Westerbeke 4.5 KW BCGTC 60Hz User manual

•
I
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
PUBUCATION 42832
1 st Edition / September 1997
~ WESJ'ERBEKE
WES T ERBEKE CORPORATION · AVON INDUSTRIAL PARK
AVON , MA 02322 • TEL: (SOB) 588-7700 · FAX: (SOB) 559-9323
~~.,"""
~M'A M~mber Naiio1l41 Morine M o.twfoctu~rsASS()CiD.tion

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this SIlfety manu4l carefully. Most accidents are caused
byfaiLure wfollowfundamenwL
rul es and pr ecautions.
Kn
ow when dangerous conditions exist and wk e the
necessary precautionsto protect yourse/};
you r personnel,
and you r machin ery.
The following SIlfety instructUms are in compliance with
theA merican Boat and Yacht Council (ABYC) swndards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is ronning , or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosur es a nd covers in place.
• Shut off electrical power before accessing electrical
equipment.
• Use ins ul ated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• 00 not connect utility shore power to vessel's AC
circuits, except through a ship-la-shore double throw
transfer switch. Damage to vessel's AC generator may
r es ult if this procedure is not followed.
• Electrical shock results from handling a charged capacitor.
Discharge capacitor
by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: 00 not touch hot engine parts or
exhaust system components . A ronning engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine
or checking th e coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injuryor death!
• Prevent flash fires. 00 not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump,
or other potential sources of spi ll ed fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line; carburetor,
or fuel filters.
• 00 not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury
or
death.
• Do not operate with the air cleaner/silencer removed.
Bac'kfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks to occur ncar the
fuel system. Keep the compartment and the engine/gener·
ator clean and free of debris to minimize the chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
af ter fueling. Check below for fumes/vapor before running
the blower. Run the blower for four minutes before start-
ing your engine.
• All fuel vapors are hi ghly explosive. Use extreme care when
handling and storing fuels. Store fuel in a well·ventilated
area away from spark-producing equipment and o ut of the
reach
of children.
•
00 not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care
in catching any fuel that might
spill. DO
NOT allow any smoking, open flames, or other
sources
of fire near the fuel sys tem or engine when servicing.
Ensure proper ven
til at ion exists when servicing the fuel
system.
• 00 not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
•
Be certain fuel line fittings are adequately tightened and
free
of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated
ABC by the NFPA are appropriate
for all applications encountered
in this environment.
Engines & Generators

SAFETY INS TR UCTIONS
ACCIDENTAL STARTING
A WARNING: Acc i dental starti ng can cause injury
Dr death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first
and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re~
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
Dr death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can
be ignited by electrical
arcing
or by l it tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing during
servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection lenninal
of the starter solenoid. Do n ot
test the battery condition by shorting the terminals
together. Sparks could ignite battery gases
or fuel vapors.
Ventilate
any compartment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery is
being charged.
• Avoid contacting the leoninals with tools, etc.! to prevent
burns
or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect
it last when servicing the battery.
BATTERY ACID
A WARNING : Sulphuric acidinbatteri es can cause
severe injuryor death!
• When servicing the battery or checking the electrolyte
level,
wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
If
it comes In contact with your skin, wash it off at once
with water. Acid may splash on the skin
or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Cari10n monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine.
Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no
warping exists. Pay close
attention to the manifold,
water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder
or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Cari10n monoxide (CO) is an invisible
odorless gas_ Inhalation produces flu-like symptoms ,
nausea Dr death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing
in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration
of copper
tubing resulting
in exhausVwater leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents,
or air conditione~. If the engine
exhaust discharge outlet is near the waterline, water could
enler the exhaust discharge outlet and close
or restrict the
flow
of exhaust. Avoid overloading the craft.
• AJthough diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present
in diesel exhaust fumes. Some of the symp-
toms or signs of carbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or de ath!
• Do not service the engine/generator while it is running. If a
situation arises
in which it is absolutely necessary to make
~ WESTERBEKE
En gines & Generators
ii

