Westerbeke 4.5KW BCGB-60HZ User manual

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OPERATORS MANUAL
FOR THE
4.5KW BeGB - 60HZ
3.8KW BeGB - 50Hz
AND
7.0KW BeGB - 60HZ
5.0KW BeGB - 50Hz
GASOLINE GENERATORS
SINGLE PHASE
PUBLICATION NO.44200
JUNE 1999
1ST EDITION
WESTERBEKE CORPORATION
MYLES STAN DISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD , TAUNTON , MA 0278fJ.7319
....

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

A WARNING:
&fIa1lSl gasses cotrtain Ciut10n Monoxide, an odorless and
colorless gas. Carbon Monoxide Is poisonous and can cause
unconselousness and death. Symptoms of Carbon Monoxide
ezposufll can Include:
-Dizziness
-Nausea
-lIBadachfJ
- Weakness and Sleepiness
- Throbbing In Temples
- Museular Twitching
- Vomiting
-Inability to Thinlc Coherently
IF YOU OR ANYONE EI.SE EXPERIENCE ANY DF THESE SYMl'TDMS,
SET OUT INTO THE FRESH AIR IMMEDIATELY. "symptoms persist,
sesJc medical attention. Shut down tIIB unit and do not fIIStaJt
until It has been Inspected and fllpalred .
,,,.,WESTERBEKE
IEngines & Generators

Engines & Generators
Declaration of Conformity
Application of Conncil 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)
ENS0081-1
ENS0082-2
ENSS020
ISO-8846-1990(E), Certification
Number, IWES003
Westerbeke Corporation
150 John Hancock Road
Myles Standish Industrial Park
Taunton, Ma. 02780-7319, USA
Marine Gasoline Generator
Westerbeke Marine
Gasoline Generator
3.SBCGB-SI4, 4.SBCGB-614
S.OBCGB-SI4, 7.0BCGB-614
All
1.) The equipment listed is only for use in Marine Applications aboard boats.
2.)
The equipmentlisted 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 Taunton. Massachusetts,
U_S_A
Date: January 1, 2001
042022
Carleton F. Baant
(Full Name)
ChiefOperating Officer
(Title)
WESTERBEKE CORPORATION
MYLES STANDISH INDUSTRIAL PARK, 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319· TEL [phone]n· FAX [phone]· WEBSITE: WWW.WESTEABEKE.COM

INTERNATIONAL MARINE CERTIFICATION INSTITUTE
Rond Point SchulMn II, Box tI
8 - 1040 BRUXELLES
BELGIQUE
1lI1: (32) 2-238-1892
fmc: (32) 2-2S8-770D
CERTIFICATE
We hereby certify the component stated below meets the EC Directive 94125/EC for
EC type-examination in accordance with ISO 8846 and has following characteristics:
TYPE
Gasoline Marine Generator
MANUFACTURER Westerbeke Corp.
ADDRESS
Avon Industrial Park,
AVON, MA02333
USA
GROUP OF .
+++++ +++++
Modell 3.5/4.5 BCGB
+++++ +++++
Model 2 5.017.0 BCGB
+++++
+++++
Model 3 +++++
+++++
+++++
Model 4
+++++ +++++ +++++
ModelS
+++++ +++++ +++++
ModelS
+++++
+++++
+++++
Model 7 +++++
+++++
+++++
ModelS
+++++ +++++ +++++
Model 9
+++++ +++++ +++++
Model 10
+++++ +++++ +++++
Model 11
+++++ +++++
+++++
Model 12
+++++ +++++ +++++
Model 13
+++++ +++++ +++++
Model 14 +++++ +++++ +++++
Model 15
+++++ +++++ +++++
ModellS
+++++ +++++
+++++
Model 17
+++++
+++++
+++++
ModellS
+++++ +++++ +++++
Model 19 +++++
+++++ +++++
Model 20 +++++ +++++
+++++
Model 21 +++++ +++++ +++++
Model 22
+++++ +++++
+++++
Model 23
+++++ +++++ +++++
.:;-

