Westerbeke BCG4.0KW, BCG6.5KW Operator's Manual

OPERATOR'S MANUAL

WESTERBEKE

BCG

4.0KW

and

BCG 6.5KW

MARINE GASOLINE

GENERATOR SETS

Publication # 35729

Edition Two
March 1988

~

WESI'ERBEKE

WESTERBEKE CORPORATION

AVDNINDUSTRIAL

PARK, AVON, MA

02322.

TEL:

(617)

588-7700

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

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

-----"'''--~"-------------~,

SAFETY PRECAUTIONS

The

following symbols appear in this manual to call attention

to and emphasize conditions

potentially dangerous to the

operator.

~WARNINGII

The

above symbol is used in the manual to warn of possible

serious personal injury or loss of

Hfe,

CAUTION

The

above symbol is used in the manual to caution personnel

of possible damage to equipment.
Read

the manual carefully and thoroughly before attempting
to operate the equipment. Know when dangerous conditions
can exist and take necessary precautions to protect personnel
and equipment.

Fuels, exhaust gases, batteries, electrical equipment, and
moving and hot parts are potential hazards that could result in
serious personal injury or death, Follow recommended

proce~

dures carefully.
Always operate bilge blowers for at least five minutes before

starting a gasoline-fueled engine; ensure no gasoline fumes

are

present before starting.

• Prevent Electric Shock

Shut off electric power before accessing electrical equip­ment.

Use

insulated mats whenever working on electrical equip·

ment.
Make sure your clothing

is

dry, not damp (particularly
shoes), and keep your skin surfaces dry when handling
electrical equipment.

Remove wristwatch and jewelry when working on electri­cal equipment.

Do

not connect utility shore power to vessel's

AC

circuits,
except through a ship-to-shore double-throw transfer
switch, Damage to vessel's

AC

generator may result if this

is

not done.

Be

extremely careful when working

on

electrical

com~

ponents. High voltage can cause injury or death,

• Exhaust Gases Are Toxic

Ensure that the exhaust system is adequate to expel gases
discharged from the engine.

Check exhaust system
regularly for leaks and make sure the exhaust manifolds
are

securely attached and no warping exists,

Be

sure the unit and its surroundings

are

well-ventilated.

• Use Extreme Care When Handling Engine Fuel
(A

constant danger

of

explosion

or

fire exists)

Do

not fill fuel tank(s) while the engine

is

running,

Do

not smoke or use

an

open flame near the engine or the

fuel tank.

• Do

Not

Alter

or

Modify the Fuel System

Be

sure all fuel supplies have a positive shut-off valve.

Be

certain fuel line fittings

are

adequately tightened and

free of leaks,
Make sure a fire extinguisher is installed nearby and

is

properly maintained.

Be

familiar with its proper

use.

Ex~

tinguishers rated ABC

by

the

NFPA

are

appropriate for all

applications encountered in this environment.

• Use Extreme Care When Servicing Batteries

Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.

Lead

acid batteries emit hydrogen, a

highly~explosive

gas,

which can be ignited

by

electrical arcing or

by

a lighted

cigarette, cigar, or pipe.

Do

not smoke or allow

an

open

flame near the battery being serviced, Shut off

all

electri-

cal equipment

in

the vicinity to prevent electrical arcing

during servicing.

• Avoid Moving Parts

Do

not service the unit while the unit is running; if a situa­tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid moving
parts and hot exhaust system components.

Do

not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, shirts or sleeves,
rings, necklaces, or bracelets that

might

be caught

in

moving parts.
Make sure

all

attaching hardware is properly tightened.

Keep

protective shields and guards

in

their respective

place at all times.
Do

not check fluid levels or the

drive~belt's

tension while

the unit

is

operating.

Do

not work

on

the equipment when mentally or physical-

ly incapacitated

by

fatigue.

IMPORTANT

PRODUCT SOFTWARE DISCLAIMER

Product

software

of

all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, parts lists and parts price lists, and other information, instructions and specifications provided from
sources other than Westerbeke, is not within Westerbeke's

control and, accordingly, is provided to Wester-

beke customers

only as a courtesy and service. WESTERBEKE CANNOT

BE

RESPONSIBLE

FOR

THE

CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES

OR

REPRESENTATIONS WITH RESPECT

THERETO, INCLUDING THE ACCURACY, TIMELINESS

OR

COMPLETENESS THEREOF, AND WILL IN NO

EVENT

BE

LIABLE

FOR

ANY TYPE OF DAMAGES

OR

INJURY INCURRED IN CONNECTION WITH,

OR

ARISING OUT OF, THE FURNISHING

OR

USE OF SUCH SOFTWARE.

For example, components and subassemblies incorporated in Westerbeke's products and supplied by
others (such as engine

blocks, fuel systems and components, transmissions, electrical components, pumps

and other products) are generally supported

by

their manufacturers with their own software, and Wester-

beke must depend on such software for the design

of

Westerbeke's own product software. Such software

may be outdated and

no

longer accurate. Routine changes made

by

Westerbeke's suppliers,

of

which

Westerbeke

rarely has notice in advance, are frequently not reflected in the supplier's software until after

such changes take

place.

Westerbeke customers should also keep in mind the time span between printings

of

Westerbeke product

software, and the unavoidable existence

of

earlier, non-current Westerbeke software editions in the field.

AddITionally,

most Westerbeke products include customer-requested special features that frequently

do

not

include complete documentation.

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 sup-

plier in question be consulted

to

determine the accuracy and currency

of

the product software being con-

sulted

by

the customer.

1

Westerbeke Generators

FOREWORD

Thank you

for

selecting a Westerbeke marine product for your use. We at Westerbeke are pleased

to

have

you as a customer.

Read

this manual carefully and observe all safety precautions included throughout. Operating procedures,

periodic preventive maintenance procedures,

installation checks, system descriptions and minor adjust­ment procedures are included herein so you can operate your equipment safely and properly, maintain the
equipment at a high level of efficiency, and expect dependable performance and long service life in return.

Should your unit require special attention, contact your Westerbeke dealer for assistance. The Westerbeke
Service Organization is trained

to

provide the support necessary

to

ensure long-term dependable perfor-

mance.

If,

within

60

days

of

submitting the Warranty Registration Form for your unit, you have not received a Cus­tomer Identification Card (see below) registering your warranty, please contact the factory in writing with
Model information, including the unit's serial number and commission date.

from:

WESTERBEKE

CORPORATION

AVON

INDUSTRIAL

PARK

AVON.

NA

02322

f-VV-

I WESTERBEKE

:::;,:.;:::::~.

::::'.::,7~::.:;;;~

:.:::

~.::~:::.n_

Mail

To:

Westerbeke

Generators

CUSTOMER IDENTIFICATION

Adam

S"ith

as

Maple

Street

Alden.

IN

12234

Model

BeG

4.0KW

Expires

717189

2

Ser. I 1234(706

TABLE

OF

CONTENTS

Section ......................................................................... Page

GENERAL

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

BCG

4.0KW

GENERAL

SPECIFICATIONS

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

10

BCG

4.0KW

SYSTEM

SPECIFICATIONS

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

11

BCG

6.5KW

GENERAL

SPECIFICATIONS

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

14

BCG

6.5KW

SYSTEM

SPECIFICATIONS

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

15

INSTALLATION

CHECKS

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

18

DESCRIPTION

OF

ENGINE

CONTROL

PANEL.

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

31

PREPARATIONS

FOR

STARTING

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

33

STARTING

PROCEDURE

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

34

STOPPING

PROCEDURE

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

36

CARBURETOR

AND

FUEL

SYSTEM

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

38

ELECTRICAL

SYSTEM

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

41

DC

CONTROL

CIRCUIT

WIRING

DIAGRAM # 37190

................................... .44 &

45

OPTIONAL

REMOTE

START

PANEL

WIRING

DIAGRAM # 35706

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

46

OPTIONAL

REMOTE

INSTRUMENT

PANEL

WIRING

DIAGRAM # 35698

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

47

COOLING

SySTEM

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

48

LUBRICATION

SYSTEM

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

54

BC

GENERATOR

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

57

GENERAL

INFORMATION

AND

CARE

OF

THE

GENERATOR

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

64

ENGINE

TROUBLESHOOTING

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

66

MAINTENANCE & ADJUSTMENTS

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

70

3

Westerbeke

Generators

TABLE OF CONTENTS

(CONTINUED)

LAY-UP & RECOMMISSIONING

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

80

SPARE

PARTS

LIST

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

83

TABLE

OF

STANDARD

HARDWARE

TIGHTENING

TORQUES

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

84

TABLE

OF

TIGHTENING

TORQUES

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

85

INDEX

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

86

Westerbeke

Generators

4

GENERAL

Introduction

This manual contains the equipment operating procedures as well as additional information needed

to

help
the operator keep the marine equipment in proper working order. Study and follow the instructions careful­ly. A planned maintenance program

is

included

in

this manual; adhering

to

the program will result

in

better

equipment performance and longer equipment life. Proper diagnosis

of

a problem is the most important

step

to

satisfactory repair; therefore, a troubleshooting table is included.

Understanding

the

Gasoline

Engine-Driven Generator

The gasoline engine driving

an

AC generator

is

in

many ways similar

to

a gasoline automobile engine. The

cylinders are vertical in-line, and the engine's cylinder head has

an

overhead camshaft which

is

belt-driven.

The engine utilizes conventional points and a condenser-type distributor which

is

horizontally mounted and
camshaft-driven. The engine incorporates a pressure-type lubrication system, and a fresh water-cooled en­gine block which is thermostatically-controlled. To a large degree, the generator's engine requires the same
preventive maintenance that

is

required of a gasoline automobile engine. The most important factors to the

generator's longevity are proper ventilation, maintenance

of

the fuel system, ignition system, cooling sys-

tem, lubrication system and the

AC

end.

Ordering

Parts

Whenever replacement parts are needed, always provide the generator model number, engine serial num-

ber, and generator serial number as they appear on the scarlet and gold name plate located on the gener­ator end. You must provide us with this information so we may properly identify your generator set.

In

addition, include a complete part description and part number

for

each part needed (see the separately fur-

nished Parts

list).

Also, be sure

to

insist upon Westerbeke factory packaged parts, because "will fit" or

generic parts are frequently not made

to

the same specifications as original equipment.

Note that component locations in the manual are referenced from the front of the engine which

is

the pul-

ley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined by the

engine; imagine straddling the engine and facing in the same direction as the front

of

the engine: the left side

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

Westerbeke generators sets are thoroughly checked and given a final run under various load conditions
before leaving the factory. Test running the generator ensures dependable operation,

long service, and a

satisfied owner.

Care at the factory during assembly and thorough testing have resulted in a Westerbeke gasoline engine­driven generator capable

of

many thousands of hours

of

dependable service. However, what the manufac-

turer cannot control

is

the treatment the unit receives in the field. That part is

up

to

the owner/operator.

5

Westerbeke Generators

Fresh

Water

Coolant

Fill

Exhaust

Mani

Lube

Oil

Dipstic

20

Amp

DC

Circu

Breaker

Zinc

Anode

Heat

Ex.cha

Weslerbeke Generators

BeG

4.0KW Marine Gasoline Generator

Lube

Oil

Fill

900 Exhaust

Elbow

DC

Battery

Ground

Connection

BCG 4.()KW Marine Gasoline Generator

Water

Tempe

ratu

re

Switch

Fresh

Water

Air

Bleed

Control

Pane

AC

Unit

Data

Tag

Fuel

Lift

Pum

Oil

Pressure

Switch

7

Intake

Flame

Arrestor

rburetor

with

Choke

r.;,w'''nor

Fuel

Shut-off

Solenoid

Lube

Oil

Drain

Hose

Exchanger

Lube

Oil

Filter

Westerbeke Generators

Fresh

Water

Coolant

Fill

Model

Data

Lube

Oil

Dir>stick

20

Amp

DC

Circuit

Starter

with

Solenoid

Westerbeke Generators

BeG

S.5KW Marine Gasoline Generator

Top

Engine

Oil

Fill

Distributor

0"

Exhaust

Elbow

Exhaust

Temperature

h

Battery

Ground

Connection

BeG

6.SKW Marine Gasoline Generator

Fuel

Shut-oil

So,lelnoi,d

Intake

Flame

Arrestor

Water

Temperature

Switc

Control

AC

Lube

Oil

Filter

9

Carburetor

with

Choke

Governor

Pressure

Switch

Anode

Heat

Exchanger

Lube

Oil

Drain

Hose

Westerbeke Generators

BCG

4.0KW MARINE GASOLINE GENERATOR SET

GENERAL SPECIFICATIONS

Engine Type

Governor

Combustion

Chamber

Bore & Stroke

Piston Displacement

Firing Order

Direction

of

Rotation

Maximum Torque (at

1800 rpm)

Compression Ratio

Compression Pressure
(Limit

of

difference between cylinders)

Valve

Timing

Valve Seat Angle

Valve Clearance

(engine cold)

Engine

Speed

Dimensions

Weight

Fuel Consumption

Inclination

Weslerbeke

Generators

Gasoline, four-cycle, two-cylinder, fresh water-cooled
Vertical,

in-line overhead valve mechanism

(8

hp at 1800 rpm, maximum).

Hoof, flyball type,

5%

speed regulation

Multi-sphere type

2.82 x 2.68 inches (71.6 x 68 mm)

33.4 cubic inches

(1.07 liters)

1-2

Clockwise, when viewed from

the

front

33

Ib-ft

(4.91

kg-m)

9.2:1

177.8 psi (12.5 kg/cm

2

)

at 400 rpm

(28

psi [2.0 kg/cm

2

])

Intake Opens

21'

BTDC

Intake Closes

59'

ABDC

Exhaust Opens

59'

BBDC

Exhaust Closes

21'

ATDC

Intake

45'

Exhaust

45'

Intake 0.008 inches (0.20 mm)
Exhaust

0.010 inches (0.25 mm)

1800 rpm 60 Hertz
1500 rpm 50 Hertz

Height:

23.00 inches (584.20 mm)
Width: 18.75 inches (476.25 mm)
Length:

25.00 inches (647.70 mm)

3091bs

(140.1

kgs)

0.8 U.S. gph (3.02 Iph) at full rated ou1put (approximate)

Continuous

14'

Temporary

20'

(not

to

exceed 20 min.)

10

INTAKE SYSTEM

Carburetor

(STD

type)

IGNITION

SYSTEM

General

Distributor
Spark Plug

Thread

Size

Spark Plug Type

FUEL

SYSTEM
General
Fuel

Lift Pump
Fuel

Screens

(on

engine)

Air

cleaner

BCG

4.0KW

SYSTEM

SPECIFICATIONS

Down

draft type, single

barrel

with

U.S.C.G.

approved flame arrester.

Battery ignition,

12-Volts,

negative ground,

distributor with points, ignition coil

and

spark

plugs.
Conventional, contact-point type
14

mm x 1.25

pitch

Westerbeke part number

035666

(Always

identify the generator model

when

ordering parts.

See

page

5.)

Conventional carburetor type with

fuel

lift pump

Regular

or unleaded gasoline with

an

octane rating

of

89

or higher.

12-Volt

DC;

lift capacity 6 ft

(1.8

m)

Reusable

screen type (one

in

Carburetor

and

one

in

electric

fuel

pump).

Metal

screen type - cleanable

Air Flow (engine combustion)

18

cfm

(0.509

cmm)

COOLING

SYSTEM

General

Operating Temperature
Fresh

Water Pump

Sea

Water

Pump

Fresh

water-cooled block,
thermostatically-controlled
with a heat exchanger.

130

- 150' F

(55

- 66'

C)

Centrifugal type,

metal

impeller, belt-driven

Positive displacement, rubber impeller, belt-driven.

11

Westerbeke Generators

BeG

II.OKW SYSTEM SPECIFICATIONS

Sea

Water Flow, at 1800 rpm
(measured before discharging
into exhaust elbow)

System Capacity (fresh water)

LUBRICATION SYSTEM

General

Oil Filter

Sump Capacity (not including filter)

Operating

Oil Pressure (engine hot)

Oil Grade

ELECTRICAL SYSTEM

Starting

Battery

Battery Capacity

DC Battery Charger

Starter

DC

No-Load Current

DC

Cranking Current

Westerbeke

Generators

3.75 -

11.0

U.S.

gpm

(14.19 - 15.14Ipm)

3.3

U.S.

qts (3.2 liters)

Pressure type by Trochoid pump,
chain-driven through balance shafts.

Full flow, paper element, spin-on type

3,0 qts (2.9 liters)

50

- 70 psi (3.5 - 4.9 kg/cm

2

)

API

specification of

SD

or

SE,

preferably SF

12-Volt,

26 A-H,

(-)

negative ground

(recommended)

(35

A-H in cold areas)

90

- 125 (Ampere-Hours)

Internal regulator

13

Volts, 0

-10

Amps.

12-Volt,

1.2f<W,

reduction type,

solenoid-mounted

90

Amp (max,) at 11.5 Volts.

175 - 200 Amps (engine cold)

12

BeG

4.0KW SYSTEM SPECIFICATIONS

AC

GENERATOR

General

Voltage

Rating (Volts AC)

60 Hertz (1800 rpm)

50 Hertz (1500 rpm)

AC Circuit Breaker

Generator

Cooling
Air Requirements, (60 Hertz),
at

1800 rpm

Brushless, four-pole, revolving

field.

Self

exciting. Capacitor saturated field excitation.

Pre-lubricated,

single-bearing design.

Reconnectable

120 Volls

or

120[240 Volts,

single-phase

120

or

120[240 Volts - 60 Hertz

220 Volts - 50 Hertz.

Voltage regulation:

±5%

no

load

to
full load.
Frequency regulation: ± 3 Hertz (5%)

no-load

to

fUll-load.

120 Volts
120[240 Volts

220 Volts

34

Amps

34[17

Amps

14

Amps

To

be rated at 120%

of

the generator's rated

amperage and voltage output.

225 elm (6.4 cmm)

NOTE: Increase air supply 15% for 50 Hertz operation (1500 rpm).

