Westerbeke 4.5 KW BCGTC - 60 Hz Operator's Manual

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Page 1 OPERATORS MANUAL WESTERBEKE GASOLINE GENERATOR CARBURETOR MODELS 4.5 KW BCGTC - 60 Hz 3.75KW BCGTC - 50 Hz 7.2 KW BCGTC - 60 Hz 6.0 KW BCGTC - 50 Hz 9.6 KW BCGTC - 60 Hz 8.0 KW BCGTC - 50 Hz Single Phase •...
Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
Page 4 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS FIRE Read this SIlfety manu4l carefully. Most accidents are caused by faiLure follow fundamenwL rules and precautions. WARNING: Fire can cause injury or death! Know when dangerous conditions exist necessary precautions protect yourse/}; your personnel, your machinery.
Page 5 Acid may splash on the skin into the eyes • service engine/generator while it is running. If inadvertently when removing electrolyte caps. situation arises in which it is absolutely necessary to make WESTERBEKE Engines Generators &...
Page 6 Follow their recommenda- moving parts. tions when installing your WESTERBEKE engine/generator. • Make sure all allaching hardware is properly tightened. ABYC (American Boat and Yacht Council) Keep protective shields and guards in their respective "Safety...
Page 7 • INSTALLATION When installing WESTERBEKE engines and generators it imponant th at strict attention be paid to the following infonnation: CODES AND REGULATIONS Strict federal regulations. ABYC guidelines. and safety codes must complied with when installing engines and generators in a marine environment.
Page 8 I the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s). Place Avon. Massachusetts, U.S.A. Date: September 1996 Carleton F. Bryant (Full Name) Chief Operating Officer (Title) WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON, MA 02322 U.S.A .• TEL.(508) 588-7700 .FAX: (508) 559-9323_ WEBSITE:WWWWESTEABEKE.COM...
Page 9 TIFICA TE We hereby certify the component stated below meets the EC Directive 94J25/EC type-examination in accordance with ISO 8846 and has following characteristics: Gasoline Marine Generator ITYPE Westerbeke Corp. MANUFACTURER Avon Industrial Park, ADDRESS Avon, MA 02333 +++++...
Page 10: Table Of Contents
TABLE OF CONTENTS Introduction ..............Engine Lubricating 0i1 ........... Warranty Procedures ............ 2 Description ..............16 Customer Identification Card ........2 Changing the Engine Oil..........16 Product Software ............2 Replacing the Oil Filter..........16 Serial Number Location ..........2 Refilling the Oil Sump ..........
Page 11: Model
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 12: Ordering Parts
WESTERBEKE will provide you with a suggested spares and accessories brochure to assist you in preparing an WARNING: Procedures, which if not properly on-board inventory of the proper WESTERBEKE parts.
Page 13: Control Panels
TOGGLE SWITCH CIRCUIT BREAKER: THE HEAVY DUTY ON/OFF CIRCUIT BREAKER SHUTS DOWN THE GENERATOR'S AC POWER. NOTE: THIS CIRCUIT BREAKER SHOULD BE IN THE OFF POSITION WHEN PERFORMING MAINTENANCE. OVERSPEED GENERATOR WESTERBEKE CIRCUIT BOARD PANEl Engines & Generators...
Page 14: Safety Shutdown Switches
SAFETY SHUTDOWN SWITCHES Low Oil Pressure Switch SAFETY SHUTDOWN SWITCHES A low oil pressure shutdown switch is located off the The engine is protected by three automatic shutdown engine's oil gallery. Normally open in a static state, this switches. Should a shutdown occur, do not attempt to restart switch's sensor monitors the engine's oil pressure.
Page 15: Fuel, Engine Oil And Engine Coolant
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 from the chemicals that can corrode internal engine surt'aces. CAUTION: Only use unleaded fuel with an octane The antifreeze petfonns double duty, as it allows the engine rating of 89 or higher.
Page 16: Preparations For Initial Start-Up
INITIAL PREPARATIONS FOR START-UP OIL FILL PRESTART INSPECTION Before starting your generator for the first time or after a pro- longed layoff, check the following items: • Check the engine oil level: add oil to maintain the level at the full mark on the dipstick. •...
Page 17: Operating Instructions
Stopping the Generator To stop the generator, move the momentary START/STOP switch to the down (stop) position then release it to the center (offlrun mode) position. This will activate the remote control panel for START/STOP functions. WESTERBEKE Engines Generators &...
Page 18: Break-In Procedure/Daily Operation
• Check for abnormal noise such as knocking, friction, vibration and blow-back sounds. • Confinn 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 19: Maintenance Schedule
Hose should be hard & tight. Replace if so11 or spongy. Check and tighten all hose clamps. Change oil every 250 hours. Governor Lubricate linkage arm periodically. 'WESTERBEKE recommends this service be periormed by an authorized mechanic. (continued) & Engines Generators...
