Westerbeke 3.0KW BPMG-60HZ Service Manual
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Westerbeke 3.0KW BPMG-60HZ Service Manual

Westerbeke 3.0KW BPMG-60HZ Service Manual

Gasoline, single phase generators
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SERVICE MANUAL
3.0KW BPMG 60Hz and 50Hz
SINGLE PHASE
GASOLI
ENERATORS
I
rPiJBLiCt~
NO. 52089
I
SECOND EDITION
MARCH 2009
~
WESTERBEKE
WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAO
MYLES STANOISH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: www.WESTERBEKECOM
~
Membu Nlltional
Mllrln~
Manufacturers Association
...
.

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  • Page 1 . . · SERVICE MANUAL 3.0KW BPMG 60Hz and 50Hz SINGLE PHASE GASOLI ENERATORS rPiJBLiCt~ NO. 52089 SECOND EDITION MARCH 2009 WESTERBEKE WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAO MYLES STANOISH INDUSTRIAL PARK' TAUNTON MA 02780 WEBSITE: www.WESTERBEKECOM Mllrln~ Membu Nlltional Manufacturers Association...
  • Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
  • Page 3 . . . mtldical attBntion. Shut down the unit and do not Inspected and repaired. A WARNING DECAL plOvlded by WESTERBEKE and should be fixed to bulkhtlBd near your engine Dr generator. WESTERBEKE also recommtllllls Installing !o!o!~ CARBON MONOXIDE OETECTORS In the Ilvlng/s/eeping quartelS of your vessel.
  • Page 4 • In case of an engine overheat, allow the engine to cool Extinguishers rated ABC by the NFPA are appropriate before touching the engine or checking the coolant. for all applications encountered in this environment. WESTERBEKE ...v" Engines & Generators...
  • Page 5 SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) Is deadly gas! dIIath! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine/ discharged from the engine.
  • Page 6 USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-I Exhaust Systems P-4 Inboard Engines E-9 DC Electrical Systems All installations must comply with the Federal Code of Regulations (FCR). WESTERBEKE Engines & Generators...
  • Page 7 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention he paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must he complied with when installing engines and generators in a marine environment.

  • Page 8: Table Of Contents

    Thermostat............41 Choke Solenoid ..........41 Valve Clearance ..........42 Timing Belt Replacement! Adjustment....42A Electronic Governor ..........Shutdown Switches ..........WIring Diagram ............AC Generator ............Specifications ............Metric Conversion Charts ...........v: WESTERBEKE Engines & Generators...

  • Page 9: Parts Identification

    PARTS IDENTIFICATION ~"",.,,, ... COIL ENGINE SERIAL ,un,.u, __ 'GNmON MODU1£ SERVICE SIDE 'CONNECTION TO COOLANT RECOVERY TANK THERMOSTAT ASSEMBLY WATER (COOLANT) TEMPERATURE SWITCH "'~--- OIL DRAIN HOSE +--HEAT FRESHWATER EXCHANGER (COOlANn MODEL ZINC ANODE SERVICE SIDE WAltH PUMP IGNITION CONTROL BAmRY VOlTAGE LEFT SIDE...

  • Page 10: Testing For Dverhaul

    TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL CONDITIONS co~pressioln pressure tendsdt0alincrease ahli \:-':::"e in a new Cause of Low Compression engme untl piston f1ngs an v ve seats a p""~geen Generally, the time at which an engine should be overhauled Thereafter, it decreases gradually with the rfo en ress 0 wear...
  • Page 11 TROUBLESHOOTING GUIDE 3.0 KW BPMG When toubleshooting indicates an electrical problem, see the The following troubleshooting tables are based upon certain ELECfRICAL SYSTEM WIRING DIAGRAM, as this may engine problem indicators and the most likely causes of the reveal other possible causes of the problem which are not listed problems below.
  • Page 12 1. Check MPU signal. 1.5 - 2.0 VAC cranking. Unit starts and runs at Idle speed 2. Faulty overspeed board. Note: MPU voltages to PC board: Cranking: 1.5 - 2.0 VAC Running: 4.0 - 5.0 VAC (2200 rpm) WESTERBEKE Engines & Generators...
  • Page 13 DISASSEMBLY ASSEMBLY PROCEDURES DISASSEMBLY Surface Preparation • Before disassembly and cleaning, carefully check for defects which cannot be found after disassembly and Thoroughly removes all substances deposited on the gasket cleaning. application surfaces using a gasket scraper or wire brush. •...