SAFETYINSTRUCT10NS
operating adjustments, use extreme care to avoid touching
moving parts and hot exhaust system components.
• Do not wear loose clothing orjewelry when servicing
eq u ipment; avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bracelets that could be caught in
moving parts.
• Make su re all allaching hardware is properly tightened.
Keep protective shields and guards
in their respective
places at all times.
• Do not check fluid levels or the drive belts' tension while
the engine / generator is operating.
• Stay clear of the drive shaft and the transmission coupling
when t he engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause healing
loss!
• Never operate a generator without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines or generators for long periods with
their enclosures open .
A WARNING: Do not work on machinery when you
ale mentally 01 physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefu lly, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR
INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
H-24 Gasoline fuel systems
P -1 Exhaust systems
P4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC , NFPA AND USCG PUBLlCAnONS FOR
INSTAWNG GASOUNE AND DIESEL ENGINES AND
GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your WESTERBEKE engine/generator.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
15 East 26th ~treet
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1 Ballerymarch Park
P.O. Box 9101
Quincy, MA 02269-9101
USCG (United States Coast Guard)
"USCG 33CFR183"
Order From:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii
r

INSTALLATION
When installing WESTERBEKE engines and generators it is impo nant th at s tri ct
attention be paid to the following infonnation:
CODES AND REGULATIONS
Strict federal regulations. ABYC guidelines. and safety codes must be complied with
when in stalling engines and generators in a marin e en v ir o nment.
SIPHON·BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or below the vessel's wate rlin e, provisions mu st be made to install a s iph on- break in
th e raw water s up ply hose to the exhaust elbow. This hose must be looped a minimum
of IS" above the vessel's waterline. Failure to use a siphon-break when th e exhaust
numif old injection port is at or below the load waterline will result in raw waLer
damage to the engine andpossibleflooding of the boaL
EXHAUST SYSTEM
Th e exhaust hose must be certified for marine use. Th e system must be designed to
prevent water from entering the exhaust under any sea c onditi ons and at an y an gle
of th e vessels hull.
A detailed 40 page Mar i ne Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
~ WESTERBEKE
Engines & Generators
iv
•

-.v' WESJERBEKE
Engines & Generators
Declaration of Conformity
Application of Council Directive(s)
Standard(s) to Which Conformity
is declared
Manufacturers Name
Manufacturers Address
Type of Equipment
Product Name
Model(s)
Product Options
Supplementary Information
EMC 89/336IEEC
ISO 8846 1990(E)
EN50081-1
EN50082-2
EN55020
ISO-8846-1990(E), Certification
Number, IWES003
Westerbeke Corporation
41 Ledin Drive
Avon Industrial Park
Avon, Ma. 02322, USA
Marine Gasoline Generator
Westerbeke Marine
Gasoline Generator
3.7/4.5BCGTE,6.017.2BCGTE
8.0/9.6BCGTE,3.7/4.5BCGTC,
6.017.2BCGTC & 8.0/9.6BTGTC
All
1.)
The equipment listed is only for use in Marine Applications aboard boats.
2.)
The equipment listed must be located below decks on the vessel and
permanently installed in it's location.
3.)
The equipment listed must be wired to the grounding system of the vessel.
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 1, 1996 Carleton
F. Bryant
(Full Name)
ChiefOperating Officer
(Title)
WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON, MA 02322 U.S.A .• TEL.[phone] .FAX: [phone]_ WEBSITE:WWWWESTEABEKE.COM

INTERNATIONAL MARINE CERTIFICATION INSTITUTE
Treves Centre, Rue de Treves 45
B-1040 8RUXELLES
BELGIQUE
tel: [phone]
fax: [phone]
eEl? TIFICA TE
We hereby certify the component stated below meets the EC Directive 94J25/EC for
type-examination in accordance with ISO 8846 and has following characteristics:
ITYPE I Gasoline Marine Generator
MANUFACTURER Westerbeke Corp.
ADDRESS Avon Industrial Park,
Avon, MA 02333
USA
IGROUP
OF
I
+++++
I
+++++
I
+++++
Model 1 3.7/4.5 BCGTE
+++++ +++++
Model 2 6.017.2 BCGTE
+++++ +++++
Model 3
80/96 BCGTE
+++++ +++++
Model 4 3.7/4.5 BCGTC
+++++
+++++
Model 5 60/7.2 BCGTC
+++++
+++++
Model 6 80/9.6 BCGTC
+++++
+++++
Model 7
+++++
+++++
+++++
Model 8
+++++
+++++ +++++
Model 9 +++++
+++++
+++++
Model 10
+++++
+++++
+++++
Model 11
+++++
+++++ +++++
Model 12
+++++
+++++
+++++
Model 13
+++++ +++++ +++++
Model 14
+++++
+++++
+++++
Model 15
+++++ +++++ +++++
Model 16
+++++
+++++ +++++
Model 17
+++++ +++++ +++++
Model 18
+++++
+++++
+++++
Model 19
+++++ +++++ +++++
Model 20
+++++
+++++
+++++
Model 21
+++++ +++++ +++++
Model 22
+++++
+++++ +++++
Model 23
+++++
+++++
+++++
Certification number
IWES003 /
Signed
..(.c'/h ?
-,\:::://r
<'-~-,
Name Lars E. 8r'§nholm
Title Managing Director
EU Notified Body No 0609
Date 02/0211998
I
I

