Westerbeke BCGA-60HZ User manual

SERVICE MANUAL
5.0KW BCG-60Hz l 4.2 K.W BCG-50Hz
5.0KW BCGA·&OHz I 4.2KW BCGA·50Hz
7 .OKW BCGC-60Hz I 5.9KW BCGC-50Hz
7 .OKW BCGD·&OHz I 5.9KW BCGD-50Hz
GASOLINE GENER~ RS ~Single Phase
I .. -.-
PUBLICATION #052020
REV#2 SEPTEMBER2014
~r~rWESTERBEKE
member J WESTERBEKE CORPORATION • 150 JOHN HANCOCK ROAD
tf'/Tfff j MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
~~~~ WEB SITE: WWW.WESTERBEKE.COM

A wARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness • Throbbing in Temples
•Nausea
•Headache
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness •Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.

SAFETY INSTRUCTIONS.·.
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by faUure to follow fundamental rules and
precail.tWm. Know when dangerous conditions eXist and
take the necessary precautiOns to protect yourself, your
personne4· and your machinery;
The following safety instructions are in compliance With· the
American Boat andYacht Council (ABYC) stanJords.
PREVENT ELECTRIC SHOCK
A WARNING: Do n11t toui:hAC electrical connet:tlons .
while engine is mnnittg. Lethal wltage is present at
these connections!
• Do not operate this machinery, Without electrical
enclosures and covets in place.
• Shut off electrical power befote accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure yoilr clothing and skin are dry, not danip
(particularly shoes) when handling electrical eqUipment.
• Remove wristwatch and alljewelry when wor.k:iilg on
electrical equipment.
PREVENT BURNS- HOT ENGINE
A WARNING: Do not ttltli:h hot engine parts or
exham system components.· A mnnillg engine gets
reryhotl
• Monitor engine antifreeze coolantlevel at the. plastic
coolant recovery tank and periodicaly at the filler cap
location on the water jacketed exhaust manifold, but only
when the engine is COLD.
A WARNING: Steam can cause Injury or death!
• In case of an engine overheat; allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Preventflash fires, :00 notsmoke or permit flames or
sparks·ro occur neattl:te carbut:etor, fuelline, filter; fuel
pump, orother potential.sources of spilled fuel or fuel
vapOrs. Use.a .sUitable container to catch all fuel·when
removing the fuel1ilie; carburetor~ fuel filters. or other
fuel systemcomponents.
•
Do notoperate with the aircleaner/silencer or flame
arrester screen removed Backfire can cause severe injury
or death.
• Do notsmoke orpermit flames orsparksto.occurnear
the fuel system. Keep·thecompartrnent
and the
engine/generator clean and. free ofdebris tO minimize the
chances of fire. Wipe up all spilledfuel and engine oil.
PREVENT.BURNS- EXPLOSION
A WARNING: ExpltJSiDils frOm fuel vapors can cause
injllf1·titdeatltl
• Follow re-fueling safety instrUctions. Keep ihe vessel's
hatches closed when fueling. •Open and ventilate eabin
after fueling,· Check' below .for funles/vapor before running
the blower. Run the engine compartment blower prior to
starting, follow the.recqmmendation ofthe vessel builder.
• Allfuel vapors ate highly explosive. Use extreme care
when handlfug and storing fuels. StOre fuelin a
well;. ventilated area away from spark,:.producing
equipment and out ofthe reach of ehildten.
• Do not fill the fuel tarik(s)while the engine is running.
• Shut offthe fuel service val\fe at the engine when servicing
thefuel system. Take care in ditching· any fuelthat might
spill. DO NOT allow any smoking, opelJ.iftames, or other
sources of fire near the fuel systetn ot engirte when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies ha\fe a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free ofleaks.
•
Make surea fire extinguisher is installed nearby and is
properly maintained. Befamiliar withits proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
II Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it last.
II Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries
emit hydrogen, a
highly explosive gas, which can be ignited
by electrical
arcing or by lit tobacco products.
Shut off all electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
11 Never connect the negative(-) battery cable to the
positive (
+) connection terminal of the starter solenoid.
Do not test the battery condition
by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
llil Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
II Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY. ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
11 When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive.
If it comes in contact with your skin, wash
it off
at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks
and make sure the exhaustmanifold/
water-injected elbow is securely attached.
