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Westerbeke 7.2 KW BCGTC - 60 Hz - User Manual

Westerbeke 7.2 KW BCGTC - 60 Hz
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I
OPERATORS
MANUAL
WESTERBEKE
GASOLINE
GENERATOR
CARBURETOR
MODELS
4.5
KW
BCGTC
-
60
Hz
3.
75KW
BCGTC
-
50
Hz
7.2
KW
BCGTC
-
60
Hz
6.0
KW
BCGTC
-
50
Hz
9.6
KW
BCGTC
-
60
Hz
8.0
KW
BCGTC
-
50
Hz
Single
Phase
PUBUCATION 42832
1
st
Edition / September 1997
~
WESJ'ERBEKE
WES
T
ERBEKE
CORPORATION
·
AVON
INDUSTRIAL
PARK
AVON
,
MA
02322
TEL:
(SOB)
588-7700 ·
FAX:
(SOB)
559-9323
~~.,"""
~M'A
M~mber
Naiio1l41
Morine
M
o.twfoctu~rsASS()CiD.tion

Table of Contents

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Summary

OPERATORS MANUAL

WESTERBEKE GASOLINE GENERATOR

Identifies the equipment as a Westerbeke gasoline generator.

CARBURETOR MODELS

Specifies that the generator is a carburetor model.

ETHANOL CONTENT WARNING

E-15 Fuel Restriction

Prohibits the use of gasoline with 10% or higher ethanol content.

CARBON MONOXIDE HAZARD WARNING

Symptoms of Carbon Monoxide Exposure

Lists potential health effects of CO exposure.

Immediate Action for CO Exposure

Provides immediate steps if CO exposure symptoms are experienced.

SAFETY INSTRUCTIONS

Introduction to Safety Precautions

General safety advice and context for the manual.

Preventing Electric Shock

Safety precautions to avoid electrical hazards.

Preventing Burns: Hot Engine

Safety advice for hot engine components.

Preventing Burns: Fire

Safety measures to prevent fires.

Preventing Burns: Explosion

Safety precautions against fuel vapor explosions.

ADDITIONAL SAFETY INSTRUCTIONS

Preventing Accidental Starting

Precautions to prevent unintentional engine starts.

Battery Explosion Hazards

Safety warnings regarding battery explosions.

Battery Acid Hazards

Hazards and precautions when handling battery acid.

Toxic Exhaust Gases

Information on carbon monoxide hazards.

MORE SAFETY INSTRUCTIONS

Avoiding Moving Parts

Safety advice to avoid injury from rotating components.

Hazardous Noise Levels

Warnings about noise levels and hearing protection.

Generator Installation Standards

Information on installation standards and regulations.

INSTALLATION GUIDELINES

Codes and Regulations Compliance

Compliance requirements for marine installations.

Siphon Break Installation

Procedure to prevent water siphoning into the engine.

Exhaust System Requirements

Requirements for marine exhaust system certification.

DECLARATION OF CONFORMITY

Applicable Council Directives

List of applicable EU directives for the product.

Declared Standards

List of standards the product conforms to.

Manufacturer Information

Name and address of the manufacturing company.

CERTIFICATE OF CONFORMITY

Equipment Type and Manufacturer

Classification of the certified equipment and manufacturer.

Certification Details

Details of the conformity certification.

OPERATORS MANUAL INTRODUCTION

Warranty Registration Procedures

Information on warranty registration and claims.

Customer Identification Card Details

Details about the customer identification card.

Serial Number Location

Location of the generator's serial and model number.

MANUAL INTRODUCTION AND GUIDANCE

Ordering Replacement Parts

Guidelines for ordering replacement parts.

Understanding Manual Notations

Explanation of symbols used for critical information.

Ensuring Generator Longevity

Key steps for ensuring long generator life.

Recommended Spares and Accessories

Information on recommended spare parts and accessories.

CONTROL PANEL FUNCTIONS

Generator Control Panel Layout

Description of controls on the generator panel.

Remote Control Panel Layout

Description of controls on the remote panel.

Overspeed Protection Circuit

Function of the overspeed shutdown circuit board.

AUTOMATIC SAFETY SHUTDOWN SWITCHES

High Exhaust Temperature Switch Function

Function and operation of the exhaust temp. switch.

High Water Temperature Switch Function

Function and operation of the high water temp. switch.

Low Oil Pressure Switch Function

Function and operation of the low oil pressure switch.

Engine Circuit Breaker Protection

Protection provided by the engine circuit breaker.

FUEL, OIL, AND COOLANT MANAGEMENT

Gasoline Fuel Requirements

Fuel requirements and care of the fuel supply.

Engine Oil Specifications

Engine oil specifications and change intervals.

Engine Coolant Mixture

Coolant mixture recommendations and properties.