TABLE OF CONTENTS
Introduction ...................................................................... .2
Engine Lubricating 0i1 ................................................... 16
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...............................................16
Ordering Parts .............................................................
.3
Notes, Cautions and Warnings .....................................3
Remote Oil Filter (Optionalj .......................................... 17
Installation..................................................................17
Protecting Your Investment......................................... .3
Spares and Accessories ................................................3
Control Panels ................................................................ ..4
DC Electrical System ..................................................... 18
12-
Volt DC Control Circuit........................................18
Batteries......................................................................18
Generator Panel ............................................................4
Remote Panel ...............................................................4
Overspeed Circuit Board..............................................4
Safety Shutdown Switches ....... ..................................... .5
Specifications ......................................................18
Battery Maintenance ........................................... 18
Battery Charging ........................................................ 18
Component Testing .................................................... 18
Safety Shutdown Switches...........................................5 Wiring Diagram #42834.............................................19
High Exhaust Temperature Switch ......................
.5 Wiring Schematic #42834..........................................20
High Water Temperature Switch.......................... .5
Wiring Diagram #42857 Remote Panel(s)................ .21
Low Oil Pressure Switch ..................................... .5
Engine Circuit Breaker ........................................ .5
Fuel, Engine Oil and Engine Coolant ............................ 6
Engine Adjustments ....................................................... 22
Engine Speed (Hertz) Adjustment..............................22
Governor .............................................................22
Gasoline........................................................................6 Governor Adjustments ........................................22
Care of the Fuel Supply ...............................................6 Governor Maintenance........................................22
Engine Oil ....................................................................6 Torquing the Cylinder Head Bolts .............................22
Engine Coolant.............................................................6 Valve Clearance Adjustment ......................................22
Coolant Recovery Tank................................................6 Choke Solenoid ..........................................................
23
Preparations for Initial Start-Up ................................... 7
Prestart Inspection ...................................................... _, 7
Operating Instructions ..................................................... 8
Generator Panel ............................................................8
Starting the Generator...........................................8
Stopping the Generator .........................................8
Remote Panel ...............................................................8
Ignition Timing...........................................................23
Spark Plugs................................................................. 23
Carburetor Adjustment ...............................................24
Drive Belts Adjustment ..............................................24
Timing Belt Inspection
and Replacement..................25
Engine Troubleshooting ................................................ .29
Generator Information .................................................. .31
Starting the Generator ...........................................8 Use of Electric Motors .............................................. .31
Stopping the Generator .........................................8 Required Operating Speed ........................................ .31
Emergency.stopping ....................................................8 Generator Frequency Adjustment ..............................
31
Starting Under Cold Conditions...................................8 Generator Maintenance .............................................. 31
Abnormal Stop .............................................................8
Generator Wiring Diagrams ......................................... .32
Break-In Procedure/Daily Operation ............................. 9
AC Electrical Connections ........................................... 33
Break-In Procedure ......................................................9
Check List ....................................................................9
Stopping the Generator ................................................9
Generator Adjustments.................................................9
Maintenance Schedule .................................................. 10
Engine Cooling Circuit.. ................................................. 12
Lay-Up & Recommissioning ......................................... .34
General .......................................................................34
Fresh Water Cooling System......................................34
Lubrication System ....................................................34
Fuel System................................................................34
Raw Water Circuit...................................................... 34
Description ................................................................. 12
Intake Manifold ..........................................................35
Thermostat.................................................................. 13 Starter Motor..............................................................35
Thermostat Test ..........................................................
13
Cylinder Lubrication .................................................35
Draining the Coolant.................................................. 13 Spare Parts..................................................................35
Refilling the Coolant..................................................
13 Batteries......................................................................35
Raw Water Pump........................................................14 Recommissioning .......................................................35
Changing the Raw Water Pump Impeller ..................14
Heat Exchanger ..........................................................14
Drive Belt Adjustment ...............................................14
Fuel System ..................................................................... 15
Gasoline.....................................................................
.15
Carburetor.................................................................. .15
BCGTC Generator Specifications ................................ 36
BCGTC Generator Parts Identification ...................... .37
Standard Hardware Torques ........................................ .38
BCGTC Generator Hardware Torques ......................... .39
Metric Conversions ....................................................... .40
Gasoline/Water Separator and Filter .......................... 15
Suggested Spare Parts ................................................. .41
Fuel Pump ..................................................................15
Gasdenser ...................................................................15
Engines & Generators
1