II Be sure the unit and its surroundings are well ventilated.
_Run blowers when running the
ge11erator set or engine.
II Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder
or dealer for installation of approved
detectors.
II For additional information, refer to ABYCTII-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in exhaust systep15. Exhaust
sulfur causes rapid deterioration
of copper tubing
resulting
in exhaust/water leakage.
II Do not install exhaust outlet where exhaust can be drawn
through portholes, vents,
or air conditioners. If the engine
exhaust discharge outlet is near the waterline. water could
enter the exhaust discharge outlet and close
or restrict the
flow
of exhaust. Avoid overloading the craft.
II Carbon monoxide gas is present in exhaust fumes. Some
of the symptoms or signs of carbon monoxide inhalation
or poisoning are:
Vomiting
Dizziness
Throbbing in temples
AVOID MOVING PARTS
Muscular twitching
Intense headache
Weakness and sleepiness
A WARNING:.Rotating parts can cause InJury
or death!
11 Do not service the engine while it is running. If a
situation arises in
which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts
and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Do not allow any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run the engine with the air intake (silencer) or
flame arrester removed.
• Do not run engines for long periods with their enclosures
open (when installed).
A WARNING: Do not work on machinery when you are
mentally or physically Incapacitated by fatigue! ·
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to 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 engine or generator should
begin with a thorough examination ofthe American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources inc~uding the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest ~:
H-2 Ventiiaclon for Boats using Gasoline
H-24 Gasoline Fuel Systems
P-1 Installation of Exhaust Systems
for Propulsion and Auxiliary Engines
P-4 Marine Inboard Engines and Transmissions
EllA.C and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Standards and Technical Information Reports for Small
Craft" ·
Order
from:
ABYC
613-Third Street, Suite 10
Apriapolis, MD 21403
Www.abycinc.org
NFPA -No.302 (National Fire Protection Association)
"Pleasure and Commercial Motor Craft"
Order from:
National Fire ProtectionAssociation
Battery March Park
Quincy, MA02269
USCG (United States Coast Guard)
"regulatedions are under titles CFR33 and CFR46 of the
Code ofRegulations"
Order from:
U.S. Government Printing Office
Washingt!)n, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WES1ERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifQld injection port is at or below the load waterline wiU result in
raw water damage to the engine andpossibleflooding of the boot.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
SIPHON-BREAK WITH STAINLESS
LOOP
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust
Hose is recommended. The use of this type of hose allows for extreme bends
and turns without the need of additional fitting and clamps to accomplish these bends .
and turns. In this regard, a single length of corrugated exhaust hose can be used. The
system MUST be designed to prevent the entry ofwatednto the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification .................................. : .......................... 2
. Testing for Overhaul ........................................... ~ ............... .3
troubleshooting Chart ......................................................... 4
Generator/Engine Disassembly ........................................... 6
Engine Assembly ...................................................... : .......... 7
Timing Belt Disassembly ..................................................... 8
Engine Disassembly (p.12-p.31) ....................................... 12
Service Data/Standards and Limits .................................. 32
Engine Hardware Torques ............................................... .33a
Special Tools • Engine ...................................................... .34
Exhaust Manifold/Heat Exchanger ................................. .35
Coolant Circulating Pump ................................................. 36
Raw Water Pump ............................................................... 37
Carburetor .......... : ................ · ............................................... 38
Distributor .......................................................................... 39
starter Motor ..................................................................... 40
Wiring Dlagram .................................................................. 44
Wiring Schematic .............................................................. 45
Remote Panel Wiring ........................................................ 46
Test·Safety Shutdown SWitcheS/Relays ............................ 47
Test Ignition Coilngnlter .................................................. .49
Panel Wiring Schematic ................................................... .50
Electronic Governor .......................................................... 51
Magnetic Plck·Up .............................................................. 52
Electronic Governor Troubleshooting ........ ~ ..................... .53
Engine Adjustments .......................................................... 54
Battery Charge Controller ................................................. 51
Specifications 7 .OKw ........................................................ 59
Specifications 5.0Kw ........................................................ 60
Generator lnformatlon ....................................................... 61
BC Generator Testing and Troubleshooting (p.63-p.72) .. 63
Governor Wiring Diagram .................................................. 73
Special Tools • Generator ................................................. 74
Terminal Board Connections ............................................. 75
Remote 011 Filter ............................................................... 75
Bolt and Nut ngMenlng Method .. .- ........ : ................... ~ ....... 76
Shore Power Transfer Switch ............................................ 77
Bolt and Nut nghtening Method ....................................... 76
Metric Conversion Data .................................................... 78
Index ................................................................................. 81
Engines & Generators
1

COOLANT
CONTROL
GENERATOR
BACK·END
FLAME AOO<OT<O,..-
SCREEN
REAR
FUEL FILTER
AIR BLEED
CONNECTION
SIPHON BREAK
WATER INJECTED
EXHAUST ELBOW
SWITCH
FRONT
PARTS IDENTIFICATION
EXHAUST
FUEL FILTER
FUEL
STARTER
MOTOR
LEFT SIDE
Eng_tnes & Generators
2
FILTER
FILL
WATER
PUMP
RIGHT SIDE
AC CIRCUIT
BREAKER
HEAT
EXCHANGER
ZINC ANODE
,FLEXIBLE ISOLATED
MOUNTS

TESTING FOR OVERHAUL
HOW TO' DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is detennined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output
is not necessarily due to trouble with the engine itself, but is
sometimes caused by improper oil, clogged filters or a faulty
carburetor.