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefuUy. Most accidents ar e
causedbyfailure tofolJow fundamenJal rules
and precau-
tions.
Know when dangerous condiJions exist and Iilke the
necessary
pr ecautions to protect yo urself, you r personne4
and yo ur machinery.
The foUowing s af ety instructio ns ar e in compliance wiJ h the
Ame rican Boat and Yacht Co un cil (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: I1D not touch AC electrical cotmeCtions
willie B/lgllIB Is IUMlng, or wlrBII connected to shore
p/JWf1r. LBthaI roltage is PrBSllnt at thBSB COllllllctiOIlS!
• Do not ope ra te this machinery without elec tri cal
e
ncl osures and covers in place.
• Shut offelec tri cal power before accessing electrical
eq
ui pm ent
• Use ins ul ated mats whenever wo rking on el ec tri c al
equipment
• Make sure yo ur clothing and skin are dry, not damp
(p articularly shoes) wben handling elec tri cal eq uipm ent
• Remove wristwatch and all jewelry when working on
elec
tri cal equipment
• Do not connect uti li ty shore power to vessel's AC
circuits, except through a ship-t(}-s hore double throw
transfer switch. Damage to vessel's
AC ge ne rator may
result
if this procedure is not followed.
• Electrical shock res ul ts from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Dr
exhaust system components. A IUMing engine gets
reryhot!
• Always check the engine coolant level at the coolant
recovery tank.
IA WARNING: Steam can cause Injury Dr death !
• In case of an engine overheat, allow the engine to cool
before touching the engine orchecking the coolant
PREVENT BURNS - FIRE
IA WARNING: Fire can cause injuryDr death!
• Prevent flash fires . Do not smoke or permit Oames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other
po tential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved
Oame
arrester removed. Backfire can cause severe injury or
dea
th .
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe
inj ury or death.
• Do not smoke or pe rmit fl am es or sparks to occur near
the fuel
sy stem. Keep the compartment and th e
en gine/gen era tor clean an d free of deb ris to minjm ize the
chances of fire. Wi pe up al l spilled fu el and engine oil.
• Be aware - di esel fuel will hom.
PREVENT BURNS - EXPlOSION
A WARNING: EzplosiollS from fuel rapors can cause
Injury Dr death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when
fue li ng . Open and ve ntilate cab in
after fueling. Check below for fumes/vapor before run·
ning th e bl owe r. Run th e blower for four mi nu tes before
starting
yo ur engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing
fue l s. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out
of the reach of children.
• Do not fill the fuel rank (s) while the engine is running.
• Shut offthe fuel service valve at the engine whe n servicing
the fuel system.Take care in catching
any fuel that might
spill. DO
NaT allow any smoking, open flames, or other
sources of fire near the fuel system orengine when servic-
ing . Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a po sitive 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
1~IWES7ERBEKE
IEngi nes & Generators
i

(

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
orduth!
• Disconnect the banery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it
last
• Make cenain all personnel are clear of the engine before
starting.
• Make certain
all covers, guards, and batches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battsry explosion can cause injury
orduth!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid baneries emit hydrogen, a
highly explosive gas, which can
be ignited by electrical
arcing or
by lit tohaceo products. Shut off all electrical
equipment
in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) banery cable to the posi-
tive (+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or
fuel vapors.
Ventilate
any compartment containing baneries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the banery charger connections while the banery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause
an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the banery.
• Always turn the battery charger off before disconnecting
the banery connections. Remove the negative lead
first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: SUlfuric acid In batteries can cause
serere Injury or death!
• When servicing the banery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion . Baneries 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: Carbon monoxide (CO) isa deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged
from the engine. Cbeck the exhaust system
regularly for leaks
and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
anention
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
fo r installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional 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 sys-
tems. Exhaust sulfur causes rapid deterioration of copper
tubing resulting
in exhaust/water leakage.
• Do not install exhaust outlet wbere 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 symp-
toms or signs of carbon monoxide inhalation or poisoning
are:
Vomiting
Dizzine
ss
Throbbing in temples
Muscular twitching
Intense headache
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 situa-
tion arises in which it is absolutely necessary to make
operating adjusbnents, use extreme care
to avoid touching
moving parts and hot exhaust system components.
~ WESTERBEKE
Engines & Generators
ii

