Westerbeke 3.5 KW BCG 50Hz, Technical Manual

Page 1: ...KW BCG 50 Hz 5 0 KW BCG 50 Hz MARINE GASOLINE GENERATOR SETS Publication 038747 Edition One March 1990 l v WESTERBEKE WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNT...

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

Page 3: ...eaks and make sure the exhaust manifolds are securely attached and no warping exists Be sure the unit and its surroundings are well ventilated Use Extreme Care When Handling Engine Fuel A constant dan...

Page 4: ......

Page 5: ...r manufacturers with their own software and Westerbeke must depend on such software for the design of Westerbeke s own product software Such software may be outdated and nolongeraccurate Routine chang...

Page 6: ...NS 27 ENGINE DESCRIPTION 37 GENERATOR OVERHAUL 46 PREPARATIONS FOR OVERHAUL 47 DISASSEMBLY FOR OVERHAUL 48 ENGINE DISASSEMBLY 50 REMOVING THE CYLINDER HEAD FROM THE CYLINDER BLOCK 53 CYLINDER HEAD DIS...

Page 7: ...119 GENERATOR DESCRIPTION AND MODEL RATING 130 TROUBLESHOOTING AND ADJUSTMENTS FOR THE BC GENERATOR 131 COMPONENT RESISTANCE VALUES 134 GENERATOR TROUBLESHOOTING 143 GENERATOR HERTZ CYCLE AND VOLTAGE...

Page 8: ...pstick 4 5 KW BeG Marine Gasoline Generator Fresh Water Coolant Fill Oil Pressure i _ Switch lube Oii ill oy Zinc Anode Heat Exchanger Westerbeke Generators 4 Exhaust Temperature Switch DC Battery Gro...

Page 9: ...4 5 KW BeG Marine Gasoline Generator Fuel Shut off Snl llnnlf1 Air Intake Flame Arrester Governor AC Unit Data T lube Oil Drain Hose 5 Westerbeke Generators...

Page 10: ...ircuit Breaker Lube Oil Dipstick Oil Pressure Switch Heat Exchanger Westerbeke Generators 7 0 KW BCG BCGA Marine Gasoline Generator Exhaust Temperature Switch 6 DC Battery Ground Connection Rt rt_ wit...

Page 11: ...0 KW BCG BCGA Marine Gasoline Generator Intake Flame Arrester Control Pane Governor Water Temperature Switch AC Connections Outlet Sea Vater Pump Zinc Anooe Lube Oil Drain Hose 7 Westerbeke Generator...

Page 12: ...eG 514 These 1 0 plate illustrations are provided for the owner operator to fill in the unit serial number and gener ator serial number for future service and part needs NOTE Output rating for 50 hert...

Page 13: ...hanism 6 0 bhp at 1800 rpm maximum Hoof flybail type 5 speed regulation Multi sphere type 2 44 x 2 38 inches 62 0 x 60 5 mm 33 4 cubic inches 547 liter 1 2 3 Oockwise when viewed from the front 13 5Ib...

Page 14: ...onal contact points and condenser 14 mm x 1 25 pitch 0 55 x 0 05 in Westerbeke part number 33805 Always identify the generator model when ordering parts Conventional carburetor type with fuel pump Reg...

Page 15: ...TUDE Positive displacement rubber impeller belt driven 3 75 4 0 U S gpm 14 19 15 14Ipm 4 2 U S qts 3 9 liters Fully Force fed type by Trochoid pump crankshaft driven Full flow paper element spin on ty...

Page 16: ...exciting Capacitor saturated field excitation Pre lubricated single bearing design Reconnectable 120 volts or 120 240 volts single phase 120 or 120 240 volts 60 hertz 220 volts 50 hertz Voltage regula...

Page 17: ...anism 9 5 bhp at 1800 rpm maximum Hoof flyball type 5 speed regulation Multi sphere type 2 62 x 3 19 inches 66 6 x 81 mm 51 6 cubic inches 846 liter 1 2 3 Clockwise when viewed from the front 13 5Ibf...

Page 18: ...ttery ignition 12 volts negative ground distributor with points condenser ignition coil and spark plugs Conventional contact points and condenser type 14 mm x 1 25 pitch 0 55 x 0 05 in Westerbeke part...

Page 19: ...LTITUDE Positive displacement rubber impeller belt driven 3 75 4 0 U S gpm 14 19 15 14Ipm 4 2 U S qts 3 9 liters Fully Force fed type by Trochoid pump crankshaft driven Full flow paper element spin on...

Page 20: ...60 hertz 220 volts 50 hertz Voltage regulation 5 no load to full load Frequency regulation 3 hertz 5 no load to full load NOTE BCGA models are 60 hertz only This model cannot be converted to 50 hertz...

