Westerbeke 7.0 KW BGC -60Hz User manual

TECHNICAL MANUAL
WESTERBEKE
4.5 KW BCG
··60 Hz
7.0 KW BCG ·60 Hz
7.0 KW BCGA· 60 Hz
3.5 KW BCG • 50 Hz
5.0 KW BCG • 50 Hz
MARINE GASOLINE
GENERATOR SETS
Publication #038747
Edition One
March 1990
l·v#'WESTERBEKE
.
~ WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
. TEL; [phone]. FAX: (508)B84-9688 • WEBSITE: www.WESTERBEKE.COM

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

SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention
to and emphasize conditions potentially dangerous to the
operator.
IWARNINGI
The above symbol is used in the manual to warn of possible
serious personal injury
or loss of life.
CAUTION
The above symbol is used in the manual to caution personnel
of possible damage to equipment.
Read
the manual carefully and thoroughly before attempting
to operate the equipment. Know when dangerous conditions
can exist and take necessary precautions
to protect personnel
and equipment.
Fuels, exhaust gases, batteries, electrical equipment,
and
moving and hot parts are potential hazardsthat could result in
serious personal injury
or death. Follow recommended proce-
durescarefully.
I>Jways operate bilge blowers for at least five minutes before
startingagasoline-fueledengine; ensure
no gasoline fumes are
present before starting.
• Prevent Electric Shock
Shut off electric powerbefore accessing electrical equip-
ment.
Use insulated matswheneverworking on electricalequip-
ment.
Make sure
your clothing is dry, not damp (particularly
shoes), and keep
your skin surfaces dry when handling
electrical equipment.
Remove wristwatch and jewelrywhen working on electri-
cal equipment.
Do
not connect utilityshore power to vessel's AC circuits,
except through a ship-to-shore double-throw transfer
switch. Damage
to vessel'sAC generator may result if this
is not done.
Be extremely careful when working on electrical com-
ponents. High voltage can cause injury or death.
• Exhaust Gases Are Toxic
Ensure that theexhaustsystem is adequateto expelgases
discharged from the engine. Check exhaust system
regularly
for leaks and make sure the exhaust manifolds
are securely attached and
no warping exists.
Be sure the unit and its surroundings are well-ventilated.
• UseExtreme Care When Handling Engine Fuel
(A constant danger of explosion or fire exists)
Do not fill fuel tank(s) while the engine is running.
Do
not smoke or usean openflame near the engine orthe
fuel tank.
• Do Not Alter or Modify the Fuel System
Be sure all fuel supplieshave a positive shut-offvalve.
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. Ex-
tinguishers rated ABC by the NFPAare appropriate for all
applications encountered in this environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.
Leadacid batteries
emit hydrogen,a highly-explosivegas,
which can be ignited
by electrical arcing or by a lighted
cigarette, cigar,
or pipe. Do not smoke or allow an open
flamenearthebatterybeingserviced. Shut
off allelectrical
equipment in the vicinity to prevent electrical arCing
during servicing.
• Avoid Moving parts
Do not service the unit while the unit is running; if a
situationarisesinwhich
it isabsolutelynecessarytomake
operating adjustments, use extremecare
to avoid moving
parts
and hot exhaust system components.
Do
not wear loose clothing or jewelry when servicing
equipment; avoid wearing loosejackets, shirts
or sleeves,
rings, necklaces,
or bracelets that might be caught in
moving parts.
Make sure all attaching hardware
is properly tightened.
Keep protective shields and guards in their respective
place
at all times.
Do
not check fluid levels or the drive-belt's tension while
the unit is operating.
Do
not workonthe equipment when mentally or physically
incapacitated
by fatigue.

