Westerbeke BCG4.0KW Operator'S Manual Download

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Summary of Contents for BCG4.0KW

Page 1: ...ATOR 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 ...

Page 2: ...Gasoline with an ETHANOL content higher than 10 E10 is not allowed and may void warranty Engines Generators ...

Page 3: ...eaks 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 al...

Page 4: ...ufacturers 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and Wester beke must depend on such software for the design of Westerbeke s own product software Such software may be outdated and no longer accurate Routine changes made by Westerbeke s suppliers of which Westerbeke rarely has notice in advance are frequently not reflected in the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...

Page 5: ...n 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 Cus tomer Identification Card see below registering your warranty please cont...

Page 6: ...TIONS 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 ...

Page 7: ...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 ...

Page 8: ...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 gener ator 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 n...

Page 9: ...r 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 90 0 Exhaust Elbow DC Battery Ground Connection ...

Page 10: ...pe 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 ...

Page 11: ...l 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 ...

Page 12: ...ine 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 ...

Page 13: ...ad 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 cm2 at 400 rpm 28 psi 2 0 kg cm2 Intake Opens 21 BTDC Intake Closes 59 ABDC Exhaust Opens 59 BBDC Exhaust Closes 21 ATDC Intake 45 Exhaust 45 Intake 0 008 ...

Page 14: ...666 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 Tem...

Page 15: ... 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 Inter...

Page 16: ...lts 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 S...

Page 17: ...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 ...

Page 18: ...tion 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...

Page 19: ...r 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 cm2 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 Intern...

Page 20: ...olts 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 SP...

Page 21: ...s the generator s engine is NOTfilled 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...

Page 22: ... 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 t...

Page 23: ...r 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 co...

Page 24: ...en gine 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 b...

Page 25: ...essure 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 cm2 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 ...

Page 26: ...ds 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 porti...

Page 27: ...xhaust 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 ex haust hose connected between the exhaust elbow and the muffler as these would trap wa...

Page 28: ... 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 anti siphon shut off valve A manually operated service shut off valve should be located between the fuel pick up at the tank and the service shut of...

Page 29: ...h 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 no...

Page 30: ...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 res...

Page 31: ... 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 gro...

Page 32: ...ressing 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 surethe positive battery connection is c...

Page 33: ... 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 SP...

Page 34: ...til 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 ...

Page 35: ...g 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 t...

Page 36: ...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 pr...

Page 37: ...aused 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 engine mounted 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 cy...

Page 38: ...t 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 atternptin...

Page 39: ... 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 dip...

Page 40: ...URNS 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 Gene...

Page 41: ...er 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 ar restor SCREENED AIR CLEANER FUEl SOlENO 0 Westerbeke Generators GOVERNOR LINKAGE 38 INLET SCREEN ...

Page 42: ...e 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 ACCESSIBL...

Page 43: ...sket 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...

Page 44: ...s to stopthis slight drain is to first turn offthe 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 overspeed condition the overspeed circuit must be reset in order to restart the gen erator If the overspeed switch itself is faulty and res...

Page 45: ...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 Conn...

Page 46: ...rage 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 component...

Page 47: ...I Page 1 of 2 lJ t t Ie f rt t l 4 r ro e GOlD B OVfR PE D L1IJ z n l c wl r t 1 1 TRIPC I 1 1 i J 0 P 5HIDH rtJlf m I rGROMMET INTO PANEL t v 1 I J 1C ln 0_1 SWITCH T Uly CNAR ER OUT PL POWER ALTERNATOR i 0 I t 1 0 r u ON L ____________________ Wc _ C____________t I PANEL Westerbeke Generators 44 YEclw flH ...

Page 48: ...RSPtED MODULE CAUSES IS d DRAIN WHEN GUIERATOR IS NOT OPERATlN TlH RUOR WifE lEAVING BOAT fOR AN TENDED tRIDD DI5eONN EeT TI1 aATTER tSTERSEKE ASOLIN MARINE GENERATORS AS HIPP D FROM TH FACTORY O CLUSIVE OPTIONAL REI OT NSTRUMfNT OR CONTROL PAN ELS OMPL IT 1 5 COA T UA RO UR d3 l eCES50RY I SrRU H T AND CONTROL PANelS DO NOT NECESSARILY SC CO RL ANO AR INTENDED TO at 1 5TAlLED ASOVE OECK ANP ISOI ...