Page 21: ...lve Seat Width IN EX Angle IN OUT Recession IN EX Valve Guide Bush Inner diameter IN EX Projection height Valves Seat width IN EX Seat angle 17 Specified Value 9 9370 100 mm 0 0472 0 0630 1 2 1 6 mm 3...

Page 22: ...346 112 64 mm Stem head recession 0 008 0 2 mm Valve Spring Free length 1 7795 1 8110 1 7441 45 2 46 0 mm 44 3 mm Length as installed 1 4961 38 0 mm Tension as installed 58 2 64 8 Ib 50 71b 26 4 29 4...

Page 23: ...8 0 0157 0 0256 0 25 0 40 mm 0 65 mm Piston ring end gap compression No 2 0 0079 0 0138 0 0256 0 20 0 35 mm 0 65 mm Piston ring end gap oil 0 0079 0 0276 0 0394 0 20 0 70 mm 1 00 mm Piston ring side c...

Page 24: ...017 0 0028 0 020 0 044 mm 0 07mm Crankshaft Crankshaft bend 0 0012 0 03 mm Uneven wear of journal and pin section 0 0008 0 02 mm Main journal diameter 1 6526 1 6535 41 976 42 000 mm Crank pin diameter...

Page 25: ...meter Front 1 6732 1 6742 42 500 42 525 mm Center 1 6535 1 6545 42 000 42 025 mm Rear 1 1811 1 1819 30 000 30 021 mm Uneven wear of camshaft journal 0 0016 0 04 mm Camshaft journal section oil clearan...

Page 26: ...049 0 125 mm 0 0098 0 25 mm Crankshaft bearing None Connecting rod bearing None Piston with pin Oversize 0 0098 0 25 mm 0 0197 0 50 mm 0 0394 0 75 mm 0 0039 0 100 mm Piston ring Oversize 0 0098 0 25 m...

Page 27: ...al section DIA Crank journal DIA U S 0 0197 Bearing center thickness 0 50 mm Cylinder block journal section DIA Crank journal DIA 23 Specified Value 0 0764 0 0783 1 94O 1 990 mm 0 8661 0 8681 22 oo 22...

Page 28: ...5 0 0687 0 50 mm 1 740 1 744 mm Big end inner diameter None Crank pin diameter 1 3969 1 3973 35 482 35 492 mm Piston For each kind listed below the cylinder bore finishing DIA O S piston outer DIA Oil...

Page 29: ...ce Q Distributor Heel gap Dwell angle Condenser capacity pF Resistive Cord Cord resistance KQ m 25 Specified Value 0 4742 0 4748 12 045 12 060 mm 0 4754 0 4760 12 075 12 090 mm 0 0014 0 0028 0 035 0 0...

Page 30: ...V Belt Belt deflection inches mm Westerbeke Generators 26 Specified Value 0 37 0 45 22 05 Ib 9 5 11 5 10 kg Allowable Limit...

Page 31: ...e Seat Width IN EX Angle IN OUT Recession IN EX Valve Guide Bush Inner diameter IN EX Projection height Valves Seat width IN EX Seat angle 27 Specified Value 9 9370 100 mm 0 0472 0 0630 1 2 1 6 mm 300...

Page 32: ...80 110 44 mm Stem head recession 0 008 0 2 mm Valve Spring Free length 1 7795 1 8110 1 7441 45 2 46 0 mm 44 3 mm Length as installed 1 4961 38 0 mm Tension as installed 58 2 64 8Ib SO 71b 26 4 29 4 kg...

Page 33: ...0 0157 0 0256 0 25 0 40 mm 0 65 mm Piston ring end gap compression No 2 0 0079 0 0138 0 0256 0 20 0 35 mm 0 65 mm Piston ring end gap oil 0 0079 0 0276 0 0394 0 20 0 70 mm 1 00 mm Piston ring side cl...

Page 34: ...7 0 0028 0 020 0 044 mm 0 07 mm Crankshaft Crankshaft bend 0 0012 0 03 mm Uneven wear of journal and pin section 0 0008 0 02 mm Main journal diameter 1 8101 1 8110 45 976 46 000 mm Crank pin diameter...

Page 35: ...meter Front 1 6732 1 6742 42 500 42 525 mm Center 1 6535 1 6545 42 000 42 025 mm Rear 1 1811 1 1819 30 000 30 021 mm Uneven wear of camshaft journal 0 0016 0 04 mm Camshaft journal section oil clearan...

