Westerbeke BCGB User manual

SERVICE MANUAL
BCGB G.-. .. ~
PUBLICATION NO.44898
JUNE 2000
1ST EDITION
WESTERBEKECORPORA TION· 150JOHNHANCOCKROAD
MYLES STANDISHINDUSTRIAL
PARK· TAUNTON MA 02780
WEBSITE: www.WESTERBEKE.COM
m
N~A Member National MariM Manufacturers Association
••••

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

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
-Nausea
-Headache
- Throbbing in Temples
- 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.
This 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.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety 11UZRual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-
tions. Know when dangerous conditions exist and take the
necessary precautions to protectyourself, your personne~
and your TIUlChinery.
The following safety instructions are in complitmce with
theAmerican Boatand Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connectlons
while engine is mnnlng, 01 when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment
• Use insulated mats whenever working on electrical
equipment
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment
• Remove wristwatch and all jewelry when working on
electrical equipment
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-ta-shore double throw
transfer switch. Damage to vessel'sAC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts 01
exhaust system components. A mnnlng engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
IA WARNING: -.." _1D/tII11lf_
• 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 01 death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, orother potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch allfuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapOIS can cause
Injury 01 death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four minutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out of the reach ofchildren.
• Do not fill the fuel tank(s) while the engine is running.
• Shut offthe fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system orengine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its 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!
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it last
• 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.
BAmRY 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 offall electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) 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.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid In batteries can cause
severe Injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
If it comes in contact with your skin, wash it offat once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: carbon mDnDxlde (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 exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for
installati~n ofapproved detectors.
• For additional infonnation refer to ABYC T-22 (educa-
tional infonnation on Carbon Monoxide).
A WARNING: carbon mDnDxlde (CO) Is an Invisible
Ddorless gas. InhalatlDn produces flu-like symptDms,
nausea Df death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
tubing resulting
in exhaust/water leakage.
• 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 ofexhaust Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the symp-
toms orsigns ofcarbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: RDtatlng parts can cause Injury
Dr death!
• Do not service the engine while it is running. Ifasitua-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing 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.
• stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can caUSll hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not wode on machinery when you are
mentally Of 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.
ENGINE INSTAllAnONS
Preparations to install an engine should begin with a thor-
ough examination ofthe American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations
(FCR).
ABYC, NFPA AND USCG PUBUCATIONS FOR
INSTALLING DIESEL ENGINES
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)
"Safety Standards for Small Craft"
Order from:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
11 Tracy Drive
Avon Industrial Park
Avon, MA02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing UNIVERSAL engines and generators it is important that strict atten-
tion 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. TIris hose must be looped a
minimum
of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifold injection port is at or below the load waterline will result in
raw water damage to the engine andpossibleflooding of the boat.
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,
instaU 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
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your UNIVERSAL
dealer.
Engines & Generators
iv

TABLE OF CONTENTS
PARTS IDENTIFICATION ......................................... 2
EXHAUST MANIFOLD/HEAT EXCHANGER .......... 36
TESTING FOR OVERHAUL ...................................... 3
RAW WATER PUMP ........................................... 37
TESTING OIL PRESSURE/COMPRESSION .......... .4 REBUILDING THE CARBURETOR ....................... 39
ENGINE TROUBLESHOOTING [CHART} ............... 5
STARTER MOTOR .............................................. .42
ASSEMBLY INFORMATION ................................... 7 ENGINE ADJUSTMENTS ...................................... .45
Sealants and Lubricants .................................... 7 Engine Speed Hertz Adjustment ..................... .45
Bolts and Fasteners ........................................... 7 Spark Plugs ..................................................... 46
GENERATOR/ENGINE DISASSEMBLY ................... 8
Valve Clearance Adjustment ........................... .47
ENGINE DISASSEMBLY ........................................ 9
TIMING BELT DISASSEMBLY ............................... 11
TIMING BELT ........................................................ 13
CYLINDER HEAD AND VALVES .......................... 15
CAMSHAFT AND ROCKER ARMS ....................... 19
PISTON 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 CASE/COUNTERBALANCE SHAFT
AND OIL PAN ...................................................... 26
HARDWARE TORQUES ....................................... 54
STANDARD HARDWARE ................................... 55
FRONT CASE/COUNTERBALANCE SHAFT
AND OIL PUMP .................................................. 28
SEALANTS AND LUBRICANTS .......................... 55
SPECIFICATIONS ............................................... 56
SPECIAL TOOLS - ENGINE ................................ 57
FRONT CASE/OIL PUMP AND OIL PAN .............. 29
BC GENERATOR ELECTRICAL TESTING ..... 58 - 71
CRANKSHAFT/BEARINGS AND OIL SEAL .......... 30
SPECIAL TOOLS - GENERATOR ........................... 72
CYLINDER BLOCK INSPECTION AND
ENGINE GENERATOR TROUBLESHOOTING
PISTON CLEARANCE .......................................... 33 [CHART] ............................................................. 73
DISTRIBUTOR .................................................... 34
METRIC CONVERSIONS DATA ........................... 75
COOLANT CIRCULATING PUMP ......................... 35
METRIC CONVERSIONS [CHART]. ..................... 76
INDEX ............................................................... 77
Engines & Generators
1

