Table of Contents
Troubleshooting
Related Manuals for Westerbeke BCGB
Summary of Contents for Westerbeke BCGB
- Page 1 SERVICE MANUAL BCGB G.-. .. PUBLICATION NO.44898 JUNE 2000 1ST EDITION WESTERBEKE CORPORA TION· 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK· TAUNTON 02780 WEBSITE: www.WESTERBEKE.COM N~A Member National MariM Manufacturers Association ••••...
- Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
- Page 3 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 bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel.
- Page 4 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read safety 11UZRual carefully. Most accidents are this caused by failure to follow fundamental rules precau- WARNING: Fire can cause injury death! tions. Know when dangerous conditions exist and take personne~ necessary precautions to protect yourself, your •...
- Page 5 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING WARNING: Accidental starting can cause Injury WARNING: carbon mDnDxlde (CO) Is deadly gas! death! • Ensure the exhaust system is adequate to expel gases that • Disconnect the battery cables before servicing the engine! discharged from the engine.
- Page 6 SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBUCATIONS FOR equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.
- Page 7 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-...
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Page 8: Table Of Contents
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 ........ -
Page 9: Parts Identification
BCGB PARI'S lOERllflCATlON A\R \NTAKE GOVERNOR COOLANT PRESSURE CAP ENG\NE Oil F\LL REMOTE PANEL CONNECT\ON WATER \NJECTED EXHAUST ELBOW \\.-U~~ -+ __ C\RCUlT BREAKER MAN\FOLD _ _ GENERATOR BACKEND . COOLANTDRA\N GASDENSER REAR FLEX\BLE MOUNT LEFT SlOE CARBURETOR ENG\NE O\L F\LL... -
Page 10: Testing For Overhaul
TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD ENGINE OVERHAUL Cause of Low Compression The following sections contain detailed information relating to the major components and systems of the engine. Generally, the time at which an engine should be overhauled Included are disassembly and inspection instructions for the is determined by various conditions such as lowered engine guidance of suitable equipped and staffed marine engine ser-... -
Page 11: Testing Oil Pressure/Compression
TESTING OIL PRESSURE ENGINE COMPRESSION NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. TESTING OIL PRESSURE ENGINE COMPRESSION TEST 1. To check the engine's compression pressure, warm up the... - Page 12 2. Displaced or twisted connecting rod. 2. Replace connecting rod. 3. Replace ring. 3. Worn piston ring. ENGINE BACKFIRES, 1. Incorrect valve clearances. 1. Adjust valves and clearances. MISFIRES 2. Adjust valves and clearances. 2. Valves are out of adjustment. ,,,,,,,,,WESTERBEKE Engines & Generators 5·...
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Page 13: Engine Troubleshooting
BCGB ENGINE TROUBLESHOOTING PROBABLE CAUSE VERIFICATION/REMEDY PROBLEM 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. Replace bearing and check lubrication system. 3. Melted bearing. -
Page 14: Assembly Information
ENGINE ASSEMBLY GENERAL INFORMATION When installing gaskets that seal around water (coolant) passages, coat both sides with WHITE SILICONE GREASE. • Be careful not to mix bolts and nuts. Metric and S.A.E. bolts are used on various engine assemblies. Do not use sealant when installing a new gasket. •... -
Page 15: Generator/Engine Disassembly
Unfasten the generator from its mounting rails or the mounting rails from the platform and remove the generator The engine component of the BCGB generator is not as from the boat. bulky or heavy as most engines [approv. 7Slbs] so it can be Once the generator is securely mounted on a work bench, disassembled and repaired on a sturdy work bench. -
Page 16: Engine Disassembly
ENGINE DISASSEMBLY INTRODUCTION 5. Disconnect and drain the oil hoses. Remove, clean, and inspect the oil gallery/filter assembly. The following text describes the disassembly, inspection, repair, and reassembly of the engine when preforming a complete engine overhaul. OIL FILTER This manual also includes a breakdown of sub assemblies, COMPONENTS engine adjustments, generator information and all related technical data. - Page 17 ENGINE DISASSEMBLY Remove the gasdenser and the connecting fuel lines from Detach and remove the ignition wires, the distributor, and the fiont of the engine and remove the fuel lift pump. the spark plugs. DISTRIBUTOR DISASSEMBLY Refer to in this manual. ENGINE ADJUSTMENTS for information on ignition wires and spark plugs.
