Westerbeke 7.0BCG User manual

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OPERATORS MANUAL
7 .0 BCG and 7 .0 BCGA • 60Hz . ·
·5.0 BGG•5\ll-z
GASOLINI·· •GEi-TORS
SINGLE PHASE
PUBLICATiON Nb~ oa~ii~o: · .. ,·
. .REVISIQN 3
OCTOBER 201e
~ 'WESIERBEKE .
.... ,.tr: ........ WESTERBEKECORPORATTON• MYLES STANDISH INDUSTRIAL PARK
A/J'N. 150 JOHN HANCOCK ROAD.• TAUNTON MA 027S0-7319 •TEL. 1·508-823-7677
~ FAX 1·508-884-9688 ~WEBSITE: WWW.WESTE'RBEKE.COM_

AWARNING:
Exhaust gasses contain Carbon ·Monoxide, an odorless aµd
colorless gas. carbon Monoxide is-poisonaas and can cause
unconsciousness and death. Sy,;,ptomB:ot Carbon Monoxide
exposure can include:
•Dizziness
• Throbbing in Temples
•Muscular Twitching
•Vomiting
•Nausea
•Headache
• Weakness and Sleepiness
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. N sympto111$ persist,
seBk medical attention. Shut down the unit and do not restart
until it h~ 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 recommendslnstalllng
CARBON MONOXIDE DETECTORS In the
living/sleeping quarters of your vessel.
W
. ·
A. RN ·1 NG They are Inexpensive and easily
.. . . obtainable at your local marine store.
Genaratora Produl:e: CARBON MONOXIDE.
Regular Maintenance Required ·
IWIWE!!!@!!!1\E
--ras.,,,,.&~
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.

SAFETY INSTRUCTIONS
INTRODUCTION
/lead this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your
personnel, ·and your machinery.
As the ownttr or operator, always observe the following
safety rules· and advisories provided/or1our .convenience.
This safety infonntJt!on iS in alignment withtheAmerkan
Bt>ataiul Yacht Cou'tleil (Al'fYCJstandtitds; however safety.
· riaks are not lifnited. to the i'4forlitdtion• in the following
page I.: The respofisibiliiy./or the identifictitiOn•of potenti.al
and ac~ risks for compliance with all stifety · tzdvisories,
maintenance activities, ll1id tither codons belOng
exclusively fiJ)he· owllertopetator.
PREVENTELECTRIC'SHOCK
"ii WARNING:· Do alittouch AC sllt:trlaal aonneations
while engine is running, or when con1111ctt1d to sllore
·power. Lethal voltage .Is present at tllese aonnections!
• 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
(particula:rly shoes) when·handling electrical equiptnent.
• Remove wristwatch and all jewelry When working on
electtfoal equipment.
PREVENT·BOflNS - HOT:·ENGINI! ~ ... ·
. i\wAflltNG: DiJ hot tOut:~.hOt 'iltJ~nS.Patts or
· mam sysftml clllllpanllnts~ 1l ian11lng engine gets
veryhotl · · · .·
• Monitor engine antifreeze coolan,t level at the plastic
coolant recovery tank and periodically
at the filler cap
location
on the waterjacketed exhaust manifold; but only
when the engine is COLD.
• ln
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 or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
funtp, or other potential sources ofspilled fuel or fuel
· vapors. Use a suitable container to catch all fuel when'
remo\Ting the fuel line, carburetor, or fuel filters.
II · I>o notopetate with the air cleaner/silencer ~moved.
Bae~ can cause severe injury or death.
• .·Do not smoke or permit flames or sparks to occur near
the fuelsysteni. Keep the compartment and the .
engine/generator clean andfree ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS- EXPLOSION
A WARNING: ExplOSions from fuel vapors can cause
Injury or tleath!
• Follow re-fueling safety instructions. Keep ·the vessel's
hatches closed when fueling.
Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running 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-ventilated area away from spark-producing
equipment and out of the reach of children.
• Do not fill the fuel tank(s) while the engine is flllllli?g.
• Shutoff the fuel service valve at the engine when
servicing the fuel system. Take care in catching any fuel
thannight spill. DO NOT allow any smoking, open
flames, or other sources of fire near the fuel system or
engine when servicing. 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. ·
• Becertain fuel line fittings are adequately tightened
and
free of leaks.
• Make sure a fire extinguisher is iii.stalled 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.
