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- Page 1 OPERATOR'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 ------------------------------ -----"'''--~"-------------~, SAFETY PRECAUTIONS The following symbols appear in this manual to call attention • Use Extreme Care When Handling Engine Fuel to and emphasize conditions potentially dangerous to the (A constant danger of explosion or fire exists) operator. not fill fuel tank(s) while the engine is running, ~WARNINGII Do not smoke or use an open flame near the engine or the fuel tank.
- Page 4 It not only makes good sense but is imperative that appropriate representatives of Westerbeke or the sup- plier in question be consulted to determine the accuracy and currency of the product software being con- sulted by the customer.
- Page 5 FOREWORD Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have you as a customer. Read this manual carefully and observe all safety precautions included throughout. Operating procedures, periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust- ment procedures are included herein so you can operate your equipment safely and properly, maintain the equipment at a high level of efficiency, and expect dependable performance and long service life in return.
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Page 6: Table Of Contents
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 ........66 MAINTENANCE & ADJUSTMENTS ......... 70 Westerbeke Generators... - 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...
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Page 8: General
(see the separately fur- nished Parts list). Also, be sure to insist upon Westerbeke factory packaged parts, because "will fit" or generic parts are frequently not made to the same specifications as original equipment. - Page 9 BeG 4.0KW Marine Gasoline Generator Lube Oil Fill Fresh Water Coolant Fill Exhaust Mani Lube Oil Dipstic Exhaust Elbow 20 Amp DC Circu Breaker Zinc Anode DC Battery Ground Connection Heat Ex.cha Weslerbeke Generators...
- Page 10 Water Tempe ratu re Switch Intake Flame Arrestor rburetor with Choke Fresh Water Air Bleed r.;,w'''nor Control Pane Fuel Shut-off Solenoid Lube Oil Drain Hose Exchanger Unit Data Tag Fuel Lift Pum Lube Oil Filter Oil Pressure Switch Westerbeke Generators...
- Page 11 BeG S.5KW Marine Gasoline Generator Distributor Top Engine Oil Fill Fresh Water Coolant Fill 0" Exhaust Elbow Model Data Exhaust Temperature Lube Oil Dir>stick Amp DC Circuit Battery Ground Connection Starter with Solenoid Westerbeke Generators...
- Page 12 BeG 6.SKW Marine Gasoline Generator Fuel Shut-oil So,lelnoi,d Intake Flame Arrestor Carburetor with Choke Water Temperature Switc Control Governor Pressure Switch Anode Heat Exchanger Lube Oil Drain Hose Lube Oil Filter Westerbeke Generators...
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Page 13: Bcg 4.0Kw General Specifications
BCG 4.0KW MARINE GASOLINE GENERATOR SET GENERAL SPECIFICATIONS Engine Type Gasoline, four-cycle, two-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (8 hp at 1800 rpm, maximum). Governor Hoof, flyball type, 5% speed regulation Combustion Chamber Multi-sphere type Bore & Stroke 2.82 x 2.68 inches (71.6 x 68 mm) Piston Displacement 33.4 cubic inches (1.07 liters) -
Page 14: Bcg 4.0Kw System Specifications
Distributor Conventional, contact-point type Spark Plug Thread Size 14 mm x 1.25 pitch Spark Plug Type Westerbeke part number 035666 (Always identify the generator model when ordering parts. See page 5.) FUEL SYSTEM General Conventional carburetor type with fuel lift pump... - Page 15 90 - 125 (Ampere-Hours) DC Battery Charger Internal regulator 13 Volts, 0 -10 Amps. Starter 12-Volt, 1.2f<W, reduction type, solenoid-mounted DC No-Load Current 90 Amp (max,) at 11.5 Volts. DC Cranking Current 175 - 200 Amps (engine cold) Westerbeke Generators...
- Page 16 1800 rpm 18 cfm (0.509 cmm) TUNE-UP SPECIFICATIONS Spark Plug Gap 0.028 - 0.036 inches (0.70 - 0.90 mm) Contact Point Clearance 0.016 - 0.020 inches (0.4 - 0.5 mm) Timing 16' ± l' BTDC at 1800 rpm Westerbeke Generators...