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

TABLE OF CONTENTS
Section ......................................................................... Page
4.5 KW BCG GENERAL SPECIFICATIONS .......................9
4.5 KW BCG SYSTEM SPECIFICATIONS ........................ 10
7.0 KW BCG & BCGA
GENERAL SPECiFiCATIONS ........................................... 13
7.0 KW BCG & BCGA
SYSTEM SPECIFICATIONS ............................................. 14
4.5 KWBCG
ENGINE SERVICE SPECIFICATIONS ............................. 17
7.0 KW BCG & BCGA
ENGINE SERVICE SPECIFICATIONS ............................. 27
ENGINE DESCRIPTION ................................................... 37
GENERATOR OVERHAUL.. ............................................ ..46
PREPARATIONS FOR OVERHAUL.. ................................ 47
DISASSEMBLY FOR OVERHAUL .................................... 48
ENGINE DISASSEMBL Y................................................... 50
REMOVING THE CYLINDER HEAD
FROM THE CYLINDER BLOCK ........................................ 53
CYLINDER HEAD DISASSEMBLY ................................... 54
CYLINDER BLOCK DISASSEMBLY ................................. 57
SPECIAL SERVICE TOOLS .............................................. 61
CYLINDER HEAD AND ENGINE BLOCK
INSPECTION AND REPAIR .............................................. 63
ENGINE INSPECTION AND REPAIR ............................... 64
SUBASSEMBLY INSPECTION,
REPAIR AND ASSEMBLY ................................................. 81
ENGINE ASSEMBL Y....................................................... 101
CYLINDER BLOCK ASSEMBLY .....................................1 02
Westerbeke Generators 2

TABLE OF CONTENTS
(CONTINUED)
CYUNDER HEAD ASSEMBLY ....................................... 109
LUBRICATION SYSTEM ................................................ 119
GENERATOR DESCRIPTION
AND MODEL RATING .................................................... 130
TROUBLESHOOTING AND ADJUSTMENTS
FOR THE BC GENERATOR ........................................... 131
COMPONENT RESISTANCE VALUES .......................... 134
GENERATOR TROUBLESHOOTING ............................ 143
GENERATOR HERTZ (CYCLE)
AND VOLTAGE CHANGES ............................................ 145
FIELD FABRICATED TOOLS ......................................... 147
INDEX ............................................................................. 151
3 Westerbeke Generators

20 Amp DC
Circuit Breaker
Lube Oil
Dipstick
4.5 KW BeG Marine Gasoline Generator
Fresh Water Coolant Fill
Oil Pressure
,,- ---..;~...i;.;._
Switch
lube Oii >::ill'oy·--
Zinc Anode
Heat Exchanger
Westerbeke Generators 4
Exhaust Temperature
Switch
DC Battery Ground
Connection
Starter with Solenoid

4.5 KW BeG Marine Gasoline Generator
Fuel Shut -off Snl.:llnnlf1
Air Intake Flame Arrester
Governor
AC
Unit Data T
lube Oil Drain Hose
5 Westerbeke Generators

20 Amp DC
Circuit Breaker
Lube Oil
Dipstick
Oil Pressure
Switch
Heat Exchanger.
Westerbeke Generators
7.0 KW BCG & BCGA Marine Gasoline Generator
Exhaust Temperature Switch
6
DC Battery Ground
Connection .
-Rt~rt_ with Solenoid

7.0 KW BCG & BCGA Marine Gasoline Generator
Intake Flame Arrester
Control Pane!
Governor
---'--Water Temperature
Switch
·AC Connections ---
Outlet
Sea \(Vater Pump
Zinc Anooe
Lube Oil Drain Hose
7 Westerbeke Generators

UNIT 1.0. PLATES
4.5 KW BeG - 614 (3.5 KW BeG - 514)
7.0 KW BeG & BCGA - 614 (5.0 KW BeG - 514)
These 1.0. plate illustrations are provided forthe owner/operator"to fill in the unit serial number and gener-
ator
serial numberforfuture service and part needs.
NOTE: Output rating for 50 hertz units are reduced. Refer to System $pecifications.
Westerbeke Generators 8

