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Westerbeke 4.5KW BCGB-60HZ Operator's Manual

Gasoline, single phase generators.
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OPERATORS MANUAL
FOR THE
4.5KW BeGB - 60HZ
3.8KW BeGB - 50Hz
AND
7.0KW BeGB - 60HZ
5.0KW BeGB - 50Hz
GASOLINE GENERATORS
SINGLE PHASE
PUBLICATION NO.44200
JUNE 1999
1ST EDITION
WESTERBEKE CORPORATION
MYLES ST ANDISH INDUSTRIAL PARK
150 JOHN HANCOCK
ROAD,
TAUNTON,
MA 0278fJ.7319
....

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Table of Contents

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   Summary of Contents for Westerbeke 4.5KW BCGB-60HZ

  • Page 1 4.5KW BeGB - 60HZ 3.8KW BeGB - 50Hz 7.0KW BeGB - 60HZ 5.0KW BeGB - 50Hz GASOLINE GENERATORS SINGLE PHASE PUBLICATION NO.44200 JUNE 1999 1ST EDITION WESTERBEKE CORPORATION MYLES ST ANDISH INDUSTRIAL PARK ..150 JOHN HANCOCK ROAD, TAUNTON, MA 0278fJ.7319...
  • Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
  • Page 3 IF YOU OR ANYONE EI.SE EXPERIENCE ANY DF THESE SYMl'TDMS, SET OUT INTO THE FRESH AIR IMMEDIATELY. "symptoms persist, sesJc medical attention. Shut down unit and do not fIIStaJt tIIB until has been Inspected and fllpalred. ,,,.,WESTERBEKE Generators Engines &...
  • Page 4: Model

    ISO 8846 1990(E) Standard(s) to Which Conformity ENS0081-1 is declared ENS0082-2 ENSS020 ISO-8846-1990(E), Certification Number, IWES003 Westerbeke Corporation Manufacturers Name Manufacturers Address 150 John Hancock Road Myles Standish Industrial Park Taunton, Ma. 02780-7319, USA Type of Equipment Marine Gasoline Generator...
  • Page 5 94125/EC for We hereby certify the component stated below meets the EC Directive type-examination in accordance with ISO 8846 and has following characteristics: Gasoline Marine Generator TYPE .:;- Westerbeke Corp. MANUFACTURER Avon Industrial Park, ADDRESS AVON, MA02333 GROUP OF +++++...
  • Page 6 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefuUy. Most accidents are caused by failure to folJow fundamenJal rules and precau- WARNING: Fire can cause injury death! Know Iilke tions. when dangerous condiJions exist necessary precautions to protect yourself, your personne4 •...
  • Page 8 Do not service the engine while it is running. If a situa- inadvertently when removing electrolyte caps. tion arises in which it is absolutely necessary to make operating adjusbnents, use extreme care to avoid touching moving parts and hot exhaust system components. WESTERBEKE Engines & Generators...
  • Page 10 USCG and the NFPA. Sections the ABYC standards of particular interest are: Ventilation H-24 Gasoline fuel systems P-I Exhaust systems P-4 Inboard engines Elecaical systems installations must comply with the Federal Code of Regulations (FCR). WESTERBEKE Engines Generators &...
  • Page 12 INSTALLATION When installing WESTERBEKE engines and generators is important that strict attention be paid to the following information: CODES AND REGULATIONS regulations, ABYC Strict federal guidelines, and safety codes must be complied with' when installing engines and generators in a...
  • Page 14: Table Of Contents

    Oil Pressure ............BCGB Hardware Torques ........Remote Oil Filter ..........Metric Conversions Chart ......... 52 BCGB Wiring Diagram ........BCGB Wiring Schematic ......'" ..Suggested Spare Parts ........53 Remote Panel Wiring ......... 25 -..v- WESTERBEKE Engines Generators &...
  • Page 15: Parts Identification

    BCGB PARTS IDENTIFICATION AIR INTAKE ENGINE Oil Fill PRESSURE CAP WATER INJECTED EXHAUST ELBOW REMOTE PANEL CONNECTION CIRCUIT BREAKER COOLANT DRAIN GENERATOR BACKEND REAR Oil PAN LEFT SIDE MOUNT 'HI,XI'" CARBURETOR RIGHT SIDE ENGINE Oil Fill HOURMETER ~~3i\t----- _---~::;;;::~:...~ RAW WATER CONTROL SWITCHES- INJECTION...
  • Page 16: Introduction