111e decrease in compression pressure is caused by many fac-
tors. It is, therefore, necessary to determine a cause or causes
on the basis ofdata produced by periodic inspection and
maintenance. Oil analysis on a seasonal basis is a good
means of monitoring engine internal wear. When caused by
worn cylinders or piston rings, the following symptoms will
occur:
1 LQw engine power output
2 Increased fuel consumption
3 Increased on consumption
4 Hard engine starting
5 Noisy engine operation
These symptoms often appear together. Symptoms 2 and 4
can result also from improper fuel regulation or a faulty car-
buretor. They are caused also by defective electrical devices
such
as the battery, starter or spark plugs. Thetefore.it is
desirable to judge the optimum engine overhaul time by the
lowered compression pressure caused by worn cylinders
and
pistons plus increased oil consumption. Satisfactory combus-
tion is obtained only under sufficient compression pressure.
. If an engine lacks compression pressure, incomplete combus-
tion of fuel will take place even if other parts of the engine
are operating properly. To determine the period ofengine
overhaul, it is important to measure the engine compression
pressure
regularly. At the same time, the engine speed at
which the measurement ofcompression pressure is made
should be checked because the compression pressure varies
with engme rpm. The engine rpm can be measured at the
front end of the crankshaft.
NOTE: To test engine compression see the ENGINE
ADJUSTMENT section of this manual.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress ofwear
of
these parts.
\Vhen decrease of compression pressure reaches the repair ·
limit, the engine must be overhauled.
The engine.requires overhaul when oil consumption
is high,
blowby evident, and compression values are at minimum or
below. Engine compression should be 178 psi (1260 Kpa) at
250 rpm. With a limit 137psi (860 Kpa). Pressure should not
differ
by more than 14psi (100 Kpa) between cylinders. See
ENGINE COMPRESSION in this manual.
ENGINE OVERHAUL
The following sections contain detailed information
relating to the major components and systems of
the engine.
Included are disassembly and inspection instructions for the
guidance of suitable equipped and staffed marine.engine ser-
vice and rebuilding facilities. The necessary procedures
should be undertaken
only .by such facilities.
Additional detailed information and specifications
are
provided in other sections of this manual, covering the
.generator, alternator, startex: motorrengine.adjustments,
cooling pumps, etc.
DISASSEMBLY
1. Before disassembly and cleaning, carefully check for
.defects which cannot be found after disassembly and
cleaning.
2. Clean the engine exterior.
3. Perform disassembly in a proper order using proper
tools.
Keep disassembled parts in order. Apply oil when neces:
· sary. Take special care to keep the fuel system parts from ·
intrusion of dust and dirt.
l"ffV'lWESTERBEKE
) Engines & Generators
3

BCG GENERATOR TROUBLESHOOTING
The following troubleshooting chart describes certain
problems relating to engine service, the probable causes
of
these problems, and the recommendations to overcome these
problems.