Page 36: ...0049 0 125 mm 0 0098 0 25 mm Crankshaft bearing None Connecting rod bearing None Piston with pin Oversize 0 0098 0 25 mm 0 0197 0 50 mm 0 0394 0 75 mm 0 0039 0 100 mm Piston ring Oversize 0 0098 0 25...

Page 37: ...rank journal OIA U S 0 0098 Bearing center thickness 0 25 mm Specified Value 0 0764 0 0783 1 940 1 990 mm 0 8661 0 8681 22 00 22 05 mm 0 0813 0 0833 2 065 2 115 mm 0 8760 0 8780 22 25 22 30 mm 0 0862...

Page 38: ...ameter 1 5642 1 5646 38 732 39 742 mm Piston For each kind listed below the cylinder bore finishing OIA O S piston outer OIA Oil clearance 0 0014 In 0 035 mm 0 0022 in 0 055 mm STO Piston outer diamet...

Page 39: ...e Q Distributor Heel gap Owellangle Condenser capacity JlF Resistive Cord Cord resistance KQ m 35 Specified Value 0 4742 0 4748 12 045 12 060 mm 0 4754 0 4760 12 075 12 090 mm 0 0014 0 0028 0 035 0 07...

Page 40: ...VBeH Belt deflection inches mm Westerbeke Generators 36 Specified Value 0 37 0 45 22 05 Ib 9 5 11 5 10 kg Allowable Limit...

Page 41: ...ing constructional features 1 With a view to obtaining a uniform and strong intake swirl the valve for No 2 and No 3 cylinders has been arranged symmetrically 2 The combustion chamber has been made co...

Page 42: ...he water pump is located at the top gasket surface of the cylinder block Furthermore the upper section of the cylinder block has been so constructed that the cooling water directly flows to the cylind...

Page 43: ...g is a tapered ring made of a special cast Iron and has an undercut In addition the oil ring has employed a combination type Compression ring No 1 Compression ring No 2 Oil ring Connecting Rods The co...

Page 44: ...total balance type counter weight Futhermore for reduced metal tapping noise level the crankshaft bearing has adopted a bearing having no oil groove at the lower surface Westerbeke Generators Thrust w...

Page 45: ...2 and No 3 cylinders are arranged symmetrically and the intake valves have been enlarged In orderto cope with higher speed rotation ofthe engine unequallypitched valve springsand aluminum rocker arms...

Page 46: ...journal No 1 Camshaft journal No 2 Camshaft journal No 3 Cam lift intake Cam lift exhaust Fuel pump cam lift IN EX open TOC close IN EX close open BOC Timing Belt For improved reliability a round too...

Page 47: ...ulley Timing Belt Tensioner The timing belt tensioner has employed a method in which no tensioner spring is used Because of this design the tension adjustment can be performed easily by means of gener...

Page 48: ...nequally pitched type with an unconventional cross section thus preventing the occurrence of surging Valve Specifications Item IN EX __ _ __H _ Diameter or valve head 30 26 section mm inch 1 18 1 02 O...

Page 49: ...asted on the contact section with the camshaft on Item IN EX Valve clearance during hot 0 25 0 30 mm inch 0 0098 0 0118 Valve Guide Bushes and Stem Oil Seals The valve guide bushes differ in their mat...

Page 50: ...mblies 50 Timing Belt Removal 51 REMOVING THE CYUNDER HEAD FROM THE CYUNDER BLOCK 53 CYUNDER HEAD DISASSEMBLY 54 CYUNDER BLOCK DISASSEMBLY 57 SPECIAL SERVICE TOOLS 61 NOTE Special Service Tools are av...

Page 51: ...nbolt the unit and carefully move it to the overhaul shop 4 Once at the overhaul shop drain all lubricating oil and coolant from the engine and exchanger system 5 Clean the exterior of the generator o...

Page 52: ...tion of this manual will help make the removal of the generator s stator housing much easier i v I I I I I r I I I i I I I 3 Take off the removable cover and with the aid of the Housing Puller Tool at...

Page 53: ...ive disks with the rotor attached 7 Remove the rotor from the drive disks and store both the rotor and the drive disks in a safe place 8 Remove the engine s flywheel Now that the generator end has bee...

Page 54: ...pect these parts 5 Remove the raw water pump the drive belt and the raw water pump s mounting brackets 6 Set the raw water pump to one side for inspection and overhaul as needed BElT GUARD 7 Disconnec...

Page 55: ...a sturdy bench while they are disassembled and repaired Timing Beh Removal 1 Remove the crankshaft pulley from the crankshaft 4 5 KW BCG 7 0 KW BCG BCGA Crankshaft Pulley 2 Remove the rocker cover and...