  • Page 14: Sealants And Lubricants

    Fuel pump plung_er 2ml at Suction port and • discharge port, Boss part Oil pump a-ring • (01.5 - to.7) • Oil pump O-ring (ot.5 - 8,5) • (ot.5 - 15.5) • Thread Oil pressure switch WESTERBEKE Engines & Generstors...
  • Page 15 Starter seal rubber • Oil; at oil change 1000rnl Engine oil overhaul 1200ml • Ollpan gasket • Bolt (upper pump case) Thread • Impeller sliding surfaces Upper pump case Joint part for water pipe guide WESTERBEKE ,..yo Engines. G.enerators &...

  • Page 16: Torque Specifications

    TORQUE SPECIFICATIONS Tightening Torque Item Thread size or Nut kg-m Ib-ft M8 x 1.25 28-30 2.&-3.0 20-22 Cylinder Block - Cylinder Head M& x 1.0 Boll 0.8-1.0 5.8-7.2 8-10 M8 x 1.25 Boll 2.3-2.5 17-18 23-25 Cylinder Block - Crank Case M8 x 1.0 Boll 8-10...
  • Page 17 Snap ring pliers (10 mm, 7N - m) ..for the tappetiock nut 9. T -bar' socket wrench (10 mm) 17. Socket wrench set rnfTl) - do. - - do.- (13 mm) - do.- (17 mm) WESTERBEKE ",y" Engines & Generators...
  • Page 18 USING SPECIAL TOOLS 5. How Use Special Tools 2. Piston pin tool 1. Flywheel cup puller After removing the piston pin clip, insert the tip of <D When disassembling the piston pin tool into the piston pin hole and ® Fasten the tools to the flywheel with lightly tap the other end of the tool with a hammer.
  • Page 19 SERVICE STANDARDS/REPAIR LlMITS/MAINTENANCE Part Name Check/lnsaect Standard ValueJMalntenance Repair limit Cylinder Head 1. Carbon deposit on the combustion 1. Remove carbon deposit and clean. chamber 2. Scratch depth and distortion of the 2. Scratch depth or distortion is O.lmm (0.004in) 2.
  • Page 20 SERVICE STANDARDSIREPAIR LlMITS/MAINTENANCE Part IIaIIIe Check/lllSllect Standard Value/Maintenance Repair Limit Connecting Rod Inner diameter of the small end. 1. 16.01mm (0.630in) 16.04mm (0.631 in) or more. Oil clearance of the big end. 2. 0.Q15 - 0.041mm (0.0006 - 0.0016in) 2. 0.060mm (0.002in) or more. 3.
  • Page 21 3) 14.96mm (0.589in) or less 4) O.llmm (0.0043In) or more 4) Clearance between rotor and (incl. wear of the pump cover) body side 5) Clearance between outer rotor 5) 0.16mm (0.006in) or more and inner rotor ...v: WESTERBEKE Engines & Generators...

