Westerbeke 4.5 BCGB - 60HZ User manual

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OPERATORS MANUAL .
FOR THE
4.5 BCGB - 60HZ
3.8 BCGB - 50Hz
AND
7.0 BCGB- 60HZ
5.0 BCGB - 50Hz
..
GASOLINE GENERATORS
SINGLE PHASE
PUBLICATION N0.044200
OCTOBER 2015
2nd REVISION
WESTERBEKE CORPORA T/ON • 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKECOM ..
. ~ . . .

A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is-poisonous and can cause
unconsciousness and death~ SymptomS tlf Carbon Monoxide
exposure can include:
•Dizziness • Throbbing in Temples
•Nausea
•Headache
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness •Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
1leek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

Gasoline with an ETHANOL conte·nt
higher than 10°/o (E10) is not allowed
and may void warranty.
TM
Engines & Generators

Blank page
I"MfUVESTERBBKE
l EnglneJ & a..nerators

SAFETY INSTRUCTIONS
INTRODUCTION
Read tlzis safety manual cqrefuUy. Most accUlents are
caused by failure to follow fundamental ntles and •
precautions. Know when dangerous conditions uist and
take the necessary precautions to protectyortrself, your
personne~ andyour machinery.
The foUowing safety instructions are in complitmce with the
American Boat and Yacllt Council (ABYC) standtzrds.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine Is nmnlng. Lethal voltage is present at
these connet:tlonsl
• Do not operate this machinery, without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment
• Use insulated 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 alljewelry when w9rking on
electrical equipment. ·
PREVENT BURNS- HOT ENGINE
A WARNING: Do not touch hot engine parts Dr
exhaust system components. A running engine gets
veryhotl
• Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodicaly at the filler cap
location on the water jacketed exhaust manifold, but only
when the engine is COLD.
A WARNING: Steam can cause Injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine orchecking the coolant.
'PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!·
• Prevent flash fires. Do not smoke orpermit flames or
sparks to occur neat the carburetor,
fuel line, filter, fuel
pump, orother potential sources of spilled fuel or fuel
vapors. Use a suitable container to c..atch all fuel when
removing the fuel line; fuel filters. orother
fuel system components. -
• Do not operate
with the air cleaner/silencer or flame
arrester screen removed. Backfire can cause severe injury
ordeath.
IIi Do not smoke orpennit flames· orsparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free
of debris to minimize the
chances
of fire. Wipe up all spilled fuel and engine oil.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can ca.
Injury or death!
• Follow re-fueling safety instructions. Keep ihe vessel's
. hatches closed when fueling. Open and ventilate cabin
after fueling.· Check' below for fumes/vapor before running
the blower. Run the engine compartment blower prior to
starting, follow the recommendation of the vessel builder.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well~ventilated area away from spark~producing
equipment and out of the reach of ohildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut offthe fuelservice valve at the engine when servicing
tho fuel system. Thke care in catching any fuel that might
spill. DONarallow any smoking,
opeTI;flames, or other
sources of fire near the fuel system ot engtrte when
servicing. Ensure proper veniil.ation exists when servicing
the fuel system.
• Do 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 ofleaks.
:
·• 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
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Thrn OFF the DC breaker on the control pan~l or tum the
unit's battery selector switch to
OFF before servicing the
engine.
• 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
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries
~mi~ hydrogen, ~
highly explosive gas, which can be 1gmted by elec~cal
arcing or by lit tobacco products. Shut o~ all ele~tncal
equipment in the vicinity to prevent electncal arcmg
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal
of the starter solenoi~.
Do not test the battery condition by shorting the termmals
together. Sparks could ignite
batt~I?' gases o~ fuel vapors.
Ventilate any compartment contammg battenes 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 terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry 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: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain
sulfuri~ acid whic? is
destructive.
If it comes in contact w1th 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: Carbon 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 manifold/
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information, refer to ABYC TH-22
(educational information
on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration
of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents,
or air conditioners. If the engine
exhaust discharge outlet is
near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow
of exhaust. Avoid overloading the craft.
• Although 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
symptoms
or signs of carbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Inability
to think coherently
Throbbing in temples
Muscular twitching
Nausea Weakness and sleepiness
·AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and
hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Do not allow-any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur.
HAZARDOUS NOISE .
A WARNING: High nolss/evels can causs hearing
loss/
• Never operate an engine without its muffler installed.
• Do not run the engine with the air intake (silencer) or
flame arrester removed.
