OPERATORS MANUAL 5.0KW BCG-60Hz / 4.2KW 5.0KW BCGA-60Hz / 4.2KW 7.0KW BCGC-60Hz /5.9KW 7.0KW BCGO-60Hz / 5.9KW BCG-50Hz BCGA-50Hz BCGC-50Hz BCGO-50Hz GASOLINE GENERATORS Single Phase PUBLICATION NO. 46983 THIRD EDITION JULy 2008 ~ WESTERBEKE WESTERBEKE CORPORATION · MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD · TAUNTON MA 02780·7319 · TEL , (508)823-7677 FAX (508)884-9688 · WEBSITE: WWW.WESTERBEK£.COM ,tfJM,T Member Nai/Oiral Marin e Manufaclurers Associfllion .
Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty.
CALIFORNIA PROPOSITION 65 WARNING Exhaust gas from diesel and gasoline engines (and some of its constituents) are known to the State of California to cause cancer, birth defects, and other reproductive harm. A WARNING: Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.
SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES A WARNING: Accidental starting can cause injury A WARNING: Carbon monoxide (CO) Is a deadly gas! ordeathJ • 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 manifoldl water-injected elbow is securely attached. • Be sure the unit and its surroundings are well ventilated. Run blowers when running the generator set or engine.
SAFETY INSTRUCTIONS • ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. • Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times. • Do not check fluid levels or the drive belt's tension while the engine is operating.
INSTALLATION When installing WES1ERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must he complied with when installing engines and generators in a marine environment.
TABLE OF CONTENTS Introduction .........................................................................2 Fuel, Engine Oil and Engine Coolant.. ............................... .4 Control Panels .................................................................;... 5 Preparations for Initial Start-Up .........................................6 Operating Instructions ........................................................7 Remote Panel ......................................................................
INTRODUCTION WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING ACCURACY, TIMEUNESS OR COMPLETENESS THEREDF AND WIU 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 also keep in mind the time span between printings of WESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE manuals.
INTRODUCTION ORDERING PARTS PROTECTING YOUR INVESTMENT Whenever replacement parts are needed, always provide the generator and engine model and serial numbers. In addition, include a complete part description and p(Ut number for each part needed (see the separately furnished Parts Catalog). Also insist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment.
FUEL, ENGINE OIL AND ENGINE COOLANT CARE OF THE FUEL SUPPLY A ENGINE COOLANT Westerbeke recommends a mixture of 50% antifreeze and 50% distilled water, when possible. Distilled water is free from the chemicals that can corrode internal engine surfaces. CAUTION: Only use unleaded fuel with an octane rating of 89 or higher. Leaded fuel will cause serious harm to your engine and riolate your warranty.
CONTROL PANELS GENERATOR CONTROL PANEL REMOTE PANEL The ON and START/STOP switches are the only functional components to operate the generator at the engine. Both switches are used to start the generator - see Starting the Generator under OPERATING INSTRUCTIONS. There are three functional components on the remote panel for generator operation: The ON switch is a two-position switch with momentary contacts in the up (on) position and a stationary contact function in the center position.
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION Before starting your generator for the first time or after a prolonged layoff, check the following items: • Visually examine the unit. Look for loose or missing parts, disconnected wires, unattached hoses, and check threaded connections. Search for any gasoline leaks. • Check the engine oil level: add oil to maintain the level at the full mark on the dipstick. • Check load leads for correct connections as specified in the wiring diagrams.
OPERATING INSTRUCTIONS NOTE: A CIRCUIT BREAKER IS LOCATED ON THE 510£ Of TH£ PANfLSHUTS DOWN THE AC GENERATOR CIRCUIT. GENERATOR CONTROL PANEL Starting the Generator To start the generator, hold the momentary ON switch in the up (on) position, then hold the momentary START/STOP switch in the up (start) position (both switches are held up together). After approximately one second, the starter will engage and the engine will crank .
OPERATING INSTRUCTIONS REMOTE PANEL Starting the Generator To start the generator, hold the momentary ON switch in the up (on) position (the green light will come on), then hold the momentary START/STOP switch in the up (start) position (both switches are held up together). After approximately one second, the starter will engage and the engine will crank (the green light will dim).
BREAK-IN PROCEDURE/DAILY OPERATION NOTE: Some unstable running may occur in a cold engine. This condition should abate as normal operating temperature is reached and loads are applied. BREAK-IN PROCEDURE After the generator has been started, check for proper operation and then encourage a fast warm-up. Run the generator between 20% to 60% of full load for the first 10 hours. A CAUTION: A CAUTION: Do not operate the generator for long periods of time without a load being placed on the generator.
