Westerbeke 3.0BCG Operator'S Manual Download

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Summary of Contents for 3.0BCG

Page 1: ...sh Waterand Ra w Water Cooled Models Fresh Water Cooled Model PUBLICATION NO 48009 REVISION 7 APRIL2018 J WESTERBEKE WESTERB KE CORPORATION MYLES STANDISH INDUSTRIAL PARK JI 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7310 U S A f Td 4 JMember National lltlarinc ManufacturersAssociati m ...

Page 2: ...ess Nausea Headache Throbbing in Temples Muscular Twitching Vomiting Weakness andSleepiness Inability to Think Coherently IF YOU OR ANYONEELSEEXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIRIMMEDIATELY Ifsymptoms persist seek medicalattention Shut down the unit and do notrestart until Ithas been inspected andrepaired This WARNING DECAL Is providedby WES fERBEKEandshouldbe fixed to a bulkhead...

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

Page 4: ...page ...

Page 5: ...olant PREVENT BURNS FIRE IA WAlllllNG FlmIBll artlmllll Prevent Bash fires Do not smoke or pennitflames or sparks to occur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate with the air cleaner silencer removeid Backfire can cause s...

Page 6: ...r Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is a deadly gas Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Pay close attention to the manifo...

Page 7: ...otes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasoline engine or generator should begin with a thorough examination of the American Boat and Yacht Council s ABYC standards These standards are from a combination of sources including the USCG and the NFPA...

Page 8: ... 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 maintain a siphon break can result in catastrophic engine damage Consult the siphon break manufacturerfor proper maintenance EXHAUST SYSTEM The exhaust system s hose MUST be ce1tified for marine use Conugated ...

Page 9: ...er 16 Changing the Impeller 16 Cooling System Fresh Water Cooled Modelst 17 Raw Water Pumps Overhaul 18 Re Assembly 19 Cooling System 20 Thermostat 21 Heat Exchanger 21 Carburetor 22 DC Circuit Battery 23 Shore Power Transfer Switch 23 Electronic Governor 24 Engine Adjustments 25 Adjusting the Drive Belt 25 Oil Pressure 25 Engine Compression Test 26 Water Pump Belt 26 Ignition Timing 26 Spark Plug...

Page 10: ...ERATOR PARTS 10 ENTIFICATION IGNITION CONTROL MODULE 1_DA FU J GROUNDk fRAP AC CIRCUIT BREAKER ENGINE SERIAL _Nl IJA ER RIGHT SIDE Engines Generators 2 LEFT SIDE ACTUATOR COOLANT TEMPERATURE SWITCH CO LANT PRESSURE CAP SERVICE SIDE DRIP PAN ...

Page 11: ...ENTIFICATION IGNITION COIL ENGINE SERIAL NUMBER MAGNETIC PICK UP SERVICE SIDE DRIP PAN FRESHWATER COOLANT MODEL 10AFUSE ENGINE SERIAL HOUR METER NUMBER t _ GENERATOR IPHONBREAK CONNECTION COOLANT PUMP ACTUATOR LEFT SIDE ARBURETOR Engin t Generators 3 WATER INJECTED EXHAUST ELBOW ZINC ANODE SERVICE SIDE RAW WATER PUMP ...

Page 12: ...thin WESTERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WAR RANTIES OR REPRESENTATIONS WITH RESPECT THERETO INCLUDING ACCURACY TIMEUNESS OR COMPLETENESS THEREOF AND WILL IN NO EVENT BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF THE FURNISHING OR USE OF SUCH SOFTWARE WESTERBEKE customers should keep in mind the t...

Page 13: ...nnot control how or where the generator is installed in the vessel or the manner in which the unit is operated and serviced in the field This is up to the buyer owner operator NOTE Seven important steps to ensure long generator life Proper engine andgenerator installation An efficient well designed exhaust system that includes an anti siphon breakto prevent waterfrom entering the engine Chang ng t...

Page 14: ...ill allow adequate space on all sides for ventilation and servic ing Locate the generator away from living quarters and away from bilge splash and vapors Referto WESTERBEKE S installation manual for detailed information on iflStalling aMarine Generatorin aboat 314n PLYWOOD BOLTED FIBERGLASSED IN PLACE BATTERY ATTACHMENTS TO STARTER MOTOR REFER TO THE WIRING DIAGRAM IN THIS MANUAL NEGATIVE LEAD USE...

Page 15: ... water flow after the engine is shutdown This flow if not stopped will fill the exhaust system a d possibly the engine as well The raw water supply hose must be looped well above the loaded water line to allow the syphon break to function during all attitudes of vessel operation to prevent syphoning when the generator is not operating er RAW WATER DRAIN HEAT EXCHANGER When the generators location ...