BCGB PARI'S lOERllflCATlON
ENG\NE Oil F\LL
WATER \NJECTED
EXHAUST ELBOW
MAN\FOLD __ -+ __ \\.-U~~
. COOLANTDRA\N
GASDENSER
HOURMETER
CONTROL
SWITCHES
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\ON
C\RCUlT BREAKER
GENERATOR
BACKEND
REAR
FLEX\BLE MOUNT
ENG\NE O\L F\LL
RAW WATER
\NJECT\ON
(SYPHON BREAK
CONNECtiON)
FUELUFT PUMP
fRONT

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is determined 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.
The decrease in compression pressure is caused by many fac-
tors. It is, therefore, necessary to determine a cause or causes
on the basis
of data 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 Low engine power output
2 Increased fuel consumption
3 Increased oil 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. Therefore 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 of engine
overhaul, it
is important to measure the engine compression
pressure regularly.
At the same time, the engine speed at
which the measurement
of compression pressure is made
should be checked because the compression pressure varies
with engine 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
of wear
of these parts.
When decrease
of compression pressure reaches the repair
limit, the engine must be overhauled.
The enginerequires 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
400 rpm With a limit 137 psi (860 Kpa). Pressure should not
differ
by more than 14 psi (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, starter motor, engine 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.
SERIAL NUMBER LOCATION~~ ~ The engine serial
FiIl in the information l";~0~Ob').. ~~\ '!umber is str;zmped
below for referenc~_ ~/ 3-:> II znto the engme block.
0~ f"'~ ~ ~I
'~ ~
!~I(
I 1
I \1 ~~==~~~~
The engine model
number
and "serial
numberare printed
on a decal on the
engine manifold.
The generator serial
number is stamped
on the top
of the
generator housing.
An additional decal
is located on the top
of the generator
housing.
Engines & Generators
3

TESTING OIL PRESSURE I ENGINE COMPRESSION
NOTE: WESTERBEKE recommends that thefollowing engine
adjustments be performed by a competent engine mechanic.
The information below is provided to assist the mechanic.
TESTING OIL PRESSURE
To test the oil pressure, remove the hex head plug from the
oil manifold and install a mechanical oil pressure gauge in its
place. After warming up the engine, set the engine speed at
1800 rpm and read the oil pressure gauge.
Oil Pressure Between 3D and 40 psi at 1800/1500 rpm.
Note: A newly started (cold) engine may have an oil pres-
sure up to 70
or 80 psi. A warmed engine can have an oil
pressure as low as. 30 psi. Oil pressure will vary depending
on the load placed on the generator.
OIL GALLERY
LOW OIL PRESSURE
The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3
+0.1 kglcm2 ). A gradual loss of oil pressure usually indicates
worn bearings.
ENGINE COMPRESSION TEST
1. To check the engine's compression pressure, 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 offthe raw water intake seacock.
5. Crank the engine with the start motor and unplug the
ignition coil and allow the compression gauge to reach a
maximum reading and record.
6. Measure the compression pressure for all the cylinders.
Ensure that compression pressure differential for each
cylinder is within the specified unit.
Compression pressure should not differ by more than 14 psi (100 Kpa).
7. If a cylinder's compression or pressure differential is
below the limit, add a small amount
of engine oil through
the spark plug hole and repeat steps 4 and
5.
(a) If additional of oil causes an increase of pressure, the
piston ring and/or cylinder wall may be worn or damaged.
(b)
If additional oil does not increase compression pressure
suspect poor valve contact, valve seizure, or valve wear.
8. Reinstall three plugs and ignition wires.
9. Open the raw water thru seacock.
COMPRESSION PRESSURE
178 PSI [1260Kpa] AT 400 RPM
COMPRESSION
GAUGE
(TYPICAL)
ADAPTER
~
Engines & Generators
4

