Westerbeke 7.0KW BCG-60HERTZ User manual

OPERATOR'S MANUAL
&
INSTALLATION GUIDE
WESTERBEKE CORPORATION
GASOLINE GENERATORS
7.0KW BCG & 7.0KW BCGA -60 HERTZ
5.0 KW BCG -50 HERTZ
Publication # 038310
Edition Two
May 1993
/-...v- 'WESTERBEKE
J WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK
• 150 JOHN HANCOCK AOAD, TAUNTON" MA 02780·7319 U.S.A.

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

Engines & Generators
Declaration ofConformity
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 89/3361EEC
ISO 8846 1990(E)
ENS0081-1
ENS0082-2
ENSS020
ISO-8846-1990(E), Certification
Numbers,
IWESOOI & IWES002
Westerbeke Corporation
41 Ledin Drive
Avon Industrial
Park
Avon, Ma. 02322, USA
Marine Gasoline Generator
Westerbeke Marine
Gasoline Generator
3.0/4.5BCG, S.0/7.0BCG
7.0/9.0BTG
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 instaUed 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
042022
Carleton F. Bryant
(Full Name)
ChiefOperating Officer
(Title)
WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON, MA 02322 U,S.A .• TEL. [phone]. FAX: [phone]. CABLE: WESTCORP

INTERNATIONAL MARINE
CERTIFICATION INSTI'rUTE
TREVES CENTRE· ruo de TR!::VES ~ TEL: Int +(32) 2 238 78 92
104.0 BRUSSELS· BELGIUM FAX: Int +(32) 2238 n 00
CERTIFICATE
We hereby certify the component stated below is in accordance
with ISO 8846
and has the following characteristics:
MANUFACTURER:
ADDRESS:
MODEL NAME .OBCG
Certification number
IWESOO1
...
Signed WA'*e~
J~ ~_
Name Lars
E. <3tanholm
Title Managing Director
Date
27-Aua-96

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Productsoftwareof all kinds, such as brochures, drawings, technical data, operator's and workshop manuals,
parts lists and parts price lists. and other information, instructions and specifications provided from sources
other than
Westerbeke, is not within Westerbeke's control and, accordingly, is provided to Westerbeke
customers only as a courtesy and service. Westerbeke cannot be responsible forthe content of such
software, makes no warranties or representations with respect thereto, including the accuracy,
timeliness or completeness thereof, and will in no event be liable for any type of damages or injury
incurred in connection with,
or arising outof, the furnishing or use of such software.
Forexample, components
and subassemblies incorporated in Westerbeke'sproducts and supplied byothers
(such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and
other products) are generally supported by their manufacturers with their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software. Such software may
be outdated and no longeraccurate. Routine changes made byWesterbeke's suppliers, ofwhich Westerbeke
rarely has notice in advance, are frequently not reflected in the supplier's software until after such changes
take place.
Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software, and the unavoidable existence of earlier, non-current Westerbeke software editions in the field.
Additionally, most Westerbeke products include customer-requested special features that frequently do not
indude complete documentation.
In summation, product software provided with Westerbeke products. whether from Westerbeke or other
suppliers,
must not and cannot be relied upon exclusively as the definitiveauthority on therespective prod uct.
It not only makes good sense but is imperativethatappropriate representatives of Westerbeke orthe supplier
in question be consulted to determine the accuracy and currency ofthe product software being consulted
bythe customer.
1 Westerbeke Generators

FOREWORD
Thank you for selecting a Westerbeke marine productfor your use. We at Westerbeke are pleased to have
you as acustomer.
Read this manual carefully and observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures, installation
checks, system descriptions and minor adjust-
ment procedures are included herein so you can operate your equipment safely and properly, maintain the
equipment
at a high level ofefficiency. and expect dependable performance and long service life in return.
Should yourunit require special attention, contact yourWesterbeke dealerfor assistance. The Westerbeke
Service Organization is trained to provide the support necessary to ensure long-term dependable perfor-
mance.
If, within 60 daysofsubmittingtheWarranty Registration Form foryourunit. you have not received aCustomer
Identification
Card (see below) registering your warranty, please contact the factory in writing with Model
information, including the unit's serial number and commission date.
fram: WESTERBEKE CORPORA liON
AVON INDUSTRIAL PARK
AVON, IU 02322
""VtT I WESTERBEKE
-,-_._ .......... ' ._-
Mall To:
Westerbeke Generators
CUSTOMER IDENTIFICATION
Adam S.ith
8S "'_ple Street
Alden, IN 12234
Model BeG 7.8 KW
Expires 11/15/89
~
2
Ser. 11234(986

