Westerbeke 3.8 BCGB - 50Hz Operator'S Manual Download Page 24 | Manualshive

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Summary of Contents for 3.8 BCGB - 50Hz

Page 1: ...Z 3 8 BCGB 50Hz AND 7 0 BCGB 60HZ 5 0 BCGB 50Hz GASOLINE GENERATORS SINGLE PHASE PUBLICATION N0 044200 OCTOBER 2015 2nd REVISION WESTERBEKE CORPORAT ON 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL...

Page 2: ...EDIATELY Ifsymptomspersist 1leekmedicalattention Shut down the unitanddo notrestart until it has been inspectedandrepaired AWARNING DECAL is providedby WESTERBEKE andshouldbe fixed to a bulkheadnearyo...

Page 3: ...Gasoline with an ETHANOL conte nt higher than 10 o E10 is not allowed and may void warranty TM Engines Generators...

Page 4: ...Blank page I MfUVESTERBBKE l EnglneJ a nerators...

Page 5: ...fuel vapors Use a suitable container to c atch all fuel when removing the fuel line fuel filters or other fuel system components Do not operate with the air cleaner silencer or flame arrester screen r...

Page 6: ...he eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engine...

Page 7: ...low all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to in a gasoline engine or generator should begin with a thorough examination of the American Boat and Yacht Council...

Page 8: ...e vessel s waterline under the vessel s various operating conditions install a siphon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper operation Failure to properly...

Page 9: ...37 Circuit Breaker 37 Internal Wiring Schematic 37 No Load Voltage Adjustment 38 Dual Exciter Model 39 Raw Water Pump 17 AC Terminal Board Connections 40 Fuel System 18 Battery Circuit Resistance Val...

Page 10: ...KOURMETER 8 A MP fUSE 20 AMP CIRCUIT BREAKER CI RBURETOR I IR INTAKE LEfT S DE R GHl S DE KEI T EXCKI NGER C q _ _EIClL Engines Generators 2 REMOTE PI NEl CONNECTION CIRCUIT BREI KER GENERATOR BI CKEN...

Page 11: ...the decade D 1990s E 2000s the second character represents the year in the decade and the fourth and fifth number represents the month of manufacture The BCGB Models were produced between 1999 and 200...

Page 12: ...e at the factory during assembly and thorough testing have resulted in a WESTERBEKE generator capable of many thousands of hours of dependable service However the manufacturer cannot control how or wh...

Page 13: ...cations Section of the manual Change the engine oil and filter after the initial 50 hours of break in operation Then follow the oil and filter change intervals as specified in the MAINTENANCE SCHEDULE...

Page 14: ...n This will dis able the remote control panel s preventing attempts to start the generator from their locations However it is always best to disconnect the battery during this time if it is not requir...

Page 15: ...nifold should be topped off and the coolant recovery tank may need to be filled to the MAX level Visually examine the unit Look for loose or missing parts disconnected wires unattached hoses and check...

Page 16: ...mal position EMERGENCY STOPPING Hthe generator does not stop using the START STOP switch remove the 8 amp fuse or disconnect the battery A CAUTION Prolonged cranking Intervals without the engine start...

Page 17: ...TOP switch may then be released to return to its center run mode position Continue holding the ON switch until the engine has sufficient oil pressure then release it to its center position NOTE Should...

Page 18: ...your log engine hours relate to the maintenance schedule Visually inspect the engine for fuel oil or water leaks Check the oil level dipstick Check the coolant level in the coolant recovery tank Chec...

Page 19: ...One is normally open when the engine is in a static state This switch functions in the automatic shutdown circuit when the unit is operating 5 psi rating The second oil pressure switch is installed o...

Page 20: ...p is tight No exhaust leaks around the elbow Inspect wiring and electrical connections Look for loose bolts hardware and correct as needed Clean re gap Initial engine oil and filter change at 50 hours...

Page 21: ...or delaminated Check and tighten all hose clamps as needed Check timing and adjust as needed Inspect clean re gap or replace Check vibration isolators brackets and mounting hardware Replace as needed...

