Westerbeke 4,5BCGTC Instruction Manual PDF

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed

and may void warranty.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION PREVENT BURNS - FIRE

Read this SIlfety manual carefully. Most acciJJenls are caused
by failure Ia follow fundilmenlal rules and precautions.
Know when dangerous conditions exist and lake the A WARNING: Fire can cause injury or death!
necessary precautions to protect yourself, your personnel,
and your machinery. • Prevent flash fires. Do not smoke or pennit flames or
Th e following SIlfety instructions are in compliance wilh sparks to occur near the carburetor. fuel line, filter, fuel
the American Boat and Yachl Council (ABYC) slandilrds. pump, or o. her po.en.ial sources of spilled fuel or fuel
vapors. Use a sui.able container.o ca.ch all fuel when
PREVENT ELECTRIC SHOCK removing the fuel line; carburetor, or fuel filters.
• Do no' opera.e wi.h a Coas. Guard Approved name
arrester removed. Backfire can cause severe injury or
A WARNING: Do not touch AC electrical connections dea.h.
while engine is ronning, or when connected to shore • Do not operate with the air cleaner/silencer removed.
power. Lethal voltage is present at these connections! Backfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks to OCCur ncar the
• Do no. opera.e .his machinery wi.hou. elec.rical fuel sys.em. Keep .he compartment and the engine/gener·
enclosures and covers in place. ator clean and free of debris to minimize the chances of
• Shu. off electrical power before accessing elec.rical fire. Wipe up all spilled fuel and engine oil.
equipment • Be aware - diesel fuel will burn.
• Use insulated mats whenever working on electrical
equipment. PREVENT BURNS - EXPLOSION
• Make sure your clo.hing and skin are dry, not damp
(part icularly shoes) when handling electrical equipment
• Remove wris.wa.ch and all jewelry when working on
A WARNING: Explosions from fuel vapors can cause
injury or death!
electrical equipment.
• Do no' connect utili.y shore power to vessel's AC
circuits, except .hrough a ship-.o·shore double .hrow • Follow re·fueling safe.y instructions. Keep .he vessel's
transfer switch. Damage to vessel 's AC generator may ha.ches closed when fueling. Open and ven.ilate cabin
resull if .his procedure is no. followed. af.er fueling. Check below for fumes/vapor before running
.he blower. Run .he blower for four minu.es before s'art·
• Electrical shock resullS from handling a charged capaci.or. ing your engine.
Discharge capacitor by shorting .erminals .ogether.
• All fuel vapors are highly explosive. Usc extreme care when
PREVENT BURNS - HOT ENGINE handling and s.oring fuels. S.ore fuel in a well-ven.ila.ed
area away from spark·producing equipment and au. of the
reach of children.
A WARNING: Do not touch hot engine parts or • Do no' fililhe fuell3nk(s) while .he engine is running.
exhaust system components. A ronning engine gets
• Shut off the fuel service valve at the engine when servicing
very hot! .he fuel sys.em. Take care in ca.ching any fuel .hat might
spill. DO NOT allow any smoking, open names, or ot her
• Always check .he engine coolan. level a•• he coolan. sources of fire near the fuel system or engine when servicing.
recovery tank. Ensure proper ventilation exists when servicing the fuel
sys.em.
A WARNING: Steam can cause injury or death! • Do no. al.er or modify the fuel system.
• Be sure all fuel supplies have a positive shu.off valve.
• In case of an engi ne overheat, allow .he engine.o cool • Be certain fuel line fittings are adequa.ely .igh.ened and
before touching the engine or checking .he coolant free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar wi.h its proper use.
ExtinguiShers rated ABC by the NFPA are appropria.e
for all applications encountered in this environment.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING TOXIC EXHAUST GASES
A WARNING: Accidental starting can cause injury A WARNING: Carbon monoxide (CO) is a deadly gas!
Dr death!
• Ensure that the exhaust system is adequate to expel gases
• Disconnect the battery cables before servicing the enginel discharged from the engine. Check the exhaust system
generator. Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust manifolds
it last. are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
• Make certain all personnel are clear of the engine before
exhaust pipe nipple.
starting.
• Be sure the unit and its surroundings are well ventilated.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine. • In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
BATTERY EXPLOSION builder or dealer for installation of approved detectors.
• For addi tional information refer to ABYC T-22 (educa-
A WARNING: Battery explosion can cause injury tional informatio n on Carbon Monoxide).
Dr death!
A WARNING: Carbon monoxide (CO) is an invisible
• Do not smoke or allow an open flame near the battery odorless gas. Inhalation produces flu-like symptoms,
being serviced. Lead acid batteries emit hydrogen, a nausea Dr death!
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco prod ucts. Shut off all electrical • Do not use copper tubing in diesel exhaust systems. Diesel
equipment in the vicinity to prevent electrical arcing during fumes can rapidly destroy copper tubing in exhaust sys-
servicing. tems. Exhaust sulfur causes rapid deterioration of copper
• Never connect the negative (-) battery cable to the posi- tubing resulti ng in exhausl/water leakage.
tive (+) connection terminal of the starter solenoid. Do not • Do not install exhaust outlet where exhaust can be drawn
test the battery condition by shorting the terminals through ponholes, vents, or air conditioners. If the engine
together. Sparks could ignite battery gases or fuel vapors. exhaust discharge outlet is near the waterline, water could
Ventilate any compartment containing baueries to prevent enler the exhaust discharge outlet and close or restrict the
accu mulation of explosive gases. To avoid sparks, do not Oow of exhaust. Avoid overloading the craft.
disturb the battery charger connections while the battery is
being charged. • Although diesel engine exhaust gases are not as toxic as
exhaust fu mes from gasoline engines, carbon monoxide
• Avoid contacting the leoninals with tools, etc" to prevent gas is present in diesel exhaust fumes. Some of the symp·
bums or sparks that could cause an explosion. Remove toms or signs of carbon monoxide inhalation or p:>isoning
wristwatch, rings, and any other jewelry before handling are:
the battery.
Vomiting
• Always tum the battery charger off before disconnecting
the bat1ery connections. Remove the negative lead first Dizziness
and reconnect it last when servicing the battery. Throbbing in temples
Muscular twitching
BATTERY ACID
Intense headache
A WARNING: Sulphuric acid in batteries can cause Weakness and sleepiness
severe injury Dr death! AVOID MOVING PARTS

• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec- A WARNING: Rotating parts can cause injury
tion. Batteries contain sulfuric acid which is destructive. If or death!
it comes Tn contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes • Do not service the engine/generator while it is running. If a
inadvertently when removing electrolyte caps. situation arises in which it is absolutely necessary to make
~ WESTERBEKE
ii
SAFETY INSTRUCnONS
operating adjustments, use extreme care to avoid touching ABYC, NFPA AND USCG PUBLICATIONS FOR
moving parts and hot exhaust system components.
INSTAWNG GASOLINE AND DIESEL ENGINES AND
• Do not wear loose clothing or jewelry when servicing
equipment; avoid wearing loose jackets, shirts, sleeves,
GENERATORS
rings, necklaces or bracelets that could be caught in Read the following ABYC, NFPA and USCG publications
moving parts. for safety codes and standards. Follow their recommenda-
tions when installing your WESTERBEKE engine/generator.
• Make sure all allaching hardware is properly tightened.
Keep protective shields and guards in their respective ABYC (American Boat and Yacht Council)
places at all times. "Safety Standards for Small Craft"
• Do not check fluid levels or the drive belts' tension while Order From:
the engine/generator is operating. ABYC
15 East 26th ~treet
• Stay clear of the drive shaft and the transmission coupling
New York, NY 10010
when the engine is running; hair and clothing can easily
be caught in these rotating parIS. NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
HAZARDOUS NOISE Order From:
NFPA
A WARNING: High noise levels can cause healing 1 Ballerymarch Park
P.O. Box 9101
loss! Quincy, MA 02269-9101
• its muffler installed.
Never operate a generator without USCG (United States Coast Guard)
"USCG 33CFR183"
• Do not run an engine with the air intake (silencer)
removed. Order From:
U.S. Government Printing Office
• Do not run engines or generator.; for long periods with Washington, D.C. 20404
their enclosures open.
A WARNING: Do not work on machinery when you

ale mentally 01 physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
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
a combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
H-24 Gasoline fuel systems
P-l Exhaust systems
P4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).

iii
INSTALLATION
When installing WESTERBEKE engines and generators it is imponant that strict
attention be paid to the following infonnation:
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 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
of 18" above the vessel 's waterline. Failure to use a siphon-break when tlte exhaust
numifold injection port is aJ or below th e load waterline will resulJ in raw waLer
danwge to the engine and possibu flooding of the boat.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and

diesel, engines and generators, is available from your WESTERBEKE
dealer.
~ WESTERBEKE
iv
Declaration of Conformity
Application of Council Directive(s) EMC 89/336IEEC

ISO 8846 1990(E)
Standard(s) to Which Conformity EN50081-1

is declared EN50082-2
EN55020
ISO-8846-1990(E), Certification
Number, IWES003
Manufacturers Name Westerbeke Corporation
Manufacturers Address 41 Ledin Drive

Avon Industrial Park
Avon, Ma. 02322, USA
Type of Equipment Marine Gasoline Generator
Product Name Westerbeke Marine

Gasoline Generator
Model(s) 3.7/4.5BCGTE,6.017.2BCGTE
8.0/9.6BCGTE,3.7/4.5BCGTC,
6.017.2BCGTC & 8.0/9.6BTGTC
Product Options All
Supplementary Information
1.) The equipment listed is only for use in Marine Applications aboard boats.
2.) The equipment listed must be located below decks on the vessel and
permanently installed in it's location.
3.) The equipment listed must be wired to the grounding system of the vessel.
I the undersigned, hereby declare that the equipment specified above conforms to
the above Directive(s) and Standard(s).
Place Avon. Massachusetts, U.S.A.
Date: September 1, 1996 Carleton F. Bryant

(Full Name)
Chief Operating Officer

(Title)
WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON, MA 02322 U.S.A .•TEL.(508) 588-7700 .FAX: (508) 559-9323_ WEBSITE:WWWWESTEABEKE.COM
INTERNATIONAL MARINE CERTIFICATION INSTITUTE
Treves Centre, Rue de Treves 45
B-1040 8RUXELLES
BELGIQUE
tel: +32 (0) 2-238-7892
fax: +32 (0) 2-238-7700
eEl? TIFICA TE
We hereby certify the component stated below meets the EC Directive 94J25/EC for
type-examination in accordance with ISO 8846 and has following characteristics:
ITYPE I Gasoline Marine Generator I

MANUFACTURER Westerbeke Corp.
ADDRESS Avon Industrial Park,
Avon, MA 02333
USA
IGROUP OF +++++ I +++++ I +++++ I

I
Model 1 3.7/4.5 BCGTE +++++ +++++
Model 2 6.017.2 BCGTE +++++ +++++
Model 3 80/96 BCGTE +++++ +++++
Model 4 3.7/4.5 BCGTC +++++ +++++
Model 5 60/7.2 BCGTC +++++ +++++
Model 6 80/9.6 BCGTC +++++ +++++
Model 7 +++++ +++++ +++++
Model 8 +++++ +++++ +++++
Model 9 +++++ +++++ +++++
Model 1 0 +++++ +++++ +++++
Model 11 +++++ +++++ +++++
Model 12 +++++ +++++ +++++
Model 13 +++++ +++++ +++++
Model 14 +++++ +++++ +++++
Model 15 +++++ +++++ +++++
Model 16 +++++ +++++ +++++
Model 17 +++++ +++++ +++++
Model 18 +++++ +++++ +++++
Model 19 +++++ +++++ +++++
Model 20 +++++ +++++ +++++
Model 21 +++++ +++++ +++++
Model 22 +++++ +++++ +++++
Model 23 +++++ +++++ +++++
Certification number IWES003 /
Signed .~./h i _.\-:::// r <'-£.- -,

