Westerbeke BCG4.0KW User manual

OPERATOR'S MANUAL
WESTERBEKE
BCG 4.0KW
and BCG 6.5KW
MARINE GASOLINE
GENERATOR SETS
Publication # 35729
Edition Two
March 1988
~ WESI'ERBEKE
WESTERBEKECORPORATION
AVDNINDUSTRIAL PARK, AVON, MA 02322. TEL: [phone]

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.
~WARNINGII
The above symbol is used in the manual to warn of possible
serious personal injury or loss of Hfe,
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 hazards that could result in
serious personal injury or death, Follow recommended proce~
dures carefully.
Always operate bilge blowers for at least five minutes before
starting agasoline-fueledengine; ensure nogasolinefumes are
present before starting.
• Prevent Electric Shock
Shut off electric power before accessing electrical equip-
ment.
Use insulated mats whenever working on electrical equip·
ment.
Make sure your clothing is dry, not damp (particularly
shoes), and keep your skin surfaces dry when handling
electrical equipment.
Remove wristwatch and jewelry when working on electri-
cal equipment.
Do not connect utility shore power to vessel's AC circuits,
except through a ship-to-shore double-throw transfer
switch, Damage tovessel's AC generator mayresult ifthis
is notdone.
Be extremely careful when working on electrical com~
ponents. High voltage can cause injury or death,
• Exhaust Gases Are Toxic
Ensure thattheexhaust system is adequate toexpel gases
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.
• Use Extreme 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 notsmoke or use an open flame nearthe engine or the
fuel tank.
• Do Not Alter or Modifythe Fuel System
Be sure all fuel supplies have a positive shut-off 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. Ex~
tinguishers rated ABC by the NFPA are 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.
Lead acid batteriesemit hydrogen, a highly~explosive gas,
which can be ignited by electrical arcing or by a lighted
cigarette, cigar, or pipe. Do not smoke or allow an open
flame near the battery being serviced, Shut off all electri-
cal equipment
in the vicinity to prevent electrical arcing
during servicing.
• Avoid Moving Parts
Do not service the unitwhile the unit is running; if a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid moving
parts and hot exhaust system components.
Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, 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 notwork on the equipment when mentally or physical-
ly incapacitated by fatigue.

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Product software
of all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, partslistsand parts price lists, and other information, instructionsand specifications provided from
sources otherthan Westerbeke, is notwithin Westerbeke's control and, accordingly, is provided to Wester-
beke 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 ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH, OR
ARISING OUT OF, THE FURNISHING OR USE OF SUCH SOFTWARE.
For example, components and subassemblies incorporated in Westerbeke's products and supplied by
others (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 Wester-
beke must depend on such software for the design
of Westerbeke's own product software. Such software
may be outdated and
no longer accurate. Routine changes made by Westerbeke's suppliers, of which
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, mostWesterbeke products includecustomer-requested special features that frequently
do not
include complete documentation.
Insummation, productsoftware provided withWesterbeke products, whetherfromWesterbeke or othersup-
pliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.
It not only makes good sense but is imperative that appropriate representatives of Westerbeke or the sup-
plier in question be consulted to determine the accuracy and currency of the product software being con-
sulted by the customer.
1 Westerbeke Generators

FOREWORD
Thank you for selecting a Westerbeke marine productfor your use. We at Westerbeke are pleased to have
you as a customer.
Read this manual carefully and observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust-
ment procedures are included herein so you can operate your equipment safely and properly, maintain the
equipment at a high level of efficiency, and expect dependable performance and long service life in return.
Should your unit require special attention, contact yourWesterbeke dealer for assistance. The Westerbeke
Service Organization is trained
to provide the support necessary to ensure long-term dependable perfor-
mance.
If, within 60 days of submitting the Warranty Registration Form for your unit, you have not received a Cus-
tomer Identification Card (see below) registering your warranty, please contact the factory in writing with
Model information, including the unit's serial number and commission date.
from: WESTERBEKE CORPORATION
AVON INDUSTRIAL PARK
AVON. NA 02322
f-VV- I WESTERBEKE
:::;,:.;:::::~. ::::'.::,7~::.:;;;~ :.::: ~.::~:::.n_
Mail To:
Westerbeke Generators
CUSTOMER IDENTIFICATION
Adam S"ith
as Maple Street
Alden. IN 12234
Model BeG 4.0KW
Expires 717189
2
Ser. I 1234(706

