Westerbeke 4.5KW BCGB-60HZ

Questions and Answers

H
Howard NicholsJul 31, 2025
What to do if my Westerbeke 4.5KW BCGB-60HZ engine cranks but fails to start?
- Q
  qwilliamsJul 31, 2025
  If the engine cranks but doesn't start, several issues could be the cause. It could be due to running out of fuel, the engine being flooded, a fuel pump malfunction, worn or faulty spark plugs, high tension wires grounding, a faulty ignition coil or distributor, a faulty run relay, a faulty wire connection, no engine compression, or a faulty idle adjustment. Also, the carburetor float needle valve might be open or damaged, in which case you should clean or replace the needle valve. The float in the carburetor might be leaking, so you should repair or replace the float. The float chamber gasket could be damaged or the securing screws loose, so replace the gasket and/or tighten the screws.
J
jasonbrooksAug 7, 2025
Why my Westerbeke Portable Generator engine does not crank?
- R
  Robert GibsonAug 7, 2025
  If the engine does not crank, it could be due to a voltage drop at the starter solenoid terminal, the engine's 20A circuit breaker tripping, a low or dead battery, loose battery connections, a faulty wire connection, a faulty start switch, a faulty start relay (K1), a faulty starter solenoid, raw water filled cylinders, filters clogged by contaminated fuel, a voltage drop at (+) at the overspeed switch, or a faulty overspeed switch (reset & start).
K
Kristen KingAug 15, 2025
What to do if Westerbeke Portable Generator engine starts, runs and then shuts down?
- K
  Kimberly SotoAug 15, 2025
  If the engine starts, runs, and then shuts down, the issue might stem from a faulty shutdown switch (related to oil pressure, water, or exhaust temperature), high engine water or exhaust temperature, a dirty fuel/water separator filter, a faulty mechanical check valve at the fuel supply (if installed), a low oil level in the sump, a faulty fuel pump, or a faulty engine temperature sensor.
D
davidramirezAug 23, 2025
Why Westerbeke 4.5KW BCGB-60HZ Portable Generator engine starts, runs but does not come up to speed?
- E
  Eric LeeAug 23, 2025
  If the engine starts and runs but doesn't reach the correct speed, it could be caused by a fuel line restriction, a faulty mechanical check valve at the fuel supply, throttle plate binding, a faulty fuel pump, a faulty wire connection, a faulty engine temperature sensor, an AC generator overload, or high exhaust pressure.

Summary

SAFETY INSTRUCTIONS

INTRODUCTION

Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules...

PREVENT ELECTRIC SHOCK

Do not touch AC electrical connections while engine is running, or when connected to shore power.

PREVENT BURNS - HOT ENGINE

Do not touch hot engine parts or exhaust system components. A running engine gets very hot!

PREVENT BURNS - FIRE

Fire can cause injury or death!

PREVENT BURNS - EXPLOSION

Explosions from fuel vapors can cause injury or death!

ACCIDENTAL STARTING

Accidental starting can cause injury or death!

BATTERY EXPLOSION

Battery explosion can cause injury or death!

BATTERY ACID

Sulfuric acid in batteries can cause severe injury or death!

TOXIC EXHAUST GASES

Carbon monoxide (CO) is a deadly gas!

AVOID MOVING PARTS

Rotating parts can cause injury or death!

HAZARDOUS NOISE

High noise levels can cause hearing loss!

INSTALLATION

CODES AND REGULATIONS

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing...

SIPHON-BREAK

Provisions must be made to install a siphon-break in the raw water supply hose...

CONTROL PANELS

GENERATOR CONTROL PANEL

Description of switches and functions on the generator's main control panel.

REMOTE PANEL

Description of components and operation of the remote generator control panel.

PREPARATIONS FOR INITIAL START-UP

PRESTART INSPECTION

Checklist of essential items to inspect before starting the generator for the first time.

OPERATING INSTRUCTIONS

Starting the Generator

Procedure for starting the generator using the control panel.

Stopping the Generator

Procedure for stopping the generator using the control panel.

EMERGENCY STOPPING

How to stop the generator in an emergency by removing the fuse or battery.