Name Lars E. Grflnholm
Title Managing Director
EU Notified Body No 0609
Date 02/0211998
TABLE OF CONTENTS
Introduction .......................................................................2 Engine Lubricating 0i1 ................................................... 16
Warranty Procedures ....................................................2 Description ................................................................. 16
Customer Identification Card ....................................... 2 Changing the Engine Oil... ......................................... 16
Product Software ......................................................... .2 Replacing the Oil Filter. ............................................. 16
Serial Number Location ............................................... 2 Refilling the Oil Sump ............................................... 16
Ordering Parts ............................................................. .3 Remote Oil Filter (Optionalj .......................................... 17
Notes, Cautions and Warnings ..................................... 3 Installation .................................................................. 17
Protecting Your Investment ......................................... .3
DC Electrical System .....................................................18
Spares and Accessories ............................................... .3 12-Volt DC Control Circuit. ...................................... .18
Control Panels ..................................................................4 Batteries ...................................................................... 18
Generator Panel ............................................................ 4 Specifications ...................................................... 18
Remote Panel .............................................................. .4 Battery Maintenance ........................................... 18
Overspeed Circuit Board ............................................. .4 Battery Charging ........................................................ 18
Safety Shutdown Switches .............................................5 Component Testing .................................................... 18
Safety Shutdown Switches .......................................... .5 Wiring Diagram #42834 ............................................. 19
High Exhaust Temperature Switch ...................... .5 Wiring Schematic #42834 ......................................... .20
High Water Temperature Switch .......................... .5 Wiring Diagram #42857 Remote Panel(s) ................ .21
Low Oil Pressure Switch ..................................... .5 Engine Adjustments .......................................................22
Engine Circuit Breaker ........................................ .5 Engine Speed (Hertz) Adjustment... ........................... 22
Fuel, Engine Oil and Engine Coolant ............................6 Governor ............................................................. 22
Gasoline ........................................................................ 6 Governor Adjustments ........................................ 22
Care of the Fuel Supply ............................................... 6 Governor Maintenance ....................................... .22
Engine Oil .................................................................... 6 Torquing the Cylinder Head Bolts ............................. 22
Engine Coolant ............................................................. 6 Valve Clearance Adjustment ...................................... 22
Coolant Recovery Tank ................................................ 6 Choke Solenoid .......................................................... 23
Preparations for Initial Start-Up ................................... 7 Ignition Timing .......................................................... .23
Prestart Inspection ...................................................... _, 7 Spark Plugs ................................................................. 23
Operating Instructions .....................................................8 Carburetor Adjustment .............................................. .24
Generator Panel ............................................................ 8 Drive Belts Adjustment ............................................. .24
Starting the Generator ........................................... 8 Timing Belt Inspection and Replacement ................. .25
Stopping the Generator ......................................... 8 Engine Troubleshooting .................................................29
Remote Panel ............................................................... 8 Generator Information ...................................................31
Starting the Generator ........................................... 8 Use of Electric Motors .............................................. .31
Stopping the Generator ......................................... 8 Required Operating Speed ........................................ .31
Emergency .stopping .................................................... 8 Generator Frequency Adjustment .............................. 31
Starting Under Cold Conditions ................................... 8 Generator Maintenance .............................................. 31
Abnormal Stop .............................................................8 Generator Wiring Diagrams ..........................................32
Break-In Procedure/Daily Operation .............................9 AC Electrical Connections ...........................................33
Break-In Procedure ...................................................... 9 Lay-Up & Recommissioning ..........................................34
Check List .................................................................... 9 General ....................................................................... 34
Stopping the Generator ................................................ 9 Fresh Water Cooling System ......................................34
Generator Adjustments ................................................. 9 Lubrication System ................................................... .34
Maintenance Schedule ..................................................10 Fuel System ............................................................... .34
Engine Cooling Circuit.. .................................................12 Raw Water Circuit ...................................................... 34
Description ................................................................. 12 Intake Manifold ......................................................... .35
Thermostat .................................................................. 13 Starter Motor ............................................................. .35
Thermostat Test .......................................................... 13 Cylinder Lubrication ................................................ .35
Draining the Coolant .................................................. 13 Spare Parts ................................................................. .35
Refilling the Coolant .................................................. 13 Batteries ..................................................................... .35
Raw Water Pump ........................................................ 14 Recommissioning ....................................................... 35
Changing the Raw Water Pump Impeller .................. 14 BCGTC Generator Specifications ................................36
Heat Exchanger .......................................................... 14 BCGTC Generator Parts Identification ...................... .37
Drive Belt Adjustment .............................................. .14
Standard Hardware Torques .........................................38
Fuel System .....................................................................15
Gasoline ..................................................................... .15 BCGTC Generator Hardware Torques ......................... .39
Carburetor .................................................................. .15 Metric Conversions ........................................................40
Gasoline/Water Separator and Filter .......................... 15 Suggested Spare Parts ..................................................41
Fuel Pump .................................................................. 15
Gasdenser ................................................................... 15
1
INTRODUCTION
This WESTERBEKE Generator is a product of WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT
WESTERBEKE'S long years of experience and advanced OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRE·
technology. We take great pride in the superior durability and
SENTATIONS WITH RESPECT THERETO, INCLUDING ACCU·
dependable perfonnance of our engines and generators.
Thank you for selecting WESTERBEKE. RACY, TIMELINESS OR COMPLETENESS THEREOF AND Will
IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGE OR
In order to get the full use and benefit from your generator,
it is important that you operate and maintain it correctly. This INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF
manual is designed to help you do this. Please read this THE FURNISHING OR USE OF SUCH SOFTWARE.
manual carefully and observe all the safety precautions WESTERBEKE customers should also keep in mind the time
throughout. Should your engine require servicing, contact span between printings of WESTERBEKE product software
your nearest WESTERBEKE dealer for assistance. and the unavoidable existence of earlier WESTERBEKE
This is your Operators Manual. A Parts Catalog is also manuals. In summation, product software provided with
provided and a Technical Manual is available from your WESTERBEKE products, whether from WESTERBEKE or
WESTERBEKE dealer. Also, if you are planning to install other suppliers, must not and cannot be relied upon exclu-
this equipment yourself, contact your WESTERBEKE dealer sively as the definitive authority on the respective product. It
for WESTERBEKE'S Installation Manual. not only makes good sense but is imperative that appropriate
representatives of WESTERBEKE or the supplier in question
WARRANTY PROCEDURES be consulted to determine the accuracy and currentness of the
Your WESTERBEKE Warranty is included in a separate product software being consulted by the customer.
folder. If you have not received a customer identification
SERIAL NUMBER LOCATION
card registering your warranty 60 days after submitting the
warranty registration form, please contact the factory in The generator serial number and model number is located on
writing with model information, including the unit's serial a decal on the the generator housing. Take the time to enter
number and commission date. the information on the blank decal provided. This will pro-
vide a quick reference when seeking technical information
and/or ordering parts.
I~l WESTERBEKE
1 Marine Engine Pl'Oducts
Customer Identification
WESTERBEKE OWNER
MAIN STREET
HOMETOWN, USA
Model BCGTC Ser. #D703XXXX
Expires 9/20/02
CUSTOMER IDENTIFICATION CARD (Typical)

The WESTERBEKE serial number is an alphanumeric
number that can assist in determining the date of
manufacture of your WESTERBEKE engine/generator. The
first character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s), the second character represents the year
in the decade, and the fourth and fifth number represents the
month of manufacture.
PRODUCT SOFTWARE
Product software (tech data, parts lists, manuals, brochures
and catalogs) provided from sourccs other than WESTER-
BEKE are not within WESTERBEKE'S CONTROL.
2
INTRODUCTION
The engine model number and serial number are located on a PROTECTING YOUR INVESTMENT
plate mounted on the engine's valve cover.
Care at the factory during assembly and thorough testing
have resulted in a WESTERBEKE generator capable of
many thousands of hours of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
ORDERING PARTS NOTE: Six important steps to ensure long generator life:
Whenever replacement parts are needed, always provide the • Proper engine and generator installation and alignment.
generator and engine model and serial numbers. In addition,
• An efficient well-designed exhaust system that includes
include a complete part description and part number for each
an anti~siphon break to prevent water from entering the
part needed (see the separately furnished Parts Catalog). Also
engine.
insist upon WESTERBEKE packaged parts because will fit
or generic parts are frequently not made to the same specifi- • Changing the engine oil and oil fdters every ZOO operat.
cations as original equipment. ing hours.
• Proper maintenance of all engine and generator compo-
NOTES, CAUTIONS AND WARNINGS nents according to the maintenance schedule in this
As this manual takes you through the operating procedures, manual.
maintenance schedules, and troubleshooting of your genera-
tor, critical information will be highlighted by NOTES, • Use clean, filtered unleaded fuel.
CAUTIONS, and WARNINGS. An explanation follows: • Winterize your engine according to the "Lay-up and
Recommissioning" section in this mnnual.
NOTE: An operating procedure essential to note.
SPARES AND ACCESSORIES
A CAUTION: Procedures, which if not strictly Certain spare parts will be needed to support and maintain
your WESTERBEKE generator or engine when cruising (see
observed, can result in the damage or destruction of
SUGGESTED SPARE PARTS). Often even simple items such
the engine or generator. as proper fuel and oil filter can be difficult to obtain along
the way. WESTERBEKE will provide you with a suggested
spares and accessories brochure to assist you in preparing an
A WARNING: Procedures, which if not properly on-board inventory of the proper WESTERBEKE parts.
followed, can result in personal injury or loss of life.
3
CONTROL PANELS
GENERATOR PANEL REMOTE PANEL
The ON and START/OFF switches are the only functional There are three functional components on the remote panel
components to operate the generator at the engine. Both for generator operation:
switches are used to start the generator - see Starting the LON switch
Generator under OPERATING INSTRUCTIONS.
2. START/STOP switch
The ON switch is a two-position switch with momentary
3. Green LED indicator light
contacts in the up (on) position and a stationary contact
function in the center position. This switch energizes the The ON switch is a two-position switch with momentary
fuel pump. contact functions in the up (Oil) position and a stationary con-
tact function in the center position. This switch energizes the
The START/OFF switch is a three-position switch with fuel pump.
momentary contact functions in the up (start) and down
The START/STOP switch is a three-position switch with
(off) positions, and a stationary contact function in the
momentary contact functions in the up (start) and down
center position. When in the center (normal) position, this
(stop) positions, and a stationary contact function in the cen-
switch allows the generator to be run, once started. When
ter position. The center position is a dual offJrun mode posi-
in the up (start) position (together with the ON switch in
tion and is normally in the off mode. When in the start (up)
the up position), this switch starts the generator, and once
released, reverts to the center position. When in, the down position, this switch starts the generator (together with the
ON switchin the up position) and once released, reverts to
(off) position, this switch stops the engine in nonnal oper-
the center position, run mode. When in the stop (down) posi-
ation as well as in an emergency situation.
tion, this switch stops the generator, and once released,
When maintenance is being performed on the generator, reverts to the center position, off mode.
the 8 amp fuse should be removed. This will disable the The Green LED indicator light indicates the engine running
remote control panel(s), preventing attempts to start the condition. It lights when the ON switch is moved to the start
generator from their locations. However, it is always best position, dims when the engine is cranking, and brightens
to disconnect the battery during this time jf it is not when the engine starts, notifying the operator to release the
required to perfonn the maintenance. START switch.
, 8 AMP FUSE: THE 8 AMP

FUSE ENERGIZES THE
. DC CIRCUIT
START/STOP
TOGGLE SWITCH
ON
REMOTE TOGGLE
PANEL SWITCH
HOURMffiR: THE HOURMETER
RECORDS ELAPSED TIME OF ENGINE
USAGE. THE TOTAL NUMBER OF
HOURS SHOULD BE USED AS A GUIDE
FOR MAINTENANCE SCHEDULING.
OVERSPEED CIRCUIT BOARD
20 AMP CIRCUIT BREAKER:
The overspeed circuit board senses the engine speed through
START/OFF
THE 20 AMP RESET CIRCUIT BREAKER pulses off the engine coil. If the engine speed exceeds 3800
PROTECTS THE ENGINE'S ELECTRICAL rpm, this overspeed circuit will activate, and will interrupt DC
TOGGLE SWITCH
SYSTEM FROM ELECTRICAL OVERLOADS.
power to the K2 relay shutting the engine down. It has an
~-I+ ___ ON automatic reset.
TOGGLE SWITCH
CIRCUIT BREAKER: THE HEAVY

DUTY ON/OFF CIRCUIT BREAKER SHUTS
DOWN THE GENERATOR'S AC POWER.
NOTE: THIS CIRCUIT BREAKER SHOULD
BE IN THE OFF POSITION WHEN
PERFORMING MAINTENANCE.
GENERATOR OVERSPEED
a
PANEl ~ WESTERBEKE CIRCUIT BOARD
4
SAFETY SHUTDOWN SWITCHES
SAFETY SHUTDOWN SWITCHES Low Oil Pressure Switch

The engine is protected by three automatic shutdown A low oil pressure shutdown switch is located off the
switches. Should a shutdown occur, do not attempt to restart engine's oil gallery. Normally open in a static state, this
without finding and correcting the cause. Refer to the head- switch's sensor monitors the engine's oil pressure. Should the
ing Engine starts, runs and then shuts down in the ENGINE engine's oil pressure fall to 5-10 psi, this switch will open
TROUBLESHOOTING section of this manual. interrupting the DC voltage to the K2-run relay thereby shut-
ting off the engine.
The following is a description of these automatic shutdown
switches:
High Exhaust Temperature Switch

