N6817119Q6029_WESTERBEKE_OPERATORS_MANUAL.pdf

OPERATOR'S MANUAL

WESTERBEKE

BCG 4.0KW and BCG 6.5KW

MARINE GASOLINE

GENERATOR SETS

Publication # 35729

Edition Two

March 1988

~ WESI'ERBEKE

WESTERBEKE CORPORATION

AVDNINDUSTRIAL PARK, AVON, MA 02322. TEL: (617) 588-7700

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 a gasoline-fueled engine; ensure no gasoline fumes 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 to vessel's AC 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 the exhaust system is adequate to expel 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 not smoke or use an open flame near the engine or the fuel tank.

• Do Not Alter or Modify the 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 batteries emit 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 unit while 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 not work 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, 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 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, 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 sup 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 product for 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 your Westerbeke 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

Ser. I 1234(706

TABLE OF CONTENTS

Section ......................................................................... Page

GENERAL

BCG 4.0KW GENERAL SPECIFICATIONS

BCG 4.0KW SYSTEM SPECIFICATIONS

BCG 6.5KW GENERAL SPECIFICATIONS

BCG 6.5KW SYSTEM SPECIFICATIONS

INSTALLATION CHECKS

DESCRIPTION OF ENGINE

CONTROL PANEL

PREPARATIONS FOR STARTING

STARTING PROCEDURE

STOPPING PROCEDURE

CARBURETOR AND FUEL SYSTEM

ELECTRICAL SYSTEM

DC CONTROL CIRCUIT

WIRING DIAGRAM # 37190 ................................... .44 & 45

OPTIONAL REMOTE START PANEL

WIRING DIAGRAM # 35706

OPTIONAL REMOTE INSTRUMENT PANEL

WIRING DIAGRAM # 35698

COOLING SySTEM

LUBRICATION SYSTEM

BC GENERATOR

GENERAL INFORMATION AND CARE

OF THE GENERATOR

ENGINE TROUBLESHOOTING

MAINTENANCE & ADJUSTMENTS

3 Westerbeke Generators

TABLE OF CONTENTS

(CONTINUED)

LAY-UP & RECOMMISSIONING

SPARE PARTS LIST

TABLE OF STANDARD HARDWARE

TIGHTENING TORQUES

TABLE OF TIGHTENING TORQUES

INDEX

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 proper working order. Study and follow the 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 distributor which is horizontally mounted and camshaft-driven. The engine incorporates a pressure-type lubrication system, and a fresh water-cooled en gine block which is thermostatically-controlled. To a large degree, the generator's engine requires the same preventive maintenance that is required of a gasoline automobile engine. The most important factors to the generator's longevity are proper ventilation, maintenance 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 separately fur 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 engine and 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 generator capable 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

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

Carburetor with Choke

Governor

Pressure Switch

Anode

Heat Exchanger

Lube Oil Drain Hose

BCG 4.0KW 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

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.)

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, distributor with points, ignition coil and spark plugs.

Conventional, contact-point type

14 mm x 1.25 pitch

Westerbeke part number 035666 (Always identify the 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 6 ft (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 by Trochoid 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)

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[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

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.)

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 draft type, single barrel wtth U.S.C.G.

approved flame arrester.

Battery ignition, 12-Volts, negative ground, distributor with 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 carburetor type 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 - 660 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)

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

INSTALLATION CHECKS

General

Since the crafts in which Westerbeke generators are installed vary in design, installation procedures will vary according to your craft's specific design. The intent of this section is not to advise boatyards or installers on procedures already well-developed and well-understood. However, the owner/operator must realize there are details of the installation which require periodic checks to ensure the best operating conditions for the equipment and safe operating conditions for the personnel on board. Proper location and installation of the gasoline generator in the vessel are of prime importance.

Factors in the installation that must be considered are ventilation, to aid in cooling the generator end; to provide air for engine combustion and to remove heat produced by the engine while operating; the exhaust system, to properly discharge raw cooling water (sea water), to quiet the exhaust, and to expel exhaust gas;

the cooling water supply; and the electrical connections.