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE'S long years of experience and advanced
technology. We take great pride
in the superior durability and
dependable perfonnance
of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your engine require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your Operators Manual. A Parts Catalog is also
provided and a Technical Manual is available from your
WESTERBEKE dealer. Also, if you are planning to install
this equipment yourself, contact your WESTERBEKE dealer
for
WESTERBEKE'S Installation Manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If you have not received a customer identification
card registering your warranty 60 days after submitting the
warranty registration form, please contact the factory in
writing with model information, including the unit's serial
number and commission date.
I~l WESTERBEKE
1 Marine Engine Pl'Oducts
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BCGTC Ser. #D703XXXX
Expires 9/20/02
CUSTOMER IDENTIFICATION CARD (Typical)
The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date
of
manufacture of your WESTERBEKE engine/generator. The
first character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s), the second character represents the year
in the decade, and the fourth and fifth number represents the
month
of manufacture.
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures
and catalogs) provided from sourccs other than WESTER-
BEKE are not within WESTERBEKE'S CONTROL.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT
OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRE·
SENTATIONS WITH RESPECT THERETO, INCLUDING ACCU·
RACY, TIMELINESS OR COMPLETENESS THEREOF AND Will
IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGE OR
INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF
THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the time
span between printings
of WESTERBEKE product software
and the unavoidable existence
of earlier WESTERBEKE
manuals. In summation, product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product. It
not only makes good sense but is imperative that appropriate
representatives
of WESTERBEKE or the supplier in question
be consulted to determine the accuracy and currentness
of the
product software being consulted by the customer.
SERIAL NUMBER LOCATION
The generator serial number and model number is located on
a decal on the the generator housing. Take the time to enter
the information on the blank decal provided. This will pro-
vide a quick reference when seeking technical information
and/or ordering parts.
Engines & Generators
2

INTRODUCTION
The engine model number and serial number are located on a
plate mounted on the engine's valve cover.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
generator and engine model and serial numbers.
In addition,
include a complete part description and part number for each
part needed (see the separately furnished Parts Catalog). Also
insist upon WESTERBEKE packaged parts because will fit
or generic parts are frequently not made to the same specifi-
cations as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting
of your genera-
tor, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result in the damage or destruction of
the engine or generator.
A WARNING: Procedures, which if not properly
followed, can result in personal injury or loss of life.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a
WESTERBEKE generator capable of
many thousands of hours of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner
in which the unit is
operated and serviced
in the field. This is up to the
buyer/owner-operator.
NOTE: Six important steps to ensure long generator life:
• Proper engine and generatorinstallation and alignment.
• An efficient well-designed exhaust system that includes
an anti~siphon break to prevent water from entering the
engine.
• Changing the engine oil and oilfdters every ZOO operat.
ing hours.
• Proper maintenance of all engine and generator compo-
nents according to the maintenance schedule in this
manual.
• Use clean, filtered unleadedfuel.
• Winterize your engine according to the "Lay-up and
Recommissioning" section in this mnnual.
SPARES AND ACCESSORIES
Certain spare parts will be needed to support and maintain
your WESTERBEKE generator
or engine when cruising (see
SUGGESTED SPARE PARTS). Often even simple items such
as proper fuel and oil filter can be difficult to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you
in preparing an
on-board inventory of the proper WESTERBEKE parts.
Engines & Generators
3