An exhaust temperature switch is located on the exhaust
elbow. Nonnally closed, this switch will open and interrupt
LOW OIL
the DC voltage to the K2-run relay (shutting off the engine) PRESSURE SWITCH
should the switch's sensor indicate an excessive exhaust tem-
perature (an inadequate supply of raw water causes high
exhaust temperatures). This switch opens at 260-270°F (127-
132°C). This switch resets at approximately 225°F (107°C).
HIGH
EXHAUST
TEMPERATURE
I
ELBOW
Engine Circuit Breaker
The generator's engine is protected by an engine mounted
manual reset circuit breaker (20 amps DC). Excessive current
draw or electrical 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
High Water Temperature Switch should occur, check and repair the source of the problem.
After repairing the fault, reset the breaker and restart the gen-
A high water temperature switch is located at the thermostat
erator.
housing. Nonnally closed, this switch, should the fresh water
coolant's operating temperature reach approximately 210°F
(99°C), will open and interrupt the DC voltage to the K2-run
relay thereby shutting off the engine. This switch resets at
195°F (107°C).
THERMOSTAT
HDUS!NG-_ _ _ .1
HIGH WATER
TEMPERATURE
SWITCH
5
FUEL, ENGINE OIL AND ENGINE COOLANT
GASOLINE ENGINE COOLANT
Westerbeke recommends a mixture of 50% antifreeze and
50% distilled water, when possible. Distilled water is free
A CAUTION: Only use unleaded fuel with an octane from the chemicals that can corrode internal engine surt'aces.
rating of 89 or higher. Leaded fuel will cause serious The antifreeze petfonns double duty, as it allows the engine
hann to your engine and violate your warranty. to run at proper temperatures by transferring heat away from
the engine to the coolant. It also lubricates and protects the
cooling circuit from rust and corrosion. Use a good quality
CARE OF THE FUEL SUPPLY antifreeze that contains supplemental cooling additives
Use only clean fuel! The clearance of the components in (SeAs) that keep the antifreeze chemically balanced, crucial
your carburetor is very critical; invisible dirt particles which to long term protection.
might pass through the filter can damage these finely finished The water and antifreeze should be pre-mixed before being
parts. It is important to buy clean fuel, and keep it clean. The poured into the cooling circuit.
best fuel can be rendered unsatisfactory by careless handling
or improper storage facilities. To assure that the fuel going NOTE: Use the new environmentally-friendly long lasting
into the tank for your engine's daily use is clean and pure, the antifreeze that is now available.
following practice is advisable: ANTIFREEZE PROTECTION CHART
Purchase a well-known brand of fuel. Antifreeze concentration 23% 30% 35% 50%
Install and regularly service a good, Coast Guard approved Freezing Temperature WF 8° F _4° F -40° F
metal bowl type filter/water separator between the fuel tank (-10°C) (-13°C) (-20°C) (-40°C)
and the engine.
ENGINE OIL COOLANT RECOVERY TANK

Use a heavy duty engine oil with an API classification of S1. A coolant recovery tank kit is supplied with each generator.
Change the engine oil after an initial 50 hours of break-in The purpose of this recovery tank is to allow for engine
operation, and every 100 hours of operation thereafter. For coolant expansion and contraction, during engine operation,
recommended oil viscosity, see the foHowing chart: without the loss of coolant and without introducing air into
the cooling system.
Operating Temperature Oil Viscosity
Above 68° F (20° C) SAE 30, 10W-30 or 15W-40
41° - 68° F (5°-20° C) SAE 20 or 10W-30
Below 41° F (5° C) SAE 10W-30
A CAUTION: 00 not allow two or more brands of

engine oil to mix. Each brand contains its own addi-
tives; additives of different brands could react in the
mixture to produce properties harmful to your engine.
COOLANT RECOVERY TANK
-..v WESTERBEKE
6
PREPARATIONS FOR INITIAL START-UP
OIL FILL
PRESTART INSPECTION
Before starting your generator for the first time or after a pro-
longed layoff, check the following items:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: After the initial running of the generator, the air in
the engine's cooling system will be purged to the coolant
recovery tank After shutdown and after the engine has COOLANT
cooled, the coolant from the recovery tank will be drawn
into the engine's cooling system to replace the purged air.
PRESSURE
CAP ----1~~~~
Before subsequent operation a/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 examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check load leads for correct connections as specified in
the wiring diagrams.
LOW
• Examine the air inlet and outlet for air flow obstructions.
• Be sure no other generator or utility power is connected to
the load lines.
COOLANT
• Be sure that in power systems with a neutral line that the RECOVERY
neutral is properly grounded (or ungrounded) as the system TANK
requires, and that generator neutral is properly connected
to the load neutral. In single phase systems an incomplete
or open neutral can supply the wrong line-to-neutral volt-
age on unbalanced loads.
A CAUTION: When starting the generator, it is

recommended that all AC loads, especially large
mOtolS, be switched OFF until the engine has come up
to speed and, in cold climates, starts to warm up. This
precaution will prevent damage caused by unantici-
pated operation of the AC machinery and will prevent a
cold engine from stalling_
7
OPERATING INSTRUCTIONS
GENERATOR PANEL
Starling the Generator
To start the generator, hold the momentary ON switch in the
A CAUTION: Prolonged cranking intervals without
the engine starting can result in filling the engine
up (on) position, then hold the momentary START/OFF
switch in the up (start) position (both switches are held up
exhaust system with raw water. This may happen
together). After approximately one second the starter will because the pump is pumping raw water through the
engage and the engine will crank. Once the engine is run- raw water cooling system during cranking. This raw
ning, the starter will disengage, and the START/OFF switch water can enter the engine's cylinders by way of the
may then be released to return to its center (run mode) posi- exhaust manifold once the exhaust system fills. Prevent
tion. Continue holding the ON switch until the engine has
this from happening by closing the raw water supply
sufficient oil pressure, then release it to its center position.
NOTE: Should the engine fail to start, release both switches, through-hull shutoff, draining the exhaust muffler, and
wait 20 seconds, and try again. Never run the starter more correcting the cause of the excessive engine cranking.
than 20 seconds at a time. Engine damage resulting from raw water entry is not a
START
warrantable issue; the owner/operator should keep this
ON
.... _? (MOMENTARY) (MOMENTARY) in mind•
</~:./' ----;)
('- .... //
lH':x.",---- CENTER OFF/RUN
C
~~::::::> CENTER OFF/RUN
UHP-.-- POSITION ',," POSITION
<, '
--<:.
~ OFF
(MOMENTARY) EMERGENCY STOPPING
START/OFF SWITCH ON SWITCH If the generator does not stop using the START/OFF switch,
Stopping the Generator remove the 8 amp fuse or disconnect the battery.
To stop the generator, move the momentary START/OFF
switch to the down (off) position then release it to the center
STARTING UNDER COLD CONDITIONS
Make certain the lubricating oil confonns with the ratings for
(normal) position.
the prevailing temperature. Check the table under ENGINE
REMOTE PANEL LUBRiCATING OIL. The battery should be fully charged to
Starling the Generator minimize voltage drop.
To start the generator, hold the momentary ON switch in the
up (on) position (the green light will come on), then hold the ABNORMAL STOP
momentary START/STOP switch in the up (start) position An abnormal stop is one in which the generator ceases to run
(both switches are held up together). After approximately one and comes to a stop as a result of an operating fault which
second the starter will engage and the engine will crank (the may cause damage to the engine, the generator, or create an
green light wi1l dim). Once the engine is running (the green unsafe operating condition. The fault stop conditions are:
light will brighten), the starter will disengage and the
1. Overspeed condition.
START/STOP switch may then be released to return to its
center (run mode) position. Continue holding the ON switch 2. High engine temperature.
until the engine has sufficient oil pressure, then release it to 3. Low oil pressure.
its center position.
4. High exhaust temperature.
NOTE: Should the engine fail to start, release both switches,
wait 20 seconds, and try again. Never run the starter more Should a fault condition occur, the engine will shut down and
than 20 seconds at a time. the green LED light on the remote panel will go off indicat-
ing that a fault has occurred. Once detected, the fault should
START
(MOMENTARY)
ON be located (see ENGINE TROUBLESHOOTING).
/?
-,...-;.//
c , ",---
,...--
//
-?
/~
(MOMENTARY)
k CENTER OFF/RUN CENTER OFF/RUN

,, POSITION 'v'
<, POSITION
, , ,
---~ STOP
(MOMENTARY)
STARTISTOP SWITCH ON SWtTCH

Stopping the Generator
To stop the generator, move the momentary START/STOP
switch to the down (stop) position then release it to the center
(offlrun mode) position. This will activate the remote control
panel for START/STOP functions.
WESTERBEKE
8
BREAK-IN PROCEDURE/DAILY OPERATION
BREAK-IN PROCEDURE NOTE: Some unstable running may occur in a cold engine.
This condition should abate as normal operating temperature
Once the generator has been started, check for proper opera-
is reached and leads are applied.
tion and then encourage a fast warm-up. Run the generator
between 20% to 60% of full load for the first 10 hours.
A CAUTION: 00 not operate the generator for long
A CAUTION: 00 not attempt to break-in your genera- periods of time without a load being placed on the
tor by running without a load. generator.
After the first 10 hours of the generators' operation, the load STOPPING THE GENERATOR
can be increased to the full-load rated output; then periodi- Remove the major AC loads from the generator one at a
cally vary the load. time. Allow the generator to run for a few minutes to stabi-
lize the operating temperature, (then see SlOpping the
Avoid overload at all times. An overload is signaled by a
Generator under OPERATING INSTRUCTIONS).
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep NOTE: After the first 50 hours of generator operation check
it within the generators' rating. Since the generator operates the maintenance schedule for the 50 hour service check.
at 3600 rpm to produce 60 hertz, or at 3000 to produce 50
hertz, control of the generator's engine break-in is governed GENERATOR ADJUSTMENTS
by the current drawn from the generator. Once the generator has been placed in operation, there may
To protect against unintentional overloading of the generator, be governor adjustments required for engine speed (hertz)
the generator's output leads should be routed through a cir- during the engine's break-in period (first 50 hours) or after
cuit breaker that is rated at the rated output of the generator. this period (see ENGINE SPEED (HERTZ) ADJUSTMENT
under ENGINE ADJUSTMENTS. A no-load voltage adjust-
NOTE: Be aware of motor starting loads and the high ment may also be required in conjunction with the engine's
current drawn required for starting motors. This starting speed adjustment (see GENERATOR INFORMATION).
amperage drawn can be 3 to 5 times normal running amper-
age (see GENERATOR INFORMATION).
CHECK LIST
Follow this checklist each day before starting your generator.
• Record the hourrneter reading in your log (engine hours
relate to the maintenance schedule).
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.

• Check the starting batteries (weekly).
• Check the drive belts for wear and proper tension
(weekly).
• Monitor the control panel gauges.

• Check for abnormal noise such as knocking, friction,
vibration and blow-back sounds.
• Confinn exhaust smoke:

When the engine is cold - White Smoke.
When the engine is warm - almost Smokeless.
When the engine is overloaded - some Black Smoke.
WESTERBEKE
9
MAINTENANCE SCHEDULE
A WARNING: Never attempt to perform any service while the engine is

running. Wear the proper safety equipment such as goggles and gloves, and
use the correct tools for each job. Disconnect the battery terminals when
servicing any of the engine's DC electrical equipment.
NOTE: Many a/the following maintenance procedures are simple but others are
more difficult and may require the expert knowledge of a service mechanic.
CHECK HOURS OF OPERATION

SCHEDULED EACH EXPLANATION OF SCHEDULED
MAINTENANCE DAY 50 100 250 500 750 1000 1250 MAINTENANCE
Fuel Supply 0 Unleaded gasoline with octane rating of 89 or
higher.
Fuel/Water Separator 0 Check for water and dirt in fuel (drain/replace filter
if necessary).
Engine Oil Level 0 Oil level should indicate between FULL and LOW on
dipstick.
Coolant Level 0 Check at recovery tank; if empty, check at manifold.
Add coolant if needed.
Drive Belts 0 Inspect for proper tension (3/8' to 1/2" deflection)
Weekly and adjust if needed. Check belt edges for wear.
Visual Inspection of Engine 0 NOTE: Keep engine suiface clean. Dirt arul Check for fuel, oil and water leaks. Inspect wiring
oil will inhibit the engine:s ability to remain and electrical connections. Keep bolts & nuts tight.
coo!. Check for loose belt tension.
Spark Plugs 0 0 0 0 0 0 Check gap; inspect for burning and corrosion.
Generator 0 0 0 0 0 0 0 Check that AC connections are clean and secure
with no chafing - see GENERATOR INFORMATION
for additional information.
Carburetor Filler Screen 0 0 0 0 0 0 Initial change at 50 hrs, then change every 250 hrs.
Starting Batteries 0 0 Every 50 operating hours check electrolyte levels
(and House Batteries) Weekly and make sure connections are very tight. Clean off
excessive corrosion.
Engine Oil 0 0 0 0 0 O· 0 Initial engine oil & filter change at 50 hrs .• then
change both every 100 hours.
'Adiustthe Valve 0 0 0 Initial adjustment at 50 hrs .• then every 500 hrs.
Clearances
Air Screen (Flame Arrester) 0 Clean at 50 hours, then every 100 hours.
Exhaust System 0 0 0 0 Initial check at 50 hrs., then every 250 hrs. Inspect
for leaks. Check siphon break operation. Check the
exhaust elbow for carbon and/or corrosion buildup
on inside passages; clean and replace as necessary.
Check that all connections are tight.
Engine Hoses 0 0 0 D D D Hose should be hard & tight. Replace if so11 or
spongy. Check and tighten all hose clamps.
Governor 0 D D D D Change oil every 250 hours.
Lubricate linkage arm periodically.
'WESTERBEKE recommends this service be periormed by an authorized mechanic. (continued)
10
MAINTENANCE SCHEDULE
NDTE: Use the engine hourmeter gauge 10 log your engine hours or record your
engine hours by running lime.
CHECK HOURS OF OPERATION