INITIAL START-UP PREPARATION

Pre-Start Inspection Checklist

Checklist for pre-start inspection of the generator.

Cooling System Air Purge Note

Guidance on purging air from the cooling system.

Starting with AC Loads Caution

Precaution for starting generator with AC loads.

OPERATING PROCEDURES

Starting and Stopping Generator Panel

Procedure for starting and stopping generator on panel.

Starting and Stopping Remote Panel

Procedure for starting and stopping generator remotely.

Emergency Generator Stop Procedure

Method for emergency generator shutdown.

Cold Weather Starting Considerations

Considerations for starting in cold weather.

BREAK-IN AND DAILY OPERATION

Generator Break-In Procedure

Instructions for the initial break-in period.

Daily Pre-Start Checklist

Daily checklist before starting the generator.

Generator Stopping Procedure

Procedure for safely stopping the generator.

Generator Performance Adjustments

Information on governor and voltage adjustments.

SCHEDULED MAINTENANCE

Fuel System Maintenance

Maintenance for fuel supply and filters.

Coolant System Maintenance

Maintenance for engine oil level and coolant.

Drive Belts Inspection

Inspection of drive belts.

Visual Engine Inspection

General visual inspection of the engine.

CONTINUED MAINTENANCE SCHEDULE

Heat Exchanger Maintenance

Maintenance for the heat exchanger.

Raw Water Pump Maintenance

Maintenance for the raw water pump.

Coolant System Flushing

Maintenance for the coolant system.

Starter Motor Maintenance

Maintenance for the starter motor.

ENGINE COOLING SYSTEM OVERVIEW

Cooling Circuit Description

Overview of the engine cooling system components.

Cooling System Maintenance Importance

Warning about the importance of cooling system maintenance.

ENGINE COOLING CIRCUIT DETAILS

Thermostat Function and Testing

Function and maintenance of the thermostat.

Coolant Draining Procedure

Procedure for draining the engine coolant.

Coolant Refilling Procedure

Procedure for refilling the engine coolant.

Coolant Level Check Warning

Warning about checking hot coolant.

COOLING SYSTEM COMPONENTS

Raw Water Pump Operation

Description and maintenance of the raw water pump.

Impeller Replacement Procedure

Procedure for replacing the raw water pump impeller.

Zinc Anode Function and Care

Purpose and maintenance of zinc anodes.

Drive Belt Tension Adjustment

Procedure for adjusting drive belt tension.

FUEL SYSTEM COMPONENTS

Gasoline Fuel Specifications

Fuel requirements and fueling precautions.

Carburetor Description

Description of the carburetor type and features.

Fuel Filter;Separator Function

Importance and function of the fuel filter/separator.

Fuel Pump Safety Checks

Checks and warnings for the fuel pump.

ENGINE LUBRICATION SERVICE

Engine Oil Specifications and Changes

Engine oil specifications and change intervals.

Changing the Engine Oil

Procedure for changing the engine oil.

Replacing the Oil Filter

Procedure for replacing the engine oil filter.

Refilling the Oil Sump

Procedure for refilling the engine oil sump.

OPTIONAL REMOTE OIL FILTER

Remote Oil Filter Installation

Instructions for installing the optional remote oil filter.

DC ELECTRICAL SYSTEM OVERVIEW

12-Volt DC Control Circuit

Overview of the DC control circuit for starting/stopping.

Battery Specifications and Maintenance

Specifications and maintenance of batteries.

Battery Charging System

Information on the battery charging system.

Electrical Component Testing

Methods for testing electrical components.

DC WIRING DIAGRAM

Wiring Diagram #42834

Diagram showing DC electrical system wiring.

DC WIRING SCHEMATIC

Wiring Schematic #42834

Schematic of the DC electrical system.

REMOTE PANEL WIRING

Remote Panel Wiring Diagram #42857

Wiring diagram for remote panels.

ENGINE ADJUSTMENT PROCEDURES

Governor Engine Speed Adjustment

Procedure for adjusting engine speed and frequency.

Governor Adjustment Points

Specific adjustment points for the governor.

Governor Maintenance Schedule

Maintenance tasks for the governor.

Cylinder Head Bolt Re-Torquing

Procedure for re-torquing cylinder head bolts.

ENGINE MECHANICAL ADJUSTMENTS

Valve Clearance Adjustment Procedure

Procedure for adjusting valve clearances.

Ignition Timing Setting

Procedure for setting ignition timing.

Spark Plug Service

Spark plug inspection, gap, and torque specifications.

Choke Solenoid Function

Function and maintenance of the choke solenoid.

ENGINE CARBURETOR AND BELT ADJUSTMENTS

Carburetor Mixture Adjustment

Procedure for adjusting the carburetor.

Drive Belt Tension Adjustment

Procedure for adjusting drive belt tension.

