Westerbeke 3.0KW BPMG Operator's Manual
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Westerbeke 3.0KW BPMG Operator's Manual

Westerbeke 3.0KW BPMG Operator's Manual

Gasoline, single phase 60hz and 50hz
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Water Cooled Models
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NO. 48009
REVISION
5
JUNE 2011
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WESTERBEKE
WEsTcRBCKE CORPORATION. MYLeS STANDISH INDUSTRIAL PARK
160JOHN HANCOCK ROAD, TAUNTON, MA 0278{J-7319 U.S.A.
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Af.MMA
Member Notional Marine ManufacturersAssociation

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  • Page 1 "' 3 Cooled GiFresh Water • ." NO. 48009 REVISION JUNE 2011 WESTERBEKE ..WEsTcRBCKE CORPORATION. MYLeS STANDISH INDUSTRIAL PARK 160JOHN HANCOCK ROAD, TAUNTON, MA 0278{J-7319 U.S.A. - - - - - - - - ----- --------- Af.MMA Member Notional Marine ManufacturersAssociation...
  • Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
  • Page 3 TlIls WARNING DECAL is provided by to a WES7'ERBEKE and should be "xed bulkheadneaf your eliglne generator. WE8TERBEKEalso recommends Installing CARBON MONOXIDE DETECTORS In the Ilvilig/steeping qualfers of vessel. YOUI TlIeyare In8xpenslve and easily . dbtalnable yOUi" local filarine store. """ WESTERBEKE Englties & Generators...
  • 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 death! tions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personnel, •...
  • Page 5 Acid may splash on the skin or into the eyes . inadvertently when removing electrolyte caps. WESTERBEKE Engines Generators &...
  • Page 6 Sections of the ABYC standards of particular interest are: H-2 Ventilation H-24 Gasoline Fuel Systems P-l Exhaust Systems P-4 Inboard Engines &9 DC Electrical Systems All installations must comply with the Federal Code of Regulations (FCR). WESTERBEKE -."y: Engines Generators &...
  • Page 7 A detailed 40 page Marine Installation Manual covering gasoline and diesel, engines and generators, is snpplied with each Westerbeke Marine product. -.-v: WESTERBEKE...

  • Page 8: Table Of Contents

    Water Intake Strainer ..........16 Changing the Impeller ..........16 *Models manufactured with heat exchangers for cooling with fresh waterlcoolant or raw water cooled models that have been converted to . fresh cooling via WESTERBEKE'S FRESH WATER COOUNG KIT. ..-v: WESTERBEKE Engines Generators...
  • Page 9 CONTROL MODULE BATTERY VOLTAGE, "'f-~)f. WATER INJO,EC,gTC;WED,,,,' 'EXHAUST« EXHAust, HOSE CONNECTION' LEFT sIDe COOLANT TEMPERATURE SWITCH ~CDOLAINT PRES!IURE EXHAUST' TEMPERATURE SWITCH METER . DIPSTICK START/STOP SWITCH CONTROL SERVICE SIDE DRIP PAN RIGIIT CIRCUIT BREIIKER SIDE , WESTERBEKE "IIV' Engines & Generators...

  • Page 10: Parts Identification Bcg

    \ 3.0 KW BPMG GENERATOR PARTS iDENTIFICATION ~'.""'u" COIL ENGINE SERIAL . SERVICE SIDE 'CONNECTION WATER INJECTED ELBOW MAGNErtC " PICK·UP HEAT FRESHWATER EXCHANGER (COOLANT) MODEL --ZING ANOOE SERVICE SIDE WATER PUMP PUMP CONTROL ENGINE NUMBER LEFT SIDE ~"'OlATI!RMDUNT FUEL Engin'I;...
  • Page 11 SERIAL equipment, contact your WESTERBEKE dealer for WES1ERBEKE'S installation manual. WARRANTY PROCEDURES Your WESTERBEKE Warranty is included in a separate Take the time to 'enter on the illustration of folder. If, after 60 days of submitting the Warranty Registry the nameplate as shown above, as this will provide a quick...
  • Page 12 NOTE: A carbon monoxide warning decalluls been provided WESTERBEKE. Affix this decal in a visible location in the UNDERSTANDING THE GASOLINE GENERATOR engine room. The gasoline engine driving an AC generator is in many SPARES AND ACCESSDRIES ways sintilar to a gasoline automobile engine.