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Page 18: Timing Belt Disassembly
TIMING BELT DISASSEMBLY 1 o/EAR COVER NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY TORQUE 7 - 9 FT-LBS 10-12Nm TORQUE 7 - 9 Ft-Lbs 10-12Nm 1 TIMING BELT COVER A TIMING BELT TENSIONER 3~CCESS COVER~ 13 CRANKSHAFT 10 FLANGE NUT 12 CRANKSHAFT BOLT SPROCKET... - Page 19 TIMING BELT DISASSEMBLY 5. Remove the timing belt. Crankshaft Bolt Removal NOTE: lfthe timing belt is to be reused, draw an arrow on Lock the crankshaft in position. the belt to indicate the direction of rotation (clockwise) .. NOTE: Do not tum the crankshaft. 2.
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Page 20: Timing Belt
ENGINE TIMING BELT Flange Installation Tensioner Spring/Timing Tensioner Installation 1. Mount the flange so that its side shown by the heavy Install the tensioner spring and timing belt tensioner. arrow in the illustration faces toward the sprocket. Hook the tensioner spring onto the bend of the timing belt tensioner bracket and the stopper pin on the cylinder block. - Page 21 ENGINE TIMING BELT clockwise At this time, check that the moveable range of teeth on the 8. Tum the crankshaft by nine camshaft sprocket oil pump sprocket is according to specifications. teeth (81°) to align the timing mark on the camshaft sprocket with the tensioner set mark on the timing belt STANDARD VALUE: 4to 5 teeth in forward direction.
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Page 22: Cylinder Head And Valves
CYLINDER HEAD AND VALVES CYLINDER HEAD TORQUE 43 - 51 FT-LBS 50-70Nm ~-----'14 NUMBERS INDICATE THE SUGGESTED ORDER DISASSEMBLY VALVE SEAL VALVE HEAD VALVE GUIDE ¢:::l ENGINE FRONT CYLINDER HEAD BOLTS LOOSENIN~ SEQUENCE 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... - Page 23 CYLINDER HEAD AND VALVES Use pliers to remove the valve stem seals. Do not reuse the VALVE ASSEMBLY INSPECTION stem seals. 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 of Prussion 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.
- Page 24 CYLINDER HEAD AND VALVES Valve Stem and Guides Measure the clearance between the valve guide and the valve stem and , if the clearance exceeds the limit, replace the VALVE STEM SEAL INSTALLER valve guide or valve, or replace both. VALVE STEM SEAL Valve Springs...
- Page 25 CYLINDER HEAD AND VALVES Cylinder Head Bolts Tighten the cylinder head bolts in the order shown in the dia- gram using a stepped-up tightening torque. INTAKE SIDE Temporarily tighten the bolts in numerical order to 14- 22ft-Ibs (20 - 30 Nm). 2.
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Page 26: Camshaft And Rocker Arms
CAMSHAFT AND ROCKER ARMS TORQUE 21 - 25 FT-LBS TORQUE 21 - 25 Ft-Lbs 2! - 35 Nm 21-35Nm - - - , NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY ® ROCKER ARM EXHAUST :~~~~:::;B~~CKER FT_LBs~9WAVE ;AS~HER 6 _ 7 TORQUE 8-10Nm 8ROCKERAR... - Page 27 CAMSHAFT AND ROCKER ARMS Rocker Arm 3. Measure the end play of the camshaft by inserting a feeler gauge in the gap between the rear of the thrust Check each component part of the rocker arm assembly and plate and the new front camshaft journal. carefully inspect the individual rockers where the arrows indicate.
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Page 28: Piston And Connecting Rods
PISTONS AND CONNECTING RODS #1 PISTON RING #2 PISTON RING gOILRING ARROW FRONT MARK STOPPER CYUNDER NOTCH NUMBER BEARING NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY REMOVING THE CONNECTING RODS/PISTONS Turn the engine over and remove the connecting rod bearing caps and the connecting rod bearings, note the markings on the bearing cap and keep the disassembled parts (connecting rod, rod cap, piston, etc. - Page 29 PISTONS AND CONNECTING RODS PISTON PIN INSPECTION Check the piston ring for damage, wear, seizure and bends replacing the rings if anything unusual is noted. Always Reinsert the piston pin into the piston hole with your thumb. replace the piston rings when installing a new piston. You should feel a slight resistance, if the bore is misaligned the pin will click or bind as it enters.