Page 20 'Exhaust Elbow Test exhaust elbow for casting integrity. Replace if WARNING: A casting is corroded or deteliorated. defective exhaust elbow can cause carbon monox- ide leakage! 'WESTERBEKE recommends thiS service be performed by an authonzed mechamc. Engines & Generators...
Page 21: Engine Cooling Circuit
COOLANT PRESSURE CAP TANK MANIFOLD BLEED PETCOCK THERMOSTAT EXHAUST FRESH WATER " COOLANT EXCHANGER . . RAW WATER FRESH WATER COOLANT PUMP DRAIN ZINC ANODE WESTERBEKE Engines Generators &...
Page 22: Thermostat
ENGINE COOLING CIRCUIT THERMOSTAT DRAINING THE COOLANT A thermostat controls the coolant temperature as the coolant Remove the manifold pressure cap, loosen the water drain continuously flows through the closed cooling circuit. When located on the left side of the engine block just under the the engine is first started the closed thermostat prevents manifold and loosen the heat exchanger drain plug.
Page 23: Raw Water Pump
CAUTION: The drive belt must be properly tensioned for the belt-driven water pumps to function properly. For the raw water pump/fresh water pump drive belt tension adjustment procedure, see DRIVE BELTS ADJUSTMENT under ENGINE ADJUSTMENTS. WESTERBEKE -.y- Engines Generators &...
Page 24: Fuel System
Most installers include a type of filter/water separator with the generator installation package as they are well aware of the problems that contaminants in the fuel can cause. FUEL "'""" WESTERBEKE Engines Generators &...
Page 25: Engine Lubricating 0I1
Make sure the oil drain hose is properly secured in its holder after all of the old oil has NOTE: Use genuine WESTERBEKE oil fillers. Generic fillers been drained. are not recommended. Always observe the old oil as it is removed. A yellow/gray REFILLING THE OIL SUMP emulsion indicates the presence of water in the oil.
Page 26: Remote Oil Filter
Contact your WESTERBEKE dealer for more information. engine room bulkhead. NOTE: Westerbeke is not responsible for engine failure due to NOTE: Refer to REPLACING THE OIL FILTER for instruc- incorrect installation of the Remote Oil Filter.
Page 27: Dc Electrical System
(and to your engine). • Keep your batteries clean and free of corrosion. WARNING: Sulfuric acid in lead baneries can cause severe burns on skin and damage clothing. Wear protective gear. WESTERBEKE Engines Generators &...
Page 28: Wiring Diagram #42834
DC ELECTRICAL SYSTEM WIRING DIAGRAM #42834 OIL TEMP SWITCH INC) 1)111111 ---11' ' '" • Engines & Generators Rev. E 3/2S/98...
Page 29: Wiring Schematic #42834
DC ELECTRICAL SYSTEM WIRING SCHEMATIC #42834 ~I ~~n2~Y STARTER STARTER SOLENO I D - - I 1 25 AMP ICIRCUIT I BREAKER " L. _ _ _ BATTERY CHARGER FUEL PUMP FUEL SOL. I ®STOP SW • 1 CKT I ( NC) HOUR METER COil DISTRIBUTOR...
Page 30: Wiring Diagram #42857 Remote Panel(S)
-< -< -< ". " . G> 0 = = "" " REMOTE PANEL 2 REMOTE PANEL 1 ------------------------------------T--------------------------------------1 r---- " START/STOP SW START/STOP SW [LED~ CKT 2 CKT 2 I'" " REMO\ "I JUMPE CKT 1 I CKT II 1/ : ON SW 1&...
Page 31: Engine Adjustments
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. ENGINE SPEED (HERTZ) ADJUSTMENT Governor Maintenance 1. Periodically lubricate the linkage arm attaching points at Governor the governor arm and throttle lever.
Page 32: Valve Clearance Adjustment
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 1.
Page 33: Carburetor Adjustment
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. CARBURETOR ADJUSTMENT DRIVE BELTS ADJUSTMENT Basic Jet Adjustment is performed with the generator operat- The drive belts must be properly tensioned.
Page 34: Timing Belt Inspection And Replacement
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 belt. NOTE: If the timing belt is to be reused, draw an arrow on...
Page 35 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. Mount the flange so that its side shown by the heavy 1.
Page 36 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. 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 37 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. 8. Tum the crankshaft clockwise by nine camshaft sprocket teeth (81") to align the timing mark on the camshaft sprocket with the tcnsioner set mark on the timing belt rear cover.