TABLE OF CONTENTS
Section ......................................................................... Page
GENERAL ...........................................................................5
7.0 KW BeG & BCGA
GENERAL SPECIFICATIONS ............................................8
7.0 KW BCG & BCGA
SYSTEM SPECiFiCATIONS ...............................................9
INSTALLATION CHECKS ................................................. 12
DESCRIPTION OF ENGINE
CONTROL PANEL ............................................................ 25
PREPARATIONS FOR STARTING ................................... 27
STARTING PROCEDURE ................................................. 28
STOPPING PROCEDURE ................................................ 31
CARBURETOR AND FUEL SYSTEM ............................... 32
ELECTRICAL SySTEM ..................................................... 35
DC CONTROL CIRCUIT
WIRING DIAGRAM # 38028 .................................... 38 & 39
OPTIONAL REMOTE START PANEL
WIRING DIAGRAM # 38024 ............................................ 40
OPTIONAL REMOTE INSTRUMENT PANEL
WIRING DIAGRAM # 38025 ............................................ 41
COOUNG SySTEM .......................................................... 42
LUBRICATION SYSTEM .................................................. 48
Be GENERATOR .............................................................. 51
SCA GENERATOR ........................................................... 52
GENERAL INFORMATION AND CARE
OF THE GENERATOR ..................................................... 57
ENGINE TROUBLESHOOTING ....................................... 59
MAINTENANCE & ADJUSTMENTS ................................. 63
3 Westerbeke Generators

TABLE OF CONTENTS
(CONTINUED)
LAY-UP & RECOMMISSIONING ...................................... 71
SPARE PARTS UST ..........................................................74
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES ..................................................75
TABLE OF TIGHTENING TORQUES ...............................76
INDEX ................................................................................ 77
Westerbeke Generators 4

GENERAL
Introduction
This manual contains the equipment operating procedures as well as additional information needed to help
the operator keepthemarine equipment in properworking order. Study
and followthe instructions carefully.
A planned maintenance program is included in this manual; adhering to the program will result in better
equipment performanceand longer equipment
life. Properdiagnosis ofaproblem is the most importantstep
to satisfactory repair; therefore, a troubleshooting table is included.
Understanding the Gasoline Engine-Driven Generator
The gasoline engine driving an AC generator is in manyways similar to a gasoline automobile engine. The
cylinders are vertical in-line. and the engine's cylinder head has an overhead camshaft which is belt-driven.
The engine utilizes conventional points and a condenser~type distributorwhich is horizontally mounted and
camshaft-driven. The engine incorporates a pressur~type lubrication system, and a fresh water~cooled
engine block which is thermostatically-controlled. To a large degree, the generator's engine requires the
same preventive maintenancethat is required ofa gasoline automobile engine. The most important factors
to the generators longevityare properventilation, maintenance ofthe fuel system. ignition system, cooling
system, lubrication system
and the AC alternator.
Ordering Parts
Whenever replacement parts are needed, always provide the generator model numberdeSignation (Le. 7.0
KW BeG). engine serial number, and generator serial number as theyappear on the data plates located on
thegenerator end and ontheexhaustmanifold. You CI11.lS. provide uswiththisinformation sowemayproperly
identify your generator set. In addition, include a complete part description and part number for
each part
needed (see the separatelyfumished Parts List). Also, be sure to insist upon Westerbeke factory packaged
parts, because "will fit" or generic parts are frequently not made to the same specifications as original
equipment.
Note that component locations in the manual are referenced from the front of the engine which
is the
pulley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined by
the engine; imagine straddlingthe engine and facing in the same direction as the front ofthe engine: the left
side is atyour left, the right side at your right.
Westerbeke generatorsets
are thoroughlychecked and given afinal run undervariousload conditions before
leaving the factory. Test running the generatorensures dependable operation, long service, and a satisfied
owner.
Care at the factory during assembly and thorough testing have resulted in a Westerbeke gasoline engine-
driven generator capable of manythousands ofhours ofdependable service. However, what the manufac-
turer cannot always control
is the manner orlocation the generator is installed in the vessel orthe manner
in which the unit is operated and serviced in the field. That part is up tothe buyer/owner-operator.
5 Westerbeke Generators