· Englhf1/1"Jt Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause Injury
or death!
a Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it
last.
a Make certain all personnel are clear of the engine before
starting.
a Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BAmRY EXPLOSION
A WARNING: Battsry sxplaslon can causs Injury
or death!
a 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?cal
arcing or by lit tobacco products. Shut off all electrical
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 could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive 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
burns or sparks that could cause an explosion. Remove
wristwatch,
rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger offbeforedisconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAmRYACID
A WARNING: Sulfuric acid In batteries can cause
sevsrs 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 offat 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!
a 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 manifolds
are securely attached and no warping exists. Pay close
attention
to the manifold, water injection elbow, and
exhaust pipe nipple.
a Be sure the unit and its surroundings are well ventilated.
a In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional infonnation on Carbon Monoxide).
A WARNING: carbon monoxld1 (CO} Is an Invisible
odorlsss gas. Inhalation pradllCIJS flu-like symptoms,
nausea or dsatbl
• 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.
a 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.
a 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 ofcarbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing
in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can causs Injury
or death!
a Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
lwlWESTERBEKE
f Engines & Generators
ii

SAFETY INSTRUCTIONS
m Do not wear loose clothing or jewelry when servicing
equipment;
tie back long hair and avoid wearing foose
jackets, shirts, sleeves, rings, necklaces orbracelets that
could be caught in moving parts.
II Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
Ill Do notcheck fluid levels or the drive belt's tension while
the engine is operating.
!Ill 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.
HAIARIOUS,NOISE .
'>':":<•···.-."'"'·-.f:.o•.- · .>·· ·· •
'~~WiRNlNG: Hi{l/l:noise-levels can caus.e hearing
fiip!
II Never operate an engine without its muffler installed.
II Do not run the engine with the air intake cSilencer) or
flame arrester removed. .
II Do not run engines for long periods with their enclosures
open (when installed).
A WARNING: /lo not work on machinery when you are
mentally or phY,ically incapacitated by fatigue!
OPERATORS MANUAL
Many ofthe preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical infonnation. Reiid, yo1fr manual
carefully, maintain your equipment, arid follow ail safety
procedures. · ·
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install 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
acombination ofsources
lnc~uding the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilatio[). for Boats using Gasoline
· H-24 Gasoline Fuer Systems
P-1 Installation of Exhaust Systems
for Propulsion and Auxiliary Engines
P-4 Marine Inboard Engines and Transmissions
Blb\C and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follo:w their recornmenda-
qonswben installing your engine.
ABYC {American Boat and Yacht Council)
"Standards and Technical Information Reports for Small
Craft"
Order from:
ABYC
613 Third Street, Suite 10
A.Juiapolis, MD 21403·
www.abyci:nc.org
NFPA -No.302 (National Fire Protection Association)
"Pleasure and Commercial Motc>rCraft"
Order from:
National Fire Protection Association
Batfofy Mart:h Park
Qumcy, MAOi269
U~'¢GJDtiite,d States Coast Gil!!-fd)
"reglifatedfons are under titles CFR33 and CFR.46 of the
Code of Regulations"
Order from:
U.S. Government Printing Office
Washington,
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 of20" above the vessel's waterline. Failure to use a siphon-break wheli -
the exhaust manifold injection portis atorbelow the load waterline will result in
raw waterdamage to the engine and possibleflooding of the boat.
If you have any doubt about the position ofthe 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
AVAIL.&,QLE FROM.