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Page 17: Bcg 6.5Kw General Specifications
Height: 23.38 inches (593.85 mm) Width: 18.69 inches (474.73 mm) Length: 26.75 inches (679.45 mm) Weight 3321bs (150.5 kgs) Fuel Consumption 1.1 U.S. gph (4.16 Iph) at full rated output (approximate) Inclination Continuous 14' Temporary 20' (not to exceed 20 min.) Westerbeke Generators... -
Page 18: Bcg 6.5Kw System Specifications
Conventional, contact-point type Distributor 14 mm x 1.25 pitch Spark Plug Thread Size Westerbeke part number 033805 Spark Plug Type (Always identify the generator model when ordering parts. See page 5.) FUEL SYSTEM Conventional carburetor type with fuel lift pump... - Page 19 90 - 125 (Ampere-Hours) Battery Capacity Internal regulator 13 Volts, 0 - 10 Amps. DC Battery Charger Starter 12-Volt, 1.2KW, reduction type, solenoid-mounted DC No-Load Current 90 Amp (max.) at 11.5 Volts. 225 - 250 Amps (engine cold) DC Cranking Current Westerbeke Generators...
- Page 20 1800 rpm 32 clm (0.906 cmm) TUNE-UP SPECIFICATIONS 0.028 - 0.036 inches (0.70 - 0.90 mm) Spark Plug Gap 0.016 - 0.020 inches (0.4 - 0.5 mm) Contact Point Clearance Timing 14° ± 1° BTDC at 1800 rpm Westerbeke Generators...
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Page 21: Installation Checks
INSTALLATION CHECKS General Since the crafts in which Westerbeke generators are installed vary in design, installation procedures will vary according to your craft's specific design. The intent of this section is not to advise boatyards or installers on procedures already well-developed and well-understood. However, the owner/operator must realize there are details of the installation which require periodic checks to ensure the best operating conditions for the equipment and safe operating conditions for the personnel on board. - Page 22 Special rigging work is best done by someone experienced and competent in handling heavy machinery. Westerbeke Generators...
- Page 23 Hot generator discharge air be removed from the generator area. The plat- form on which the generator and ks mounting rails are located should be strong enough to support the gen- erator during all angles of vessel operation. Westerbeke Generators...
- Page 24 This allows air to enter through this vent to prevent siphoning. GEMEUIOR HLOII IInH LIME Westerbeke Generators...
- Page 25 Exhaust Back-Pressure The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust back-pressure. Exhaust back-pressure should be checked before a gener- ator is put into service. (Refer to the illustration.) Excessive back-pressure will affect the engine's performance and the generator's power output.
- Page 26 Dry stack-type exhaust systems (shown FLAf'PE~ to the right) must be attached to the gen- coVEN erator engine's exhaust manifold by ---1 means of a flexible connector pipe. This system must be properly supported and ~=====14r.~,L 7'f"".M. insulated to prevent water from entering MUI"FLI::R .:! :' into the engine's cylinders.
- Page 27 Exhaust Elbow Installation The Westerbeke Corporation offers a 45°and 90 exhaust elbow as well as an exhaust riser you can install on your generator. Refer to the instructions below when installing the exhaust elbow purchased for your generator. 1. Coat only one side of the exhaust gasket with ·"High Tack"...
- Page 28 Moisture must not be allowed to accumulate in the vent's line. FUEL LINE ALWAYS ABOVE FUEL TANK TOP LEVEL FUEL TANK TOP LEVEL --"..::---~~-~~.:::.-.:--:::::=:~--:-d _'-'...\ NO ANTI-SIPHON DEVICE OR ELECTRICALLY OPERATED VALVE HEEDED NOT ACCEPTABLE FUEL FUEL TANK TOP LEVEL Westerbeke Generators...
- Page 29 IWARNING\ Gasoiine ieakage in or around the generator compartment is a potential cause of fire and/or explosion. Repair leaks promptly and make sure the compartment is property ventilated. Westerbeke Generators...
- Page 30 Oil Drain Hose An oil sump drain hose is installed on the engine with the discharge end secured by a bracket at the front 01 the engine. Oil may be drained from this hose by removing the cap and the discharge end of the hose from the support bracket and lowering the hose into a container.
- Page 31 (which turns OFF the engine), should the switch's sensor indicate an excessive exhaust temperature (an inadequate supply of sea water coolant causes high exhaust temperatures). This switch opens at 260 - 270 F (127 -132 C) and resets at approximately 225 F (107 Westerbeke Generators...