Page 16: ...ynthetic oil NOTE Be very careful not to overfill the oil sump Overfilling oft ie oil sump will result in erratic operation ofthe engine white smokeyloil laden exhaust discharge possible hard starting or no start andfouled sparkplugs Reference Service Bulletin 256 ENGINE COOLANT WESTERBEKE recommends a mixture of50 antifreeze and 50 distilled water Distilled water is free from the chemicals that c...

Page 17: ... to the engine STOPPING To Stop Press the rocker switch to stop and release The engine will shutdown and the LED light will tum off GENERATOR OPERATION STAR1 Depress switch to START position START LEO will Iite engine wil I crank RUN LEO will remain on when engine is running STOP Depress switch to STOP posi I ion Engine wi 11 stop RUN LEO wi II turn orr STERBEKE ENOiNE Sn PJST ARTDECAi Abnormal St...

Page 18: ...t Look for loose or missing parts disconnected wires unattached hoses and check threaded connections Search for any gasoline leaks Check the coolant level in bott1 the plastic recovery tank and at the manifold SPIN ON OILFILTER NOTE After the initial running ofthe generator the air in the engine s cooling system will be purged to the coolant recovery tank Open the air bleed petcock to ensure that ...

Page 19: ...eengine down An 20Ain line fuse protects the battery charging circuit If this fuse fails the engine will continue to run but the battery will IJ t be charging 10AFUSE 2DAFUSE BATTERY CHARGING 11 EXHAUST TEMPERATURE SWITCH An exhaust temperature switch located at thebase ofthe exhaust elbow sensors an excessive exhaust temperature an inadequate supply ofcooling water Atemperature above 240 F will s...

Page 20: ...lubricated Over filling the engines sump will result in erratic operation and or smokey white oil laden exhaust hard starting and possibly no start Check for water and dirt in fuel Drain filter if necessary Repla e filter every 250 operating hours or once ayear Fresh unleaded gasoline with an octane rating of 89 or higher Check for fuel oil and water and exhaust leaks Check for rust or corrosion I...

Page 21: ...ators Engine Mounts Zinc Anode Generator Drive Bell IEVERY 500 OPERATING HOURS OR YEARLY R11w Waler Pump IEVERY 500 OPERATING HOURS OR EVERY TWO YEARS Coolant System Valve Clearances Starter Motor Dlverter Valve Check vibration isolators brackets and mounting brackets Remove and replace zinc anode Open heat exchanger and cap s and clean out debris Replace gasket and 0 rings if needed Measure sprin...

Page 22: ...E THIS SURFACE CLEAN BEFORE INSTALLING FILTER CHANGING THE Oil FILTER OIL FILTER ASSEMBLY OIL PRESSURE SWITCH OIL FILTER WRENCH When removing the used oil filter you may find it helpful to punch a hole in the upper and lower portion of the old filter to drain the oil into a container before removing it This helps to lessen spillage An automotive filter wrench should be helpful in removing the old ...

Page 23: ...ces offire near the fuel system when servicing Ensur proper ventilation exists when servicing the fuel system FUEL PUMP Periodicallyche Ck the fuel connections to and out ofthe pump and make sure that nQ leakage is present and that the fittings are tight and secure The engine mounted fuel pump is maintenance free A WARNING Fuel leakage at the fuel pump orits connections Is afire hazardandshouldbe ...

Page 24: ...gas discharge pressure An internal engine thermostat controls the water temperature This thermostat is maintenance free CHANGING THE RAW WATER PUMP 1 Close the raw water intake valve to prevent water from syphoning from the pump 2 Remove the pump cover Note the direction the blades are turned when installing the new impeller bend the blades in the same direction 3 Using pliers grasp the hub of the...

Page 25: ...irection the impeller blades are working in so as to install the replacement impeller with blades working in the same direction 2 Using pliers grab the impeller hub and withdraw the impeller from the pump Inspect the inside of the pump the cam the inner wear plate and the inside surface of the cover plate for wear Replace any worn components 3 Wipe the inside surface of the pump dry Apply a film o...

Page 26: ...l the replacement impeller with blades working in the same direction 2 Remove the impeller using a pair of pliers grasping the hub and pulling it out of t11e pump with a twisting motion 3 Remove the screw and sealing washer that hold the cam in place Remove the cam and inner wear plate behind it 4 Remove the brass circlip A and brass plate found behind the wear plate 5 Remove the dust pla te and c...