SAFETY SHUTDOWN SWITCHES SAFETY SHUTDOWN SWITCHES The engine is protected by a variety of shutdown switches. Should a shutdown occur. do not attempt to restart withqut finding and correcting the cause. Refer to the heading Engine slarts, runs and then shuts down in the ENGINE TROUBLESHOOTING section of this manual. The following is a description of these automatic shutdown switches: OIL FILTER ASSEMBLY Exhaust Temperature Switch An exhaust temperature switch is located on the exhaust elbow.
MAINTENANCE SCHEDULE A WARNING: Neller attempt to perform any scfllice while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery terminals when sefllicing any of the engine's DC electrical equipment. NOTE: Many of the following maintenance procedures are simple but others are more difficult and may require the expert knowledge of a service mechanic.
MAINTENANCE SCHEDULE NOTE: Use the engine hounneter gauge to log your engine hours or record your engine hours by running time. SCHEDULED MAINTENANCE Heat Exchanger CHECK EACH DAY HOURS OF OPERATION 50 100 250 500 :::J 0 0 0 0 *Starter Motor Clean or replace anode. Open heat exchanger end cap and clean out debris. Remove every 1000 hours for professional cleaning and pressure testing. 0 Remove pump cover and inspect impeller for wear; replace if needed. Also replace gasket.
COOLING SYSTEM FRESH WATER COOLING CIRCUIT CHANGING COOLANT NOTE: Refer to the ENGINE COOLANT section for the recommended antifreeze and water mixture to be used as the fresh water 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. Fresh water coolant is pumped through the engine by a circulating pump, absorbing heat from the engine.
COOLING SYSTEM THERMOSTAT A thermostat controls the coolant temperature as the coolant continuously flows through the closed cooling circuit. When the engine is first started the closed thermostat prevents coolant from flowing (some coolant is by-passed around the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens. The thermostat is accessible and can be checked, cleaned, or replaced easily. Carry a spare thermostat and gasket.
COOLING SYSTEM RAW WATER INTAKE STRAINER RAW WATER PUMP NOTE: Always install the strainer at or below the waterline so The raw water pump is a self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller has flexible blades 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 aboard (an impeller kit).
FUELSVSTEM GASOLINE ENGINE FUEL FILTER Use unleaded 89 octane or higher gasoline. When fueling, follow U.S. Coast Guard regulations, close off all hatches and companionways to prevent fumes from entering the boat, and ventilate after fueling. NOTE: The generator compartment should have a gasoline fume detector/alarm properly installed and working. Periodically check the fuel connections and the bowl for leakage. Replace the fliter element after the first 50 hours then follow the MAINTENANCE SCHEDULE.
ENGINE OIL When installing the new oil filter element, wipe the filter gasket's sealing surface on the bracket free of oil and apply a thin coat of clean engine oil to the rubber gasket on the new oil filter. Screw the filter onto the threaded oil filter nipple on the oil filter bracket, and then tighten the filter firmly by hand. ENGINE OIL CHANGE 1. Draining the Oil Sump. Discharge the used oil through the sump drain hose (attached to the front of the engine) while the engine is warm.
THE BATTERY CHARGING CIRCUIT The DC Circuit on the BCGB functions to start, operate and stop the generator's engine. The circuit is best understood by reviewing the DC Wiring Diagram and Wiring Schematic. The engine's DC wiring is designed with three simple basic , circuits: start, run and stop. Battery Maintenance Review the manufacturer's recommendations and then establish a systematic maintenance schedule for your engine's starting batteries and house batteries.
ELECTRONIC GOVERNOR Electronic Governor System Calibration The system is composed of three basic components: 1. With no power to the governor, adjust the GAIN to 9:00 o'clock. 2. Start the engine and adjust the speed by turning lhe speed pot clockwise to desired speed. 1. Controller. Mounted in the instrument panel. Z. Sensor. Installed on the bellhousing over the flywheel ring gear. 3. Actuator. Mounted at the front of the engine and attached with linkage to the throttle arm of the injection pump.
TROUBLESHOOTING THE ELECTRONIC GOVERNOR PROBLEM CDRRECnDN TEST/CHECK 1. Check DC voltage between terminal #12 and +connection on hourmeter when ON switch is depressed. 1. Charge starting battery. Start unit, troubleshoot battery, charge circuit. 2. Check the AC signal from the MPU while cranking, voltage should be 1.5 • 2.5 VAC. 2. Check the MPU resistance value and positioning. Adjust and replace as needed. 3. Check the actuator. 4. Check the controller. 3. Check the resistance value.