YOUR WESTERBEKE
DEALER
SIPHON-BREAK WITH STAINLESS
LOOP
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust Hose is recommended. The use ofthis type ofhose allows for extreme bends
and turns without the need of additiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length ofcorrugated 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 heal.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unH. A pdf Is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification ........................................................ 2
Introduction .................................................................... 3
Warranly Procedures ................................................3
Serial Number Location...........................................3
Fuel, Engine Oil and Engine Coolant ............................. 5
Preparations for Initial Start-Up .................................... 6
Control Panels ................................................................ 7
Operating Instructions .................................................... 8
Operating Instructions (Remote Paneis) ........................ 9
Break-In Procedure (Daily Operation) .......................... 1o
Safety Shutdown SWitcbes ........................................... 11
Maintenance Schedule ................................................. 12
Cooling System ............................................................. 14
Raw Water Pump ................... ., .............................. 15
Raw Water Intake Strainer..................................... 15
Changing Coolant .................................................. 16
Drive Belt Adjustment ........................................... 16
Thern1ostat .............................................................l7
lleat Exchanger...................................................... 17
Fuel Syslem ................................................................... 18
Fuel Lift Pun1p ....................................................... t8
Gasoline/Water Filter............................................. 18
Carburetor Filter Screen......................................... 18
Carburetor .............................................................. 19
Engine Lubrication Oil ..................................................20
Oil Change ............................................................. 20
Remote Oil Filter ................................................... 21
Starter Motor .......... ~ ..................................................... 22
Testing .................................................................... 22
Battery Charging Circuit... ............................................ 24
Testing.................................................................... 25
Engine Troubleshooting ................................................ 26
Engine Adjustments ...................................................... 28
Speed/Hertz Adjustment ........................................ 28
Governor Maintenance...........................................28
Spark Plugs .................:.......................................... 29
Choke Solenoid...................................................... 29
Valve Adjustment...................................................30
Ignition tirning ....................................................... 30
Torquing Cylinder Head ........................................ 30
Wiring Diagram (Engine) ............................................... 31
Wiring Schematic (Engine) ........................................... 32
Wiring Diagrams (Panels) ............................................. 33
Generator Information .................................................. 34
\Viring Diagram ..................................................... 35
Circuit Breaker....................................................... 35
Wiring Diagram (60Hz) .........................................36
No-Load Adjustmem..............................................37
Generator Resistance Values..................................38
Shore Power Transfer Switch ................................39
Lay-Up and Recommissioning .................................... ..40
Specifications...............................................................42
Torque Specifications................................................... 44
Suggested Spares .......................................................... .45

PARTS IDENTIFICATION
20AmpDC
Circuit Breaker
Lube Oil
Dipstick
Fresh Water Coolant FUI
Model Data Tag
Oil Pressure --~
Switch
... /
Heat Exchanger .
Control Panel
8A &15AFUSES~
AC Connections---
Outlet
Gasdenser
Lube OH Fill
ExhaustTemperature Switch
Air lntak~ Flame Arrester
Lube Oil Drain Hose
lwiWESTERBEKE
Engines &Generators
2
Distributor
45° Exhaust Elbow
DC Battery Ground
Connection
REAR
Starterwith Solenoid
FRONT
i--~-Water Temperature
Switch
Sea Water Pump
Zinc Anode

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE'S long years of experience and advanced
technology. We take great pride in the superior durability
and dependable perfonnance 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 generator require servicing, contact
your nearest
WESTERBEKE dealer for assistance.
· · This is your Operators Manual. AParts Catalog is also
provided and a Technical Manual is available from your
WESTERBEKE dealer. 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
Engines &.Generators
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BCG - Ser. # ---- - ---
. Expires·_----·
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 REPRESENTATIONS WITH RESPECT THERETO,
. INCLUDINGACCURACY,
TIMELINESS OR COMPLETE-
NESS THEREOF
AND WILL IN NO EVENT BE LIABLE
POR'ANYTYPE OF DA0MAGE OR INJURY INCURRED IN
CONNECTION WITH OR ARISING OUTOF 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 by the customer.
SERIAL NUMBER LOCATION
The engine's model and serial number can be found on I.D.
sticRers affixed to either side ofthe generator housing. The
engine's serial number can also befound stamped into the
engine block on a flat surfacejust above and inboard of the
lube oil filter. Take the time to enter this information on the
illustration of the I.D. sticker below, as this will provide a
quick reference when seeking te~hnical information and/or
ordering service/repair parts. $:JJ
SPECIFICATION
MODEL ___ ~----
RPM __ ________ _
KW ___ G _______ _
· KVA -~---------
VOLTS ________ _
AMPS ___ G ____ _
ENG. HP----~-
ENG. SER. NO.
GEN. SER. NO.
PF/PHASE----
WIRES ________ _
RATING _______ _
INSUL CLASS .•
TEMP. RISE----
BATIERY ------
C.1.D. ----------
50 HZ.
I
Fill in the informa.tionfor your reference.
Engine l.D. Plate
60, HZ.
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
specifications as original equipment.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour
generator,, 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 your
engine.
A WARNING: Ptocedures, which If not prapedy
fa/lawed, can result in personal injury ar lass 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 spares 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 filters 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.
NOTE: Also available are Spare Parts Kits (last page in this
manual). These provide basic service spares needed in maintaining
the drive engine. Visit our website: www.westerbeke.com to learn
about these kits.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide .
detector in
the vessels living quarters. Carbonmonoxide,
even
in small amounts, is deadly.
The presence of carbon monoxide indicates an exhaust leak
from the engine or generator or from the exhaust
elbow/e:xhaust hose.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable of
many thousands ofhours 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.
