Westerbeke BCGB, Service Manual

Page 1: ...G PUBLICATION NO 44898 JUNE 2000 1ST EDITION WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE www WESTERBEKE COM m N A Member National MariM Manufa...

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

Page 3: ...hink Coherently IF YOU OR ANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIR IMMEDIATELY Ifsymptoms persist seekmedicalattention Shut down the unit and do not restart until it has been...

Page 4: ...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 operate wi...

Page 5: ...cid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING carbon mDnDxlde CO Is adeadlygas Ensure that the exhaust system is adequate to ex...

Page 6: ...ith other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTAllAnONS Preparations to install an engine...

Page 7: ...is at or below the load waterline will result in raw water damage to the engine andpossibleflooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to...

Page 8: ...ISTON AND CONNECTING RODS 21 Ignition Timing 47 COMPONENT TESTING 48 WIRING DIAGRAM ENGINE 49 WIRING SCHEMATIC ENGINE 50 WIRING SCHEMATIC REMOTE PANEL 51 SERVICE DATA STANDARDS AND LIMITS 52 FRONT CAS...

Page 9: ...ES 8 AMP FUSE CARBURETOR 25 AMP CiRCUiT BREAKER START MOTOR OCGROUND STUD GOVERNOR A R NTAKE COOLANT PRESSURE CAP LEFT SlOE RIGHT SlOE HEAT EXCHANGER lY I seKI ng nes Generators 2 REMOTE PANEL CONNECT...

Page 10: ...rpm can be measured at the front end of the crankshaft NOTE To test engine compression see the ENGINE ADJUSTMENT section ofthis manual OVERHAUL CONDITIONS Compression pressure tends to increase a litt...

Page 11: ...e warm up the engine then shut it down 2 Remove the three spark plug caps and remove the three spark plugs 3 Install a compression adapter and gauge in the spark plug hole 4 Close off the raw water in...

Page 12: ...n plug 5 Loose oil pipe connector 6 Broken rocker cover gasket 7 Loose rocker cover attaching bolts OIL LEVEL RISING 1 Dead cylinder 2 Displaced or twisted connecting rod 3 Worn piston ring 1 Incorrec...

Page 13: ...lve 3 Valve stem seized 3 Replace valve and valve guide 4 Broken valve spring 4 Replace valve spring 5 Compression leaks through cylinder head gasket 5 Replace gasket 6 Piston ring seized 6 Replace pi...

Page 14: ...IONS thru out this manual Sealants and Lubricants Oil based PERMATEX 2 and its HIGH TACK equivalent are excellent all purpose sealers They are effective in just about any joint in contact with coolant...

Page 15: ...fuel lines are closed offand drained Clean up all fuel and oilspills and properly dispose of the rags YWHEEL ARMATURE Unfasten the generator from its mounting rails or the mounting rails from the pla...

Page 16: ...RTER MOTOR 3 Disconnect the exhaust temperature switch and disassemble the exhaust elbow and manifold from the engine Set this assembly aside for servicing Refer to EXHAUSTSYSTEM in this manual Remove...

Page 17: ...er pump remove the drive belt and then remove the raw water pump Remove the engines coolant pump For servicing refer to COOLANT PUMP 11 Detach and remove the ignition wires the distributor and the spa...

Page 18: ...eplaced during an engine overhaul The adjustments inspection and replacement procedures may be performed without removing the generator from the boat THE TIMING BELT PART NUMBER IS 043036 Timing Belt...

Page 19: ...crankshaft in position NOTE Do not tum the crankshaft 2 Remove the crankshaft bolt Timing Belt Inspection Replace the belt if any of the following conditions exist Hardening of the back rubber leaves...

Page 20: ...g Timing Tensioner Installation 1 Install the tensioner spring and timing belt tensioner 2 Hook the tensioner spring onto the bend of the timing belt tensioner bracket and the stopper pin on the cylin...

Page 21: ...osen the temperorarily tightened tensioner nut on the water pump side 1 or 2 turns and tension the belt making use of the spring force 8 Tum the crankshaft clockwise by nine camshaft sprocket teeth 81...

Page 22: ...move the rocker cover and rocker cover gasket Loosen each of the cylinder head bolts a little at a time so as to avoid the possibility of distorting the cylinder Repeat several times until the bolts a...

Page 23: ...lve stem is bent or worn replace the valve Check contact between the valve and valve seat by applying a thin coat of Prussion Blue or Redhead on the valve seat contact face then insert the valve into...

Page 24: ...onfiguration After correction the valve and the valve seat should be lapped with lapping compound INSTALLATION Valve Stem Seal VALVE SEAT CONTACT WIDTH 035 051 in 0 9 1 3 mmJ Install the valve spring...