PROBLEM
PROBABLE CAUSE
HARD STARTING
OR FAILURE TO START
1. Contaminated fuel.
2. Timing belt.
3. AC generator overload.
4. Check valve at fuel supply.
5. Defective starter.
6. Faulty ignition.
7. Raw water in cylinders.
SMOKY EXHAUST
WHITE, PURPLE OR BLUE SMOKE
1. Excessive engine oil..
This chart may be of assistance in determining the need for
an engine overhaul. For back-end troubleshooting, refer to the
BC GENERATOR ELECTRICAL TESTING section in this
manual.
VERIFICATION/REMEDY
1. Check system.
2. Inspect timing belt-replace.
3. Remove loads before starting ..
4. Repair or replace ..
5. Repair or replace starter.
6. Check ignition system.
7. Failure of exhaust system or syphon break. Clear
cylinders. Engine may need overhaul.
1. Correct oil level.
2. Excessive rise of oil into combustion chamber.
2. Engine overhaul.
a.Poor piston contact.
a. Check standard.
b.Seized piston ring.
b. Replace or clean.
c. Excessive piston-to-cylinder clearance.
c. Replace or correct.
d. Worn valve stem and valve guide.
d. Replace.
e.Low engine oil viscosity.
e. Replace.
f. Excessive oil pressure.
f. Correct.
g.Piston rings are worn or unseated.
g. Engine overhaul.
3. Insufficient compression.
3. See LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAY
1. Poor compression.
1. See LOW COMPRESSION.
2. Improper valve clearance.
2. Valve adjustment.
3. Insufficient intake air (air cleaner clogged). 3. Replace air cleaner.
4. Improper fuel. 4. Replace with proper fuel.
EXCESSIVE OIL OIL LEAKAGE
CONSUMPTION 1. Defective oil seals.
1. Replace oil seals.
2. Broken gear case gasket.
2. Replace gasket.
3. Loose gear case attaching bolts.
3. Retighten bolts.
4. Loose drain plug.
4. Retighten plug.
5. Loose oil pipe connector.
5. Retighten oil connections.
6. Broken rocker cover gasket.
6. Replace gasket.
7. Loose rocker cover attaching bolts.
7. Retighten attaching bolts.
OIL LEVEL RISING
1. Dead cylinder.
1. Check compression.
2. Displaced or twisted connecting rod.
2. Replace connecting rod.
3. Worn piston ring.
3. Replace ring.
ENGINE BACKFIRES,
1. Incorrect valve clearances.
1. Adjust valves and clearances.
MISFIRES 2. Lean fuel/air mixture
2. Check carburetor.
3. Restricted exhaust.
3. Check catylisVexhaust.
Engines & Generators
4

BCG ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEDY
ABNORMAL SOUND
CRANKSHAFT AND MAIN BEARING
OR NOISE
1. Badly worn bearing.
1. Replace bearing and grind crankshail.
2. Badly worn crankshaft.
2. Grind crankshaft.
3. Melted bearing.
3. Replace bearing and check lubrication system.
CONNECTING ROD AND CONNECTING ROD BEARING
1. Worn connecting rod big end bearing.
1. Replace bearing.
2. Worn crankpin.
2. Grind crankshaft.
3. Bent connecting rod.
3. Correct bend or replace.
PISTON, PISTON PIN, AND PISTON RING
1. Worn cylinder.
1. Rebore cylinder to oversize and replace piston.
2. Worn piston pin. 2. Replace piston.
. 3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and ring worn or damaged.
4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft.
1. Replace.
2. Excessive valve clearance. 2. Adjust.
3. Worn timing gear. 3. Replace.
4. Worn fan pulley bearing.
4. Replace.
LOW COMPRESSION MAIN ENGINE TROUBLES
1. Incorrect valve clearance. 1. Adjust valve clearance.
2. Inadequate contact of valve seat. 2. Lap valve.
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 piston and piston ring.
7. Worn piston ring and cylinder, 7. Overhaul engine.
8. Worn engine bearings. 8. Overhaul engine.
EXCESSIVE FUEL
CONSUMPTION
1. Noisy knocking. 1. See KNOCKING.
2. Smoky exhaust. 2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn. 3. Repair or replace.
4. Poor compression. 4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing. 5. Adjust.
6. Improper valve clearance.
6. Adjust.
INSUFFICIENT INTAKE AIR
1. Air intake obstructed.
1. Remove obstruction.
NOZZLE TROUBLES
1. Seized nozzle.
1. Replace.
2. Worn nozzle. 2. Replace.
KNOCKING
ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
a.Overheated cylinder.
a. See OVERHEATING; LOW OUTPUT.
b.Carlbon deposits in cylinder. b. Clean.