Engine Combustion Air
Requirements,

(60 Hertz),

at

1800 rpm

TUNE-UP

SPECIFICATIONS

Spark

Plug Gap

Contact Point Clearance

Timing

18

cfm

(0.509 cmm)

0.028 - 0.036 inches (0.70 - 0.90 mm)

0.016 - 0.020 inches (0.4 - 0.5 mm)

16' ± l'

BTDC at 1800 rpm

13

Westerbeke

Generators

BCG

S.!iKW

MARINE

GASOLINE GENERATOR

SET

GENERAL SPECIFICATIONS

Engine Type

Governor

Combustion Chamber

Bore

& Stroke

Piston Displacement

Firing

Order

Direction

of

Rotation

Maximum

Torque

(at 1800 rpm)

Compression Ratio

Compression Pressure
(Limit

of

difference between cylinders)

Valve Timing

Valve Seat Angle

Valve Clearance

(engine cold)

Engine

Speed

Dimensions

Weight

Fuel Consumption

Inclination

Westerbeke

Generators

Gasoline, four-cycle, three-cylinder, fresh water-cooled

Vertical, in-line overhead valve mechanism

(14

hp

at 1800 rpm, maximum).

Hoof, flyball type, 5% speed regulation

Multi-sphere type

2.99 x 2.87 inches (76 x

73

mm)

60.6 cubic inches (0.993 liters)

1-2-3

Clockwise, when viewed

from

the front

40.5 Ib-It (5.6 kg-m)

9.2:1

177.8 psi (12.5 kg/cm

2

)

at 350

rpm

(28 psi [2.0 kg/cm

2

n

Intake Opens

19'

BTDC

Intake Closes

51'

ABDC

Exhaust

Opens

51'

BBDC

Exhaust Closes

19'

ATDC

Intake

45'

Exhaust

45'

Intake 0.0071 inches (0.18 mm)
Exhaust

0.0017 inches (0.18 mm)

1800 rpm 60 Hertz
1500 rpm

50

Hertz

Height: 23.38 inches (593.85 mm)
Width: 18.69 inches (474.73 mm)
Length: 26.75 inches (679.45 mm)

3321bs (150.5 kgs)

1.1

U.S.

gph

(4.16 Iph) at full rated output (approximate)

Continuous

14'

Temporary

20'

(not

to

exceed 20 min.)

14

BCG 6.5KW SYSTEM SPECIFICATIONS

INTAKE SYSTEM

Carburetor (STD type)

IGNITION SYSTEM

General

Distributor

Spark Plug Thread Size

Spark Plug

Type

FUEL

SYSTEM

General

Fuel

Lift Pump

Fuel Screens

(on engine)

Air cleaner

Air

Flow (engine combustion)

COOLING SYSTEM

General

Operating Temperature

Fresh Water

Pump

Sea

Water Pump

Down draft type, single barrel wtth U.S.C.G.
approved flame arrester.

Battery ignition,

12-Volts, negative ground,
distributor with points, ignition coil and spark
plugs.

Conventional, contact-point type

14

mm

x 1.25 pitch

Westerbeke part number

033805

(Always identify the generator model

when ordering parts. See page

5.)

Conventional carburetor type with fuel lift pump

Regular

or

unleaded gasoline with an octane rating

of

89 or higher.

12-Volt DC; lift capacity 6 ft (1.8 m)

Reusable screen type (one in Carburetor and one
in electric

fuel pump).

Metal screen type - cleanable

32

clm (0.906 cmm)

Fresh water-cooled

block,
thermostatically-controlled
with a heat exchanger.

130 - 1500 F

(55

-

66

0

C)

Centrifugal type, metal impeller, belt-driven

Positive displacement, rubber impeller, belt-driven.

15

Westerbeke Generators

BCG

6.SKW SYSTEM SPECIFICATIONS

Sea

Water Flow, at 1800 rpm

(measured before discharging

into exhaust

elbow)

System Capacity

(fresh water)

LUBRICATION SYSTEM

General

Oil

Filter

Sump Capacity (not including filter)

Operating

Oil Pressure (engine hot)

Oil Grade

ELECTRICAL SYSTEM

Starting

Battery

Battery Capacity

DC Battery Charger

Starter

DC

No-Load Current

DC Cranking Current

Westerbeke

Generators

3.75 - 4.0 U.S. gpm (14.19 - 15.14Ipm)

5.2 U.S. qts (4.9Itters)

Pressure type

by

Trochoid pump,

chain-driven through a

balance shaft.

Full flow, paper element, spin-on type

3.0 qts (2.9 liters)

50

-

70

psi (3.5 - 4.9 kg/cm

2

)

API

specification of

SD

or

SE,

preferably SF

12-Volt,

26 A-H,

(-)

negative ground

(recommended)

(35

A-H in cold areas)

90 - 125 (Ampere-Hours)

Internal regulator

13

Volts, 0 -

10

Amps.

12-Volt, 1.2KW, reduction type,
solenoid-mounted

90

Amp

(max.) at 11.5 Volts.

225 - 250 Amps (engine cold)

16

BCG S.5KW SYSTEM SPECIFICATIONS

AC

GENERATOR

General

Voltage

Rating (Volts

AC)

60 Hertz (1800 rpm)

50 Hertz (1500 rpm)

AC Circuit Breaker

Generator Cooling
Air Requirements, (60 Hertz),
at

1800 rpm

Brushless, four-pole, revolving field.
Self exciting. Capacitor saturated field excitation.
Pre-lubricated, single-bearing design.
Reconnectable 120

Volts

or

120/240 Volts,

single-phase

120

or

120/240 Volts -60 Hertz

220

Volts - 50 Hertz.

Voltage regulation:

±5%

no

load

to

full load.

Frequency regulation:

± 3 Hertz (5%)

no-load

to

full-load.

120

Volts

120/240 Volts

220 Volts

54 Amps
54/27 Amps

27.8

Amps

To be rated at 120% of the generator's rated

amperage and voltage output.

250 cfm (6.23 cmm)

~:

Increase air supply 15%

for

50 Hertz operation (1500 rpm).

Engine Combustion Air
Requirements, (60 Hertz),
at

1800 rpm

TUNE-UP

SPECIFICATIONS

Spark

Plug Gap

Contact Point Clearance

Timing

32

clm

(0.906 cmm)

0.028 - 0.036 inches (0.70 -0.90 mm)

0.016 - 0.020 inches (0.4 - 0.5 mm)

14° ±

1°

BTDC at 1800 rpm

17

Westerbeke Generators

INSTALLATION CHECKS

General

Since the crafts in which Westerbeke generators are installed vary in design, installation procedures will vary
according

to

your

craft's specific design. The intent of this section

is

not

to

advise boatyards

or

installers on

procedures already

well-developed and well-understood. However, the owner/operator must realize there

are details

of

the installation which require periodic checks

to

ensure the best operating conditions for the

equipment and safe operating conditions for the personnel on board. Proper location and

installation of the

gasoline generator in the vessel are

of

prime importance.

Factors in the

installation that must be considered are ventilation,

to

aid in cooling the generator end;

to

provide air

for

engine combustion and

to

remove heat produced

by

the engine while operating; the exhaust

system,

to

properly discharge raw cooling water (sea water),

to

quiet the exhaust, and

to

expel exhaust gas;

the cooling water supply; and the electrical connections.

CAUTION

For safety reasons, the generator's engine is NOT filled with lubricating oil for shipment. Before

leaving the factory, however, each generator set

is

thoroughly tested with oil in its engine.

This testing, among other things, provides

all internal parts with a coating of oil. This oil acts

as a preservative, providing reliable protection against corrosion for at least one year

if the

generator is properly stored.

Inspection

of

Equipment

The generator

is

shipped from the factory securely mounted and properly crated. Accessory equipment is

shipped in a separate

small box, usually packed within the generator's crate.

Before accepting shipment

olthe

generator set from the transportation company, the crate should be opened

and the contents inspected for concealed damage.

If either visible

or

concealed damage is noted,

you

should

require the delivery agent sign "Received in damaged condition" on the proper delivery receipt. Also check

the contents

of

the shipment against the packing list and make sure that the proper notation

is

made if any

discrepancies exist. These noted discrepancies are your protection against loss or damage. Claims con­cerning loss

or

damage must be made

to

the carrier, not

to

the Westerbeke Corporation.

Westerbeke

Generators

18

Rigging

and

Lifting

The generator

is

fitted with lifting eyes. Rope

or

chain slings capable

of

supporting the generator's weight

should be attached

to

the eyes and the generator lifted by means

of

tackle attached

to

these slings. The lift-

ing eyes have been designed

to

carry the full weight of the generator; therefore, auxiliary slings are not re-

quired

or

desired.

CAUTION

Slings

must not be so short as

to

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

placed

on the generator's lifting eyes

by

the lifting Sling must not be in excess

of

100 from the

vertical plain.

ENGINE

SLING LIFTING

ANGLE

MUST

HOT

EXCEED

10'

LI

FT I NG

EYE

The general rule in moving generators

is

to

see that all equipment used is amply strong and firmly fixed in

place. Move the engine a little at a time and see that it

is

firmly supported. Eliminate the possibility

of

acci-

dents

by

avoiding haste. Do not lift the generator

by

its crankshaft pulley. In certain sttuations

tt

may be

necessary

to

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

the engine must be

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

conditions,

If the opening of the hatchway

is

extremely small, it

is

possible

to

reduce,

to

some extent, the

outside dimensions

of

the generator by removing external components such as the cooling system's piping,
the heat exchanger, certain filters, the mounting rails and other obstructive equipment. This accessory equip­ment

should

be

removed

by

a competent mechanic and special care should be taken

to

avoid damage

to

any exposed parts. In addttion, be careful not

to

allow dirt from entering any opening created by the removal

of

equipment. Removed parts should be returned to their respective position as soon as the generator has

cleared the obstruction and is ready to be positioned on its mounting

platform.

In

case it becomes necessary

to

hoist the generator front-end upwards

or

generator-end upwards, the at-

tachment

of

lifting slings must be done carefully

to

avoid the possibility

of

damaging the parts on which the

weight

of

the slings may bear. Special rigging work

is

best done

by

someone experienced and competent

in

handling heavy machinery.

19

Westerbeke Generators

Generator

Mounting -Location

The complete generator unit is mounted on lightweight rails

by

means

of

four flexible isolator mounts that

help preventthe transfer of vibration from the generator

to

the rails. Each generator mounting rail has several

1/2-inch bolt holes

so

bolts can be employed

to

properly secure the generator

to

ks mounting platform.

These holes are on 15 inch mounting centers.

(1/2-

MOUNTING

HOLES)

The location should be dry, above low-lying vapor areas, and in an area where bilge water and water from
above cannot splash on the generator.

It should be properly ventilated and accessible

for

minor servicing

and repairs. Access

for

major repairs should be given consideration as well. The location should be proper-

ly ventilated

to

provide fresh cooling air for the generator end, for engine combustion needs, and

to

remove

heat produced

by

the engine while operating. The generator set needs fresh cool air in whatever location

in

the vessel it

is

installed. Hot generator discharge air

must

be removed from the generator area. The plat-

form on which the generator and

ks mounting rails are located should be strong enough

to

support the gen-

erator during all angles

of

vessel operation.

Westerbeke

Generators

20

Exhaust System

IIWARNINGI

CARBON MONOXIDE

EXHAUST

GAS

IS

DEADLY. Carbon monoxide

is

a dangerous gas that

can cause unconsciousness and

is

potentially lethal. Some of the symptoms or signs of carb-

on monoxide inhalation or poisoning are listed below.

o Dizziness

o Vomiting

o

Intense Headache

o Muscular Twitching

o Weakness and Sleepiness

o Throbbing

in

Temples

All

exhaust systems should be such that the entry of sea water into the engine's exhaust manifold and

cylinders is prevented while the engine is not running, or while the vessel

is

under

sail

or

power in which case

the vessel may experience heeling

or

backing down from following seas

or

any other conditions. Special

attention must be taken

to

make certain the exhaust system is secure and tight and free of leaks.

The sea water supply through-hull sea cock fittings

must

be

of the flush-hull type. High-speed scoop type

fittings must not

be

used, as they tend

to

encourage siphoning.

When a water lift type exhaust system

is

used, the exhaust muffler should be mounted as close

to

the

en­gine as practical. The exhaust discharge
should always drop downward into the
exhaust muffler. Loops in the exhaust
hose between the water-injected exhaust
elbow and the water lift muffler should be
avoided, as these will trap and hold water.

For

installations

where

the

exhaust

manifold/water-injected exhaust elbow

is

at

or

below

the

vessel's

water

line,

provisions must be made

to

install a

siphon-break

or

a vent in the sea water

supply hose

to

the water-injected ex-

haust elbow. This stops the flow of sea

water that runs through the sea water

cooling system from filling the exhaust
and engine cylinders when the engine

is
shut down. This sea water supply hose
must be looped above the water line and
the siphon-break or vent

installed in the
high point of the loop above the water
line. This siphon-break

or

vent must

al-

ways be above the water line during

all

angles of vessel operation

to

prevent
siphoning. The vent, when used, must
have its vent hose

or

tube routed so it can

remain above the water line and empty of

water when the engine is shut down. This

allows air

to

enter through this vent

to

prevent siphoning.

"""u"i-

I!~~

~

~

21

GEI£RllOR

Alan

wtm

LIU

SIPHOI

utAI-----+:':

GEMEUIOR

HLOII

IInH

LIME

HI

WATER

STUIHR

PUHP

m

IIAHR

"''-'.'

PUMP

Westerbeke Generators

Exhaust Back-Pressure

The exhaust discharge hose must be of adequate size and

minimal run

to

prevent excessive exhaust back-pressure.

Exhaust back-pressure should be checked before a

gener-

ator

is

put into service. (Refer

to

the illustration.) Excessive
back-pressure will affect the engine's performance and the
generator's power output.

To measure for back-pressure, use a mercury manometer, a
pressure gauge,

or

a water column. A boatyard or marine

mechanic should have a manometer or a pressure gauge.

Measure the engine's back-pressure at the exhaust elbow
while the generator is under a full load.

Refer

to

the pressure specifications listed below.

A water column can be made

by

taking a clear plastic tube

and taping one end

of

the tube along a yardstick and fitting

the other end

of

the tube with a 1/4 inch NPT (National Pipe

Tap) pipe fitting.

Measure the engine's back-pressure at the exhaust elbow

~

while the generator is under a full load.

Dimension

A cannot exceed

39

inches of water.

Back pressure, as measured

by

a gauge instrument, should

not exceed the following specifications:

Specifications:

3 inches

of

mercury (0.104 kg/cm

2

)

39 inches

of

water

in

a water column

(.099 kg/cm2 at

4°

C)
22 ounces psi
1 1/2 psi

"

..

"

"

"

."

..

Ii

~.

Mercury

Manometer

1/.

NPT

Plug

\

\

Exhaust
Elbow

Exhaust

Excessive back-pressure can be caused by a small diameter exhaust hose, a small muffler, sharp bends in

the exhaust hose, improper fittings, water pockets, and a high volume of water in the exhaust system

due
to the length of the exhaust discharge hose. The use of elbows and fittings in the exhaust discharge hose's
routing should be limited since these will create flow restrictions and contribute

to

exhaust back-pressure.
The generator's exhaust system must be separate from any other engine's exhaust system. Dry portions of
the exhaust system between the engine's exhaust

manffold and the water injected exhaust elbow must be

insulated

to

hold

in

the heat.

Weslerbeke

Generators

22

Dry stack-type exhaust systems (shown

to

the right) must be attached

to

the gen-

erator

engine's

exhaust manifold

by
means of a flexible connector pipe. This
system must be

properly supported and

insulated

to

prevent water from entering

into the engine's

cylinders. Provisions

must

be

made

for

discharging

the

engine's cooling sea water.

Exhaust

System

Failures

FLAf'PE~

coVEN

~lf

. I

! '

I

---1

~=====14r.~,L

7'f"".M.

MUI"FLI::R

,I

I:

XHSUL

TJ:DN

.:!

:'

'1

'

~

.1/2"

X.F.5.

-

COHDr::N-;::::S;p;~i'-'

P][I"E

SAT:tOH

TRAP

PXTI:

..

EXHAUST

LIHf

SE:A

WATER

%NTAKe:

TIH;lOUGH_

HULL

I'"1:Tl":t

....

DRY

STACK

EXHAUST

When the engine's sea water

is

fed into an exhaust system so that the full stream of this water strikes a sur­face, erosion takes place. This erosion may cause premature failures. The proper design of either a water
jacketed

or

water injected "wet" exhaust system

to

prevent this problem requires that the sea water inlet

be
positioned so that the entering stream of sea water does not directly strike a surface. In addition, the velocity
of the entering sea water stream should be as low as possible, which can be achieved

by

having inlet fittings

as big in diameter as possible.

The best protection against carbon monoxide poisoning

is

a daily inspection of the complete exhaust sys-

tem. Check for leaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating sur-

rounding areas excessively.

If excessive heat

is

present, correct the situation immediately. If you notice a

change in the sound or appearance of the exhaust system, shut down the unit immediately and have the

system inspected and repaired at once

by

a qualified mechanic.

Make sure there are no unnecessary objects suspended from any portion of the exhaust

lines. Exhaust risers

installed off the exhaust manifold should not exceed 8 Ibs

in

total weight when rigidly constructed. Exces-

sive weight could cause deflection

or

distortion of the lines, resulting

in

damage or leaks. Inspect insulated

portions of the exhaust system

to

ensure there

is

no deterioration of the insulation.

CAUTION

Prolonged

cranking

intervals

without

the

engine starting can result in filling

the

engine-

mounted

exhaust system

with

sea waler coolant. This

may

happen because

the

sea

water

pump

is

pumping

sea water

through

the

sea water

cooling

system

during

crank-

ing.

This

sea water can enter

the

engine's cylinders

by

way

01

the

exhaust

manifold

once

the

exhaust system fills. Prevent

this

from

happening

by

closing

the

sea water

supply

through-hull

shut-off, drain

Ihe

exhaust

mulller,

and correct

Ihe

cause

lor

the

excessive

engine

cranking

needed

to

obtain a start. Engine damage resulting

from

this

Iype

of

sea

waler

entry

is

nol

a warrantable issue;

the

owner/operalor

should

keep

this

in

mind.

23

Weslerbeke Generators

Exhaust Elbow Installation

The Westerbeke Corporation offers a 45°and

900exhaust

elbow as well as

an

exhaust riser you can install on your

generator. Refer

to

the instructions below when installing

the exhaust elbow purchased for your generator.

1.

Coat only one side of the exhaust gasket with ·"High

Tack"

adhesive sealant. Place this coated surface
against the exhaust manifold's exhaust port flange (the
gasket should stick

to

the flange without falling off).

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

haust elbow against the exhaust manifold's flange so

the exhaust manifold's flange rests snug against the

ex-

haust elbow's flange with the gasket centered between

the two. Now slip the exhaust clamp over both flanges.