CARBURETOR ADJUSTMENTS CARBURETOR The carburetor is a single barrel, side-draft type with a cleanable metal screen air intake filter/spark arrester. ELECTRIC The choke is operated by a 12 VDC solenoid. This choke solenoid is activated when the ON switch is depressed and stays activated so long as the ON switch is held depressed. Once the ON switch is released the choke solenoid deactivates. Air Screen/Flame Arrester The air screen can easily be removed.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. TIMING BELT INSPECTION AND REPLACEMENT 5. Remove the timing bell. NOTE: lfthe timing belt is to be reused, draw an arrow on the belt back to indicate the direction of rotation (clock· wise). Timing Belt Removal A CAUTION: Water or oil on the timing belt severely reduces the service lite of the belt.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. Crankshaft Bolt Removal Flange Installation i. 1. Mount the flange so that its side shown by the heavy anow in the illustTation faces toward the sprocket. Lock the crankshaft in position. NOTE: Do not turn the crankshaft. FLANGE 2. Remove the crankshaft bolt.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. At this time, check that the moveable range of teeth on the oil pump sprocket is according to specifications. Standard value: 4 to 5 teeth in forward direction. 1 to 2 teeth in reverse direction. Tensioner Spring/Timing Tensioner Installation 1. Install the tensioner spring and timing belt tensioner. 2.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. 8. Turn the crankshaft clockwise by nine camshaft sprocket teeth (817) to align the timing mark on the camshaft sprocket with the tensioner set mark on the timing belt rear cover.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT IGNITION TIMING NOTE: Retorque the cylinder head bolts before adjusting the engine's valves (see TORQUING THE CYLINDER HEAD BOLTS). 1. Attach a timing light to the #1 spark plug and mark the front timing pointer to indicate 15°.
ENGINE ADJUSTMENTS SPARK PLUGS DRIVE BELT ADJUSTMENT The spark plugs should be cleaned and regapped after the first 50 hour break-in period, then inspected every 250 hours thereafter and replaced as needed. The drive belt must be properly tensioned. Excessive drive belt tension can cause rapid wear of the belt and reduce the service life of the fresh water pumps bearing. A slack belt or the presence of oil on the belt can cause belt slipping. 1. Remove the belt guard.
GENERATOR INFORMATION USE OF ELECTRIC MOTORS GENERATOR FREQUENCY ADJUSTMENT The power required to start an electric motor is considerably more than is required to keep it running after it is started. Some motors require much more current to start them than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types.
AC TERMINAL CONNECTIONS BCGA & C 120Vl60Hz #31 230Vl50HZ 240V/60Hz #11 #11 #21 #42< #41 #41 CIRCUIT BREAKER ~. ISOLATED POST (NEUTRAL) L1 N L2. #31 CIRCUIT BREAKER ISOLATED POST (NEUTRAL) L1 #22 #42 #11 #21 #31 CIRCUIT BREAKER 115V150HZ - ISOLATED POST I N L1 N ISOLATED POST N L1 BCGA & C GENERATOR WINDINGS SCHEMATIC El1~ ~1 • L..*:JE22 -----I ,.----------T11 t-------- T31 EWl '"-------T41 L..--------T42 '-----------T21 L..
BeG & 0 AC TERMINAL CONNECTIONS 120V/60Hz 1 230Vl50HZ 240V/60Hz + 1 1 5 4 CIRCUIT BREAKER 115V1'50HZ 6 2 CIRCUIT BREAKER CIRCUIT BREAKER ISOLATED POST L1 l1 ISOLATED POST L2. N BeG & 0 GENERATOR WINDINGS SCHEMATIC ~ ;:[*1:· r ------- - - - I I I I I ROTOR WINDINP I I I I I I I . I I ! I I I I I I I I L- -:C~~R ~----o2 , I I STATOR WINDING I I STATOR WINDING I j I w,:Ji.-rn --,---06 6t,'F g 7 CAPACITOR.
SHORE POWER TRANSFER SWITCH 230 VOLT/50 HERTZGenerator TWO WIRE CONFIGURATION 120 VOLT/GO HERTZ TWO WIRE CONFIGURATION Generator ~ NOTE: Diagram shows connections for a twowire, 120 Voit system from the generator, with three-wire. 120-Voll boat system. ~ w Ll :N - Ship·to· Shore Switch (3 Pole) Q .J III /...-- ......., '---t--t----f-@9\Neutral iiif?! ~ ~ Z L1 .
BC GENERATOR SINGLE PHASE INTEGRAL CONTROLLER (I.C.) Testing the Battery Charging Circuit 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 opening. 1. Bridge Rectifier Charging Voltage: 13.1 • 13.4 volts DC Charging Amperage: 0 • 17.0 amps DC A separate group of stator windings supplies AC voltage to a bridge rectifier which converts the AC current to supply the I.e. unit. The I.e.