Page 49: ... 6 5KW r I RED ii PURPLE I I T4 f I 9 liMP STARTING 6 AMP RUHHING I I I I I I I I I YELLOW Ii HO PURPLE I 114 PURPlE SIR IfE 14 2 2 AMP I 1 3 1 I 6 6 I 14 3 I 0 I 6 6 I 14 4 I I L 4_5 114 BLACK I 2 AMP L I I L C _ _ _ _ _ _ _ _ _ _ _ 1 12 AMP SHIRTING 112 YELLOW lURED STRIPE 19 AIoIP STARTING G AMP RUNNING 112 REO Ii PURPLE STRIPE Weslerbeke Generators 46 MODEL I OWG HUMBER 11S43 1 B16 9 ilKWI 363...

Page 50: ...i puRrLE OIL Plnssuln 0 i TOT2 2 14PURPLt I T42 V 2AMP 8 4 16 PURPL E 1 I TOT2_3 14LTOlUE IeT4 Ei I u 16LT BLUE I TO T2A 11 14 TAN T4 4 I 1 6 8 1I H TAN 1 I TO T2 5 14 BLACK I ZAMP I I 14 5 IS v 16 BLACK o 1 12 puR wiRED l 3AMP STARTING T T II STRIPE 6 Ar 1P RUNNING I TO TI Z 1 12YEUW RED 12AMP STARTINC I STRIPE L __ _ 8 13 1 3 2 MII iLiI Llllld 1l lB s 28 UG E O HOURS WIHE LENGTH FROM GENERATOR T...

Page 51: ...ses 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 o...

Page 52: ...oolant 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 kt...

Page 53: ...e 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 bloc...

Page 54: ...ction 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 Jr...

Page 55: ...elt 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...

Page 56: ...er 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 ...

Page 57: ...e 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 th...

Page 58: ...e 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 ...

Page 59: ... 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 ...

Page 60: ...gs 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 ...

Page 61: ... 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 ...

Page 62: ... 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 t...

Page 63: ...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 rig...

Page 64: ...0 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 ...

Page 65: ...oads 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 Lj 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 insulat...

Page 66: ... 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...

Page 67: ...tors 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 h...

Page 68: ...able 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 r...

Page 69: ...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...

Page 70: ... 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 ...

Page 71: ...t 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 Relie...

Page 72: ...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 ...

Page 73: ...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 a...

Page 74: ...ion 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 ne...

Page 75: ...ator 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 connec...

Page 76: ...fications 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 generato...

Page 77: ...e 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 lub...

Page 78: ... 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 o...

Page 79: ...n 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...

Page 80: ...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 ...

Page 81: ...r 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 va...

Page 82: ...28 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 Wes...

Page 83: ...centration 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 sealin...

Page 84: ... 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 ele...

Page 85: ...cement 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 v...

Page 86: ...t 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...

Page 87: ...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 ...

Page 88: ...linder 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...

Page 89: ...57 Belt Tension 52 Bolts Torquing Cylinder Head 77 Break In Precautions 36 C CAUTIONS ENGINE SHIPPED WITHOUT OIL 18 LIFTING THE GENERATOR 19 PROLONGED CRANKING INTERVALS 23 EXHAUST ELBOW CLAMP TORQUE 24 GASOLINE LEAKAGE 26 HULL FITTINGS 28 OVERCHARGING CONDlTlONS 28 STARTING THE GENERATOR WITH AC LOADS OFF 34 PROLONGED CRANKING INTERVALS 34 CHARGING CIRCUIT 41 QUICK CHARGING THE SATTERY 41 EXCESSI...

Page 90: ...ctions 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 ENGINE TROUBLESHOOTING 66 Equipment Inspection of 18 Exhaust Back Pressure Installatio...

Page 91: ...RQUES 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...

Page 92: ... 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 D...

Page 93: ...rting 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 Gaso...

Page 94: ...ICING 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 BATIERIES 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 Westerbe...

Page 95: ...YOUR NOTES Westerbeke Generators 92 ...

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