Page 25: ...bs 40 50Nm 3 TIghten the bolts in numerical order to the specified torque CYLINDER HEAD TORQUE 43 51ft lbs 60 70Nm Rocker Cover Install the rocker cover using a new gasket slightly coat both sides wit...

Page 26: ...AL DIAMETER STANDARD 1 6118 1 6124in 40 940 40 955mm CHECKJOURNAL BEARINGS FOR WEAR DAMAGE Camshaft NOTE Ifthe Journal is seized also check the cylinder head 3 Measure the cam height and if it is less...

Page 27: ...0 6693mm II Or I OIL HOLES OIL HOLES INSTALLATION 1 Apply a coating of engine oil to the camshaft journals and cams and insert the camshaft through the rear of the cylinder head 2 Install the camshaf...

Page 28: ...the ring remover remove the piston rings While removing the piston rings note the order they are removed and which side of the ring faces the piston crown 1 PISTON RING 2 PISTON RING STOPPER NOTCH GU...

Page 29: ...80 0 048810 1 22 1 24mm No 2 0 0476 O 0484io 1 21 1 23mm Oil 0 1108 0 1116io 2 815 2 835mm PISTON RING END GAP No 1 No 2 Oil PISTON staodard 0 0059 0 0118io 0 15 0 30mm 0 0138 0 0197io 0 35 0 50mm 0 0...

Page 30: ...until it is seated on the bottom surface of the base If the press fitting load is out of the specification replace the pin piston assembly or connecting rod or both PISTON PIN PRESS FITTING LOAD 1102...

Page 31: ...embly according to the identification marks for the crankshaft and the connecting rod CRANKSHAFT NO 3 NO 2 NO 1 r NO 1 ARM CRANKSHAFT PIN DIAMETER Identification marks 1 1 2 G 3 C Journal Diameter 1 4...

Page 32: ...uts alternately to install the cap properly Tighten the nuts to the proper torque CAP NUT TIGHTENING TORQUE 11 90 turn 15Nm 90 tum A CAUTION If the cylinderheadhas been installed before installing the...

Page 33: ...ANCE SHAFT REMOVAL 1 Remove the plug on the cylinder block and insert an O 32in Smm rod into the hole to lock the counterbalance shaft 15 1OIL DRAIN ASSEMBLY NUMBERS INDICATE THE SUGGESTED ORDER OF DI...

Page 34: ...even wear on the contact surfaces of the cylinder block or on the pump gear side of the pump DRIVEN ANCE Ar GEAR ot1 DRIVE GEAR FRONT CASE INSPECTION Check the front case for cracks or other damage al...

Page 35: ...ase assembly through the gasket and tighten the bolts to the specified torque FRONT CASE BOLTS TORQUE 6 7ft Jbs 8 10 Nm There are two different length front case bolts Make certain they are positioned...

Page 36: ...t the pump cover Oil Pump Seal Press the seal into the oil pump cover flush with the surface using the seal installer tool INSTAUING THE OIL PUMP SEAL DRIVE GEAR OIL PUMP ASSEMBLY FRONT CASE CONFIGURA...

Page 37: ...e seizure and cracks Check the joumalscontact surface for uneven wear and replace if badly damaged 2 Measure the outside diameter of the journal and the inside dianieter of the main bearing If the cle...

Page 38: ...e CRANKSHAFT BEARINGS SPECIFICATIONS Upper and Lower When the bearings are to be replaced select the correct ones and install them in positions according to the identification marks stamped on the cra...

Page 39: ...insert a feeler gauge in the gap between the crankshaft journal side surface and the thrust bearing endsurface to measure the end play CRANKSHAFT END PLAY 1 5740 1 5748 in 0 05 0 025mm CRANKSHAFT REA...

Page 40: ...Calculate the difference between the minimum cylinder bore in the thrust direction and the piston outer diameter shown in the illustration If the difference exceeds the specified range replace the pis...

Page 41: ...0 K Q 3 COVER ASSEMBLY Check that when a screwdriver is passed near the iron core of the pick Up assembly the needle of the tester deflects 10BREAKER PLATE VACUUM CONTROL 1 O RING 11 HOUSING ASSEMBLY...

Page 42: ...check the pump body and impeller for cracks and damage Inspect the weep holes for signs of water leakage and rust that would indicate a faulty seal The pulley should tum the shaft and impeller smoothl...

Page 43: ...the exhaust elbow Once the engine has been re installed and running carefully check these assemblies and hose connections for leaks HEAT EXCHANGER The heat exchanger should be inspected and serviced d...

Page 44: ...and not be reusable 3 Pull out the impeller with long nose pliers or pry out with a pair of screwdrivers RAW WATER PUMP COMPONENTS 4 Remove the wear plate and the O ring S Remove the cam screw washer...