• An efficient well-designed exhaust system thaJ includes an
anti-siphon break to prevent water from entering the
engine.
• Changing the engine oil and oil filters every I 00 operating
hours.
• Proper maintenance of all engine and generator
components according to the maintenance schedule in
this manual.
• Use clean, filtered unleaded fuel
• Winterize your engine according to the JAY-UP AND
RECOMMISSIONING section in this manual.
UNDERSTANmNG THE GASOLINE ENGINE
The gasoline engine driving an AC generator is in many
ways similar to a gasoline automobile engine. The cylinders
are vertical 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 preventative
maintenance that is required ofa 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 back-end.
Engines & Generators
4

GASOLINE
FUEL, ENGINE OIL AND ENGINE COOLANT
ENGINE COOLANT
·A CAUTION: Ilse unleaded 89 Octaae gasal/ae or
higher. Etbana/ gasa/lne'must not exceed E10 (100/o).
BefSDll°'e ·wif~ hillher.1111rce11tages of·Ethaaol are, not
a~/e;far.·use.!R·tbesemo*/s and caa void the
warranty.
Gaisoline With an ETHANOL content ·
highar than 108/e lE10) is nOt •llowed'
and mllY void warr~nty. .:
Care Of The Fuel Supply
Use only clean properly filtered fuel! The cl~~ 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 parts. 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 awell-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 enghie oilas calledfbr in the
Specifi~ Sectionoftbis manual. Change the
eilgine: oil and filter afterthe initial SQ hoUrs of
break-in opetatian. TJ:ten followthe -0ilan.d filter
changeintervals ti specified inMAINTENANCE
SCHEDULEinthis manual.
Wesrerbeke Corporationdoes not approve or
disapprove the use of syntheticoils. If synthetic
oils are used, engine break-in ~ust be pertbr:in~
using conventional oil. Oil change iJ:ltervals_ must
beas listed in the MAINTENANCE SCHEDULE
sectiOD. of this manuai and not-extended if sYnthetic
oils are used.
NOTE: The infor,mationabove supersedes all
previous statementsregarding synthetic oil.
WESTERBEKE recommends amixture of 50% antifreeze
and 50% distilled water. Distilled water is free from the
chemicals that can corrode internal engine surfaces.
. The antifreeze performs double du~. 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 circuitfrom rust and corrosion. Look for a good
quality antifreeze that contains Supplemental Cooling
Additives (SCAs) thatkeep the antifreeze chemically
balanced, crucial to long term protection.
The distilled water and ·antifreeze should be premixed before
beingpoliredinto the cooling circuit.
, NOTE: Lookfor tlie new environmentally-friendly 'wng lasting
antifre~ that is now available.
A proper SO/SO mixture as recommended will protect the
engine coolant temperature to tempCratures of -40°R
COOLANT RECOVERY TANK
Acoolant recovery tank kitis supplied with each generator.
The pmpose ofthis recovery tank is to allow for engine
coolant expansion and contraction during engine.operation,
without the loss ofcoolant and without introducing aii: into
the cooling system. \ \{i
NOTE: Thi.s tank, with its short run of plastic hose, is best
located ator above the level of the engine's exhaust manifold.

PREPARATIONS FOR INITIAL START·UP
PRESTARTINSPECTION
COOLANT·
FILL
Bef91'e starting your generator for the first time orafter a pro-
longed
layoff, check the following items:
• Check the engine oil level: add Qil to maintain the level at
the full mark on the dipstick.
a Check the fuel supply and examine the fuel filter/separ:ator
bowls for contaminants.
a Check the DC electrical system. Inspect wire connections
and battery cable connections.
a Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial running of tlJ.e generator, the air in
the engine's cooling system will bepurged to the coolant
rec<JVery tank. Open the airbleed petcock to ensure that
the cooling system is purged <Jf air. After shutdi:Jwn and
after the engine has cooled, the coolant from the rec<JVery
tank will be drawn into the engine's cooling system to
replace the purged air.
Before subsequent operation of the generator, the engine's
manifold
should be topped off, and the coolant recovery
tank may need to be filled to the MAX leveL
• Visually exainine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded
connections. Search for any gasoline leaks.
OIL DIPSTICK
4-MAX.FULL
a .Che(:kl()ad leads for correct <;onnections .as specified in
the Wiring diagrams.
• Examine the air inlet ~d outlet for air flow obstructions.