Page 22: ...water coolant is conducted through the tube walls to the raw water which is then pumped into the exh11y_st system where finally it is discharged overboard g COOLANT RECOVERY TANK COOLANT DRAIN In oth...

Page 23: ...Y TANK CHANGING COOLANT The engine s coolant must be changed according to the MAINTENANCE SCHEDULE If the coolant is allowed to become contaminated it can lead to overheating problems A CAUTION Proper...

Page 24: ...is threaded with a wrench while loosening the anode with another wrench This prevents the hex boss from possibly tearing off the exchanger shell After removing the zinc note the condition of it If the...

Page 25: ...he impeller housing producing the pumping action On no account should this pump be run dry There should always be a spare impeller and impeller cover gasket aboard an impeller kit Raw water pump impel...

Page 26: ...EL SHUT OFF SOLENOID FUEL Lin PUMP Periodically check the fuel connections to and out of the pump and make sure that no leakeage is present and that the fittings are tight and secure The DC ground con...

Page 27: ...he air screen flame arrester can easily be removed by releasing the hold down clamp Clean after the first 50 hours of operation every 100 hours from then on Clean the air screen in kerosene carburetor...

Page 28: ...st filling into the engine AWARNING Used engine oil contains hannful contaminants Avoidprolongedskin contact Clean skin andnails thoroughly using soap and water Launder or discard clothing orrags cont...

Page 29: ...ical oil pressure gauge in its place After warming up the engine set the engine speed at 1800 rpm and read the oil pressure gauge Oil Pressure Between 30 and 40 psi at 1800 rpm Note A newly started co...

Page 30: ...ine oil filter and thread on WES1ERBEKE s remote oil filter kit as shown Always install this kit with the oil filter facing down as illustrated Contact your WES1ERBEKE dealer for more information NOTE...

Page 31: ...1 1 R7 0 0 NOTE To by pass the o erspeed Shutdown for test purposes when troubleshooting move the connection T3 over to and __ connect with T5 _ E n giii iniiiiie s G e neliir iiila toiiiirs Do not o...

Page 32: ...RTER SOLEHOI D r f2 IIAIIP Tl OVEISPEED SHUT DOIII _ J2 __ __ i _ l altE jQ IEJlll NOTE To by pass the Overspeed Shutdown for test purposes when troubleshooting move the connection T3 over to and conn...

Page 33: ...ELIRED 14 WHT 14 RED VIO I I I L 1 PIGTAIL ADAPTER KIT N0 045109 This is a 15 pin male plug with 12 wires to use when connecting into the 6 wires of earlier model remote start stop panels with 3 switc...

Page 34: ...surges under load adjust this eye bolt to move the spring away from the leverhub check speed adjustment 3 Bumper Screw Adjustment This screw is used to remove a no load surge ONLY NEVER tum the bumpe...

Page 35: ...d alternator and the other drives the raw water pump The tension adjustment procedure for both belts is as follows 1 Remove the belt guard 2 To adjust the governor drive belt loosen the two governor m...

Page 36: ...EARANCE INTAKE VAlVES 0 20mm 008in EXHAUST VALVES 0 30inm 012in VALVE CLEARANCE 28 IGNITION TIMING 1 Attach a timing light to the 1 spark plug and mark the front timing pointer to indicate 15 Locate t...

Page 37: ...timing mark on the camshaft sprocket and timing belt rear cover NOTE always tum the crankshaft clockwise TIMING MARK 2 Remove the plug on the left surface of the cylinder block and insert a rod with a...

Page 38: ...anvas fiber exposed CRACKS OR PEELING RUBBER 5 EXPOSED __ Do 7 Tensioner Inspection 6 8 ABNORMAL WEAR FLUFFY STRAND TOOTH MISSING AND CANVAS ER EXPOSED 1 Replace the tensioner if the pulley binds ratt...

Page 39: ...hat the moveable range of teeth on the oil pump sprocket is according to specifications Standard value 4to 5teeth In forward direction 1to 2teeth In reverse direction FORWARD REVERSE OIL PUMP SPROCKET...

Page 40: ...that the timing belt teeth are engaged with the camshaft sprocket teeth along the portion of the sprocket shown by the curved arrow in the illustration below Then tighten the tensioner nut 16 22 H lb...