Page 45: ...tat and gasket apply a thin coat of sealant to both sides of the gasket 3 A thermostat can be checked for proper operation by placing it in a pan of cold water and then raising the tem perature of the...

Page 46: ...vacuum hose Remove the cotter pin from the electric choke control lever and remove the electric choke assembly 4 Remove the four cover screws and washers Lift the carburetor top cover straight up and...

Page 47: ...zle Snug down the nozzles retaining screw Do not overtighten the screw NOTE With the carburetor disassembly clean and inspect all the components replace any damaged or worn parts 15 Place the carburet...

Page 48: ...scharge at engine start up and shut down NOTE At idle speed oil pressure will be lower than the rating ofthe oil pressure switch Jump this switch to prevent engine shutdown at idle speed Run Mixture J...

Page 49: ...t the same time the washers for the pinion shaft end play adjustment will come off STARTER MOTOR INSPECT FOR WEAR CHIPPING 4 Return test With a battery connected to the solenoid ter minal M and to the...

Page 50: ...if the service limit is exce ed Also check the commutator outside surface for dirtiness and roughness Ifrough polish the commutator with fine crocus cloth Brush and Brush Holder Inspection 1 Check the...

Page 51: ...on shaft end play adjustment Set the end play thrust gap to between 0 5 to 2 mm by inserting an adjusting washer between the center bracket and the reduction gear a Fit the pinion shaft reduction gear...

Page 52: ...adjusted as well If the governor surges under load adjust this eye bolt to move the spring away from the lever hub check speed adjustment 3 Bumper Screw Adjustment This screw is used to remove a no lo...

Page 53: ...ater pump The tension adjustment procedure for both belts is as follows 1 Remove the belt guard 2 To adjust the governor drive belt loosen the two governor mounting bolts To adjust the raw water pump...

Page 54: ...et Rocker cover torque 2 9 5 1 Ib n 4 7 Nm VALVE CLEARANCE Valve Clearance Intake 0 20mm 008 inches Exhaust 0 30mm 0012 inches IGNITION TIMING 1 Attach a timing light to the 1 spark plug and mark the...

Page 55: ...as B and should measure no less than 11 5 volts ___ CLICK ON AC voltage measurements should be made with a true RMS AC meter to insure measurement accuracy ENGINE GROUND GROUND AND B CONNECTIONS RELAY...

Page 56: ...GRAM 43864 OIICE IIlLSaI rMTTBn IZ VDC I Cl II lII I I L MIX CL PIIESS I 1 sma Il1O CL PIIESS RItCH II1II I F Till VIO lIMT 114 RED VIO 114 RED 114 RED IIC REHIHT lIS ORG liS T I I i o IIC BLI IIC RFO...

Page 57: ...AKER FI STOP SW r I CHltNC L I I I I I Ki KZ F2 l ______ L _ L _ _ _ _ _ I ON STUT C FUEL PUMP FUEL SOL HOUR METER 115402 DIODE TI CHOKE SOL KI START 1 L_ L _ c CKTZtNO EXHAUST TEMP SWITCH OIL PitESS...

Page 58: ...ANEL r 1 1 i BlK STA RT STOP SW NI _ 1 4 B L K____ I LED I I I RED I RED CKT I L i K ON SW WHITE WHITE WHITE I f I I I I L_ I I i L______________ _ ____________ Engines Generators 51 14 WHT RED 14 YEL...

Page 59: ...591 6 565 6 580 Exhaust 0 2571 0 2579 6 530 6 550 Stem to Guide Clearance Intake 0 0008 0 0020 0 02 0 05 0 0039 0 10 Exhaust 0 0020 0 0033 0 0050 0 0085 0 0059 0 15 Valve Guide Length Intake 1 73 44 E...

Page 60: ...between Big End and Small End Cylindericity of Journal and Pin 0 004 0 05 Less than 0 0002 0 005 Connecting Rod Twist O OO4 0 1 Concentricity of Journal and Pin Connecting Rod Big End to Crankshaft S...

Page 61: ...Connecting Rod Camshaft thrust plate bolt 10 12 7 9 Connecting rod cap nut 15 900 turn 11 900 turn Rocker arm adjust nut 8 10 6 7 Crankshaft Bearing Cylinder Head Valve Oil seal case bolts 10 12 7 9 C...

Page 62: ...2 545 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 M36 55mm 700 950 992 1345 1925 2610 2744 3720 SEALANTS LUBRICANTS GASm...

Page 63: ...ine Combustion all models Engine Cooling 225 250 CFM 6 3 7 0cmm 42 CFM 1 2 cmm 100 CFM 2 8 cmm General Fresh Water Pump Fresh water cooled block through raw water cooled heat exchanger circuit Centrif...