• Do not run engines for long periods with their enclosures
open (when installed).
A WARNING: Do not work on machinery when you are
1111ntally or 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
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to in~ 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 lnc~uding the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest ~:
H-2 Ventilation for Boats using Gasoline
· H-24 Gasoline FuerSystems
P-1 Installation ofExhaust Systems
for Propulsion and Auxiliary Engines
P-4 Marine Inboard Engines and Transmissions
B-llAC and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (PCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
Read the following ABYC, NPPA and USCG publications .
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Y4cht Council)
"Standards and Technical Information Reports for Small
Craft"
Order
from:
ABYC
613-Third Street, Suite 10
Aprtapolis, MD 21403
\vww.abycinc.org
NFPA - No.3oi (National Fire Protection Association)
"Pleasure and Commercial Motor Craft"
Order from:
National Fire Protection Association
Battery March Park
Quincy, MA 02269
USCG.(United States Coast Guard)
''regulatedions are under titles
CFR33 and CFR46 of the
Code ofRegulations"
Order
from:
U.S. Government Printing Office
Washingt9n, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine
damage. Consult the siphon-break manufacturerfor proper maintenance.
AVAILABLE FROM
YOUR WESTERBEKE
··DEALER
EXHAUST SYSTEM
SIPHON~ifiiEAJ(WiTH STAINLESS
LOOP'
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use
of this type of hose allows for extreme bends
and turns without the need
of additional fitting and clamps to accomplish these bends
and turns. Inthis regard, a single length
of corrugated exhaust hose can be used. The
system MUST be designed to prevent the entry
of water into the exhaust system
under any sea conditions and at any angle
of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ................................................ 2
Engine Adjustments ............................................. 26
Introduction .. -~················· ...................................... 3
Serial Number Location .................................. .3
Fuel, Engine Oil and Engine Coolant .................. 5
Control Panels ..................................................... 6
Speed Hertz Adjustment................................. 26
Torquing the Cylinder Head Bolts ................ 26
Spark Plugs.............;....................................... 27
Drive Belt Adjustment.................................... 27
Valve Clearance ............................................. 28
Preparations for Initial Start-Up ......................... 7 Choke Solenoid
.. ~ ........................................... 28
Operating Instructions ........................................ 8
Remote Panel.................................................9
Timing Belt.....................................................29
Engine Compression ....:.................................32
Break-In Procedure/Dally Operation ................. 1o
Safety Shutdown SWitches ................................ ll
Maintenance Schedule ..................................... 12
Component Testing ............................................ 33
Engine Troubleshooting ..................................... 34
Generator lnformatlon ............................. : ......... 36
Cooling System .................................................. 14
Changing Coolant........................................... 15
Thermostat......................................................16
Heat Exchanger ..............................................16
Raw Water Intake Strainer..............................
17
BC Generator Single Phase ............................... 37
Circuit Breaker.............................................. .37
Internal Wiring Schematic.............................. 37
No-Load Voltage Adjustment......................... 38
Dual Exciter Model ........................................39
Raw Water Pump............................................
17
AC Terminal Board Connections ...................... .40
Fuel System ....................................................... 18
Battery Circuit/Resistance Values (Charts) ..... 40
Carburetor....................................................: .. 18
Testing the Exciter Windings ........................... .41
Fuel Lift Pump................................................18 Field Testing Capacitor..................................
.41
Gasdenser........................................................18
Gasoline/Water Separator...............................18
Carburetor Adjustments .................................... 19
Engine Lub~icating 011 ....................................... 20
Testing Component Resistance Values ............ 42
Battery Charging Circuit ..................................... 43
Testing the Battery Charger............................ 43
Testing the Battery Charging Circuit .............44
Oil Pressure ....................................................... 21
Testing the Bridge Rectifier .......................... .45
Remote Oil Filter ............................................... 22
Shore Power Transfer SWitch ............................ 46
BCGB Wiring Diagram ........................................ 23
Lay-up and Recommissioning ......................... ..47
BCGB Wiring Schematic .................................... 24
Generator Specifications .................................. 49
Remote Panel Wiring ......................................... 25
Standard Hardware ........................................... 50
BCGB Hardware Torques ................................... 51
Metric Conversions Chart .......................... : ...... 52
Suggested Spare Parts ........................... : .......... 53
j..,-#WESIEHBEICE
I Eng,.. • 0enemors
1