  • Page 13: Installation

    Locate the generator away from living quarters, and . .l.IflOERNEA.TH VIEW away from bilge splash and vapors. AC CDNNECUON ~~~~~ Refer to WESTERBEKE'S installation manual for detailed information on installing Marine Generator in boat. DRIP TRAY/P.AN FOUR 1/2" BOLTS DIMENSIONAL DRAWINGS For dimensional drawings.

  • Page 14: Raw Water Discharge

    AVAILABLE FROM RAW WATER . / ' - - ' , water injected exhaust elbow must be looped a ntinimum of : YOUR WESTERBEKE SU~PPLY /--7--,;:-\-- HOSE 12 inches (30cm) above the vessels loaded water line.

  • Page 15: Fuel, Engine Oil And Engine Coolant

    FUEL, ENGINE OIL AND ENGINE COOLANT ENGINE COOLANT GASOLINE WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from CAUTION: Only use unleaded fuel with an octane chemicals that can corrode internal engine surfaces.

  • Page 16: Remote Panel

    The statlfstop seqllence is identical. Once installed, the engine can be operated by STOPPING either panel. To Stop: Press the rocker switclll<>stoP ,and release. The /V\T/WESTERBEKE will1.lJm 'LED~¥ht • engine will shutdown and the off. START GENERATOR OPERATION I"...

  • Page 17: Preparations For Initial Start-Up

    This precaution will prevent damage caused by unanticipated operation of the AC machinery and will prevent a cold engine from stalling. t + - - - OIL FILTER INCOMING FUE~ CONNECTS \ TOWATER PUMP FULL WESTERBEKE Engines & Generators...

  • Page 18: Safety Shutdown Switches

    WORKS NICELY An 20Ain-1ine fuse protects the battery charging circuit. If this fuse fails, the engine will continue to run but the battery will.~ot be charging. =4)) ~'-' 20A FUSE 10A FUSE WESTERBEKE BAmRY CHA.RGING Engln_e'!:& Generators...

  • Page 19: Maintenance Scbedule

    Initial engine oil & filter change at 50 hrs., then Engine Oll/Filter change both every 100 hours. 'WESTERBEKE recommends this service be performed by an authorized OVER-FILLING mechanic. CAUTION: The oil sump on this generators engine can unintentionally be over-filledl After shut·down, the oil in the engines internal passages can...
  • Page 20 MAINTENANCE SCHEDULE NOTE: Use the engine hour meter gauge to log your engine hours or record your engine hours running time. 'WESTERBEKE recommends this service be pertormed by an authorized mechanic. CHECK HOURS OF OPERATION SCHEDULED EXPLANATION OF SCHEDULED EACH...

  • Page 21: Engine Lubricating Dii

    Screw the filter onto the threaded oil filter stub, and tighten the filter firmly by hand. DlL ORA!N NOTE: Use genuine WESTERBEKE oil filters. Generic filters are not recommended. REFILLING THE OIL SUMP WARNING: Used engine oil contains harmful Addfresh oil through the valve cover.

  • Page 22: Fuel System

    Fuel leakage at the fuel pump or its connections is fire hazard and should be corrected. Make sure proper ventilation exists whenever servicing fuel system components. NOTE: The generator compartment should have a gasoline fume detectorlalarm properly installed and working. WESTERBEKE Engines & Generators...

  • Page 23: Cooling System

    This mixture of exhaust gas and cooling water is discharged overboard by the engine's gas discharge pressure. An iutemal engine thermostat controls the water temperature. This thermostat is .'F!lOM RAW WATER maintenance free. STRAINER WESTERBEKE -.,.y' . EngiT)e",& Generators...

  • Page 24: Raw Water Pump

    NOTE: Should a pump sluift water seal leak occur, this drain tube will allow the leak to drain away from the unit. Keep this drain tube clear of obstructions. . 'WIPE SURFACE CLEAN DRAIN TUBE ,.!BtFORE INSTALLING THE "COVER """" WESTERBEKE Engines & Generators...

  • Page 25: Raw Water Pumps [Overhaul]

    RAW WATER PUMP IMPELLER INSPECTION: CHECK AT THE BASE OF DESCRIPTION EACH BLADE BY BENDING VIGOROUSLY. REPLACE THE IMPELLER IF THERE Coolllllt water) cooled generators have dual water ..-:::=~:--<~ AMiE AN CRACKS. pumps while th.e raw water cooled models use a single water pump.