Page 56: ...ase water or other substances which may cause the belt to deteriorate or swell 6 Inspect the timing belt for deterioration swelling crack ing and peeling or deformed teeth replace the belt if it is fo...

Page 57: ...the sequence shown below Repeat this sequence several times until the bolts are unfastened Remove the cylinder head and cylinder head s gasket NOTE Discard the cylinder head gasket when it is removed...

Page 58: ...ng retainer lock Valve spring retainer Compression spring eD Valve Valve spring seat Valve stem oil seal Valve guide bushing 4 5 KW BCG and 7 0 KW BCG BCGA DISASSEMBLY ORDER 1 Cylinder Head Ay 2 Cylin...

Page 59: ...e flange bolt for camshaft thrust ring 4 Remove the camshaft Using a wooden dowel placed atthe rear end ofthe camshaft drive out the camshaft by tapping it with a hammer CAUTION Exercise care when rem...

Page 60: ...or equivalent snap on Craftsman SK remove the following parts 1 Valve spring retainer lock 2 Compression spring 3 IN and EX valve I Oil seal NOTE As the valves and their associated parts are removed...

Page 61: ...belt pulley Water pump Oil pan Oil strainer Oil pump Oil seal retainer 2l Piston and connecting rod Crank shaft and bearing 4 5 KW BCG and 7 0 KW BCG BCGA DISASSEMBLY ORDER 1 Crank shaft timing belt...

Page 62: ...Remove the water pump 1 togetherwith the oil level gauge guide 2 1 2 and 3 may have been removed earlier 4 Remove the oil pan a Loosen the oil pan attaching bolts b Using a putty knife or firm gasket...

Page 63: ...the connecting rod cap Push the connecting rod and piston assembly upward out the top of the cylinder block NOTE Temporarily assemble the connecting rod and cap so as not to disturb the correct combi...

Page 64: ...10 Remove the crankshaft bearing thrust washer 11 Remove the stud bolt oil pressure switch etc as required Westerbeke Generators 60...

Page 65: ...l No 37729 4 5KWBCG 7 0KWBCG BCGA 37728 37731 37732 37725 4 5 KW BCG 37727 7 0KWBCG BCGA 37726 37730 61 Tool Name Valve rocker shaft puller Valve spring replacer Piston pin remover and replacer Valve...

Page 66: ...NOTES Westerbeke Generators 62...

Page 67: ...ocker Arms and the Rocker Shaft 68 Checking Valve Springs 69 Checking the Cylinder Block 69 Checking the Pistons 71 Checking Piston Rings 71 Checking the Connecting Rods 72 Checking the Piston Pins 73...

Page 68: ...aluminum Checking the Cylinder Head 1 Replace the cylinder head if it shows signs of water leaks gas leaks or cracks 2 Measure the extent of warping flatness on the lower surface that mates with the c...

Page 69: ...ndicator by moving the valve stem from side to side NOTE Separate the valve from the valve seat before measuring Measure at a position closest to the valve guide bushing Measuring Method 2 Check the d...

Page 70: ...nor or rough surface may be repaired with a valve grinder Contact width 0 0472 0 0630 in 1 2 1 6 mm NOTE Check the valve s contact area and position by applying a thin coat of Prussian Blue or red lea...

Page 71: ...mm Allowable Limit Intake 0 2732 in 6 940 mm Exhaust 0 2730 in 6 935 mm 4 Check of each valve s head stock thickness Replace the valve if it is beyond the allowable limit Valve Head Stock Thickness Li...

Page 72: ...e is reconditioned hand lap each valve onto its seatwith a good brand of lapping compound 5 Remeasure the contact width of both the valves and each cylinder head valve seat and ensure that they confor...

Page 73: ...t the specified installed length Replace the springs if they prove to be weakened Installed Length 1 4961 in 3S 0 mm Installed Load Standard 5S 2 64 Slbs 26 4 29 4 kgs Allowable Limit so 71bs 23 0 kgs...

Page 74: ...ave worn beyond the specified wear limit the cylinder block requires boring to restore each cylinder s true wall surface Standard Bore Diameter 4 5 KW BCG 2 4409 2 4421 in 62 00 62 03 mm 7 0KWBCG BCGA...

Page 75: ...955 61 985 mm 7 0KWBCG 2 6201 2 6213 in BCGA 66 550 66 580 mm Standard Cylinder ta Piston Oearance 4 5KWBCG 0 0014 0 0022 in 0 035 0 055 mm 7 0KWBCG 0 0016 0 0024 in BCGA 0 040 0 060 mm Allowable Cyli...