• Be sore no other generator or utility power is connected to
the load lines. ·
a Be sure that in power systems with a neutral line that the
neutral isproperly.grounded,.(or.ungrolJJlded) as the system
requires, and. that generat()r neutl'at is properly connected
to the load neutral. In single phase systems .~ incomplete
or open neutral can supply the V'lrong line-to-neutral volt-
~ge onunbalanced loads.
A CAUTION: If/lien start!PI! ti!• fP11Jllflllor, n Is
teOO/llllltllltltld tbatallM loar$,_ 11$/lf1Dlallylarg11
·motors, be swltdled tiff until• 1111!Ji.n11 b.f!s t:Oflle up
'" speff/ anti, In cold t:lialates, ·starts to watm up. This
precaution will prtJvent damage callSfld by unantlBJ.
patsd operation althe AC machinery and will prevent a
cold qine tram stalling.
Engines & Generators
6

CONTROL PANELS
DESCRIPTION
The generator mounted control panelis equipped with an
ON switch (black), a START switch(white) and a STOP
switch (red).
The
ON switch provides power to the start circuit. nus
switch by-passes the protective oil pressure shutdown switch
until the oil pressure reaches 5 -
10 psi.
The STARTswitch energizes the start solenoid/starter which
cranks the engine. This switch will
not operate unless the on
switch is depressed and held at the same time.
The STOP switch will twn
off the engine/generator. nus
switch must be depressed until the stop sequence is complete.
The panel also has two fuses to protect the DC circuit:
•·A Stow-blo 15Amp Fuse to protect the start circuit.
•An 8 Amp Fuse to protect the engine operating circuff ancf
any optional remote. ~a'!_efs.
15 AMP FUSE
HOURMETER
RECORDING HOURS
FOR MAINTENANCE
8 AMP FUSE
REMOTE START/STOP PANEL (OPTIONAL)
An optional remote start/stop panel is available for
controlling the generator from a remote location.
This panel has the same ON, START, and STOP functions
previously described. Also included is a green LED light
which glows once the engine/generator has reached 600
rpm's. The purpose of the LED is to alert the operator to
release the START switch. It is also an .'ndication that the
engine/generator
is running.
REMOTE INSTRUMENT PANEL (OPTIONAL}
An optional remote instrument panel is available which
includes a water temperature gauge, oil pressure gauge,
DC charging voltmeter, operating hourmeter
•. aQd start/stop
switches. ·
REMOTE INSTRUMENT PANEL INSTALLATION
The remote instrument panel has two sending units to be
installed on the engine block, a water temperature sender and
an oilpressure gauge sender. Plugged ports for each are
located on the engine.
The water temperature sender is
installed in the thennostat housing and the oil pressure sender
is adjacent to the oil pressure switch. Use sealing compound
on the threads
of both senders. Electrical connections for
each sender are tied
off next to the senders location ( in the
wiring harness).
The blue wire is for the oil pressure sender and the tan wire
is for the water temperature sender.
If there is ajumper
between terminal board connections
T-1 and T-2, it should be
removed. Refer to the REMOTEINSTRUMENTWIRING
DIAGRAM in this manual.
NOTE: When installing the optional remote panels, it is the
installers responsibility to comply with the U.S. Coast Guard
standards
33 CFR part 183.
Engines &Generators
7

OPERATING INSTRUCTIONS
STARTING 111EGENERATOR
A WARNING: .. Ventilate the generator compatfment
for a minimum of five mlnut• prior to starting. The
WJntilatlng blowers remove any explosive gasoline
fumes from the generator comjlarlment and bilges~
•.
1. Depress the ON switch and hold it down (5-15 sec~nds),
this primes carburetor. Continu.e to depress ON.
2. Depress the START (white), when the geneyator
· starts, release the START switch. Continue to .engage
the ON switch a few seconds longer. . ·
NOTE: Keeping the ON switch depressed by-passes
the oil pressure shutdown circuit allowingthe oil
pressure
to rise enough to close the switch an.ti
maintain the ignition circuit
3. Release the ON switch.
·A CAUTION: AllAC loads mast be swllched off .·1
when starting. This precaution will pre"6nt damage
caused by unanticipated operation of AC machinery
and will prevent a cold engine ttom.sttllllag.
-"-
Once The engine is running apply a ligbtJoad to the gener-
ator
and allow the engine to wartn up ti:> qperating temper-
ature
(130°-150° Fl 55°-56°C) before applying heavy loads.
lf an optional instrument panel is installed, tnonitorthe.·
gauges for nonnal readings. · · · · ·.
NOTE: Soin~·unstable running may occ1'tNiJacd!(:l,~ng:i11.e.