Page 27: ... seat and slide it over the shaft white ceramic facing out and seat it in the body of the pump Place some glycerin on the inner area and with a twisting motion slide it over the shaft until the ceramic of the spring seal touches the white ceramic face 7 Install the brass plate and circlip A 8 Install the wear plate locking it in position on the dowel pin Dual Pumps The wearplate is assembled above...

Page 28: ... the engines coolant during engine operation with out introducing air into the system This recovery tank is provided with fresh water cooled models and with the fresh water coolant conversion kit and must be installed before operating the engine NOTE This tank with its short run ofplastic hose is best located at or above the level ofthe engine s manifold NOTE Periodically check the condition ofthe...

Page 29: ...an and test the heat exchanger NOTE Operating in silty and pr tropical waters may require that a heat exchanger cleaning be perfonned more often than every 1000 hours EXHAUST a 1 COOLANT DRAIN H RAW WATER DRAIN CLEAN OUT DEBRIS O RING AND GASKET ZINC ANODE A zinc anode or pencil is located in the raw water cooling circuit within the heat exchanger The purpose of the zinc anode is to sacrifice itse...

Page 30: ... there is a fuel problem Idle Mixture Jet The idler mixture jet is factory adjusted and plugged De Richening Valve The de richening valve closes off a fuel port that is supplying additional fuel on a cold stmt after start up This is a thennal electric device that slowly moves a needle outward when AC is applied to the device after start up to close this fuel port To check this device with the engi...

Page 31: ... engine running it should indicate 13 14 volts If only battery voltage is indicated check the terminal connections at the battery Battery Maintenance Review the manufacturer s recommendations and then establish a systematic maintenance schedule for your engine s starting batteries and house batteries Check the electrolyte level and specific gravity with a hydrometer Use only distilled water to bri...

Page 32: ...ve all loads and tum off the AC circuit breaker to insure that loads will not be subjected to voltage variations while these adjustment are made Ill Decrease the speed pot to prevent overspeed at start up IB Tum the other adjustment pots to the middle position Start th engix e monitor speed and adjust to the hek rating of the unit by adjusting the SPEEO Pl as needed Verify that the AC voltage outp...

Page 33: ...then returns to the oil sump to repeat the continuous cycle When the oil pressure exceeds the specified prei sure the oil pushes open the relief valve in the oil pump and returns to the oil sump keeping the oil pressure within it s specified range TESTING OIL PRESSURE To test the oil pressure remove the oil switch and install a mechanical oil pressure gauge in it s place it will be necessary to co...

Page 34: ...r valve wear 6 Reinstall the two plugs connect the wires and open the thru hull valve seacock IGNITION TIMING The magneto employs the electric ignition advance system that advances ignition timing with an increase of engine speed While mnning the engine check the ignition tinting with a timing light There are nine 9 markings fDC ATDC 5 and BTDC 5 10 15 20 25 30i0 35 on the flywheel cup Check the t...

Page 35: ...he system The condition ofthe zinc anode should be checked monthly and the anode cleaned or replaceq as required Spare anodes should be carried on board NOTE Refer to the Cooling Syste1it pagesjot Fresh Water Cooled Thennostat and Zinc Anode assemblies THERMOSTAT Raw Water Cooled Models A thermostat controls the coolant temperature as the raw water continuously fiows through the closed cooling cir...

Page 36: ...IDE FEELER GAUGE 5 Adjust the intake and exhaust valve clearance for rYlitider i a Loosen the lock nut INTAKE SIDE b Insert a feeler gauge between the valve end and the adjusting screw c Set the valve clearance by the adjusting screw ALVE CLEARANCE INTAKE 0 13 0 17mm 0 005 0 007in E EXHAUST 0 18 0 22mm 0 007 0 0091n d Tighten the lock nut e Again check the valve clearance 6 Tum the driven gear and...

Page 37: ...embly g Altemafor Bracket 2 Turnthe crru ikshaft aild align O mark on the drive pulley and the O inarkon the cylinder bead 3 Remove the timing belt from the driven pulley side 4 Install the timing belt froni the drive pulley side NOTE Afterinstalling the timing belt when the aligning O ino rk on the drive pulley with O on the cylinder block Please confirm that the 1 O or 2 0 mark on the driven pul...

Page 38: ...l pump 3 Fau ty PC board 4 Improper drive belt tension 5 Low DC battery voltage 6 High exhaust back pressure 7 Dirty fuel filter 8 Generator overload 9 Valves need adjustment The following troubleshooting tables are based upon certain engine problem indicators and the most likely causes of the problems PROBLEM PROBABLE CAUSE Engine misfires 1 Poor quality fuel 2 Faulty ignition control module 3 Di...