- Page 32 Battery acid may splash on the skin or into the eyes inadvertent- ly when removing the electrolyte caps. Check the battery's electrolyte level and specific gravity to ensure maximum engine starting efficiency. Make sure the battery's terminals are clean and tight. Westerbeke Generators...
- Page 33 Refer to the "SYSTEM SPECIFICATIONS" section 01 this manual for the airflow requirements of the generator sets, page 13 for the BCG 4.0KW, and page 17 for the BCG 6.5KW. Westerbeke Generators...
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Page 34: Description Of Engine Control Panel
The engine-mounted control panel is protected by three fuses. The F1 ignition circuit and the F3 panel cir- cuit are protected by individual 8 Amp fuses. The F2 starter circuit is protected by a single 15 Amp fuse. Westerbeke Generators... - Page 35 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 the operator to release the starter toggle switch in addition to continue indicat- ing that the generator set is running. Westerbeke Generators...
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Page 36: Preparations For Starting
Follow the procedures as presented, for the conditions indicated, and your Westerbeke generator set will give you reliable performance and long service life. Take the steps described below in starting your engine for the first time or after a prolonged shutdown or lay-up. -
Page 37: Starting Procedure
NOTE: Some unstable running may occur in cold engine, but this condition should smooth out as the operating temperature is reached (130 -150' [55 - 66' Gj) and when a load is ap- plied to the generator. Generators Westerbeke... - Page 38 The overspeed shutdown must always be installed and functioning. Any tampering with the overspeed shutdown module, which would cause it to malfunction, could be a cause of injury should the generator's belt-driven governor fail and cause the generator to run away. Westerbeke Generators...
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Page 39: Stopping Procedure
Clean and drain the bowls as needed. Start the generator, following the procedure outlined in the "STARTING PROCEDURES" section, page 34, and allow the engine's operating temperature to reach 130 -150' F (55 - 66' C) before placing the generator under a heavy load. Westerbeke Generators... - Page 40 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. Westerbeke Generators...
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Page 41: Carburetor And Fuel System
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. GOVERNOR LINKAGE SCREENED CLEANER FUEl SOlENO 0 INLET SCREEN " Westerbeke Generators... - Page 42 6. EI!ERIiIZE THE fUEL PUHP TO REfILL THE IIIIIIL Although most boatbuilders supply a water trap/filter, some do not. Westerbeke offers a sedimenter/water trap/filter as an optional extra at moderate cost. The filter Is supplied wtth fittings for either hose or metal tubing fuel lines.
- Page 43 DO NOT allow any smoking, open flames, or other sources of fire near the fuel system when servicing. Make sure proper ventilation exists when servicing the fuel system. Westerbeke Generators...
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Page 44: Electrical System
125 Ampere-Hours (minimum) for the generator sets covered by this manual. CAUTION When quick-charging the battery with an external charger, be sure to disconnect the battery cables from the battery. Leaving the charging circuit connected while quick-charging will damage the diodes in the integral controller'S circuitry. Westerbeke Generators... - Page 45 C. Remove the positive lead from point #4 and connect the negative (-) lead to point #4. Touch points #1, #2, and #3. The needle should deflect, indicating a passage of current Westerbeke Generators...
- Page 46 White/ Yellow (+1 Plus Terminal 01 Recti/ior While IGreen (-) Negative Terminal 01 Rectifier White I Black Ground V While/Red O.C.Charge NOTE white/Green (-) Negative and White/Black Ground are interchangeable. Westerbeke Generators...
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Page 47: Dc Control Circuit Wiring Diagram # 37190
Ie-- - - - - - - ---'f--- -t-l--4---r- rGROMMET INTO PANEL "v!> ro'e GOlD OVfR~PE£D L1IJ~z!n "~ ~c./wl", .. r't{ $TRIPC " ,==1 " .." "~ "0;;' r'·"u:~" '''~ON _t------ L. ____________________ ".""~."""'!Wc'."'"._"'" •• "'".'C_ __________ '". YEclw!flH $'">''' PANEL Westerbeke Generators... - Page 48 0-16· 1(;-20' 20-Z!>' 2~-:2' 32-40' 40-~0· ,>~:f,5'1 TERMINAL:; '~"7 ° TEll-I TO TB3-' I -10 Te,-z T6~-Z I" <J Tel-, TO T(>4-1 I : ! I'" ;:~~ ~oo :::=~ ," 1<1 '<1 " ,. TBZ-4 TO Ta " " .rnz~ T~_5 I· Westerbeke Generators...