    INTRODUCTION WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT This WES1ERBEKE Generator is a product of WES1ERBEKE'S long years of experience and advanced OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRE- technology, We take great pride in the superior durability and SENTATIONS WITH RESPECT THERETO, INCLUOING ACCU- dependable performance of our engines and generators.
  • Page 17: Model

    NOTE: A carbon monoxide warning decal has been provided are verticle in-line, and the engine's cylinder head has an by WESTERBEKE. Affix this decal in a visable location in overhead camshaft which is chain-driven. The engine utilizes engine room. a solid-state distributor which is horizontally mounted and camshaft-driven.
  • Page 18: Fuel, Engine Oil And Engine Coolanl

    FUEL, ENGINE OIL AND ENGINE COOLANT GASOLINE 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 surlaces.
  • Page 19: Control Panels

    CONTROL PANELS GENERATOR CONTROL PANEL REMOTE PANEL The ON and START/STOP switches are the only functional There are three functional components on the remote panel components to operate the generator at the engine. Both for generator operation: switches are used to start the generator - see Starting the 1.
  • Page 20: Preparations For Initial Start.up

    OFF until the engine has come up speed and, in cold climates, starts warm up. This precaution will prevent damage caused by unantici· pated operation of the AC machinery and will prevent a cold engine from stalling..v- WESTERBEKE Engines & Generators...
  • Page 21: Operating Instructions

    OPERATING INSTRUCTIONS GENERATOR CONTROL PANEL Starting the Generator GENERATOR CONTROL PANEL 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 22: Remote Panel

    To stop the generator, move the momentary START/STOP switch to the down position then release it to the center (stop) (off/run mode) position. This will de-energize the K2 run relay in the generator's control panel and stop the generator. WESTERBEKE Engines & Generators...
  • Page 23: Break·ln Procedure/daily Operation

    • Check for abnormal noise such as knocking, vibration and blow-back sounds. • Confirm exhaust smoke: When the engine is cold - White Smoke. When the engine is warm - almost Smokeless. When the engine is overloaded - some Black Smoke. WESTERBEKE Engines & Generators...
  • Page 24: Safety Shutdown Switches

    SAFETY SHUTDOWN SAFETY SHUTDOWN SWITCHES The engine is protected by a variety of shutdown switches. Should a shutdown occur, do not attempt to resfllrt without finding and correcting the cause. Refer to the heading OIL FILTER Engine starts, runs and then shuts down in the ENGINE TROUBLESHOOTING section of this manual.
  • Page 25: Maintenance Schedule

    . Check that all connections are tight. Hose should be hard tight. Replace soft or Engine Hoses & spongy. Check and tighten all hose clamps. 'WESTERBEKE recommends this service be performed by an authorized mechanic. (continued) Engines Generators &...
  • Page 26 'Exhaust Elbow Test exhaust elbow for casting integrity. Replace if casting is corroded or deteriorated. WARNING: A defecffve exhaust elbow can cause carbon monoxide leakage! 'WESTERBEKE recommends this service be performed by an authorized mechanic. Engines & Generators...
  • Page 27: Cooling System

    In other words, the engine is cooled fresh water coolant, this coolant is cooled by raw water, and the raw water carries Westerbeke marine engines are designed and equipped for the transferred heat overboard through the exhaust system. fresh water cooling. Heat produced in the engine...
  • Page 28: Changing Coolant

    Carry a spare cap. FROM COOLANT MANIFOLD • RECOVERY TANK PRESSURE TO COOLANT RECOVERY TANK COOLANT RETRACTION COOLANT EXPANSION SEALS CHECKING THE PRESSURE CAP -...v- WESTERBEKE Engines Generators &...
  • Page 29: Thermostat

    COOLING SYSTEM If the zinc anodes need replacement, hold the hex boss into THERMOSTAT which the zinc anode is threaded with a wrench while A thermostat controls the coolant temperature as the coolant loosening the anode with another wrench. This prevents the continuously flows through the closed cooling circuit.
  • Page 30: Raw Water Intake Strainer