SCHEDULED EACH EXPLANATION OF SCHEDULED
MAINTENANCE DAY 50 100 250 500 750 1000 1250 MAINTENANCE
Heal Exchanger D D D D D D D Clean or repiace anode. Open heal exchanger end
cap and clean out debris. Remove every 1000 hours
for professional cleaning and pressure testing.
Raw Water Pump D D D Remove pump cover and inspect impellertor wear;
replace 0 needed. Also replace gasket Lubricate
both when reassembling.
Coolant System D Drain, flush, and refill cooling system with appro-
priate antoreeze mix.
'Starter Motor D D Check solenoid and motor for corrosion. Remove
and lubricate. Clean and lubricate the Start motor
pinion dlive.
Distributor D D Check ignition timing. Check condition of distlibu-
tor cap and rotor.
'Engine Cylinder D D Incorrect valve clearance will resuft in poor engine
Compression and performance; check compression pressure and timing,
Valve Clearance and adjust valve clearances.
'Engine Timing Belt D Remove and replace.
NOTE: Failure to replace the timing beft at the rec-
ommended interval could resuft in timing beft fail-
ure resufting in major damage to the engine.
'Exhaust Elbow D Test exhaust elbow for casting integrity. Replace if
casting is corroded or deteliorated. WARNING: A
defective exhaust elbow can cause carbon monox-
ide leakage!
'WESTERBEKE recommends thiS service be performed by an authonzed mechamc.
11
ENGINE COOLING CIRCUIT
DESCRIPTION The engine's coolant temperature is thennostatically
The generator's engine is fresh water cooled (engine coolant) controlled.
by an engine-mounted heat exchanger. Raw water is pumped The engine's cooling system should be drained, flushed out,
through the heat exchanger by a belt-driven, positive and refilled with a fresh mixture of coolant at 750 operating
displacement impeller pump. Mtcr the raw water cools the hours or every two years.
fuel in the gasdenser and cools the engine coolant in the heat
exchanger, it mixes with the engine's exhaust gases, cools the
exhaust hose, and discharges overboard. A CAUTION: Proper cooling system maintenance is
The engine's coolant is circulated by a belt-driven centrifu- critical; almost half of engine failures can be traced
gal-type metal impeller pump mounted on the front of the back to cooling system corrosion.
engine.
COOLANT PRESSURE CAP
TANK
MANIFOLD
BLEED
PETCOCK
THERMOSTAT
EXHAUST
FRESH WATER
COOLANT
"
. . RAW WATER EXCHANGER
FRESH WATER
COOLANT PUMP
DRAIN
ZINC
ANODE
~ WESTERBEKE
12
THERMOSTAT DRAINING THE COOLANT
A thermostat controls the coolant temperature as the coolant Remove the manifold pressure cap, loosen the water drain
continuously flows through the closed cooling circuit. When located on the left side of the engine block just under the
the engine is first started the closed thermostat prevents manifold and loosen the heat exchanger drain plug.
coolant from flowing (some coolant is by-passed through a
hole in the thermostat to prevent the exhaust manifold from REFILLING THE COOLANT
overheating). As the engine warms up, the thermostat gradu- Slowly pour clean premixed coolant into the manifold.
ally opens. The thermostat is accessible and can be checked,
cleaned, or replaced easily. CarTy a spare thermostat and gas- NOTE: Open the air bleed petcock on the exhaust manifold to
ket. help remove air from the system. When a steady flow of
coolant appears at the drain, close the water drain plug, fill
the system and close the petcock.
Start the engine and bring it to operating temperature.
Monitor the coolant in the manifold and add as needed. Fill
the manifold to the filler neck and install the pressure cap.
Remove the cap on the coolant recovery tank and fill with
coolant halfway between LOW and MAX, and replace the
cap.
Run the engine and observe the coolant expansion flow into
the recovery tank.
TO COOLANT
RECOVERY TANK
FROM COOLANT
RECOVERY TANK
COOLANT EXPANSION
COOLANT RETRACTION
After checking for leaks, stop the engine and anow it to cool.
Coolant should drain back into the cooling system as the
engine cools down. Add coolant to the recovery tank if
needed. Clean up any spilled coolant.
NOTE: Periodically check the condition of the pressure cap.
Ensure that the upper and lower rubber seals are in good
condition and check that the vacuum valve opens and closes
tightly. Carry a spare cap.
THERMOSTAT TEST
If you suspect a faulty thermostat, place it in a pan of water and A WARNING: Always check the coolant level at the
bring to a boil. A working thermostat should open about 1/2". coolant recovery tank. If the engine is /Jot, allow it to
cool before checking. HOT COOLANT and STEAM can
cause INJURY or DEATH! 00 not check the coolant at
the manifold unless the engine is cool!
""'" WESTERBEKE
13
RAW WATER PUMP HEAT EXCHANGER
The raw water pump is a self-priming, rotary pump with a Cool raw water flows through the inner tubes of the heat
non-ferrous housing and a Neoprene impeller. The impeller exchanger. As the engine coolant passes around these tubes
has flexible blades which wipe against a curved cam plate the heat of the internal engine is conducted to the raw water
within the impeller housing, producing the pumping action. which is then pumped into the exhaust system and discharged.
On no account should this pump be run dry. There should The engine coolant (now cooled) flows back though the
always be a spare impeller and impeller ccver gasket aboard engine and the circuit repeats itself.
(an impeller kit). Raw water pump impeller failures occur when
lubricant (raw water) is not present during engine operation. The engine coolant and raw water are independent of each
Such failures are not warrantable, and operators are cautioned other; this keeps the engine's water passages clean from the
to make sure raw water flow is present at start-up. The raw harmful deposits found in raw water.
water pump should be inspected periodically for broken or TO ENGINE BLOCK
HEAT EXCHANGER
tom impeller blades. See MAINTENANCE SCHEDULE.
~t FROM RAW WATER PUMP
RAW
WATER IN t
GASKET
ZINC
ANODE1 COOLANT
DRAIN
END CAP
t
TO HEAT
EXCHANGER
FROM REPLACE REPLACE
NEW CLEAN AND
GASDENSER
RAW WATER PUMP REPLACE
ZINC ANODES
A zinc anode (or pencil) is located in the raw water cooling
CHANGING THE RAW WATER PUMP IMPELLER circuit within the heat exchanger. The purpose of the zinc
anode is to sacrifice itself to electrolysis action taking place
NOTE: Coat the replacement impeller blade tips with petro- in the raw water cooling circuit, thereby reducing the effects
leum jelly before installing. of electrolysis on other components of the system. The con-
dition of the zinc anode should be checked monthly and the
anode cleaned or repJaced, as required. Spare anodes should
A CAUTION: The raw water intake valve (seacock) be carried onboard. The area in the exchanger where the
must be closed when servicing any components of the anode is located should periodically be cleaned of anode
raw water system, and must be re-opened before start- debris. Take care not to lose the small O-ring that nestles
between the heat exchanger end gasket and the ccver.
ing the engine.
DRIVE BELT ADJUSTMENT
A CAUTION: The drive belt must be properly tensioned

for the belt-driven water pumps to function properly.
For the raw water pump/fresh water pump drive belt tension
adjustment procedure, see DRIVE BELTS ADJUSTMENT
under ENGINE ADJUSTMENTS.
-.y- WESTERBEKE
14
FUEL SYSTEM
GASOLINE These gasoline filters must have metal bowls (not "see-
through") to meet U.S. Coast Guard requirements. The metal
Use unleaded 89 octane or higher gasoline. When fueling, bowls have drain valves to use when checking for water and
follow U.S. Coast Guard regulations, close off all hatches
impurities.
and companionways to prevent fumes from entering the boat,
and ventilate after fueling.
NOTE: The generator compartment should have a gasoline
fume detector/alarm properly installed and working.
A WARNING: Shut off the fuel valve at the tank Ii

when servicing the fuel system. Take care in catching
any fuel that may spill. DO NOT allow any smoking, ,I
open flames or other sources of fire near the fuel sys-
GASOLlNEJWATER
tem when servicing. Ensure proper ventilation exists SEPARATOR
when servicing the fuel system.
CARBURETOR FUEL PUMP

The carburetor is a single barrel downdraft type with a sole- Periodically check the fuel connections to and out of the pump
noid-activated electric choke and electric fuel shutoff solenoid. and make sure that no leakeage is present and that the fittings
are tight and secure. The DC ground connection at one of the
pump's mounting bolts should be dean and well secured by the
mounting bolt to ensure proper pump operation.
A WARNING: Fuel leakage at the fuel pump or its

connections is a fire hazard and should be corrected.
Make sure proper ventilation exists whenever servicing
fuel system components.
GASDENSER
The gasdenser consists of a portion of the fuel line that is
coiled around the raw water intake line and insulated. It is
located between the raw water intake and the raw water
pump. The gasdenser cools the fuel to prevent vapor lock.
RAW WATER INTAKE

FUEL IN
CARBURETOR
GASOLINE/WATER SEPARATOR AND FILTER

A primary fuel filter of the water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
....
TO CARBURETOR
be carried to the fuel system on the engine.
Most installers include a type of filter/water separator with

the generator installation package as they are well aware of
the problems that contaminants in the fuel can cause. FUEL
"'""" WESTERBEKE
15
ENGINE LUBRICATING OIL
DESCRIPTION
Use a heavy duty engine oil with an API classification of SJ. A WARNING: Used engine oil contains harmful
Change the engine oil after an initial 50 hours of break-in contaminants. Avoid prolonged skin contact. Clean skin
operation and every 100 hours of operation thereafter. For and nails thoroughly using soap and water. Launder or
recommended oil viscosity see the following chart:
discard clothing or rags containing used oil. Discard
Operating Temperature Oil Viscosity used oil properly.
Above 68" F (20" C) SAE 30, 10W-30 or 15W-40
41" - 68" F (5"_20" C) SAE 20 or 10W-30 REPLACING THE OIL FILTER
Below 41" F (5" C) SAE 10W-30 When removing the used oil filter, you may find it helpful to
punch a hole in the upper and lower portion of the old filter
to drain the oil into a container before removing it. This helps
to lessen spiI1age. An automotive filter wrench should be
A CAUTION: 00 not allow two or more brands of helpful in removing the old oil filter, Place some paper towels
engine oil to mix. Each brand contains its own addi· and a plastic bag around the filter when unscrewing it to catch
tives; additives of different brands could react in the any oil that's in the filter. Inspect the old oil filter as it is
removed to make sure that the rubber sealing gasket comes
mixture to produce properties harmful to your engine.
off with the old oil filter. If this rubber sealing gasket remains
sealed against the oil filter adapter, gently remove it. When
CHANGING THE ENGINE OIL installing the new oil filter element, wipe the filter gasket's
sealing surface on the oil filter adapter free of oil and apply a
The engine oil should be warm. Remove the oil drain hose
thin coat of clean engine oil to the rubber gasket on the oil
from its attachment bracket and lower it into a container and
filter. Screw the filter onto the threaded oil filter nipple, and
allow the oil to drain, or attach a pump to the end of the drain
tighten the filter firmly by hand.
hose and pump the old oil out. Make sure the oil drain hose
is properly secured in its holder after all of the old oil has NOTE: Use genuine WESTERBEKE oil fillers. Generic fillers
been drained. are not recommended.
Always observe the old oil as it is removed. A yellow/gray REFILLING THE OIL SUMP
emulsion indicates the presence of water in the oil. Although
this condition is rare, it does require prompt attention to Add fresh oil through the valve cover. After refilling the oil,
prevent serious damage. Call a competent mechanic if water run the engine for a few moments while checking the engine's
is present in the oil. Raw water present in the oil can oil pressure. Make sure there is no leakage around the new
be the result of a fault in the exhaust system attached to the oil filter or from the oil drain system, and then stop the
engine and/or a siphoning through the raw water cooling engine. Then check the quantity of oil with the lube oil dip-
circuit into the exhaust, filling it up into the engine. stick. Fill to, but not over, the FULL mark on the dipstick.
OIL DRAIN HOSE
OIL CONTAINER
....v- WESTERBEKE
16
REMOTE OIL FILTER (OPTIONAL)
INSTALLATION To install, simply remove the engine oil filter and thread on
WESTERBEKE's remote oil filter kit as shown. Always
This popular accessory is used to relocate the engine's oil fil-
install this kit with the oil filter facing down as illustrated.
ter from the engine to a more convenient location such as an
engine room bulkhead. Contact your WESTERBEKE dealer for more information.
NOTE: Refer to REPLACING THE OIL FILTER for instruc- NOTE: Westerbeke is not responsible for engine failure due to
tions on removing the oil filter. incorrect installation of the Remote Oil Filter.
FASTEN SECURELY TO A BULKHEAD
(SCREWS ARE OWNER SUPPLIED).
APPLY A THIN COAT OF CLEAN OIL TO THE D-RING