KNOCKING WITH DARK SMOKE
1. Poor compression. 1. See LOW COMPRESSION; HARD STARTING.
LOW OIL PRESSURE
1. Worn Bearings.
1. Engine overhaul replace bearings.
2. Relief valve malfunction.
2. Overhaul oil pump.
3. Clogged oil cooler/filter.
3. Repair and replace.
4. Diesel dilution of the oil.
4. Injection pump repair.
5

GENERATOR/ ENGINE DISASSEMBLY
DESCRIPTION
The engine component of the BC generator is not as bulky or
heavy as most engines (approx. 75lbs) so it can be
disassembled and repaired on a sturdy work bench. make
certain however that the engine is securely fastened so it can
not topple off the bench and that the bench also is secure and
can not tip over.
Set the generator breakers and panel switches in the off
position. Disconnect the AC wiring connections at the
terminal block/circuit breaker and unplug the harness at the
control pane. Disconnect the battery cable connections and
the engine ground cables.
Close off the raw water seacock and disconnect the raw
water components. Separate the exhaust at the water injection
elbow and disconnect the fuel supply.
A CAUTION: Make certain the fuel lines are closed
off and drained. Clean up all fuel and oil spills and
properly dispose of the rags.
STARTER
MOTOR
.HOUSING
TYPICAL BC GENERATOR
BACK-END ASSEMBLY
Unfasten the generator from its mounting rails or the
mounting rails from the platform and remove the generator
from the boat.
Once the generator is securely mounted on the work bench,
drain the engine oil and coolant.
Remove the starter
motor. Disconnect and remove the wiring
harness, be certain to tag all the wiring ·connections so you
can separate them.
Separate
the generator back-end from the engine. Once the
!;lousing is removed, the remaining generator components can
~be disassembled from the engine back-plate.
NOTE: For servicing and testing of the back-end(generator),
refer to the GENERATOR section in this manual.
ASSEMBLY
BOLTS
~REMOVE USING AN BMM (11/16") SOCKET
~=2!::.'<!/T TO DRAIN THE OIL OR PUMP THE WARMED
·· COOLANT DRAIN
. LOCATED JUST BELOW
·THE INTAKE MANIFOLD .
OIL UP THRU THE HOSE.
6
GENERATOR BACK·END
SEE SPECIAL TOOLS fOR .
DISASSEMBLING THE
GENERATOR COMPONENTS

ENGINE ASSEMBLY
GENERAL INFORMATION
• Be careful not to mix bolts and nuts. Metric 11nd S.A.E.
bolts are used on various engine assemblies.
• During assembly, recheck clearances and insure that parts
are being assembled in their proper order and facing in the
correct direction in relation to the engine block, such as,
pistons, piston rings, bearings and bearing caps.
• Apply lubricating oil to moving parts during assembly.
Insure that moving parts, when assembled on the engine,
rotate or slide and are not subject to binding or
excessive
tension.
• If !here are mating marks scribed during disassembly,
reference them correctly for assembly.
• Use new gaskets, lockwashers, 0-rings, packings and seals.
• Tighten the bolts and nuts on important parts of the engine
to specified torques using a reliable torque wrench.
• When required, use liquid sealants when required on nuts,
bolts and gaskets. Refrain from using tape sealants.
• Most gaskets and many bolt washers are asymmetrical,
make certain they are positioned properly.
Torquing Hardware
Prevent mechanical damage by running fasteners down in
three
steps-1/2, 2/3, and 1/1 torque. Exceptions are torque-to-
yield
bolts and rocker arm shaft fasteners. The former are
torqued as indicated. The latter-rocker shaft fasteners-should be
brought
down in very small increments, working .from the
center bolts out. Gaskets, especially head gaskets, might be
damaged during assembly, they should be positioned with .great
care. See TORQUE SPECIFICATIONS 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, raw water, oil, or fuel. Alight
coating of
oil or LIQUID TEFLON can be used on rubber
gaskets and a-rings.
LOC1ITE hydraulic red sealant should be used on oil adapter
hoses and the oil filter assembly.
Coat both surfaces ofthe oil pan gasket with high temp RED
Sll..ICONE SEALER.