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Page 49: Optional Remote Start Panel Wiring Diagram # 35706
OPTIONAL REMOTE START PANEL WIRING DIAGRAM # 35706 OPTIONRl REMOTE START PANEL (REAR VIEW} PART' 33183 r - - - - - - - - - - - - - - - - - - - - - , 116 RED 112 YHLOIi/W/REO STRIPE Alf-... -
Page 50: Optional Remote Instrument Panel Wiring Diagram # 35698
REMOTE INSTHUf\lENT PANEL (REAR VIEW) ASS"f PN 1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , REO/W/PURPLt STRIPE !/le RFli... -
Page 51: Cooling System
COOLING SYSTEM Description Westerbeke marine gasoline engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to the fresh water which circulates throughout the en- gine. This circulating fresh water cools the engine block and tts internal moving parts. The heat is transferred externally from the fresh water to sea water by means of a heat exchanger, similar in function to an automo- tive radiator. - Page 52 10' F (5' C) lower than the actual atmospheric temperature expected. B. Filling the Fresh Water System A coolant recovery tank kit is supplied with each Westerbeke gasoline generator. The purpose of this recovery tank Is to allow for engine coolant expansion and contraction, during engine operation, without the loss of coolant and without introducing air into the cooling system.
- Page 53 Since 1980, each type of thermostat has a hole punched through it. The hole is a bypass to prevent the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have this design characteristic. Westerbeke Generators...
- Page 54 On no account should this pump be run dry. There should always be a spare impeller and impeller cover gasket on board (an impeller kn). NOTE: Impeller failures resulting from a loss of sea water coolant are not warrantable failures. Westerbeke Generators...
- Page 55 (See the figure below.) Spare drive belts should be carried on board. 3/0· TO 112· DHl[CTIDN FRESH WATER PUMP lOUR PUll CRAUSHAFT PULLEY Governor and Water Pump Belt Tension Westerbeke Generators...
- Page 56 Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow through their independent cooling circutts. Please refer to the Parts List for individual part numbers and descriptions for your generator's cooling system. WATER INJECTED...
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Page 57: Lubrication System
Your generator set is fitted with an oil pressure sensing switch as standard equipment. Should your engine's oil pressure drop below a safe operating pressure, the sensor will shut the engine OFF to prevent any inter- nal damage to your generator's engine from occurring by interrupting the DC voltage to the ignition coil. Westerbeke Generators... - Page 58 Immediately after an oil filter change and oil fill, run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil filter. Westerbeke Generators...
- Page 59 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. Oil Dipstick Upper Li.it (Nor.al leveli) -"-'-t~::=:==:=:===1 Lower Crankcase Westerbeke Generators...
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Page 60: Bc Generator
D. Bridge Rectifier and Integral Controller Generator Frequency Frequency isa direct result of engine/generator speed: 1800 RPM - 60 Hertz, 1500 RPM -50 Hertz To change the generator's frequency, refer to the "MAINTENANCE AND ADJUSTMENTS" section of this manual, page Westerbeke Generators... - Page 61 Ask your local Westerbeke dealer for a Be GENERAL TROUBLESHOOTING GUIDE before performing the steps listed at the bottom of the next page.
- Page 62 THE 11 PLUG IS SHOWN CONNECTED TO THE CAPACITOR ONLY FOR DEMON- STRATION PURPOSES. <:> '" BeG 4.0KW GENERATOR AC load Connection Ter.inal Block Generator End (over Plate ::::,~--tF;III- Capacitor ' " No-load Uoltage Adjustment Plugs 50 Hertz Plug CAUTION: ALLOW ANY THESE PLUGS TO TOUCH...
- Page 63 Ask your local Westerbeke dealer for a BC GENERAL TROUBLESHOOTING GUIDE before performing the steps listed at the bottom the next page.
- Page 64 60 Hertz: 60.5 - 61.5 50 Hertz: 50.5 - 51.5 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 62. Westerbeke Generators...
- Page 65 Load Connections The generator's data plate gives the voltage, current and frequency rating of the generator. An AC wiring decal is affixed to the inside of the louvered cover on the generator end. A diagram of the various AC volt- age connections is provided on the decal.