WHEN INSTALLING THIS KIT. THREAD THE KIT ON,
THEN TIGHTEN (BY HAND) AN ADDITIONAL 3/4
TURN AFTER THE D-RING CONTACTS THE BASE.
~PPLYI'!~I~. ~OA~OF CLEAN Oil TO

WHEN INSTALLING.
WHEN THE F!lTER CONTACTS THE BASE,
TIGHTEN IT (BY HAND) A 3/4 TURN MORE.
"SlY' WESTERBEKE
17
DC ELECTRICAL SYSTEM
12-VOLT DC CONTROL CIRCUIT BATTERY CHARGING
The DC Circuit on the BCGTC functions to start, operate and The generator supplies a continuous 17 amp charge from its
stop the generator's engine. The circuit is best understood by battery charger to the starting battery.
reviewing the DC Wiring Diagram and Wiring Schematic.
The engine's DC wiring is designed with three simple basic
circuits: start, run and stop.
BATIERY
The engine has a 12 volt DC electrical control circuit that is CHARGER
shown on the Wiring Diagrams. Refer to these diagrams
when troubleshooting or when servicing the DC electrical
system or the engine.
BAmRIES
A CAUTION: To avoid damage to the banery charg-

BLACK
GREEN
ing circut, never shut off the engine banery switch
YELLOW
while the engine is running. Shut off the engine banery
switch, however, to avoid electrical shorts when work- RED
ing on the engine's electrical circuit.
Specifications COMPONENT TESTING

The minimum recommended capacity of the battery used in All DC voltage measurements are made to the engine battery
the engine's 12-volt DC control circuit is 300 CCA. negative ground point unless specified otherwise. In making
test measurements, make sure that a good ground for the
Battery Maintenance meter is established, preferably the point where the negative
Review the manufacturer's recommendations and then estab- battery is connected to the engine. Battery positive voltage is
lish a systematic maintenance schedule for your engine's indicated as B+ and should measure no Jess than 11.5 volts.
starting batteries and house batteries. AC voltage measurements should be made with a true RMS
AC meter to insure measurement accuracy.
• Monitor your voltmeter for proper charging during engine
operation. Relay. The relays used in the control system have coils
which are polarized by the fact that they have internal free
• Check the electrolyte level and specific gravity with a wheeling suppression diodes across them. Relay coil terminal
hydrometer. 86 must be maintained (+), tenninaI85(-). The relay coil is
rated 12V DC, and the coil resistance is typically 85 ohms.
• Use only distilled water to bring electrolytes to a proper With B+ on terminal 86, direct grounding of terminal 85 is
level.
permissible for testing purposes.
• Make certain that battery cable connections are clean and
tight to the battery posts (and to your engine).
• Keep your batteries clean and free of corrosion.
A WARNING: Sulfuric acid in lead baneries can

cause severe burns on skin and damage clothing. Wear
protective gear.
~ WESTERBEKE
18
WIRING DIAGRAM #42834
OIL TEMP SWITCH INC)
[ ~ 1)111111
~
+
n
1
!-Ll ---11' '
.-
'"
.
•
Engines & Generators Rev. E 3/2S/98
19
WIRING SCHEMATIC #42834
'+ 12 VDC
r ,
-t>1 ~~n2~Y STARTER
'- ' SOLENO I D
r- - - I
STARTER
~------------------~~----~
~ 1 25
CD AMP
r ,
( ICIRCUIT
L.. ?- ! BREAKER
,
,
KI
~___________3~O ~8l'____________~'
,L. _ _ _ , I
BATTERY
CHARGER
FUEL PUMP
fI
! AMP
FUEL SOL.
r \-, CD STOP SW
q. I- 1 CKT I ( NC) HOUR METER
L ~! I
,
I COil DISTRIBUTOR
~~'________~'O~K2~8l'__________________________~____~
~ ______ : ~-----+-_----"J/
7'0
CHOKE SOL.
t)/S40~,DJODE n
n
r- K2~RUN
ESY:.m~CSHT ® OVERSPEED
SHUT DOWN
__------~T~'--+_--~8T'~
DIODE
I N4002
~8T5~--~
OIL
PRESS.
(_~
\-r
ell. ,";,.
SWITCH
13 T2
JUMPER
~ ~
,,/
TSI I TB! 2 T81 3 TBI , / ....... TBI S RU~ INDICATDR TO! •
I I '" I " /
ON I START I STOP SW I" - - - - - -D- - - - - - - - - - - - - - 1
I SWITCH J SWITCH I CI5JU~~) I / " I
!... -~.i _~ -~oL _...I !.... ___ ..J~ - - _ .... _ - - - -IWSTRUIIENTS- _ _ _ _ _ _ _ _ _ _ _ _ _ I
L __ I L_I_I L_j_1
CKT2~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ I REMOTE PME!...
l!QllL
I. All WIRE iI6AWG(IOSD[G C SOOV-AlPHAI
1858/19-lm-W-i687BD TYPE 6) UNLESS
SPECIFIED OTHERWISE.
2. WARNING - RELAYS KI. K2 HAVE INTERNAL
olODES ACROSS THE I R CO I LS, POLAR ITY AS
INDICATED MUST BE MAINTAIIIED TO AVOID
DAMAGE TO THE RELAYS,
Engines & Generators Rev. E 3/28/98
20
~
-<
~ ~ 0
-< -< ~
". ". G>
0
= =
0= = ~
=
-j --I
"" "
REMOTE PANEL 2 REMOTE PANEL 1
I)
r----
,, -------------------------------------T--------------------------------------1 ,1 0
4 TBI
,, , ' 2 ' 3 5 6
, ,, , I ,''' I ,'''
:or rn
,, ,, \
START/STOP SW
:~ 6 ~ V
START/STOP SW "J~ 6 c
,,,
-y
CKT 2 I~ ~
[LED~
~
CKT 2 REMOV E
:-"1 1/
:~ 5~ ,,
~I
:~ 5 ~ I JUMPER
LED 1 =~
CKT 1 I CKT I I I~ 4 ~
:~ 4~ I-- ,,, , I" "
ON SW I - 1& 3 .c' , ~ ON SW ' - 1& 3 .c- V-
,,,
r
I = J 2c- ,,
,,
I -r=J 2 .c-
l'
,, 1
I'" 1 IS I'"
, '-
i'~ i
L-
,, ,
~
-<
~ ~ 0
-< -< ~
" . ". G>
=
= = -< -<
0 0= = ~
"" "
iJ
REMOTE PANEL
r - - - - - - - ------------------------------------, 1 2 3
0
4 ~ ~ TBI
,,, (~ ( ( h:
, '\
START/STOP SW I~ 6 ~ ,,
CKT 2 I'" " ,, \
~
~I I~ 5
REMOVE
1 =~ " ,, JUMPER
LED ,
CKT 1 I 4
I'" " ,,
;~ ON SW '-- ~ 3"
,,
,,
I =J I~ 2 ~
I'" "
I~ 1 ~
,,
,
,, '-
I'" " ,
,
L ___________________________________________ J
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following engine
adjustments be performed by a competent engine mechanic.
The information below is provided to assist the mechanic.
ENGINE SPEED (HERTZ) ADJUSTMENT Governor Maintenance

Governor 1. Periodically lubricate the linkage arm attaching points at
the governor arm and throttle lever. Use a graphite lubri-
The belt-driven, mechanically operated governor maintains the cant or equivalent.
engine's rpm under various load conditions. Engine speed
determines the hertz and voltage output of the generator.
NOTE: Free movement of this linkage arm is important for
p"roper governor/throttle operation.
Governor Adjustments 2. Governor oil capacity - 3 ounces 10/30 engine oil.
Operate the generator to bring the unit up to operating temper- NOTE: Do not overfill the governor.
ature before adjusting the governor.
3. Change the governor oil every 250 hours of operation.
NOTE: If the governor is severely out of adjustment, manually To change the oil, remove the governor from the engine,
adjust the linkage at no-load to obtain a safe output voltage
remove the oil fill and the fill level plug, and drain all the
before proceeding with the adjustment.
oil. Reinstall on the engine and fill with 3 ounces of 10/30
There are three adjusting points on the governor (see i1lustra- engine oil. Replace the plugs.
tion).
4. Periodically adjust the governor belt tension (see DRIVE
1. Increase/Decrease Speed Adjustment. This adjusting bolt BELTS ADJUSTMENT). Since belts stretch slightly, this
sets the no-load speed of the engine. (The linkage ann stretching wil1, to some degree, affect the govenor's
between the governor ann and throttle lever should be action.
adjusted to hold the throttle full open when the engine is
not running.) Make sure this linkage moves freely and that TORQUING THE CYLINDER HEAD BOLTS
the ball joint connectors are properly lubricated. Use After the initial break-in period (approximately 50 hours), the
graphite lube for this purpose. Disconnect the ball joint and cylinder head bolts should be re-torqued.
apply graphite lube to the inside of the joint.
Tighten the cylinder head bolts according to the sequence
2. Hunting/ReguliltWnAdjustment_ If the variation in engine shown. Make sure the engine is cold when this is done, and
speed between no-load and full-load is too great, adjust this loosen one head bolt one-half turn and then tighten it
eye bolt to draw the spring closer to the lever hub. The between 43-51 lb-ft (60-70 Nm). Then proceed to the next
increase/decrease speed bolt may need to be adjusted as head bolt in the sequence. Tighten the RS (rocker cover stud)
well. securely.
If the governor surges under load, adjust this eye bolt to
6 4 2 7
move the spring away from the lever hub (check speed
adjustment).
3. Bumper Screw Adjustment. This screw is used to remove a
no-load surge ONLY. NEVER turn the bumper screw into
the governor so far that it increases the no-load speed.
FRONT OF
ENGINE
ARM
Oil FILL
B 3 5
CARBURETOR
THROTILE
LEVER
REGULATION
ADJUSTMENT
SPEED An."" "'T>"Nl
GOVERNOR
Engines & Generators Rev.611f98
22
ENGINE ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT IGNITION TIMING

NOTE: Retorque the cylinder head bolts before adjusting the 1. Attach a timing light to the #1 spark plug and mark the
engine's valves (see TORQUING THE CYLINDER HEAD front timing pointer to indicate 18°. Locate the timing
BOLTS).
mark on the crankshaft pulley and mark it with white
1. Remove the rocker cover and gasket. chalk or a crayon.
2. Adjust the intake and exhaust valves in the firing order of 2. Start the engine and warm it up to its normal operating
the engine (1-3-2), as follows: temperature. Make sure the generator is operating without
Rotate the crankshaft in its nonnaI direction of rotation, a load on it.
placing the No. I piston at the IDC (Top Dead Center) of 3. Using the timing light, align the timing mark in the front
its compression stroke with the intake and exhaust valves crankshaft pulley so it is just slightly before the first tim-
completely closed. Then adjust the intake and exhaust ing pointer. Do this by loosening and slowly rotating the
valve clearances for cylinder No. ]. distributor body. Use the following timing specifications:
Valve clearances: Timing Specifications: 18° ± .so BIDC at 3600 rpm (no
Intake valves - 0.20 mm (.008 in) load on generator)
Exhaust valves - 0.30 mm (.012 in)
tGNITION TIMING
Repeat the above procedure to adjust the intake and exhaust
valves for No.3 cylinder, then repeat this procedure once
more to adjust the intake and exhaust valves for No.2
cylinder.
3. Replace the rocker cover along with a new rocker cover
gasket.
Rocker cover torque: 2.9-5.1 Ib-ft (0.4-0.7 kg-m)
SPARK PLUGS
The spark plugs should be cleaned and rcgapped after the
VALVE first 50 hour break-in period, then inspected every 250 hours
CLEARANCE
ADJUSTMENT thereafter and replaced as needed.
CHOKE SOLENOID A WARNING: Do not remove the spark plugs while

The choke solenoid is a 12 volt DC operated unit that func- the engine is hot. Allow the engine to cool before
tions to close the choke plate in the carburetor when the ON removing them.
switch is depressed during engine start-up.
The choke solenoid de-energizes once the engine starts and Spark plug gap: 0.028 - 0.031 in. (0.7 - 0.8 mm).
the ON switch is released. Some unstable running may be
Spark plug torque: 10.8 -15.2lb-ft (1.5 - 2.1 kg-m).
present when the engine starts cold but should smooth out as
the engine reaches operating temperature. NOTE: Loc-tite Anti-Seize applied to the threaded portion of
the spark plugs will retard corrosion, making future removal
Keep this solenoid dry and periodically lubricate the linkage
between the solenoid and the choke lever. of the spark plugs easier. WEAR AND
CARBON
BURNT CONDITION
SPARK PLUG
INSPECTION I---D""GE AND
DETERIORATION
CHOKE
SOLENOID
~ WESTERBEKE
Engines & Generators Rev. 6(1198
23
ENGINE ADJUSTMENTS
CARBURETOR ADJUSTMENT DRIVE BELTS ADJUSTMENT

