Westerbeke 9.0 BCG User manual

TECHNICAL MANUAL
WESTERBEKE CORPORATION
BCG 4.0 & 6.5 KW AND BTG 9.0 KW -60 HERTZ
BCG 3.0 & 4.8 KW AND BTG 7.0 KW -50 HERTZ
MARINE GASOLINE GENERATORS
SINGLE PHASE
Publication #036209
Edition Three
December
1991
jr~ 'WESTERBEKE
~
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
TEL: [phone]· FAX: [phone] • WEBSITE: www.WESTERBEKE.COM

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

SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention
to and emphasize conditions potentially dangerous to the
operator.
IWARNINGI
The above symbol is used in the manual to warn of possible
serious personal injury orloss
of life.
CAUTION
The above symbol is used in the manual to caution personnel
of possible damage to equipment.
Read the manual carefully and thoroughly before attempting
to operate the equipment. Know when dangerous conditions
can exist and take necessary precautions
to protect personnel
and equipment.
Fuels, exhaust gases, batteries, electrical equipment, and
moving and hotparts are potential hazardsthat could result in
serious personal injuryor death. Follow recommended proce-
dures carefully.
Always operate bilge blowers for at least five minutes before
startingagasoline-fueledenginej ensurenogasolinefumesare
present before starting.
• Prevent Electric Shock
Shut off electric power before accessing electrical equip-
ment.
Use insulated matswheneverworking on electrical equip-
ment.
Make sure your clothing is dry, not
damp (particularly
shoes), and keep your skin surfaces
dry when handling
electrical equipment.
Remove wristwatch and jewelrywhen working on electri-
cal equipment.
Do notconnect utilityshore power tovessel's AC circuits,
except through a ship-to-shore double-throw transfer
switch. Damagetovessel's
AC generator mayresult if this
is not done.
Be extremely careful when working on electrical com-
ponents. High voltage can cause injury or death.
• Exhaust Gases Are Toxic
Ensurethattheexhaustsystem isadequatetoexpel gases
discharged
from the engine. Check exhaust system
regularly for leaks and make sure the exhaust manifolds
are securelyattached and no warping exists.
Be sure the unitand its surroundings are well-ventilated.
• Use Extreme Care When Handling Engine Fuel
(A constant danger ofexplosion or fire exists)
Do notfill fuel tank(s) while the engine is running.
Do notsmokeoruse an open flame neartheengineorthe
fuel tank.
• po Not Alter or Modify the Fuel System
Be sure all fuel supplies have a positive shut-off valve.
Be certain fuel line fittings are adequatelytightened and
free
of leaks.
Make sure a fire extinguisher is installed nearby and is
properly maintained.
Be familiar with its proper use. ex-
tinguishers rated ABC by the NFPA are appropriate for all
applications encountered in this environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.
Leadacidbatteriesemithydrogen,ahighly-explosivegas,
which can
be ignited by electrical arcing or by a lighted
cigarette, cigar, or pipe.
Do not smoke or allow an open
flame nearthe battery being serviced. Shut off all electri-
cal equipment in the vicinity
to prevent electrical arcing
during servicing.
• Ayoid Moving parts
Do notservice the unitwhile the unitis runningj if a situa-
tion arises in which
it is absolutely necessary to make
operating adjustments, use extremecare
to avoid moving
parts and hotexhaust system components.
Do not wear loose clothing or jewelry when servicing
equipmentj avoid wearing loose jackets, shirts orsleeves,
rings, necklaces, or bracelets that
might be caught in
moving parts.
Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
place atall times.
Do not check fluid levels or the drive-belt's tension while
the unitisoperating.
Do notworkon the equipmentwhen mentallyorphysical-
ly incapacitated by fatigue.