CAUTION

For safety reasons, the generator's engine is NOT filled with lubricating oil for shipment. Before leaving the factory, however, each generator set is thoroughly tested with oil in its engine.

This testing, among other things, provides all internal parts with a coating of oil. This oil acts as a preservative, providing reliable protection against corrosion for at least one year if the generator is properly stored.

Inspection of Equipment

The generator is shipped from the factory securely mounted and properly crated. Accessory equipment is shipped in a separate small box, usually packed within the generator's crate.

Before accepting shipment olthe generator set from the transportation company, the crate should be opened and the contents inspected for concealed damage. If either visible or concealed damage is noted, you should require the delivery agent sign "Received in damaged condition" on the proper delivery receipt. Also check the contents of the shipment against the packing list and make sure that the proper notation is made if any discrepancies exist. These noted discrepancies are your protection against loss or damage. Claims con cerning loss or damage must be made to the carrier, not to the Westerbeke Corporation.

Westerbeke Generators 18

Rigging and Lifting

The generator is fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight should be attached to the eyes and the generator lifted by means of tackle attached to these slings. The lift ing eyes have been designed to carry the full weight of the generator; therefore, auxiliary slings are not re quired or desired.

CAUTION

Slings must not be so short as to place significant stress on the generator's lifting eyes. Strain placed on the generator's lifting eyes by the lifting Sling must not be in excess of 100 from the vertical plain.

ENGINE

SLING LIFTING

ANGLE MUST HOT

EXCEED 10'

LI FT I NG

EYE

The general rule in moving generators is to see that all equipment used is amply strong and firmly fixed in place. Move the engine a little at a time and see that it is firmly supported. Eliminate the possibility of acci dents by avoiding haste. Do not lift the generator by its crankshaft pulley. In certain sttuations tt may be necessary to lift the engine in positions other than the horizontal position. Certain situations exist by which the engine must be lowered endwise through a small hatchway which cannot be made larger. Under these conditions, If the opening of the hatchway is extremely small, it is possible to reduce, to some extent, the outside dimensions of the generator by removing external components such as the cooling system's piping, the heat exchanger, certain filters, the mounting rails and other obstructive equipment. This accessory equip ment should be removed by a competent mechanic and special care should be taken to avoid damage to any exposed parts. In addttion, be careful not to allow dirt from entering any opening created by the removal of equipment. Removed parts should be returned to their respective position as soon as the generator has cleared the obstruction and is ready to be positioned on its mounting platform.

In case it becomes necessary to hoist the generator front-end upwards or generator-end upwards, the at tachment of lifting slings must be done carefully to avoid the possibility of damaging the parts on which the weight of the slings may bear. Special rigging work is best done by someone experienced and competent in handling heavy machinery.

19 Westerbeke Generators

Generator Mounting - Location

The complete generator unit is mounted on lightweight rails by means of four flexible isolator mounts that help preventthe transfer of vibration from the generator to the rails. Each generator mounting rail has several 1/2-inch bolt holes so bolts can be employed to properly secure the generator to ks mounting platform.

These holes are on 15 inch mounting centers.

(1/2- MOUNTING HOLES)

The location should be dry, above low-lying vapor areas, and in an area where bilge water and water from above cannot splash on the generator. It should be properly ventilated and accessible for minor servicing and repairs. Access for major repairs should be given consideration as well. The location should be proper ly ventilated to provide fresh cooling air for the generator end, for engine combustion needs, and to remove heat produced by the engine while operating. The generator set needs fresh cool air in whatever location in the vessel it is installed. Hot generator discharge air must be removed from the generator area. The plat form on which the generator and ks mounting rails are located should be strong enough to support the gen erator during all angles of vessel operation.

Westerbeke Generators 20

Exhaust System

IIWARNINGI

CARBON MONOXIDE EXHAUST GAS IS DEADLY. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. Some of the symptoms or signs of carb on monoxide inhalation or poisoning are listed below.

o Dizziness o Vomiting o Intense Headache o Muscular Twitching o Weakness and Sleepiness o Throbbing in Temples

All exhaust systems should be such that the entry of sea water into the engine's exhaust manifold and cylinders is prevented while the engine is not running, or while the vessel is under sail or power in which case the vessel may experience heeling or backing down from following seas or any other conditions. Special attention must be taken to make certain the exhaust system is secure and tight and free of leaks.