BeGB 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
HARD STARTING
OR FAILURE TO START
SMOKY EXHAUST
EXCESSIVE OIL
CONSUMPTION
ENGINE BACKFIRES,
MISFIRES
Probable Cause
1. High exhaust pressure.
2. Timing belt.
3. AC generator overload.
4. Check valve at fuel supply.
5. Defective starter.
6. Faulty fuel regulator.
7. Raw water in cylinders.
WHITISH, PURPLE OR BLUE SMOKE
1. Excessive engine oil.
2. Excessive rise of oil into combustion chamber.
a. Poor piston contact.
b. Seized piston ring.
c. Excessive piston-to-cylinder clearance.
d. Worn valve stem and valve guide.
e. Low engine oil viscosity.
f. Excessive oil pressure.
g. Piston rings are worn or unseated.
3. Insufficient compression.
BLACKISH OR DARK GRAY
1. Poor compression.
2. Improper valve clearance.
3. Insufficient intake air (air cleaner clogged).
4. Improper fuel.
OIL LEAKAGE
1. Defective oil seals.
2. Broken gear case gasket.
3. Loose gear case attaching bolts.
4. Loose drain 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. Incorrect valve clearances.
2. Valves are out of adjustment.
This chart may be of assistance in determining the need for
an engine overhaul. For back-end troubleshoting, refer to the
BC GENERATOR ELECTRICAL TESTING section in this
manual.
VerificationJRemedy
1. Install a larger diameter exhaust.
2. Inspect timing belt-replace.
3. Remove loads before starting.
4. Repair or replace ..
5. Repair or replace starter.
6. Replace regulator.
7. Failure of exhaust system or syphon break. Clear cylinders-
Engine may need overhaul.
1. Correct oil level.
2. Engine overhaul.
a. Check standard.
b. Replace or clean.
c. Replace or correct.
d. Replace.
e. Replace.
r. Correct.
g. Engine overhaul.
3. See LOW COMPRESSION; HARD STARTING.
1. See LOW COMPRESSION.
2. Valve adjustment.
3. Replace air cleaner.
4. Replace with proper fuel.
1. Replace oil seals.
2. Replace gasket.
3. Retighten bolts.
4. Retighten plug.
5. Retighten oil connections.
6. Replace gasket.
7. Retighten attaching bolts.
1. Check compression.
2. Replace connecting rod.
3. Replace ring.
1. Adjust valves and clearances.
2. Adjust valves and clearances.
,,,,,,,,,WESTERBEKE
I Engines & Generators
5·

BCGB ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE VERIFICATION/REMEDY
ABNORMAL SOUND
CRANKSHAFT AND MAIN BEARING
OR NOISE
1. Badly worn bearing. 1. Replace bearing and grind crankshaft.
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.
S. Worn engine bearings. S. 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.Carbon 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.
Engines &Generators
6

ENGINE ASSEMBLY
GENERAL INFORMATION
• Be careful not to mix bolts and nuts. Metric and 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 there are mating marks scribed during disassembly,
reference them correctly for assembly.
• Use new gaskets, lockwashers, O-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-I/2,
213, and III 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. A light
coating
of oil orLIQUID 1EFLON can be used on rubber
gaskets and o-rings.
LOCTlTE hydraulic red sealant should be used on oil adapter
hoses and the oil filter assembly.
Coat both surfaces
of the oil pan gasket with high temp RED
SILICONE SEALER.
When installing gaskets that seal around water (coolant)
passages, coat both sides with
WHITE SILICONE GREASE.
Do not use sealant when installing a new gasket.
HIGH-COPPERADHESIVE 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. HYLOMAR
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 connect water coolantpassages.
Bolts and Fasteners
Lightly oil head bolts and other fasteners as you assemble
them. Bolts and other plugs that penetrate the waterjacket
should be sealed with
PERMA1EX #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. LOCKTITE offers levels of
locking according to the job.
Heavily oil all sliding and reciprocating components, always
use clean engine oil.
Engines & Generators
7

GENERATOR I ENGINE DISASSEMBLY
DESCRIPTION
The engine component of the BCGB generator is not as
bulky or heavy as most engines [approv.
7Slbs] 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.
Setthe generator breakers and panel switches in the offposi-
tion. Disconnect the
AC wiring connections at the terminal
block/circuit breaker and unplug the harness at the control
panel. Disconnect the battery cable connections and the
engine ground cables.
Close offthe raw water seacock and disconnect the raw
water components. Separate the exhaust hose at the water
injection elbow and disconnect the fuel supply and return
lines.
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.
YWHEEL
ARMATURE
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 a 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 as you
separate them.
Separate the generator back-end from the engine by
removing the 3 bolts (one is the engine ground), one stud and
one allen flat head that fasten the engine back-plate to the
housing. Once the housing 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
y
'iJ'",I[,\.\.\.\.\.'/
'~ \\'-\.\.\:
~,/\~ /
j III
~~/
\
i
GENERATOR BACK-END
~ 1
GENERATOR BACK-END
SEE SPECIAL TOOLS FOR
DISASSEMBLING THE
GENERATOR COMPONENTS.
Engines & Generators
8