CONTROL PANELS
GENERATOR PANEL
The ON and START/OFF switches are the only functional
components to operate the generator at the engine. Both
switches are used to start
the generator -see Starting the
Generator under OPERATING INSTRUCTIONS.
The ON switch is a two-position switch with momentary
contacts in the up (on) position and a stationary contact
function in the center position. This switch energizes the
fuel pump.
The START/OFF switch is a three-position switch with
momentary contact functions in the up (start) and down
(off) positions, and a stationary contact function in the
center position.
When in the center (normal) position, this
switch allows the generator to be run, once started. When
in the up (start) position (together with the ON switch in
the up position), this switch starts the generator, and once
released, reverts to the center position. When in, the down
(off) position, this switch stops the engine in nonnal oper-
ation as well as in an emergency situation.
When maintenance is being performed on the generator,
the 8
amp fuse should be removed. This will disable the
remote control panel(s), preventing attempts to start the
generator from their locations. However, it is always best
to disconnect the battery
during this time jf it is not
required to perfonn the maintenance.
START/OFF
TOGGLE SWlTCH
8 AMP FUSE: THE 8 AMP
FUSE ENERGIZES THE
. DC CIRCUIT
,
HOURMffiR: THE HOURMETER
RECORDS ELAPSED TIME OF ENGINE
USAGE. THE TOTAL NUMBER OF
HOURS SHOULD BE USED AS A GUIDE
FOR MAINTENANCE SCHEDULING.
20 AMP CIRCUIT BREAKER:
THE 20 AMP RESET CIRCUIT BREAKER
PROTECTS THE ENGINE'S ELECTRICAL
SYSTEM FROM ELECTRICAL OVERLOADS.
~-I+ ___ ON
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.
REMOTE PANEL
There are three functional components on the remote panel
for generator operation:
LON switch
2. START/STOP switch
3. Green
LED indicator light
The ON switch is a two-position switch with momentary
contact functions in the up (Oil) position and a stationary con-
tact function in the center position.
This switch energizes the
fuel pump.
The START/STOP switch is a three-position switch with
momentary contact functions
in the up (start) and down
(stop) positions, and a stationary contact function in the cen-
ter position.
The center position is a dual offJrun mode posi-
tion and is normally in the off mode. When in the start (up)
position, this switch starts the generator (together with the
ON switchin the up position) and once released, reverts to
the center position, run mode. When
in the stop (down) posi-
tion, this switch stops the generator, and once released,
reverts to the center position,
off mode.
The Green LED indicator light indicates the engine running
condition. It lights when the ON switch is moved to the start
position, dims when the engine is cranking, and brightens
when the engine starts, notifying the operator to release the
START switch.
START/STOP
TOGGLE SWITCH
REMOTE
PANEL
OVERSPEED CIRCUIT BOARD
ON
TOGGLE
SWITCH
The overspeed circuit board senses the engine speed through
pulses off the engine coil. If the engine speed exceeds 3800
rpm, this overspeed circuit will activate, and will interrupt DC
power to the K2 relay shutting the engine down. It has an
automatic reset.
GENERATOR
PANEl
a
~ WESTERBEKE
OVERSPEED
CIRCUIT BOARD
Engines & Generators
4

SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES
The engine is protected by three automatic shutdown
switches. Should a shutdown occur, do
not attempt to restart
without
finding and correcting the cause. Refer to the head-
ing Engine starts, runs and then shuts down
in the ENGINE
TROUBLESHOOTING section of this manual.
The following is a description of these automatic shutdown
switches:
High Exhaust Temperature Switch
An exhaust temperature switch is located on the exhaust
elbow. Nonnally closed, this switch will open and interrupt
the
DC voltage to the K2-run relay (shutting off the engine)
should the switch's sensor indicate an excessive exhaust tem-
perature (an inadequate supply
of raw water causes high
exhaust temperatures).
This switch opens at 260-270°F (127-
132°C). This switch resets at approximately 225°F (107°C).
HIGH
EXHAUST
TEMPERATURE
I
High Water Temperature Switch
ELBOW
A high water temperature switch is located at the thermostat
housing. Nonnally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the DC voltage to the K2-run
relay thereby shutting off the engine. This switch resets at
195°F (107°C).
THERMOSTAT
HDUS!NG- ___ .1
HIGH WATER
TEMPERATURE
SWITCH
/
Low Oil Pressure Switch
A low oil pressure shutdown switch is located off the
engine's oil gallery. Normally open
in a static state, this
switch's sensor monitors the engine's oil pressure. Should the
engine's oil pressure fall to 5-10 psi, this switch will open
interrupting the
DC voltage to the K2-run relay thereby shut-
ting off the engine.
LOW OIL
PRESSURE SWITCH
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical overload anywhere in the instrument panel
wiring
or engine wiring will cause the breaker to trip. In this
event the generator will shut down because the opened
breaker interrupts the
DC circuit to the K2-run relay. If this
should occur, check and repair the source of the problem.
After repairing
the fault, reset the breaker and restart the gen-
erator.
Engines & Generators
5