WESTERBEKE
Engines & Generators
Declaration of ~onformity
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 89/336/EEC
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.SBCG, S.017.0BCG
7.0/9.0BTG
All
I.) 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 AVOIb Massachusetts, U.S.A.
Date: September 1, 1996
042022
(!~&&10;~~
(Signature)
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 INSTITUTE
mevEs CENTRE· rue de miOVES 4S TEL: Inl +(32) 2 238 78 92
1040 BRUSSELS· B.ELGIUM FAX.: Inl +(32) 2 238 n 00
CERTn'ICATE
We hereby certify the componentstated below is in accordance
,
with ISO 8846 and has the following characteristics:
Certification number
IWESOO2 /"
Signed bf/...-. -£
e.:
-L . ./
Name Lars E. af'anholm
Title Manaaing Director
Date
27-Aua-96

TABLE OF CONTENTS
Section.......................................................................... page
GENERAL ......................................................................... 11
INSTALLATION CHECKS ................................................. 12
IMPORTANT RULES ........................................................ 29
OPERATION ..................................................................... 30
MAINTENANCE ................................................................ 35
BCG 4.0KW MARINE GASOUNE GENERATOR
SET GENERAL SPECIFICATIONS .................................. 39
BCG 4.0KW SYSTEM SPECIFICATIONS ........................ 40
BCG 6.5KW MARINE GASOUNE GENERATOR
SET GENERAL SPECIFICATIONS .................................. 43
BCG 6.5KW SYSTEM SPECIFICATIONS ........................ 44
BTG 9.0KW MARINE GASOUNE GENERATOR
SET GENERAL SPECIFICATIONS .................................. 47
BTG 9.0KW SYSTEM SPECiFiCATIONS ......................... 48
BCG 4.0KW, BCG 6.5KW AND BTG 9.0KW
ENGINE SERVICE SPECiFiCATIONS ............................. 51
TIGHTENING TORQUES REQUIREMENTS ................... 59
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES ................................................. 61
GENERATOR OVERHAUL ............................................... 63
PREPARATIONS .............................................................. 64
DISASSEMBLY FOR OVERHAUL. ................................... 65
ENGINE DISASSEMBLY .................................................. 67
REMOVING THE CYUNDER HEAD
FROM THE CYUNDER BLOCK ....................................... 72
CYUNDER HEAD DiSASSEMBLy ................................... 73
CYUNDER BLOCK DiSASSEMBLy ................................ 77
1 Westerbeke Generators

Westerbeke Generators
TABLE OF CONTENTS
(CONTINUED)
SPECIAL SERVICE TOOLS .............................................. 84
CYLINDER HEAD AND ENGINE BLOCK
INSPECTION AND REPAIR .............................................. 85
ENGINE INSPECTION AND REPAIR ............................... 86
SUBASSEMBLY INSPECTION, REPAIR,
AND ASSEMBLY ............................................................. 109
ENGINE ASSEMBL Y....................................................... 133
CYLINDER BLOCK ASSEMBLY ..................................... 134
CYLINDER HEAD ASSEMBLY ....................................... 142
BOLTING THE CYLINDER HEAD TO
THE CYLINDER BLOCK ................................................. 147
TIMING BELT ASSEMBLy .............................................. 148
ADJUSTING VALVE CLEARANCES ............................... 153
LUBRICATION SySTEM ................................................. 157
COOLING SYSTEM ........................................................ 160
GOVERNOR .................................................................... 163
CARBURETOR AND FUEL SYSTEM .............................. 165
DC ELECTRICAL SYSTEM ............................................. 169
BCG 4.0KW AND BCG 6.5KW DC
WIRING DIAGRAM # 35439 ................................ 170 & 171
BTG 9.0KW DC WIRING
DIAGRAM # 36397 ......................................................... 172
REMOTE START PANEL WIRING
DIAGRAM #35706 .......................................................... 173
REMOTE INSTRUMENT PANEL
WIRING DIAGRAM # 35698 ........................................... 174
REMOTE PANEL INSTALLATION .................................. 175
GENERATOR DESCRIPTION AND
MODEL RATING ............................................................. 181
2

TABLE OF CONTENTS
(CONTINUED)
TROUBLESHOOTING AND ADJUSTMENT
FOR THE BT GENERATOR ........................................... 183
BT GENERATOR AC VOLTAGE
CONNECTION ................................................................ 197
TROUBLESHOOTING AND ADJUSTMENT
FOR THE BC GENERATOR ........................................... 201
RESISTANCE VALUES
OF COMPONENTS ........................................................ 203
GENERATOR TROUBLESHOOTING ............................ 213
BC GENERATOR HERTZ (CYCLE)
AND VOLTAGE CHANGES ............................................ 215
SERVICE BULLETINS .................................................... 219
FIELD FABRICATED TOOLS .....................................•... 222
INDEX ............................................................................. 227
3
Westerbeke Generators