    COOLING SYSTEM RAW WATER INTAKE STRAINER RAW WATER PUMP with The raw water pump is a self-priming, rotary pump 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 carn plate A clean raw water intake strainer is a vital component of the within the impeller housing, producing the pumping action.
  • Page 31: Fuel System

    FUEL SYSTEM GASOLINE Use unleaded 89 octane or higher gasoline. When fueling, A WARNING: Fuel leakage the fuel pump or its follow U.S. Coast Guard regulations, close off all hatches and connections is fire hazard and should be corrected. companionways to prevent fumes from entering the boat, and Make sure proper ventilation exists whenever servic- ventilate after fueling.
  • Page 32: Carburetor Adjustments

    100 hours from then on. Clean the air screen in kerosene. AIR SGFtEEII-----""""7<fZ- TO ROCKER ARM COVER AIR INTAKE FLAME ARRESTER CHOKE THROTILE FROM FUEL LIFT PUMP In---------f-;:-->1fI.C IDLE MIXTURE CARBURETOR FILTER SCREEN FUEL SOLENOID HEX HD PLUG CARBURETOR WESTERBEKE Engines Generators &...
  • Page 33: Engine Lubricating Oil

    Make sure the oil drain hose NOTE: is properly secured in its holder after all of the old oil has Use genuine WESTERBEKE oilfilters. Genericfilters been drained. are not recommended. Always observe the old oil as it is removed. A yellow/gray REFILLING THE DlL SUMP emulsion indicates the presence of water in the oil.
  • Page 34: Oil Pressure

    OIL PRESSURE NOTE: WESTERBEKE recommends that the following engine adjustments be peifonned a competent engine mechanic. The infonnation below is provided to assist the mechanic. DESCRIPTION LOW OIL PRESSURE The lubricating system is a pressure feeding system using an The specified safe minimum oil pressure is 4.3 1.4 psi (0.3...
  • Page 35: Remote Oil Filter

    Contact your WESTERBEKE dealer for more information. NOTE: NOTE: Westerbeke is not responsible for engine failure due to Refer to ENGINE OIL CHANGE in this manual for incorrect installation of the Remote Oil Filter. instructions on removing the oilfilter.
  • Page 36: Bcgb Wiring Diagram

    ..4.5KW /7.0KW BeGB GENERATOR WIRING DIAGRAM #43864 i.16 VIO/WIIT '14 RH '=l;;:m ..416 8Lk '----+-t-----t-H-t-H-t-t---"-'-'''''---*--jll' ' " R£lHYIO tit RED/VIO '---'!. " " " '-"fN'IWESTERBEKE Engines & Generators...
  • Page 37: Bcgb Wiring Schematic

    " CKTZOIO) K2-RUM •• " " EXHAUS~ ~ OV£ISPEEll TEMP '''" DIODE SWITCH JUGOZ " 0" " 'liDS. \.., $WI reH ."'TER SWITCH PlUs. SWITCH _r'L~ !L._ .o..'"'-L • _ .12L fi!I [~:L ~ I!_-.ll "'" WESTERBEKE Engines Generators &...
  • Page 38: Remote Panel Wiring

    REMOTE PANEL WIRING SCHEMATIC #043912 REMOTE PANEL ' - - - - - - - t - - - i \ ' I CKT I ON SW WHITE WHITE *14 RED/VIO VIEWED FROM MATING END Engines Generators &...
  • Page 39: Engine Adjustments

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peifonned a competent engine mechanic. The information below is provided to assist the mechanic. ENGINE SPEED (HERTZ) ADJUSTMENT Governor Maintenance Governor 1. Periodically lubricate the linkage arm attaching points at the governor arm and throttle lever.
  • Page 40: Spark Plugs

    ENGINE ADJUSTMENTS SPARK PLUGS DRIVE BELT ADJUSTMENT The spark plugs should be cleaned and regapped after the The drive belt must be properly tensioned. Excessive drive fIrst 50 hour break-in period, then inspected every 250 hours belt tension can cause rapid wear of the belt and reduce the service life of the fresh water pump's bearing.
  • Page 41: Valve Clearance

