Westerbeke 4.5 KW BGC -60Hz 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'ERBEK

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

Fresh Water Coolant Fill Model Data Lube Oil Dir>stick 20 Amp DC Circuit Starter with Solenoid Westerbeke Generators BeG S.5KW Marine Gasoline Gene

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 wi

BCG 4.0KW MARINE GASOLINE GENERATOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Piston Displacement Firing Or

INTAKE SYSTEM Carburetor (STD type) IGNITION SYSTEM General Distributor Spark Plug Thread Size Spark Plug Type FUEL SYSTEM General Fuel Lift Pump Fuel

BeG II.OKW SYSTEM SPECIFICATIONS Sea Water Flow, at 1800 rpm (measured before discharging into exhaust elbow) System Capacity (fresh water) LUBRICATIO

BeG 4.0KW SYSTEM SPECIFICATIONS AC GENERATOR General Voltage Rating (Volts AC) 60 Hertz (1800 rpm) 50 Hertz (1500 rpm) AC Circuit Breaker Generator Co

BCG S.!iKW MARINE GASOLINE GENERATOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Piston Displacement Firing O

BCG 6.5KW SYSTEM SPECIFICATIONS INTAKE SYSTEM Carburetor (STD type) IGNITION SYSTEM General Distributor Spark Plug Thread Size Spark Plug Type FUEL SY

BCG 6.SKW SYSTEM SPECIFICATIONS Sea Water Flow, at 1800 rpm (measured before discharging into exhaust elbow) System Capacity (fresh water) LUBRICATION

Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty.Engines & Generators

BCG S.5KW SYSTEM SPECIFICATIONS AC GENERATOR General Voltage Rating (Volts AC) 60 Hertz (1800 rpm) 50 Hertz (1500 rpm) AC Circuit Breaker Generator Co

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

Rigging and Lifting The generator is fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight should be attac

Generator Mounting -Location The complete generator unit is mounted on lightweight rails by means of four flexible isolator mounts that help preventth

Exhaust System IIWARNINGI CARBON MONOXIDE EXHAUST GAS IS DEADLY. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially

Exhaust Back-Pressure The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust back-pressure. Exhaust back-p

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 connecto

Exhaust Elbow Installation The Westerbeke Corporation offers a 45°and 900exhaust elbow as well as an exhaust riser you can install on your generator.

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.

.~ AMTI-SIPHON DEVICE OR ELECTRICALLY ~ OPERATED FUEL STOP VALVE -----~~~)"""";-:::";-:::::~/~-7::~~~F~U~E~L~TA~N~K~T:o:p ~L~

-----------------------------------"'''--~"-------------~, SAFETY PRECAUTIONS The following symbols appear in this manual to

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 d

CAUTION DO NOT use a scoop-type through-hull fitting as a means of supplying sea water to the gen-erator. Water pressure against this type fitting, w

High Water Temperature Shutdown Switch (normally closed) A high water temperature switch is located on the thermostat housing. This switch will open

Ventilation The ventilation requirements of the generator sets include the following: combustion air is required for the engine cylinders; cooling ai

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 pan

Optionsl Remote instrumenlllnd Remote Start Panels An optional remole instrument panel is available, which includes starting controls. This panel als

PREPARATIONS FOR STARTING This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and

STARTING PROCEDURE IWARNINGI CARBON MONOXIDE EXHAUST GAS IS DEADLY 1. Ventilate the generator compartment for a minimum of 5 minutes prior to starting

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

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 t

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and worksho

Starting Under Cold Conditions Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below when opera

CARBURETOR AND FUEL SYSTEM Gasoline Use unleaded or leaded gasoline with an octane rating of 89 or better. In cold weather particularly, water vapor i

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

The engine-mounted electric lift pump contains the second fuel filter screen. This pump supplies fuel to the engine's carburetor during e

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

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 ohmmet

through the diodes located internally at these points. D. With the (-) negative lead still connected to point #4, touch point #5. The needle should no

DC CONTROL CIRCUIT WIRING DIAGRAM #35439 L - -4:0KV,--:-BC =--COIL CONNECTIONS 6,~KW Be -THRLJ 6186 [XHAUS T TEMP. SWITCH I Page 1 of 2 lJ-++-t--t--+-