7.0 KW BCG &BCGA Marine Gasoline Generator
20 Amp DC
Circuit Breaker
Fresh Water Coolant Fill
HeatExChanger~
Westerbeke Generators 6
Lube Oil Ffll
Exhaust Temperature Switch
Distributor
45° Exhaust Elbow
DC Battery Ground
Connection
.Starter with
Solenoid

7.0 KW BCG & BCGA Marine Gasoline Generator
Fuel Shut· off Solenoid
Air Intake Flame Arrester
Control
Panel ~
Governor
---- Water Temperature
Switch
AC Connections ---
Outlet
Sea Water Pump
Gasdenser
Lube Oil Drain Hose
7 Westerbeke
Generators

7.0 KW BCG & BCGA MARINE GASOLINE GENERATOR SET
GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque (at 1800 rpm)
Compression Ratio
Compression Pressure
(Limit ofdifference between cylinders)
Valve Timing
Valve Seat Angle
Valve Clearance
(engine warm)
Engine Speed
Dimensions
Dry Weight
Fuel Consumption
Inclination
Westerbeke Generators
Gasoline, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(8 bhp at 1800 rpm, maximum).
Hoof, flyball type,
5% speed regulation.
Multi-sphere
type.
2.62 x 3.19 inches (66.6 x 81 mm)
51.6 cubic inches (.846 liter)
1-2-3
Clockwise, when viewed from the front.
13.5Ibf-ft
9.5:1
213.3 psi (15.0 kglcm2) at 400 rpm
(28 psi [2.0 kg/cm2 ])
8
Intake Opens 2SO BTDC
Intake Closes 62° ABDC
Exhaust Opens 6z:' BBDC
Exhaust Closes 28° ATDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0118 inches (0.30 mm)
1800 rpm 60 hertz.
1500 rpm 50 hertz.
Length: 26.50 inches (673.1 mm)
Width: 18.34 inches (465.8 mm)
Height: 23.44 inches (595.4mm)
Approx. 3091bs (140.1 kgs)
0.8 U.S. gph (3.02 Iph) at full rated output (approximate).
Continuous 14°
Temporary 20° (not to exceed 20 min.)

7.0 KW BeG & BCGA SYSTEM SPECIFICATIONS
INTAKE SYSTEM
Carburetor (STD type)
IGNITION SYSTEM
General
Distributor
Spark Plug Thread Size
Spark Plug Type
FUEL SYSTEM
General
Fuel
Fuel Pump
Fuel Screens (on engine)
Air cleaner
Air Row (engine combustion)
COOUNG SYSTEM
General
Operating Temperature
Fresh Water Pump
Raw Water Pump
Manual with butterfly shaped
valve, single barrel
with U.S.C.G. approved flame arrester.
Battery ignition, 12-volts (negative ground),
distributorwith points, ignition coil and spark
plugs.
Conventional, contact-point type.
14 x 1.25 mm pitch (0.55 x 0.05 in.)
Westerbeke part number33805
(Always identifythe generator model
when ordering parts.)
Conventional carburetor type with fuel pump.
Regular or unleaded gasoline with an octane rating
of 89 orhigher.
12.volt DC; lift capacity 5ft (1.5 m)
Reusable screen type Oocated at inlet to carburetor).
Metal screen type -cleanable.
26.8 cfm (0.758 cmm) at 1800 rpm.
Fresh water-cooled block,
thermostatically-controlled
with a heat exchanger.
130 -150°F (55 - We)
Centrifugal type, belt-driven, 1.13:1 to crankshaft.
Positive displacement, rubber impeller, belt..(jriven.
9 Westerbeke Generators