(

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry 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 atall times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing
can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Ne v er operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: 00 not wade on machine/), when you are
mentally or physically i ncapacitated by fatigue!
OPERATORS MANUAl.
Many of the preceding safety tips and wamings 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 install a gasoline engine or generator should
begin with a thorough examination
of theAmerican 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-I Exhaust systems
P-4 Inboard engines
E-9
DC Elecaical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYMFPA AND USCG PUBLICATIONS FOR
INST NG DlESa ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat andYacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
II Tracy Drive
Avon Indusaial Park
Avon,
MA 02322
U SCG (Urtited States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
~ WESTERBEKE
E ngines & Ge ne ra to rs
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 environmenl
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 siplwn-break when
the exhaust manifoldinjection port
is at or beww tM /oad waterline will result in
raw water damage to the engine andpossibleflooding of the boaL
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
operarion.
Failure to properly maimain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators , is available from your WESTERBEKE
dealer.
-..v- WESTERBEKE
Engines & Generators
iv

(

TABLE OF CONTENTS
Parts Identification ................................................ 2 Engine Adjustments ............................................ .26
Introduction.............................................................3 Speed Hertz
AdjustmenL ...............................26
Serial Number Location ..................................
.3
Torquing the Cylinder Head Bolts ................26
Fuel, Engine Oil and Engine CoolanL...............5
Control Panels ..................................................... 6
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·ln Procedure/Daily Operation . ................ 10
Safety Shutdown Switches ................................ 11
Maintenance Schedule ..... ............... '" .............. 12
Component Testing ........................................... .33
Engine Troubleshooting ............. '" .................... .34
Generator Information ...................................... .36
Cooling System .................................................. 14
Changing Coolant........................................... 15
BC Generator Single Phase ............................... 37
AC Terminal Board Connections ..................... ..40
Thermostat...................................................... 16
Battery Circuit/Resistance Values ................... 40
Heat Exchanger .............................................. 16
Raw Water Intake Strainer.............................. 17
Raw Water Pump............................................ 17
BC Generator Single Phase ............................... 41
Testing Component Resistance .................... ..42
Integral Controller ........................................ ..43
Fuel System ....................................................... 18
Testing the Battery Charger ......................... ..43
Carburetor....................................................... 18
Fuel Lift Pump................................................ 18
Gasdenser........................................................ 18
GasolinelWater Seperator............................... 18
Carburetor Adjustments .................................... 19
Engine Lubricating OiL ....................................20
B tt Ch . C· ·t
aery argmg Ircul ..................................... 44
Testing the Battery Charging CircuiL........... ..45
Shore Power Transfer Switch .......................... ..46
Lay·up and Recommissioning ......................... ..47
Generator Specifications '" ............................. ..49
Oil Pressure . ...................................................... 21
Standard Hardware ........................................... 50
Remote Oil Filter ............................................... 22
BCGB Hardware Torques ................................... 51
BCGB Wiring Diagram . ....................................... 23
Metric Conversions Chart . ................................ 52
BCGB Wiring Schematic ............................ '" ..... 24
Suggested Spare Parts ...................................... 53
Remote Panel Wiring ......................................... 25
-..v- WESTERBEKE
Engines & Generators
1

BCGB PARTS IDENTIFICATION
ENGINE Oil Fill
WATER INJECTED
EXHAUST ELBOW
COOLANT DRAIN
HOURMETER
Oil PAN
LEFT SIDE
CARBURETOR
CONTROL _---~::;;;::~:...~
SWITCHES-
8 AMP FUSE
25 AMP CIRCUIT
BREAKER
START MOTOR
OC GROUND
STUD
HEAT EXCHANGER
RIGHT SIDE
Engines & Generators
2
AIR INTAKE
PRESSURE CAP
REMOTE PANEL
CONNECTION
CIRCUIT BREAKER
GENERATOR
BACKEND
REAR
'HI,XI'" MOUNT
ENGINE Oil Fill
~~3i\t----- RAW WATER
Oil FilTER
INJECTION
(SYPHON BREAK
CONNECTION)
FUEL LIFT PUMP
FRONT