The sea water supply through-hull sea cock fittings must be of the flush-hull type. High-speed scoop type fittings must not be used, as they tend to encourage siphoning.

When a water lift type exhaust system is used, the exhaust muffler should be mounted as close to the en gine as practical. The exhaust discharge should always drop downward into the exhaust muffler. Loops in the exhaust hose between the water-injected exhaust elbow and the water lift muffler should be avoided, as these will trap and hold water.

For installations where the exhaust manifold/water-injected exhaust elbow is at or below the vessel's water line, provisions must be made to install a siphon-break or a vent in the sea water supply hose to the water-injected ex haust elbow. This stops the flow of sea water that runs through the sea water cooling system from filling the exhaust and engine cylinders when the engine is shut down. This sea water supply hose must be looped above the water line and the siphon-break or vent installed in the high point of the loop above the water line. This siphon-break or vent must al ways be above the water line during all angles of vessel operation to prevent siphoning. The vent, when used, must have its vent hose or tube routed so it can remain above the water line and empty of water when the engine is shut down. This allows air to enter through this vent to prevent siphoning.

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PUHP

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Exhaust Back-Pressure

The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust back-pressure.

Exhaust back-pressure should be checked before a gener ator is put into service. (Refer to the illustration.) Excessive back-pressure will affect the engine's performance and the generator's power output.

To measure for back-pressure, use a mercury manometer, a pressure gauge, or a water column. A boatyard or marine mechanic should have a manometer or a pressure gauge.

Measure the engine's back-pressure at the exhaust elbow while the generator is under a full load.

Refer to the pressure specifications listed below.

A water column can be made by taking a clear plastic tube and taping one end of the tube along a yardstick and fitting the other end of the tube with a 1/4 inch NPT (National Pipe Tap) pipe fitting.

Measure the engine's back-pressure at the exhaust elbow ~ while the generator is under a full load.

Dimension A cannot exceed 39 inches of water.

Back pressure, as measured by a gauge instrument, should not exceed the following specifications:

Specifications:

3 inches of mercury (0.104 kg/cm2

39 inches of water in a water column (.099 kg/cm2 at 4° C)

22 ounces psi 1 1/2 psi

Ii ~.

Mercury Manometer

1/.

NPT Plug

Exhaust Elbow

Exhaust

Excessive back-pressure can be caused by a small diameter exhaust hose, a small muffler, sharp bends in the exhaust hose, improper fittings, water pockets, and a high volume of water in the exhaust system due to the length of the exhaust discharge hose. The use of elbows and fittings in the exhaust discharge hose's routing should be limited since these will create flow restrictions and contribute to exhaust back-pressure.

The generator's exhaust system must be separate from any other engine's exhaust system. Dry portions of the exhaust system between the engine's exhaust manffold and the water injected exhaust elbow must be insulated to hold in the heat.

Weslerbeke Generators 22

Dry stack-type exhaust systems (shown to the right) must be attached to the gen erator engine's exhaust manifold by means of a flexible connector pipe. This system must be properly supported and insulated to prevent water from entering into the engine's cylinders. Provisions must be made for discharging the engine's cooling sea water.

Exhaust System Failures

FLAf'PE~ coVEN ~lf . I

I ---1 ~=====14r.~,L 7'f"".M.

MUI"FLI::R ,I I:

XHSUL TJ:DN .:! :'

'1 '

~ .1/2" X.F.5. - COHDr::N-;::::S;p;~i'-' P][I"E SAT:tOH

TRAP

PXTI: .. EXHAUST LIHf

SE:A WATER

%NTAKe: TIH;lOUGH_ HULL I'"1:Tl":t

DRY STACK EXHAUST

When the engine's sea water is fed into an exhaust system so that the full stream of this water strikes a sur face, erosion takes place. This erosion may cause premature failures. The proper design of either a water jacketed or water injected "wet" exhaust system to prevent this problem requires that the sea water inlet be positioned so that the entering stream of sea water does not directly strike a surface. In addition, the velocity of the entering sea water stream should be as low as possible, which can be achieved by having inlet fittings as big in diameter as possible.