  • Page 22: Engine Disassembly

    ENGINE DISASSEMBLY ' " v;;- " ~35- ~4OHoh ..Bolts, nuts, and washers are indicated by the symbols below, ..~32- ~3SHoIo H820 - Hexagon headed bolt Diameter a mm Length 20 mm <1115- <112OHoIO Na - Normal hexagon nut Diameter 8 mm ..
  • Page 23 ENGINE DISASSEMBLY POWER UNIT Cylinder head. valves and relating parts Part name Check point. etc. Note: Must be replaced by new parts whenever they are once Gasket & O-ring removed for·disassembling. • Carbon deposit in combustion chamber Cylinder head • Surface width and roughness between valve seat and valve •...
  • Page 24 ENGINE DISASSEMBLY POWER UNIT Crank shaft, pistons, cylinder/crank case and related parts Check point, etc. Part name • Oil clearance at main bearings • Oil clearance at big end of connecting rod Note: Align the tab of the metal bearing with the notch in the Crankshaft cylinder/crank case Note: There are two type of metal bearings...
  • Page 25 ENGINE DISASSEMBLY PISTON RINGS ~PISTON CONNECTING ROD ENGINE DRIVE PUllEY---l-__ \t ~ff ~'JQ:::J:ol SPRING TENillONER ENGINE DRIVE PULLEY SHEAVE ARRANGEMENT VIEW FROM UNDER BASE FRAME Engines & Generators...
  • Page 26 ENGINE DISASSEMBLY POWER UNIT Cam shaft, oil pump and related parts Part name Check pOint:etc. • Smooth movement of decompressor weight Cam shaft Note: This part is very wfi)akagainst impact. Timing belt Note: Be sure to keep clean free from oil and grease Note: Be sure to keep clean free from oil and grease Drive pulley Note: Pay attention of direction...
  • Page 27 • Outer diameter of piston skirt If 31.97 mm.(1.259 in) or 31.99 mm Out of the limit to use Standard value less, it needs replacement. 1.2594 in If 58.90 mm (2.3189 in) or 58.960mm less, it needs replacement, 2.3213 in WESTERBEKE Engines & Generators...
  • Page 28 INSPECTION AND MEASUREMENTS • Cam shaft • Outer diameter of rocker arm shaft Standard Out of the limit Out of the limit to use Standard value value to use If 12.94 mm (0.509 in) or 12.99mm Outer dia. in If 17.95 mm (0.707 0.511 in less, it needs replacement.
  • Page 29 INSPECTION AND MEASUREMENTS • Oil clearance at big end of connecting rod Standard value Out of the limit to use 0.015 - 0.041 mm If 0.060 mm (0.002 in) or 0.0006 - 0.0016 in more, it needs replacement. • Oil clearance between cam shaft and holder Standard value .
  • Page 30 INSPECTION AND MEASUREMENTS Measurement with thickness gauge • Side clearance at big end of connecting rod Standard value Out of the limit to use • Clearance between piston ring and ring groove 0.1 - 0.25mm If 0.6 mm (0.024 in) or more, Standard value Out of the limit to use 0.004 - 0.D1 in...
  • Page 31 (5.8-7.2 Ib - ft) I.D. code X and X - For lower bearing holder Note: Do not crank up the crankshaft. ~----;;:;~*7{::~tl~ Plastigage 6) Disassemble the crankcase. 7) Measure the compressed plastigage width at its widest point. WESTERBEKE Engines & Generators...
  • Page 32 INSPECTION AND MEASUREMENTS • Metel bearing thickness code Standard value Out of the limit to use The codes are painted on the side of the bearing. 0.Q15 - 0.041 mm H 0.06 mm (0.002 in) or 0.0006 - 0.0016 in less, it needs replacement /Colorcode ~====-~...
  • Page 33 Remarks: Since the lapping compound is supplied in a set of three grades (coarse, medium and fine), lap the valve with all them in order from coarse, medium and fine..-v: WESTERBEKE G"neralors Eng/n"s &...
  • Page 34 ASSEMBLY POWER UNIT Reassembling Engine • Cam shaft Reassemble the engine in the reverse order of • Carefully press the oil pump pin so that it does disassembling with careful attention to the not come out of the cam shaft. following points.
  • Page 35 ASSEMBLY • Oil pump • Plunger • Pour the engine oil of approximately 2.0 ml into • When setting the plunger stopper into the the oil pump through the inlet and outlet ports. plunger case, pay attention to the orientation of •...
  • Page 36 ASSEMBLY 2. While holding down the slit of the spacer Check of correct selling of each piston ring expander with a thumb, set the upper rail as its 1. Check to see if the slit of each piston ring is not slit is deviated from the slit of the spacer set in the piston thrust direction or piston pin expander...
  • Page 37 ASSEMBLY • Cylinder and Crank case • When fitting the metal bearing to the cylinder and crank case, set the tab in the notch. • Apply the engine oil for the 4-stroke cycle engine to the metal bearing. • Degrease the mating surface between the cylinder and crank case.