WIRING SCHEMATIC #46876 + 12 vee BATTERY DISCONNECT SWITCH NOTE: An on-off switch should be Installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat. Twelve volt engine starters typically draw 200 to 300 amps when crankiflg.
WIRING DIAGRAM #46876 A.UX. OL PRESS ., SWITCH INICI OL PRESS AC GEN. SWITCH WOl "" ~ o~ . « « '" '" - ~ rus£ '"c ~ '" + 116 V10fW r w .
REMOTE PANEL WIRING SCHEMATIC REMOTE PANEL #043912 WITH 1 FOOT HARNESS START/STOP SW #14 5LK RED #14 WHT/RED #14 YELIRED #14 WHT #14 RED/VIO VIEWED FROM MATING END EXTENSION HARNESS 15 Feet PN# 043914 30 Feet PN# 043860 Engines & Generators 34
ENGINE TROUBLESHOOTING The following troubleshooting tables are based upon eertain engine problem indicators and the most likely causes of the problems. NOTE: 171e engines control system (electrical system) is protected by a 20 Ampere manual reset circuit breaker located on the control panel. When troubleshooting indicates an electrical problem, see the ELECTRICAL SYSTEM WIRING DIAGRAM, as these may reveal other possible causes of the problem which are not listed below.
ENGINE TROUBLESHOOTING PROBLEM Low oil pressure, PROBABLE CAUSE 1. 2. 3. 4. 5. 6. PROBLEM Low oil level. Wrong SAE type oil in the engine, Faulty or wrong type oil filter, Relief valve is stuck, Faulty oil pump. Faulty engine bearings. Black exhaust smoke discharge from the engine. 1. Dirty flame arrester. 2. Faulty carburetor. 3. Idle mixture jet too rich. 4. Faulty choke/solenoid, 5. Valves are worn or incorrectly adjusted. 7. Faulty oil filter, High oil pressure. PROBABLE CAUSE 6.
LAY-UP & RECOMMISSIONING Fuel System [Gasoline] G~NERAL Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the offseason or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves. Top off your fuel tanks with unleaded gasoline of 89 octane of higher. A fuel conditioner such as STABIL gasoline stabilizer should be added. Change the element in your gasoline/water separator and clean the metal bowl.
LAY-UP &RECOMMISSIONING Starter Motor SPARE PARTS Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter penn its 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. Lay-up time provides a good opportunity to inspect your WESTERBEKE engine to see if external items such as drive belts or coolant hoses need replacement.
5.0KW BCG/BCGA GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3-cylinder, 4-cycle, , overhead camshaft w/counterbalance shaft, water cooled gasoline engine Bore & Stroke 2.56 x 2.61 inches (65.0 x 66.3 mm) Total Displacement 40.3 cubic inches (0.66 liters) Bearings Fou r main bearings Fresh water-cooled block through raw water-cooled heat exchanger circuit General Fresh Water Pump Centrifugal type, metal impeller, belt-driven.
7.0 KW BCGC/BCGD GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3-cylinder. 4-cycle, , overhead camshaft w/counterbalance shaft, water cooled gasoline engine Bore &Stroke 2.56 x 2.61 inches (65.0 x 66.3 mm) Total Displacement 40.3 cubic inches (0.66 liters) Bearings Four main bearings Compression Chamber Semi-spherical Compression Ratio 9.8:1 Hp@1800/1500 rpm 8.0/6.
GENERATOR HARDWARE TORQUES Timing Bell Crankshaft bolt Nm Nm ft.lbs. Front case bolts 8-10 6-7 Oil pump cover Dolts 8-10 6-7 Fronl Case, Counterbalance Shall ft.lbs.
STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 =Millimeters (mm) x .0394 =Inches Feet (ft) x .305 :::: Meters (m) x 3.281 = Feet Miles x 1.609 Kilometers (km) x .0621 :::: Miles DISTANCE EQUIVALENTS 1 Degree of latitude 60 Nm :::: 111.120 km 1 Minute of latitude 1 Nm :::: 1.852 km VOLUME 3 Cubic Inches (in3) x 16.387 =Cubic Centimeters x .061 ::::in Imperial Pints (IMP pt) x .568 :::: Liters (ll x 1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137:::: Liters (l) x.
SUGGESTED SPARE PARTS WESTERBEKE MARINE GASOLINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION '-'&---'1/ MANIFOLD CAP MOLDED HOSE KIT WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL (YOUR BRAND) FOR AN OIL _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ CHANGEANDALSOA GALLON OF PREMIXED COOLANT FOR THE COOLING SYSTEM. - HARDWARE KIT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits, each packaged in a rugged, rust free toolbox.
Engines & Generators WMDWl2102