The best protection against carbon monoxide poisoning is a daily inspection of the complete exhaust sys tem. Check for leaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating sur rounding areas excessively. If excessive heat is present, correct the situation immediately. If you notice a change in the sound or appearance of the exhaust system, shut down the unit immediately and have the system inspected and repaired at once by a qualified mechanic.

Make sure there are no unnecessary objects suspended from any portion of the exhaust lines. Exhaust risers installed off the exhaust manifold should not exceed 8 Ibs in total weight when rigidly constructed. Exces sive weight could cause deflection or distortion of the lines, resulting in damage or leaks. Inspect insulated portions of the exhaust system to ensure there is no deterioration of the insulation.

CAUTION

Prolonged cranking intervals without the engine starting can result in filling the engine mounted exhaust system with sea waler coolant. This may happen because the sea water pump is pumping sea water through the sea water cooling system during crank ing. This sea water can enter the engine's cylinders by way 01 the exhaust manifold once the exhaust system fills. Prevent this from happening by closing the sea water supply through-hull shut-off, drain Ihe exhaust mulller, and correct Ihe cause lor the excessive engine cranking needed to obtain a start. Engine damage resulting from this Iype of sea waler entry is nol a warrantable issue; the owner/operalor should keep this in mind.

23 Weslerbeke Generators

Exhaust Elbow Installation

The Westerbeke Corporation offers a 45°and 900exhaust elbow as well as an exhaust riser you can install on your generator. Refer to the instructions below when installing the exhaust elbow purchased for your generator.

1. Coat only one side of the exhaust gasket with ·"High Tack" adhesive sealant. Place this coated surface against the exhaust manifold's exhaust port flange (the gasket should stick to the flange without falling off).

2. Place the clamp over the elbow's flange. Place your ex haust elbow against the exhaust manifold's flange so the exhaust manifold's flange rests snug against the ex haust elbow's flange with the gasket centered between the two. Now slip the exhaust clamp over both flanges.

3. A. Tighten the clamp just enough so the exhaust elbow can remain attached to the manifold and still be rotated.

B. The exhaust elbow discharge must be directed downward so the miXiure of sea water and exhaust gases will flow/fall downward into the exhaust muf fler which must be positioned below the exhaust elbow. There should be no loops or rises in the ex haust hose connected between the exhaust elbow and the muffler, as these would trap water and pos sibly allow water to flow back into the engine during starting or at shut down.

4. Adjust the elbow by rotating it until the desired aJign ment with the exhaust piping is acquired.

5. Carefully tighten the clamp between 2 to 3 Ib-ft, or 24 to 35 Ib-in, or 0.27 to 0.41 kg-m.

CAUTION

Approach the :3 II>-It torque limit with caution.

The clamp's threads will break if more than 3 lI> ft is applied to Ihe clamp.

If a leak exists, correct it immediately.

* Manufactured by Permatex Company, Brooklyn, N. Y.

Weslerbeke Generators 24

45° ELBOW

CLRMP

CLAMP

90· ELBOW

EXHAUST RISER

ClAMP

Fuel System

The generator must have its own fuel supply line; in other words, it must have fis own pickup tubes and primary filter/water separator. DO NOT tee off another engine's fuel supply. Installations where the fuel tank(s) are at or above the generator, with the fuel supply lines to the engine's carburetor routed below the level of the fuel tank's top, must have a means of shutting off the fuel to the generator's engine when the en gine is not running. This installation procedure helps guard against the possibility of gasoline siphoning through the supply line into the engine through the carburetor, should the carburetor float needle valve stick in the open position or not seat properly, or should the fuel line rupture between the engine and fuel tank.

