Westerbeke 5.0KW BCG-60Hz User manual

OPERATORS MANUAL
5.0KW BCG-60Hz / 4.2KW BCG-50Hz
5.0KW BCGA-60Hz / 4.2KW BCGA-50Hz
7.0KW BCGC-60Hz /5.9KW BCGC-50Hz
7.0KW BCGO-60Hz / 5.9KW BCGO-50Hz
GASOLINE GENERATORS
Single Phase
PUBLICATION NO . 46983
THIRD EDITION
JULy 2008
~ WESTERBEKE
WESTERB EKE CORPORATION · MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD · TAUNTON MA 02780·7319 · TEL , [phone]
FAX [phone] · WEBSITE : WWW . WE STERBEK£.COM
,tfJM,TMember Nai/Oira l Marin e Manufaclurers Associfllion
.w d

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

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness
- Throbbing in Temples
-Nausea
- Muscular Twitching
-Headache
- Vomiting
- Weakness and Sleepiness
-Inability to Think Coherently
IF YOU DR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET DUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek 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
MDNOXIDE DETECTORS in the living/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself, your personnel,
andyour machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: 00 not touch AC electrical connectlDRS
while engine is running, or when connected to shore
power. Lethal voltage is present at these cDnnectiDns!
• 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 all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage
to vessel's AC generator may
result
if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting tenninals together.
PREVENT BURNS - HOT ENGINE
A WARNING: OD not touch hot engine parts Of
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause injury Of death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking thecoolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Df death/
• Prevent flash fires. Do not smoke or pennit flames or
sparks
to occur near the carburetor, fuel line, filter, fuel
pump, or other potential 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 flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks 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.
• Be aware diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: ExplosiDns from fuel vapors can cause
injury or death/
• Follow re-fueling safety instructions. Keep the vesseFs
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. 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 tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching
any fuel that might
spill.
DO NOT allow any smoking, open flames, or other
sources of
fire near the fuel 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 positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper
use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in
this environment.
Engines & Generators

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
ordeathJ
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it
last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by elect~ical
arcing or by lit tobacco products. Shut off all electncal
equipment
in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks ~ould ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb the battery charg0r 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 offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last whenservicing 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 protec-
tion. Batteries contain sulfuric acid which is destructive.
If
it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
inadvertently
when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: 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 manifoldl
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.
• Don't run the generator set or engine unless the bo~t is
equipped with a functioning marine carbon monoXlde
detector that complies with ABYCA-24. Consult your boat
builder
or dealer for installation of approved detectors.
• For additional information refer to ABYC T-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 systt:ms.
Exhaust sulfur causes rapid deterioration ofcopper tubmg
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 ofthe
symptoms or signs ofcarbon monoxide inhalation or
poisoning
are:
Vomiting
Dizziness
Headache
Nausea
AVOID MOVING PARTS
Inability to think coherently
Throbbing
in temples
Muscular twitching
Weakness and sleepiness
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 operat-
ing adjustments, use extreme care to avoid touching mov-
ing parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing
equipment; tie backlong 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.
• Stay clear of the drive shaft and the transmission coupling
when the engine is ruuning; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never 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: Do not work on machinery when you are
mentally Dr 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.
ENGINE INSTALLATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination
of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL 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 and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater,
MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Govemment Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WES1ERBEKE 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 he 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 he looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection
pOri is at or below the load waterline will result in
raw water damage to the engine andpossibleflooding 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 manufacturer
for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must he 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
Engines & Generators
iv

TABLE OF CONTENTS
Introduction ......................................................................... 2
Fuel, Engine Oil and Engine Coolant.. ............................... .4
Control Panels ................................................................. ; ... 5
Preparations for Initial Start-Up ......................................... 6
Operating Instructions ........................................................ 7
Remote Panel ........ .............................................................. 8
Break-in Procedure/Daily Operation ................................... 9
Safety Shutdown Switches ................................................ 10
Maintenance Schedule ..................................................... 11
Cooling System .................................................................. 13
Changing Coolant....................................................... 13
Thermostat..................................................................14
Zinc Anode.................................................................14
Raw Water Strainer ....................................................
15
Raw Water Pump........................................................ 15
Fuel System ....................................................................... 16
GasolinelWater Separator...........................................16
Fuel Filter................................................................... 16
Engine Oil ......................................................................... 17
Oil Change ................................................................. 17
Battery Charging Circuit ................................................... 18
Electronic Governor .......................................................... 19
Troubleshooting The Electronic Governor ........................ 20
Carburetor Adjustments .. .................................................. 21
Engine Adjustments .......................................................... 22
Timing Belt ..............................................................
,.22
Compression Test .......................................................22
Valve Clearance..........................................................26
Injection Timing.........................................................26
Torquing The Cylinder Head Bolts............................26
Spark Plugs.................................................................27
Drive BeltAdjustment ...............................................27
Choke Solenoid..........................................................27
Generator Information ....................................................... 28
Generator Wiring Schematic ............................................ .29
BCGA AC Terminal Connections ........................................ 29
BCG AC Terminal Connections .......................................... 29 A
BCG Generator Wiring Schematic ..................................... 29A
Shore Power Transfer SWitch ........................................... .30
BC Generator Single Phase ............................................... 31
Wiring Schematic (#46876) ..............................................32
Wiring Diagram (#46876)..................................................33
Remote Panel Wiring ........................................................ 34
Engine Troubleshooting .... ................................................. 35
Lay-up and Recommissioning ........................................... 37
Specifications .................................................................... 39
Specifications .................................................................... 39 A
Hardware Torques ............................................................. .40
Metric Conversions ......................................................... :.41
Suggested Spare Parts ..................................................... .42
Engines & Generators
1

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
(jependable 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. APaIts 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
caI·d registering your WaITanty 60 days after submitting the
WaITanty registration form, please contact the factory in
writing with model infonnation, including the unit's serial
number
and commission date.
,.."."WESTERBEKE
, Engines &Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires Ser. #
Customer Identification Card (Typical)
The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date of
manufacture of
your WESTERBEKE engine/generator. The
first character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s E=2000s), the first number represents the
year in the decade, and the second and third numbers
represent the month ofmanufacture.
PRODUCT SOFTWARE
Product software, (tech data, parts lists, manuals, brochures
and catalogs), provided from sources other than WESTER-
BEKE are not within WESTERBEKE'S CONTROL.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT
OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRE-
SENTATIONS WITH RESPECT THERETO, INCLUDING ACCU-
RACY, TIMEUNESS OR COMPLETENESS THEREDF 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 aceuracy and currentness of the
product software being consulted by the customer.
SERIAL NUMBER LOCATION~~ The engine serial
Fill in the information
~h:;olQ'f,..~· ryumber is s~am[Jed
below for reference. /;::/:v ~ j' rnto the engrne block.
lY /..:/"~' ibli
~ f'" "%;11L
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 HIII,'_YI.rLfJ
are
on a decal
on
the side of the
generator.
.,
Engines & Generators
2

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 p(Ut 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 ofyour 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 ofthe 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 andgenerator installation and alignment.
• An efficient well-designed exhaust system that includes
an anti-siphon break to prevent water from entering the
engine.
• Changing the engine oilandoilfilters every 100 operat-
ing hours.
• Proper maintenance of aIL engine and generator compo-
nents according to the maintenance schedule in this
manual.
•
Use clean, filtered UIlleaded fueL
• '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 ofa 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
3