  • Page 38: Fuel Pump

    TIghten 25-30Nm the cap screws gradually in opposing order. Torque at 28 - 30 Nm (20 - 22 Ib-ft) • After tightening the nut, bend up the lock washer by a part. WESTERBEKE Engines & Generators...

  • Page 39: Pump

    Use an oil test kit and send a sample of the engine oil to a qualified oil test lab for analysis. WIPE THIS SURFACE OIL FILTER ASSEMBLY CLEAN BEFORE /lV~/~Ll./lV" FILTER PRESSURE SWITCH ---c. Oil pump cover WESTERBEKE Engines & Generators...

  • Page 40: Fuel Filter

    FUEL SYSTEM FUEL PUMP DISASSEMBLY Before disassembly, make a aligning line on the out Valve body side of fuel pump for correctly reassembling. Remove screw, and take off: Inspection: .Wear and damage • Outer plate • Gasket • Valve body Turn the piston clockwise or counter clockwise until you look the pin from the cutaway of the pump body.

  • Page 41: Starter Motor

    Remove the long bolts from the motor base and disconnect the wiring connection hardware. This will separate the base from the housing allowing access to the brush holder assembly . WESTERBEKE ...v" Engines & Generators...
  • Page 42 Carburetor Bowl Drain A bowl drain slotted plug is located on the lower right comer of the carburetor bowl. This is located just inboard of the actuators ball joint/clevis., CARBURETOR WITH SPEED ACTUATOR -...v: WESTERBEKE Engines & Generators...

  • Page 43: Raw Water Pump

    RAW WATER PUMP IMPELLER INSPECTION: CHECK AT THE BASE OF DESCRIPTION EACH BLADE BY BENDING VIGDROUSL~ SCREWS REPLACE THE IMPELLER IF THERE Coolant (fresh water) cooled generators have dual water ARE ANY CRACKS. pumps while the raw water cooled models use a single water pump.
  • Page 44 Install the new impellers with a rotating motion so the blades are working in the same direction of those of the removed impeller. DuolPumps Assemble the upper pump to the lower pump as illustrated making sure the mounting screws are tight. PULLEY WESTERBEKE Engines & Generators...

  • Page 45: Engine Tuning

    ENGINE TUNING TEST RUN AND INSPECTION AFTER COMPLETE ASSEMBLY After reassembly, the engine must be tuned. This will ensure • Check that the engine oil is continuously circulating from that the engine operates at its maximum efficiency. the oil pump to the valve rockers through the cylinder head.

  • Page 46: Engine Adjustments

    ENGINE ADJUSTMENTS ENGINE COMPRESSION TEST WATER PUMP BELT 10 check the engine's compression pressure, wann up tl,e To remove, replace or adjust the belt, loosen the pivot bolt engine, then shut it down. and release the adjusting bolt. Slide tlle water pump bracket to slacken the belt for removal.

  • Page 47: Oil Pressure Test

    ENGINE ADJUSTMENTS ADJUSTING THE DRIVE BELT BELT ASSEMBLY VIEWED FROM BENEATH The engine's drive belt is located under the engine. To access the belt, for inspection and/or adjustment, remove the cover as shown. Inspect the belt for wear along the edges and for proper belt tension (belt should be tight).

  • Page 48: Spark Plugs

    ENGINE ADJUSTMENTS SPARK PLUGS The spark plugs should be cleaned and re-gapped after the first 50 hour break-in period, then inspected every 250 hours thereafter and replaced as needed. WARNING: Do not remove the spark plugs while the engine is hot. Allow the engine to cool before removing them.