7
When installing gaskets that seal around water (coolant)
passages, coat both sides with WHITE Sll..ICONE GREASE.
Do not use sealant when installing a new gasket.
HIGH-COPPER ADHESIVE SPRAYS are useful for hold-
ing a gasket in position during assembly.
Specialized gasket sealers such as HYLOMAR work well in
applications requiring non-hardening properties. HYL011AR
is particularly effective on copper cylinder-head gaskets and
resists fuel, oil , and water.
NOTE: TAPE SEALANTS should be used on pipe plugs and
fitting that
~onnect water coolantpassages.
Bolts and Fasteners
Lightly oil head bolts and other fasteners as you assemble
them. Bolts and other plugs that penetrate the water jacket
should
be sealed with PERMATEX #2 or HIGH TACK.
When assembling the flywheel, coat the bolt threads with
LOCTITE blue.
LITHIUM based grease is waterproof, ideal for water pump
bearings and stuffing boxes.
Antiseize
compounds and thread locking adhesives such as
LOCTITE protect threaded components yet allow them to
come apart when necessary. LOCKTTIE offers levels of
locking
according to the job.
Heavily
oil all sliding and reciprocating components, always
use clean engine oil.

TIMING BELT DISASSEMBLY
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
TORQUE 1- 9 Ft-Lbs
10-12Nm
1 TIMING BELT
COVER A
3ACCESS COVER~
12 CRANKSHAFT
BOLT
TORQiJE 98 - 105 FT-LBS
135-145 Nm
INSTRUCTIONS FOR INSPECTING AND REPLACING
THE TIMING BELT
WES'IERBEKE requires as normal maintenance, replacing
the timing belt after 1000 engine operating hours. The timing
belt should
always be replaced 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 Removal
1. Turn the crankshaft clockwise to align the timing mark on
the camshaft sprocket and timing belt rear cover.
NOTE: Always tum the crankshaft clockwise.
2. Remove the plug on the left surface of the cylinder block
and insert a rod with a diameter of 0.31 in (8 mm) to lock
the counterbalance shaft.
NOTE: Be sure to use an inserting rod with a diameter of
0.31 in (8 mm).
TORQUE 1-9 FT-LBS
10-12Nm
\ \
15 EAR COVER
,OIL PUMP SPROCKET
13 CRANKSHAFT 1 Q FLANGE NUT
SPROCKET .TORQUE 36 - 40 FT-LBS
[50-56 Nm]
8
OD 0.31 In [8 mmJ
3. Loosen the timing belt tensioner nut.
4. Move the timing belt tensioner toward the water pump,
and temporarily tighten the nut to hold the tensioner in
that position.
CRANKSHAFT
SPROCKET

TIMING BELT DISASSEMBLY
5. Remove the timing belt.
NOTE: If the timing belt is to be reused, draw an arrow on
the belt to indicate the direction of rotation (clockwise).
Cams~aft Sprocket Removal
1. Remove the camshaft sprocket bolt without turning the
camshaft.
SPROCKET BOLT
Oil Pump Sprock~t Flange Nut Removal
1. Remove the plug from the left side of the cylinder block.
2. Insert an 0.31 in (8 mm) diameter round bar to lock the
counterbalance
shaft
3. Remove the oil pump sprocket flange nut.
9
Crankshaft Bolt Removal
1. Lock the crankshaft in position.
NOTE: Do not turn the crankshaft.
2. Remove the crankshaft bolt.
Timing Belt Inspection
Replace the belt if any of the following conditions exist:
• H!lfdening of the back rubber, leaves no indent when
pressed with fingernail (back side is glossy).
• Cracks on rubber back.
• Cracks or peeling of canvas.·
• Cracks on tooth bottom. "
• Cracks on
belt
• Abnormal wear of belt sides. The sides are normal ifthey
are sharp as
if cut by a knife.
• Abnormal wear on teeth.
• Tooth missing and canvas fiber exposed.
HARDENING
$
CRACKS ON UNDERSIZE
CRACKS ON TOP
Tensioner Inspection
-~" ~
~
CRACKS ON EDGE
"/~
~
ROUNDED EDGES
FLUFFY STRANDS
TOOTH MISSING
CANVAS EXPOSED
1. Replace the tensioner ifthe pulley binds, rattles or is noisy
when turned.

ENGINE TIMING BELT
Flange Installation .