  • Page 26: Re-Assembly

    NOTE: Install the new impellers with a rotaJing motion so the blades are working in the same direction of those of the PULLEY removed impeller. Dual Pumps Assemble the upper pump to the lower pump as illustrated making sure the mounting screws are tight. WESTERBEKE Engines <>enerators & -.c...:_"_-_-=--.~,~.

  • Page 27: Cooling System

    CHANGING COOLANT ENGINE COOLANT The engine's coolaot must be chaoged according to the WESTERBEKE recommends a ntixture of 50% antifreeze MAINTENANCE SCHEDULE. If the coolaot is allowed to and 50% distilled water. Distilled water is free from the become contaminated, it can lead to overheating problems.

  • Page 28: 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 'Engines Generators &...

  • Page 29: Carburetor

    Ball joint linkage between actuator and throttle. Lube periodically (use graphite lubricant) to maintain smooth operation. DC REGIJLATlJR. SCREEN Remove the circlip to access the screen for cleaning ,,"TllliTn. LEVER ';;;:II" KEEP mE LINKAGE WELL LUBRICATED WESTERBEKE ~i!n~;ators En!1lnes &...

  • Page 30: Shore Power Transfer Switch

    Ground < Generator/Shore .!!! Switch L-L';:'-"', ShTp~1b-Shore ~witch ·~~L1 r---~------~~@3 ®} Ship's LOAD '-:(N::-.-U'"" ... -:I):-,"';@)5 ®J ,~-.,' . Shlp's ';;" Ground Shore Ground Shore Power . 230 VOLT/50 HERtz TWO WIRE CONFIGURATION SYSTEM WESTERBEKE -.,.y'" Engines & Generators...

  • Page 31: Electronic Governor

    ELECTRONIC GOVERffOR ~,<.u DESCRIPTION The system is composed if three basic components. 1. Controller. The PC board that governs the system is locat~d in the control panel. 2. Sensor. Mounted on the flywheel cover, the sensor mea- . CONTROL sures the speed of the eng\fle (via the ring gear). (P2) PANEL 3.

  • Page 32: Engine Adjustments

    ENGINE ADJUSTMENTS ADJUSTING THE DRIVE BELT BELT ASSEMBLY VIEWED FROM BENEATH The engine's drive belt is located under the engine. To access the belt, for inspection and/or adjustment, remove the cover as shown. Inspect the belt for wear along the edges and for proper belt tension (belt should be tight).

  • Page 33: Engine Compression Tes

    ENGINE ADJUSTMENTS ENGINE COMPRESSION TEST WATER PUMP BELT To remove, replace or aajust the belt, loosen the pivot bolt To check the engine's compression pressure, warm up the engine, then shut it down. and release the adjusting bolt. Slide the water pump bracket slacken the belt for removal.

  • Page 34: Spark Plug

    ENGINE ADJUSTMENTS SPARK PLUGS The spark plugs should be cleaned and re-gapped after the first 50 hour break-in period, then inspected every 250 hours thereafter and replaced as needed. WARNING: Do not remove the spark plugs while the engine is hot. Allow the engine to cool before removing them.

  • Page 35: Valve Clearance

    ENGINE ADJUSTI'v'IENTS VALVE CLEARANCE It is routine maintenance to adjust the valve clearance after the firstfifty hours of operation. Valve clearance adjustment EXHAUST must be perfonned when the engine is cool and the piston INTAKE. SIDE must be the top dead center of the compression stroke. SIDE Perform the following adjustment steps: ADJUSTING...

  • Page 36: Replacing The Timing Belt

    ENGINE ADJUSTMENTS .INSPECTION/REPLACING OF THE TIMING BELT o~·.· ~J~t ~D cracks, wear, lengthening or other damage is found, replace the timing belt UMIT OF ELONGATION: MORE THAN 10mm (0.4111) OEFLECTION BY PUSHING WITH YOUR FINGER Replacement of the Timing Belt 1.
  • Page 37 TROUBLESHOOTING GUIDE 3.0 KW When toubleshooting indicates an electrical problem, see the The following troubleshooting tables are based upon certain ELECTRICAL SYSTEM WIRING DIAGRAM, as this may engine problem indicators and the most likely causes of the reveal other possible causes of the problem which are not listed. problems below.