Page 76: ...2 0 0008 0 0024 in 0 02 0 06 mm Checking the Connecting Rods limit 0 0256 in 0 65 mm limit 0 0256 in 0 65 mm limit 0 0394 In 1 00 mm limit 0 0047 In 0 12 mm limit 0 0043 in 0 11 mm 1 Check the side of...

Page 77: ...xceeds the allowable limit specified below Allowable Limit 0 0020 in 0 050 mm Checking the Connecting Rod Bearings 1 Check each connecting rod bearing carefully and replace it if it is worn scored or...

Page 78: ...h 0 n95 0 7815 in 19 80 19 85 mm Checking the Crankshaft 1 Check the crankshaft for cracks or other damage If necessary replace the crankshaft 2 Check to see that the oil passages of the crankshaft ar...

Page 79: ...36 976 37 000 mm 1 8101 1 8110 in 45 976 46 000 mm 1 5739 1 5748 in 39 976 40 000 mm R O I46 0 7 1 J 99mm R 0 26 0 42 3 20 3 61mm NOTE When grinding the crankshaft the corner sections of the main jou...

Page 80: ...ft 1 Check the camshaft for cracks wear or damage and replace it if necessary 2 Measure the runout If it exceeds the allowable limit replace the camshaft Allowable Limit of Runout 0 0012 0 03 mm 3 Mea...

Page 81: ...r 1 6535 1 6545 in 42 000 42 025 mm Rear 1 1811 1 1819 in 30 000 30 021 mm Uneven Wear of Camshaft Journal 0 0016 in 0 04 mm 5 Measure the crankshaft oil clearance a Lay a strip of plastigauge across...

Page 82: ...thrust washer Thrust Clearance STD 0 0008 0 0087 in 0 02 0 22 mm Limit 0 0118 in 0 30 mm Checking the Crankshaft Timing Belt Pulleys Measure the outside diameter of both the crankshaft and camshaft p...

Page 83: ...r To ensure the seating of the O ring push the O ring at the position of the 3 embossed marks on the cover as indicated in the figure 3 Type T oil seal crankshaft rear oil seal Using an appropriate to...

Page 84: ...Umit 0 0039 in 0 10 mm 2 Replace the ring gear by the following procedure a Heat the ring with a torch b Remove the ring gear by striking its circumference c Heat the new ring gearto 250 3000 C 480 5...

Page 85: ...esh Water Pump 84 Thermostat Removal and Inspection 85 Disassembling and Inspecting the Raw Water Pump 86 Electric Fuel Pump 87 Disassembling and Rebuilding the Carburetor 88 Inspecting the Distributo...

Page 86: ...and relief valve 2 Remove the drive and driven gear a Remove the 5 bolts and oil pump cover b Remove the drive and driven gear Westerbeke Generators 82 D T type oil seal OilpumpAy Compression spring C...

Page 87: ...4 Using a feeler gauge and flat block measure the side clearance as shown Side Clearance STO 0 0014 0 0028 in 0 035 0 07 mm Limit 0 0059 in 0 15 mm 5 Using a feeler gauge measure the clearance between...

Page 88: ...lve spring and retainer to the pump body b lnstall the cotter pin 2 Install the drive and driven gears a Insert the drive and driven gear to the body b Install the pump cover tighten the 5 screws Tigh...

Page 89: ...en by more than 0 31 inches 8 mm when the water temperature reaches 1500 F 640 C 3 Replace the thermostat if the valve remains open at normal temperatures or if the valve is loose when the valve is fu...

Page 90: ...our cover screws 2 Remove the cover and the gasket 3 Remove the rubber impeller and the wear plate 4 Remove the rubber a ring 5 Remove the cam screw washer and the cam Now the raw water pump is stripp...

Page 91: ...and make sure that no leakage is present and that the fittings are tight and secure Also check that the DC electrical connection supplying 12 volts DC to the pump is clean tight and secure The DC grou...

Page 92: ...ces to the set One 1 aluminum seat gasket One 1 idle mixture screw O ring One 1 rotary throttle shaft valve One 1 throttle shaft valve spring One 1 fuel filter element One 1 manifold gasket 00 COPPER...

Page 93: ...car buretor to the intake manifold Lift the carburetor from the in take manifold 4 Remove the electric choke s stabilizing screw and the indi cated one of four cover screw and washer Remove the electr...

Page 94: ...nd remove the float Make sure you catch the needle valve that hangs from the float retaining hook under the float s pivot arm and place it aside 8 Remove all of the old cover gasket from both halves o...

Page 95: ...ook Now check the float level distance from the housing mating surface with the housing held vertically Distance A from mating surface 3 16 in 4 76 mm Carburetor Top Cover Needle Valve Seat Wire Retai...