Basic Jet Adjustment is performed with the generator operat- The drive belts must be properly tensioned. Excessive drive
ing. Screw the jet slowly in until it seats, then back it out belt tension can cause rapid wear of the belt and reduce the
1-1/2 to 2 turns. service life of the fresh water pump's bearing. A slack belt or
NOTE: An idle mixture jet adjusted too far off its seat can the presence of oil on the belt can cause belt slipping, result-
induce a sooty exhaust discharge at engine start-up and shut- ing in high operating temperatures.
down. The BCGTC generator has two drive belts, one for the gover-
NOTE: At idle speed, oil pressure will be lower than the rating nor and one for the raw water pump/fresh water pump. The
afthe oil pressure switch. Jump this switch to prevent engine tension adjustment procedure for both belts is as follows:
shutdown at idle speed. 1. Remove the belt guard.
Run Mixture Jet. This mixture jet is presized at the factory 2. To adjust the governor drive belt, loosen the two governor
and is not adjustable. The idle mixture jet adjustment can be mounting bolts.
made in the 3600 rpm range to improve engine performance. To adjust the raw water pump/fresh water pump drive
belt, loosen the two raw water pump mounting bolts.
3. With the belt(s) loose, inspect for wear, cracks and frayed
edges, and replace if necessary.
4. To loosen or tighten the governor drive belt, slide the gov-
ernor in or out as required, then retighten its mounting
bolts.
FLAME To loosen or tighten the raw water pump/fresh water
ARRESTER
pump drive belt, slide the raw water pump in or out as
required, then retighten its mounting bolts.
5. The drive belts are properly adjusted if they can be
deflected no less than 3/8 inch (10mm) and no more than
1/2 inch ( 12mm) as the belt is depressed with the thumb
at the midpoint between the two pulleys on the longest
span of the belt.
NOTE: Maintain a 22 lb pressure to the belt's outer face
for proper belt operation. Spare belts should always be
carried on board.
LINKAGE
ARM
A WARNING: Never attempt to check or adjust a

drive belt's tension while the engine is in operation.
6. Operate the generator for about 5 minutes, then shut down

the generator and recheck the belt(s) tension.
7. Replace the belt guard.
IDLE
MIXTURE --k'<::~~
SC!iEW
FUEL SHUT-OFF
SOLENOID
CARBURETOR
24
ENGINE ADJUSTMENTS
TIMING BELT INSPECTION AND REPLACEMENT 5. Remove the timing belt.

NOTE: If the timing belt is to be reused, draw an arrow on
Timing Belt Removal the belt back to indicate the direction o/rotation (clock-
wise).
it. CAUTION: Water or oil on the timing belt severely
reduces the service life of the belt. Keep the timing
belt sprocket and tensioner free of oil and grease.
These parts should never be cleaned. Replace if serio
ously contaminated with dirt or oil. If oil is evident on
these parts, check the front case, oil pump oil seals,
and camshaft oil seals for a possible oil leak.
1. Turn the crankshaft c10ckwise to align the timing mark on

the camshaft sprocket and timing belt rear cover.
NOTE: always turn the crankshaft clockwise. Camshaft Sprocket Removal
TIMING MARK
1. Remove the bolt without turning the camshaft.
2. Remove the plug on the left surface of the cylinder block

and insert a rod with a diameter of8mm (0.31in.) to lock
the counterbalance shaft.
NOTE: Be sure to use an inserting rod with a diameter of
8mm (0.31 in.).
__E;;~~~~ROO
65 MM (2.6 IN) .
Oil Pump Sprocket Flange Nut Removal.

CYLINDER
BLOCK
1. Remove the plug from the left side of the cylinder block.
2. Insert an 8 mm (0.31 in.) diameter round bar to lock the
counterbalance shaft.
3. Loosen the timing belt tensioner nut. 3. Remove the nut.
4. Move the timing belt tensioner toward the water pump,
and temporarily tighten the nut to hold the tensioner in
that position.
TIMING BELT TENSIONER
PUMP
OIL PUMP SPROCKET
""" WESTERBEKE
25
ENGINE ADJUSTMENTS
Crankshaft Bolt Removal Flange Installation

1. Lock the crankshaft in position. 1. Mount the flange so that its side shown by the heavy
NOTE: Do not turn the crankshaft. arrow in the illustration faces toward the sprocket.
FLANGE
2. Remove the crankshaft bolt. BEARING
Timing Belt Inspection

Replace the belt if any of the following conditions exist:
1. Hardening of back rubber-back side is glossy, without
resilience, and leaves no indent when pressed with fin-
gernail.
SPROCKET
2. Cracks on rubber back.
Crankshaft Bolt Installation
3. Cracks or peeling of canvas.
4. Cracks on tooth bottom. 1. Lock the crankshaft.
5. Cracks on belt.
NOTE: Do not turn the crankshaft.
6. Abnormal wear of belt sides. The sides are normal if 2. Tighten the crankshaft bolt to the specified torque.
they are sharp as if cut by a knife. Oil Pump Sprocket Flange Nut Installation
7. Abnormal wear on teeth.
1. Insert a round bar into the plug hole in the left side of the
8. Tooth missing and canvas fiber exposed. cylinder block to keep the counterbalance shaft from turn-
ing.
2. Install the oil pump sprocket.
3. Tighten the nut to the specified torque.
1. 2.
ACKS
CRACKS~
OR PEELING
3.
0 4.
ROUNDED EDGE
~ABNORMAL
~,.
OIL PUMP
......... WEAR NUT SPROCKET
~ (flUffY STRAND)
Camshaft Sprocket Bolt Installation

5. 6. 1. Tighten the bolt to the specified torque.
TOOTH MISSING
RUBBER ---If.r!S AND CANVAS
EXPOSED ~BEREXPOSED
~
7. 8.
Tensioner Inspection
1. Replace the tensioner if the pulley binds, rattles or is noisy
when turned.
~ WESTERBEKE
26
ENGINE ADJUSTMENTS
Tensioner Spring/Timing Tensioner Installation At this time, check that the moveable range of teeth On
the oil pump sprocket is according to specifications.
1. Install the tensioner spring and timing belt tensioner.
Standard value: 4 to 5 teeth in forward direction
2. Hook the tensioner spring onto the bend of the timing belt 1 to 2 teeth in reverse direction
tensioner bracket and the stopper pin on the cylinder
block.
OIL PUMP
3. Move the timing belt tensioner as close as possible to the SPROCKET
water pump; temporarily tighten the tensioner nut.
REVERSE
4. If the movable range of the oil pump sprocket exceeds

the specified range, correct as follows:
a. Pull out the round bar from the plug hole in the left
TENS lONER SPRING side of the cylinder block.
b. Turn the oil pump sprocket one turn at a time until
the round bar can again be inserted.
Timing Belt Installation
c. Check that the movable range of the oil pump
1. Align the triangular marking on the camshaft sprocket sprocket is in the specified value.
with a marking on the timing belt rear cover. S. Set the timing belt over the crankshaft sprocket and
2. Align the notch in the crankshaft sprocket flange with then over the oil pump sprocket and camshaft sprocket,
the marking on the front casco in that order.
3. Align the triangular marking on the oil pump sprocket NOTE: Ensure that the tension side of the timing belt is
with the marking on the front case, and then insert a 65 not slack. Keep the round bar inserted until the timing
mm (2.56 in.) or longer, 8 mm (0.31 in.) diameter belt has been placed. After this step, be sure to remove
round bar into the plug hole in the left side of the the round bar.
cylinder blOC~k.~;;;;;::;;~::,....__ 6. Apply counterclockwise force to the camshaft sprocket
to make the belt taut on the tension side, and make
MARKING ON sure that all timing marks are lined up.
TIMING BELT ~
REAR COVER
CAMSHAFT
SPROCKET
TRIANGULAR
MARKING ON
CAMSHAFT
SPROCKET
TENSION SlOE
TIMING BELT
TENSIONER
7. Loosen the temperorarily tightened tensioner nut on

the water pump side 1 or 2 turns, and tension the belt
making use of spring force.
~""''L_.L-r_TRIANGULAR MARKING
..-.: ON OIL PUMP SPROCKET
NOTCH IN MARKING
ON FRONT
CRANKSHAFT
SPROCKET CASE ~ WESTERBEKE
FLANGE Engines & Generators
27
ENGINE ADJUSTMENTS
8. Tum the crankshaft clockwise by nine camshaft

sprocket teeth (81") to align the timing mark on the
camshaft sprocket with the tcnsioner set mark on the
timing belt rear cover.
A CAUTION: This operation is performed to give a

proper tension to the timing belt, so do NOT turn the
crankshaft counterclockwise and push the belt to
check the tension.
9. Make sure that the timing belt teeth are engaged with
the camshaft sprocket teeth along the portion of the
sprocket shown by the curved arrow in the illustration
below. Then tighten the tcosioner nut.
10. Pull the timing belt in the center of the tension side
toward the sealing gasket line for the belt cover, as
i1lustrated. Make sure that the clearance between the
back of the belt and the sealing line is the standard
value.
Standard Value: 12mm (0.47in.)
\\-;1r>-__ 12 mm (GA7IN)
11. Pull out a rod from the plug hole on the left surface of
the cylinder block and apply the specified sealant.
Then tighten the plug to the specified torque.
Specified sealant value: 3M AID Part No. 8660 or
equivalent
Tightening torque: 15-22 Nm (11-16 ft.lbs.)
-.v- WESTERBEKE
28
ENGINE TROUBLESHOOTING
The following troubleshooting tables are based upon certain When troubleshooting indicates an electrical problem, see the
engine problem indicators and the most likely causes of the DC Electrical System Wiring Diagram and Schematic, as
problems. they may reveal other possible causes of problems not listed
below.
PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE

Engine does not 1. Voltage drop at starter solenoid Engine starts, runs 1. Faulty shutdown switch,
crank. terminal. and then shuts (oil pressure, water or exhaust
2. Engine 20A circuit breaker has down. temperature).
tripped. 2. High engine water or exhaust
3. Battery is low or dead. temperature.
4. Loose battery connections. 3. Dirty fuel/water separator filter.
5. Faulty wire connection. 4. Mechanical check valve at the fuel
6. Faulty start switch. supply faulty.
7. Faulty start relay (K1). 5. Low oil level in sump.
8. Faulty starter solenoid. 6. Faulty fuel pump.
9. Raw water filled cylinders. 7. Faulty engine temperature
sensor.
Engine cranks but 1. Out of fuel.
Engine starts, runs 1. Fuel line restriction.
fails to start. 2. Engine is flooded. but does not come 2. Mechanical check valve at the
a. Carburetor float needle valve open up to speed.
or damaged. Clean or replace the fuel supply is faulty.
needle valve. 3. Throttle plate binding.
b. Float in carburetor is leaking. 4. Faulty fuel pump.
Repair or replace float. 5. Faulty wire connection.
c. Float chamber gasket damaged or 6. Faulty engine temperature
securing screws are loose. Replace sensor.
gasket and/or tighten screws.
7. AC generator overload.
3. Fuel pump inoperative.
8. High exhaust pressure.
4. Worn or faulty spark plugs.
5. High tension wires grounding (wet
Engine hunts. 1. Low battery voltage.
system). 2. Generator is overloaded.
6. Faulty ignition coil. 3. Cracked distributor cap.
7. Faulty distributor. 4. Faulty high tension wires.
8. Faulty wire connection. 5. Faulty fuel pump.
9. Faulty overspeed circuit board. 6. High exhaust back-pressure.
Replace. 7. Valves are out of adjustment.
10. Faulty run relay (K2).
11. Timing belt.
12. No engine compression.
13. Faulty idle adjustment.
29
ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE

Engine misfires. 1. Poor quality fuel. High oil pressure. 1. Dirty oil or wrong SAE type oil in the
2. Incorrect timing. engine.
3. Dirty flame arrester. 2. Relief valve is stuck.
4. Cracked distributor cap. No DC charge to the 1. Faulty connections to
5. Faulty ignition wires. starting battery. battery voltage regulator.
6. Spark plugs are worn. 2. Faulty battery voltage regulator.
7. High exhaust back-pressure. 3. Faulty bridge rectifier.
8. Valve clearances are incorrect. 4. Faulty generator charger
windings.
Engine backfires. 1. Spark plug wires are connected
wrong. Blue exhaust smoke 1. Lube oil is diluted.
2. Incorrect timing. discharge from the 2. High lube oil level.
3. Engine is flooded. See Engine is engine. 3. Crankcase breather hose is clogged.
flooded under Engine cranks but 4. Valves are worn or adjusted
fails to start. incorrectly.
4. Dirty flame arrester. 5. Piston rings are worn
5. Cracked distributor cap. or unseated.
6. High exhaust back·pressure. Black exhaust smoke 1. Dirty flame arrester.
Engine overheats. 1. Coolant loss. Pressure test discharge from the 2. Faulty carburetor.
cooling system. engine.
2. Faulty raw water pump impeller. Poor performance 1. Main jet clogged. Remove and clean.
3. Belts are loose or broken. at generator speed. 2. Carburetor inlet filter clogged.
4. Raw water pump worn.· Remove and clean.
5. Faulty thermostat. 3. Fuel pump clogged. Remove and
Low oil pressure. 1. Low oil level. replace.
2. Wrong SAE type oil in the engine. 4. Air intake filter screen dirty. Remove
3. Wrong type oil filter. and clean.
4. Relief valve is stuck.
5. Faulty oil pump.
6. Faulty engine bearings.
~ WESTERBEKE
30
GENERATOR INFORMATION
USE OF ELECTRIC MOTORS REQUIREO OPERATING SPEED
The power required to start an electric motor is considerably Although individual units may vary slightly, the normal
more than is required to keep it running after it is started. voltage and frequency of typical 60 (50) hertz engine-driven
Some motors require much more current to start than others. generators described in this manual are approximately as fol-
Split-phase (AC) motors require more current to start, under lows: run first with no load applied, then at half the generator's
similar circumstances, than other types. They are commonly capacity, and finally loaded to its full capacity as indicated on
used on easy-starting loads, such as washing machines, or the generator's data plate.
where loads are applied after the motor is started, such as
small power tools. Because they require 5 to 7 times as much The output voltage should be checked periodically to ensure
current to start as to run, their use should be avoided, when- proper operation of the generating plant and the appliances it
ever possible, if the electric motor is to be driven by a small supplies.
generator. Capacitor and repulsion-induction motors require
from 2 to 4 times as much current to start as to run. The CUT- GENERATOR FREQUENCY ADJUSTMENT
rent required to start any motor varies with the load con-
• Frequency is a direct result of engine/generator speed, as
nected to it. An electric motor connected to an air
indicated by the following:
compressor, for example, will require more current than a
motor to which no load is connected. • When the generator is run at 3600 rpm, the AC voltage
output frequency is 60 hertz.
In general, the current required to start 115 volt motors
connected to medium starting loads will be approximately • When the generator is run at 3000 rpm, the AC voltage
as follows: output frequency is 50 hertz.
AMPS FOR AMPS FOR Therefore, to change the generator's frequency, the generator's
MOTOR SIZE RUNNING STARTING drive engine's speed must be changed. A reconfiguring of the
(HP) (AMPERES) (AMPERES) AC output connections at the generator must also be made.
1/6 3.2 6.4 TO 22.4
1/4 4.6 9.2 TO 32.2 GENERATOR MAINTENANCE
1/3 5.2 10.4 TO 72.8 Maintaining cleanliness is important. Do not allow salt, dust,
or carbon from engine exhaust to build up on either the gen-
1/2 7.2 14.4 TO 29.2
erator or its engine.
3/4 10.2 20.4 TO 40.8
1 13 26 TO 52
NOTE: In the above table the maximum "AMPS FOR

STARTING" is more for some small motors than for larger
ones. The reason for this is that split-phase (the hardest start-
ing types) are used in the smaller motors only.
Because the heavy surge of current needed for starting BAND
motors is required for only an instant, the generator will not
be damaged if it can bring the motor up to speed in a few
seconds. If difficulty is experienced in starting motors, tum
off all other electrical loads and, if possible, reduce the load
on the electric motor.
-FLANGE
FRONT COVER
REAR
CAPACITOR
P
CONTROL BOX
GENERATOR COMPONENTS
31
GENERATOR WIRING DIAGRAMS
RED +
;-----------,'
,, '
,, 2
,
, 3
Allicr:::
.ll.
WINDING RESISTANCE AT 20° C TEMPERATURE
,
Cnm_mi 0Jll PART
A-A
ROTATING
B
BATTERY
CHARGER
WINDING
C-C
STATOR
WINDING
EXC
0
WINDING
L,:-t Hz 3.058 .n.. o.i41

- - - --.n..
~-2
('.433 .n..
50~!
4-.334 .n..
'-3 ,o-g
MODEL 4.5 KW c·-S'-5A .n. 3. 4S"~ .n
4-, 'io-1-
0·491 .!1. 4.5.34 .n.
'·6 'o-if
0·55;t ....n.. 3. ;r.q.. ..n.
R[ +
,-----------1 ~
SOHI
, '8
,,, 2
Allicr::;
, 3
:__ mmniOjjj
,
.It
L,:-t Hz
MODELS 7.2 KW AND 9.6 KW

Rev. 6/1/98
32
AC ELECTRICAL CONNECTIONS
B UA.._...J
r--------., +
iAR]i I
B'~-...J
WHITE
rv
CIRCUIT BREAKER
I
I
I
I
4------, 120 VAC
60 HZ
I
AR]i I
I
C
...,..----{) 4
L
(CONNECT
JUMPER)
..... _-------- VA----05

1-------,
5------~
r:___:h 240/120 VAC
DITWlo
189HZ
50
HZ
60 HZ
(REMOVE
666 JUMPER)
LJ
CONNECT fOR REQUIRED FREQUENCY
AND OUTPUT VOLTAGE
A - ROTOR 6-------, 220 VAC

BI- BATTERY CHARGE WINDING 3 : r±----Jh 50 HZ
MODEL 4.5 KW _ "'" - (REMOVE
B2- BATTERY CHARGE WINDING 4 -0 JUMPER)
MODELS 7.2 KW AND 9.6 KW
C - STATOR WINDING
D - CAPACITOR WINDING N L
A WARNING: When changing from 60Hz to 50Hz,

make certain the ground wire (white & green stripe) is
properly repositioned according to this diagram.
Engines & Generators Rev. 6/1/98
33
LAY-UP & RECOMMISSIONING
GENERAL FUEL SYSTEM
Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for Jay-up during the off- or higher. A fuel conditioner such as STABIL gasoline stabi-
season or for long periods of inactivity. Others prefer to lizer should be added. Change the element in your
accomplish lay-up preparation themselves. gasoline/water separator and clean the metal bowl.
Re-install and make certain there are no leaks. Clean
The procedures which follow will allow you to perform your up any spilled fuel.
own lay-up and recommissioning, or wi1l serve as a checklist
if others do the procedures. Start the engine and allow it to run for 5-10 minutes. Check
for any leaks that may have been created in the fuel system
These procedures should provide protection for your during this servicing and correct them. Clean up any fuel
engine/generator during a Jay-up and also help familiarize spills.
you with its maintenance needs.
If you have any questions regarding lay-up procedures, caB RAW WATER CIRCUIT
your local servicing dealer. He will be more than willing to
Close the through-huH fitting. Remove the raw water intake
provide assistance.
hose from the fitting. Place the end of this hose into a 5-gallon
bucket of clean fresh water. Before starting the engine, check
FRESH WATER CODLING SYSTEM the zinc anode in the heat exchanger on the engine and clean
A 50-50 solution of antifreeze and distilled water is recom- or replace it as required. Clean the raw water strainer, if one
mended for use in the fresh water cooling system at all times. is installed on the inside of the hull.
This solution may require a higher concentration of antifreeze, Start the engine and anow the raw water pump to draw the
depending on the area's winter climate. Check the solution to fresh water through the system. When the bucket is empty,
make sure the antifreeze protection is adequate. stop the engine and refill the bucket with an antifreeze solu-
Should more antifreeze be needed, drain an appropriate amount tion slightly stronger than needed for winter freeze protection
from the engine block and add a more concentrated mixture. 10 your area.
Operate the engine to ensure a complete circulation and mix- Start the engine and allow all of this mixture to be drawn
ture of the antifreeze concentration throughout the cooling through the raw water system. Once the bucket is empty, stop
system. Then recheck the antifreeze solution's strength. the engine. This antifreeze mixture should protect the raw
water circuit from freezing during the winter lay-up, as well
LUBRICATION SYSTEM as providing corrosion protection.
With the engine warm, drain all the engine oil from the oil Remove the impeller from your raw water pump (some
sump. Remove and replace the oil filter. (Place some paper antifreeze mixture will accompany it, so catch it in a bucket).
towels and a plastic bag around the filter to catch the oil dur-
ing its removal.) Examine the impeller. Get a replacement, if needed, and a
cover gasket. Do not replace the impeller (into the pump)
When installing the new oil filter, be sure to apply a small until recommissioning, but replace the cover and gasket.
amount of oil on the rubber sealing gasket at the base of the
filter. Fill the sump with the correct amount of oil for your
engine model. (Refer to the SPECIFICATIONS section of
this manual.) Use an oil with an API specification of SJ.
Run the engine and check for proper oil pressure and make
sure there are no leaks or fuel spills.
A CAUTION: Do not leave the engine's old engine

oil in the sump over the lay-up period_ Engine oil and
combustion deposits combine to produce harmful
chemicals which can reduce the life of your engine's
internal parts.
~ WESTERBEKE
34
LAY-UP & RECOMMISSIONING
INTAKE MANIFOLD RECOMMISSIONING

Clean the filter screen in the flame arrester, and place a clean The recommissioning of your WESTERBEKE engine after a
doth lightly soaked in lube oil around the flame arrester to seasonal lay-up generally follows the same procedures as
block any opening. Also place an oil-soaked cloth in the those presented in the PREPARATIONS FOR INITIAL START-
through-hull exhaust port. Make a note to remove cloths prior to UP section regarding preparation for starting and normal
start-up! starts. However, some of the lay-up procedures will need to
be counteracted before starting the engine.
STARTER MOTOR 1. Remove the oil-soaked cloths from the intake manifold
Lubrication and cleaning of the starter drive pinion is advisable, and from the through-hull exhaust port.
if access to the starter permits its removal. Make sure the bat- 2. Remove the raw water pump cover and gasket. Discard the
tery connections are shut off before attempting to remove the
gasket. Install the raw water pump impeller removed dur-
starter. Take care in properly replacing any electrical connec-
ing lay-up (or a replacement, if required). Install the raw
tions removed from the starter.
water pump cover with a new cover gasket.
CYLINDER LUBRICATION 3. Remove the spark plugs, wipe clean, re-gap, and install to
proper tightness.
Spray fogging oil into the open air intake, with the flame
arrestor removed, while the generator is running. The fogging 4. Reinstall the batteries that were removed during the lay-
oil will stall out the engine and coat the valves, cylinders and up, and reconnect the battery cables, making sure the ter-
spark plugs for winter protection. minals are clean and that the connections are tight. Check
to make sure the batteries are fully charged.
NOTE: The spark plugs will need to be removed for cleaning
and regapping at spring commissioning. 5. Note that it is not necessary to flush the antifreeze/fresh
water solution from the raw water coolant system. When
SPARE PARTS the engine is put into operation, the system will self-flush
in a short period of time with no adverse affects.
Lay-up time provides a good opportunity to inspect your
WESTERBEKE engine to see if external items such as drive 6. Start the engine in accordance with procedures in the
belts or coolant hoses need replacement. Check your basic PREPARATIONS FOR INITIAL SDlRT-UP section of this
spares kit and order items not on hand, or replace those items manual.
used during the lay-up, such as filters and zinc anodes.
BATTERIES
If batteries are to be left on ·board during the lay-up period,
make sure that they are fully charged, and will remain that
way, to prevent them from freezing. If there is any doubt that
the batteries will not remain fully charged, or that they will
be subjected to severe environmental conditions, remove the
batteries and store them in a wanner, more compatible envi-
ronment.
A WARNING: Lead acid batteries emit hydrogen, a

highly·explosive gas, which can be ignited by electri·
cal arcing or a lighted cigarette, cigar, or pipe. Do not
smoke or allow an open flame near the battery being
serviced. Shut off all electrical equipment in the
vicinity to prevent electrical arcing during servicing.
35
BCGTC GENERATOR SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Type 3 cylinder, 4 cycle, overhead camshaft
wlcounterbalance shaft, carbureted,
water cooled gasoline engine
Bore and Stroke 2.56 x 2.61 in. (65.0 mm x 66.3 mm) General Fresh water-cooled block through raw
water-cooled heat exchanger circuit
Total Displacement 40.3 cu. in. (.66 liter)
Fresh Water Pump Centrifugal type, metal impeller,
Bearings Four main bearings
belt-driven
Combustion Chamber Semi-spherical
Raw Water Pump Positive displacement, rubber impeller,
Compression ratio 9.8 - 1 belt-driven
Firing Order 1- 3- 2 Raw Water Flow, 7.0-7.5 gpm (26.4-28.3 Ipm)
at 3600 RPM measured before discharge into
Direction of Rotation Counterclockwise viewed from the back
water injected exhaust elbow.
end
Cooling Water Capacity 3.5 qts. (3.4 liters)
Inclination 25 continuous, all directions
0
30 temporary, all directions