4.5 KW BCG MARINE GASOLINE GENERATOR SET
GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion
Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque (at 1800 rpm)
Compression Ratio
Compression Pressure
(Limit of difference between cylinders)
Valve Timing
Valve Seat Angle
Valve Oearance
(engine warm)
Engine Speed
Dimensions
Dry Weight
Fuel Consumption
Inclination (all directions)
Gasoline, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(6.0 bhp at 1800 rpm, maximum).
Hoof, flybail type, 5% speed regulation.
Multi-sphere type.
2.44 x 2.38 inches (62.0 x 60.5 mm)
33.4 cubic inches (.547 liter)
1-2-3
Oockwise, when viewed from the front.
13.5Ibf-ft
10.0:1
198.1 psi (14.0 kg/cm2) at 400 rpm
(28 psi [2.0 kg/cm2 ])
Intake Opens 32° BTDC
Intake Ooses 52° ABDC
Exhaust Opens 5SO BBDC
Exhaust Ooses 2SO ATDC
Intake 45°
Exhaust 45°
Intake 0.010 inches (0.25 mm)
Exhaust 0.012 inches (0.30 mm)
1800 rpm 60 hertz.
1500 rpm 50 hertz.
Length: 26.50 inches (673.1 mm)
Width: 18.34 inches (465.8 mm)
Height: 23.44 inches (595.4 mm)
Approx. 3031bs (137.4 kgs)
0.9 U.S. gph (3.41 Iph) atfull rated output (approximate).
Continuous 14°
Temporary 20° (not to exceed 20 min.)
9 Westerbeke Generators

INTAKE SYSTEM
Carburetor (STD type)
PN 037832
Manifold
IGNITION SYSTEM
General
Distributor
Spark Plug Thread Size
Spark Plug Type
FUEL SYSTEM
General
Fuel
Fuel Pump
PN 037818
Fuel Screens (on engine)
Air cleaner
4.5
KW BCG SYSTEM SPECIFICATIONS
Manual with butterfly shaped valve, single barrel
with U.S.C.G. approved flame arrester.
Naturallyaspirated.
Battery ignition, 12-volts (negative ground),
distributorwith points condenser, ignition coil
and spark plugs.
Conventional, contact-points and condenser.
14
mm x 1.25 pitch (0.55 x 0.05 in.)
Westerbeke part number33805
(Always identifythe generator model
when ordering parts.)
Conventional carburetortype with fuel pump.
Regular
or unleaded gasoline with an octane rating
of 89
or higher.
12-volt DC; lift capacity 5
ft (1.5 m)
Reusable screen type (located at inlet to carburetor).
Metal screen type -cleanable.
Air Flow (engine combustion) 18 cfm (0.509 cmm) at 1800 rpm.
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
PN 037919
Westerbeke
Generators
Fresh water-cooled block, thermostatically-controlled
with a heat exchanger.
130 -150°F (55 - 66"C)
Centrifugal type, belt-driven, 1.13:1.
10

4.5 KW BCG SYSTEM SPECIFICATIONS
Raw Water Pump
PN 032617
Raw Water Row, at 1800 rpm
(measured before discharging
into exhaust elbow)
System Capacity (fresh water)
LUBRICATION SYSTEM
General
Oil Filter
PN 036918
Sump Capacity (not including filter)
Operating Oil Pressure (engine hot)
Oil Grade
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
DC Battery Charger
Starter
PN 034552
DC No-Load Current
DC Cranking Current
OUTPUT LOSS BY ALTITUDE
Positive displacement, rubber impeller, belt-driven.
3.75 -4.0 U.S. gpm (14.19 -15.14Ipm)
4.2 U.S. qts (3.9 liters)
Fully -Forcefed type by Trochoid pump,
crankshaft-driven.
Full flow, paper element, spin-on type.
3.0 qts (2.8 liters)
50 -70 psi (3.5 -4.9 kg/cm2)
API SPECIFICATION OF SE; SF; SG OR SJ.
12-volt, 24 A-H, (-) negative ground
(recommended) (28 A-H in cold areas).
24 -28 (ampere-hours)
Integral controller 13-volt, 10 amp
Oocated in theAC alternator).
12-volt, 1.2 KW, Magneto engaging type.
90 amp (max.) at 11.5 volts.
100 -125 amps (engine cold).
8% at 3,281 ft (1,000 m)
16% at 6,562 ft (2,000 m)
25% at 9,843 ft (3,000 m)
35% at 13,124ft (4,000 m)
11
Westerbeke Generators