BCGB PARTS \DEHllflCAllOH
.-
ENGINE Oil fill
WI'TER INJECTED ·
EXKI'UST ElBOW
COOli'NT DRIUN
KOURMETER
8 A.MP fUSE
20 AMP CIRCUIT'
BREAKER
CI'RBURETOR
I'IR INTAKE
LEfT S\DE
R\GHl S\DE
KEI'T EXCKI'NGER
C....q,_,_EIClL
Engines & Generators
2
REMOTE PI'NEl
CONNECTION
-·
CIRCUIT BREI'KER
GENERATOR
BI'CKEND
REAR
flEXIBlE MOUNT
. RI'W WATER
INJECTION
(SYPHON BREAK
COK~ECTIOK)
fUEl UfT PUMP
FRONl

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE'S long years ofexperience
and advanced
technology. We take great pride in the superior durability and
dependable performance ofour 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.
,.....,rWESTERBEKE
I Engines & Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BCGB Ser. #XXXXX-0910
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 ofyour WESTERBEKE engine/generator.
The
first character indicates the decade (D=1990s, E=2000s),
the second character represents the year in the decade, and
the fourth and fifth number represents the month of
manufacture. The
BCGB Models were produced between
1999 and 2002.
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures
and catalogs) provided from sources other than
WESTERBEKE 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, TIMEUNESS OR COMPLETENESS THEREOF AND WIU
IN NO EVENT BE UABLE 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 ofWESTERBEKE product software
and the unavoidable existence ofearlier 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 ofWESTERBEKE
or the supplier in question
be consulted to determine the accuracy and currentness of the
product software being consulted bv. the customer.
SERIAL NUMBER LOCATION/"\ ·The engine serial
· Fill in the information ~A'/:/),< ~ fJUfnber is st~mped
below f()r referenc~, ~/ ~f>V ))\ ~~ znto the engme block.
~~A- " ~l
?~
I ~I' .::JijiPiliiiiijiiiiiilliiijjiiiiiiiiijiiiiiijiiiiiii'\
I J
.~. II'
The engine model
number and serial
number
are printed
on a decal on the
engine manifold.
The generator serial
number
is stamped
on the top of the
generator uu~'·"""'·
An additional decal
is located on the top
of the generator .
housing.
Engines &Generators
3

INTRODUCTION
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 willfit
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, andWARNINGS. 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.
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visable location in
the engine room.
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.
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 generator installation and alignment.
• An efficientwell-designed exhaustsystem that includes
an anti-siphon breaktopreventwater from entering the
engine.
• Changing the engine oil and oilfilters every I 00 operat-
ing hours.
• Proper maintenance of allengine 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 manuaL
UNDERSTANDING THE GASOLINE GENERATOR
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are verticle in-line, and the engine's cylinder head has an
overhead camshaft which is chain-driven. The engine utilizes
a solid-state distributor which is horizontally mounted and
camshaft-driven. The engine incorporates a pressure 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 maintenance
that is required
of a gasoline automobile engine. The most
important factors to the generator's longevity are proper
ventilation, maintenance
of the fuel system, ignition system,
cooling system and the generator backend.
Engines & Generators
4

FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE
A CAUTION: lls8 unleaded 89 Octane gasoline or
higher. Ethanol gasoline must not exceed E10 (11JD!o).
Gasoline with higher percentages of Ethanol are not
acceptable for use in these models and may void the
warranty.
Only use unleaded gasoline with an Octane rating of 8910r,
higher. The use of a lower Octane gasoline will result in a loss of
engine power and performance. Ethanol blended gasoline must
not exceed EHf(lO%). Use of higherblend is not acceptable for
use in these models.
NOTE: The generator compartment shouldhave a gasoline fume
deu:ctor/alarm properly installed and working.
A WARNING: Shut off the fuel valve at the tank
when servicing the fuel system. Take care in catching
any fuel that may spill. DO NOT allow any smoking,
open flames or other sources of fire near the fuel Sys·
tem when servicing. Ensure proper ventilation exists
when servicing the fuel system.
Care Of The Fuel Supply
Use only clean properly filtered fuel! The fit and tolerance of
some components in the unit's fuel system are very critical;
dirt particles which might pass through the filter can damage
these finely finished pari$. 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, ilil 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 as called for in the
Specifications Section
of the manual. Change the engine oil
and filter after the initial 50 hours of break-in operation.
Then follow the oil and filter change intervals as specified in
the
MAINTENANCE SCHEDULE in this manual.
Westerbeke Corporation does not approve or disapprove
the use of synthetic oil. If synthetic oil is used, engine
break-in
must be performed using conventional oil. Oil
change intervals must be as listed in te MAINTENANCE
SCHEDULE section of the manual and not extended if
synthetic oils are used.
NOTE: The information above supersedes all previous
statements regarding synthetic oil.
ENGINE COOLANT
WESTERBEKE recommends a mixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
The antifreeze performs double duty. 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. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs') that keep the antifreeze chemically
balanced, crucial to long term protection.
The distilled 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.
A proper 50/50 mixture as recommended will protect the
engine coolant to temperatures of -4Qop.
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.
NOTE: This tank, with its shon run of plastic hose, is best
located at or above
the level of the engine's exhaust
manifold.
Engines & Generators
5

CONTROL PANELS
GENERATOR CONTROL PANEL
The ON and START/STOP 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/STOP switch is a three-position switch with
momentary contacts in the up (start) position and a stationary
contact function
in the center and down (stop) positions. The
center (normal) position allows the generator to be run, once
started, and
also enables the remote panel(s) to control the
start/stop functions. The up (start) position starts the generator
and once released, reverts to the center position. The down
~·position stops the engine in normal operation as well as
in an emergency situation, as it directly (unlike the remote
panel stop switch) controls power to the starter, fuel pump
and injector, and ignition relay coils, thus stopping the engine
should a malfunction
o~cur. During times when maintenance
is being performed on the generator, the START/OFF switch
should
be placed in the stationary (off) position. This will dis-
able 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 ifit is not required
to perform the maintenance.
GENERATOR CONTROL PANEL
REMOTE
PANEL
REMOTE PANEL
There are three functional components on the remote panel
for generator operation:
1. ON switch
1. START/STOP switch
2. Green LED indicator light
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/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
center position The center position is a dual OFF/RUN mode
position and is normally in the off mode. When in the start
(up) position, this switch starts the generator (together with
the ON switch in the up position) and once released, reverts
to the center position, run mode. When in the stop (down)
position, 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 realease the
START switch.
REMOTE PANEL
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.
NOTE: After the initial running of the generator, the air in
the engine :SO cooling system will be purged to the coolant
recovery tank. Open the airbleedpetcock to ensure that
the cooling system is purged of air. Aftershutdown and
after
the engine has cooled, the coolant from the recovery
tank will be drawn into the engines cooling system to
replace the purged air.
Before subsequent operation of the generator, the engines
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
voltage on unbalanced loads.
A CAUTION: When starting the generator, It Is
recommended that all AC loads, IISpecially large
motors, 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 unanticl·
pated operation of the AC machinery and will prevent a
cold engine from stalling.
Engines & Generators
7

OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Starting the Generator
To start the generator, hold the momentary ON switch in the GENERATOR CONTROL PANEL
up (on) position , 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 . Once the engine is
running, 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/STOP SWITCH
ON SWITCH
/ .... ~;-:>START
~"' ,"'
Starting under Cold Conditions
Make certain the lubricating oil conforms with the ratings for
the prevailing temperature. Check the table under
ENGINE
LUBRICATING OIL. The battery should be fully charged to
minimize voltage drop.
Stopping the Generator
To stop the generator, move the momentary START/STOP
switch to the down (oft) position then release it to the center
(normal) position.
EMERGENCY STOPPING
Hthe generator does not stop using the START/STOP switch,
remove the 8 amp fuse or disconnect the battery.
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.
Abnormal St~p
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 shutdown.
On the remote panel the green LED light will tum offindicat-
ing an engine shutdown. Once detected, the fault should be
located and corrected (see
ENGINE TROUBLESHOOTING).
Engines & Generators
8

OPERATING INSTRUCTIONS
REMOTE PANEL
Starting 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 will 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.
OFF/RUN·
~... __ '·,,
--<:~ STOP'. OFF
START/STOP SWITCif
ON SWITCH
Stopping the Generator
To stop the generator, move the momentary START/STOP
switch to the down (stop) position then release it to the center
(off/run mode) position. This will de-energize the K2 run
relay in the generator's control panel and stop the generator.
Engines & Generators
9
REMOTE PANEL

BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE
After 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: Do not attempt to break-In your genera-
tor by running without a load.
After the fust 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 1800 rpm to produce 60 hertz, or at 1500 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 normal running amper-
age. See GENERATOR INFORMATION in this manual.
CHECK LIST
Follow this checklist each day before starting your generator.
• Record the hourmeter 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 belt for wear and proper tension (weekly).
• Check for abnormal noise such as knocking, vibration and
blow-back sounds.
• Confirm 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 loads are applied.
A CAUTION: Do 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 stabilize the
operating temperature and press the STOP switch down, (see
CONTROL PANELS).
NOTE: After the first 50 hours of generator operation check
the maintenance schedule for 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 (HER1Z) ADJUSTMENT
under ENGINEADJUSTMENTS. A no-load voltage adjust-
ment may also be required in conjunction with the engine's
speed adjustment (see GENERATIOR
INFORMATION).
Engines & Generators
10

SAFETY SHUTDOWN
SAFETY SHUmOWN SWITCHES
The engine is protected by a variety of shutdown switches.
Should a shutdown occur, do no.t attempt to restart without; ..
finding and co"ecting the cause. Refer to the heading
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 locat~ on the exhaust
elbow. Normally 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-
1320C). This switch resets at approximately 225°F (107°C).
TEMPERATURE
SWITCH
High Water Temperature Switch
A high water temperature switch is located at the thermostat
housin,g. Normally closed, this switch, should'the fresh water
·cooiant's operating temperature reach approximately 210op
(99°C),_will open and interruptthe
DC voltage to the K2 ~un
relay thereby s1mttin_g_ otf the'engine. This swftcli resets at ·
1_95op (107°C). ... .
TEMPERATURE
SENDOR
Low Oil Pressure sWitch
Dual low oil pressure switches are located offthe engine's oil
gallery manifold.
One is normally open when the engine is in
a static state. This switch functions in the automatic shutdown
circuit when the unit is operating (5 psi rating).
The second
oil pressure switch is installed only on
SEA RAY spec. gener-
ators. This switch is normally closed and functions in their
low oil pressure alarm system (10 psi rating).
Should the oil pressure drop to 10 psi while the generator is
operating, the
SEA RAY spec. switch will close activating
their low oil pressure alarm. Should the oil pressure drop fur-
ther to 5 psi, the automatic shutdown circuit switch will open
interupting
DC voltage to the K2 run relay thereby shutting
off the generator.
High RPM Shutdown Switch
OVERSPEED ·
BOARD
An Overspeed PC Board in the DC circuit monitors coil
pulses. Shouldthe engine
rpm reach 2175 (approximately),
arelay on this board will open and break the DC circuit
to the K2 run relay, Shuttingthe unit down. The relay will
automatically close once the engine stops.
Engine Circuit Breaker
The generator's engine is protected by an engine mourited
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
breakerinterrupts the
DC circuit to the 1<2-run relay. If this
should occur, check and repair the source
of the problem.
After repairing the fault, reset the breaker and restart the
generator. ·
Engines &Generators
11
..