0
LUBRICATING SYSTEM
Governor Mechanical
Type Forced lubrication by gear pump
Oil Filter Fuel flow, paper element spin-on
FUEL SYSTEM disposals
Oil Capacity 2.7 qts. (2.6 liters)
Fuel Pump Electric fuel pump
Oil Grade API specification SJ class
Fuel Unleaded 89 octane or higher gasoline
Distributor Breakerless distributor AC GENERATOR SPECIFICATIONS
Spark Plugs 14 mm Type 2 pole capacitor regulated
50/60 hertz-1.0 power factor
Ignition Coil 12 volt
Rating (minimum) r~m Model Hz KVA VAC
Flame Arrester Metal screen type
3000 3.75 Kw 50 3.75 230
Carburetor Single-barrel downdraft type 3000 6.0 Kw 50 6.0 230
3000 8.0 Kw 50 8.0 230
ELECTRICAL SYSTEM - 3600 4.5 Kw 60 4.5 120
12 volt reduction gear wlsolenoid 3600 7.2 Kw 60 7.2 120
Start Motor
3600 9.6 Kw 60 9.6 120
Starting Battery 12 volt negative ground Consult factory for 120/240 volt application
Battery Capacity 300 cold cranking amps (CCA) (min) TUNE-UP SPECIFICATIONS
Battery Charging Integral electriC, 17 amps
Spark Plug Gap 0.031 ± .002 inches (0.8 ± 0.05 mm)
AIR REQUIREMENTS Spark Plug Torque 10.8 - 15.2 Ib-ft
Generator Cooling 225--250 CFM Valve Clearances Intake valves: 0.20 mm (.008 in)
(6.3-7.0 cmm) Exhaust valves: 0.30 mm (.012 in)
Engine Combustion 42 CFM (1.2 cmm) Timing Specifications 0 0
18 ± .5 BTDC at 3600 rpm
(all models) (no load on generator)
Engine Cooling 100 CFM (2.8 cmm) Cylinder Head 60 - 70 Nm 43-51 ft-Ibs
Boll Torque see TORQUING THE CYLINDER HEAD
BOLTS under ENGINE ADJUSTMENTS
-..v- WESTERBEKE
Engines & Generators Rev. 6/1/98
36
BCGTC GENERATOR PARTS IDENTIFICATION
CARBURETOR
GOVERNOR
FRESH WATER
FILL CAP
WATER
OIL FILTER
TEMPERATURE -------1
SWITCH
Oil PRESSURE
SWITCH
: : i - - - - - RAW WATER
PUMP
DC BATIERY
GROUND CONNECTION
DATA TAG
STARTER ZINC ANODE

WITH SOLENOID
Oil
RIGHT SIDE DRAIN HOSE
Oil
FILL CAP
DISTRIBUTOR
WATER INJECTED
EXHAUST ELBOW
COIL
FRESH WATER
DRAIN PLUG
LEFT SIDE
~ WESTERBEKE
37
STANDARD HARDWARE TORQUES
NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.
Grade 4 Pitch Ib-n kg-m Grade 7T, 8T and 8·.8 Pitch Ib-n kg-m
6mm bolt head/nut 1 2.9-5.1 0.4-0.7 6mm bolt head/nut 1 5.S-S.7 0.S-I.2
Smm bolt head/nut 1.25 7.2-11.6 1.0-1.6 Smm bolt head/nut 1.25 14.5-21.7 2.0-3.0
10mm bolt headinut 1.25 13.7-22.4 1.9-3.1 10mm bolt head/nut 1.25 2S.9-39.S 4.0-5.5
10mm bolt headinut 1.5 13.0-21.7 I.S-3.0 10mm bolt head/nut 1.5 26.S-37.6 3.7-5.2
12mm bolt head/nut 1.25 (ISO) 25.3-39.S 3.5-5.5 12mm bolt head/nut 1.25 (ISO) 54.2-75.9 7.5-10.5
12mm bolt headinut 1.5 25.3-39.8 3.5-5.5 12mm bolt head/nut 1.5 50.6-65.1 7.0-9.0
12mm bolt headinut 1.75 21.7-36.2 3.0-5.0 12mm bolt head/nut 1.75 43.4-61.5 6.0-S.5
13mm bolt headinut 1.5 32.5-50.6 4.5-7.0 13mm bolt head/nut 1.5 57.9-S6.S S.0-12.0
14mm bolt headinut 1.5 36.2-57.9 5.0-S.0 14mm bolt headinut 1.5 72.3-10S.5 10.0-15.0
14mm bolt head/nut 2 34.0-55.7 4.7-7.7 14mm bolt head/nut 2 6S.7-101.3 9.5-14.0
16mm bolt head/nut 1.5 54.2-79.6 7.5-11.0 16mm bolt headinut 1.5 10S.5-166.4 15.0-23.0
16mm bolt head/nut 2 51.4-76.7 7.HO.6 16mm bolt head/nut 2 101.3-159.1 14.0-22.0
Grade 6T Grade 5 Cap Screw
Bmm bolt head/nut 1 4.3-6.5 0.6-0.9 1/4 UNC 9-11 1.2-1.5

Bmm bolt head/nut 1.25 10.S-15.9 1.5-2.2 1/4 UNF lH3 1.5-1.S
10mm bolt head/nut 1.25 21.7-32.5 3.0-4.5 5/16 UNC IS-20 2.5-2.S
10mm bolt head/nut 1.5 19.5-30.4 2.7-4.2 5/16 UNF 21-23 2.9-3.2
12mm bolt head/nut 1.25 (ISO) 36.2-57.9 5.0-S.0 3/S UNC 2S-33 3.7-4.6
12mm bolt head/nut 1.5 36.2-50.6 5.0-7.0 3/S UNF 30-35 4.1-4.S
12mm bolt head/nut 1.75 34.7-49.2 4.S-6.S 7/16 UNC 44-49 6.1-6.S
7/16 UNF 50-55 6.9-7.6
1/2 UNC 6S-73 9.4-10.1
1/2 UNF 73-S0 10.Hl.l
38
BCGTC GENERATOR HARDWARE TORQUES
TIming Belt Nm ft. Ibs. Front Case, Counterbalance Shaft Nm ft.lbs.
Crankshaft bolt 135-145 98-105 Front case bolt 8-10 6-7
Timing belt cover bolt 10-12 7-9 OJ! pump cover bolt 8-10 6-7
Camshaft sprocket bolt 80-100 58-72 Oil pan bolt 10-t2 7-9
Oil pump sprocket nut 50-57 36-41 Oil drain plug 35-45 25-33
Timing tensioner nut 22-30 7-9 Oil screen bolt 15-22 11-16
Timing belt rear cover bolt 10-12 Oil pump driven gear bolt 34-40 25-29
Water Pump Rear cover bolt 10-12 7-9
Water pump 8-10 6-7 Piston and Connecting Rod
Rocker Arms and Rocker Shaft Connecting rod cap nut 15+90 tum
0
11 + 90° tum
Rocker cover shaft 29-35 21-25 Crankshaft, Bearing
Camshaft thrust plate bolt 10-12 7-9 Oil seal case bolt 10-12 7-9
Rocker arm adjust nut 8-10 6-7 Bearing cap bolt 50-55 36-40
Cylinder Head, Valve Cylinder Block
Cylinder head bolt (cold engine) 60-70 43-5t Taper plug 1/16 8-12 6-9
Taper plug 1/8 t5-22 11-16
Water drain plug 35-45 25-33
Taper plug pt-l/4 35-45 25-33
~ WESTERBEKE
39
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 25.40 15 381.00 1 0.0394 15 0.5906
2 50.80 20 508.00 2 0.0787 20 0.7874
3 76.20 25 635.00 3 0.1181 25 0.9843
4 101.60 30 762.00 4 0.1575 30 1.1811
5 127.00 35 889.00 5 0.1969 35 1.3780
10 254.00 40 1016.00 10 03937 40 1.5748
10 MIlliMETERS = lCENTIMETER, 100 CENTIMETERS = 1 METER = 39.37 INCHES (3.3 FEET)
INCHES TO METERS METERS TO INCHES

Inches Meters Inches Meters Meters Inches Meters Inches
1 0.0254 7 0.1778 0.1 3.937 0.7 27.559
2 0.0508 8 0.2032 0.2 7.874 0.8 31.496
3 0.0762 9 0.2286 0.3 11.811 0.9 35.433
4 0.1016 10 0.2540 0.4 15.748 1.0 39.370
5 0.1270 11 0.2794 0.5 19.685 1.1 43.307
6 0.1524 12 0.3048 0.6 23.622 1.2 47.244
TO CONVERT METERS TO CENTIMETERS, MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS

Yards Meters Yards Meters Meters Yards Meters Yards
1 0.91440 6 5.48840 1 1.09361 6 6.56168
2 1.82880 7 6.40080 2 2.18723 7 7.65529
3 2.74320 8 7.31520 3 3.28084 8 8.74891
4 3.65760 9 8.22960 4 4.37445 9 9.84252
5 4.57200 10 9.14400 5 5.46807 10 10.93614
MOVE DECIMAL POINT FOR HIGHER VALUES - e.g. 6,000 METERS = 6,561.68 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

Ib kg Ib kg kg Ib kg Ib
1 0.454 6 2.722 1 2.205 6 13.228
2 0.907 7 3.175 2 4.409 7 15.432
3 1.361 8 3.629 3 6.614 8 17.637
4 1.814 9 4.082 4 8.818 9 19.842
5 2.268 10 4.536 5 11.023 10 22.046
GALLONS TO LITERS LITERS TO GALLONS
Gallons Liters Gallons Liters Liters Gallons Liters Gallons
1 3.79 10 37.86 1 0.26 60 15.66
2 7.57 20 75.71 2 0.53 90 23.77
3 11.36 30 113.57 5 1.32 120 31.32
4 15.14 40 151.42 10 2.64 150 39.62
5 18.93 50 189.28 20 5.28 180 47.54
PINTS TO LITERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 0.47 6 2.84 1 2.11 6 12.68
2 0.95 7 3.31 2 4.23 7 14.79
3 1.42 8 3.79 3 6.34 8 16.91
4 1.89 9 4.26 4 8.45 9 19.02
5 2.37 10 4.73 5 10.57 10 21.13
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 OF
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 °C
40
SUGGESTED SPARE PARTS
WESTERBEKE MARINE GASOLINE GENERATORS
Zinc Anodes
.G~Carry several.
Spall< Plugs
,
Heat Exchanger End Gasket Always carry a full set. Raw Water Impeller and Gasket
Check annually.
Oil Filter
Have several aboard. Fuel Lift Pump
Change every 100 hours. Solid Slate Model. Have a
spare on board.
and Gasket
Carry matched pairs.
Oistributor Cap and Wires Inspect every 100 hours. Always carry a spare aboard.
SPARE PARTS KITS

WESTERBEKE also offers two Spare Parts Kits,
each packaged in a rugged hinged toolbox. KIT B
Kit A includes the basic spares. Impeller Kit
Kit B is for more extensive off-shore cruising. Water Pump Repair Kit
KIT A Thermostat Kit
Impeller Kit Zinc Anodes
Heat Exchanger Gasket Complete Gasket Kit
Oil Filter Heat Exchanger Gasket
Drive Belts Oil Filter
ZineAnodes Drive Belts
Spark Plugs Spark Plugs
~ WESTERBEKE
41

Westerbeke 4,5BCGTC Instruction Manual PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Westerbeke 4,5BCGTC Instruction Manual PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

Engines & Generators

INTRODUCTION PREVENT BURNS - FIRE

Engines & Generators

ACCIDENTAL STARTING TOXIC EXHAUST GASES

A WARNING: Sulphuric acid in batteries can cause Weakness and sleepiness

severe injury Dr death! AVOID MOVING PARTS

A WARNING: Do not work on machinery when you

Engines & Generators

CODES AND REGULATIONS

A detailed 40 page Marine Installation Manual covering gasoline and

Application of Council Directive(s) EMC 89/336IEEC

Standard(s) to Which Conformity EN50081-1

Manufacturers Name Westerbeke Corporation

Manufacturers Address 41 Ledin Drive

Type of Equipment Marine Gasoline Generator

Product Name Westerbeke Marine

Product Options All

Place Avon. Massachusetts, U.S.A.

Date: September 1, 1996 Carleton F. Bryant

Chief Operating Officer

ITYPE I Gasoline Marine Generator I

IGROUP OF +++++ I +++++ I +++++ I

Certification number IWES003 /

Signed .~./h i _.\-:::// r <'-£.- -,

Engines & Generators

CUSTOMER IDENTIFICATION CARD (Typical)

Engines & Generators

Engines & Generators

, 8 AMP FUSE: THE 8 AMP

CIRCUIT BREAKER: THE HEAVY

SAFETY SHUTDOWN SWITCHES Low Oil Pressure Switch

High Exhaust Temperature Switch

Engines & Generators

ENGINE OIL COOLANT RECOVERY TANK

A CAUTION: 00 not allow two or more brands of

COOLANT RECOVERY TANK

A CAUTION: When starting the generator, it is

Engines & Generators

k CENTER OFF/RUN CENTER OFF/RUN

STARTISTOP SWITCH ON SWtTCH

• Check your fuel supply.

• Monitor the control panel gauges.

• Confinn exhaust smoke:

A WARNING: Never attempt to perform any service while the engine is

CHECK HOURS OF OPERATION

Engines & Generators

CHECK HOURS OF OPERATION

'WESTERBEKE recommends thiS service be performed by an authonzed mechamc.

Engines & Generators

DRIVE BELT ADJUSTMENT

A CAUTION: The drive belt must be properly tensioned

A WARNING: Shut off the fuel valve at the tank Ii

CARBURETOR FUEL PUMP

A WARNING: Fuel leakage at the fuel pump or its

RAW WATER INTAKE

GASOLINE/WATER SEPARATOR AND FILTER

Most installers include a type of filter/water separator with

OIL DRAIN HOSE

APPLY A THIN COAT OF CLEAN OIL TO THE D-RING

~PPLYI'!~I~. ~OA~OF CLEAN Oil TO

A CAUTION: To avoid damage to the banery charg-