Page 39: ...oard shuts down Engine starts but shuts down 1 Control PC Board Will stay running if start switch is kept depressed NOTE MPU voltages to PC board Cranking 1 5 2 0 VAC Running 4 0 5 0 VAC 2200rpm BY PASSING THE OVERSPEED BOARD A faulty Overspeed PC Board can be the cause of an unwanted shutdown It can also be the cause when the engine is started and runs for 10 15 seconds and then shuts down 1 Refe...

Page 40: ...0 BATTERY IZ VDC ll8 Blk STARTER SOLENOID 4 7fl STARTSOLENOfO FUSE IOA R MOT SHUTDOWN TERMINAL UNIT CAN I POSITIVE I RESTART 2 AUX SHUTDOWN UNIT CAN 3 ENERGEHCY STOP NOT RESORT 4 GROUND C l JUMPER SI MUST 6 REMOVED OVERSPEED PC BOARD PN 0453 17 CONTROL PC BOARD PN 045369 TERMlllA LS 1 I 2 ARE FOR FlRESOY CONNECTION TERMINALS 3 4 ARE FOR EMERGENCY STOP SWITCH ti S GRN REO COIL RELAY ENGINE CONNECTO...

Page 41: ...ot 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 it 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 Run the generator first with n...

Page 42: ...Rotor Diode 4 Shorted Rotor Thermister 5 Shorted Rotor Capacitor 6 Open Rotor Diode 1 Faulty Capacitor 2 Open Exciter Winding 3 Shorted Exciter Winding 1 Faulty Rotor Diode 2 Faulty Rotor Winding 3 Faulty Ex iter Capacitor AC Voltage Drop with 1 Faulty Rotor Diode Inductive Load 2 Faulty Exciter Capacitor 3 Amperage Overload Refer to the following page for the BCG Internal Wiring Schematic and the...

Page 43: ...e engine runs 10 15 seconds and then shuts down can be caused by a faulty over speed board 1 Refer to the Wtting Diagram in this manual 2 Unplug the brown 6 wire that connects between pin 12 ofthe 15 pin plug connector and the ignition module The wire plug connection is in the harness between the two components 3 Without unplugging any connections on the coil relay place ajumper between connection...

Page 44: ...hannful chemicals whicb canreduce the life of yourengine sintemal parts INTAKE MANIFOLD Clean the filter screen in the flame arrester and place a clean cloth lightly soaked in lube oil around the flame arrester to block any opening Also place an oil soaked cloth in the thru hull exhaust port Make note to remove cloths prior to start up FUEL SYSTEM Top off your fuel tanks with unleaded oline of 9 o...

Page 45: ...engine is being stored and there is a prob ability offreezing flush the engine with fresh water and then prior to shutting the unit dowp Substitute the fresh water supply with a concentrated antifreeze mixture and run this through the engine to provide freeze and corrosion protection for both the engine and exhaust system When recommissioning make certain the thru hull intake valve is open so the ...

Page 46: ...N SYSTEM Wet sump system trochoid type pump Fuel flow paper element spin on disposals 1 5 qts 91 4 L API Service Categor SJ SL SM SN or better SAE 10W 30or15W 40 General Raw Water Pump Raw Water Flow into water injected exhaust elbow Operating Temperature Water cooled via raw water pump Positive displacement type rubber impeller belt driven 1 75 GPM before thermostat opens 2 0 GPM thermostat open ...

Page 47: ...3125 17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47164 0 734375 18 65312 1 4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7 14375 25 32 0 78125 19 84375 19 64 0 296875 7 54062 51 64 0 796875 20 24062 5 16 0 3125 7 93750 13 16 0 8125 20 63750 21 64 0 328125 8 33437 53 64 0 828125 21 03437 11 32 0 34375 8 73125 27 32 0 8...

Page 48: ...TA ND o mNG ______ _____ SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising KIT A IMPELLER KIT OIL FILTER GENERATOR DRIVE BELT ZINC ANODES WITH GASKET SPARK PLUGS 20A FUSE WATER PUMP BELT FUEL FILTER KIT 10A FUSE HEAT EXCHANGER ZINC Engines Generators 40 KIT B IMPELLER ...

Page 49: ...djusted again to 1 prior to releasing the unit for shipment Important Note Maximum performance of the drive belt and prevention of potential failure due to incorrect tension requires the belt be to adjusted to 1 at the recommended 50 hour maintenance service Generator drive belts for regular maintenance replacement part numbers remain the same wlll be sold as a k it with instructions that includes...

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