Fresh Water Ail" Bleed·
AC
Unit Data Tagi
Fuel Lift Pump
Oil Pressure Switch
Westerbeke Generators
BeG 4.0KW Marine Gasoline Generator
4
Intake Flame Arrestor
F~ea Shut-off·
SoienolcF
Sea Water Pump

Exhaust Manifold
20 Amp DC Circuit
Breaker
Zinc Anode.
. Heat EX.changer
BeG 4.0KW Marine Gasoline Generator
lube Oil Fill
5
Exhaust Temperature Switch
. 90" Exhaust Elbow
'v... ~.. "/"
, DC Battery Ground
. Conrl'ectio~n'
Westerbeke Generators

BeG 6.5KW Marine Gasoline Generator
Westerbeke Generators 6

BeG 6.5KW Marine Gasoline Generator
Distributor
Fresh Water Coolant FiU
.
Model Data Tag
20 Amp DC Circuit
7
·90
Q
Exhaust E!bow
Exhaust Temperature
·Swilch ............... ~
DC Battery Ground
Connect:ion
Westerbeke Generators

~
!a
CD
a-
CD
~
CD
Ci)
CD
:::J
CD
a
3
C»
Fuel Shut-off Solenoid
AC Connections Outlet
RIGHT SIDE
ir Intake Flame Arrestor
rburetor with Choke
..... """"'I lube Oil Dipstick
L~ DC Charging Alternator

CD
~
S
..
e-
CD
~
CD
G')
CD
:s
CD
a
o
;
Fresh Water Fill C:ClP
Model:: I. D. Plate
Raw Water Pump
Heat Exchanger

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, partslistsand partsprice lists, and otherinformation, instructionsand specifications provided from
sources otherthan Westerbeke, is notwithin Westerbeke's control and, accordingly, is provided
to Wester-
beke customers only as a courtesy and service. Westerbeke
cannot be responsible for the 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 in-
curred in connection with, or arising out of, the furnishing or use of such software.
For example, components and subassemblies incorporated in Westerbeke's products and supplied
by
others (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 Wester-
beke must depend on such software for the design
of Westerbeke's own product software. Such software
may be outdated and no longer accurate. Routine changes made
by Westerbeke's suppliers, of which
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, mostWesterbeke products include customer-requested special features that frequently do not
include complete documentation.
In summation, productsoftware provided with Westerbeke products, whetherfromWesterbeke or othersup-
pliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.
It not only makes good sense but is imperative that appropriate representatives ofWesterbeke or the sup-
plier in question be consulted
to determine the accuracy and currency of the product software being con-
sulted
by the customer.
Westerbeke
Generators
10

GENERAL
Introduction
This manual is a general guide to the installation, start-up, operation and maintenance of your Westerbeke
marine gasoline engine-driven generator. The information contained in this manual is vital
to your engine's
dependable, long-term operation.
A. Read it.
B. Keep it in a safe, dry place.
C. Keep it handy for reference at all times.
Understanding the Gasoline 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 a pOints and condensertype distributorwhich is vertically mounted and camshaft driven.
The engine incorporates a pressuretype lubrication system, and a fresh water-cooled engine blockwhich
is
thermostat-controlled. Toa largedegree,the generator's engine requires the same preventive maintenance
that is required ofa gasoline automobile engine. The mostimportant factors
to the generator'slongevityare
properventilation, maintenance ofthe fuel system, ignition system, cooling system and the generator end.
Ordering Parts
Whenever replacement parts are needed, always providethe generator model number (Le. 6.5 BC 3 cylinder
gasoline generator), engine serial number, and generator serial number as they appear on the scarlet and
gold name plate located on the generatorend. You must provide uswith this information so we may proper-
ly identifyyour generatorset. In addition, include a complete part description and part number for each part
needed (see the separatelyfurnished 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 equip-
ment.
Note that component locations in the manual are referenced from the front of the engine which is the pul-
ley/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 thefront ofthe engine: the left side
is at
your left, the right side at your right.
Westerbeke generators sets are thoroughly checked and given a final run under various load conditions
beforeleavingthefactory. This is done
to ensure 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 many thousands of hours of dependable service. However, the manufacturer
cannot control is the treatment the unit receives in the field. That part is up
to the owner/operator.
11 Westerbeke Generators