This condition should smooth our (l$,th.e e~gtne 'warms' up
and when the generator loads a~ appJit4
A CAUTION: Prolonged t;ra11klng Intervals without
the engine starting can result In fllllngthe engine
exhaust with, raw water. This may happen because the
pump is pumping raw water through tile raw water.
c11olin!J system during cranking. This miff waler can
entettll.e engine's cylinders by way of the exhaust
manifold once the exhaust system fills. Prevent this
frorll happening byt:Joslng the raw water supply
throug/Fhull Shutoff, draining the exhaust muffler, and
cogecting the cause of the excessive engine cranking.
Engine damagetesultlngfrom raw water entry is not a
warrantable issue: the (Jwner/operator should keep this
in mind. ·
STOPPING THE GENERATOR
1. Remove the AC loads from the generator and allow the
generatorto run for an added 3 to S minutes (this stabilizes
its operating temperature).
. 2. Depress the STOP (red) switch.
~. When the generator stops, release the STOP switch.
NOTE: In an emergency, if the generator will not stop using
the stop switch, remove the 8 amp ju.se in the control
panel.
· .·Engines & Generators
8

OPERATING INSTRUCTIONS
ABNORMAL STOP
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 shut
down,
and the green LED light on the remote panel will go off
indicating that a fault
has occurred. Once detected, the fault
should
be located (see ENGINE TROUBLESHOOTING).
OVERSPEED SHUTDOWN
Inthe case of an overspeed shutdown, the overspeed circuit
must bereset before re-starting
the generator. Simply depress
the Stop switch mtarily then proceed with the normal start
sequence.
If the overspeed switch itself is faulty and re-setting it by
depressing the STOP switch will not reset the circuit, lift the
T-1 coil connection from the overspeed switch and tape the
end of the T-1 wire with electrical tape. By-pass this circuit
only as a test. Re-start the generator, if this by-pass is
successful, replace the faulty overspeed switch.
Do not run the generator with out replacing the overspeed
switch.
A WARNING: Do not operate the generator with
the overspeed switch by-passed.
Refer to the CONTROL PANEL WIRING DIAGRAM in this
manual.
NOTE: Overspeed switches draw a small amount of
amperage (25 milliamps) at all times once the generator is
connected to its starting battery. This amounts to approxi-
mately 18 amp-hours in a month. It is not necessary to be
concerned with this slight amperage draw during normal
. seasonal operation.
However, ifthe generator set is to be
unusedfor many months, it is best to either remove the 8
amp ignitionfuse from
the controlpanel on the generator or
tum
off the generator's starting battery switch..
A CAUTION: It is very important that the overspeed
shutdown always be installed and functioning. Any
tampering with the overspeed shutdown module, which
would cause it to malfunction, could be a cause of
injury should the generator's belt-driven governor fail
and cause the generator to run away.
REMOTE PANELS
The remote startpanel and the remote instrumentpanel
operate the same as the generator mountedcontrolpanel
exceptthat they have green LED lights for starting at a
remote location (where
the sound of the generator.may not
be audible). The green LED lights indicate when the
generator is running at about 600 rpms. That is when the start
switch should be released. For the remote start/stop sequence
refer to
STARTING THE GENERATOR on the previous page.
Engines & Generators
g

BREAK•IN PROCEDURE/DAILY OPERATION
BREAK·INPROCEDURE
After the.generator has been started, check for proper operation
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 /aad~
After the first 10 hours of the generators' operation, the load
can be increased to the full-:load rated output; then periodically
vary the foad. ·· ·
.
Avoid <lverlo~d ~all time:;. ¥ 9yertoa.d i~ .signa}~ by a
smoky eXhaust with l'edoCed: output voltage. and frequency~
Monitor the currentbeing:d.rawn from i:he generator and keep
it within the genei;a.tors~ tating. 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 cjfi:he generator, .
the generator;s output leads should be routed through a circuit
breaker that is· rated· at· the rated output of the generator. ·
NOTE: Be aware of motorstarting toads anti th~ high
current drawn required for starting motors. This starting
amperage drawn can be 3 to 5 timesnormalrunning r:zmper-
age. See GENERATOR INFORMATION in.thisfrtanua.L
CHECKLIST
Follow this checklist each day before starting your generator.
• R.ecord the hounneter reading in your log (engine hotirs
relate to the maintenance schedule).•
• Visually inspect the engine for fuel, oil, or water leaks:
II Check the oil level (dipstick).
• Check the coolant levelin the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
a Check the drive belts for wear and proper tension (weekly).