Page 41: ...5 volts AC voltage measurements should be made with a true RMS AC meter to insure measurement accuracy ENGINE GROUNO GROUND AND B CONNECTIONS RELAYS The relays used in the control system have coils wh...

Page 42: ...engine compression NOTE The engines control system electrical system is protected by a 20 Ampere manual reset circuit breaker located on the control panel PROBLEM PROBABLE CAUSE Engine starts runs 1...

Page 43: ...y 4 Dirty flame arrester Black exhaust smoke 1 Dirty flame arrester 5 Cracked distributor cap 6 Lean mixture discharge from the 2 Faulty carburetor engine 3 Idle mixture jet too rich Engine overheats...

Page 44: ...ot leg for the vessel s distribution panel This will ensure good motor starting response from the generator 36 Generator Frequency Adjustment Frequency is a direct result of engine generator speed as...

Page 45: ...olts or 230 volts two wire at 50 hertz Refer to the SPECIFICATIONS section of this manual for generator ratings The generator s data plate gives the voltage current and frequency rating of the generat...

Page 46: ...discharged before handling as they store electricityand can pack apoten tially lethal charge even when disconnected from their powersource NOTE Simply cross the capacitor s two terminals with an insu...

Page 47: ...crease or decrease approximately 8 10 volts between connectors used in any pair combination to achieve the prescribed no load voltag illustrationed above A WARNING Make certain the Insulating covers o...

Page 48: ...E CAPACITOR AND REP ACE WITH THE SAME RATING 7 0BC ROTOR CHARGER STATOR EXCITER WINDING RESISTANCE VALUES OHMS 4 0 0 1 0 4 2 2 4 5BC ROTOR CHARGE STATOR EXCITER Engines Generators 40 GENERATOR INTERNA...

Page 49: ...itor meter test the capacitor following the instructions included with the meter and compare the results with the value shown on the capacitor When a capacitor meter is not available perform the follo...

Page 50: ...hing the shaft no continuity should exist If continu ity is found a short exists Repeat this same check on the second group of windings Rotate the engine s crankshaft 180 to position the sec ond diode...

Page 51: ...our voltmeter for proper charging during engine operation Check the electrolyte level and specific gravity with a hydrometer Use only distilled water to bring electrolytes to a proper level Make certa...

Page 52: ...n is now handled internally Whenever replacing an early controller with the newerfour wire model remove the ballast resistor and its wiring NO ADJUSTMENTI FACTORY SET BLACK 0 Normal AC voltage running...

Page 53: ...gister an arbitrary Ohmvalue at each point it touches D Leaving the negative lead on point 4 touch point 5 with the positive lead The meter should register no Ohm value E Place the positive lead on po...

Page 54: ...Transfer Switch Set the transfer switch shown in the diagrams to the OFF position This switch prevents simultaneous connection of shore power to generator output A CAUTION Damage to the generator can...

Page 55: ...fuel conditioner such as MARINESTABIL stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up a...

Page 56: ...with an anti corrosion coating Check that the transmission vent is open Spare Parts Lay up time provides a good opportunity to inspect your WESTERBEKE engine to see if external items such as drive be...

Page 57: ...ation must be provided to maintain the generator s compartment temperature below 122 F 50 C General Fresh Water Pump Raw Water Pump Raw Water Row Rate Operating Temperature CooHng Water Capacity Fresh...

Page 58: ...8 9 395 536 440 597 605 820 14 435 590 675 915 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546...

Page 59: ...and Connecting Rod Camshaft thrust plate bolt 10 12 7 9 Connecting rod cap nut 15 900turn 11 900turn Rocker arm adjust nut 8 10 6 7 Crankshaft Bearing Cylinder Head Valve Oil seal case bolts 1D 12 7...

Page 60: ...361 6 6 56168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR...

Page 61: ...RTS KIT WESTERBEKE offers two Spare Parts Kits each packaged in a rugged hinged toolbox Iqt A includes the basic spares Kit B is for more extensive off shore cruising KIT A Impeller Kit Heat Exchanger...

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Page 64: ...Engines Generators 1219 2015...

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