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed a competent engine mechanic. The injonnation below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT IGNITION TIMING NOTE: Retorque the cylinder head bolts before adjusting the 1. Attach a timing light to the #1 spark plug and mark the...
  • Page 42: Timing Belt

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The infonnation below is provided to assist the mechanic. TIMING BELT INSPECTION AND REPLACEMENT 5. Remove the timing belt. NOTE: the timing belt is to be reused, draw an arrow on...
  • Page 43 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. Flange Installation Crankshaft Bolt Removal 1. Lock the crankshaft in position. Mount the flange so that its side shown by the heavy arrow in the illustration faces toward the sprocket.
  • Page 44 ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The injonnation below is provided to assist the mechanic. Tensioner Spring/Timing Tensioner Installation At this time, check that the moveable range of teeth on the oil pump sprocket is according to specifications.
  • Page 45: Engine Compression

    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. Tum the crankshaft clockwise by nine camshaft sprocket ENGINE COMPRESSION TEST teeth (817) to align the timing mark on the camshaft...
  • Page 46: Component Testing

    COMPONENT TESTING NOTE: WESTERBEKE recommends that the following engine testing adjustments be perjonned a competent technician. GENERAL TAP THE GROUND All DC voltage measurements are made to the engine battery CONNECTION TO negative ground point unless specified otherwise. In making...
  • Page 47: Engine Troubleshooting

    NOTE: When troubleshooting a loss of ignition spark and the overspeed switch is suspect: By-pass the switch by lifting the T3 connector (overspeed terminal board) and connecting to the vacant T4 spade connector. Start the engine and spark returns, the overspeed switch is at fault. Refer to the OVERSPEED WIRING DIAGRAM . WESTERBEKE ..v' Engines & Generators...
  • Page 48 ENGINE TROUBLESHOOTING PROBABLE CAUSE PROBLEM PROBABLE CAUSE PROBLEM No DC charge to the Faulty connections to Poor quality fuel. Engine misfires. starting battery. battery charging control. Incorrect timing. Faulty battery charging control. Dirty flame arrester. Faulty bridge rectifier. Cracked distributor cap. Faulty generator charger Faulty ignition wires.
  • Page 49: Generator Information

    GENERATOR INFORMATION USE OF ELECTRIC MOTORS Generator Frequency Adjustment The power required to start an electric motor is considerably Frequency is a direct result of engine/generator speed, as more than is required to keep it running after it is started. indicated by the following: Some motors require much more current to start them than •...
  • Page 50: Bc Generator Single Phase

    This mutual build up NOTE: This circuit breaker is available as a WESTERBEKE of voltage in the four rotating poles and in the exciter wind- add-on kit for earlier model generators; contact your ings quickly reaches the saturation point of the capacitor(s) WESTERBEKE dealer.
  • Page 51 Simply cross the capacitor's two terminals with an or the voltage needs to be lowered and the lowest num- insulated (plastic handle) screwdriver. This will discharge bered plug is connected, refer to the WESTERBEKE BC any excess electricity. Generator Troubleshooting Guide), Engines &...
  • Page 52 Be GENERATOR SINGLE PHASE NOTE: WESTERBEKE recommends that the following generator tests and adjustments be performed by a qualified technician. DUAL EXCITER CIRCUIT 60 Hz 120 VOLT CONFIGURATION ILLUSTRATION INTEGRAL CONTROLLER >. [BATTERY CHARGER! 50Hz LEAD ,fi~if"· ..-;./...
  • Page 53: Ac Terminal Board Connections

    THE CAPACITOR AND REPLACE WITH THE SAME RATING. -6r:n-- -- - - ! L ' ---------" : 50i: 6050 ' ' ' " ' 7.0BC ROTOR I "' '" CHARGER !_~i~1i:~t ~IO~t_l ~~~~~ERR DUAL EXCITER CIRCUIT -..v- WESTERBEKE Engines Generators &...
  • Page 54: Bc Generator Single Phase

    Be GENERATOR SINGLE PHASE TESTING THE EXCITER WINDINGS 3. With an ohmmeter set on the high R scale, place its plus (+) lead on one capacitor connection and the negative (-) Single Dual lead on the other capacitor connection. A resistance Capacitor Exciter should be read and should rise slowly as the meter...
  • Page 55: Testing Component Resistance