This (anti-siphon) shut-off valve can be electrically-operated (with a manual override) to open when the gen erator's engine is started, and to close when the generator's engine is shut down. A manually-operated valve can also be installed and should be operational from the generator's start/stop panel or from the vessel's deck. Installations where the generator is located above the fuel tank(s), whereby the routing of the fuel supply line to the generator's carburetor remains above the top level of the fuel tank, do not require this (anti siphon) shut-off valve. A manually-operated service shut-off valve should be located between the fuel pick up at the tank and the service shut -off valve located at the fuel connection to the generator.

The two illustrations that follow were taken from the Coast Guard publication Fuel System Compliance Guideline. These illustrations show basic fuel system layouts that incorporate anti-siphon protection.

All fuel lines should be routed and supported to prevent leaks from vibration and chaffing. The line should be supported every 12 - 14 inches. Use as few connections as possible in the plumbing of these lines.

The fuel tank's vent should be located so that its discharge route cannot allow water to enter through to the fuel tank(s). Moisture must not be allowed to accumulate in the vent's line.

FUEL LINE ALWAYS ABOVE FUEL TANK TOP LEVEL

FUEL TANK TOP LEVEL

~ - --"..::---~~-~~.:::.-.:--:::::=:~--:-d

NO ANTI-SIPHON DEVICE OR ELECTRICALLY

OPERATED VALVE HEEDED

NOT ACCEPTABLE

FUEL

FUEL TANK TOP LEVEL

.~ AMTI-SIPHON DEVICE OR ELECTRICALLY

~ OPERATED FUEL STOP VALVE

--- --~~~)"""";-:::";-:::::~/~-7::~~~F~U~E~L~TA~N~K~T:o:p ~L~E~V:E~L~:/""~~i~~~~""","'-I fU E L

FUEL LINE BELOW FUEL TANK lOP LEVEL

ANTI-SIPHON DEVICE OR ELECTRICALLY OPERATED FUEL STOP

VALVE AT fUEL TANK WITHDRAWAL FITTING

ANTI-SIPHON DEVICE OR ELECTRICALLY

TANK lOP LEVEL I OPERATED FUEL STOP VALVE

FUEL LIKE ABOVE FUEL TANK

T OP lE~V~EL~;_~=-~~.::::.~=:::~=:~ fUEL LINE BELOW fUEL TANK

TOP LEVEL

ANTI-SIPHON DEVICE OR ELECTRICALLY OPERATED FUEL

STOP VALVE AT POINT WHERE FUEL DISTRIBUTION LINE

GOES BELOW FUEL TANK TOP LEVEL

NOTE: The use of mechanical spring-type check valves instead of a solenoid shut-off valve is not recommended, since these may tax the fuel lift pump's ability to draw fuel through them.

A check valve can trap debris under its seat which inhibits the valve's ability to close. In ad dition, if a check valve's cracking pressure is 100 high, this can contribute to vapor lock.

Should a mechanical type, spring-loaded check valve be used, it should be an adjustable type, such as a Weatherhead #43 x 6. This adjustable type valve should be adjusted to have a cracking pressure that will prevent siphoning when the generator is not operating but not so excessive as to prevent the fuel lift pump from drawing fuel through the valve.

Strongly recommended is the installation of an approved filter/separator in the fuel supply between the fuel tank and the generator's engine to help remove contaminants in the fuel before the fuel reaches the engine mounted fuel lift pump and carburetor.

IWARNING\

Gasoiine ieakage in or around the generator compartment is a potential cause of fire and/or explosion. Repair leaks promptly and make sure the compartment is property ventilated.

Westerbeke Generators 26

Oil Drain Hose

An oil sump drain hose is installed on the engine with the discharge end secured by a bracket at the front 01 the engine. Oil may be drained from this hose by removing the cap and the discharge end of the hose from the support bracket and lowering the hose into a container. The hose cap fitting is 1/4 inch NPT (National Pipe Tap) and can be extended, or have a pump added, for easier removal of the old oil, if desired.

