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OPERATORS MANUAL
5.0KW BCG-60Hz / 4.2KW BCG-50Hz
5.0KW BCGA-60Hz / 4.2KW BCGA-50Hz
7.0KW BCGC-60Hz /5.9KW BCGC-50Hz
7.0KW BCGO-60Hz / 5.9KW 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
.w
d
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Table of Contents
Troubleshooting
Related Manuals for Westerbeke 5.0KW BCG-60Hz
Summary of Contents for Westerbeke 5.0KW BCG-60Hz
- Page 1 OPERATORS MANUAL 5.0KW BCG-60Hz / 4.2KW BCG-50Hz 5.0KW BCGA-60Hz / 4.2KW BCGA-50Hz 7.0KW BCGC-60Hz /5.9KW BCGC-50Hz 7.0KW BCGO-60Hz / 5.9KW BCGO-50Hz GASOLINE GENERATORS Single Phase PUBLICATION 46983 THIRD EDITION JULy 2008 WESTERBEKE WESTERBEKE CORPORATION · MYLES STANDISH INDUSTRIAL PARK JOHN HANCOCK ROAD ·...
- Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
- Page 3 GET DUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart until it has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator.
- Page 4 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precau- WARNING: Fire can cause injury Df death/ tions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, •...
- Page 5 SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) Is deadly gas! ordeathJ • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine! discharged from the engine.
- Page 6 SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.
- Page 7 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. SIPHON-BREAK For installations where the exhaust manifold/water injected exhaust elbow is close to or will be below the vessel's waterline, provisions must...
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Page 8: Table Of Contents
TABLE OF CONTENTS Introduction ................. Fuel, Engine Oil and Engine Coolant........4 Control Panels ..............; ... Preparations for Initial Start-Up ......... Operating Instructions ............Remote Panel ..............Break-in Procedure/Daily Operation ........Safety Shutdown Switches ..........Maintenance Schedule ............. Cooling System .............. -
Page 9: Introduction
Please read this manual carefully and observe all the safety precautions WESTERBEKE customers should also keep in mind the time throughout. Should your engine require servicing, contact span between printings of WESTERBEKE product software your nearest WESTERBEKE dealer for assistance. - Page 10 A carbon monoxide warning decal been provided are verticle in-line, and the engine's cylinder head has an WESTERBEKE. Affix this decal in a visable location in overhead camshaft which is chain-driven. The engine utilizes the engine room. a solid-state distributor which is horizontally mounted and camshaft-driven.
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Page 11: Fuel, Engine Oil And Engine Coolant
FUEL, ENGINE OIL AND ENGINE COOLANT CARE OF THE FUEL SUPPLY ENGINE COOLANT Westerbeke recommends a mixture of 50% antifreeze and 50% distilled water, when possible. Distilled water is free CAUTION: Only use unleaded fuel with an from the chemicals that can corrode internal engine surfaces. -
Page 12: Control Panels
CONTROL PANELS REMOTE PANEL GENERATOR CONTROL PANEL There are three functional components on the remote panel The ON and START/STOP switches are the only functional for generator operation: components to operate the generator at the engine. Both switches are used to start the generator - see Starting the 1. -
Page 13: Preparations For Initial Start-Up
PREPARATIONS FOR INITIAL START-UP PREST ART INSPECTION • Visually examine the unit. Look for loose or missing Before starting your generator for the first time or after a parts, disconnected wires, unattached hoses, and check prolonged layoff, check the following items: threaded connections. -
Page 14: Operating Instructions
OPERATING INSTRUCTIONS NOTE: A CIRCUIT BREAKER GENERATOR CONTROL PANEL IS LOCATED ON THE 510£ Of TH£ PANfLSHUTS Starting the Generator DOWN THE AC GENERATOR CIRCUIT. 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). -
Page 15: Remote Panel
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). -
Page 16: Break-In Procedure/Daily Operation
BREAK-IN PROCEDURE/DAILY OPERATION NOTE: Some unstable running may occur in a cold engine. BREAK-IN PROCEDURE This condition should abate as normal operating temperature After the generator has been started, check for proper opera- is reached and loads are applied. tion and then encourage a fast warm-up. Run the generator between 20% to 60% of full load for the first 10 hours. -
Page 17: Safety Shutdown Switches
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. -
Page 18: Maintenance Schedule
Check that all connections are tight. Engine Hoses Hose should be hard & tight. Replace if soft or spongy. Check and tighten all hose clamps. *WESTERBEKE recommends this service be performed by an authorized mechanic. (continued) & Engines Generators... - Page 19 WARNING: A defective exhaust elbow can cause carbon monoxide leakagel Carburetor Drip Tray Inspect and drain at regUlar intervals. Do not allow fuel to collect in drain. *WESTERBEKE recommends this service be performed by an authorized mechanic. Engines & Generators...