1. Mount the flange so that its side shown by the heavy
arrow in the illustration faces toward the sprocket.
FLANGE
A-Jffi~
-~
WASHER
CRANKSHAFT SPROCKET
Crankshaft Bolt Installation
1. Lock the crankshaft.
NOTE: Do not tum the crankshaft.
2. Tighten the crankshaft bolt to the specified torque.
Oil Pump Sprocket Flange Nut Installation
1. Insert the round .bar into the plug hole in the left side of
the cylinder block
to keep the counterbalance shaft from
turning.
2. Install the oil pump sprocket.
3. Tighten the nut to the specified torque.
D
.,...?
Camshaft Sprocket Bolt Installation
1. Tighten the bolt to the specified torque.
CAMSHAFT BOLT TORQUE 58 • 72 Ft·lbs (80 ·100 Nm)
SPROCKET BOLT
Tensioner Spring/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 cylinder block.
3. Move the timing belt tensioner as close as possible to the
water pump; temporarily tighten the tensioner nut.
Timing Belt Installation
1. Align the triangular marking on the camshaft sprocket
with a marking on the timing belt rear cover.
10
2. Align the notch in the crankshaft sprocket flange with the
marking on the front case.
3. Align the triangular marking on
the oil pump sprocket
with
the marking on the front case, and then insert a 2.56 in.
(65 mm.) or longer, 0.31 in (8mm.) diameter round bar into
the plug hole in the left side ofthe cylinder block.
TRIANGLE MARK ON
CAMSHAFT SPROCKET
NOTCH IN CRANKSHAFT
SPROCKET
MARK ON FRONT CASE

ENGINE TIMING BELT
At this time, check that the moveable range of teeth on the
oil pump sprocket is according to specifications.
STANDARD VAlUE: 4 to 5 teeth In forward direction.
1 to 2 teeth in reverse direction.
4. If the movable range of the teeth on the oil pump sprocket
exceeds the specified range, correct as follows:
a. Pull out the round barfrom the plug hole in the left
side
of the cylinder block.
b. Turn the oil pump sprocket one turn
at a time until the
round bar can again be inserted.
c. Check that the movable range
of the oil pump sprocket
is in the specified value.
5. Set the timing belt over the crankshaft sprocket and then
over the oil pump sprocket
and camshaftsprocket, in that
order.
NOTE: Ensure that the tension side of the timing belt is not
slack. Keep the round barinserted until the timing belt has
been placed. After this step, be sure to remove the round bar.
6. Apply counterclockwise force to the camshaft sprocket to
make the belt taut on the tension side, and make sure that
all timing marks are lined up.
CAMSHAFT SPROCKET
TENSION SlOE
7. Loosen the temperorarily tightened tensioner nuton the
water pump side 1 or 2 turns, and tension the belt making
use
of the spring force.
8.
Turn the crankshaft clockwise by nine camshaft sprocket
teeth
(81 ") to align the timing mark on the camshaft
sprocket with the tensioner set mark on the timing belt
rear cover.
A CAUTION: This operation is pertonned to give a
proper tension to the timing belt, so do not tum the
crankshaft counterclockwise and push the belt to
check the tension.
TENSIONER SET MARK
9. Make sure that th~ timing belt teeth are engaged with the
camshaftsprocket teeth along the portion
of the sprocket
shown by the curved arrow in the illustration below. Then
tighten the tensioner nut.
11
lO.Pull the timing belt in the center of the tension side
toward the sealing gasket line for the belt cover, as illus-
trated. Make sure that the clearance between the back of
the belt and the sealing line is the standard value.
STANDARD VAlUE: 0.47in. (12mm)
SEALING GASKET
LINE
0.47 In [12 mm)
ll.Pull out the rod from the plug hole on the left surface of
the cylinder block and apply the specified sealant. Then
tighten the plug to the specified torque.
Sp~cified sealant value: 3M ATD Part No. 8660 or
equivalent.
TIGHTENING TORQUE: 11-16 ft.lbs. (15·22 Nm)

ENGINE DISASSEMBLY
ASSEMBLY
Remove the thermostat assembly and clean the interior
chambers. Inspect the seals in the pressure cap when
reassembling. Replace the thermostat and gasket.