Abnormal Stop

Identifies fault conditions that cause automatic engine shutdown.

REMOTE PANEL OPERATION

Starting and stopping the generator using the remote panel controls.

BREAK-IN PROCEDURE;DAILY OPERATION

BREAK-IN PROCEDURE

Run the generator between 20% to 60% of full load for the first 10 hours.

CHECK LIST

Daily checklist of essential items to inspect before starting the generator.

STOPPING THE GENERATOR

Procedure for stopping the generator after loads are removed.

SAFETY SHUTDOWN SWITCHES

High Exhaust Temperature Switch

Function and trip point of the high exhaust temperature shutdown switch.

Low Oil Pressure Switch

Function and trip points of the low oil pressure shutdown switch.

High Water Temperature Switch

Function and trip point of the high water temperature shutdown switch.

High RPM Shutdown Switch

Function and reset procedure for the high RPM shutdown switch.

Engine Circuit Breaker

Description of engine circuit breaker protection and reset.

COOLING SYSTEM

CHANGING COOLANT

Refilling the Coolant

Changing the Raw Water Pump Impeller

ENGINE LUBRICATING OIL

CHANGING THE ENGINE OIL

Replacing the Oil Filter

REFILLING THE OIL SUMP

OIL PRESSURE

TESTING OIL PRESSURE

LOW OIL PRESSURE

4.5 KW; 7.0 KW BCGB GENERATOR WIRING DIAGRAM #43864

4.5 KW;7.0 KW BCGB GENERATOR WIRING SCHEMATIC #43864

ENGINE ADJUSTMENTS

ENGINE SPEED (HERTZ) ADJUSTMENT

Governor adjustments to set engine speed for desired frequency and voltage output.

TORQUING THE CYLINDER HEAD BOLTS

DRIVE BELT ADJUSTMENT

VALVE CLEARANCE ADJUSTMENT

IGNITION TIMING

TIMING BELT INSPECTION AND REPLACEMENT

Procedures for inspecting and replacing the engine timing belt.

ENGINE TROUBLESHOOTING

Engine does not crank.

Lists probable causes for the engine failing to crank.

Engine cranks but fails to start.

Lists probable causes for the engine cranking but not starting.

Engine starts, runs and then shuts down.

Lists probable causes for the engine starting and then shutting down.

Engine starts, runs but does not come up to speed.

Lists probable causes for the engine not reaching the correct speed.

Engine hunts.

Lists probable causes for irregular engine speed (hunting).

Engine misfires.

Lists probable causes for the engine misfiring.

Engine backfires.

Lists probable causes for the engine backfiring.

Engine overheats.

Lists probable causes for the engine overheating.

Low oil pressure.

Lists probable causes for low engine oil pressure.

High oil pressure.

Lists probable causes for high engine oil pressure.

No DC charge to the starting battery.

Lists probable causes for no DC charge to the battery.

Blue exhaust smoke discharge from the engine.

Black exhaust smoke discharge from the engine.

Poor performance at generator speed.

BC GENERATOR SINGLE PHASE

SINGLE EXCITER NO-LOAD VOLTAGE ADJUSTMENT

DUAL EXCITER CIRCUIT MODEL

TESTING THE EXCITER WINDINGS

Rotating Field;Auxiliary Windings and Diodes

Main Stator Windings

INTEGRAL CONTROLLER (I.C.)

Testing the Battery Charging Circuit

BATTERY CHARGING CIRCUIT

TESTING THE CHARGING CIRCUIT

SHORE POWER TRANSFER SWITCH

Switching Shore Power to Generator Power

GENERATOR SPECIFICATIONS

ENGINE SPECIFICATIONS

AC GENERATOR (SINGLE PHASE)

TUNE-UP SPECIFICATIONS

BCGB GENERATOR HARDWARE TORQUES

Westerbeke 4.5KW BCGB-60HZ Specifications

General

Power Output	4.5 kW
Frequency	60 Hz
Fuel Type	Gasoline
Starting System	Electric Start
Cooling System	Liquid Cooled
AC Voltage	120/240V
Rated Output	4.5 kW
Model	4.5KW BCGB-60HZ