3.

A.

Tighten the clamp just enough so the exhaust elbow

can remain attached

to

the manifold and still be

rotated.

B.

The exhaust elbow discharge must be directed

downward

so the miXiure of sea water and exhaust

gases will flow/fall downward into the exhaust

muf-

fler which must be positioned below the exhaust

elbow. There should be no loops or rises in the

ex­haust hose connected between the exhaust elbow
and the muffler, as these would trap water and

pos­sibly allow water to flow back into the engine during
starting

or

at shut down.

4.

Adjust the elbow

by

rotating it until the desired

aJign-

ment with the exhaust piping

is

acquired.

5. Carefully tighten the clamp between 2

to

3 Ib-ft,

or

24

to

35 Ib-in, or 0.27

to

0.41

kg-m.

CAUTION

Approach

the

:3

II>-It

torque

limit

with

caution.

The

clamp's

threads

will break

if

more

than 3

lI>-

ft

is applied

to

Ihe

clamp.

If

a leak exists, correct it immediately.

* Manufactured by Permatex Company, Brooklyn,

N.

Y.

Weslerbeke Generators

24

45°

ELBOW

CLRMP

CLAMP

90·

ELBOW

EXHAUST

RISER

ClAMP

Fuel

System

The generator must have its own fuel supply line; in other words, it must have fis own pickup tubes and

primary filter/water separator.

DO NOT tee off another engine's fuel supply. Installations where the fuel

tank(s) are

at

or

above the generator, with the fuel supply lines

to

the engine's carburetor routed below the

level

of

the fuel tank's top, must have a means

of

shutting off the fuel

to

the generator's engine when the en-

gine

is

not running. This installation procedure helps guard against the possibility

of

gasoline siphoning

through the

supply line into the engine through the carburetor, should the carburetor float needle valve stick

in the open position

or

not seat properly, or should the fuel line rupture between the engine and fuel tank.

This (anti-siphon) shut-off

valve can be electrically-operated (with a manual override)

to

open when the gen-

erator's engine

is

started, and

to

close when the generator's engine

is

shut down. A manually-operated valve

can also be installed and should be operational from the generator's start/stop panel

or

from the vessel's

deck. Installations where the generator

is

located above the fuel tank(s), whereby the routing

of

the fuel

supply line

to

the generator's carburetor remains above the

top

level of the fuel tank,

do

not require this (anti­siphon) shut-off valve. A manually-operated service shut-off valve should be located between the fuel pick­up at the tank and the service shut -off valve located at the fuel connection

to

the generator.

The

two

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

Guideline.

These illustrations show basic fuel system layouts that incorporate anti-siphon protection.

All fuel lines should be routed and supported

to

prevent leaks from vibration and chaffing. The line should

be

supported every

12 -14

inches. Use as few connections as possible in the plumbing

of

these lines.

The fuel tank's vent should be located so that its discharge route cannot allow water

to

enter through to the

fuel tank(s). Moisture must not be allowed

to

accumulate in the vent's line.

FUEL

LINE

ALWAYS

ABOVE

FUEL

TANK

TOP

LEVEL

FUEL

TANK

TOP

LEVEL

~

-

--"..::---~~-~~.:::.-.:-

-:::::=:~--:-d

NO

ANTI-SIPHON

DEVICE

OR

ELECTRICALLY

OPERATED

VALVE

HEEDED

NOT

ACCEPTABLE

FUEL

FUEL

TANK

TOP

LEVEL

25

_'-'...\

Westerbeke Generators

.~

AMTI-SIPHON

DEVICE

OR

ELECTRICALLY

~

OPERATED

FUEL

STOP

VALVE

---

--~~~)"""";-:::";-:::::~/~-7::~~~F~U~E~L~TA~N~K~T:o:p

~L~E~V:E~L~:/""~~i~~~~""","'-I

fU

E L

~

FUEL

LINE

BELOW

FUEL

TANK

lOP

LEVEL

ANTI-SIPHON

DEVICE

OR

ELECTRICALLY

OPERATED

FUEL

STOP

VALVE

AT

fUEL

TANK

WITHDRAWAL

FITTING

ANTI-SIPHON

DEVICE

OR

ELECTRICALLY

TANK

lOP

LEVEL

I

OPERATED

FUEL

STOP

VALVE

FUEL

LIKE

ABOVE

FUEL

TANK

T

OP

lE~V~EL~;_~=-~~.::::.~=:::~=:~

fUEL

LINE

BELOW

fUEL

TANK

TOP

LEVEL

ANTI-SIPHON

DEVICE

OR

ELECTRICALLY

OPERATED

FUEL

STOP

VALVE

AT

POINT

WHERE

FUEL

DISTRIBUTION

LINE

GOES

BELOW

FUEL

TANK

TOP

LEVEL

NOTE: The use

of

mechanical spring-type check valves instead

of

a solenoid shut-off valve is

not

recommended, since these may tax the fuel lift pump's ability

to

draw fuel through them.

A check

valve can trap debris under its seat which inhibits the valve's ability

to

close. In ad-

dition,

if

a check valve's cracking pressure

is

100

high, this can contribute

to

vapor lock.

Should a mechanical type, spring-loaded check valve be used, it should be an adjustable type,
such as a Weatherhead

#43 x 6.

This adjustable type valve should be adjusted

to

have a

cracking pressure that will prevent siphoning when the generator is not operating but not

so

excessive as

to

prevent the fuel lift pump from drawing fuel through the valve.

Strongly recommended

is

the installation of an approved filter/separator in the fuel supply between the fuel

tank and the generator's engine

to

help remove contaminants in the fuel before the fuel reaches the engine-

mounted

fuel lift pump and carburetor.

IWARNING\

Gasoiine

ieakage

in

or

around

the

generator

compartment

is a potential

cause

of

fire

and/or

explosion. Repair leaks promptly and make sure the compartment

is

property ventilated.

Westerbeke

Generators

26

Oil Drain

Hose

An

oil sump drain hose

is

installed on the engine with the discharge end secured

by

a bracket at the front

01

the engine. Oil may be drained from this hose

by

removing the cap and the discharge end of the hose from

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

is

1/4 inch NPT (National

Pipe Tap) and can be extended, or have a pump added,

for

easier removal

of

the old oil, if desired.

Connecting

Pressure Sensing lJevices

to

Oil Galleries

Oil

pressure sensing devices, such as senders and switches, must not be connected

to

an engine's oil gal-

lery with the use of extended nipples

or

tees. The reason

is

simply that continued engine vibration causes

fatigue of the fittings used

to

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

and quickly seizes.

When additional sensing devices such as switches

or

sensors need

to

be installed that function on engine

oil pressure, these devices must be bulkhead-mounted and connected

to

the oil gallery using an appropriate

grade of lubricating oil hose. Any fittings used

to

connect the hose

to

the gallery must be

of

steel

or

malle-

able iron composition. Brass must not be used for this application.

Sea Water Intake

System

Make sure the intake system (sea water cooling system) is in proper order. Check that the hull inlet, sea

cock and strainer are unobstructed.

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

inlet thread of the sea water pump. The strainer should be

of

the type that may be withdrawn for cleaning

while the vessel

is

at sea and should be mounted below the water line

to

ensure self-priming. Inspect the

sea water

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

there are no air leaks at any

of

the connections.

Cooling

System

The generator's engine

is

fresh water-cooled by an engine-

mounted heat exchanger.

Sea water

is

used as the heat

exchange's cooling medium. Sea water

is

pumped into

the exchanger

by

a sea water pump and

is

then injected

into the exhaust discharge, carrying with it the heat

removed from the engine's fresh water

cooling system.

Sea water should be supplied

to

the sea water pump
through a flush-type through-hull fitting using a wire-rein­forced hose between the

through-hull fitting and the

sea
water pump. This sea water should be directed through a
visual-type sea water strainer and then delivered

to

the
pump. Hoses routed from the through-hull fitting to the
strainer and

to

the sea water pump should be wire-rein-

forced

to

prevent the hose from collapsing during the gen­erator's operation (suction from the pump may collapse a
non-reinforced hose).

Sea water strainers should be

mounted at

or

below the water line

to

make sure the

sea

water line remains primed.

27

BElT

TENSION

3/8-112

INCH

DEFLECTION

AT

LONGEST

SPAN

Weslerbeke Generators

CAUTION

DO NOT

use a scoop-type through-hull fitting as a means

of

supplying sea water

to

the gen­erator. Water pressure against this type fitting, while the vessel is under way, can push sea
water past the sea water

pump's

impeller into the generator's exhaust system, filling it and the

engine as

well. Flush-type, clear, through-hull fittings are recommended and should be lo-

cated on the

hull so as

to

be below the watertine during all angles

of

boat operation.

The use of common-type street elbows

is

not recommended for plumbing the sea water circuit. These

generally have very restrictive inside diameters. Machined fittings with true inside diameters are preferred.

Electrical

System

The electrical system should be checked

to

make sure all wiring harnesses are property tied

down

with

clamps

or

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

to

prevent chafing

from vibration. Check

to

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

to

the

appropriate terminals.

DC

Electrical

Connections

A common ground for the negative

(-)

DC

terminal connection is found at the bell housing

of

the generator,

next

to

the starter, in the form

of

a threaded grounding stud. The battery ground should be connected at

this stud.

Connect the battery's positive

(+)

connection to the starter solenoid tagged for this connection.

CAUTION

To avoid an overcharging condition, and a possible equipment failure, DO NOT disconnect
the

DC

battery source while the engine

is

running.

Grounding

The generator set must be grounded

to

comply with United States Coast Guard regulation 33 CFR-183 which
specifies that a common conductor be connected between the generator set and the vessel's main propul­sion engine's grounded starter motor circuit. This conductor (the common ground) prevents accidental pas­sage

of

cranking current through fuel systems and smaller electrical conductors common

to

the engines.

This conductor must be the same size as the largest battery cable.

Automatic Shutdown

High Exhaust Temperature Shutdown Switch (normally closed)

An

exhaust temperature switch

is

located on the exhaust elbow. This switch will open and interrupt the

DC

voltage

to

the ignition coil (which turns OFF the engine), should the switch's sensor indicate an excessive

exhaust temperature (an inadequate supply

of

sea water coolant causes high exhaust temperatures). This

switch opens at

260 - 2700 F (127

-1320 C)

and resets at approximately 2250 F (107

0

C).

Westerbeke

Generators

28

High Water Temperature Shutdown Switch (normally closed)

A high water temperature switch

is

located on the thermostat housing. This switch will open and interrupt

the

DC voltage

to

the ignition coil (which turns OFF the engine), should the fresh water coolant's operating

temperature reach approximately

205'

F (96'

C).

This switch resets at

195'

F (107' C).

Low

Oil Pressure Shutdown Switch (normally open)

A

low oil pressure shutdown switch is located off the engine's oil gallery. The switch's

is

kept closed bye

engine oil pressure.

Should the engine's oil pressure fall

to

10 - 15 psi, the switch will open interrupting the

DC voltage

to

the ignition coil (which turns OFF the engine).

High RPM

Shutdown Switch

An overspeed shutdown switch shuts OFF the generator set by grounding out the ignition system should

the engine's speed reach approximately 2175 rpm. Reset this switch by momentarily depressing the STOP

switch. (Make sure the cause

of

the engine overspeed shutdown

is

corrected.)

Generator

(AC Outpul)

Make sure that the AC output connections within the generator's distribution

box

are tight and in accord-

ance with the specific

AC Load Connections diagram found later

in

this manual. (See the "BC GENERATOR"

section

of

this manual, page 57.)

Batteries

Make sure the positive (

+ ) battery connection

is

connected to the battery connection of the starting solenoid.

The negative

(-)

battery connection should be connected

to

the system ground (the engine block).

IWARNINGI

Do not smoke

or

allow an open flame near batteries. Lead acid batteries emit hydrogen, a

highly-explosive gas.

IWARNINGI

When servicing the battery

or

checking the electrolyte level, wear rubber gloves, a rubber

apron,

and

eye

protection.

Battery

acid

may

splash

on

the

skin

or

into

the

eyes

inadvertent-

ly when removing the electrolyte caps.

Check the battery's

electrolyte level and specific gravity

to

ensure maximum engine starting efficiency. Make

sure the battery's terminals are

clean and tight.

29

Westerbeke Generators

Ventilation

The ventilation requirements

of

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

engine cylinders; cooling air

is

required for the generator end and also

lor

removing the heat produced by

the generator's engine during operation; and ventilating air

is

required

to

clear the bilges below the gener-

ator, as

well as the compartment in which the generator

is

located, of potentially toxic and flammable gasoline

vapors.

Keep in mind that hot air rises, so heated air

should be removed from the upper area

of

the generator com-

partment and

cool fresh air should be directed

to

the lower areas of the compartment. Ventilation should

be accomplished with the aid

of

blowers especially when the vessel is not underway. Refer

to

the "SYSTEM

SPECIFICATIONS"

section

01

this manual for the airflow requirements

of

the generator sets, page

13

for the

BCG

4.0KW, and page 17 for the

BCG

6.5KW.

Westerbeke

Generators

30

DESCRIPTION OF ENGINE CONTROL PANEL

General

The engine-mounted control panel is equipped with an ON switch, a START switch, and a STOP switch. The

panel also has three fuses to protect the circuit. The three switches serve the

following functions:

1.

ON Switch· The ON switch provides power

to

the START circuit. This switch also bypasses the protec-

tive oil pressure shu1down switch until the engine's oil pressure reaches

15

psi.

2.

START·

The START switch energizes the starter's solenoid which cranks the engine. This switch will

not operate unless the

ON switch is depressed and held at the same time.

3.

SIQE: The STOP switch is used

to

stop the generator. This switch must be depressed until the gen-

erator comes

to

a complete stop.

The engine-mounted control panel

is

protected

by

three fuses. The

F1

ignition circuit and the

F3

panel cir-

cuit are protected

by

individual 8 Amp fuses. The

F2

starter circuit is protected

by

a single

15

Amp

fuse.

31

Westerbeke

Generators

Optionsl Remote

instrumenlllnd

Remote Start Panels

An optional remole instrument panel is available, which includes starting controls. This panel also includes
a water temperature gauge,

oil pressure gauge, battery voltmeter, operating hourmeter and start-stop con-

trol switches.

REMOTE

START

PANEL

REMOTE

INSTRUMENT PANEL

IWARNINGI

When installing the optional remote start panel

or

the optional remote instrument panel,

IT

is

the

installer's responsibility

to

comply

with U.S. Coast Guard Standards 33

CFR

PART 183.

An optional remote start panel is available for

controlling the generator from a remote location.

Remote start panels include a green

LED

which lights when the engine runs at approximately 600 rpm. The

purpose of the LED is

to

alert the operator

to

release the starter toggle switch

in

addition

to

continue indicat-

ing that the generator set is running.

Westerbeke Generators

32

PREPARATIONS FOR STARTING

This section

of

the manual provides the operator with preparation, initial starting, break-in, starting (cold

or

warm), and stopping procedures. Follow the procedures as presented,

for

the conditions indicated, and

your Westerbeke generator set will give you

reliable performance and long service life.

Take the steps described below

in

starting your engine for the first time

or

after a prolonged shutdown

or

lay-up.

Fill your engine with oil up

to

but not over the upper limit on the

dipstick (the installation

angle of your generator set may have

an effect on the dipstick reading).

Select a readily available

lubricating oil with an

API

specification

of

SD,

SE

or

SF and an

SAE number suitable

forthe

temperature in your operating area

(see page

54).

Forthe

quantity

of

oil needed in your generator's

engine,

referlo

the "SYSTEM SPECIFICATION" section

of

this

manual, page

12

for

the BCG 4.0KW, and page 16

for

the

BCG

6.5KW.

Each unit is supplied with a coolant recovery

ktt

(part

#24977)

as standard equipment, to which the following applies:

upp

ER

LIM! T

(NORMRL

LEVEL)

LOWER

LIMIT

A. Remove the pressure cap from the engine's exhaust manifold and slowly fill the engine's cooling sys-

tem with a mixture

of

water and antifreeze suitable for your temperature zone. (See the "COOLING

SYSTEM"

section

of

this manual, page 49.) Replace the pressure cap on the manifold.

B. Make sure the plastic recovery tank

is

properly mounted near the unit (with the bracket provided) in a

location where it can be monitored and

filled easily (see page 49). The recovery tank should be mounted

at manifold

level

or

above.

C.

Coolant should be added

to

the plastic recovery tank after the engine has been filled and started. After

its operating temperature has been reached, make sure

all air

is

expelled out

of

the engine's manifold

and the engine's cooling system. With the manifold filled and the pressure cap

installed, fill the plastic

recovery tank

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

Fill the

fuel tank with unleaded or leaded gasoline that has an octane rating

of

89 or higher.

Make sure the

Installation Checks have been made in accordance with those specified in the "INSTALLA-

TION CHECKS"

section

of

this manual (refer

to

page 18) and that there

is

no AC load on the generator.

JJ

Westerbeke Generators

STARTING PROCEDURE

IWARNINGI

CARBON

MONOXIDE EXHAUST GAS IS DEADLY

1.

Ventilate the generator compartment for a minimum

of

5 minutes prior

to

starting the generator. The ven-

tilating blowers remove potentially explosive gasoline fumes from the generator compartment and bilge.

2.

Depress the ON

SWITch

and hold it depressed for 5

to

15 seconds

to

make sure the fuel system on the en-

gine is primed

to

the carburetor. Continuing

to

depress the ON switch, proceed

to

step

#2.

3. Depress the START switch. When the generator starts, release only the START switch. Keep the ON

switch depressed

for

a few seconds longer. (Keeping the ON switch depressed bypasses the oil pressure

shutdown circuit until the oil pressure rises enough

to

close the switch internally and maintain the ignition

circuit.)

4.

Release the ON switch.

NOTE: The engine has an electric choke which is activated when the ON

SWITch

is depressed

and while the engine

is

operating.

CAUTION

When starting the generator, all AC loads, especially large motors, should be switched OFF
until the engine has come

up

to

speed and, in cold climates, starts

to

warm up. This precau-

tion will prevent damage caused

by

the unanticipated operation of AC machinery and will

prevent

a cold engine from stalling.

CAUTION

Prolonged cranking intervals without the engine starting can result in filling the engine­mounted exhaust system with

sea

water coolant. This may happen because the

sea

waler pump is pumping sea water through the

sea

waler

COOling

system during crank-

ing.