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: Only use unleaded fuel with an octane
rating of 89 or higher. Leaded fuel will cause serious
hann to your engine and violate your warranty.
CARE OF THE FUEL SUPPLY
Use only clean fuel! The clearance of the components in
your carburetor is very critical; invisible dirt particles which
might pass through the filter can damage these finely finished
parts.
It is important to buy clean fuel, and keep it clean. The
best fuel can be rendered unsatisfactory by careless handling
or improper storage facilities. To assure that the fuel going
into the tank for your engine's daily use is clean and pure, the
following practice is advisable:
Purchase a well-known brand of fuel.
Install and regularly service a good, Coast Guard approved
metal bowl type filter/water separator between the fuel tank
and the engine.
ENGINE OIL
Use a heavy duty engine oil with an API classification of S1.
Change the engine oil after an initial 50 hours of break-in
operation, and every 100 hours
of operation thereafter. For
recommended oil viscosity, see the foHowing chart:
Operating Temperature
Oil Viscosity
Above 68° F (20° C) SAE 30, 10W-30 or 15W-40
41° - 68° F (5°-20° C)
SAE 20 or 10W-30
Below 41° F (5° C) SAE 10W-30
A CAUTION: 00 not allow two or more brands of
engine oil to mix. Each brand contains its own addi-
tives; additives ofdifferent brands could react in the
mixture to produce properties harmful to your engine.
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.
The antifreeze petfonns double duty, as it allows the engine
to run at proper temperatures by transferring heat away from
the engine
to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
antifreeze that contains supplemental cooling additives
(SeAs) that keep the antifreeze chemically balanced, crucial
to long term protection.
The water and antifreeze should
be pre-mixed before being
poured into the cooling circuit.
NOTE: Use the new environmentally-friendly long lasting
antifreeze that is now available.
ANTIFREEZE PROTECTION CHART
Antifreeze concentration
23% 30% 35% 50%
Freezing Temperature WF 8° F
_4° F
-40° F
(-10°C) (-13°C) (-20°C) (-40°C)
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each 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.
COOLANT RECOVERY TANK
-..v WESTERBEKE
Engines & Generators
6

PREPARATIONS FOR INITIAL START-UP
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.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
OIL FILL
NOTE: After the initial running of the generator, the air in
the engine's cooling system will bepurged to the coolant
recovery tank After shutdown and after the engine has
cooled, the coolantfrom the recovery tank will be drawn
into the engine's cooling system to replace the purged air.
COOLANT
PRESSURE ----1~~~~
CAP
Before subsequent operation a/the generator, the engine's
manifold should be topped off, and the coolant recovery
tank may need to be filled to the
MAX level.
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the load lines.
• Be sure that in power systems with a neutral line that the
neutral is properly grounded (or ungrounded)
as the system
requires, and that generator neutral is properly connected
to the load neutral.
In single phase systems an incomplete
or open neutral can supply the wrong line-to-neutral volt-
age on unbalanced loads.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially large
mOtolS, be switched OFF until the engine has come up
to speed and, in cold climates, starts to warm up. This
precaution will prevent damage caused by unantici-
pated operation of the AC machinery and will prevent a
cold engine from stalling_
COOLANT
RECOVERY
TANK
Engines & Generators
7
LOW