7.0 KW BCG & BCGA SYSTEM SPECIFICATIONS
Raw Water Flow. at 1800 rpm
(measured before discharging
into exhaust elbow)
System Capacity (fresh water)
LUBRICATION SYSTEM
General
Oil Filter
Sump capacity (not including filter)
Operating
Oil Pressure (engine hot)
Oil Grade
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
DC Battery Charger
Starter
DC No-Load Current
DC Cranking Current
Westerbeke Generators
3.75 -4.0 U.S. gpm (14.19 -15.14Ipm)
4.2 U.S. qts (3.9 liters)
Fully -Force fed type byTrochoid pump,
crankshaft
--driven.
Full flow, paper element, spin-on type.
P.N.036918
3.0 qts (2.8 liters)
50·70 psi (3.5 -4.9 kg/cm2)
API specification of SE, SF or SG.
12-volt. 24 A-H, (-) negative ground
(recommended)
(28 A-H in cold areas).
24 -28 (ampere-hours)
Integral controller 13-volt. 10 amp
(located
in the AC alternator).
12-volt, 1.2
t<NV, Magneto engaging type.
90 amp (max) at 11.5 volts.
100 -125 amps (engine cold).
10

7.0 KW BeG & BCGA SYSTEM SPECIFICATIONS
AC GENERATOR
General
Voltage
Brushless, four-pole, revolving field.
Self exciting. Capacitor saturated field excitation.
Pre-lubricated, single-bearing design.
Reconnectable 120 volts or 120/240volts,
single-phase.
120 or 120/240 volts - 60 hertz
220 volts -50 hertz.
Voltage regulation: ±S% no-load to
full-load.
Frequency regulation:
::t 3 hertz (5%)
no-load tofull-load.
NOTE: BCGA models are 60 hertz only. This model cannot be converted to 50 hertz.
Rating (volts AC)
60 Hertz (1800 rpm)
50 Hertz (1500 rpm)
AC Circuit Breaker
Generator Cooling
Air
Requirements, (60 hertz),
at 1800 rpm
120 volts
120/240 volts
220 volts
58 amps
58/29amps
23 amps
To be rated at 120% ofthe generator's rated
amperage and voltage output.
250 cfm (7.0 cmm)
NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm).
Engine Combustion Air
Requirements, (60 hertz),
at 1800 rpm
TUNE-UP SPECIFICATIONS
Spark Plug Gap
Contact Point Clearance
Timing
Dwell Angle
26.8 cfrn (0.758 cmm)
0.028 -0.031 inches (0.70 -0.80 mm)
0.017 ~ 0.018 inches (0.4 -0.5 mm)
100 ::t .5° BTDC at 1800 rpm
58 - sse
11
Westerbeke Generators

INSTALLATION CHECKS
General
Since the crafts in which Westerbeke generators are installed varyin design, installationprocedureswill vary
according to your craft's specific design. The intent ofthis section is not to advise boatyards or installers
on procedures al ready well..cJevel oped and well-understood. However, the owner/operatormust realize there
are details of the installation which require periodic checks to ensure the best operating conditions for the
equipment
and safe operating conditionsforthe personnel on board. Properlocation and installation of the
gasoline generator in the vessel are of prime importance.
Factors
in the installation that lIJ.US1. be considered are ventilation, to aid in cooling the generator end; to
provide airfor engine combustion
and to remove heat produced bythe engine while operating; the exhaust
system, to properly discharge raw cooling water (sea water); toquiet the exhaust and to expel exhaust gas;
the cooling water supply; the electrical connections, both AC and DC. and a fuel system thatwill provide an
unrestricted fuel supply and properly filtered fuel to the fuel pump on the engine.
CAUTION
Forsafety reasons, the generator'sengine is notfilled with lubricating oil forshipment. Before
leaving the factory, however, each generator set is thoroughly tested with oil in its engine.
This testing, among otherthings, provides all internal parts with acoating ofoil. This oil acts
as a preservative, providing reliable protection against corrosion for at least one year ifthe
generator
is properly stored.
Inspection of Equipment
The generator is shipped from the factory securely mounted and properly crated. Accessory equipment is
shipped in aseparate small box, usually packed within the generator's crate.
Before accepting shipmentofthegenerator set fromthetransportation company, thecrate should be opened
and the contentsinspectedforconcealed damage. Ifeithervisibleorconcealed damage is noted, you should
require the deliveryagent sign "Received in damaged condition" on the properdelivery receipt Also, check
the contents of the shipment against the packing list
and make sure that the proper notation is made if any
discrepancies exist. These noted discrepancies are your protection against loss or damage. Claims
concerning loss ordamage lllJJ.SI. be made tothe carrier. notto Westerbeke Corporation.
Westerbeke Generators 12