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Page 20: Cooling System
COOLING SYSTEM CHANGING COOLANT FRESH WATER COOLING CIRCUIT The engine's coolant must be changed according to the NOTE: Refer to the ENGINE COOLANT section for the MAINTENANCE SCHEDULE. If the coolant is allowed to recommended antifreeze and water mixture to be used as the become contaminated, it can lead to overheating problems. -
Page 21: Thermostat
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 GASKET thermostat to prevent the exhaust manifold from over- heating). -
Page 22: Raw Water Strainer
COOLING SYSTEM RAW WATER INTAKE STRAINER RAW WATER PUMP The raw water pump is a self-priming, rotary pump with a NOTE: Always install the strainer at or below the waterline so non-ferrous housing and a Neoprene impeller. The impeller the strainer will always be self-priming. has flexible blades which wipe against a curved cam plate A clean raw water intake strainer is a vital component of the within the impeller housing, producing the pumping action. -
Page 23: Fuel System
FUELSVSTEM GASOLINE ENGINE FUEL FILTER unleaded 89 octane or higher gasoline. When fueling, Periodically check the fuel connections and the bowl for follow U.S. Coast Guard regulations, close off all hatches and leakage. Replace the fliter element after the first 50 hours companionways to prevent fumes from entering the boat, and then follow the MAINTENANCE SCHEDULE. -
Page 24: Engine Oil
ENGINE OIL ENGINE OIL CHANGE When installing the new oil filter element, wipe the filter gasket's sealing surface on the bracket free of oil and Draining the Oil Sump. Discharge the used oil through apply a thin coat of clean engine oil to the rubber gasket the sump drain hose (attached to the front of the engine) on the new oil filter. -
Page 25: Battery Charging Circuit
THE BATTERY CHARGING CIRCUIT Battery Maintenance The DC Circuit on the BCGB functions to start, operate and stop the generator's engine. The circuit is best understood by Review the manufacturer's recommendations and then estab- reviewing the DC Wiring Diagram and Wiring Schematic. lish a systematic maintenance schedule for your engine's The engine's DC wiring is designed with three simple basic starting batteries and house batteries. -
Page 26: Electronic Governor
ELECTRONIC GOVERNOR Electronic Governor System Calibration 1. With no power to the governor, the GAIN to 9:00 system is composed of three basic components: adjust o'clock. 1. Controller. Mounted in the instrument panel. 2. Start the engine and adjust the speed by turning lhe speed Sensor. -
Page 27: Troubleshooting The Electronic Governor
TROUBLESHOOTING THE ELECTRONIC GOVERNOR PROBLEM TEST/CHECK CDRRECnDN Unit starts, then overspeeds 1. Check DC voltage between terminal 1. Charge starting battery. Start unit, troubleshoot and shuts down. #12 and connection on hourmeter battery, charge circuit. when ON switch is depressed. NOTE: When troubleshooting, manually operate the throttle to prevent an overspeed or disconnect... -
Page 28: Carburetor Adjustments
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. -
Page 29: Engine Adjustments
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by 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 Timing Belt Removal the belt back to indicate the direction of rotation (clock·... - Page 30 ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed a competent engine mechanic. The information below is provided to assist the mechanic. Flange Installation Crankshaft Bolt Removal 1. Mount the flange so that side shown by the heavy Lock the crankshaft in position.
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Page 31: Timing Belt
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below provided to assist the mechanic. At this time, check that the moveable range of teeth on Tensioner Spring/Timing Tensioner Installation the oil pump sprocket is according to specifications. -
Page 32: Compression Test
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed a competent engine mechanic. The information below is provided to assist the mechanic. clockwise 8. Turn the crankshaft by nine camshaft sprocket ENGINE COMPRESSION TEST teeth (817) to align the timing mark on the camshaft 1. -
Page 33: Valve Clearance
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... -
Page 34: Spark Plugs
ENGINE ADJUSTMENTS DRIVE BELT ADJUSTMENT SPARK PLUGS The drive belt must be properly tensioned. Excessive drive The spark plugs should be cleaned and regapped after the belt tension can cause rapid wear of the belt and reduce the first 50 hour break-in period, then inspected every 250 hours service life of the fresh water pumps bearing. -
Page 35: Generator Information
The output voltage should be Carbon Monoxide cheeked periodically to ensure proper operation of the generating WESTERBEKE recommends mounting a carbon monoxide plant and the appliances it supplies. If an AC voltmeter or amp- detector in the vessel's living quarters. Carbon monoxide, meter is not installed to monitor voltage and load, check it with a even in smaU amounts, is deadly. - Page 36 AC TERMINAL CONNECTIONS BCGA & C 230Vl50HZ 115V150HZ 120Vl60Hz 240V/60Hz #22 #42 #42< CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER ISOLATED ISOLATED ISOLATED ISOLATED POST POST POST POST (NEUTRAL) (NEUTRAL) GENERATOR WINDINGS SCHEMATIC BCGA & C El1~ ~1 • , . - - - - - - - - - - T 1 1 L..*:JE22 t-------- T3 1...