This sea water can enter the engine's cylinders by way

ollhe

exhaust manifold

once the exhaust system fills.

Prevent this from happening by closing the

sea

water
supply through-hull shut-off, drain the exhaust muffler, and correct the cause for the
excessive engine cranking needed

10

obtain a start. Engine damage resulting from this

type

01

sea

waler entry is not a warrantable issue; the owner/operator should keep this

in mind.

Once the engine starts, check instruments (if instruments are installed) for proper oil pressure and battery

charging voltage. Never attempt

to

engage the starter while the engine is running. Apply a light load

to

the

generator and allow the engine's operating temperature to come

up

to

110 -

120'

F (44 -

49'

C) before ap-

plying any heavy loads.

NOTE: Some unstable running may

occur

in a cold engine, but this condition should smooth

out as the operating temperature

is

reached (130

-150'

F [55 -

66'

Gj) and when a load

is

ap-

plied to the generator.

Westerbeke

Generators

34

Remote

Starling

Procedure

The remote start panel is the same as the engine-mounted start panel except that it has a green

LED

light.

When starting at a remote location, the green LED lights when the generator is running at approximately

600
rpm, which indicates when the START switch can be released, since the starting of the generator may not
be audible.

A.

When starting the generator set at a remote location, release the START switch when the green

LED
lights, but continue depressing the ON switch. After releasing the START switch, continue holding the
ON switch until the oil pressure is sufficient

to

close the oil pressure safety switch, providing the nor-

mal B + path

to

the ignition system.

B.

After the generator is started, the generator's starter will not crank until someone again operates the

ON switch first.

Remote

Stopping

Procedure

To

STOP the generator, depress the STOP switch, which opens the normally closed B + path for voltage to

the engine's ignition circuit. The

STOP switch must be held open until the generator comes

to

a complete

stop. Remote start

panels may be connected

to

the generator set as indicated. A jumper has

to

be removed

between the T

-1

and T-2 connections at the panel connection terminal board. (Refer

to

the wiring diagram

in the

"ELECTRICAL SYSTEM" section

of

this manual, page

44,

lower left-hand corner.)

Overspeed

Shutdown

Should the generator shut

down

from an overspeed condition, the overspeed circuit must be reset before

atternpting

to

restart the generator. Resetting the overspeed switch

is

done by simply depressing the

STOP

switch momentarily and then proceeding with the normal starting procedure.

If the overspeed switch itself

is

faulty and resetting it

by

depressing the STOP switch will not reset the cir-

cuit,lifttheT-l

coil

connectionlromthe

swttch and tape the end of the

T-l

wire with electrical tape. DO NOT

operate the generator with the overspeed switch bypassed. Bypass this circuit only

to

lest

the overs peed

circutt. Replace the overspeed switch to maintain this safety circuit's integrity.

The overspeed shutdown must

always be installed and functioning. Any tampering with the

overspeed shutdown

module, which would cause it

to

malfunction, could be a cause of injury

should the generator's belt-driven governor fail and cause the generator to run away.

35

Westerbeke Generators

STOPPING PROCEDURE

1.

Remove the AC electrical load from the generator and allow the generator

to

run

for 3 to

5 minutes

to

sta-

bilize its operating temperatures.

2.

Depress the STOP switch and hold it until the generator is completely stopped.

3.

Now

release the STOP switch.

Break-In

Precautions

Because the generator set operates at 1800 rpm

to

produce 60 Hertz,

or

at 1500

rpm

to

produce 50 Hertz,

control of the generator's engine break-in is governed

by

the current

drawn

from the generator.

DO

NOT

attempt

to

break-in

your

generator set

by

running it without a load.

Upon starting the generator set, check

for

proper operation. For the first 10 hours of the generator's opera-

tion, run the generator set between

20 and 60 percent of full-load.

After the first 10 hours

of

the generator's operation, the load may be increased

to

the rated full-load output.

Periodically vary the load.

Avoid overload at all times. An overload is signalled

by

a smoky exhaust, with reduced

output

voltage and

frequency. Monitor

the

current being drawn from the generator and keep it within the generator's rating.

Be aware of

motor

starting

loads

and the high current draw required

for

starting

motors

(see page 64

for

an

"Amps

for

Starting" chart).

Starting

Under

Normal

Conditions

Follow the procedure

below

for

routine starting of the generator:

Check the engine's

lubricating oil level prior

to

each

day's

use. Add oil as needed and maintain the oil level

at the high mark on the dipstick.

Check the

coolant level in the plastic recovery tank.

NOTE: Excessive loss

of

fresh water coolant from the plastic recovery tank indicates a

cool-

ing system leak. Check the entire cooling system; pressurize the system

to

locate the leak.

In

cases

of

excessive coolant loss, the system must be refilled as outlined under the

"PREPARATIONS FOR STARTING" section of this manual, page 33.

Visually examine the unit;

look

for

any

abnormalities and correct them as needed.

Check

to

make sure there is sufficient fuel

in

the tank and examine the filter/separator bowls

lor

contaminants.

Clean and drain the bowls as needed.

Start the generator, following the procedure outlined in the "STARTING PROCEDURES" section, page 34,
and

allow the engine's operating temperature

to

reach 130

-150'

F (55 -

66'

C) before placing the generator

under a heavy

load.

Westerbeke

Generators

36

Starting

Under

Cold

Conditions

Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below
when operating your generator set in cold weather.

LUBRICATING OIL TURNS VISCOUS - Make certain that the lubricating oil used conforms with the ratings
for the prevailing atmospheric temperature. Refer

to

the "LUBRICATION SYSTEM" section

of

this manual,

page 54,

for

an atmospheric/oil viscosity specification table.

VOLTAGE ACROSS BATIERY TERMINALS DROPS

- Make certain that the battery

is

fully charged

to

mini-

mize voltage

drop

across the battery terminals.

37

Westerbeke Generators

CARBURETOR

AND

FUEL SYSTEM

Gasoline

Use unleaded

or

leaded gasoline with

an

octane rating of 89

or

better.

In cold weather particularly, water vapor is produced by condensation when air is present in the fuel tank.
Keep fuel tank(s) full and completely free

of

dirt and water.

The carburetor is a single barrel, down-draft type with a cleanable metal screened air intake filter/spark ar­restor.

SCREENED

AIR

CLEANER

FUEl

SOlENO

0

Westerbeke

Generators

GOVERNOR

LINKAGE

/

38

INLET

SCREEN

"

Optional Fuel

Filler

HOSE

FITTING

A primary fuel filter of the water entrap-

ment type should be installed between the
fuel tank and the engine. A primary filter,
shown here, is available from your local
Westerbeke representative

or

your boat-

builder. This filter,

adapted

for

the

boatbuilder's

use,

comes complete with

fittings for either hose

or

metal tubing.

Mount

It

in

an

accessible place, inspect it
often, and drain off water accumulation
frequently.

TUBE

PIPING

If a water trap type filter is not installed be-

tween the

fuel

tank

and the engine-

mounted fuel system, any water

in

the fuel

system will tend

to

inhibit proper starts.

In

addition, particles will pass on

to

the lift

pump's filter, clogging it in time.

Although

most

boatbuilders supply a

water trap/filter, some

do

not. Westerbeke

offers a sedimenter/water trap/filter

as

an
optional extra at moderate cost. The filter
Is

supplied wtth fittings for either hose

or

metal tubing fuel lines.

Replacing Filter Elements

Generator models covered by this manual have two

fuel filter screens.

One

is

in

the carburetor (this fil-

ter

is

referred

to

as

the inlet filter screen).

To remove this filter screen, unscrew the filter

plug

and remove the fuel filter screen behind the plug.

Clean

the filter screen

or

replace it with a new one.

Periodically check this filter screen.

39

A

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

··i

..

,

...

.-

REMOVE

PLUG

TO

CLEAN

INLET

FUEL

(

SCREEN

AJ-

......

INSTALLATION

INSTRUCTIONS

1.

BOU

SEDIMEIITI\lIIIEI!

iRAP

SECURELY

TO

AM

ACCESSIBLE

STRUCTURE

so

PllsmONEB

TlIfH

II

RECEPTICLE

TO

CATCH

mIlI/IS[

CIIN

BE

PLAtED

UNDER

IT.

Z.

IF

fUEl

IS

TO

BE

PIPED

IIITII

COPPE~,

IIR

IIUIID'

TUBIIIG,

USE

NUTS

AIID

fERRULES

PRDUIOED.

BE

SURE

TilE

lUllING

PROJECTS

1/4

fMCH

THROUGH

THE

FERRULE

BEFORE

TIGIITENIMG

THE

MOT.

3.

If

fUEL

IS

til

BE

PIPED

IIlTIl

HOSE,

USE

TilE

TWO

BRASS

BIIRBED

FITTINGS

AHO

waSHERS

SUPPLIED.

BE

tERTRIM

THRt

IHE

HOSE

SELECTED

HAS

DIIISONAL

BRAID

INSERTED

no

mNG

ON

THE

BARBI,

THAT

IT

IS

NEOPRENE

LUIED.

AND

THAT

IT

IS

U§~~

IIPPIIOII£II.

4.

IF

VATER

IS

PRESEHT

III

THE

FUEL,

IT

lIIll

COLLECT

5LIIIIL'

IN

lin:

IIOITD"

Df

THE

SEomIlTER.

VHEN

THE

RED

fLOAT

RING

REACH£S

rHE

DRAIN

LIKE

ON

TilE

PLASTIC

BOWL,

LOOSEN

THE

BOTToH

DRAIN

PLUS

uml

ALL

WATER

RUIIS

DUT.

6.

TI&HiEH

DRAIN

PLUG

SECURELY

SO

NO

AIR

CRII

EIITER

IHE

s,ml!.

6.

EI!ERIiIZE

THE

fUEL

PUHP

TO

REfILL

THE

IIIIIIL

Westerbeke Generators

The engine-mounted electric lift pump contains
the second fuel filter screen. This pump supplies
fuel

to

the engine's carburetor during engine

operation. A cleanable filter screen

is

contained

in the pump's base.

Remove the base

by

placing a wrench on the hex

nut and twisting it loose from the bayonet fittings.
Clean the screen as needed. A new base gasket