GASKET
APPLY SEALANT
TO GASKET WHEN
INSTALLING
THERMOSTAT
THERMOSTAT
ASSEMBLY
Loosen the raw water pump, remove the drive belt and then
remove the raw water pump.
RAWWATER'i
PUMP
Drain and inspect tJ:.le fuel hoses. ·
FUEL FILTER
ASSEMBLY
Inspect the 0-ring and replace the filter element.
Remove the engines coolant pump. For servicing, refer to
COOlANT PUMP.
Detach and remove the ignition wires, the distributor and
spark plugs. Refer to DISTRIBUTOR DISASSEMBLY in this
manual.
See ENGINEADJUSTMENTS for information on ignition
wires and spark plugs.
SPMfAPLOO~
-..v- WESTERBEKE
Engines & Generators
12

CYLINDER HEAD AND VALVES
4 CYLINDER HEAD
TORQUE 43- 51 FT-L/35
60-lONm
REMOVING THE CYLINDER HEAD
FROM THE CYLINDER BLOCK
Disassemble the cover bolts as shown above, taking care not
to lose the washer and insert. Remove the rocker cover and
rocker cover gasket.
Loosen each ofthe cylinder head bolts, a little at a time so
as to avoid the possibility ofdistorting the cylinder. Repeat
several times ·until the bolts are unfastened. Follow the
sequence shown in the diagram.
Remove the cylinder head and the cylinder head gasket.
3
13
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
8 6
CYLINDER HEAD BOLTS
LOOSENIN~ SEQUENCE

CYLINDER HEAD AND VALVES
Use pliers to remove the valve stem seals. Do not reuse the
stem seals.
CYLINDER HEAD INSPECTION
Before cleaning check the cylinder head for water leaks,
cracks and other possible damage.
Clean by completely removing the oil, scaling, carbon and
·sealant After flushing the oil passage, blow air thru to ensure
that no portion ofthe oil passage is clogged.
To check the cylinder head bottom surface for flatness and·
distortion, as indicated in the diagram, use a straight edge
and a feeler gauge, If distortion exceeds the limit correct
by grinding.
CHECKING CYLINDER HEAD FLATNESS
CYLINDER HEAD FLATNESS
Standard 0.00191n (0.05mm) Limit 0.00791n (0.2mm)
CYLINDER HEAD GRINDING LIMIT
0.00791n (0.2mm)
Total resurfacing depth of cylinder head and block
CYLINDER HEAD HEIGHT (NEW)
4.287- 4.295in (108.9 -1o9.1mm)
A CAUTION: No more than 0.079in (0.2mm) of
stock may be removed fro"! the cylinder head and
cylinder block mating surfaces in total.
See the STANDARDS AND UMIT'S CHARTfor cylinder
head rework dimensions ofthe valve seat hole.
14
VALVE ASSEMBLtiNSPECTION
Valve StemNalve Seat
If the valve stem is bent or worn, replace the valve. Check
contact between the valve and valve seat by applying a thin
coat ofPrussion Blue (or Redhead) on the valve seat contact
face, then insert the valve into the valve guide and press-fit
the valve on the valve seat. Do not rotate the valve.
Check ifthe valve seat contact face contacts the center posi-
tion 0fthe valve contact face. If it is not correct concentric,
correct the valve seat. If the margin is out of the limit, replace
the valve.
THICKNESS OF VALVE HEAD MARGIN
Intake
Exhaust
Standard
0.039in (1.0mm)
0.0511n (1.3mm)
Limit
0.02Din (0.5mm)
0.031 in (O.Bmm)
CONTACT WITii
VALVE SEAT
[to be at center
of seat)
- ---r--
VALVE HEAD
THICKNESS [MARGIN]
L
VALVE LENGTH: Intake 3.961n (0100.6mm)
·Exhaust 3.9681n (100.Bmm)
VALVE SEAT WIDTH OF CONTACT
Standard 0.0351n - 0.051 (0.9 -1.3mm)
Valve Spring
VALVE
lENGTH
Measure the free height of the valve spring and replace the
spring ifit is out oflimit.
VALVE SPRING FREE LENGTH
Standard 1.823in (46.3mm) ____ Limit 1.783in (45.3 mm)
Also-check the spring for squareness and ifit exceeds the
limit replace the spring.
VALVE SPRING SQUARENESS
Standard less than 2"------
-~ %~ JiJ
TESTING SQUARENESS/ANGLE