Rigging and Lifting
The generator is fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight
should be attached
to the eyes and the generator lifted by means of tackle attached to these slings. The
lifting eyes have been designed
to carry the full weight of the generator; therefore, auxiliary slings are not
required
or desired.
CAUTION
Slingsmust
not be so shortasto place significantstressonthe generator's lifting eyes. Strain
placed on the generator's lifting eyes by thelifting sling must not be in excess of 10°from the
vertical plain.
[.SIIIE
SLING LIFTING
ANGLE MUSl IIOT
EXCEED 10·
LIFT IIIG
EYE
The general rule in moving generators is to see that all equipment used is amply strong and firmly fixed in
place. Movetheenginealittle at atimeandseethatitisfirmlysupported. Eliminatethepossibility of accidents
by avoiding haste. Do not liftthegenerator by itscrankshaft pulley. In certain situations it maybe necessary
to liftthe engine in positions otherthan the horizontal position. Certain situations exist by which the engine
must
be lowered endwise through a small hatchwaywhich cannot be made larger. Underthese conditions,
if the opening of the hatchway is extremely small, it is possible to reduce, to some extent, the outside
dimensionsofthegenerator
by removing external components such asthecooling system's piping, the heat
exchanger, certain filters, the mounting rails and other obstructive equipment. This accessory equipment
should be removed
by a competent mechanic and special care should be taken to avoid damage to any
exposed parts. In addition, be careful not
to allow dirt and foreign matter to enter any opening created by
the removal of engine components. Removed parts/components should
be returned to their respective
position as soon as the generatorhas cleared the obstruction and is ready
to be positioned on its mounting
platform. Be sure to use new gaskets where and when needed.
In case it becomes necessary to hoist the generator front-end upwards or generator-end upwards, the
attachment of lifting slings must be done carefully
to avoid the possibility of damaging the parts on which
theweight
of theslings may bear. Special rigging work isbestdoneby someoneexperienced and competent
in handling
heavy machinery.
13 Westerbeke Generators

Generator Mounting -Location
The complete generator unit is mounted on lightweight rails by means of fourflexible isolator mountsthat
help preventthetransfer
of vibrationfromthegenerator to therails. Each generatormounting rail has several
1/2 inch bolt holes so bolts can be employed to properly secure the generator to its mounting platform.
These holes are on 13.5
or 14.5 inch mounting centers. Consult the sales brochure for exact mounting
specifications.
(1/2- ~OUNTING HOLES)
The mounting location lIJ.J.ml bedry, abovelow-lyingvaporareas, and in anareawhere bilgewaterand water
from above cannot splash
or drip on the generator or drive engine. The drive engine and generator lr!!.lSI.
be accessible for minor servicing and repairs. Access for major repairs should be given consideration as
well. The generator set aJ1J.S1. be properly ventilated to provide fresh cooling air for the generator end, for
engine combustion needs, and
to remove heat produced by the engine while operating. The generator set
needs fresh cool air in whatever location in the vessel it is installed.
Hot generator discharge air !IJ.J.!.S1 be
removed from the generator area. The platform on which the generator and its mounting rails are located
~ be strong enough to supportthe generator during all angles of vessel operation.
Westerbeke Generators
14