Page 64: ...rocket is loosened or tightened MD990767 VALVE SPRING COMPRESSOR MD 999597 SPECIAL TOOLS ENGINE NOTE Tht se special tools are available from your local Mitsubishi Automotive Dealer VALVE STEM SEAL INS...

Page 65: ...ormed by a qualified technician Proper safety precautions must be followed as most of these tests are executed with the generator operating or connected to ships power AC voltage is lethal If generato...

Page 66: ...epair parts such as diodes fuses bridge rectifier etc PRELIMINARY CHECKING Before electrical testing check for proper engine speedlhertz adjustment Low engine speed will cause low AC voltage output hi...

Page 67: ...c EXCITER 2 2n D CHARGER O 14n IVIODEL DUAL A ROTOR 4 on EXCITER CIRCUIT 8 STATOR O 3n c EXCITER 2 2n D CHARGER O GBn BALLAST RESISTER EARLY MODELS r 30A D DCCHARGE I I I I r I I GND I 1Ai1I tl J fil...

Page 68: ...er lead at the connection at the base of the diode Compare readings with the figures below STANDARD RESISTANCE VALUES ROTATING FIELD I AUXILIARY WINDINGS Single CapaCitor 3 8 Ohms Dual Capacitor 4 0 O...

Page 69: ...by placing the ohmmeter s probes across the two exposed leads ROTOR WINDINGS RESISTANCE VALUES Single Capacitor 3 8 ohms Dual Capacitor 4 0 ohms Dual Exciter Circuit 4 0 ohms TESTING THE WINDING LEAD...

Page 70: ...r s discharge back into the exciter windings 1bis AC voltage reading is taken between the 60 Hertz connector and the connection plugged into the capacitor s while the generator is operating at its rat...

Page 71: ...G THE MAIN STATOR WINDINGS Test the main stator windings at the AC terminal board by first removing all the AC output leads the ground connection and the brass interconnects This will isolate the six...

Page 72: ...ps Test between terminal 3 and tenninal 6 If con tinuity exists there is a short in the windings There also should be no continuity between the terminals and the generator case ground MAIN STATOR WIND...

Page 73: ...at zero ohms the capacitor is faulty shorted i If the meter fails to go down to zero the capacitor is faulty open circuited Indications of a defective capacitor I I CHECKING FOR CONTINUITYBETWEEN LEAD...

Page 74: ...should measure 0 14 ohm No continuity should exist between these two leads and the ground or the main stator windings RESISTANCE BETWEEN AC LEADS 0 14 OHMS RESISTANCE BETWEEN DUAL EXCITERS 0 08 OHMS A...

Page 75: ...ctions for cleanliness and tightness including the ground before replac ing the I e unit NOTE When the generator is jiFSt started the l C unit will produce a low charging rate This charging rate will...

Page 76: ...If the voltage output is higher or lower than specified proceed 4 Shut offthe generator Make sure the correct Hertz lead 60 Hertz 6 or 50 Hertz 5 is plugged into the capacitor s c DUAL CAPACITOR 50Hz...

Page 77: ...imately 8 10 volts between connectors used in any pair combination to achieve the prescribed no load voltage C 50Hz 60Hz 7 8 9 r 1 A WARNING Make certain the insulating covers on the unusedleads are i...

Page 78: ...ON BCGENERATORS ELECTRICAL COMPONENTS DUAL EXCITER SHOWN CAPACITOR 30 AMP FUSE r CURRENT MODEL B CGENERATORS ELECTRICAL COMPONENTS SINGLE CAPACITOR SHOWN TERMINAL BOARD TO CIRCUIT BREAKER NTEGRAL CONT...

Page 79: ...4 holes Material Cold rolled Steel Lifting Eye Tool This tool allows a mechanic to safely remove the generator end from the engine by attaching this Generator End Lifting Eye to the four screw holes...

Page 80: ...rature 3 Dirty fuel filters 4 Mechanical check valve at the fuel supply faulty S Low oil level in sump 6 Faulty fuel pump 7 High exhaust back pressure Before restarting the engine the cause of the pro...

Page 81: ...st RPM S Spark plug wires are connected voltage 2 Faulty condenser check replace wrong Incorrect timing Engine is flooded Dirty flame arrester Low no load 1 Low engine speed adjust RPM S voltage 2 Fau...

Page 82: ...ms g x 035 Ounces Pounds Ib x 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 x 2 036 Hg Inches of Mercury Hg x 3 377 Ki...

Page 83: ...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 V...

Page 84: ...g Engine Compression 4 Disassembly Engine 9 Testing for Overhaul 3 Disassembly Engine Generator 8 Testing Oil Pressure 4 Distributor 34 Thermostat 38 Drive Belt Adjustment 46 Timing Belt Disassembly 1...

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Page 86: ...Engines Generators 1028WM DW6 2000...