- Page 30 PISTONS AND CONNECTING RODS Oil Ring NOTE: See Crankshaft/Bearing section for measuring the oil clearance with a Plastigauge. Assemble the oil ring spacer into the piston ring groove. Use a rod aligner to check the connecting rod for bend and Then, after assembling the upper side rail, assemble the twist.
- Page 31 PISTONS AND CONNECTING RODS Installing the Piston Assembly Apply an ample amount of oil to the outside surfaces of the piston and the piston rings. Position the piston rings and oil NO.3 ring (side rail spacer) end gaps as shown. NO.2 SIDE RAIL NO;1...
- Page 32 PISTONS AND CONNECTING RODS Installing the Connecting Rod Bearing Caps Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined before reuse. If the bolt threads are "necked down", the bolt should be replaced. Necking can be checked by running a nut with fingers to the full length of the bolt threads.
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Page 33: Front Case/Counterbalance Shaft And Oil Pan
FRONT CASE COUNTERBALANCE SHAFT AND OIL PAN GASKET ENGINE BLOCK FRONT CASE TORGUE 6 - 7 R-Lbs NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY COOLANT DRAIN OIL SCREEN ASSEMBLY OIL PUMP COVER CONFIGURATION OF FRONT CASE ASSEMBLY OIL DRAIN ASSEMBLY OIL PAN REMOVAL 2. - Page 34 FRONT CASE COUNTERBALANCE SHAFT AND OIL PUMP FRONT CASE· INSPECTION 4. Using a special tool drive the counterbalance shaft front bearing from the cylinder block. Check the front case for cracks or other damage also inspect the oil holes. the oil holes are clogged, use compressed air or solvent to clean them out.
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Page 35: Front Case/Counterbalance Shaft And Oil Pump
FRONT CASE I COUNTERBALANCE SHAFT AND OIL PUMP Crankshaft Oil Seal INSTALLATION Counterbalance Rear Bearing 1. Install the special tool guide pins (bearing Installer) in the tapered hole of the cylinder block as shown . \ t)r---, OIL HOLE "::J BEARING Front Case Assembly 2. -
Page 36: Front Case/Oil Pump And Oil Pan
FRONT CASE lOlL PUMP AND OIL PAN DRIVE GEAR OIL PUMP ASSEMBLY TIMING MARKS Oil Pump Cover Gasket Fit a new oil pump cover gasket into the groove in the oil FRONT CASE CONFIGURATION pump cover. The flat side of the gasket is positioned against the pump cover. -
Page 37: Crankshaft/Bearings And Oil Seal
CRANKSHAFT BEARINGS AND OIL SEAL OIL SEAL CASE BOLT TORQUE 1 - 9 Ft-Lbs /10-12Nm NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY CYLINDER BLOCK \\ ~~ _ _ - - - . THRUST BEARING CRANKSHAFT BEARING: (UPPER) INSPECT THE JOURNALS FOR UNEVEN·WEAR. - Page 38 CRANKSHAFT, BEARING AND OIL SEAL 0.059 IN {1.5MMJ CRANKSHAFT BEARINGS SPECIFICATIONS Upper and Lower When the bearings are to be replaced, select the correct ones and install them in positions according to the identification marks stamped on the crankshaft and the top surface of the cylinder block.
- Page 39 CRANKSHAFTI BEARING AND OIL SEAL MEASURING END PLAY Push the crankshaft to the rear. Then, insert a feeler gauge in the gap between the crankshaft journal side surface and the thrust bearing end surface to measure the end play. CRANKSHAFT END PLAY 1.5740 -1.5748 in (0.05 - 0.025mm) CRANKSHAFT BEARINGS CRANKSHAFT REAR OIL SEAL INSTALLING THE THRUST BEARINGS...