INSTALLATION CHECKS
General
Since the crafts in which Westerbeke generators are installed vary in design, installation procedureswill vary
accordingtoyour craft's specific
design. The intent ofthis section is not to advise boatyards or installers on
procedures already well-developed and well-understood. However, it is important that the owner/operator
realize there are details ofthe installation which require periodic checks to ensure the best operating condi-
tions for the equipment
and safe operating conditions for the personnel on board. Proper location and in-
stallation ofthe gasoline generator in the vessel are of prime importance.
Installation factors that must be considered are ventilation which provides airfor engine combustion, cools
the generator's end, and removes heat produced by the engine during and afteroperation; the exhaust sys-
tem which properly discharges raw cooling water (sea water), quiets the exhaust, expels exhaust gas, and
cools the exhaust gases, the raw water supply and discharge circuit for the engine, fuel supply and AC and
DC electrical connections.
CAUTION
For safety reasons, the generator's engine is notfilled with lubricating oil for shipment. Before
leaving the factory, however, each generator set is thoroughly tested with the properamount
of
oil in its engine and with an antifreeze mixture used in both the raw and freshwater cooling
systems. This testing, among otherthings, provides all internal partswith acoating of oil. This
oil and antifreeze acts as a preservative to coat the inside of the engine, providing reliable
protection against corrosion for at least one year if the generator is properly stored.
Inspection of Equipment
The generator is shipped from the factory securely mounted and properly crated. Accessory equipment is
shipped in a separate small box, usually packed within the generator's crate.
Before accepting shipment of the generator set from the transportation company, the crate should be
opened and the contents inspected for concealed damage. If either visible orconcealed damage is noted,
you should require the delivery agent sign "Received in damaged condition" on the proper delivery 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 or damage ~ be made to the ca"ie" not to 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 oftackle attached tothis sling. The lifting
eyes have been designed to carry the full weight of the generator; therefore, auxiliary slings are not required
or desired.
CAUTION
Slings must not be so short as to place Significant stress on the generator'slifting eyes. Strain
placed on the generator's lifting eyes by the lifting sling must not be in excess of 10° from the
vertical plain.
The general rule in moving generators is to see that all equipment used is amply strong and firmly fixed in
place. Move the engine a little at atime and see that it is firmly supported. Eliminate the possibility of acci-
dents by avoiding
haste. Do not lift the generator by its crankshaft pulley. In certain situations it may be
necessaryto lift the engine in positions other than the horizontal position. Certain situations exist by which
the engine must be lowered endwise through a small hatchway which cannot be made larger. Under these
conditions, If the opening of the hatchway is extremely restrictive, it is possible to reduce, to some extent,
the outside dimensions ofthe generator by removing external components such as the alternator, the cool-
ing 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 contaminants to enter any open-
ing created by the removal of equipment. Removed parts should be returned to their respective position
oncethe generator
has been placed in the compartment in which it will operate. Replace sealing gaskets of
components
removed as needed.
In case it becomes necessary to hoist the generator front-end upwards or generator-end upwards, the at-
tachment of lifting slings must be done carefully to avoid the possibility ofdamaging the parts on which the
weight ofthe slings may bear. Special rigging work is best done by someone experienced and competent
in handling heavy machinery.
13
Westerbeke Generators

Generator Mounting - Location
The complete generator unit is mounted on lightweight rails by means of four flexible isolator mounts that
help preventthetransfer
of vibrationfromthegenerator to the rails. Each generatormounting rail hasseveral
1/2 inch bolt holes so bolts can be employed
to properly secure the generator to its mounting platform.
These holes are on 14.5 inch mounting centers.
The location should be dry, above low-lying vapor areas, and away from being splashed
by bilge water or
water from above. It should be properlyventilated and accessible for minor servicing and repairs. Access
formajorrepairs should begiven considerationaswell. The locationshould be properlyventilated
to provide
fresh cooling airfor the generator end and for engine combustion. The generator set needs fresh cool air
in whatever location
in the vessel it is installed. Hot generator discharge air ~ be removed from the
generator area. The platform on which the generator and its mounting rails are located should be strong
enough
to supportthe generatorduring all angles ofvessel operation.
Westerbeke Generators
14