    Be GENERATOR SINGLE PHASE Testing Component Resistance Values Rotating Field/Auxiliary Windings and Diodes 2. Diodes 8 - 9.5 ohms (approximate) using a 260 Simpson Analog Meter Two sets of windings are found in the rotor assembly. An AC To check the diode, unsolder the connection from the top voltage is produced in two groups of windings as the rotor of the diode.
  • Page 56: Integral Controller

    NOTE: Different types and/or brands of test meters may produce opposite test results. GROUND TO GENERATOR CASE POINT NOTE: Earlier model controllers had white/green (-) negative and whitelblack ground connections that are interchangeable. POINT #4 POINT 15 MOUNTING HOLE WESTERBEKE Engines Generators &...
  • Page 57 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 58: Testing The Battery Charging Circuil

    TESTING THE BATTERY CHARGING CIRCUIT BATTERY CHARGER The generator supplies a continuous 17 amp charge from its battery charger to the starting battery. To test the battery charger put a multimeter between the positive (+) and TO CIRCUIT BREAKER negative (-) leads to the battery. should indicate 13.5V to 14V with the engine running.
  • Page 59: Shore Power Transfer Switch

    SHORE POWER TRANSFER SWITCH 120 VOLT/50 HERTZ TWO WIRE CONFIGURATION 230 VOLT/50 HERTZ TWO WIRE CONFIGURATION Generator NOTE: Diagram shows connections for a two- wire. 120-Volt system from the generator. with three_wire,120_Volt boat system. PN 32009 GENERATOR PH 32010 GROUND PH 32133 Ship·lo·Shore Switch 13 Pole) '"...
  • Page 60: Lay·up And Recommissioning

    LAY-UP & RECOMMISSIONING General Fuel System [Gasoline] Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane including engines and generators, for lay-up during the off- STABIL or higher. A fuel conditioner such as gasoline season or for long periods of inactivity.
  • Page 61 Lay-up time provides a good opportunity to inspect your if access to the starter permits its removal. Make sure the WESTERBEKE engine to see if external items such as drive battery connections are shut off before attempting to remove belts or coolant hoses need replacement. Check your basic the starter.
  • Page 62: Generator Specifications

    0.031 ±.002 inches (0.8±0.05 mm) Battery Capacity 150 Cold Cranking Amps(CCA)(min) Spark Plug Torque 10.8 -15.2Ib-ft Battery Charging Integral electnc, 17 amps Cylinder Head Torque 60 - 70 Nm 43 - 51 ft-Ibs BoltTorque See TORQUING THE CYLINDER HEAD "'" WESTERBEKE Engines & Generators...
  • Page 63: Standard Hardware

    HYLOMAR work well in applications requir· Heavily oil all sliding and reciprocating components when assembling. Always ing non·hardening properties. HYLOMAR is particlarly effective on use clean engine oil! copper cylinder·head gaskets as it resists fuel. oil and water. 1'!!"'tIY'~WESTERBEKE Engines & Generators...
  • Page 64: Bcgb Hardware Torques

    Taper plug 114 NPT 35-45 25-33 Coolant temperature switch 12-18 9-13 23-34 pressure 12-18 9-13 Generator mounts 34-47 switch pressure 12-18 sender 9-13 Exhaust manifold 16-23 12-17 Water Pump Thermostat housing 8-11 8-10 Water pump ""'" WESTERBEKE Engines & Generators...
  • Page 65: Metric Conversions Chart

    Liters Liters Liters Pints Liters Pints Pints 2.84 12.68 0.47 2.11 0.95 3.31 4.23 14.79 1.42 3.79 6.34 16.91 1.89 4.26 8.45 19.02 2.37 4.73 10.57 21.13 TEMPERATURE 105 140 175 212 80 100 °C WESTERBEKE 'SlY: Engines Generators &...
  • Page 66: Suggested Spare Parts

    SUGGESTED SPARE PARTS WESTERBEKE MARINE GASOLINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION DISTRIBUTER CAP WITH WIRES FUEL LIFT SPARE FUSES PUMP SPARE PARTS KIT - - - - - - - WESTERBEKE offers two Spare Parts Kits, each packaged in a rugged hinged toolbox.
  • Page 69 WESIERBEKE Engines & Generators...

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