must be installed each time the pump base

is

removed and reinstalled. Make sure a good seal

Filter

Screen

exists when replacing the base cover.

~~~::-t--Magnet

sealing Gasket

BOiseCo'ler

~WARNINGI

Shut off the fuel service valve

althe

engine when servicing the fuel system. Take care

in

catch-

ing any fuel

thai may spill from within the pump when the base is removed. DO NOT allow

any smoking, open flames, or other sources

of

fire near the fuel system when servicing. Make

sure proper ventilation exists when servicing the fuel system.

Westerbeke Generators

40

ELECTRICAL SYSTEM

Engine

12·Voll DC

Control

Circuit

The engine that drives the generator end has a 12-Volt DC electrical control circuit, as shown on the wiring

diagrams which follow on pages

44 and 45. Refer

to

these diagrams when troubleshooting or servicing

electrical components on the engine.

CAUTION

To avoid damage

to

the battery's charging circuit, never shut off the engine's battery switch

while the engine

is

running.

However, shut off the engine's battery switch

to

avoid electrical shorts when working on the

engine's electrical circuit with the engine stopped.

An overspeed shutdown switch shuts off the generator set

should the engine's speed reach approximately 2175 rpm.

This shutdown circuit consumes

25

milliamps (.25 or 1

14th

of

an Amp) at all times once the generator

is

connected

to

tts

battery.

As

this only amounts

to

about 18 Amp-hours in a

month,

it

is unnecessary

to

be concerned with this slight dis­charge during normal seasonal operation. If the generator set
were

to

be unattended for many months, the two easiest ways

to

stop this slight drain

is

to

first turn off the main battery switch

providing

12

volts

to

the generator set. The second way

to

stop this slight drain

is

to

remove the ignition fuse on the gen-

erator-mounted control panel.

Should the generator shutdown from

an

overs peed condition,
the overspeed circuit must be reset in order to restart the gen­erator. If the overspeed switch itself is faulty and resetting it

by

depressing the STOP switch will not reset

it,

lift the T

-1

coil

connection from the overspeed switch and tape the terminal

B

RMP

IGNITION

FUSE

end with electrical tape. DO NOT operate the generator with the overspeed swttch bypassed. Bypass the

overspeed switch only for testing purposes. Replace the overspeed switch

to

maintain this safety circuit's

integrtty.

Battery

Specification

The minimum recommended capacity of the battery used in the engine's 12-Volt DC control circuit is

90

-

125 Ampere-Hours (minimum) for the generator sets covered

by

this manual.

CAUTION

When quick-charging the battery with an external charger, be sure

to

disconnect the battery
cables from the battery. Leaving the charging circuit connected while quick-charging will
damage the diodes in the integral controller'S circuitry.

41

Westerbeke Generators

Testing

the

Batlery Charging

CirclIil

1.

AC

Stator Winding,'

O.

14

Ohms

Lift the two AC leads off the bridge rectifier and measure with

an

ohmmeter the resistance between these

two

leads should measure 0.14 Ohm. No continuity should exist between these two leads and the ground.

2.

Bridge Rectifier

Normal

AC

voltage running

to

the rectifier (while the engine is operating at 1800 rpm) is measured across

the

two

AC

connections on the bridge rectifier.

(See

the illustration below.)

AC

voltage running

to

the bridge rectifier (approximate):

No-load off the generator 16.0 Volts

AC

Full-load off the generator 17.5 Volts

AC

+

BRIDGE

RECTifIER

DC

I.e.

INTEGRAL

CONTROLLER

Normal

DC

voltage running out of the rectifier

(in

Volts

DC)

is

measured across the two

DC

connections

of the bridge rectifier; that

is,

+ and - .

DC

voltage running from the bridge rectifier (approximate):

No-load off the generator 17.0 Volts

DC

Full-load off the generator 18.5 Volts

DC

3.

Testing the Bridge Rectifier

A.

Set

your Ohmmeter's scale on

RX1

( +

DC)

and

set the

needle

to

zero.

B.

Connect

the

(+)

positive

lead

from

the

Ohmmeter

to

point #4. Taking the Ohmmeter's

negative

(-)

lead, momentarily touch points #1,

#2, #3, and #5. The Ohmmeter

should register

no deflection for any of the points touched.

C.

Remove the positive

(+)

lead from point

#4

and connect the negative

(-)

lead to point #4.

Touch points #1, #2, and #3. The

needle

should deflect, indicating a passage of current

Westerbeke Generators

POlnl

~2

POint #1

42

POint #5

(Rectifier

Mounting

Hole)

through the diodes located internally at these points.

D.

With the

(-)

negative lead still connected

to

point

#4,

touch point

#5.

The needle should not deflect.

E.

Place the

(+)

positive lead on point #1 and the

(-)

negative lead on point

#3.

The Ohmmeter again

should not register any deflection (no deflection indicated infinite resistance). Reverse these connec-

tions and the Ohmmeter

should again register no deflection. IF THE RECTIFIER FAILS ANY OF THE

PREVIOUS TESTS (A - E), REPLACE THE RECTIFIER BECAUSE

IT

IS

DEFECTIVE.

4.

Integral Controller (I.C.)

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

to

the

generator's starting battery while the generator is operating.

Charging

Voltage:

Charging Amperage:

13.0 - 14.0 Volts DC
0-10AmpsDC

A separate

group

of

stator windings supplies AC voltage

to

a bridge rectifier which converts the AC current

into

DC current

to

supply the I.C. unit. The I.C. unit senses the needs

of

the starting battery and supplies a

DC charge when one is needed. If you suspect that the I.C. unit is faulty (that

is,

if the battery's charge is

low), check the charging circuit's components and performance by following steps #1 -

3.

Check all con-

nections

for

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

NOTE: When the generator

is

first started, the I.C. unit will produce a low charging rate. This

charging rate

will rise as the generator

is

operated for awhile.

NOTE

*

While

IGreen

(-)

Negative

Terminal

01

Rectifier

While/Red

O.C.Charge

white/Green

(-)

Negative

and

White/Black

Ground

are

interchangeable.

43

White/

Yellow

(+1

Plus

Terminal

01

Recti/ior

White I Black

Ground

V

Westerbeke Generators

DC CONTROL CIRCUIT WIRING DIAGRAM #35439

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Westerbeke Generators

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COOLING SYSTEM

Description

Westerbeke marine gasoline engines are designed and equipped

for

fresh water cooling. Heat produced in

the engine

by

combustion and friction

is

transferred

to

the fresh water which circulates throughout the en-

gine. This circulating fresh water cools the engine block and

tts internal moving parts. The heat is transferred

externally from the fresh water

to

sea water by means

of

a heat exchanger, similar in function

to

an automo-

tive radiator.

Sea water flows through the tubes

of

the heat exchanger

While

fresh water flows around the

tubes; engine heat transferred

to

fresh water is conducted through the tube walls

to

the sea water which

is

pumped into the exhaust system and discharged overboard. In basic terms, the engine

is

cooled

by

fresh

water, the fresh water

is

cooled

by

sea water, and the sea water carries the transferred heat over the side

through the exhaust system. The fresh water and sea water circuits are independent

of

each other. Using

only fresh water within the engine allows the

cooling water passages

to

stay clean and free from harmful

deposits. The

two

independent circuits and their components are discussed in the following paragraphs.

Fresh

Water

Circuit

NOTE: Refer

to

paragraphs A and B in this section on the recommended antifreeze and water

mixture

to

be used as the fresh water coolant, and for information on filling the fresh water

system.

Fresh water

Is

pumped through the engine by a belt-driven circulating pump, absorbing heat from the en-

gine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through

the thermostat into the exhaust manifold, then

to

the heat exchanger where

tt

is

cooled, and then is returned

to the engine block through the suction side

of

the fresh water circulating pump. When the engine

is

started

cold, external fresh water flow

is

prevented

by

the closed thermostat (although some fresh water flow is

bypassed around the thermostat

to

prevent the exhaust manifold from overheating). As the engine warms

up, the thermostat gradually opens, allowing the engine's fresh water coolant

to

flow unrestricted

to

the ex-

ternal portion

of

the cooling system.

A. Fresh Water Coolant (Antifreeze) Mixture.

A freshwater and antifreeze mixture should be used year-round. Water, when

tt

freezes, expands sufficient-

ly

to

split the heat exchanger and crack the engine block. A water/antifreeze mixture

of

proper concentra-

tion will prevent freezing (see page 49 for an antifreeze/water mixture chart).

Use soft water with few

impurtties, such as tap water (potable water)

or

rainwater. Never use hard

or

foul

water. Use of hard water

or

water containing impurities will lead to the collection

of

scale in the engine and

heat exchanger which will reduce the cooling system's efficiency.

Antifreeze of

poor

quality

or

without rust inhibitors will cause corrosion within the

COOling

system. Always

use antifreeze which is compatible with aluminum

cooling system components and which

is

made

by

a reli-

able manufacturer. Never

mix

different brands

of

antifreeze.

Make sure that the

cooling system

of

the engine

is

well cleaned before adding antifreeze.

Recommended antifreeze

for

year round use

is

ZEREX

or

PRESTONE with rust inhibitors.

In order

to

control the concentration

of

the mixture, mix the antifreeze and fresh waterthoroughly before ad-

ding it

to

the cooling system.

Westerbeke Generators

48

Antifreeze

Concentration

Freezing

Temperature

ANTIFREEZE CONCENTRATION

DATA

%

13

23

30

35

45

50

60

, F

23

14

5

-4

-22 -40

-58

('

C)

(-5) (-10) (-15)

(-20)

(-30) (-40) (-58)

NOTE:

An

antifreeze concentration should be selected on the basis

of

a temperature which

is about

10' F (5'

C)

lower than the actual atmospheric temperature expected.

B. Filling the Fresh Water System

A coolant recovery tank kit

is

supplied with each Westerbeke gasoline 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.

This coolant recovery tank should be installed

at,

or above, the engine's manifold level, in a location where

it can be easily

monttored and where coolant can be easily added if needed (see the figure below). A stain-

less steel mounting bracket is supplied with each ktt along with a 30-inch length

of

clear plastic hose and

clamps

to

connectthe hose between the engine's manifold fitting

to

the hose spud on the base

of

the recovery

tank.

COOLANT RECOVERY

TANK

\

'.;

\

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f t

I'

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Coolant Recovery Tank, Recommended Installation

49

Westerbeke Generators

FUNCTION

OF

MANIFOLD

PRESSURE

CAP

From Coolant Tank

to Coolant Yank

COOLANT

EXPANSION

Coolant from the engine, when heated during the engine's operation, will expand,

lift

the spring-loaded

manifold pressure cap, and enter the recovery tank via the hose connecting the recovery tank

to

the manifold.

When the engine is shut

down

and cools, a small check valve in the pressure cap is opened

by

the contrac-

tion

of

the engine's coolant, allowing some

of

the coolant in the recovery tank

to

be drawn back into the

engine's cooling system, free

of

air and without loss. Periodically check that the passage

(Al

between the

90· fitting on the manifold and the filler neck in the manHold is clear so coolant can flow in either direction.

Fill the fresh water system as follows:

1.

Remove the pressure cap from the manifold.

2.

Pour a clean, fresh water coolant mixture into the manHold and allow enough time for the coolant

to

fill

the fresh water cooling system and expel

all

air.

3.

Replace the pressure cap on the manifold.

4.

Remove the plastic cap from the coolant recovery tank and fill the tank with coolant halfway between the

ADD mark and the MAX mark. Replace the cap on the manifold.

5.

Start and run the engine long enough for the engine

to

warm up so the thermostat will open, allowing the

coolant to flow through the engine block and to the rest of the fresh water cooling system.

6.

Add coolant

to

the recovery tank, as required,

to

top

off the fresh water cooling system.

Thermostat

Generally, thermostats are of

two

types. One

is

simply a choking device which opens and closes as the
engine's temperature rises and falls. The second type has a bypass mechanism. Usually this is a disc on
the bottom

of

the thermostat which moves downward to close off

an

internal bypass passage within the

head.

Since 1980, each type

of

thermostat has a hole punched through it. The hole is a bypass

to

prevent
the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have
this design characteristic.

Westerbeke Generators

50

Sea Waler

Circuil

The sea water flow

is

created by a belt-driven,

positive displacement, neoprene impeller pump.

The pump draws sea water directly from the

ocean through the sea

cock

and sea water

strainer

and passes

the

water

to

the

heat
exchanger's sea water inlet. The sea water pas­ses through the heat exchanger's tubes, from

which heat from the fresh water system is ab-

sorbed and then is discharged from the cooling
system overboard through the water-injected wet

exhaust system.

A zinc anode,

or

pencil, is located in the sea water

cooling circuit within the heat exchanger. The

purpose of the zinc anode

is

to

sacrifice itself

to

electrolysis action taking place

in

the sea water

cooling

circun, thereby reducing the effects of
electrolysis on other components of the system.
The condition of the zinc anode should

be

check-

ed monthly and the anode cleaned

or

replaced,

as required.

Spare anodes should be carried on

board.

Sea Water

Pump

~

.

...

.. t

.

::

NEW

ANODE

••..

REPLACE

REPLACE

Zinc Anode Condnions

CLEAN

OR

REPLACE

The sea water pump is a self-priming,

belt.<Jriven

rotary pump with a non-ferrous housing and a neoprene
impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing,
producing the pumping action.

On

no account should this pump

be

run dry. There should always be a

spare impeller and impeller cover gasket on board

(an

impeller

kn).

NOTE: Impeller failures resulting from a loss of sea water coolant are not warrantable failures.

51

Westerbeke Generators

Governor

and

Water

Pump

Bell

Tension

iWARNINGI

Never attempt

to

adjust the drive belt's tension

whOa

the engine is in operation.

CAUTION

Excessive governor and water pump drive bell tension can cause rapid wear of the belt and
reduce the service life

of

the fresh water pump and governor shaft bearings. Excessive slack

or

the presence

of

oil on the belt can cause belt slipping, resulting in high operating tempera-

tures, as

well as

poor

regulation during generator load changes.

The governor and water pump drive belt is property adjusted if the belt can be deflected no less than 3/8
inch and

no

more than 1/2 inch

(10

mm,

12

mm) as the belt is depressed with the thumb

at

the midpoint be-

tween the

two

pulleys on the longest span

of

the belt. (See the figure below.) Spare drive belts should be

carried on board.

Westerbeke

Generators

lOUR

PUll

3/0·

TO

112·

DHl[CTIDN

Governor and Water Pump Belt Tension

52

FRESH

WATER

PUMP

CRAUSHAFT

PULLEY

Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow
through their independent cooling circutts. Please refer to the Parts List for individual part numbers and
descriptions for your generator's

cooling system.

COOLANT

RECOVERY

TANK

HERT

WATER

INJECTED

ELBOW

OVERHERT

ALARM

Typical Cooling System

53

WATER

•

IleOMI.'

SEn

VATER

Westerbeke Generators

LUBRICATION SYSTEM

Engine

Oil

For the engine's lubrication, use a lubricating oil designated

for

gasoline service. Use a good grade

of

oil

having an

API

specification

of

SO

or

SE,

preferably

SF.

DO NOT use oils designated

OS.

Engine

Oil

Viscosity

(SAE

Number)

Use oil having a viscosity best suited

to

the atmospheric temperature. Refer

to

the oil viscosity chart below.

TEMPERATURE

ENGINE

OIL

Oil

Pressure

c"

F"

-30

-20

-10

o

10

20

30

-20

0

20

40

60

80

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40

50

100

120

The engine's oil pressure is indicated by the oil pressure gauge (when equipped with one)

or

is

monitored

by

the standard oil pressure switch.

During normal operation, the engine's oil pressure will range between 35 and 55 psi (engine hot).

NOTE: A newly started, cold engine can have an oil pressure reading upwards

of

60

to

60 psi.
A warmed engine can have an oil pressure reading as low as 35 psi. These readings may also
vary depending upon the load that is placed on the generator.

Your generator set is fitted with an oil pressure sensing switch as standard equipment. Should your engine's
oil pressure

drop

below a safe operating pressure, the sensor will shut the engine OFF

to

prevent any inter-

nal damage

to

your generator's engine from occurring by interrupting the DC voltage

to

the ignition coil.

Westerbeke

Generators

54

Engine Oil

Change

(10

include

filler)

1. Draining the Oil Sump

Discharge the old oil through the sump drain hose (at-

tached at the front of the engine) while the engine

is

still
warm. Drain the old oil completely, replace the hose in
its bracket, and replace the end cap securely.

Always observe the old oil as it

is

removed. A yellow/gray

emulsion indicates the presence

of

water in the oil. Al-

though this condition is rare, it does require prompt at­tention

to

prevent serious damage. Call a competent
mechanic should water be present in the oil. Sea water
present in the oil can be the result of a fault in the exhaust
system attached

to

the engine, and/or water siphoning

through the sea water cooling circuit into the exhaust,

filling it up into the engine (refer

to

the exhaust illustra-

tions on pages

21

and 23).

2.

Replacement of the

Oil

Filter

When removing the used oil filter, you may find it helpful

and cleaner

to

punch a hole in the upper and lower por-

tion

of

the old filter

to

drain the oil from it into a container

before removing

it.

This helps to lessen spillage. A small

style automotive filter wrench should be helpful in remov-

ing the old oil filter. Place some paper towels and a plas-

tic bag around the filter when unscrewing it

to

catch any

oil left in the filter.

(Oil

or

any other fluid on the engine
reduces the engine's cooling ability. Please keep your
generator's engine clean.)

Inspect the old oil filter as it

is

removed

to

make sure that the rubber sealing gasket

came off with the old oil filter.

If this rubber sealing gas­ket remains sealed against the engine block, gently
remove it. The replaceable cartridge-type oil filter re­quires

no

cleaning inside, so

IT

may be properly disposed

of.

When installing the new oil filter element, wipe the filter

gasket's sealing surface on the engine block free of oil

and apply a thin coat

of

clean engine oil

to

the rubber gas-

I

\1\1\11'111

II!

IlliI'III1T?"

I

,

ket on the oil filter. Screw the filter onto the threaded oil filter stub, and then tighten the filter firmly

by

hand

NOTE: Generic filters are not recommended, as the material standards or diameters of im­portant items

on

generic parts might be entirely different from genuine parts. Immediately

after an oil filter change and oil fill, run the engine

to

make sure the oil pressure is normal and

that there are

no

oil leaks around the new oil filter.

55

Westerbeke Generators

3.

Filling the Oil Sump

Add fresh oil through the oil filler cap on 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 dipstick. Fill to, but not over,

the high mark on the dipstick, should the engine require

additional oil.

Westerbeke

Generators

56

Oil

Filler

Cap

Rocker

Cover

Oil

Dipstick

Upper

Li.it

(Nor.al

leveli)

-"-'-t~::=:==:=:===1

Lower

Crankcase

Be

GENERATOR

The

Be

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

of

the engine

to

produce an AC output. The stator houses two sets of windings: the main stator windings and the exciter
windings. When the generator is started, residual magnetism in the four rotating poles induces a current in
the stator exciter windings. This flow

of

current then induces a greater current flow through the four rotat-

ing poles which then generates an even larger current

in

the exciter windings. This mutual build

up

of

cur-

rent in the four rotating poles and

in

the exciter windings quickly reaches the saturation point of the

capacitor(s) and a regulated energy field is then maintained

in

the stator. At the same time, this regulated

field

produces a steady voltage

in

the stator windings which can then be drawn off the generator's

AC

ter-

minals

to

operate

AC

equipment.

D

r a - -

------

-

--

- - - - ---- - - -

----

- - - - - - - ----

---,

, I

I I

I ,

I

DC

I

I

AC

I

, I

r---------,

,

I

I

,

,

101

I

, I
I I

I I

I ,

, ,

, ,

'

I I I

A '

I'

:

II

I , ,

, , ,

',0

lODE

I I

, ,

AC

BRIDGE

RECTIFIER

1.

C.

I

INTEGRAL

CONTROLLER

I

,

I

I

____

,

________________

--l

------01

I

T I

[ I

R I

M I

------02,'

-

------03

N ,

A I

------0.

liB

. ,

L '

o '

C I

------05·'

BALLAST

RESISTOR

'-'0

.......

_60

HZ

I.

C.

DC

CHARGE

INTEGRAL

CONTROLLER

EARLIER

MODELS

, I ,

I I

~.~~=-====~?~:-.J

I I

I i

1

o

5

o

•

o 3 o

6

o

: ,

I ,

I..

_________

.J

c

I

t:iPHj:t

'---------

---_._-'

Be S.SKW

and

6.0KW

2

o

AC

TERMINAL

BLOCK

!

~C?J

!

L

___________

J

Be 4.0KW

and

4.4KW

Generator Internal Wiring Schematic with

DC

Battery Charging Circuit

A.

Rotating Field/Auxiliary

Windings

wtth Diodes

C.

Exciter Windings and Capacitor(s)

Generator

Frequency

B.

Integral Controller with Ballast Resistor

(Earlier Models)

D.

Bridge Rectifier and Integral Controller

Frequency

isa

direct result of engine/generator speed: 1800

RPM -60

Hertz, 1500

RPM

-50

Hertz To change

the generator's frequency, refer

to

the "MAINTENANCE AND ADJUSTMENTS" section of this manual, page

70.

57

Westerbeke Generators

No-load

Voltage

Adjustment:

BGG 4.0KW

1.

Remove the louvered metal plate covering the terminal connections and the capacitor (see page 59).

2. Start the generator and allow it

to

run for approximately five minutes so the engine can warm up. Make

sure the generator is operating without any equipment drawing

AG

current from the generator (that

is,
shut OFF all electrical appliances). Make sure the engine's speed (Hertz) is correct. Adjust the governor
as needed

to

obtain the correct engine speed before proceeding.

3.

Referring

to

the

AG

load connections diagram below, check the generator's no-load voltage

by

measur-

ing the voltage across the neutral lead and the hot

lead with a volt meter. Make sure you record this read-

ing. The generator's no-load voltage is 115 -

124 volts at 60.5 - 61.5 Hertz.

If

the voltage output

is

higher

or

lower than specified, proceed.

N

l,

N

l2

N

l2

L,

1 4

3

1

4_3

t

4

3

1 4

3-

1

4-=-3

5_

a2

6

5

2a6

5_2_

6

6_

5a2-6

L,

L,

,N

N

110v 50 Hz

120v

60Hz

220v 50 Hz

240v

60Hz

220v

50Hz

4.

Shut off the generator. Make sure the correct Hertz lead

(60

Hertz #6, or 50 Hertz

#5)

is plugged into the

capacitor. Refer

to

the illustration on the

top

of the next page.

JWARNING!

DO

NOT attempt

to

make a no-load voltage adjustment while the generator

is

operating. The

capacitor can hold a

450 - 500 volt charge. Touching any wiring can result in a severe electri-

cal shock.

In addition, attempting

to

make a no-load voltage adjustment while the generator

is operating can cause fingers

to

be caught

in

the generator's rotor.

5.

Refer

to

the illustrations the next page before making any adjustments. Note that there are three plugs

grouped for the right capacitor terminal, #7,

#8,

and

#9.

If the generator's no-load voltage is low, then

disconnect the lower numbered plug and connect the plug with the next higher number.

If the generator's
no-load voltage is high, then disconnect the higher numbered plug and connect the plug with the next
lower number. Note that the plug presently connected

to

this terminal may be

anyone

of

the three plugs

available.

6.

If the generator's no-load voltage cannot be adjusted because the voltage needs

to

be increased and the

highest numbered plug

is

already connected to the right terminal,

or

the voltage needs

to

be lowered and

the lowest numbered plug is connected, then

follow the steps at the bottom