  • Page 49: Valve Clearance

    ENGINE ADJUSTMENTS VALVE CLEARANCE It is routine maintenance to adjust the valve clearance after the first fifty hours of operation. Valve clearance adjustment EXHAUST must be performed when the engine is cool and the piston INTAKE SIDE must be the top dead center of the compression stroke. SIDE Perform the following adjustment steps: ADJUSTING SCREW...
  • Page 50 "2 & mark on the driven pulley are aligned with the "V''' mark on the cylinder head. NOTE: Always keep the timing belt away from any oil and grease. V'MARK DRIVEN PULLEY ALTERNATOR BRACKET TIMING BELT ...v: WESTERBEKE Engines & Generators...

  • Page 51: Electronic Governor

    '" ~~~~ ELECTRONIC GOVERNOR CONTROLLER DESCRIPTION GOVERNOR The system is composed if three basic components. PC BOARO 1. Controller. The PC board that governs the system is located in the control panel. 2. Sensor. Mounted on the flywheel cover, the sensor mea- CONTROL sures the speed of the engine (via the ring gear).

  • Page 52: Shutdown Switches

    SAFETY SHUTDOWN SWITCHES EXHAUST TEMPERATURE SWITCH SAFETY SHUTDOWN SWITCHES exhaust temperature switch located at the base of the This engine is protected by three shutdown switches and exhaust elbow sensors an excessive exhaust temperature two fuses. Should a shutdown occur, do not attempt to (an inadequate supply of cooling water).

  • Page 53: Wiring Diagram

    PART NUMBERS: REMOTE STOPISTART PANEL N048056 PANEL EXTENSION HARNESS 15FT «048200,30 FT «048201 GREEN TO STARTER GROUND REO ISOLATION POST ISOLATION POST WHITE ..o,,_j-------, 220V·50Hl WHITE GREEN CONNECTIONS FOR 230V 50Hz AC OUTPUT CONNECTIONS 120V 60Hz ..WESTERBEKE LOAD Engines & Generetors...

  • Page 54: Ac Generator

    To Should a failure occur in the permanent magnet generator, monitor voltage and load. check it with a portable meter and contact your Westerbeke dealer of the Westerbeke factory. ampprobe. NOTE: It would be important to inspect the pulley and drive Generator Maintenance belt under the generator base frame.

  • Page 55: Specifications

    Raw Water Flow 2.5 - 3.0 GPM Fuel flow. paper element, spin-on disposals. Oil flfter (into water injected 9.5 -11.3 LPM exhaust elbow) Oil Capacity 1.5 qts. (91.4 L) Operating Temperature Oil Grade API SJ 10W-30, 15W-40 ...v WESTERBEKE Engines Generators &...

  • Page 56: Metric Conversion Charts

    Pound lib) 0.4536 Kiloorams (kol Ton ltoo) 907.18 Kiloorams (kol Ton lton) 0.907 Tonne II) MulUelv Farce To get equivalent number of: K1loo",m Iko\ 9.807 Newtons INl Ounce 102) 0.2780 Newtons INl Pound Clb\ 4.448 Newtons-.lNJ ,... WESTERBEKE Engines & Generators...
  • Page 57 (OF· 32) x .56 UQUID WEIGHTS Diesel Oil 1 US gallon = 7.13 Ibs g~lIon Fresh Water = 1 US = 8.33 Ibs Gasoline': 1 US gallon = 6.1 Ibs Salt Water = 1 US gallon 8.56 Ibs WESTERBEKE Engines. Generators &...
  • Page 58 29/32 27/64 0.421875 10.71562 0.921875 23.41562 59/64 0.4375 11.11250 0.9375 23.81250 7/16 15116 29/64 0.453125 11.50937 0.953125 24.20937 61/64 15/32 0.46875 11.90625 31/32 0.96875 24.60625 0.484375 12.30312 0.984375 25.00312 31/64 63/64 0.500 12.70000 1.00 25.40000 WESTERBEKE "MI'" Engines & Generators...
  • Page 59 INDEX AC Generator ......Oil Pressure ......AD Assembly ....... 27 Oil Pump ......28,32 Assembly Procedures ....... 6 Overspeed Switch ......44 Camshaft ....... .19 Parts identification ......
  • Page 60 Engines & Generators lD92WMDW6JD5...

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