Page 38: Engine Troubleshooting
ENGINE TROUBLESHOOTING When troubleshooting indicates an electrical problem, see the The following troubleshooting tables are based upon certain engine problem indicators and the most likely causes of the DC Electrical System Wiring Diagram and Schematic, as problems. they may reveal other possible causes of problems not listed below.
Page 39 Low oil pressure. Low oil level. Air intake filter screen dirty. Remove Wrong SAE type oil in the engine. and clean. Wrong type oil filter. Relief valve is stuck. Faulty oil pump. Faulty engine bearings. WESTERBEKE Engines & Generators...
Page 40: Generator Information
GENERATOR INFORMATION USE OF ELECTRIC MOTORS REQUIREO OPERATING SPEED The power required to start an electric motor is considerably Although individual units may vary slightly, the normal more than is required to keep it running after it is started. voltage and frequency of typical 60 (50) hertz engine-driven Some motors require much more current to start than others.
Page 41: Generator Wiring Diagrams
GENERATOR WIRING DIAGRAMS ;-----------, Allicr::: .ll. WINDING RESISTANCE AT 20° C TEMPERATURE Cnm_mi 0Jll ROTATING BATTERY STATOR PART CHARGER WINDING WINDING WINDING L,:-t 50~! .n.. .n.. .n.. .n.. 3.058 ('.433 o.i41 4-.334 - - - -- ,o-g MODEL 4.5 KW c·-S'-5A 4S"~ 'io-1-...
Page 42: Ac Electrical Connections
AC ELECTRICAL CONNECTIONS r--------., UA.._...J iAR]i WHITE B'~-...J CIRCUIT BREAKER 4 - - - - - - , 120 VAC 60 HZ AR]i (CONNECT JUMPER) ...,..----{) 4 _-------- VA----05 ..1 - - - - - - - , 5------~ 240/120 r:___:h DITWlo...
Page 43: Lay-Up & Recommissioning
LAY-UP & RECOMMISSIONING GENERAL FUEL SYSTEM 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 Jay-up during the off- or higher. A fuel conditioner such as STABIL gasoline stabi- season or for long periods of inactivity.
Page 44: Intake Manifold
Lay-up time provides a good opportunity to inspect your WESTERBEKE engine to see if external items such as drive 6. Start the engine in accordance with procedures in the PREPARATIONS FOR INITIAL SDlRT-UP section of this belts or coolant hoses need replacement.
Page 45: Bcgtc Generator Specifications
BTDC at 3600 rpm ± (all models) (no load on generator) Engine Cooling 100 CFM (2.8 cmm) Cylinder Head 60 - 70 Nm 43-51 ft-Ibs Boll Torque see TORQUING THE CYLINDER HEAD BOLTS under ENGINE ADJUSTMENTS -..v- WESTERBEKE Engines & Generators Rev. 6/1/98...
Page 46: Bcgtc Generator Parts Identification
: : i - - - - - RAW WATER PUMP DC BATIERY GROUND CONNECTION DATA TAG ZINC ANODE STARTER WITH SOLENOID RIGHT SIDE DRAIN HOSE FILL CAP DISTRIBUTOR WATER INJECTED EXHAUST ELBOW COIL FRESH WATER DRAIN PLUG LEFT SIDE WESTERBEKE Engines Generators &...
Page 47: Standard Hardware Torques
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Grade 7T, 8T and 8·.8 Pitch Ib-n kg-m Grade Pitch Ib-n kg-m 6mm bolt head/nut 5.S-S.7 0.S-I.2 6mm bolt head/nut 2.9-5.1 0.4-0.7 bolt head/nut...
Page 48: Bcgtc Generator Hardware Torques
Bearing cap bolt Rocker arm adjust 8-10 Cylinder Block Cylinder Head, Valve Taper plug 1/16 8-12 Cylinder head bolt (cold engine) 60-70 43-5t Taper plug 1/8 t5-22 11-16 25-33 Water drain plug 35-45 Taper plug pt-l/4 35-45 25-33 WESTERBEKE Engines & Generators...
Page 49: Metric Conversions
METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches Inches Inches Inches 25.40 381.00 0.0394 0.5906 50.80 508.00 0.0787 0.7874 76.20 635.00 0.1181 0.9843 101.60 762.00 0.1575 1.1811 127.00 889.00 0.1969 1.3780 254.00 1016.00 03937 1.5748 10 MIlliMETERS lCENTIMETER, 100 CENTIMETERS 1 METER 39.37 INCHES (3.3 FEET) INCHES TO METERS...
Page 50: Suggested Spare Parts
Carry matched pairs. Always carry a spare aboard. Oistributor Cap and Wires Inspect every 100 hours. SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits, KIT B each packaged in a rugged hinged toolbox. A includes the basic spares. Impeller Kit off-shore cruising.

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