ENGINE DISASSEMBLY
INTRODUCTION
The following text describes the disassembly, inspection,
repair, and reassembly
of the engine when preforming a
complete engine overhaul.
This manual also includes a breakdown
of sub assemblies,
engine adjustments, generator information and all related
technical data.
NOTE: The cylinder head, rocker arms and valves can be
inspected andadjusted with the engine in the boat. TIming belt
adjustment and replacement
can also be accomplished without
removing the engine.
Suggested Sequence of Disassembly
1. Remove the heat exchanger and set it aside for servicing.
See HEAT EXCHANGER in this manual.
2. Remove the starter motor. The starter motor should be
cleaned, inspected, and repainted. Refer to
STARTER
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 the water temperature. switch and sender and
disassemble the thermostat assembly.
THERMOSTAT ASSEMBLY
5. Disconnect and drain the oil hoses. Remove, clean, and
inspect the oil gallery/filter assembly.
OIL FILTER
COMPONENTS
cj),
~
\1.
OIL FILTER
6. Loosen the belt guard thumb screws and remove the belt
guard sections and their gaskets.
7. Disconnect the linkage arm between the governor and the
carburetor at the ball joint and remove the carburetor.
When servicing the carburetor, refer to the
CARBURETOR SECTION in this manual.
S. Release the governor belt and remove the governor
assembly and belt. See GOVERNOR
MAINTENANCE.
GOVERNOR -- __ ...c"A
GOVERNOR AND
GOVERNOR BELT
COOlANT
PUMP
ASSEMBLY
"-
~
~COVER GUARD
THUMB SCREW
Engines & Generators
9

ENGINE DISASSEMBLY
9. Remove the gasdenser and the connecting fuel lines from
the fiont
of the engine and remove the fuel lift pump.
INSPECT HOSES
FUEL UFT PUMP & GASDENSER
10. Loosen the raw water 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 spark plugs.
Refer to DISTRIBUTOR DISASSEMBLY in this manual.
See ENGINE ADJUSTMENTS for information on ignition
wires and spark plugs.
DISTRIBUTOR
COMPONENTS
IGNITION WIRES
Engines & Generators
10

TIMING BELT DISASSEMBLY
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
TORQUE 7-9 Ft-Lbs
10-12Nm
1 TIMING BELT
COVER A
3~CCESS COVER~
TORQUE 7- 9 FT-LBS
10-12Nm
\
1 o/EAR COVER
i
6 TIMING BELT
TENSIONER
12 CRANKSHAFT
BOLT
13 CRANKSHAFT 10 FLANGE NUT
SPROCKET TORQUE 36 - 40 FT-LBS
[50-56Nm]
TIMING BELT ADJUSTMENT,
INSPECTION AND REPLACEMENT
CAN BE PERFORMED WITH
ENGINE IN THE BOAT
TORQUE 98 - 105 FT-LBS
135-145 Nm
TIMING BELT
COVER C
INSTRUCTIONS FOR INSPECTING AND REPLACING
THE TIMING BELT
WES1ERBEKE 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.
TIMING MARK.--=~.//;.J
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).
I
-----~L6 In [65 mm]
---"'"""""~
ROD 0.31 In [8 mm]
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.
Engines & Generators
CRANKSHAFT
SPROCKET
11

TIMING BELT DISASSEMBLY
5. Remove the timing belt.
NOTE: lfthe timing belt is to be reused, draw an arrow on
the beltto indicate the direction
of rotation (clockwise) ..
Camshaft Sprocket Removal
1. Remove the camshaft sprocket bolt without turning the
camshaft.
SPROCKET BOLT
Oil Pump Sprock~ 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.
OIL PUMP SPROCKET
Crankshaft Bolt Removal
1. Lock the 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 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 if they
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.
Engines & Generators
12

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
CRANKSHAFT SPROCKET
Crankshaft Bolt Installation
1. Lock the crankshaft.
NOTE: Do not tum the crankshaft.
A-Z=i
-~
WASHER
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
.-4
Camshaft Sprocket Bolt Installation
1. Tighten the bolt to the specified torque.
CAMSHAFT BOLT TORQUE 58 - 72 Ft-Ibs (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.
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.) orlonger, 0.31 in (Smm.) diameter round bar into
the plug hole in the left side
of the cylinder block.
MARK ON TIMING
BELT REAR COVER_~
TRIANGLE MARK ON
CAMSHAFT SPROCKET
TIMING BELT
~"d.~:t=~'=='--" TRIANGLE MARK .
NOTCH IN CRANKSHAFT
SPROCKET
MARK ON FRONT CASE
Engines & Generators
13