4.5 KW BCG SYSTEM SPECIFICATIONS
TUNE-UP SPECIFICATIONS
Spark
Plug Gap
Contact Point Clearance
Timing
OweliAngle
AC
GENERATOR
General
Voltage
Rating (volts AC)
60 Hertz (1800 rpm)
50 Hertz (1500 rpm)
AC Circuit Breaker
Generator Cooling
Air Requirements, (60 hertz),
at 1800 rpm
0.028 - 0.031 inches (0.70 - 0.80 mm)
0.017 - 0.018 inches (0.4 - 0.5 mm)
11° ± .5° BTDC at 1800 rpm
58 -SSO
Brushless, four-pole, revolving field.
Self exciting. Capacitor saturated field excitation.
Pre-lubricated, single-bearing design.
Reconnectable
120 volts or 120/240 volts,
single-phase.
120 or 120/240 volts - 60 hertz
220 volts - 50 hertz.
Voltage regulation: ±5% no-load to
full-load.
Frequency regulation: ± 3 hertz (5%)
no-load to full-load.
120 volts
120/240 volts
220 volts
37.5 amps
37.5/18.7 amps
16 amps
To
be rated at 120% ofthe generator's rated
amperage and voltage output.
225 - 240 cfm (6.4 - 6.6 cmm)
NQIE: Increase air supply 15% for 50 hertz operation (1500 rpm).
Engine Combustion Air
Requirements, (60 hertz),
at
1800 rpm
Westerbeke Generators
18 cfm (0.509 cmm)
12

7.0 KW BCG & BCGA MARINE GASOUNE GENERATOR SET
GENERAL SPECIFICATIONS
EngineType
Governor
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction ofRotation
Maximum Torque
(at 1800 rpm)
Compression Ratio
Compression Pressure
(Umit ofdifference between cylinders)
Valve Timing
Valve Seat Angle
Valve Oearance
(engine warm)
Engine Speed
Dimensions
Dry Weight
Fuel Consumption
Inclination (all directions)
Gasoline, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(9.5 bhp at 1800 rpm, maximum).
Hoof, flyball type,
5% speed regulation.
Multi-sphere type.
2.62 x 3.19 inches (66.6 x 81 mm)
51.6 cubic inches (.846 liter)
1-2-3
Clockwise, when viewed from the front.
13.5Ibf-ft
9.5:1
213.3 psi (15.0 kg/cm2) at400 rpm
(28 psi [2.0 kg/cm2 ])
Intake Opens 200 BTDC
Intake Closes 62
0
ABDC
Exhaust Opens 62
0
BBDC
Exhaust Ooses 200 ATDC
Intake 45
0
Exhaust 45
0
Intake 0.010 inches (0.25 mm)
Exhaust 0.012 inches (0.30 mm)
1800 rpm 60 hertz.
1500 rpm 50 hertz.
Length: 26.50 inches
(673.1 mm)
Width: 18.34 inches (465.8 mm)
Height: 23.44 inches (595.4mm)
Approx. 3281bs (148.8
kgs)
1.3 U.S. gph (4.92 Iph) at full rated output (approximate).
Continuous
14
0
Temporary 20
0 (not to exceed
20 min.)
13
Westerbeke Generators