Page 96: ...retor Be sureto replacethe old washer Then replace stabilizing screw swasherand tighten the stabilizing screw Replace the remaining three cover screw s washers and tighten the cover screws in the indi...

Page 97: ...he screws on the carburetor are properlytightened and replace the carburetor on the intake manifold using a new manifold gasket along with a gasket sealant Resecure the carburetor to the intake manifo...

Page 98: ...or damage Replace all damaged parts o Q 8 o U 00 V OO r r l 1 _ J Insulation M n 12 00 CJ t J CJ 00 1 j 000 f lOO 00 I I do I I I I I Measuring POints DBetween center electrode and segments No 1 thro...

Page 99: ...nce Replace only the resistor if it fails this test Inspecting the Spark Plugs Inspect each spark plug for cracks chips or for fouling Oean orreplace the spark plugs if necessary Make sure that new or...

Page 100: ...panel In the eventthe starter fails to turn the engine over check the engine and starter circuit If no fault is found remove the starter and test it 1 Starter Circuit a Charged condition of battery b...

Page 101: ...mutatorshaft Replace it ifdefective b Measure the commutator 0 0 and the depth of undercut Correct or replace the commutator if defective Also check the commutator outside surface for dirtiness and ro...

Page 102: ...Ifthe pinion has no standard gap adjust by increasing or reducing the adjusting washer between the solenoid and the front bracket Increasing the number of washers reduces the gap Description Starter...

Page 103: ...0197 in max paragraph remove the lever spring 12 Solenoid a Attraction Test Connect the battery between the S and M ter minals of the solenoid If the plunger is attracted and the pinion moves out the...

Page 104: ...NOTES Westerbeke Generators 100...

Page 105: ...rts when assembled on the engine rotate or slide and are not subject to binding or excessive tension E If there are mating marks scribed during disassembly reference them correctly for assembly F Use...

Page 106: ...l pan V Water pump Crankshaft timing belt pulley 4 5 I YV BCG AND 7 0 I YV BCG BCGA ASSEMBLY ORDER 1 Crankshaft and Bearings 2 Piston and Connecting Rod Assembly 3 Oil Seal Retainer 4 Oil Pump 5 Oil S...

Page 107: ...ust washer 3 Install the crankshaft 4 Install the crankshaft bearing cap with the crankshaft lower bearing No oil groove in lower bearing a Apply a small amount of engine oil to the threaded portion o...

Page 108: ...on ring compressor install the piston with the connecting rod into the cylinder bore making sure that the front marks face the correct direction 6 Assemble the piston with the connecting rod by placin...

Page 109: ...necting rods have been installed ensure that the crankshaft turns slightly 9 Replace the Oil Seal and O Ring a Type T oil seal Crankshaft front oil seal Using a suitable seal installer install the oil...

Page 110: ...ydiscontinued spot in a size equivalentto3 mm to 4 mm diameter following the procedure given in the figure NOTE Be sureto assemblethe oil pan within fifteen minutes after the application of the FIPG I...

Page 111: ...ssemble the water pump ay with the oil level gauge guide Tightening Torque 11 3 16 9 ft Ib 1 56 2 34 kg m 16 Assemble the cylinder head IN EX manifold and flywheel related parts 107 Westerbeke Generat...

Page 112: ...NOTES Westerbeke Generators 108...

Page 113: ...I The parts which do not permit their reuse 4 5 KW BCG and 7 0 KW BCG BCGA ASSEMBLY ORDER 1 Valve Guide Bushings 2 Valve Stem Oil Seal 3 Valve Spring Seat 4 Valves 5 Compression Spring 6 Valve Spring...

Page 114: ...e valve spring is not installed 2 Assemble the valve spring seat and valve stem NOTE Apply the engine oil to the sliding portion of the valve stem 3 Using a valve spring compressor assemble the valve...

Page 115: ...ange bolt Make sure the flange bolt gasket is installed b Apply engine oil to the lip portion of the oil seal and press the oil seal by means of the tool 038751 Bolt M10 length below head 40 45 mm c R...

Page 116: ...e valve rocker shaft Rocker Shaft Installation 1 0 o o NOTE Care must be exercisedto ensurethat the valve rocker arm or plate is assembled properly Installation of Cylinder Head and Timing Belt 1 Inst...

Page 117: ...ng Torque 5 2 7 8 fl Ib 0 72 1 08 kg m d Align the knock pin of the plate washer with the hole and install the timing belt pulley Tightening Torque 25 5 38 2 ft Ib 3 52 5 28 kg m 4 Install the cranksh...