• Check for abnormal .noise such as knocking, vibration and
blow-by sounds.
• Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is wann -almost Smokeless.
When the engine is overloaded - some Black Smoke.
NOTE: Some unstable running may occur ~n 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 fu:im the generator one at a time.
Allow the generator tb.run for a few minutes to stabilize the
operating temperature and press the STOP switch down, (see
CONTROL PANELS).
NOTE: After the first SO hours of generator operation check
. the nuzintelltlnce schedule for the 50hourservice check.
. GENERAToR ADJUSTMENTS
Once the generator has beeh 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 (HERTZ) ADJUSTMENT
under ENGINE ADJUSTMENTS. 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 SWITCHES
.SAFm SHUroOWN SWITCHES
The engine is protected by a variety of shutdown switches.
Should a shutdown
occur, do notattempt to restart without
finding
and correcting the cause. Refer to the heading
Engine starts, runs and then shuts dbwn in the ENGINE
TROUBLESHOOTING section of this manual. .
The following is a desCription of these automatic shutdown
switches:
EXHAUST
TEMPERATURE
SWITCH
Exhaust Temperature Switch
An exhaust temperature switch is located on the exh;~ust
elbow. This switch will open and interrupt the DC voltage tn
the ignition coil (which turns OFF the engine), should the
switch's sensor indicate an excessive exhaust temperature (an
inadequate supply.of raw water coolant causes high exhaust
temperatures). This switch opens at 260" -270° F
(
127° - 132" C) and resets at approximately 22."i'F (107'' C)
High Water Temperature Switch
A high water temperature switch is located on the thcm10st.at
housing. This switch will open and inte1rupt the DC voltage
to the ignition coil (which turns OFF the engine). should the
fresh water coolant's operating temperature reach
approximately 205" F (96" C). ·
This switch resets at 195" F (!OTC).
low Oil Pressure Switch
A low oil pressure shutdown switch is located offthe
engine's oil gallery. The switch is kept closed by engine oil
pressure. Should the engine's oil pressure fall to 10 - .15 psi,
t11e switch will open interrupting the DC voltage to the
ignition coil (which turns
OFF the engine).
1.·~¥.-V~
Oil FILTER. ~Ji
r.;:;;
LOW OIL PRESSURE SWITCH
High RPM Shutdown Switch
An overspeed shutdown switch shuts OFF the generator set
by grounding out the ignition system should the engine's
speed reach approximately 2175 rpm. Reset the switch b)
momentarily depressing the STOP switch. (Make sure the
cause
of the engine overspeed shutdown is cnrre.cted).
Engine Circuit Breaker
The. generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw orelectrical 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
breaker interrupts the DC circuit
to the K2-run relay. If this
should occur, check and repair the source ofthe problem.
After repairing the fault, reset the breaker and restart
the
generator.
l"flV'iWESTERBEKE
~ Engines'&'Generators
11

SCHEDULED
MAINTENANCE
Fuel Supply
Fuel/Water Separator
Engine Oil Level
Coolant Level
MAINTENANCE SCHEDULE
A WAllNING: Nsver attetnpt to perfQrm any service while the engine Is
running. Wear tbeprap11raletyeq'1i/1"1ent such as g11119/e$ and gloves, and
11$8 the curreot t~ols ,,,, ,.ch/o/l.111$coanect the battery terminals when
serrlcin9 any of the e11gi11e'I DC BlilctriQal equipment.
NOTE: Many of the following mamtenance procedures are $imp le but others are
more difficult and may require the expert knowledge of a service mechanic.
CHECK
EACH
DAY
5Q
0
0
0
0
HOURS OF OPERATION
MAINTENANCE DESCRIPTION
100 25.0 500 .750 1000 1250
.·
. i
·cc- .
Unleacled gasoline with octane rating of89 of higher .:
Check for water and dirt In fuel (drain/repl~e filter if
· necessary).
Oil level should indicate between MAX and LOWon ·
.
clipstick •.
1 crieC:k~recovery tan~j.jf empfy, check at manifold.
.:Acid#P91ilJJt:if·n.eeded.
Drive Belts D · · ·
••· • · ·· 1 "lli$g~oftorpr~perterlston (3/8''. fo 1/2· defle~on)
.. I a,ng ~cllll~lifntieded• 9~1ick belt edges ror wear.