- Page 66 NOTE, OIAGRAM SHOWS CONNECTIONS fOR A IWO- GI'~ WIRE, 120-VOLT SYSTEM fROM THE GENERATOR, WITH THREE-WIRE, I20-VOlT ---"B"'O"'AT'-iS YS TE M. L -________ Ship-to-Shore Switch (3 Pole) 329BB AMPS/POLE) 321HI9 (BI'! AMPG/POLE;) 32918 (.l:n, AMPS/POLE) PH 32133 (209 AMPS/POLl::) Shore Power Switch Connection Diagrams Westerbeke Generators...
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Page 67: General Information And Care Of The Generator
Run the generator at first with no load applied, then at half the generator's capacITy, and finally loaded to its full capacity as indicated on the generator's data plate. See the rpm/Hertz/frequency chart on the next page. Westerbeke Generators... - Page 68 3. The rear armature bearing is lubricated and sealed; therefore, no maintenance is required. If the bearing becomes rough or noisy, replace it. Generator Troubleshooting A complete and illustrated text on troubleshooting the BC series of generators is furnished in the Technical Manual which is available through your local dealer. Westerbeke Generators...
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Page 69: Engine Troubleshooting
Engine does not crank. 1. Battery is low or dead. 2. Engine's DC 20-Amp breaker has tripped. 3. Sea water filled cylinders. 4. Loose battery connections. 5. Voltage drop at starter solenoid terminal. 6. Bad starter solenoid. 7. Faulty START switch. Westerbeke Generators... - Page 70 2. Belts are loose or broken. 3. Sea water pump's impeller is faulty. 4. Sea water pump is worn. 5. Faulty hose. 6. Thermostat is stuck closed. 7. Heat exchanger is clogged. 8. Faulty gauge (check with a thermometer). Westerbeke Generators...
- Page 71 3. Dirty oil or wrong SAE type oil is in the engine. 1. Low oil level. Low oil pressure. 2. Faulty gauge. 3. Wrong SAE type oil is in the engine. 4. Relief valve is stuck. 5. Faulty oil pump. Westerbeke Generators...
- Page 72 2. Choke is stuck closed. 3. Carburetor is flooding. Blue exhaust smoke is discharged 1. Valves are worn or adjusted incorrectly. from the exhaust. 2. Piston rings are worn or unseated. 3. Lubrication oil is diluted. 4. Crankcase breather hose is clogged. Westerbeke Generators...
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Page 73: Maintenance & Adjustments
MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/operator can perform without the benefit of sophisticated and expensive tools and instruments. Preventive Maintenance (Engine) Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs. Adherence to these schedules will make sure the equipment is maintained in the best possible condition and that it will perform to expectations. - Page 74 1. Remove, clean, and pressure test the primary heat exchanger. (A local automotive radiator shop should be able to clean and test the heat exchanger.) NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours. Westerbeke Generators...
- Page 75 AC output leads to the AC terminal block in accordance wtth the "AC Vol- tage Connections" diagram specified for your generator set, which appears in the "BC GENERATOR" sec- tion of this manual, page 62. Westerbeke Generators...
- Page 76 3. Using the timing light, align the timing groove in the front crankshaft pulley with the timing pointer. Do this by loosening and slowly rotating the distributor body. Refer to the timing specifications below. Timing Specifications: BCG4.0KW 16' ± l' BTDC at 1800 rpm BCG6.5KW l' BTDC at 1800 rpm ±...
- Page 77 IIDJUSHtEKf The increase/decrease speed boll may need to be adjusted as well. If the governor surges while under a load, adjust this eye bolt to move the spring away from the lever hub. (Check the speed adjustment.) Westerbeke Generators...
- Page 78 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 on the engine and fill it with the proper quantity of SAE 10/30 engine oil, and replace the plugs. Westerbeke Generators...
- Page 79 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 the engine's speed, page 74. SCREENED (LEANER THROTTlE ~~~Yl~~~~~~~ SlOP FUEl SOLENO D IDLE MIXTURE JEI Westerbeke Generators...
- Page 80 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) Westerbeke Generators...
- Page 81 2 cylinder's intake and the No.3 cylinder's ex- haust valve clearances. Adjust all valves to 0.0071 inches (0.18 mm) with the engine cOld. Replace the rocker cover along with a new rocker cover gasket. Rocker cover torque: 5.8· 8.7Ib·ft (0.8·1.2 kg·m) Westerbeke Generators...