Page 118: ...the timing belt tensioner only to the extent that it can swing slightly c Screw an M6 screw pitch 1 mm length 20 30 mm fully into place from which the resin cap was removed using yourthumb and index f...

Page 119: ...ibutor a Turn the crankshaft and camshaft in such a way that the No 1 cylinder may be set to the top dead center on the compression stroke At this time the slit at the rear end of the camshaft is off...

Page 120: ...on Fuel Line In Male Bayonet Connector 24941 or 30786 Fuel Connection 12 Volt DC Connection DC Ground Wire Connection Fuel Connection Pump 10 Install the following parts to the front side of the engin...

Page 121: ...he Engine 1 Rotor and fan assembly to flywheel and distributor 2 Assemble the stator housing to the engine using field fabricated tool Secure to back plate 3 Mount control panel and install wiring har...

Page 122: ...NOTES Westerbeke Generators 118...

Page 123: ...pushes open the relief valve in the oil pump and returns to the oil pan thereby keeping the oil pressure within its specified range Orifice Cylinder head Oil pressure gauge Camshaft journal No 2 No 3...

Page 124: ...oil level or incorrect grade 3 Faulty oil pressure switch or sender 4 Clogged oil filter 5 Clogged oil pump strainer 6 Worn or fatigued oil pressure relief valve spring 7 Faulty electrical circuit 12...

Page 125: ...connec tions 3 Startthe engine letting it operate at 1800 rpm and allow engine to warm up 4 Measure the oil pressure If it is less than the specification listed below check the engine s lubricating s...

Page 126: ...g pump 1 Loose or broken raw water pump drive belt 2 Faulty raw water pump 3 Clogged heat exchanger 4 Scale in exhaust elbow 1 Test with above unit and or replace 2 Check and tighten con nections or r...

Page 127: ...gasket damaged or securing screws are loose 1 Main jet clogged 2 Carburetor inlet filter clogged 3 Air intake filter screen dirty 123 Remedy 1 Check choke adjustment cam and operation 2 Check fuel sup...

Page 128: ...PANEL Westerbeke Generators DC CONTROL CIRCUIT WIRING DIAGRAM 38028 OIL PRESSURE SWITCH WIRING Page 1 of2 DIAGRAM z 124 i WATER TEMP SWITCH 14 YELLOW RED I RED PURPLE 14 RED I PURPLE STOP SWITCH HOUA...

Page 129: ...AND OVERSPEED MODULE CAUSES A 15ma DRAIN WHEN GENERATOR IS NOT OPERATING THEREFORE WHEN LEAVING BOAT FOR AN EXTENDED PERICXl DISCONNECT THE BATTERY 2 WESTERBEKE GASOLINE MARINE GENERATORS AS SHIPPED...

Page 130: ...T I 1 121 0 ON W PUR STRIPE 2 QED W PUR STRIPE lli It ll YEL W I ED STRIPE e 539 Il e I j 4RED kl PUR TO TBI 2 T4 1 I 1 6 PURPLE lee I 111 4 PURPLE TO TBI 4 T4 Z T3 Z T3 1 e e T4 3 Lt e 5 T4 4 Il g I...

Page 131: ...the 12 6 to 13 volt range as voltage regulation controls this function If the battery s voltage exceeds 15 volts this indicatesthat the battery is being overcharged and the battery will be damaged if...

Page 132: ...tches open at too Iowa temperature 4 Overspeed module 5 Switch and wiring 128 Remedy 5 Check coil 6 Check distributor points condenser cap and wires 7 Check wires and con nections for shorts breaks an...

Page 133: ...ler connections are clean and tight 2 Observe if gauges and light are on when engine is not running Test the normally open oil pressure switch by disconnecting one lead If lights go out replace oil pr...

Page 134: ...thin NEMA MGI 22 4O definition when operating at full load Cooling Centrifugal blower directly connected Armature Balanced laminated steel double dipped and baked Ratings 120 240 volts AC 60 hertz or...

Page 135: ...w basic tools are necessary for diagnosis and repair These are hand tools an amp probe and a quality volt ohmmeter capable of reading less than one ohm due to the precision required in reading compone...

Page 136: ...T E R D2 03 _____ o4 L B L o C B I L o5 K I I I I 06 __ J I I L _________ J I I Ie 91 I I t CAPiiITOR t I L ____________ J 4 5 BC Single Capacitor Components A Rotating Field and Diodes B Main Stator...

Page 137: ...y D r I I I I I DC I AC CHARGE I I r I AC i I _ I C I I I I BRIDGE INTEGRAL I I RECTIFIER CONTROLLER I I I _________ J IDIODE II DIODE I L _ I I I I I L _________ 1 12 7 8 7 8 BCGA Single Capacitor 1...