·weekly
V!sual Inspection of engine 0
Sparks Plugs
Starting Batteries
(and House Batteries)
Engine Oil
Generator
Fuel Lift Pump
and G11sdenser
Air Screen (Flame Arrester)
Exhaust System
Engine Hoses
Raw Water Pump
Belt Driven Governor
0
weekly
NOTE;. Keep. engine surtace.cle~n·Dirta~r:frJif •tjbep~:tor fuer; oil aild v\iaterleaks;• Inspect wiring. and ·
wlll lnhi/Jit too engifie'S ab.lffJYt~iem~in.cgpl. '· .• eleetncat cortnectio~s. Keep bolts & nutS tight. Check·
tor19~sebe~tt!nsiqn. ·. · ·. -"-
[j
0
0
D
0
0
0 ·
.. ··D··.•
I .•
c-
0 0 0
0 D D
0 D
0 D
D D D
0 D
·o~
D
D D
0
..
0
..
D.
D
0 0
••
c' Eve~ 50 ope~ting h~!Jrs check electrolyte levels
and make sure ~nnections are very tight Glean off
ei.<c.essive. porrosion.
0 Initial engine oil and filter change at 50 hours, then
change both every 100 hours.
D Check that AC· connections· are clean and secure with
no chafing-see GENERATOR INFORMATION for.
addition~l lnformation.
0
>o
Periodically Inspect tor leaks.
·Clean. at 50hrs~; then every 100 hours.
Initial check at 50J1ours; then every 250 hours.
lnspept for leaks. Ch.eek anti-siphon. valve operation.
Check the e,xtiaust elbow for carbon and/or corrosion
buildup on inside passages; clean and replace as
necessary~ Clleck that:all c~n.oections are tight
D Hose should be. hard &tight Replace ~ hoses
oecome spongy. Check ~nd tighten all hose clamps.
O D 0 0 D 0 Visually inspect tor leaks. Remove the pump cover
and. inspect cover surface and cam 1or wear, Inspect
impeller. Ensure impeller shaft is secure and does not
wobble. Replace items as needed.·Rebuild/replace
pump as needed.
D 0 D D 0
~ Change gooernor oil every 250 !lours. Adjust
governor· operation as needed.
lw;UfSSTElllJI!~
I Engine/$ & Generators
12

MAINTENANCE SCHEDULE
NOTE: l :H t''ngtne hourtli1/'!er );;UUtte Jo /p'.!,_ r1>ur r·n,~ine i!uuts· tir H'\:01'1
e11gi11e huun r1111nmg ti11n'.
,-i -----,,--·---~-~·-~--~-' 1 - ---r- ------"-----
I CHECK j HOURS Of OPERATION _j
I SCHEDULED EACH -- - · -- -- - - ---- ·- ~
50
l EXPLANATION Of SCHEDULED
~~~~TEN~N._ff_ -~y -~0_ 110~ 250 _ 50~750 r1_000 __ 11_!)0 ___ ~- MAINTE~~~f~ ________ _
I Heat Exchanger 1· 0 O O ! O 1 O O ' 0 c:.:an or replace anofle Open heat exchanger end
! , I ;,,,p and clean out c!ebns Remove ever; 1000 hours
L : \ for and pressure testing
I Coolant System ' O f!usl-:. and refill cooling system wittl
I j ;mtltreeze rn:x every 500 holirS ot
I I I
l Start~-r_M_o_t_o;------·---<c----+----+---f
1
' ---+-1
1
'
-0--+1--j,___..__O_--+---C--hr-:c_.k_s_o_le-110_1_d_a_n1-.-m-{-1to_r_fo_r_c--o-n--o-si-on-_-R_e_m_o_vc-n--<
l and luonc:ite Clean and !utJricate !lie start motor
I I l · I pnnon dnve.
r Distributor ----+--0--<>---+i --1-· 0 -- - Ci1(;Ck 1go1t1on
;----------·----- __ _,_ _ _,_ __ ·-rr d1S!!1'.lu!Qr cap and rotor.
I
·Engine Cylinder Ii
111
O O lncorrec1 valve clearance will result in
Compression and
l Valv__e_~t:aran~: ____ ~ 1
I ·Engine Timing Belt
t···---·----,..-~~-------<~---·--------+----+---
0
1 ·Exhaust Elbow
0
I
!---------·-----+----+-----+-·
I Carburetor Filter Screen
0 0
13
Inspect every 500 hours. Replace a! 3000 hours
Test exhaust elbow for casting
castmg is corroded or deteriorated
Replace 1!
WARNING: A detective extiaust elbow can cause
carbor rnonoxide
Clean after 50 t;ours of operation. Clean and
every 250 operating hours.