TABLE OF CONTENTS
Section .........................................................................Page
GENERAL ...........................................................................5
BCG 4.0KW GENERAL SPECIFICATIONS ..................... 10
BCG 4.0KW SYSTEM SPECIFICATIONS ........................ 11
BCG 6.5KW GENERAL SPECIFICATIONS ..................... 14
BCG 6.5KW SYSTEM SPECIFICATIONS ........................ 15
INSTALLATION CHECKS ................................................ 18
DESCRIPTION OF ENGINE
CONTROL PANEL. ........................................................... 31
PREPARATIONS FOR STARTING ................................... 33
STARTING PROCEDURE ................................................ 34
STOPPING PROCEDURE ................................................ 36
CARBURETOR AND FUEL SYSTEM ............................... 38
ELECTRICAL SYSTEM ..................................................... 41
DC CONTROL CIRCUIT
WIRING DIAGRAM # 37190 ....................................44 & 45
OPTIONAL REMOTE START PANEL
WIRING DIAGRAM # 35706 ............................................ 46
OPTIONAL REMOTE INSTRUMENT PANEL
WIRING DIAGRAM # 35698 ............................................ 47
COOLING SySTEM .......................................................... 48
LUBRICATION SYSTEM .................................................. 54
BC GENERATOR .............................................................. 57
GENERAL INFORMATION AND CARE
OF THE GENERATOR ..................................................... 64
ENGINE TROUBLESHOOTING ....................................... 66
MAINTENANCE & ADJUSTMENTS ................................. 70
3
Westerbeke Generators

TABLE OF CONTENTS
(CONTINUED)
LAY-UP & RECOMMISSIONING ...................................... 80
SPARE PARTS LIST .......................................................... 83
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES .................................................. 84
TABLE OF TIGHTENING TORQUES ............................... 85
INDEX ................................................................................ 86
Westerbeke Generators
4

GENERAL
Introduction
This manual contains the equipment operating procedures as well as additional information needed to help
the operator keep the marine equipment in properworking order. Study and followthe instructions careful-
ly. A planned maintenance program
is included in this manual; adhering to the program will result in better
equipment performance and longer equipment life. Proper diagnosis of a problem is the most important
step
to satisfactory repair; therefore, a troubleshooting table is included.
Understanding the Gasoline Engine-Driven Generator
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 belt-driven.
The engine utilizes conventional points and a condenser-type distributorwhich
is horizontally mounted and
camshaft-driven. The engine incorporates a pressure-type lubrication system, and a fresh water-cooled en-
gineblockwhich isthermostatically-controlled. To a large degree, the generator's engine requires the same
preventive maintenancethat is required of a gasoline automobile engine. The most important factors to the
generator's longevity are proper ventilation, maintenance
of the fuel system, ignition system, cooling sys-
tem, lubrication system and the
AC end.
Ordering Parts
Whenever replacement parts are needed, always provide the generator model number, engine serial num-
ber, and generator serial number as they appear on the scarlet and gold name plate located on the gener-
ator end. You must provide us with this information so we may properly identify your generator set. In
addition, include a complete part description and part number for each part needed (see the separatelyfur-
nished Parts list). Also, be sure to insist upon Westerbeke factory packaged parts, because "will fit" or
generic parts are frequently not made
to the same specifications as original equipment.
Note that component locations in the manual are referenced from the front of the engine which
is the pul-
ley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined by the
engine; imagine straddling the engineand facing in the same direction as the front
of the engine: the left side
is at your left, the right side at your right.
Westerbeke generators sets are thoroughly checked and given a final run under various load conditions
before leaving the factory. Test running the generator ensures dependable operation, long service, and a
satisfied owner.
Care at the factory during assembly and thorough testing have resulted in a Westerbeke gasoline engine-
driven generatorcapable
of many thousands of hours of dependable service. However, what the manufac-
turer cannot control
is the treatment the unit receives in the field. That part is up to the owner/operator.
5 Westerbeke Generators

Fresh Water Coolant Fill
Exhaust Mani
Lube Oil Dipstic
20 Amp DC Circu
Breaker
Zinc Anode
Heat Ex.cha
Weslerbeke Generators
BeG 4.0KW Marine Gasoline Generator
Lube Oil Fill
90
0
Exhaust Elbow
DC Battery Ground
Connection

BCG 4.()KW Marine Gasoline Generator
Water Tempe ratu re Switch
Fresh Water Air Bleed
Control Pane
AC
Unit Data Tag
Fuel Lift Pum
Oil Pressure Switch
7
Intake Flame Arrestor
rburetor with Choke
r.;,w'''nor
Fuel Shut-off
Solenoid
Lube Oil Drain Hose
Exchanger
Lube Oil Filter
Westerbeke Generators

Fresh Water Coolant Fill
Model Data
Lube Oil Dir>stick
20 Amp DC Circuit
Starter with Solenoid
Westerbeke Generators
BeG S.5KW Marine Gasoline Generator
Top Engine Oil Fill
Distributor
0" Exhaust Elbow
Exhaust Temperature
h
Battery Ground
Connection