  • Page 38: Troubleshooting Guide

    IS seconds, a faulty overspeed board exists. NOTE: The above should only be peiformed as a test. The' generator with a by-passed overspeed board should not be run under normal use. This can present a hazard. WESTERBEKE' -.,.y: fitties. Gener~tors & •...

  • Page 39: Wiring Diagram

    GENERATOR WIRING DIAGRAM RESISTANCE VALUES IN OHMS IN BLACK ITALIC 12.5 -18.5a -2.m .EXCf1ER COIL ;MAG. COIL HlKIRED BlK/RED MAG.PICK-UP 95()"100ro tl6 YEL till !IlK 6 BlK ." 148-222D SRIELDE SPARK IGNITION [ONITlON PUL8fRCOIL I (; ORG COIL PLUGS MOOUL.E 1116 REDI KT 116 liE tl6 BLl!

  • Page 40: Generator Information

    WESTERBEKE Engines Generators &...

  • Page 41: Bcg/Bpmg Troubleshooting

    BCGIBPMG'DESCRIPTION and TROUBLESHOOTING REFER ALso THE SPECIFICATION PAGE TROUBLESHOOTING CHART (BCG) CAUSE FAULT BRUSHLESS CAPACITOR No AC Output Voltage Shorted Stator. GENERATOR (BCG) Open Stator. . ; Engine RPM at 2200 Shorted Rotor Diode. Shorted Rotor Thermister. generoJot turns at Shorted Rotor Capacitor.

  • Page 42: Bcginternal Wiring Diagram

    This can present a hazard. components. 3. Without unplugging any connections on the coil relay, place a jumper between connection #30 and #87. WESTERBEKE Engines & Generators...

  • Page 43: Lay-Up And Recommissioning

    Lay-up time provides a good opportunity to inspect your WESTERBEKE engine to see if external items such as drive LUBRICATION SYSTEM belts or coolant hoses need replacement. Check your basic...

  • Page 44: Flushing The Cooling System

    LAY-UP AND RECOMMISSIONING RECOMMISSIONING The recommissioning of your WESTERBEKE engine after a 4. Check the condition of the zinc anode in the circuit and seasonal lay-up generally follows the same procedures as clean or replace the anode as needed. those presented in the PREPARATIONS FOR STARTING 5.

  • Page 45: Genetator Specifications

    3.0 KW BCG/BPMG GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS COOLING SYSTEM Engine Type Two cylinder, four stroke gasoline engine, General Water cooled via raw water pump. Bore & Stroke 2.32 x 2.36 inches (59 x 60 mm) Raw Water Pump Positive displacement Iype, rubber impeller, belt dnven.
  • Page 46 Degree Celsius (OC) = (OF - 32) x .56 LIQUID WEIGHTS Diesel Oil 1 US gallon 7.131bs Fresh Water = 1 US gallon = 8.33 Ibs Gasoline = 1 US gallon = 6.1 Ibs Salt Water 1 US gallon = 8.56 Ibs WESTERBEKE Gent!~ators E!!9iI!!.S &...
  • Page 47 13/32 29/32 0.421875 10.71562 0.921875 23.41562 27/64 59/64 0.9375 23.81250 0.4375 11.11250 15/16 7/16 .61164> 0.453125 11.50937 0.953125 24.20937 29/64 0.46875 11.90625 ·31/32 0.96875 24.60625 15/32 0.984375 25.00312 31/64 0.464375 12.30312 63/64 1.00 25.40000 0.500 12.70000 WESTERBEKE Engln.es & Generators...

  • Page 48: Metric Conversions

    METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches Inches Inches Inches 381.00 _ 0.5906 25.40 0.0394 0.7874 50.80 508.00 0.0787 0.9843 76.20 635.00 0.1181 1.1811 101.60 762.00 0.1575 1.3780 127.00 889.00 0.1969 254.00 0.3937 1.5748 1016.00 10 MILLIMETERS 1 CENTIMETER, 100 CENTIMETERS 1 METER 39.37 INCHES (3.3 FEET) INCHES TO METERS...

  • Page 49: Suggested Spare Parts

    SUGGESTED SPARE PARTS WESTERBEKE MARINE· GASOLINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION . 'GASOLINE FUEL FILTER. THERMOSTAT CARTRIDGE ' . iANDGASKET . AND O-RINGS -T--.-1-. ; 10A FUSE , (ON SlOE OF • CONTROL PANEL). "'--- ------.-...
  • Page 50 WESTERBEKE Engines & Generators 1153612011...

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