DC CONTROL CIRCUIT WIRING DIAGRAM #35439 Page 2 of 2 SCHEMATIC DIAGRAM '+ 12VDC BATTERY BATTHW RETURN e ~u .. r .1.01. SHRT(R r I .., '.&qu

OPTIONAL REMOTE START PANEL WIRING DIAGRAM # 35706 OPTIONRl REMOTE START PANEL (REAR VIEW} PART' 33183 r---------------------, I 116 RED I I I I

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 c

:!:l ~ !Il. ~ til ~ Cl til :l ~ o iil 9K\1 8T SEE 0\1(,.30397 TO T81-2 TO T63-2 TO T82-1 TC Ttol2·2 TOT83-5 TO T81-1 TO HI3-j REMOTE INSTHUf\lENT PANE

COOLING SYSTEM Description Westerbeke marine gasoline engines are designed and equipped for fresh water cooling. Heat produced in the engine by combu

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)

FUNCTION OF MANIFOLD PRESSURE CAP From Coolant Tank to Coolant Yank COOLANT EXPANSION Coolant from the engine, when heated during the engine's o

Sea Waler Circuil The sea water flow is created by a belt-driven, positive displacement, neoprene impeller pump. The pump draws sea water dire

Governor and Water Pump Bell Tension iWARNINGI Never attempt to adjust the drive belt's tension whOa the engine is in operation. CAUTION Excessiv

Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow through their independent cooling c

LUBRICATION SYSTEM Engine Oil For the engine's lubrication, use a lubricating oil designated for gasoline service. Use a good grade of oil havin

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 engi

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

TABLE OF CONTENTS Section ... Page GENERAL ...

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

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 t

<:> '" C YO THE 11 PLUG IS SHOWN CONNECTED TO THE CAPACITOR ONLY FOR DEMON-STRATION PURPOSES. BeG 4.0KW GENERATOR H. Capacitor ::::,~-

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 t

"'" • w -' N ... ~ ~ :: '" e '" "' THE 17 PLUG IS SHOWN CONNECTED TO THE CAPACITOR ONLY FOR DEMON-ST

Load Connections The generator's data plate gives the voltage, current and frequency rating of the generator. An AC wiring decal is affixed to t

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

GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electric motor is considerably more than is requir

4-Pole Generator Voltage Load Speed Frequency 120V (110) 240V (220) Applied (rpm) (Hertz) Plants Plants None 1830 62 122 240 (1530) (52)

ENGINE TROUBLESHOOTING Introduction The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the probable c

TABLE OF CONTENTS (CONTINUED) LAY-UP & RECOMMISSIONING ... 80 SPARE PARTS LIST ...

Trouble Engine starts, runs and then shuts down. Back firing through carburetor. Engine overheats. 67 Possible Cause 1. Faulty automatic shutdown swit

Trouble Engine hunts. Engine misfires. High oil pressure. Low oil pressure. Westerbeke Generators 68 Possible Cause 1. Throttle linkage is binding. 2.

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

MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/

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 req

Preventive Maintenance (Generator) Maintenance on the generator end is minimal: 1. Keep the generator clean, dry, and well-ventilated. 2. Ensure that

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 fr

Governor Adjustments Operate the generator set to bring the unit up to ITS operating temperature before attempting an adjustment. NOTE: If the govern

Governor Maintenance 1. Periodically lubricate the attaching points at both ends of the governor arm. Use a graphite lubricant or an equivalent. NOTE

Carburetor Adjustment 1. Idle Mixture Jet Disconnect the throttle linkage arm from the governor control arm and reduce the engine's speed with t

GENERAL Introduction This manual contains the equipment operating procedures as well as additional information needed to help the operator keep the ma

Torquing Cylinder Head Bolts Tighten the cylinder head bolts according to the sequence shown in the illustration below. Make sure the engine is cold

Valve Clearance Adjustment: BCG 4.0KW NOTE: Retorque the cylinder head bolts before adjusting the engine's valves. 1. Remove the rocker cover a

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.

LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during th

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 bu

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 f

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 s

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standar

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

INDEX A Adjustment, Carburetor ...

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

Choke, Electric ...

G Gasoline ...

Mounting - Location, Generator (Installation Checks) ... 20 N No-Load Volt

Replacing Filter Elements ...

Voltage Adjustment, No-Load, BCG 6.5KW ....... 60 W iWARNINGsl

YOUR NOTES Westerbeke Generators 92