OPERATING INSTRUCTIONS
GENERATOR PANEL
Starling the Generator
To start the generator, hold the momentary ON switch in the
up (on) position, then hold the momentary START/OFF
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. Once the engine is run-
ning, the starter
will disengage, and the START/OFF switch
may then be released to return to its center (run mode) posi-
tion. Continue holding the ON switch until the engine has
sufficient oil pressure, then release
it to its center position.
NOTE: Should the enginefail to start, release both switches,
wait 20seconds,
and try again. Never run the starter more
than
20 seconds at a time.
START
.... _? (MOMENTARY)
</~:./'
lH':x.",---- CENTER OFF/RUN
UHP-.-- POSITION
<, '
--<: .. ~ OFF
(MOMENTARY)
START/OFF SWITCH
Stopping the Generator
----;)
ON
(MOMENTARY)
('- .... //
C
~~::::::> CENTER OFF/RUN
',," POSITION
ON SWITCH
To stop the generator, move the momentary START/OFF
switch to the down (off) position then release it to the center
(normal) position.
REMOTE PANEL
Starling 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
wi1l dim). Once the engine is running (the green
light will brighten), the starter will disengage and the
START/STOP switch may then be released to return to its
center (run mode) position. Continue holding the
ON switch
until the engine has sufficient oil pressure, then release it to
its center position.
NOTE: Should the enginefail to start, release both switches,
wait
20 seconds, and try again. Never run the starter more
than
20 seconds at a time.
START
ON
/?
(MOMENTARY)
(MOMENTARY)
-,...-;.//
-?
c
,...-- /~
,
CENTER OFF/RUN
",--- //
k
'v'
CENTER OFF/RUN
POSITION POSITION
< ,
, , ,,
,
---~
STOP
(MOMENTARY)
STARTISTOP SWITCH ON SWtTCH
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.
A CAUTION: Prolonged cranking intervals without
the engine starting can result in filling the engine
exhaust system with raw water. This may happen
because the pump is pumping raw water through the
raw water cooling system during cranking. This raw
water can enter the engine's cylinders by way of the
exhaust manifold once the exhaust system fills. Prevent
this from happening by closing the raw water supply
through-hull shutoff, draining the exhaust muffler, and
correcting the cause of the excessive engine cranking.
Engine damage resulting from raw water entry is not a
warrantable issue; the owner/operator should keep this
in mind •
EMERGENCY STOPPING
If the generator does not stop using the START/OFFswitch,
remove the 8
amp fuse or disconnect the battery.
STARTING UNDER COLD CONDITIONS
Make certain the lubricating oil confonns with the ratings for
the prevailing temperature. Check the table under ENGINE
LUBRiCATING OIL. The battery should be fully charged to
minimize voltage drop.
ABNORMAL STOP
An abnormal stop is one in which the generator ceases to run
and
comes to a stop as a result of an operating fault which
may cause
damage to the engine, the generator, or create an
unsafe operating condition. The fault
stop conditions are:
1. Overspeed condition.
2. High engine temperature.
3.
Low oil pressure.
4. High exhaust temperature.
Should a fault condition occur, the engine will shut down and
the green
LED light on the remote panel will go off indicat-
ing that a fault has occurred. Once detected, the fault should
be located (see
ENGINE TROUBLESHOOTING).
WESTERBEKE
Engines & Generators
8

BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
Once the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between
20% to 60% of full load for the first 10 hours.
A CAUTION: 00 not attempt to break-in your genera-
tor by running without a load.
After the first 10 hours of the generators' operation, the load
can be increased to the full-load rated output; then periodi-
cally vary the load.
Avoid overload at all times.
An overload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators' rating. Since the generator operates
at 3600 rpm to produce 60 hertz, or at 3000 to produce 50
hertz, control of the generator's engine break-in is governed
by the current drawn from the generator.
To protect against unintentional overloading
of the generator,
the generator's output leads should be routed through a cir-
cuit breaker that is rated at the rated output
of the generator.
NOTE: Be aware of motor starting loads and the high
current drawn requiredfor starting motors. This starting
amperage drawn can
be 3 to 5 times normalrunning amper-
age (see GENERATOR INFORMATION).
CHECK LIST
Follow this checklist each day before starting your generator.
• Record the hourrneter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check the drive belts for wear and proper tension
(weekly).
• Monitor the control panel gauges.
• 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.
NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
is reached
and leads are applied.
A CAUTION: 00 not operate the generator for long
periods of time without a load being placed on the
generator.
STOPPING THE GENERATOR
Remove the major AC loads from the generator one at a
time. Allow the generator to run for a few minutes to stabi-
lize the operating temperature, (then see SlOpping the
Generator under OPERATING INSTRUCTIONS).
NOTE: After thefirst 50 hours of generator operation check
the maintenance schedulefor the 50 hour service check.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may
be governor adjustments required for engine speed (hertz)
during the engine's break-in period (first
50 hours) or after
this period (see
ENGINE SPEED (HERTZ) ADJUSTMENT
under ENGINEADJUSTMENTS. A no-load voltage adjust-
ment may also be required in conjunction with the engine's
speed adjustment (see GENERATOR INFORMATION).
WESTERBEKE
Engines & Generators
9