MAINTENANCE SCHEDULE
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. When servicing/replacing DC components, tum off the DC circuit breaker on the control
panel, or tum off the battery switch.
SCHEDULED MAINTENANCE
I DAILY CHECK BEFORE START-UP
Coolant Level
Engine Oil Level
Fuel/Water Separator (owner installed)
Fuel Supply
Visual Inspection of Engine
I INITIAL 50 HOURS OF OPERATION
*Spark Plugs
Engine 011 and Filter
*Exhaust System
Air Screen/Flame Arrester
*Valve Adjustment
Inlet Fuel Filler
Fuel Filter
Mechanical Governor
I EVERY 50 OPERATING HOURS OR MONTHLY
Drive Belt (water pump)
Starting Batteries
Electric Fuel Pump
Zinc Anode
I EVERY 100 OPERATING HOURS OR YEARLY
Engine Oil and Filter
Air Intake and Filter
EXPLANATION OF SCHEDULED MAINTENANCE
Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Oil level should indicate between MAX and LOW on dipstick. Do not overfill!
Check for water and dirt in fuel. Drain filter if necessary. Replace filter every 250 operating
hours or once a year.
Fresh unleaded gasoline with an octane rating of 89 or higher. Lower octane will affect engine
performance. 10% ethanol maximum.
Check for fuel, oil and water and exhaust leaks. Check that the water injected exhaust elbow
securing v-clamp is tight. No exhaust leaks around the elbow. Inspect wiring and electrical
connections. Look for loose bolts/hardware and correct as needed.
Clean/re-gap.
Initial engine oil and filter change at 50 hours, then change both every 100 hours.
Initial check at 50 hours, then every 250 hours or once a year. Carefully inspect for leaks.
Check that the exhaust hoses are properly attached and that the securing clamps are tight.
Check the integrity/mounting security of the water injected exhaust elbow.
Remove, clean and re-install screen pack. Inspect rubber sealing ring and replace if
necessary, then once a year. •
Check adjustment of valve. Check again at 500 hours.
Initial change, then every 250 hours or once a year.
Initial change, then every 250 hours or once a year.
Initial oil change, then every 250 hours or once a year.
Inspect for proper tension (3/8' to 112" deflection) and adjust if needed. Check belt
for slipping, cracking and wear. Adjust tension or replace as needed. Replace cover.
Check electrolyte levels Make sure cables and connections are in good order. Clean
off corrosion if needed. Apply petroleum jelly to terminals for corrosion protection.
Inspect for leaks, ensure fuel and electrical connections are clean and tight.
Inspect and clean zinc anode. Replace if necessary. Note the condition, then determine
your own inspection schedule.
Change engine oil and filter.
Remove, clean and re-install screen pack. Inspect rubber sealing ring and replace if
necessary.
*WESTERBEKE recommends this service be performed by an knowledgeable mechanic.
1-.v-IWESI'ERBEKE
) Engines &Generators
.12'