Connecting Pressure Sensing lJevices to Oil Galleries

Oil pressure sensing devices, such as senders and switches, must not be connected to an engine's oil gal lery with the use of extended nipples or tees. The reason is simply that continued engine vibration causes fatigue of the fittings used to make such a connection. If these fittings fail, the engine loses its oil pressure and quickly seizes.

When additional sensing devices such as switches or sensors need to be installed that function on engine oil pressure, these devices must be bulkhead-mounted and connected to the oil gallery using an appropriate grade of lubricating oil hose. Any fittings used to connect the hose to the gallery must be of steel or malle able iron composition. Brass must not be used for this application.

Sea Water Intake System

Make sure the intake system (sea water cooling system) is in proper order. Check that the hull inlet, sea cock and strainer are unobstructed. Sea cocks and strainers should be at least one size greater than the inlet thread of the sea water pump. The strainer should be of the type that may be withdrawn for cleaning while the vessel is at sea and should be mounted below the water line to ensure self-priming. Inspect the sea water lines to make sure there are no collapsed sections, which would restrict water flow. Make sure there are no air leaks at any of the connections.

Cooling System

The generator's engine is fresh water-cooled by an engine mounted heat exchanger. Sea water is used as the heat exchange's cooling medium. Sea water is pumped into the exchanger by a sea water pump and is then injected into the exhaust discharge, carrying with it the heat removed from the engine's fresh water cooling system.

Sea water should be supplied to the sea water pump through a flush-type through-hull fitting using a wire-rein forced hose between the through-hull fitting and the sea water pump. This sea water should be directed through a visual-type sea water strainer and then delivered to the pump. Hoses routed from the through-hull fitting to the strainer and to the sea water pump should be wire-rein forced to prevent the hose from collapsing during the gen erator's operation (suction from the pump may collapse a non-reinforced hose). Sea water strainers should be mounted at or below the water line to make sure the sea water line remains primed.

BElT TENSION

3/8-112 INCH

DEFLECTION AT

LONGEST SPAN

Weslerbeke Generators

CAUTION

DO NOT use a scoop-type through-hull fitting as a means of supplying sea water to the gen erator. Water pressure against this type fitting, while the vessel is under way, can push sea water past the sea water pump's impeller into the generator's exhaust system, filling it and the engine as well. Flush-type, clear, through-hull fittings are recommended and should be lo cated on the hull so as to be below the watertine during all angles of boat operation.

The use of common-type street elbows is not recommended for plumbing the sea water circuit. These generally have very restrictive inside diameters. Machined fittings with true inside diameters are preferred.

Electrical System

The electrical system should be checked to make sure all wiring harnesses are property tied down with clamps or plastic ties and that all wiring harnesses are spaced at intervals close enough to prevent chafing from vibration. Check to make sure all engine harness connections are tight and that they are made to the appropriate terminals.

DC Electrical Connections

A common ground for the negative (-) DC terminal connection is found at the bell housing of the generator, next to the starter, in the form of a threaded grounding stud. The battery ground should be connected at this stud.

Connect the battery's positive (+) connection to the starter solenoid tagged for this connection.

CAUTION

To avoid an overcharging condition, and a possible equipment failure, DO NOT disconnect the DC battery source while the engine is running.

Grounding

The generator set must be grounded to comply with United States Coast Guard regulation 33 CFR-183 which specifies that a common conductor be connected between the generator set and the vessel's main propul sion engine's grounded starter motor circuit. This conductor (the common ground) prevents accidental pas sage of cranking current through fuel systems and smaller electrical conductors common to the engines.

This conductor must be the same size as the largest battery cable.

Automatic Shutdown

High Exhaust Temperature Shutdown Switch (normally closed)

An exhaust temperature switch is located on the exhaust elbow. This switch will open and interrupt the DC voltage to the ignition coil (which turns OFF the engine), should the switch's sensor indicate an excessive exhaust temperature (an inadequate supply of sea water coolant causes high exhaust temperatures). This switch opens at 260 - 2700 F (127 -1320 C) and resets at approximately 2250 F (1070 C).

Westerbeke Generators 28

High Water Temperature Shutdown Switch (normally closed)

A high water temperature switch is located on the thermostat housing. This switch will open and interrupt 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 (107' C).