BeG 6.SKW Marine Gasoline Generator
Fuel Shut-oil So,lelnoi,d
Intake Flame Arrestor
Water Temperature Switc
Control
AC
Lube Oil Filter
9
Carburetor with Choke
Governor
Pressure Switch
Anode
Heat Exchanger
Lube Oil Drain Hose
Westerbeke Generators

BCG 4.0KW MARINE GASOLINE GENERATOR SET
GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction
of Rotation
MaximumTorque (at 1800 rpm)
Compression Ratio
Compression Pressure
(Limit
of difference between cylinders)
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
Weslerbeke Generators
Gasoline, four-cycle, two-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(8 hp at 1800 rpm, maximum).
Hoof, flyball type,
5% speed regulation
Multi-sphere type
2.82 x 2.68 inches (71.6 x 68 mm)
33.4 cubic inches (1.07 liters)
1-2
Clockwise, when viewed from
the front
33 Ib-ft
(4.91 kg-m)
9.2:1
177.8 psi (12.5 kg/cm2) at 400 rpm
(28 psi [2.0 kg/cm2 ])
Intake Opens 21' BTDC
Intake Closes
59' ABDC
Exhaust Opens 59' BBDC
Exhaust Closes 21' ATDC
Intake
45'
Exhaust 45'
Intake 0.008 inches (0.20 mm)
Exhaust 0.010 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 23.00 inches (584.20 mm)
Width: 18.75 inches (476.25 mm)
Length: 25.00 inches (647.70 mm)
3091bs (140.1 kgs)
0.8 U.S. gph (3.02 Iph) at full rated ou1put (approximate)
Continuous
14'
Temporary 20' (not to exceed 20 min.)
10

INTAKE SYSTEM
Carburetor (STD type)
IGNITION SYSTEM
General
Distributor
Spark Plug Thread Size
Spark Plug Type
FUEL SYSTEM
General
Fuel
Lift Pump
Fuel Screens (on engine)
Air cleaner
BCG 4.0KW SYSTEM SPECIFICATIONS
Down draft type, single barrel with U.S.C.G.
approved flame arrester.
Battery ignition,
12-Volts, negative ground,
distributorwith points, ignition coil
and spark
plugs.
Conventional, contact-point type
14 mm x 1.25 pitch
Westerbeke part number
035666
(Always identifythe generator model
when ordering parts. See page 5.)
Conventional carburetor type with fuel lift pump
Regular or unleaded gasoline with an octane rating
of
89 or higher.
12-Volt DC; lift capacity 6ft (1.8 m)
Reusable screen type (one in Carburetor and one
in electric fuel pump).
Metal screen type -cleanable
Air Flow (engine combustion)
18 cfm (0.509 cmm)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
Sea Water Pump
Fresh water-cooled block,
thermostatically-controlled
with a heat exchanger.
130 -150' F (55 -66' C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven.
11 Westerbeke Generators

BeG II.OKW SYSTEM SPECIFICATIONS
Sea Water Flow, at 1800 rpm
(measured before discharging
into exhaust elbow)
System Capacity (fresh water)
LUBRICATION SYSTEM
General
Oil Filter
Sump Capacity (not including filter)
Operating Oil Pressure (engine hot)
Oil Grade
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
DC Battery Charger
Starter
DC No-Load Current
DC Cranking Current
Westerbeke
Generators
3.75 - 11.0 U.S. gpm (14.19 -15.14Ipm)
3.3 U.S. qts (3.2 liters)
Pressure type byTrochoid pump,
chain-driven through balance shafts.
Full flow, paper element, spin-on type
3,0 qts (2.9 liters)
50 -70 psi (3.5 -4.9 kg/cm2)
API specification of SD or SE, preferably SF
12-Volt, 26 A-H,
(-) negative ground
(recommended)
(35 A-H in cold areas)
90 -125 (Ampere-Hours)
Internal regulator 13 Volts, 0 -10 Amps.
12-Volt, 1.2f<W, reduction type,
solenoid-mounted
90 Amp (max,) at 11.5 Volts.
175 -200 Amps (engine cold)
12

BeG 4.0KW SYSTEM SPECIFICATIONS
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
Brushless, four-pole, revolving field.
Self exciting. Capacitor saturated field excitation.
Pre-lubricated, single-bearing design.
Reconnectable 120 Volls
or 120[240Volts,
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
34 Amps
34[17 Amps
14 Amps
To be rated at 120% of the generator's rated
amperage and voltage output.
225 elm (6.4 cmm)
NOTE: Increase air supply 15% for 50 Hertz operation (1500 rpm).
Engine Combustion Air
Requirements, (60 Hertz),
at 1800 rpm
TUNE-UP SPECIFICATIONS
Spark Plug Gap
Contact Point Clearance
Timing
18
cfm (0.509 cmm)
0.028 -0.036 inches (0.70 -0.90 mm)
0.016 -0.020 inches (0.4 -0.5 mm)
16' ± l' BTDC at 1800 rpm
13
Westerbeke Generators