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
Drive Belts
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is
running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many a/the following maintenance procedures are simple but others are
more difficult
and may require the expert knowledge of a service mechanic.
CHECK
HOURS OF OPERATION
EACH EXPLANATION OF SCHEDULED
DAY 50 100 250 500 750 1000 1250 MAINTENANCE
0
Unleaded gasoline with octane rating of 89 or
higher.
0
Check for water and dirt in fuel (drain/replace filter
if necessary).
0
Oil level should indicate between FULL and LOW on
dipstick.
0
Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
0
Inspect for proper tension (3/8' to 1/2" deflection)
Weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine
0 NOTE: Keep engine suiface clean. Dirt arul
Check for fuel, oil and water leaks. Inspect wiring
oil will inhibit the engine:s ability to remain
and electrical connections. Keep bolts & nuts tight.
coo!.
Check for loose belt tension.
Spark Plugs
0 0 0 0 0 0
Check gap; inspect for burning and corrosion.
Generator
0 0 0 0 0 0 0
Check that AC connections are clean and secure
with no chafing - see GENERATOR INFORMATION
for additional information.
Carburetor Filler Screen
0 0 0 0 0 0
Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries
0 0
Every 50 operating hours check electrolyte levels
(and House Batteries)
Weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil
0 0 0 0 0 O· 0
Initial engine oil & filter change at 50 hrs .• then
change both every 100 hours.
'Adiustthe Valve
0 0 0
Initial adjustment at 50 hrs .• then every 500 hrs.
Clearances
Air Screen (Flame Arrester)
0
Clean at 50 hours, then every 100 hours.
Exhaust System
0 0 0 0
Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check siphon break operation. Check the
exhaust elbow for carbon and/or corrosion buildup
on inside passages; clean and replace as necessary.
Check that all connections are tight.
Engine Hoses
0 0 0 D D D
Hose should be hard & tight. Replace if so11 or
spongy. Check and tighten all hose clamps.
Governor
0 D D D D
Change oil every 250 hours.
Lubricate linkage arm periodically.
'WESTERBEKE recommends this service be periormed by an authorized mechanic.
(continued)
Engines & Generators
10

SCHEDULED
MAINTENANCE
Heal Exchanger
Raw Water Pump
Coolant System
'Starter Motor
Distributor
'Engine Cylinder
Compression and
Valve Clearance
'Engine Timing Belt
'Exhaust Elbow
MAINTENANCE SCHEDULE
NDTE: Use the engine hourmeter gauge 10 log your engine hours or record your
engine hours by running lime.
CHECK
HOURS OF OPERATION
EACH
EXPLANATION OF SCHEDULED
DAY
50 100
250
500 750 1000 1250
MAINTENANCE
D D D D D D D
Clean or repiace anode. Open heal exchanger end
cap and clean out debris. Remove every 1000 hours
for professional cleaning and pressure testing.
D D D
Remove pump cover and inspect impellertor wear;
replace 0 needed. Also replace gasket Lubricate
both when reassembling.
D
Drain, flush, and refill cooling system with appro-
priate antoreeze mix.
D D
Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the Start motor
pinion dlive.
D D
Check ignition timing. Check condition of distlibu-
tor cap and rotor.
D D
Incorrect valve clearance will resuft in poor engine
performance; check compression pressure and timing,
and adjust valve clearances.
D
Remove and replace.
NOTE: Failure to replace the timing beft at the rec-
ommended interval could resuft in timing beft fail-
ure resufting in major damage to the engine.
D
Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteliorated. WARNING: A
defective exhaust elbow can cause carbon monox-
ide leakage!
'WESTERBEKE recommends thiS service be performed by an authonzed mechamc.
Engines & Generators
11