Westerbeke 3.0KW BCG, Operator'S Manual

Page 1: ...oled Models _ 3 CGiFresh Water Cooled Modell NO 48009 REVISION 5 JUNE 2011 WESTERBEKE WEsTcRBCKE CORPORATION MYLeS STANDISH INDUSTRIAL PARK 160JOHN HANCOCK ROAD TAUNTON MA 0278 J 7319 U S A Af MMAMemb...

Page 2: ...Gasoline with an ETHANOL content higher than 10 E10 is not allowed and may void warranty Engines Generators...

Page 3: ...hrobbing in Temples 0 Muscular Twitching o Vomiting o Weakness andSleepilress o Inability to Think Coherently IF YOU OR ANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIR IMMEDIATELY If...

Page 4: ...uretor fuel line filter fuel pump or other potential sources ofspilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not oper...

Page 5: ...d may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadlygas Ensure that the exhaust system is adequate to expe...

Page 6: ...o 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 engi...

Page 7: ...line wiu result in raw water damage to the engine andpossibleflooding ofthe boat Ifyou have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under th...

Page 8: ...hanging the Impeller 16 Cooling System Fresh Water Cooled Models 17 Raw Water Pumps Overhaul 18 Re Assembly 19 Cooling System 20 ThermostaL il Heat Exchanger 21 Carburetor 22 DC ClrcuitlBattery 23 Sho...

Page 9: ...METER START STOP SWITCH CONTROL AC 3 0KW BC G GENERATOR I PARTS lD ENTlfICATION CONTROL MODULE LEFT sIDe COOLANT TEMPERATURE SWITCH CDOLAINT PRES IURE EXHAUST TEMPERATURE SWITCH DIPSTICK SERVICE SIDE...

Page 10: ...BPMG GENERATOR i PARTS iDENTIFICATION u COIL SERVICE SIDE FRESHWATER COOLANT MODEL MAGNErtC PICK UP CONNECTION CONTROL PUMP LEFT SIDE OlATI RMDUNT Engin I Generators 3 WATER INJECTED ELBOW HEAT EXCHA...

Page 11: ...technical data parts lists manuals hrochures and catalogs provided from sources other than WESTERBEKE are not within WES1ERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFT...

Page 12: ...turer cannot control how or where the generator is installed in the vessel or the manner in which the mtit is operated and serviced in the field This is up to the buyer owner operator NOTE Seven impor...

Page 13: ...pace on all sides for ventilation and servic ing Locate the generator away from living quarters and away from bilge splash and vapors Referto WESTERBEKE S installation manualfor detailed information o...

Page 14: ...reak is to stop the raw water flow after the engine is shutdown This flow if not stopped will fill the exhaust system and possibly the engine as well The raw water supply hose must be looped well abov...

Page 15: ...on of this manual and not be extended if synthetic oils are used NOTE The information above supersedes all previous statements regarding synthetic oil NOTE Be very careful not to overfill the oil sump...

Page 16: ...calise severe damage to the engine STOPPING To Stop Press the rocker switclll stoP and release The engine will shutdownand the LED ht will1 lJm off STAR T GENERATOR OPERATION I Depre witch to START pO...

Page 17: ...missing parts disconnected wires unattached hoses and check threaded connections Search for any gasoline leaks A CAUTION When starting the generator it is recommended that allACloads especially large...

Page 18: ...r ifthere is an electrical overload This circuit breaker should be manually switched off when servicing the engine generator to ensure that no poweris coming into the boat The breaker is reset manuall...

Page 19: ...or 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 INFORMATI...

Page 20: ...nd replace as necessary Check that all connections are tight D D D 0 D D Hose should be hard tight Replace if soft or spongy Check and tighten all hose clamps 0 D D D D D Inspect and replace if necess...

Page 21: ...OIL FILTER ASSEMBLY PRESSURE SWITCH Vhen removing the used oil filter you may find it helpful to p ll eh a hole in the upper and lower portion of the old filter to drain the oil into a container befo...

Page 22: ...Coats Guard requirements The metal bowls have drain valves to use when checking for water and impurities FUEL PUMP Periodically check the fuel connections to and out ofthe pump and make sure that no...

Page 23: ...al engine thermostat controls the water temperature This thermostat is maintenance free CHANGING THE RAW WATER PUIVIP 1 Close the raw water iutake valve to prevent water from syphoning from the pump 2...

Page 24: ...n so as to install the replacement impeller with blades working in the same direction 2 Using pliers grab the impeller hub and withdraw the impeller from the pump Inspect the inside of the pump the ca...

Page 25: ...shown in the illustration Remove th wear plate to expose the impeller Notice the direction the impeller blades are working in so as to install the replacement impeller with blades working in the same...