BCG S.!iKW 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 Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
Westerbeke Generators
Gasoline, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(14
hp at 1800 rpm, maximum).
Hoof, flyball type, 5% speed regulation
Multi-sphere type
2.99 x 2.87 inches (76 x
73 mm)
60.6 cubic inches (0.993 liters)
1-2-3
Clockwise, when viewed
from the front
40.5 Ib-It (5.6 kg-m)
9.2:1
177.8 psi (12.5 kg/cm2) at 350
rpm
(28 psi [2.0 kg/cm2n
Intake Opens 19' BTDC
Intake Closes 51' ABDC
Exhaust Opens
51' BBDC
Exhaust Closes
19' ATDC
Intake 45'
Exhaust 45'
Intake 0.0071 inches (0.18 mm)
Exhaust 0.0017 inches (0.18 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 23.38 inches (593.85 mm)
Width: 18.69 inches (474.73 mm)
Length: 26.75 inches (679.45 mm)
3321bs (150.5 kgs)
1.1 U.S. gph (4.16 Iph) at full rated output (approximate)
Continuous
14'
Temporary 20' (not to exceed 20 min.)
14

BCG 6.5KW SYSTEM SPECIFICATIONS
INTAKE SYSTEM
Carburetor (STD type)
IGNITION SYSTEM
General
Distributor
Spark Plug Thread Size
Spark Plug Type
FUEL SYSTEM
General
Fuel
Lift Pump
Fuel Screens (on engine)
Air cleaner
Air Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
Sea Water Pump
Down drafttype, single barrel wtth U.S.C.G.
approved flame arrester.
Battery ignition, 12-Volts, negative ground,
distributorwith points, ignition coil and spark
plugs.
Conventional, contact-point type
14 mm x 1.25 pitch
Westerbeke part number 033805
(Always identify the generator model
when ordering parts. See page 5.)
Conventional carburetortype with fuel lift pump
Regular
or unleaded gasoline with an octane rating
of 89 or higher.
12-Volt DC; lift capacity 6 ft (1.8 m)
Reusable screen type (one in Carburetor and one
in electric fuel pump).
Metal screen type -cleanable
32 clm (0.906 cmm)
Fresh water-cooled block,
thermostatically-controlled
with a heat exchanger.
130 -1500 F (55 - 66
0
C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven.
15 Westerbeke Generators

BCG 6.SKW SYSTEM SPECIFICATIONS
Sea Water Flow, at 1800 rpm
(measured before discharging
into exhaust elbow)
System Capacity (fresh water)
LUBRICATION SYSTEM
General
Oil Filter
Sump Capacity (not including filter)
Operating Oil Pressure (engine hot)
Oil Grade
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
DC Battery Charger
Starter
DC No-Load Current
DC Cranking Current
Westerbeke
Generators
3.75 -4.0 U.S. gpm (14.19 -15.14Ipm)
5.2 U.S. qts (4.9Itters)
Pressure type by Trochoid pump,
chain-driven through a balance shaft.
Full flow, paper element, spin-on type
3.0 qts (2.9 liters)
50 -
70 psi (3.5 -4.9 kg/cm2)
API specification of SD or SE, preferably SF
12-Volt, 26 A-H,
(-) negative ground
(recommended)
(35 A-H in cold areas)
90 -125 (Ampere-Hours)
Internal regulator 13 Volts, 0 - 10 Amps.
12-Volt, 1.2KW, reduction type,
solenoid-mounted
90 Amp (max.) at 11.5 Volts.
225 -250 Amps (engine cold)
16

BCG S.5KW SYSTEM SPECIFICATIONS
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
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
54 Amps
54/27 Amps
27.8
Amps
To be rated at 120% of the generator's rated
amperage and voltage output.
250 cfm (6.23 cmm)
~: Increase air supply 15% for 50 Hertz operation (1500 rpm).
Engine Combustion Air
Requirements, (60 Hertz),
at 1800 rpm
TUNE-UP SPECIFICATIONS
Spark Plug Gap
Contact Point Clearance
Timing
32 clm (0.906 cmm)
0.028 -0.036 inches (0.70 -0.90 mm)
0.016 -0.020 inches (0.4 -0.5 mm)
14° ± 1° BTDC at 1800 rpm
17
Westerbeke Generators