.9-3.1

10mm

bolt

head/nut

1.25

2S.9-39.S

4.0-5.5

10mm

bolt

headinut

1.5

13.0-21.7

I.S-3.0

10mm

bolt

head/nut

1.5

26.S-37.6

3.7-5.2

12mm

bolt

head/nut

1.25

(ISO)

25.3-39.S

3.5-5.5

12mm

bolt

head/nut

1.25

(ISO)

54.2-75.9

7.5-10.5

12mm

bolt

headinut

1.5

25.3-39.8

3.5-5.5

12mm

bolt

head/nut

1.5

50.6-65.1

7.0-9.0

12mm

bolt

headinut

1.75

21.7-36.2

3.0-5.0

12mm

bolt

head/nut

1.75

43.4-61.5

6.0-S.5

13mm

bolt

headinut

1.5

32.5-50.6

4.5-7.0

13mm

bolt

head/nut

1.5

57.9-S6.S

S.0-12.0

14mm

bolt

headinut

1.5

36.2-57.9

5.0-S.0

14mm

bolt

headinut

1.5

72.3-10S.5

10.0-15.0

14mm

bolt

head/nut

2

34.0-55.7

4.7-7.7

14mm

bolt

head/nut

2

6S.7-101.3

9.5-14.0

16mm

bolt

head/nut

1.5

54.2-79.6

7.5-11.0

16mm

bolt

headinut

1.5

10S.5-166.4

15.0-23.0

16mm

bolt

head/nut

2

51.4-76.7

7.HO.6

16mm

bolt

head/nut

2

101.3-159.1

14.0-22.0

Grade

6T

Grade 5 Cap

Screw

Bmm

bolt

head/nut

1

4.3-6.5

0.6-0.9

1/4

UNC

9-11

1.2-1.5

Bmm

bolt

head/nut

1.25

10.S-15.9

1.5-2.2

1/4

UNF

lH3

1.5-1.S

10mm

bolt

head/nut

1.25

21.7-32.5

3.0-4.5

5/16

UNC

IS-20

2.5-2.S

10mm

bolt

head/nut

1.5

19.5-30.4

2.7-4.2

5/16

UNF

21-23

2.9-3.2

12mm

bolt

head/nut

1.25

(ISO)

36.2-57.9

5.0-S.0

3/S

UNC

2S-33

3.7-4.6

12mm

bolt

head/nut

1.5

36.2-50.6

5.0-7.0

3/S

UNF

30-35

4.1-4.S

12mm

bolt

head/nut

1.75

34.7-49.2

4.S-6.S

7/16

UNC

44-49

6.1-6.S

7/16

UNF

50-55

6.9-7.6

1/2

UNC

6S-73

9.4-10.1

1/2

UNF

73-S0

10.Hl.l

Engines & Generators

38

BCGTC

GENERATOR

HARDWARE

TORQUES

TIming

Belt

Nm

ft.

Ibs.

Front

Case,

Counterbalance

Shaft

Nm

ft.lbs.

Crankshaft

bolt

135-145

98-105

Front

case

bolt

8-10

6-7

Timing

belt

cover

bolt

10-12

7-9

OJ!

pump

cover

bolt

8-10

6-7

Camshaft

sprocket

bolt

80-100

58-72

Oil

pan

bolt

10-

t2

7-9

Oil

pump

sprocket

nut

50-57

36-41

Oil

drain

plug

35-45

25-33

Timing

tensioner

nut

22-30

7-9

Oil

screen

bolt

15-22

11-16

Timing

belt

rear

cover

bolt

10-12

Oil

pump

driven

gear

bolt

34-40

25-29

Water

Pump

Rear

cover

bolt

10-12

7-9

Water

pump

8-10

6-7

Piston

and

Connecting

Rod

Rocker

Arms

and

Rocker

Shaft

Connecting

rod

cap

nut

15+90

0

tum

11

+

90°

tum

Rocker

cover

shaft

29-35 21-25

Crankshaft,

Bearing

Camshaft

thrust

plate

bolt

10-12

7-9

Oil

seal

case

bolt

10-12

7-9

Rocker

arm

adjust

nut

8-10

6-7

Bearing

cap

bolt

50-55

36-40

Cylinder

Head,

Valve

Cylinder

Block

Cylinder

head

bolt

(cold

engine)