of

the next page. Ask your

local Westerbeke dealer

for a Be

GENERAL TROUBLESHOOTING GUIDE before performing the steps

listed

at

the bottom of the next page.

NOTE: Make sure the insulating covers on the unused leads are in place and are not In con­tact with each other or in contact with the generator's housing.

Westerbeke

Generators

58

<:>

'"

C
YO

THE

11

PLUG

IS

SHOWN

CONNECTED

TO

THE

CAPACITOR

ONLY

FOR

DEMON-

STRATION

PURPOSES.

BeG

4.0KW

GENERATOR

H.

Capacitor

::::,~--tF;III-

'"

,

No-load

Uoltage

Adjustment

Plugs

50

Hertz

Plug

CAUTION:

DO

NOT

ALLOW

ANY

OF

THESE

PLUGS

TO

TOUCH

THE

GENERATOR"S

HOUSING.

WINDINGS

WXLL

BURN

IF

THESE

PLUGS

TOUCH

THE

HOUSING

OR

OTHER

W1RES.

A.

Check the resistance

of

the exciter windings

BCG 4.0KW : 1.9

Ohms

C.

Check the engine's speed.

60 Hertz:

60.5·61.5

50 Hertz:

50.5·

51.5

AC

load

Connection

Ter.inal

Block

B.

Check the capacitor.

Generator

End

(over

Plate

BCG 4.0KW: 31.5 uF ±

5'

Adjust the engine's speed

by

use of the governor speed adjustment, page

74,

to

obtain the correct Hertz.

NOTE: Refer

to

the "NOTE" at the bottom

of

page

62.

59

Weslerbeke Generators

No-Load Voltage Adjustment: BeG 6.5KW

1.

Remove the louvered metal plate covering the terminal connections and the capacitor (see page 61).

2.

Start the generator and allow

tt

to

run for approximately five minutes so the engine can warm up. Make

sure the generator

is

operating without any equipment drawing AC current from the generator (that

is,
shut OFF all electrical appliances). Make sure the engine's speed (Hertz) is correct. Adjust the governor
as needed

to

obtain the correct engine speed before proceeding.

3.

Referring to the AC load connections diagram below, check the generator's no-load voltage

by

measur-

ing the voltage across the neutral lead and the hot lead with a volt meter. Make sure

you

record this read-

ing. The generator's no-load voltage

is

115 - 124 volts at 60.5 - 61.5 Hertz. If the voltage output is higher

or

lower than specified, proceed.

N

l,

N

L2

N

L2

I.,

1

4

3

1

483

1 4

3

I 4

3e

1

4e::::s3

5.

.2

6

5

2.S

5e2e

6

5 2

68

5e2e6

l,

l,

l.

N

110v 50 Hz

120v

SO

Hz

220v

50Hz

240v

SO

Hz

4.

Shut off the generator. Make sure the correct Hertz lead

(60

Hertz

#6,

or

50

Hertz

#5)

is plugged into the

capacitor. Refer

to

the illustration on the

top

of

the next page.

~WARNINGI

DO NOT attempt

to

make a no-load voltage adjustment while the generator is operating. The

capacitor can hold a

450

volt charge. Touching any wiring can result in a severe electrical

shock.

In addition, attempting

to

make a no-load voltage adjustment while the generator is

operating can cause fingers

to

be caught

in

the generator's rotor.

5. Refer

to

the illustrations on the next page before making any adjustments. Note that there are three plugs

grouped for the right capacitor terminal,

#7,

#8, and #9. If the generator's no-load voltage

is

low, then

disconnect the

lower numbered plug and connect the plug with the next higher number. If the generator's

no-load voltage is high, then disconnect the higher numbered plug and connect the plug with the next
lower number. Note that the plug presently

connected

to

this terminal may be

anyone

of

the three plugs

available.

6. If the generator's no-load voltage cannot be adjusted because the voltage needs to be increased and the

highest numbered

plug is already connected

to

the right terminal, or the voltage needs

to

be lowered and

the lowest

numbered plug

is

connected, then follow the steps listed at the bottom

of

the next page. Ask

your

local Westerbeke dealer for a BC GENERAL TROUBLESHOOTING GUIDE before performing the

steps listed at the bottom

01

the next page.

NOTE: Make sure the insulating covers on the unused leads are in place and are not

in

con-

tact with each other

or

in contact with the generator's housing.

Westerbeke

Generators

so

"'"

•

w

-'

N

...

~

~

::

'"

e

'"

"'

THE

17

PLUG

IS

SHOWN

CONNECTED

TO

THE

CAPACITOR

ONLY

FOR

DEMON-

STRATION

PURPOSES.

BCG

6.SKW

GENERATOR

58

Hertz

Plug

A.

Check the resistance of the exciter windings

BCG 6.5KW : 1.9

Ohms

C.

Check the engine's speed.

60 Hertz: 60.5 - 61.5
50 Hertz: 50.5 - 51.5

AC

Load

Connection

Ter.inal

Block

Capacitor

Adjustment

Plugs

CAUTION:

DO

NOT

ALLOW

THESE

PLUGS

TO

TOUCH

THE

GEHERATOR"S

HOUSING.

WINDINS

WILL

BURN

IF

PLUGS

TOUCH

HOUSING

OR

OTHER

WIRES.

B.

Check the capacitor.

BCG 6.5KW: 31.5 uF

±

5"

Adjust the engine's speed

by

use of the governor speed adjustment, page

74,

to

obtain the correct Hertz.

NOTE: Refer

to

the "NOTE" at the bottom

of

page

62.

61

Westerbeke Generators

Load

Connections

The generator's data plate gives the voltage, current and frequency rating

of

the generator. An AC wiring

decal

is

affixed

to

the inside

of

the louvered cover on the generator end. A diagram of the various AC volt-

age connections is provided on the decal.

The generator

is

a single-phase, reconnectable 120 Volts AC two-wire

or

120/240 Volts AC three-wire, at 60

Hertz;

or

110 Volts AC two-wire, 110/220 Volts AC three-wire,

or

220 Volts AC two-wire, at 50 Hertz. Refer

to the

"SYSTEM SPECIFICATIONS" section of this manual for generator ratings, page

13

for

the BCG 4.0KW,

and page 17

for

the BCG 6.5KW.

NOTE: The frame ground wire must be moved when changing from 110 Volts,

50

Hertz

to

/220

Volts, 50 Hertz.

A circuit breaker should be installed between the generator and the AC load. This circuit breaker should be
rated at 120%

of

the generator's AC output and be able

to

react quickly to overloads, subject

to

motor

start-

ing considerations.

N

N

l

2

N

L

1

1 b 4 3

5.

82

6

1

483

I

4CJ

3

1 4

34111

5,2

6.

Ltl

N

240\160 Hz

t

4e:::::::lD3

5

206

5-2-

6

54111286

L,

L

j

N

110

...

50Hz

120

...

60 Hz

220

...

50 Hz

220v

50Hz

For making connections

to

the AC terminal block, use terminal ends for

#10

studs which will accept multi-

strand wire sized

for

the number

of

conductors in the bundle, the rating of the conductor's insulation, and

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

to

the generator's data plate for the gener-

ator's amperage and voltage ratings.)

NOTE: When changing Hertz produced

by

the generator, an engine speed adjustment at the
governor must be made. The AC output connections on the above illustrated terminal blocks
must be selected for the voltage and Hertz

to

be produced. A plug at the capacitor must be

changed

for

50 (#5)

or

60 (#6) Hertz use. Early models with 3 wire connections

to

the in-

tegral controller require a 50 (#5) or

60

(#6) Hertz connection change at the bridge rectifier

in the DC charging circuit. Refer

to

the "Generator's Internal Wiring Schematic" on page

57.

Weslerbeke

Generators

62

Shore

Power

Connections

If the installer connects shore power

to

the vessel's

AC

circuit, this must be done

by

means of the SHORE
POWER/OFF/SHIPS GEN., center position-off transier switch shown below. Use of this switch prevents
simultaneous connection

of

shore power to generator output.

CAUTION

Damage

to

the generator can result if utility shore power and generator output are connected

at

the same time. This type

of

generator damage is not covered under the warranty; it

is

the

installer's responsibility

to

make sure all

AC

connections are correct.

Generator

HOTE:

!lIAGRIlM

SHOWS

CONNECTIONS

FOR

IIiO-

~

WIRE.

12f1-VOLT

SYSTEM.

fOR

THREE-WIRE

t

=

SYSTEM

USE

DOll

EO

LINES

fOR

THE

DTllfR

HOT

LEGS.

1

L-

___

----,

I

,/--

....

L-----,HD

~~,_

r-----\a>

tID

!

""I

I

,

,

---,

I

I

,

I

I

1

L-+'------~"~-'1'~\--~,

I I

,

__

",,/

I

r;

,,-->

-'~-~:]s,,,p,

'-

/

LOAD

~

I"

''''0-''_''''''''

__

...;...

______

-11

,.

~

ShOfe

PCNJilf

SHIP-IO-SHORE

SWITCH

(3

POLO

PH

3268H

149 AMPS/POLU

PH

32089

(8i1

AHPS/POLfl

PM

32e18

(125

AMPS/PDL£)

PH

32133

(289

M-IPS/POlE 1

Generator

rN

GI'~

NOTE,

OIAGRAM

SHOWS

CONNECTIONS

fOR A IWO-

WIRE,

120-VOLT

SYSTEM

fROM

THE

GENERATOR,

-

WITH

THREE-WIRE,

I20-VOlT

L-

________

---"B"'O"'AT'-iS

YS

TE

M.

Ship-to-Shore Switch

(3

Pole)

PH

329BB

(48

AMPS/POLE)

PH

321HI9

(BI'!

AMPG/POLE;)

PH

32918

(.l:n,

AMPS/POLE)

PH

32133

(209

AMPS/POLl::)

Shore Power Switch Connection Diagrams

63

Westerbeke Generators

GENERAL INFORMATION AND CARE OF THE GENERATOR

Use

of

Electric

Motors

The power required

to

start an electric motor is considerably more than

is

required

to

keep n running after

n

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. These motors are commonly used on

easy-starting loads, such as washing machines, or where loads are applied after the

motor

is started, such

as small power tools. Because they require 5

to

7 times as much current

to

start as

to

run, their use should

be avoided, whenever possible, if the electric motor is

to

be driven

by

a small generator. Capacitor and

repulsion-induction motors require from 2

to

4 times as much current

to

start as

to

run. The current required

to start any

motor

varies with the load connected

to

n.

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 ap-

proximately as follows:

MOTOR

AMPS

FOR

AMPS FOR

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 that 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 the hardest starting types (spin-phase) are not

made in larger sizes.

Because the heavy surge

of

current needed for starting motors

is

required for only an instant, the generator

will not

be

damaged if n can bring the motor up

to

speed in a few seconds. If difficulty is experienced in

starting motors, turn off all other electrical loads and, if possible, reduce the load on the electric motor.

Required

Operating

Speed

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

of

typical 6O-(50-)Hertz engine-

driven generators described in this manual are shown on the chart on the next page.

Run the generator

at

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.

See the rpm/Hertz/frequency chart on the next page.

Westerbeke

Generators

64

4-Pole Generator Voltage

Load Speed

Frequency 120V (110) 240V (220)

Applied (rpm) (Hertz) Plants Plants

None 1830 62 122 240

(1530) (52) (112) (224)

Half

1800

60 120 240

(1500)

(50) (110) (220)

Full 1755

59 110 220

(1455) (49)

(100) (200)

The output voltage should be checked periodically

to

ensure proper operation

of

the generating plant and

the appliances

tt

supplies.

If an AC voltmeter

or

ampmeter is not installed

to

monitor voltage and load, check

tt

wtth a portable meter

and amp-probe.

Preventive

Maintenance

(Generator)

Maintenance on the generator is minimal.

1.

Keep the generator clean,

dry

and well-ventilated.

2.

Make sure all connections are clean and tight and that cables carrying AC voltage are properly supported
and protected against chafing.

3.

The rear armature bearing is lubricated and sealed; therefore,

no

maintenance

is

required. If the bearing

becomes rough

or

noisy, replace

it.

Generator

Troubleshooting

A complete and illustrated text on troubleshooting the BC series

of

generators is furnished in the Technical

Manual which

is

available through your local dealer.

65

Westerbeke

Generators

ENGINE TROUBLESHOOTING

Introduction

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

probable causes of the problems, and the recommendations

to

overcome these problems.

Note that the engine's control system (electrical system) is protected

by

a 20-Ampere manual reset circuit

breaker located next

to

the starter

motor

and the

(-)

ground terminal. Refer

to

the model photographs at the

beginning

of

this manual

for

a photograph showing the exact position

of

this reset circuit breaker.

Trouble

Engine cranks but fails

to

start.

Engine does not crank.

Westerbeke Generators

66

Possible Cause

1 . Out

of

fuel.

2.

Engine is flooded.

3.

Filters are clogged

by

contaminated fuel.

4.

Voltage

drop

at ( + ) at overspeed switch.

5.

Worn or faulty spark plugs.

6.

Bad ignition coil.

7.

High-tension leads grounding (wet system).

8.

Automatic Shutdown switch is faulty.

9.

Fuel pump inoperative because filter is
clogged.

10.

Filter in carburetor

is

clogged.

11.

Tripped overspeed switch (reset and start).

1.

Battery

is

low

or

dead.

2.

Engine's DC 20-Amp breaker has tripped.

3.

Sea water filled cylinders.

4.

Loose battery connections.

5.

Voltage

drop

at starter solenoid terminal.

6.

Bad starter solenoid.

7.

Faulty START switch.

Trouble

Engine starts, runs and then
shuts down.

Back firing through carburetor.

Engine overheats.

67

Possible Cause

1.

Faulty automatic shutdown switch

(oil, water,

or

eXhaust).

2.

Faulty overspeed switch (reset and start;
bypass

SWITch

to

test).

3.

Faulty fuel pump.

4.

Faulty STOP switch.

5.

Engine circutt breaker

is

tripping.

6.

Dirty fuel filters.

7.

Low oil level in sump.

8.

Mechanical check valve at the fuel supply
fuel pump

is

unable

to

draw

fuel through this valve.

1.

Ignition timing is wrong.

2.

Engine is flooded.

3.

Choke

is

stuck closed.

4.

Spark plug wires are connected wrong

--

check firing order.

5.

Distributor cap is cracked.

6.

Dirty air cleaner.

1.

Coolant loss (pressure test the cooling system).

2.

Belts are loose

or

broken.

3.

Sea water pump's impeller

is

faulty.

4.

Sea water pump is worn.

5.

Faulty hose.

6.

Thermostat

is

stuck closed.

7.

Heat exchanger

is

clogged.

8.

Faulty gauge (check with a thermometer).

Westerbeke

Generators

Trouble

Engine

hunts.

Engine misfires.

High

oil

pressure.

Low

oil

pressure.

Westerbeke

Generators

68

Possible

Cause

1.

Throttle linkage

is

binding.

2.

Dirty

fuel

filters.

3.

Defective

fuel

pump.

4.

Governor

is

out

of

adjustment.

5.

Valves

are

out of adjustment.

6.

Generator

is

overloaded.

7.

Cracked distributor.

8.

Faulty high-tension

leads.

1.

Ignition timing

is

wrong.

2.

Spark plugs

are

worn.

3.

Valve

clearances

are

incorrect.

4.

Dirty carburetor.

5.

Dirty air

cleaner.

6.

Poor quality

fuel.

1.

Faulty

gauge.

2.

Relief

valve

is

stuck.

3.

Dirty

oil

or wrong

SAE

type

oil

is

in

the

engine.

1.

Low

oil

level.

2.

Faulty

gauge.

3.

Wrong

SAE

type

oil

is

in

the

engine.

4.

Relief

valve

is

stuck.

5.

Faulty

oil

pump.

Trouble

No

DC charge

to

the

starting battery.

Black exhaust smoke

Is

discharged

from

the engine.

Blue exhaust smoke

is

discharged

from

the exhaust.

69

Possible Calise

1.

Connections

to

the alternator are loose

or

faulty.

2.

Faulty alternator.

3.

No

eXCITation

to

the regulator's yellow

lead.

1.

Dirty air intake.

2.

Choke is stuck closed.

3.

Carburetor is flooding.

1.

Valves are worn

or

adjusted incorrectly.

2.

Piston rings are worn

or

unseated.

3.

Lubrication oil is diluted.

4.

Crankcase breather hose is clogged.

Westerbeke

Generators

MAINTENANCE AND ADJUSTMENTS

Introduction

This section contains a scheduled preventive maintenance program and several adjustment procedures the
owner/operator can perform without the benefit of sophisticated and expensive tools and instruments.

Preventive

Maintenance

(Engine)

Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
Adherence

to

these schedules will make sure the equipment is maintained

in

the best possible condition and

that it will perform

to

expectations. Those items marked

by

an asterisk (") are recommended

to

be per-

formed

by

an authorized dealer

or

distributor.

Daily

(before

each

use)

1.

Check the oil sump level. Maintain the oil level at or near the upper level mark on dipstick.

2.

Check the coolant level in the plastic recovery tank. Maintain the coolant level halfway between the
MAX

and ADD marks.

3.

Visually inspect the unit; check for loose belts, chafed

or

broken wires, loose brackets and fittings,

damaged hoses, loose clamps, and other equipment not properly secured.

4.

Check the fuel supply. Fill the tank(s) with a good grade

of

unleaded

or

leaded gasoline that has an

octane rating

of

89

or

higher.

5.

Check the primary filter/water separator. Drain and service this filter as required. (A primary filter/water

separator

is

optional, but strongly recommended. See page 39.)

6.

If an optional instrument panel

is

installed, check the engine's gauges for proper oil pressure, operat-

ing temperature, and starting battery charging voltage once the engine is operating.

7.

If AC gauges are installed, check the generator's output meters

for

proper AC voltage and output fre-

quency.

Monthly

Check the condition

of

the zinc anode in the heat exchanger's sea water circuit. Clean

or

replace the anode,

as required. Keep the area inside the heat exchanger clean

of

zinc anode debris.

Servicing

After

Initial 50

Hours

01

Operation

1.

Change the engine's lubrication oil and oil filter.

2.

Clean

or

replace the fuel filter screen in the carburetor and in the electric fuel lift pump.

3.

Retorque the cylinder head bolts.

Weslerbeke

Generators

70

4.

Adjust valve clearances.

5.

Adjust the alternator and water pump drive belt tension, if required.

6.

Adjust the engine's no-load speed,

IT

required (Hertz). Please note that this adjustment is not a warrant-

able adjustment during

or

after the unit's break-in.

Servicing After Every 100 Hours

of

Operation

1.

Change the engine's lubrication oil and oil filter.

2.

Adjust the alternator and water pump drive belt tension,

IT

required.

Servicing After Every 250 Hours

of

Operation

Clean

or

replace the fuel filter element in the carburetor and in the electric fuel lift pump.

Servicing After Every 500 Hours

of

Operation

*1. Adjust the valve clearances.

3.

Drain, flush, and refill the fresh water cooling system

*4. Check the condition

of

the starter motor drive pinion; lubricate pinion.

5.

Check the outside of the engine. Make sure any oil on the engine's surface is cleaned. Any dirt or oil
on the engine inhibits the engine's ability

to

cool. Please keep the engine clean.

6.

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

Servicing After Every 800 Hours

of

Operation

*1. Check the battery-charging alternator

for

proper operation.

*2. Check the tightness of bolts, nuts, and clamps.

Servicing After Every i 000 Hours

of

Operation

1.

Remove, clean, and pressure test the primary heat exchanger.

(A

local automotive radiator shop should

be able

to

clean and test the heat exchanger.)

NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning
be performed more often than every

1000 hours.

71

Westerbeke Generators

Preventive

Maintenance

(Generator)

Maintenance on the generator end

is

minimal:

1.

Keep the generator clean, dry, and well-ventilated.

2.

Ensure that all connections are clean and tight, and that cables carrying AC voltage are properly sup­ported and protected against chafing.

*3. The rear armature bearing is lubricated and sealed; no maintenance is required. However,

H the bear-

ing becomes noisy

or

rough-sounding, have it replaced.

Generator

Frequency

Adjustment

Frequency

is

a direct result

of

engine/generator speed, as indicated

by

the following:

When the generator

is

run at 1800 rpm, the AC voltage output frequency is 60 Hertz. When the generator is

run at 1500 rpm, the

AC voltage output frequency is 50 Hertz.

Therefore,

to

change the generator's frequency, the generator's speed must be changed.

To

accomplish

the frequency change, connect the

AC output leads

to

the AC terminal block in accordance wtth the "AC Vol­tage Connections" diagram specified for your generator set, which appears in the "BC GENERATOR" sec­tion

of

this manual, page 62.

Westerbeke

Generators

72

Ignition

Timing

1.

Attach a timing light

to

the #1 spark plug and mark the front crankshaft pulley timing notch. Locate the

timing pointer on the front gear case ant mark it as

well (use a piece

of

soap, white chock,

or

white crayon

when making this mark).

2.

Start the engine and warm it

up

to

its normal operating temperature. Make sure the generator

is

operat-

ing without a load on it.

3.

Using the timing light, align the timing groove in the front crankshaft pulley with the timing pointer. Do this

by

loosening and slowly rotating the distributor body. Refer

to

the timing specifications below.

Timing Specifications:

/

TIMING

MAR

K

-\--~~~

BeG

4.0KW

Electric

Choke

BCG4.0KW
BCG6.5KW

16' ±

l'

BTDC at 1800 rpm

14' ±

l'

BTDC at 1800 rpm

lIMING

POINTER

BeG

G.

SKW

THnNG

MARK

(1800

RPM)

The electric choke uses a 12-Volt heating element which opens the choke automatically once the engine

starts and remains running.

Some hunting will be present when the generator

is

started,

is

on choke, and

is

running without a load on the generator.

IWARNINGI

To avoid burns on fingers or hands, DO NOTtouch the choke

housing while the engine is operating.

Allow the engine

to

cool before making choke adjustments.

Adjustthe choke

by

loosening the three cover-securing screws and

by

rotating the cover clockwise

to

set the choke ENRICH and

counterclockwise to set the choke LEAN. The choke

is

initially set

at the factory.

73

~

LEAN

Weslerbeke Generators

Governor

Adjustments

Operate the generator set

to

bring the unit up

to

ITS

operating temperature before attempting an adjustment.

NOTE: If the governor

is

severely out of adjustment, manually adjust the linkage without any

load on the generator

to

obtain a safe output voltage before proceeding with the adjustment.

Three adjusting points are on the governor. (Refer

to

the illustration below.)

1.

Bumper Screw This screw is used

to

remove a no-load

surge

ONLY.

NEVER

turn the bumper screw into the
governor far enough so that it increases
the

no-load speed. To adjust the gover­nor, turn the bumper screw in until the
engine stops surging. Now bring the
Increase/Decrease

Speed Screw (on

the governor) up until the generator

runs between 60.5

to

61.5 cycles no-

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

to

the generator and ensure the gener­ator does not surge under these three
load intervals.

NOTE: Only If

the generator surges
at any of these load intervals are
you

to

follow steps

#2

and

#3

below.

2.

Increase/Decrease Speed This adjust-

ing

bolt sets the no load speed of the

engine. (The

linkage arm between the

governor arm 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 lubricant at
this connection. Disconnect the

ball

joint and apply a graphite lubricant

to

the inside of the joint.

3.

HuntinglBeculatjQo

!f

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

boll may

need

to

be

adjusted as well.

BCG

6.5KW Governor

INCREASE/DECREASE

SPEED

SCREW

CARBURETOR

THROTTLE

LEVER

BCG

4.0KW Governor

LIIUA6E

ADJUSTMENT

CARBURETOR

THROTTLE

IIDJUSHtEKf

INCREASE/DECREASE

SPEED

SCREW

If the governor surges while under a load, adjust this eye bolt

to

move the spring away from the lever hub.

(Check the speed adjustment.)

Westerbeke Generators

74

Governor

Maintenance

1.

Periodically lubricate the attaching points at both ends of the governor arm. Use a graphite lubricant or
an equivalent.

NOTE: Free movement

of

this linkage arm is important for proper governor/throttle operation.

2.

Governor oil

capac~y:

BCG 4.0KW

is

1.5 ounces

of

SAE

#10/30

motor

oil.

BCG

6.5KW

is

3.0 ounces

of

SAE

#10/30

motor

oil.

NOTE: Do not overfill the governor.

3.

Change the governor's oil every 1000 hours of operation.

4.

The drive belt should be maintained in good condition. Replace the belt if it becomes worn or shows signs

of

cracking.

To

change the oil, remove the governor from engine and remove the oil fill and fill level plug and drain all the

oil from the governor. Reinstall the governor on the engine and fill it with the proper quantity

of

SAE

10/30

engine oil, and replace the plugs.

75 Westerbeke Generators

Carburetor Adjustment

1.

Idle Mixture Jet

Disconnect the throttle

linkage arm from the governor control arm and reduce the engine's speed with the

idle stop screw. Turn the idle mixture screw clockwise

(In)

until the engine skips; back the screw out
(counterclockwise) slowly until the engine smooths then skips again; then turn the screw clockwise (in) 1/4
to

1/2

of

a turn. The idle mixture should be satisfactory at this setting.

2.

Run Mixture Jet

This mixture jet

is

pre-sized

at

the factory and

is

not adjustable. An adjustment

to

the idle jet screw, while

the unit

is

operating at 1800 rpm, will have an affect on the unit's performance. Refer

to

the "Governor Ad-

justments" section

of

this manual for instructions on how

to

adjust the engine's speed, page

74.

Westerbeke Generators

SCREENED

AIR

(LEANER

THROTTlE

SlOP