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Page 37: 29A
AC TERMINAL CONNECTIONS BeG & 0 120V/60Hz 230Vl50HZ 115V1'50HZ 240V/60Hz CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER ISOLATED ISOLATED POST POST GENERATOR WINDINGS SCHEMATIC BeG & 0 ;:[*1:· r ------- - - - I BATIERY CHARGING CIRCUIT 50 Hz ROTOR WINDINP STATOR WINDING ~----o2 STATOR WINDING... -
Page 38: Shore Power Transfer Switch
SHORE POWER TRANSFER SWITCH 230 VOLT/50 HERTZ TWO WIRE CONFIGURATION 120 VOLT/GO HERTZ TWO WIRE CONFIGURATION Generator Generator NOTE: Diagram shows connections for a two- wire, 120 Voit system from the generator, with three-wire. 120-Voll boat system. GENERATOR GROUND PN 32133 Ship·to·... -
Page 39: Bc Generator Single Phase
BC GENERATOR SINGLE PHASE Testing the Battery Charging Circuit INTEGRAL CONTROLLER (I.C.) Bridge Rectifier The Integral Controller (I.C.) is an encapsulated, solid-state unit that supplies a DC charging voltage to the generator's Normal AC voltage running to the rectifier (while the starting battery while the generator is opening. -
Page 40: Wiring Schematic (#46876)
WIRING SCHEMATIC #46876 BATTERY DISCONNECT SWITCH BATTERY !2VDC NOTE: An on-off switch should be Installed in this circuit to disconnect the starter from the battery in BATTERY CHARGER an emergency and when HOUR METER leaving the boat. Twelve volt engine starters typically draw 200 to 300 amps when crankiflg. -
Page 41: Wiring Diagram (#46876)
WIRING DIAGRAM #46876 A.UX. OL PRESS SWITCH INICI OL PRESS AC GEN. SWITCH WOl "" « « '" rus£ '" '" '" 116 V10fW "" « "" tl4 RED/VIO '" 112 YEL/RED FIJSE t'2 RED SWITCH tl& RED/WHT START/STOP SWITCH tl6 WHT "116 116 RED/VIO... -
Page 42: Remote Panel Wiring
REMOTE PANEL WIRING SCHEMATIC REMOTE PANEL #043912 WITH 1 FOOT HARNESS START/STOP SW #14 5LK #14 WHT/RED YELIRED #14 WHT #14 RED/VIO VIEWED FROM MATING END EXTENSION HARNESS 15 Feet PN# 043914 30 Feet PN# 043860 Engines & Generators... -
Page 43: Engine Troubleshooting
ENGINE TROUBLESHOOTING The following troubleshooting tables are based upon eertain NOTE: 171e engines control system (electrical system) is engine problem indicators and the most likely causes of the protected a 20 Ampere manual reset circuit breaker problems. 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... - Page 44 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE Low oil pressure, Dirty flame arrester. Low oil level. Black exhaust smoke discharge from the Wrong SAE type oil in the engine, 2. Faulty carburetor. engine. Faulty or wrong type oil filter, 3.
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Page 45: Lay-Up And Recommissioning
LAY-UP & RECOMMISSIONING G~NERAL Fuel System [Gasoline] Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane STABIL including engines and generators, for lay-up during the off- of higher. A fuel conditioner such as gasoline season or for long periods of inactivity. - Page 46 Lay-up time provides a good opportunity to inspect your Lubrication and cleaning of the starter drive pinion is advis- WESTERBEKE engine to see if external items such as drive able, if access to the starter penn its its easy removal. Make belts or coolant hoses need replacement.
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Page 47: Specifications
5.0KW BCG/BCGA GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3-cylinder, 4-cycle, , overhead camshaft w/counterbalance shaft, water cooled gasoline engine General Fresh water-cooled block through raw Bore & Stroke 2.56 x 2.61 inches (65.0 x 66.3 mm) water-cooled heat exchanger circuit Total Displacement 40.3 cubic inches (0.66 liters) Fresh Water Pump... - Page 48 7.0 KW BCGC/BCGD GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3-cylinder. 4-cycle, , overhead camshaft w/counterbalance shaft, water cooled gasoline engine General Fresh water-cooled block through raw 2.56 x 2.61 inches (65.0 x 66.3 mm) Bore & Stroke water-cooled heat exchanger circuit Total Displacement 40.3 cubic inches (0.66 liters) Fresh Water Pump...
- Page 49 GENERATOR HARDWARE TORQUES ft.lbs. Timing Bell Fronl Case, Counterbalance Shall ft.lbs. 8-10 Crankshaft bolt Front case bolts 135-145 98-105 Oil pump cover Dolts 8-10 Timing belt cover bolts 10-12 Oil pan bolts 10-12 7·9 Camshaft sprocket bolts 80-100 58-72 Oil drain plug 35-45 25-33 Oil pum p sprocket nuts...
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Page 50: Metric Conversions
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 Cubic Inches (in3) x 16.387... -
Page 51: Suggested Spare Parts
SUGGESTED SPARE PARTS WESTERBEKE MARINE GASOLINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION MANIFOLD CAP '-'&---'1/ MOLDED HOSE KIT WESTERBEKE RECOMMENDS CARRYING ENOUGH HARDWARE KIT SPARE ENGINE OIL (YOUR BRAND) FOR AN OIL _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ CHANGEANDALSOA GALLON OF PREMIXED COOLANT FOR THE COOLING SYSTEM. - Page 53 Engines & Generators WMDWl2102...
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