- Page 82 BCG 6.5KW 10.8 - 15.9 Ib-ft (1.5 - 2.2 kg-m) Check each plug for damage and/or wear. 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. Westerbeke Generators...
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Page 83: Lay-Up & Recommissioning
Change the element in your primary fuel filter/water separator, if the fuel system contains one, and clean the separator sediment bowl. Clean the filter screen in the fuel lift pump and in the carburetor. Westerbeke Generators... - Page 84 Check your basic spares kit and order ITems not on hand, or replace those ITems used during the lay-up, such as filters and zinc anodes. Refer to the "SPARE PARTS" section of this manual, page 83. Westerbeke Generators...
- Page 85 Recommissioning The recommissioning of your Westerbeke unit after a seasonal lay-up generally follows the same proce- dures as those presented in the "PREPARATIONS FOR STARTING" section, page 33, regarding preparation for starting and normal starts. However, some of the lay-up procedures will need to be counteracted before starting the engine.
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Page 86: Spare Parts List
From the list provided directly above and from these inquiries, you can determine what spare parts may be needed. In addition, if you are planning a long ocean voyage, consult your local Westerbeke dealer for a listing of the Westerbeke dealers located on your route. -
Page 87: Table Of Standard Hardware Tightening Torques
3,7 - 4,6 3/8 UNF 30 - 35 4,1 - 4,8 7/16 UNC 44 - 49 6,1 - 6,8 7/16 UNF 50 - 6,9 - 7,6 1/2 UNC 68 - 73 9.4-10,1 1/2 UNF 73 - 80 10,1-11.1 Westerbeke Generators... -
Page 88: Table Of Tightening Torques
36.2 - 43.4 5.0 - 6.0 (*See the Torquing Cylinder Head Bolts section on page 77.) Crankshaft pulley to crankshaft 36.2 - 43.4 5.0 - 6.0 BCG4.0KW BCG6.5KW 65.2 - 72.4 9.0 - 10.0 Rocker cover to cylinder block BCG4.0KW 5.1 - 9.4... -
Page 89: Index
LEAVING OLD OIL IN THE SUMP OVER THE LAY-UP PERIOD ........... 80 Carburetor Adjustment ..........................76 CARBU RETOR AND FUEL SySTEM ......................38 CARE OF THE GENERATOR, GENERAL INFORMATION AND ..............64 Charging Circuit, Testing the Battery ......................42 Westerbeke Generators... - Page 90 Choke, Electric ............................73 Connecting Pressure Sensing Devices to Oil Galleries (Installation Checks) .......... 27 Connections, DC Electrical (Installation Checks) ..................28 Connections, Load ............................62 Connections, Shore Power ......................... 63 CONTENTS, TABLE OF ..........................3 CONTROL CIRCUIT WIRING DIAGRAM #37190, DC ..............44 and 45 CONTROL PANEL, DESCRIPTION OF ENGINE ..................
- Page 91 Load Connections ............................62 Location, Generator Mounting (Installation Checks) ................. 20 LUBRICATION SYSTEM ..........................54 MAINTENANCE AND ADJUSTMENTS ....................... 70 Maintenance, Governor ..........................75 Maintenance, Preventive (Engine) ......................70 Maintenance, Preventive (Generator) ......................65 Motors, Use of Electric ..........................64 Westerbeke Generators...
- Page 92 Rigging, Lifting and (Installation Checks) ....................19 Remote Instrument and Start Panels, Optional ..................32 REMOTE INSTRUMENT PANEL WIRING DIAGRAM #35698 ..............47 REMOTE START PANEL WIRING DIAGRAM #35706 ................46 Remote Starting Procedure ........................35 Remote Stopping Procedure ........................35 Westerbeke Generators...
- Page 93 Use of Electric Motors ..........................64 Valve Clearance Adjustment: BCG 4.0KW ....................78 Valve Clearance Adjustment: BCG 6.5KW ....................78 Ventilation (Installation Checks) ........................30 Viscosity, (SAE Number), Engine Oil ......................54 Voltage Adjustment, No-Load, BCG 4.0KW ....................58 Westerbeke Generators...
- Page 94 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 Zinc Anode Conditions ..........................51 Westerbeke Generators...
- Page 95 YOUR NOTES Westerbeke Generators...
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