60-70

43-5t

Taper

plug

1/16

8-12

6-9

Taper

plug

1/8

t5-22

11-16

Water

drain

plug

35-45

25-33

Taper

plug

pt-l/4

35-45

25-33

~

WESTERBEKE

Engines & Generators

39

METRIC

CONVERSIONS

INCHES

TO

MILLIMETERS

MILLIMETERS

TO INCHES

Inches

mm

Inches

mm

mm

Inches

mm

Inches

1

25.40

15 381.00 1 0.0394 15 0.5906

2

50.80

20 508.00 2 0.0787

20 0.7874

3

76.20

25

635.00

3

0.1181 25

0.9843

4

101.60

30 762.00

4

0.1575

30

1.1811

5

127.00

35

889.00 5 0.1969

35 1.3780

10

254.00

40 1016.00 10 03937 40

1.5748

10

MIlliMETERS =

lCENTIMETER,

100

CENTIMETERS

= 1

METER

= 39.37

INCHES

(3.3

FEET)

INCHES TO METERS METERS TO INCHES

Inches

Meters

Inches

Meters

Meters

Inches

Meters

Inches

1 0.0254

7

0.1778

0.1

3.937 0.7 27.559

2

0.0508 8 0.2032 0.2 7.874

0.8 31.496

3

0.0762

9 0.2286 0.3 11.811 0.9

35.433

4

0.1016 10 0.2540 0.4

15.748

1.0 39.370

5 0.1270

11

0.2794 0.5

19.685

1.1

43.307

6

0.1524 12 0.3048 0.6 23.622

1.2 47.244

TO

CONVERT

METERS

TO

CENTIMETERS,

MOVE

DECIMAL

POINT

TWO

PLACES

TO

THE

RIGHT

YARDS TO METERS METERS TO YARDS

Yards

Meters

Yards Meters Meters

Yards

Meters

Yards

1 0.91440

6 5.48840 1 1.09361 6 6.56168

2

1.82880 7 6.40080 2 2.18723 7 7.65529

3

2.74320 8 7.31520

3

3.28084

8 8.74891

4

3.65760 9

8.22960 4

4.37445

9 9.84252

5

4.57200

10 9.14400

5 5.46807

10

10.93614

MOVE

DECIMAL

POINT

FOR

HIGHER

VALUES -e.g.

6,000

METERS = 6,561.68

YARDS

POUNDS TO KILOGRAMS KILOGRAMS

TO

POUNDS

Ib

kg

Ib

kg

kg Ib

kg

Ib

1 0.454

6

2.722

1

2.205

6 13.228

2

0.907

7 3.175 2

4.409

7 15.432

3 1.361 8 3.629 3 6.614

8

17.637

4 1.814

9

4.082

4 8.818 9 19.842

5

2.268

10 4.536 5 11.023

10

22.046

GALLONS

TO

LITERS LITERS TO GALLONS

Gallons

Liters

Gallons

Liters

Liters

Gallons

Liters

Gallons

1 3.79

10

37.86 1 0.26 60 15.66

2 7.57 20 75.71 2 0.53

90

23.77

3 11.36

30 113.57 5 1.32 120 31.32

4 15.14

40

151.42 10 2.64 150 39.62

5 18.93

50 189.28 20 5.28 180 47.54

PINTS TO LITERS LITERS TO PINTS

Pints

Liters

Pints

Liters

Liters

Pints

Liters

Pints

1 0.47 6 2.84 1 2.11

6

12.68

2

0.95

7 3.31 2 4.23 7 14.79

3

1.42

8

3.79

3 6.34 8 16.91

4

1.89

9 4.26

4

8.45

9 19.02

5

2.37

10 4.73 5 10.57

10

21.13

TEMPERATURE

32

40

50

60 70

75

85

95

105 140

175

212

OF

I I I I I I I I I I I I

I

I I I I

I

I I I

I

I

I

0

5

10

15 20

25

30

35

40

60

80

100

°C

Engines & Generators

40

SUGGESTED

SPARE

PARTS

WESTERBEKE

MARINE

GASOLINE

GENERATORS

Zinc

Anodes

.G~

Carry several.

Spall<

Plugs

Heat

Exchanger

End

Gasket

Oil

Filter

Have

several aboard.

Change every

100

hours.

Oistributor

Cap

and

Wires

WESTERBEKE

also offers two Spare Parts Kits,

each

packaged

in a rugged

hinged

toolbox.

Kit

A includes the basic spares.

Kit

B is for more extensive off-shore cruising.

KIT

A

Impeller Kit
Heat Exchanger Gasket
Oil Filter
Drive Belts
ZineAnodes
Spark Plugs

Always carry a full set.

Fuel

Lift

Pump

Solid Slate Model. Have a

spare

on

board.

Carry matched pairs.
Inspect every 100 hours.

SPARE

PARTS

KITS

Engines & Generators

41

,

Raw

Water

Impeller

and

Gasket

Check annually.

and

Gasket

Always

carry a spare

aboard.

KIT

B

Impeller Kit

Water

Pump

Repair Kit

Thermostat

Kit

Zinc Anodes

Complete Gasket Kit

Heat

Exchanger

Gasket

Oil Filter
Drive Belts

Spark Plugs