Low Oil Pressure Shutdown Switch (normally open)

A low oil pressure shutdown switch is located off the engine's oil gallery. The switch's is kept closed bye engine oil pressure. Should the engine's oil pressure fall to 10 - 15 psi, the switch will open interrupting the DC voltage to the ignition coil (which turns OFF the engine).

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 this switch by momentarily depressing the STOP switch. (Make sure the cause of the engine overspeed shutdown is corrected.)

Generator (AC Outpul)

Make sure that the AC output connections within the generator's distribution box are tight and in accord ance with the specific AC Load Connections diagram found later in this manual. (See the "BC GENERATOR" section of this manual, page 57.)

Batteries

Make sure the positive ( + ) battery connection is connected to the battery connection of the starting solenoid.

The negative (-) battery connection should be connected to the system ground (the engine block).

IWARNINGI

Do not smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a highly-explosive gas.

IWARNINGI

When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Battery acid may splash on the skin or into the eyes inadvertent ly when removing the electrolyte caps.

Check the battery's electrolyte level and specific gravity to ensure maximum engine starting efficiency. Make sure the battery's terminals are clean and tight.

29 Westerbeke Generators

Ventilation

The ventilation requirements of the generator sets include the following: combustion air is required for the engine cylinders; cooling air is required for the generator end and also lor removing the heat produced by the generator's engine during operation; and ventilating air is required to clear the bilges below the gener ator, as well as the compartment in which the generator is located, of potentially toxic and flammable gasoline vapors.

Keep in mind that hot air rises, so heated air should be removed from the upper area of the generator com partment and cool fresh air should be directed to the lower areas of the compartment. Ventilation should be accomplished with the aid of blowers especially when the vessel is not underway. Refer to the "SYSTEM SPECIFICATIONS" section 01 this manual for the airflow requirements of the generator sets, page 13 for the BCG 4.0KW, and page 17 for the BCG 6.5KW.

Westerbeke Generators 30

DESCRIPTION OF ENGINE CONTROL PANEL

General

The engine-mounted control panel is equipped with an ON switch, a START switch, and a STOP switch. The panel also has three fuses to protect the circuit. The three switches serve the following functions:

1. ON Switch· The ON switch provides power to the START circuit. This switch also bypasses the protec tive oil pressure shu1down switch until the engine's oil pressure reaches 15 psi.

2. START· The START switch energizes the starter's solenoid which cranks the engine. This switch will not operate unless the ON switch is depressed and held at the same time.

3. SIQE: The STOP switch is used to stop the generator. This switch must be depressed until the gen erator comes to a complete stop.

The engine-mounted control panel is protected by three fuses. The F1 ignition circuit and the F3 panel cir cuit are protected by individual 8 Amp fuses. The F2 starter circuit is protected by a single 15 Amp fuse.

31 Westerbeke Generators

Optionsl Remote instrumenlllnd Remote Start Panels

An optional remole instrument panel is available, which includes starting controls. This panel also includes a water temperature gauge, oil pressure gauge, battery voltmeter, operating hourmeter and start-stop con trol switches.

REMOTE START PANEL REMOTE INSTRUMENT PANEL

IWARNINGI

When installing the optional remote start panel or the optional remote instrument panel, IT is the installer's responsibility to comply with U.S. Coast Guard Standards 33 CFR PART 183.

An optional remote start panel is available for controlling the generator from a remote location.

Remote start panels include a green LED which lights when the engine runs at approximately 600 rpm. The purpose of the LED is to alert the operator to release the starter toggle switch in addition to continue indicat ing that the generator set is running.

Westerbeke Generators 32

PREPARATIONS FOR STARTING

This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and stopping procedures. Follow the procedures as presented, for the conditions indicated, and your Westerbeke generator set will give you reliable performance and long service life.

Take the steps described below in starting your engine for the first time or after a prolonged shutdown or lay-up.

Fill your engine with oil up to but not over the upper limit on the dipstick (the installation angle of your generator set may have an effect on the dipstick reading).