Page 26: ...rin on the outer surface of the ceramic seal seat and slide it over the shaft white ceramic facing out and seat it in the body of the pumW Place some glycerin on the inner area and with a twisting mot...

Page 27: ...con traction of the engines coolant during engine operation with out introducing air into the system This recovery tank is provided with fresh water cooled models aod with the fresh water coolaot con...

Page 28: ...move clean and pressure test the engine s heat exchanger A local automotive radiator shop should be able to clean and test the heat exchanger NOTE Operating in silty and or tropical waters may require...

Page 29: ...closes off a fuel port that is supplying i additional fuel on a cold start after start up This is a thermal electric device that slowly moves a needle outward when DC power is applied after start up t...

Page 30: ...ith the engine runuing it should indicate 13 14 volts Ifonly battery voltage is indicated check the tenuinal connections at the battery Battery Maintenance Review the manufacturer s recommendations an...

Page 31: ...correctly SENSOR ADJUSTMENT PROCEDURE Speed This adjustment is used to raise or lower the engine s speed This generator engine is set to run at 2200 RPM Gain Adjusts the overall set of the engine If...

Page 32: ...the oil pressure exceeds the specified pressure the oil pushes open the relief valve in the oil pump and returns to the oil sump keeping the oil pressure within it s specified range TESTING OIL PRESSU...

Page 33: ...6 Reinstall the two plugs connect the wires and open the thru hull valve seacock IGNITION TIMING The magneto employs the electric ignition advance system that advances ignition timing with an increase...

Page 34: ...e raw water cooling circuit th reby reducing the effects of electrolysis on other components of the system The condition of the zinc anode should be checked monthly and the anode cleaned or replaceq a...

Page 35: ...en the valve end and the adjusting screw e Set the valve clearance by the adjusting screw VALVE CLEARANCE INTAKE 0 13 0 17mm 0 095 0 007in EXHAUST 0 18 0 22mm 0 007 O OOgin d TIghten the lock nut e Ag...

Page 36: ...rnator bracket 2 Thm the crankshaft and allgn 0 mark on the drive pulley and the 0 mark on the cyllnder head 3 Remove the timing belt from the driven pulley side 4 Installthe timing beltfrom the drive...

Page 37: ...pump 3 Faulty PC board 4 Improper drive belt lension 5 Low DC battery voltage 6 High exhaust back pressure 7 Dirty fuel filter B Generator overload 9 Valves need adjustment The following troubleshoot...

Page 38: ...e MPU voltages to PC board Cranking 1 5 2 0 VAC Running 4 0 5 0 VAC 2200 rpm BY PASSING THE OVERSPEED BOARD Afaulty Overspeed PC Board can be the cause of an unwanted shutdown It can also be the canse...

Page 39: ...7 HIGH TENSION LEADS 6 8nO 1D OOO CARBERATOR SOLENOID 20 ACTUATOR 3 0 3 1 NOTE TESTER USED FLUKE MULTlMETER UN IT CAN TOLERANCE 20 RESTART U iITCAN NOT RESTART OVERSPEED PC BOARD PN 045377 J NElIREWOT...

Page 40: ...ade in larger sizes Because the heavy surge of current needed for starting motors is required for only an instant the generator will not be damaged ifit can bring the motor up to speed in a few second...

Page 41: ...2 3 1 2 3 Shorted Stator Open Stator Shorted Rotor Diode Shorted Rotor Thermister Shorted Rotor Capacitor Open Rotor Diode Faulty Capacitor Open Exciter Winding Shorted Exciter Winding Faulty Rotor D...

Page 42: ...wn or if the engine runs 10 15 seconds and then shuts down can be caused by a faully over speed board 1 Refer to the Wiring Diagram in this manual 2 Unplug the brown 6 wire that connects between pin 1...

Page 43: ...harmful chemicals which can reduce the life of your engine s intemalparts Clean the filter screen in the flame arrester and place a clean cloth lightly soaked in lube oil around the flame arrester to...

Page 44: ...for the winter This procedure is best accomplished by disconnecting the water intake hose from the vessels thru hull fitting Close the intake valve before disconnecting tbe bose Insert the hose end i...

Page 45: ...Cold Cranking Amps CCA 11 Amp 70 Amps DC LUBRICATION SYSTEM Wet sump system trochoid Iype pump Fuel flow paper element spin on disposals 1 5 qls 91 4 L API SJ SL or SM SAB IOW 30 or 15W 40 General Raw...

Page 46: ...454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg Inches...

Page 47: ...85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7 143...

Page 48: ...2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28064 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...

Page 49: ...TS WESTERBEKE also offers two Spare Parts Kits i each packaged in a rugged hinged toolbox Kit A includes the basic spares iKit B is for more extensive off shore cruising 1 KIT A IMPELLER KIT OIL FILTE...

Page 50: ...WESTERBEKE Engines Generators 1153612011...