7.0 KW BCG & BCGA SYSTEM SPECIFICATIONS
INTAKE
SYSTEM
Carburetor (STD type)
PN037832
Manifold
IGNITION SYSTEM
General
Distributor
Spark
Plug Thread Size
Spark Plug Type
FUEL SYSTEM
General
Fuel
Fuel
Pump
PN037818
Fuel Screens (on engine)
Air cleaner
Air
Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
PN 037919
Westerbeke Generators
Manual with butterfly shaped valve, single barrel
with U.S.C.G. approved flame arrester.
Naturally aspirated.
Battery ignition, 12-volts
(negative ground),
distributorwith points condenser, ignition coil
and spark plugs.
Conventional, contact-points and condenser type.
14 mm x 1.25 pitch (0.55 x 0.05 in.)
Westerbeke part number 33805
(Always identifythe generator model
when ordering parts.)
Conventional carburetor type with fuel pump.
Regular or unleaded gasoline with an octane rating
of
89 or higher.
12-volt DC; lift capacity 5ft (1.5 m)
Reusable screen type Oocated at inletto carburetor).
Metal screen type - cleanable.
26.8 cfm (0.758 cmm) at 1800 rpm.
Fresh water-cooled block, thermostatically-controlled
with a
heat exchanger.
130 - 150°F (55 - 66"C)
Centrifugal type, belt-driven, 1.13: 1to crankshaft.
14

7.0 KW BCG & BCGA SYSTEM SPECIFICATIONS
Raw Water Pump
PN 032617
Raw Water Flow, at 1800 rpm
(measured before discharging
into
exhaust elbow)
System Capacity (fresh water)
LUBRICATION SYSTEM
General
Oil FAter
PN 036918
Sump Capacity (not including filter)
Operating
Oil Pressure (engine hot)
on Grade
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
DC Battery Charger
Starter
PN 034552
DC No-Load Current
DC Cranking Current
OUTPUT LOSS BY ALTITUDE
Positive displacement, rubber impeller, belt-driven.
3.75 - 4.0 U.S. gpm (14.19 -15.14Ipm)
4.2 U.S. qts (3.9 liters)
Fully -Force fed type byTrochoid pump,
crankshaft-driven.
Full flow, paper element, spin-on type.
3.0 qts (2.8 liters)
50 - 70 psi (3.5 - 4.9 kg/cm2)
API SPECIFICATION OF S~ SF; SG OR81.
12-volt, 24 A-H, (-) negative ground
(recommended) (28 A-H in cold areas).
24 - 28 (ampere-hours)
Integral controller 13-volt, 10 amp
~ocated in the AC alternator).
12-volt, 1.2 KW, Magneto engaging type.
90 amp (max.) at 11.5 volts.
100 -125 amps (engine cold).
8% at 3,281 ft (1,000 m)
16% at 6,562 ft (2,000 m)
25% at 9,843 ft (3,000 m)
35% at 13,124 ft (4,000 m)
15
Westerbeke Generators

7.0 KW BCG & BCGA SYSTEM SPECIFICATIONS
TUNE-UP SPECIFICATIONS
Spark Plug Gap
Contact Point Oearance
Timing
OweliAngle
AC GENERATOR
General
Voltage
0.028 -
0.031 inches (0.70 -0.80 mm)
0.017 -0.018 inches (0.4 -0.5 mm)
10° ± .5° BTDC at 1800 rpm
58 -66"
Brushless, four-pole, revolving field.
Self exciting. Capacitor saturated field excitation.
Pre-lubricated, single-bearing design.
Reconnectable 120 volts or 120/240 volts,
single-phase.
120 or 120/240 volts -60 hertz
220 volts -50 hertz.
Voltage regulation: ±5% no-load to
full-load.
Frequency regulation: ± 3 hertz (5%)
no-load to full-load.
NOTE: BCGA models are 60 hertz only. This model cannot be converted
to 50 hertz.
Rating (volts AC)
60 Hertz (1800 rpm)
50 Hertz (1500 rpm)
AC Circuit Breaker
Generator Cooling
Air Requirements, (60 hertz),
at 1800 rpm
120 volts
120/240 volts
220 volts
58 amps
58/29 amps
23 amps
To be rated at 120% ofthe generator's rated
amperage and voltage output.
250 cfm (7.0 cmm)
NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm).
Engine Combustion Air
Requirements, (60 hertz),
at 1800 rpm
Westerbeke Generators
26.8 cfm (0.758 cmm)
16