INTRODUCTION
This WES1ERBEKE Generator is a product of
WES1ERBEKE'S long years of experience and advanced
technology, We take great pride in the superior durability and
dependable performance of our engines and generators.
Thank you for selecting WES1ERBEKE.
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 WES1ERBEKE dealer for assistance.
This is your Operators Manual. A Parts Catalog is also
provided and a Technical Manual is available from your
WES1ERBEKE dealer. Also,
if you are planning to install
this equipment yourself, contact your
WES1ERBEKE dealer
for
WES1ERBEKE'S Installation Manual.
WARRANTY PROCEDURES
Your WES1ERBEKE 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 fonn, please contact the factory in
writing with model information, including the unit's serial
number and commission date.
I~'WESTERBEKE
, Engines &Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BeGB Ser. #D703XXXX
Expires 9/20/02
CUSTOMER IDENTIFICATION CARD (Typical)
The WES1ERBEKE serial number is an alphanumeric
number that can assist in determining the date
of
manufacture of your WES1ERBEKE 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 sources other than WES1ER-
BEKE are not within WES1ERBEKE'S CONTROL.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT
OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRE-
SENTATIONS WITH RESPECT THERETO, INCLUOING ACCU-
RACY, TIMELINESS OR COMPLETENESS THEREOF ANO Will
IN NO EVENT BE LIABLE FOR ANY TYPE OF OAMAGE OR
INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF
THE FURNISHING OR USE OF SUCH SOFTWARE.
WES1ERBEKE customers should also keep in mind the time
span between printings
ofWES1ERBEKE product software
and the unavoidable existence
of earlierWES1ERBEKE
manuals. In summation, product software provided with
WES1ERBEKE products, whether from WES1ERBEKE 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 WES1ERBEKE or the supplier in question
be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
SERIAL NUMBER LOCATIDN~'\ The engine serial
Fill in the information . 1~(,~Ob'l-;:\ .,!umberis stamped
below for reference.
~i"'''' \1 mto the engme block.
0~ f''' ~f-- ~I
I~ ~
7",
I
'*'
I'
:I'~\
'. II ~~;a~~=~
. ,
The engine model
number and serial
number are printed
on a decal on the
engine manifold.
The gen~rator serial
number IS stcllnp"d
on the top
generator hOI~~~
The Itenerator
specifications are
printed on a decal
on the side
of the
generator.
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 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.
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 ofhours ofdependable 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 exhaust system that includes
an anti-siphon break to prevent water from enteringthe
engine.
• Changing the engine oil and oil filters every 100 operat·
inghours.
• Proper maintenance of all engine and generator compo-
nents accordingto 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 ofthe fuel system, ignition system,
cooling system
and the generator backend.
"'" WESTERBEKE
Engines & Generators
4

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 harm to your engine and violate your warranty.
CARE OF THE FUEL SUPPLY
Use only clean fuel! 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 SJ.
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 following 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: Do not aI/ow two or more brands of
engine oil to mix. Each brand contains its own addi·
tives; additives of different 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 surlaces.
The antifreeze performs double duty, as it allows the engine
to run at proper temperatures
by transfening 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
(SCAs) 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-jnendly 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
(-WOC)
(-13°C) (-20°C) (-40°C)
COOLANT RECOVERY TANK
A coolantrecovery 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.
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/STOPswitch 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
§!Qp position stops the engine in nonnal operation as wen 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 occur. 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 if it is not required
to perfonn the maintenance.
GENERATOR CONTROL PANEL
REMOTE
PANEL
CONNECTION
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 OFFIRUN 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.
STOP
SWITCH
25 AMP CIRCUIT
AMP FUSE
REMOTE PANEL
RECOROING HOURS
FOR MAINTENANCE
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: Afterthe initial running of the generator, the air in
the engine
~ cooling system will be purged to the coolant
recovery tank. Open the air bleed petcock to ensure that
the cooling system
is purged of air. Aftershutdown and
after the engine has cooled, the coolantfrom the recovery
tank will be drawn into the engine
~ cooling system to
replace the purged air.
Before subsequent operation afthe 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 ormissing
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-ta-neutral
voltage on unbalanced loads.
A CAUTION: When starting the generator, it is
recommended that all AC loads, especially 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 unantici·
pated operation of the AC machinery and will prevent a
cold
engine from stalling.
MANIFOLD
PRESSURE
CAP
...v- WESTERBEKE
Engines & Generators
7
COOLANT RECOVERY TANK
DIPSTICK
MAX. LEVEL
1._",,,, __ OIL LEVEL