~~~Yl~~~~~~~

FUEl

SOLENO

D

IDLE

MIXTURE

JEI

76

Torquing

Cylinder

Head Bolts

Tighten the cylinder head bolts according

to

the sequence shown in the illustration below. Make sure the

engine

is

cold when this is done. Loosen one head bold one-half turn and then tighten It

to

the specified

torque. Then proceed

to

the next head bolt in the sequence numbering shown.

BeG

4.8KW

TIGHTENING

SEQUENCE

8(G Ii.SlW

TIGMTEKIKG

SEQUENCE

Torque Specifications:

BCG

4.0KW 28.9 -36.2 Ib-ft

(4.0

- 5.0 kg-m)

BCG

6.5KW 36.2 - 43.4 Ib-ft

(5.0

- 6.0 kg-m)

77

Westerbeke Generators

Valve Clearance

Adjustment:

BCG 4.0KW

NOTE:

Retorque the cylinder head bolts

before adjusting the engine's valves.

1.

Remove the rocker cover and the gasket.

2.

Rotate the crankshaft in the normal direction

of

rotation and place the No. 1 piston at TDC
(Top Dead Center) on its compression stroke.
AdJustthe intake and exhaust valve clearances
for the No.1

cylinder. Make sure the valves for

this cylinder are closed when this adjustment

is

performed.

3.

Rotate the crankshaft 360'. The valves for

cylinder NO.2 should now be closed.

Nowad-

just the valves for cylinder

No.2.

Adjust the intake valves

to

0.008 inches (0.20

ADJUST

EXHAUST

VALVES

TO

0.008

INCHES

(0.20

14M)

ADJUST

INTAKE

VALVES

TO

0.010

INCHES

(0.25

14M)

mm), and the exhaust valves

to

0.010 inches (0.25 mm) with the engine cold.

4.

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

Rocker cover torque:

5.1

- 9.4 Ib·ft (0.7 - 1.3 kg-m)

Valve Clearance

Adjustment:

BCG 6.5KW

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

1.

Remove the rocker cover and the gasket.

2.

Rotate the crankshaft in the normal direction of

rotation and place the No.1 piston atTDC (Top

Dead Center) on its compression stroke.

Ad·

just the intake valve clearances for the No. 1
and No. 3 cylinders, and the exhaust valve

clearances

for

the No. 1 and

No.2

cylinders.

Make sure these valves are closed when per·

forming this adjustment.

3.

Rotate

the

crankshaft

360°

and

adjust

the

No.

2 cylinder's intake and the

No.3

cylinder's ex-

haust valve clearances.

Adjust all valves

to

0.0071

inches (0.18 mm) with

the engine

cOld.

ADJUST

EXHAUST

VALVES

TO

0.0071

INCHES

(0.18

14M)

ADJUST

INTAKE

VALVES

TO

0.0071

INCHES

(0.18

14M)

4.

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

Rocker cover torque:

5.8·

8.7Ib·ft

(0.8·1.2

kg·m)

Westerbeke Generators

78

Spark

Plugs

To service the spark plugs, clean, gap

or

replace the plugs as needed.

CAUTION

DO

NOT remove the spark plugs while

the engine is hot.

Allow the engine

to

cool before removing the spark plugs.

Spark plug

gap: 0.028 -0.036 inches

(0.7 -0.9 mm)

Spark plug torque:
BCG 4.0KW

13.1

- 17.4 Ib-ft

(1.8 -2.4 kg-m)

BCG 6.5KW 10.8 - 15.9 Ib-ft

(1.5 -2.2 kg-m)

Check each

plug

for

damage and/or wear.

WEAR

AND

ADHESION

OF

CARBON

PlUG

GRP

BURNT

CONDITION

DRMRGE

AND

DETERIORATION

DAMAGE

NOTE: Loc-tite "Anti-Seize" applied

to

the threaded portion of the spark plugs will retard cor-

rosion, making future removal

of

the spark plugs easier.

79

Westerbeke

Generators

LAY-UP AND RECOMMISSIONING

General

Many owners rely on their boatyards

to

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

during the off-season

or

for long periods

of

inactivity. Others prefer

to

accomplish lay-up preparation them-

selves.

The procedures which follow will allow you

to

perform your own lay-up and recommissioning, or

to

use as

a check

list if others

do

the procedures. These procedures should afford your engine protection during a

lay-up and also help familiarize you with the maintenance needs of your engine.

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

Fresh Water

Cooling

System

A 50-50 solution

of

antifreeze and fresh water

is

recommended 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. Now recheck the antifreeze solution's strength.

Lubrication

System

With the engine warm, drain all the lubricating 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 during 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. Use an oil with an

API

specification

of

SD,

SE

or

SF.

Run

the engine and check for proper oil pressure and make sure there are

no

leaks.

CAUTION

DO NOT leave

the engine's old lubricating oil in the sump over the lay-up period. Lubricat-

ing 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 regular

or

unleaded gasoline with

an

octane rating of

89

or higher. Fuel addi-

tives should be added at this time

to

control algae and condition the fuel. Care should be taken that the ad-

ditives used are compatible with the primary filter/water separator used in the system. Change the

element
in your primary fuel filter/water separator, if the fuel system contains one, and clean the separator sediment
bowl. Clean the filter screen in the fuel lift pump and in the carburetor.

Westerbeke Generators

80

Sea Water

Circuit

Close the through-hull sea cock. Remove the sea water intake hose from the sea cock. Place the end of
this hose into a

5-gallon bucket of clean fresh water. Before starting the engine, check the zinc anode found

in the primary heat exchanger on the engine and clean or

replace it as required. Clean the sea strainer, if

one is

installed in the inside

of

the hull.

Start

the engine and allow the sea water pump

to

draw fresh water through the system. When the bucket

is empty, stop the engine and

refill the bucket with an antifreeze solution slightly stronger than needed for

winter freeze protection

in

your area.

Start the engine and allow all of this mixture to be drawn through the sea water system. Once the bucket

is
empty, stop the engine. This antifreeze mixture should protect the sea water circuit from freezing during the
winter

lay-up, as well as providing corrosion protection.

Remove the

impeller from your sea water pump (some antifreeze mixture will accompany

IT,

so catch

it

in

a

bucket). Examine the

impeller. Acquire a replacement, if needed, and a cover gasket. Do not replace the
impeller (into the pump) until recommissioning, but replace the cover and gasket. See the "Cylinder Lubrica­tion" section

below.

Intake

Manifold and

Through-Hull

Exhaust

Place a clean cloth, lightly soaked in lubricating oil, around the air arrester. Be sure

to

remove this cloth

before recommissioning. Make a note

to

remove the cloth prior

to

start-up. The through-hull exhaust port

can be

blocked in the same manner.

Starter

Motor

Lubrication and cleaning

of

the starter drive pinion is advisable, if access

to

the starter permits its easy

removal. Make sure the battery connections are shut off before attempting

to

remove the starter. Take care

in

properly replacing any electrical connections removed from the starter.

Cylinder

Lubrication

Fogging the engine should be done as the last of the antifreeze mixture

is

drawn into the sea water circuit.

Remove the air intake screen (the air filter) and spray

Marvel Mystery Oil

or

another commercially available

fogging oil into the carburetor while the engine is running. Spray enough oil

to

stall the engine. This will

coat the

walls

of

the cylinders, pistons, and valve surfaces with this protective oil. Remove the spark plugs

and spray a small amount of this oil into each spark plug hole and turn the engine over

two

or

three com-

plete revolutions

by

hand. Reinstall, but

do

not tighten, the spark plugs, as these will need

to

be

cleaned

and gapped prior

to

recommissioning. Close off the carburetor's air filter with an oily rag.

Spares

Lay-up time provides a good opportunity to inspect the equipment

to

see if external items such as drive belts

or

coolant hoses need replacement. Check your basic spares kit and order

ITems

not on hand,

or

replace

those

ITems

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

to

the "SPARE PARTS" section

of

this manual, page

83.

81

Westerbeke Generators

Batteries

If batteries are

to

be

left on board during the lay-up period, make sure they are fully charged, and will remain

that way,

to

prevent them from freezing. If there exists any

doubt

that the batteries will not remain fully

charged,

or

that they will be subjected to severe environmental conditions, remove the batteries and store

them in a warmer, more compatible environment.

Recommissioning

The recommissioning of your Westerbeke unit after a seasonal lay-up generally follows the same proce-

dures as those presented in the "PREPARATIONS

FOR

STARTING" section, page

33,

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 sea water

pump

cover and gasket. Discard the gasket. Install the sea water pump impeller
removed during lay-up (or a replacement, if required). Install the sea water pump cover with a new cover
gasket.

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited

by

electrical

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 ar-

cing during servicing.

3.

Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making

sure the terminals are clean and that the connections are tight. Check

to

make sure the batteries are fully-

charged.

4.

Check the condition

of

the zinc anode

in

the sea water circuit and clean

or

replace the anode as needed.

Note that it is not necessary to flush the antifreeze/fresh water solution from the sea water coolant

sys-

tem. When the

unIT

is

put into operation, the system will self-flush in a short period

of

time

WITh

no

ad-

verse affects.

5.

Start the

unIT

in accordance with those procedures found in the "STARTING PROCEDURES" section

of

this manual, page

34.

Westerbeke

Generators

82

SPARE PARTS LIST

Since

a possibility exists in which the engine may need

to

be serviced at sea or while in a port other than

your home port, certain spare parts should be kept on board

to

help minimize delays in your voyage. Please

refer

to

your engine's Parts List

for

part numbers when ordering spare parts.

Listed below are those spare parts that should be carried on board at

all times.

1.

An Impeller Kit

2.

An Electric Fuel Lift Pump Filter and a Secondary Fuel Filter.

3.

One Sea Water Pump Belt and One Fresh water Pump Belt

4.

Hose Clamps

5.

A Spare Oil Filter with a Spare Quart of Engine Oil and a Gallon

of

Premixed Antifreeze

6.

Spark Plugs, Ignition Wires, and a Distributor Cap

7.

Fuses

Other parts, whose life expectancy cannot be accurately predetermined, should be carried on board (in ad-

dition

to

those listed above) especially if the vessel

is

to

be taken on long ocean voyages. These parts are

listed below.

1.

Cooling System Hoses

5.

A Starter

6.

A 20

Amp

DC Circuit Breaker

7.

An Electric Fuel Lift Pump

8.

A Sea Water Pump

9.

Battery Terminal Connectors

The spare parts listed directly above are those we

recommend be carried on board during

long

ocean

voyages.

You

may

wish

to

ask

other

boat

owners

who

have

similar

crafts

and

who

have

completed

long

ocean voyages as

to

what spare parts they carried on board and what parts were needed at specific times

of

the voyage. From the list provided directly above and from these inquiries, you can determine what spare

parts may be needed.

In addition, if

you

are planning a long ocean voyage, consult your local Westerbeke

dealer for a listing

of

the Westerbeke dealers located on your route.

83

Westerbeke

Generators

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES

Unless stated otherwise

for

a specific assembly, use the following torque values when tightening standard

hardware,

Pitch

Ib-ft

kg-m

Grade

<II

6mm

bolt head/nut 1

2,9 -

5,1

0.4 - 0,7

8mm bolt head/nut 1,25

7,2

- 11,6

1.0

- 1,6

10mm

bolt head/nut

1.25

13,7

- 22.4

1,9 -

3,1

10mm bolt head/nut

1.5

13,0-

21,7

1,8

- 3,0

12mm bolt head/nut

1,25 (ISO) 25,3 - 39,8

3,5

- 5,5

12mm bolt head/nut

1,5

25,3

- 39,8

3,5

- 5,5

12mm bolt head/nut 1,75

21,7

- 36,2

3,0

- 5,0

13mm bolt head/nut

1,5

32,5

- 50,6

4,5

- 7,0

14mm bolt head/nut

1.5

36,2

- 57,9

5,0

- 8,0

14mm bolt head/nut

2

34,0 - 55,7

4,7

- 7,7

16mm bolt head/nut 1,5

54,2

- 79,6

7,5

-11,0

16mm bolt head/nut

2

51.4 -

76,7

7,1

-10,6

Grade

61

6mm

bolt head/nut 1

4,3 - 6,5

0,6

- 0,9

8mm bolt head/nut

1.25 10,8 - 15,9

1.5

- 2,2

10mm

bolt head/nut

1,25

21.7

- 32,5

3,0

- 4,5

10mm

bolt head/nut

1.5

19,5

- 30.4

2,7

- 4,2

12mm bolt head/nut

1.25 (ISO)

36,2

- 57,9

5,0

- 8,0

12mm bolt head/nut

1.5

36,2

- 50,6

5,0

- 7,0

12mm bolt head/nut 1,75

34,7

- 49,2

4,8

- 6,8

Grade

7T

flT

and

8 8

6mm bolt head/nut

1

5,8 -

8.7

0,8

- 1.2

8mm bolt head/nut 1,25

14,5-

21,7

2,0

- 3,0

10mm

bolt head/nut 1,25

28,9

- 39,8

4,0

- 5,5

10mm

bolt head/nut 1,5

26,8

- 37,6

3,7

- 5,2

12mm bolt head/nut

1,25 (ISO) 54,2 - 75,9

7,5 -10,5

12mm bolt head/nut

1,5

50,6

-

65,1

7,0 - 9,0

12mm bolt head/nut

1.75

43.4 - 61.5

6,0

- 8,5

13mm bolt head/nut 1,5

57,9

- 86,8

8,0 -12,0

14mm bolt head/nut

1,5

72,3 -108,5

10,0 -15,0

14mm bolt head/nut

2

68.7 -101,3

9,5

- 14,0

16mm bolt head/nut 1,5

108.5

- 166.4

15,0 - 23,0

16mm bolt head/nut

2

101,3 -159,1

14,0 - 22,0

Grade 5 QapsQrflW

1/4 UNC

9 -

11

1.2 - 1,5

1/4

UNF

11c

13

1.5 - 1.8

5/16 UNC

18

- 20 2,5 - 2,8

5/16 UNF

21

- 23

2,9 - 3,2

3/8 UNC

28 -

33

3,7 - 4,6

3/8 UNF

30 -

35

4,1

- 4,8

7/16 UNC

44 - 49

6,1

- 6,8

7/16 UNF

50 -

55

6,9 - 7,6

1/2 UNC

68 -

73

9.4-10,1

1/2 UNF

73

-

80

10,1-11.1

Westerbeke

Generators

84

Cylinder head bolts*

BCG 4.0KW
BCG6.5KW

TABLE OF TIGHTENING TORQUES

28.9 - 36.2

36.2 - 43.4

4.0 - 5.0

5.0 - 6.0

(*See the

Torquing

Cylinder

Head

Bolts

section on page 77.)