Page 138: ...at the connection at the base of the diode Compare readings with the value above Ifa distinct difference is noted in the ohm value carefully unsolder the lead on the top of the diode and remove the d...

Page 139: ...n u z n m DIODE The diode s rating is far in excess of the circuit s requirements Most likely a diode failure will result from an overspeed or load surge A diode failure would be attributed to a manuf...

Page 140: ...hertz leads or the 9 and the 60 hertz leads for the 7 0 BCGA model unplugged from the capacitor This residual voltage must be present for the exciter circuit to function Do not unplug capacitor leads...

Page 141: ...es are used in the 7 0 KW BCG generator set With acapacitor meter testthe capacitorfollowing the instructionsfound with the meter and compare the results with the value shown on the capacitor When a c...

Page 142: ...on the bridge rectifier AC Voltage to the bridge rectifier approximate a No load off generator 16 0 volts AC b Full load off generator 17 5 volts AC Normal DC voltage out of rectifier volts DC This vo...

Page 143: ...ctifier d With then negative lead still at Point 15 Rectifier Kountine Hole 1 _ Point 13 Note Some ohmmeters will reverse steps band c tached to point 4 touch point 5 with the positive lead The needle...

Page 144: ...a DC charge as needed If the integral controller is believed to be faulty resulting in a low starting battery check the charging circuit components 0 and all connections in the circuit and to the batt...

Page 145: ...ce of the belt clriven governor on gasoline models and internal governor action on diesel models is of prime importance Gasoline Models No Load Full Load Hertz 60 5 61 5 Hertz 59 0 60 0 Voltage 115 12...

Page 146: ...usting bolt sets the no load speed of the engine The linkage arm between the governor arm and throttle lever should be adjusted to hold the throttle full open when the engine is not running Make sure...

Page 147: ...or windings A 1 Engine speed is too fast 2 Capacitor connections are incorrect 3 Faulty capacitor 1 Poor governor reaction loss of engine speed 2 Overload on the generator 3 Diode s in rotor shorting...

Page 148: ...r 2 Check winding resistance for open or short 3 Check capacitors 1 Adjust hunting regulation on the governor Adjust to proper no load voltage hertz 1 Adjust hunting regulation on the belt driven gove...

Page 149: ...engine and adjust the governor speed screwto 1850 1880 rpm for 60 hertz or 1550 1580 rpm for50 hertz Stopthe engine and plug the correct hertz lead into the capacitor 5 or 50 for 50 hertz and 6 or 60...

Page 150: ...t be necessary In the event a no load adjustment is needed proceed as follows A Shut off the generator IWARNINGI Do not attempt to make a no load voltage adjustment while the generator is operating Th...

Page 151: ...rom damaging the windings in the generator housing by allowing the generator housing to be removed straifght off the engine or to be placed straight on the engine Refer to the removal and replacement...

Page 152: ...the eye bolt this tool would be able to pull the bearing back into place without any twisting Please refer to these drawings before the generator end is removed WELD A 1 2 13UMC HEX NUT TO ONE SIDE OF...

Page 153: ...ifting eye on baseplate and weld securely This tool allows a mechanic to safely remove and install the generator drive disks by aligning the disks with the Drive Plate Guide Pin The Pin screws into th...

Page 154: ...NOTES Westerbeke Generators 150...

Page 155: ...Checking Rocker Arms and the Rocker Shaft 68 Checking the Camshaft 76 Checking the Connecting Rod Bearings 73 Checking the Connecting Rods 72 Checking the Crankshaft 74 Checking the Crankshaft Timing...

Page 156: ...SSEMBLy 101 ENGINE DESCRIPTION 37 ENGINE DISASSEMBLY 50 ENGINE INSPECTION AND REPAIR 64 ENGINE SERVICE SPECIFICATIONS 4 5 KW BCG 17 ENGINE SERVICE SPECIFICATIONS 7 0 KW BCG BCGA 27 Exciter Windings 13...

Page 157: ...s 39 PREPARATIONS FOR OVERHAUL 47 PRODUCT SOFTWARE DISCLAIMER 1 R Refacing the Valve and Valve Seat 68 Removal of External Parts and Subassemblies 50 REMOVING THE CYLINDER HEAD FROM THE CYLINDER BLOCK...

Page 158: ...TOR 131 Troubleshooting the Oil System 120 U UNIT I D PLATES 8 v Valve Actuating Mechanism 41 Valve Guide Bushes and Stem Oil Seals 45 Valve Rocker Arms 45 Valve Rocker Shafts 45 Valves and Valve Spri...