TIMING BELT SERVICE

Timing Belt Removal

Steps for removing the timing belt.

Camshaft Sprocket Removal

Steps for removing the camshaft sprocket.

Oil Pump Sprocket Nut Removal

Steps for removing the oil pump sprocket nut.

TIMING BELT AND CRANKSHAFT SERVICE

Crankshaft Bolt Removal

Steps for removing the crankshaft bolt.

Timing Belt Replacement Criteria

Conditions requiring timing belt replacement.

Flange and Crankshaft Bolt Installation

Procedure for installing the flange and crankshaft bolt.

TIMING BELT INSTALLATION

Tensioner Spring and Tensioner Installation

Installation of the tensioner spring and timing belt tensioner.

Timing Belt Installation Procedure

Procedure for installing the timing belt.

FINAL TIMING BELT ADJUSTMENTS

Ensuring Timing Belt Tooth Engagement

Ensuring proper engagement of timing belt teeth.

Checking Timing Belt Tension

Checking timing belt tension using clearance.

Sealing Plug Installation

Sealing and tightening the plug after timing belt work.

ENGINE TROUBLESHOOTING GUIDE

Engine Fails to Crank

Probable causes for the engine not cranking.

Engine Cranks, Fails to Start

Probable causes for engine cranking but not starting.

Engine Starts and Shuts Down

Probable causes for engine shutting down unexpectedly.

Engine Fails to Reach Speed

Probable causes for engine not reaching full speed.

CONTINUED ENGINE TROUBLESHOOTING

Engine Misfires and Backfires

Probable causes for engine misfiring and backfiring.

Engine Overheating and Low Oil Pressure

Probable causes for engine overheating and low oil pressure.

High Oil Pressure and No DC Charge

Probable causes for high oil pressure and no battery charge.

Exhaust Smoke Issues

Causes for blue or black exhaust smoke.

GENERATOR PERFORMANCE AND MAINTENANCE

Using Electric Motors with Generator

Guidance on using electric motors with the generator.

Generator Speed and Frequency

Generator operating speeds for frequency output.

Adjusting Generator Frequency

How to adjust generator frequency.

General Generator Maintenance

General maintenance for the generator.

GENERATOR WIRING AND RESISTANCE

Generator Wiring Diagrams

Diagrams illustrating generator wiring configurations.

Winding Resistance Specifications

Table of winding resistance values.

AC ELECTRICAL CONNECTIONS

Connecting for Frequency and Voltage

Instructions for connecting for specific frequency/voltage.

LAY-UP AND RECOMMISSIONING

General Lay-Up Procedures

Introduction to lay-up and recommissioning procedures.

Cooling System Lay-Up

Lay-up procedures for the fresh water cooling system.

Lubrication System Lay-Up

Lay-up procedures for the lubrication system.

Fuel System Lay-Up

Lay-up procedures for the fuel system.

LAY-UP PROCEDURES FOR COMPONENTS

Intake Manifold and Starter Motor Lay-Up

Lay-up procedure for intake manifold and starter motor.

Cylinder Lubrication for Storage

Procedure for cylinder lubrication during lay-up.

Spare Parts Inspection During Lay-Up

Inspection of spare parts during lay-up.

BCGTC GENERATOR TECHNICAL SPECIFICATIONS

Engine Specifications Summary

Detailed engine specifications.

Fuel System Specifications

Specifications for the fuel system components.

Electrical System Specifications

Specifications for the electrical system.

AC Generator Specifications Summary

Detailed AC generator specifications.

GENERATOR PARTS IDENTIFICATION

Right Side Component Identification

Identification of parts on the right side of the engine.

Left Side Component Identification

Identification of parts on the left side of the engine.

HARDWARE TORQUE SPECIFICATIONS

Torque Values for Standard Hardware Grades

Torque values for various hardware grades.

BCGTC GENERATOR SPECIFIC TORQUES

Timing Belt Component Torques

Torque values for timing belt components.

Front Case and Shaft Component Torques

Torque values for front case and counterbalance shaft.

Water Pump and Rocker Arm Torques

Torque values for water pump and rocker arm components.

METRIC AND IMPERIAL CONVERSIONS

Length Conversion Tables

Tables for converting lengths between units.

Weight and Volume Conversion Tables

Tables for converting weight and volume.

Temperature Conversion Chart

Chart for converting temperatures between units.

SUGGESTED SPARE PARTS LIST

Individual Spare Parts Recommendations

Recommendations for carrying individual spare parts.

Spare Parts Kit Contents

Description of contents for spare parts kits.

Westerbeke 7.2 KW BCGTC - 60 Hz Specifications

General IconGeneral
BrandWesterbeke
Model7.2 KW BCGTC - 60 Hz
CategoryInverter
LanguageEnglish

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