Crankshaft pulley

to

crankshaft
BCG4.0KW
BCG6.5KW

Rocker cover

to

cylinder block
BCG4.0KW
BCG6.5KW

Spark plug

to

cylinder head
BCG4.0KW
BCG6.5KW

Timing belt cover

to

cylinder head

(All Models)

Timing belt cover

to

cylinder block

(All Models)

Timing belt tensioner

to

cylinder block

BCG4.0KW

BCG6.5KW

Valve adjusting screws

(All Models)

Oil pan drain plug
(All Models)

85

36.2 - 43.4

65.2 - 72.4

5.1

- 9.4

5.8 - 8.7

13.1-17.4

10.8

-15.9

1.4 - 2.9

7.2 - 11.6

7.2-11.6

9.4 -13.0

9.4 -13.0

18.1-25.3

5.0 - 6.0

9.0 - 10.0

0.7 - 1.3

0.8

-1.2

1.8 - 2.4

1.5 - 2.2

0.2 - 0.4

1.0-1.6

1.0 - 1.6

3.0 - 4.5

3.0 - 4.5

2.5 - 3.5

Westerbeke Generators

INDEX

A

Adjustment, Carburetor ...............................................................................................................................

76

Adjustment, No-Load Voltage,

BCG

4.0KW

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

58

Adj ustment, No-Load Voltage,

BCG

6.5KW

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

60

Adjustment,

Valve

Clearance,

BCG

4.0KW

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

78

Adj

ustment,

Valve

Clearance,

BCG

6.5KW

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

78

Adjustments, Governor ................................................................................................................................

74

ADJU

STMENTS,

MAl

NTENANCE

AND

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

70

Anode Conditions, Zinc ...............................................................................................................................

51

ANTI

FREEZE

CONCENTRATION

DATA

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

.49

Automatic Shutdown

(I

nstallation Checks) ................................................................................................

28

B

Back-Pressure, Exhaust (Installation

Checks)

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

22

Batteries (Installation Checks) .....................................................................................................................

29

Battery Charging Circutt, Testing the ..........................................................................................................

42

Battery Specification ...................................................................................................................................

.41

BC

GEN

ERA

TOR

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

57

Belt Tension .................................................................................................................................................

52

Bolts,

Torquing

Cyl

inder

Head

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

77

Break-I

n Precautions ...................................................................................................................................

36

C

CAUTIONS

ENGINE SHIPPED WITHOUT OIL .........................................................................................

18

LI

FTING

TH

E GENERATOR ..................................................................................................

19

PROLONGED CRANKING INTERVALS ......................................................... , ...................... 23

EXHAUST ELBOW CLAMP

TORQU

E ................................................................................... 24

GAS

OLIN E LEAKAG E .......................................................................................................... , 26

HULL

FITTINGS

""""'"''

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

""""""""""""""'"

.................... , 28

OVERCHARG I

NG

CON

DlTlONS .......................................................................................... ,

28

STARTING

THE

GENERATOR

WITH

AC

LOADS

OFF

.......................................................... 34

PROLONG

ED

CRANKI

NG

INTERVALS

""""""""""""""''''''''''

......................................... , 34

CHARGING

CI

RCUIT

'"''

.................................................. , ............................................ , .......

41

QUICK-CHARG I

NG

TH

E SA

TTERY

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

41

EXCESSIVE

BELT

TEtJSIOtJ

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

52

GENERATOR AND

SHORE

POWER

CONNECTIONS .......................................................... 63

REMOVI

NG

SPARK

PLUGS

.................................................................................................. 79

LEAVING

OLD

OIL

IN

THE

SUMP

OVER

THE

LAY-UP

PERIOD

........................................... 80

Carburetor Adjustment ................................................................................................................................

76

CARBU

RETOR

AND

FUEL

SySTEM

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

38

CARE

OF

THE

GENERATOR,

GENERAL

INFORMATION

AND

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

64

Charging Circuit, Testing the Battery .........................................................................................................

.42

Westerbeke Generators

86

Choke, Electric ............................................................................................................................................ 73

Connecting Pressure Sensing Devices

to

Oil Galleries (Installation Checks) .......................................... 27

Connections,

DC Electrical (Installation Checks) ...................................................................................... 28

Connections, Load ...................................................................................................................................... 62

Connections,

Shore Power ......................................................................................................................... 63

CONTENTS, TABLE

OF

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

CONTROL CIRCUIT WIRING DIAGRAM #37190, DC ................................................................... 44 and 45

CONTROL PANEL, DESCRIPTION

OF

ENGINE .......................................................................................

31

Cooling System (Installation Checks) ........................................................................................................ 27

COOLING SySTEM ..................................................................................................................................... 48

Cylinder Head

Bolts, Torquing ................................................................................................................... 77

D

DC CONTROL CIRCUIT WIRING DIAGRAM #37190 .................................................................... 44 and 45

DESCRIPTION

OF

ENGINE CONTROL PANEL ........................................................................................

31

DISCLAIMER, IMPORTANT PRODUCT SOFTWARE .................................................................................. 1

Drain Hose,

Oil (Installation Checks) ......................................................................................................... 27

E

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

73

Electrical Connections, DC (Installation Checks) ...................................................................................... 28

Electrical System (Installation Checks) ...................................................................................................... 28

Electric Motors, Use

of

................................................................................................................................ 64

ELECTRICAL SySTEM ................................................................................................. ,

.. , .. , .. , ..

""""""""",41

Elements, Replacing Filter,

.. , ..

""""

..

",

.. , ..

"",

..

,."",

.. , .. , .. , .. , .. , .. , .. , .. , .. , ..

"."

.. , .. , .. , ..

",

.. , .. , .. , .. , ..

"".,.,

..

".""

..

",

39

Engine 12-

Volt DC Control Circuit ..............................................................................................................

41

ENGINE CONTROL PANEL, DESCRIPTION OF .......................................................................................

31

Engine Oil ,

..

, ....

"",.,

..

,"",

..

,",

.. , .. , ..

,"',

..

,.,

.. , ... , .. , .. , .. , ..

".,,.,

.. , .. , .. , ..

,,',

..

,""",

.. , .. , .. , ..

,""""",

..

,",

.. , ..

,""""',

..

,'"

54

Engine Oil Change (to include filter) ..................................................................... , .......... ,

..

, ..................... , 55

Engine

Oil Viscosity (SAE Number)

.. , ..

,",

..

,""",

.. , .. , ..

".,

.. , .. , .. , ..

".,

..

,",

.. , .. , .. , ..

,'

..

,',

.. , .. , .. , .. , .. , ..

,""",

..

".,

..

,'"

54

ENG

I NE TROUBLESHOOTING",

.. " .. , ..

,."",

.. , ..

"."",

.. , .. , .. , .. , .. , .. , ..

""",

.. , ..

".,

.. , ..

".,

.. , .. , .. , .. , .. , ..

,.,.".,

.. , ..

""",

66

Equipment,

I nspection

of",

.. , .. , .. " ..

""

..

""

.. , .. , .. , ... , ..

" .... ".,

.. , ..

""

..

".,

.. , ..

"",

..

""

.. , .. , ..

,.,

.. , ..

".".,

..

,.,

.. , ..

,."."." 18

Exhaust Back-Pressure

(I

nstallation Checks).,

..

"",

.. , .. , ..

""

.. , .. , .. , ..

""",

..

"",.".,

.. , .. , .. , ..

""

.. , ..

",.,

.. , .. , ..

""",.

22

Exhaust Elbow I nstallation

(I

nstallation Checks) ...................................................................................... , 24

Exhaust

System

(I

nstallation Checks)",

.. " .. , ..

"",

.. , .. , .. , .. , ..

""

.. , ..

""

.. , .. , ..

"",."""".,

.. , ..

""

.. , ..

",

..

,.".,

.. , ..

"".,

21

Exhaust System Failures

(I

nstallation

Checks).""""

..

""",."""""""."

.. , .. , .. , .. , ..

".,

..

",

..

"""".",

.. , ..

"".,

..

,."

23

F

Failures, Exhaust System

(I

nstallation Checks),

.. , ..

""",

..

""

.. , ..

""""",

.. , ..

""

..

""

..

"""

..

"""""""""""""",

23

Filter Elements, Replacing, .... "

..

"."

.. , .. , .. , .. " .. , .. , .. , .. " ..

"""

..

""""

.. , .. , .. , ..

""",

.. , .. , ..

"""

..

"""""

..

""""

..

"."."

39

FORWARD

.. , ..

"" .... ,

..

,.,

.. , .. , .. , .. , .. " .. , .. , .. , ..

"",

.. , .. " .. , .. , .. , ..

,""'

..

"",

.. ' .. , .. " .. , .. , .. , .. , .. , ..

,',

.. , .. , .. , .. , ..

,',

..

,',

.. , ..

,.""",,2

Fresh Water Circuit., .... ,

.. , ..

""

.. " ..

"",

.. , .. , .. " ..

""

.. , ..

".,

.. , .. , ..

""

.. , .. , .. , .. , ... , .. , .. , .. , .. , .. , ..

,.,

.. , .. , ..

".,

..

,.,

..

",

.. , ..

"""

48

Frequency, Generator ....

" .... "

.. , .. " .. , ..

""

.. " .. , .. , .. , .. , .. , ..

".,

.. , .. , .. , .. " .. , .. , ..

"",."."",

..

",

.. , ..

""

..

""""

..

"""",

..

"., 57

Fuel Filter, Optional,.,

.. , .. , .. , .. , ..

"",

.. " ..

""."

.. , .. , .. , ..

""

..

"""".,

.. , .. " .. , .. , ..

"",

..

""

..

""

..

",

.. , .. , ..

""""",

.. , ..

",

..

"." 39

Fuel System

(I

nstallatlon Checks) "

..

,",

.. , .. , ..

',.',

.. , .. , .. , ..

,",

..

,."

.. , .. , ..

,,",

.. , .. , ..

,""',

.. , ..

,"",

..

,",

..

,",.,',

.. , ..

,",.,

..

25

FUEL SYSTEM, CARBURETOR

AND"""",

.. , .. , ..

""

..

, ..... ,

.. , .. , ..

"."."

.. , ..

""""",""""

..

"""

...

"".",

..

",

..

"""

..

,38

87

Weslerbeke

Generators

G

Gasoline ....................................................................................................................................................... 38

GENERAL.. ..................................................................................................................................................... 5

GENERAL

INFORMATION AND CARE OF THE GENERATOR ................................................................. 64

GENERAL

SPECIFICATIONS BCG 4.0KW ................................................................................................. 10

GENERAL SPECIFICATIONS BCG 6.5KW ................................................................................................. 14

Generator (AC

Output) (Installation Checks) ............................................................................................. 29

GENERATOR,

BC ........................................................................................................................................ 57

Generator Frequency .................................................................................................................................. 57

Generator Mounting - Location (Installation Checks) ................................................................................

20

Generator Troubleshooting ......................................................................................................................... 65

Governor Adjustments ................................................................................................................................. 74

Governor and Water Pump Belt Tension .................................................................................................... 52

Governor Maintenance ................................................................................................................................ 75

Grounding (Installation Checks) ................................................................................................................. 28

H

HARDWARE TIGHTENING TORQUES, TABLE OF STANDARD ............................................................... 84

Head Bolts, Torquing Cylinder .................................................................................................................... 77

Hose,

Oil Drain (Installation Checks) .......................................................................................................... 27

Ignition Timing ............................................................................................................................................. 73

IMPORTANT PRODUCT SOFTWARE DISCLAIMER .................................................................................... 1

INDEX ........................................................................................................................................................... 86

Inspection

of

Equipment ............................................................................................................................. 18

INSTALLATION CHECKS ............................................................................................................................ 18

Instrument, Remote, and

Start Panels, Optional ........................................................................................ 32

Intake System, Sea Water (Installation Checks) ......................................................................................... 27

L

LAY-UP AND RECOMMiSSiONING ............................................................................................................

80

Lifting and Rigging (Installation Checks) .................................................................................................... 19

Load Connections ........................................................................................................................................ 62

Location, Generator Mounting (Installation Checks) .................................................................................

20

LUBRICATION SYSTEM

.............................................................................................................................. 54

M

MAINTENANCE AND ADJUSTMENTS ....................................................................................................... 70

Maintenance, Governor ...............................................................................................................................

75

Maintenance, Preventive (Engine) .............................................................................................................. 70

Maintenance, Preventive (Generator) ......................................................................................................... 65

Motors, Use of Electric ................................................................................................................................ 64

Westerbeke

Generators

88

Mounting - Location, Generator (Installation

Checks)

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

20

N

No-Load Voltage Adjustment:

BCG

4.0KW

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

58

No-Load Voltage Adjustment:

BCG

6.5KW

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

60

o

Oil

Change (to include filter), Engine .........................................................................................................

55

Oil

Drain

Hose (Installation

Checks)

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

27

Oil,

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

54

Oil

Galleries, Connecting pressure

Sensing

Devices

to (Installation

Checks)

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

27

011

Pressure

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

54

Oil

Viscosity

(SAE

Number), Engine ..........................................................................................................

54

Operating

Speed,

Required

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

64

Optional

Fuel

Filter ......................................................................................................................................

39

Optional

Remote

Instrument

and

Remote

Start

Panels

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

32

Ordering Parts ............................................................................................................................................... 5

Overspeed Shutdown .................................................................................................................................

35

p

PANEL,

DESCRIPTION

OF

ENGINE

CONTROL

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

31

PARTS

LIST,

SPARE

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

83

Parts,

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

Power Connections,

Shore .........................................................................................................................

63

Precautions, Break-In ..................................................................................................................................

36

PREPARATION

FOR

STARTING

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

33

Pressure,

Exhaust,

Back (Installation

Checks)

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

22

Pressure,

Oil

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

54

Preventive Maintenance

(Engine)

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

70

Preventive Maintenance (Generator) .........................................................................................................

65

Procedure,

Remote

Starting .......................................................................................................................

35

Procedure,

Remote

Stopping .....................................................................................................................

35

PROCEDURE,

STARTING

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

34

PROCEDURE,

STOPPiNG

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

36

PRODUCT

SOFTWARE

DISCLAIMER,

IMPORTANT

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

Pump,

Sea

Water ........................................................................................................................................

51

Fi

Rigging, Lifting

and

(Installation

Checks)

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

19

Remote

Instrument

and

Start

Panels,

Optional .........................................................................................

32

REMOTE

INSTRUMENT

PANEL

WIRING

DIAGRAM

#35698 ...................................................................

47

REMOTE

START

PANEL

WIRING

DIAGRAM

#35706 ...............................................................................

46

Remote

Starting Procedure ........................................................................................................................

35

Remote

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

35

89

Westerbeke Generators

Replacing Filter

Elements

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

39

Requires

Operating

Speed

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

64

S

Sea

Water Circun .........................................................................................................................................

51

Sea

Water Intake System (Installation

Checks)

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

27

Sea

Water Pump ..........................................................................................................................................

51

Shore Power Connections ..........................................................................................................................

63

Shutdown, Automatic (Installation

Checks)

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

28

Shutdown, Overspeed .................................................................................................................................

35

SOFTWARE

DISCLAIMER,

PRODUCT

SOFTWARE

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

SPARE

PARTS

LIST

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

83

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

79

Start

Panels,

Optional

Remote

Instrument

and

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

32

STARTING,

PREPARATION

FOR

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

33

STARTING

PROCEDURE

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

34

Starting Procedure,

Remote

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

35

Starting Under

Cold

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

37

Starting Under Normal Conditions ..............................................................................................................

36

STOPPING

PROCEDURE

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

36

Stopping Procedure,

Remote

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

35

SYSTEM

SPECIFICATIONS

BCG

4.0KW

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

11

SYSTEM

SPECIFICATIONS

BCG

6.5KW

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

15

T

TABLE

OF

CONTENTS

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

TABLE

OF

STANDARD

HARDWARE

TIGHTENING

TORQUES

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

84

TABLE

OF

TIGHTENING

TORQUES

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

85

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

50

Timing, Ignition ............................................................................................................................................

73

Torquing Cylinder

Head

Bolts .....................................................................................................................

77

TROUBLESHOOTING,

ENGINE

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

66

Troubleshooting, Generator ........................................................................................................................

65

u

Understanding the Gasoline Engine-Driven Generator ................................................................................ 5

Use

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

64

v

Valve

Clearance Adjustment:

BCG

4.0KW

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

78

Valve

Clearance Adjustment:

BCG

6.5KW

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

78

Ventilation (Installation

Checks)

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

30

Viscosity,

(SAE

Number), Engine

Oil

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

54

Voltage Adjustment, No-Load,

BCG

4.0KW

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

58

Westerbeke Generators

90

Voltage Adjustment, No-Load,

BCG

6.5KW

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

60

W

iWARNINGsl

CARBON MONOXIDE GAS ...................................................................................................

21

SMOKING NEAR

BATIERIES

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

29

SERVICING

BA

TIERIES

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

29

INSTALLING OPTIONAL REMOTE PANELS ......................................................................... 32

CARBON MONOXIDE GAS ................................................................................................... 34

OVERSPEED SHUTDOWM ....................................................................................................

35

SERVICING FUEL SySTEM ...................................................................................................

40

ADJUSTING BELT TENSiON ................................................................................................. 52

MAKING A NO-LOAD VOLTAGE ADJUSTMENT ...................................................................

58

MAKING A NO-LOAD VOLTAGE ADJUSTMENT ...................................................................

60

SERVICING ELECTRIC CHOKE ............................................................................................

73

SERVICING

BA

TIERIES

....................................................................................................... 82

WATER

PUMP

BELT

TENSION

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

52

WIRING

DIAGRAM

#37190,

DC

CONTROL

CiRCUiT

.................................................................. .44

and

45

WIRING

DIAGRAM

#35706,

OPTIONAL

REMOTE

START

PANEL

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

46

WIRING

DIAGRAM

#35698,

OPTIONAL

REMOTE

INSTRUMENT

PANEL

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

47

z

Zinc Anode Conditions ...............................................................................................................................

51

91

Westerbeke Generators

YOUR NOTES

Westerbeke

Generators

92