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Page 40: Cylinder Block Inspection And Piston Clearance
CYLINDER BLOCK INSPECTION AND PISTON CLEARANCE 1"1 NUMBERS INDICATE THE SEALING CAPS (35) SUGGESTED ORDER DISASSEMBLY 2DDWEL--_ "01· STIJIlS KNOCK BUSHINGS 6 X CRINDER BLOCK INSPECTION 1. Before inspecting, clean the cylinder block to ensure that the water and oil holes are not plugged. clogged, clear with compressed air. -
Page 41: Distributor
DISTRIBUTOR COVER ASSEMBLY ROTOR VACUUM CONTROL CHECK THE DISTRIBUTER CAP FOR CRACKS, WEAR AND EVIDENCE OF ARCHING OR BURNING, IF ANY OF THESE CONDITIONS EXIST, REPLACE THE DISTRIBUTER CAP. O-RING HOUSING ASSEMBLY NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY BREAKER PLATE READ WIRE SET IGNITER... -
Page 42: Coolant Circulating Pump
COOLANT CIRCULATING PUMp· REMOVING THE COOLANT PUMP 1. Loosen the belt guards thumbscrews and remove the engine's belt guard from its brackets at the front of the COOLANT PUMP engine. 2. Ease the belt tension by releasing the raw water pump and remove the engine drive belt [on carburetor models it will be necessary to remove the governor belt]. -
Page 43: Exhaust Manifold/Heat Exchanger
EXHAUST MANIFOLD HEAT EXCHANGER EXHAUST MANIFOLD HEAT EXCHANGER The heat exchanger should be inspected and serviced during The exhaust manifold, which was disassembled from the cylinder head, should be inspected before reassembly. an engine overhaul. 1. Disconnect the hoses and remove the hose fittings, INSTALL NEW GASKETS petcock, drain plugs and zinc anode. -
Page 44: Raw Water Pump
This will allow the bearings parts would almost match the cost of a new pump, and seals to be disassembled for inspection. WESTERBEKE recommends purchasing a new pump and NOTE: It be necessary to use a drift and arbor press using the old pump for spares. - Page 45 THERMOSTAT ASSEMBLY I FUEL PUMP COOLANT RECOVERY TANK FUEL PUMP Flush out the recovery tank and the hose that connects to the This solid state lift pump requires no maintenance. To test: sim- ulate a start, the pump should produce a clicking sound indicat- pressure cap assembly.
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Page 46: Rebuilding The Carburetor
REBUILDING THE CARBURETOR CLEAN THE AIR SCREEN WITH KEROSENE CARBURETOR COVER VALVE THROmE CONTROL LEVER DISASSEMBLY, INSPECTION, AND ASSEMBLY Release the flame arrester clamp and remove the flame arrester. Disconnect the electric choke wire, the vacuum hose attached to the manifold, the fuel supply line, and the throttle control linkage (not shown). - Page 47 REBUILDING THE CARBURETOR 7. Shake the float. If you hear any sand like particles WA:iHtll~ COPPER SCREW §i"'i""C~IVI'R moving inside, replace the float. 8. Use a lOmm wrench and remove the needle valve seat. REPLACE THE Make certain the seats aluminum gasket is also removed Vl'Jt.)ncn.)-_..u~ FOUR CARBURETOR TOP COVER...
- Page 48 I:IEBUILDING THE CARBURETOR CARBURETOR ADJUSTMENTS CHOKE SOLENOID 21. Reconnect the throttle control linkage, the fuel supply line, the vacuum hose, and the electric choke wire. The choke solenoid is a 12 volt DC operated unit that func- 22. Replace the flame arrester on the carburetor and tighten tions to close the choke plate the carburetor when the ON the flame arrester clamp.
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Page 49: Starter Motor
STARTER MOTOR 4. Return test:. With a battery connected to the solenoid ter- minal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position ATTRACTION TEST when released from holding by hand. 3. - Page 50 STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and between terminals S and body. No continuity should be found between S an9 M. Continuity should be found between S and the body and M and the body. , Brush and Brush Holder Inspection 1.
- Page 51 STARTER MOTOR Field Coil Inspection 2. Greasing. Whenever the starter has been overhauled, apply grease to the following parts: 1. Check for insulation between one end (brush) of the a. Armature shaft gear and reduction gear. coil and yoke. b. All bearings. Check for continuity between both ends (brushes) of the coil c.
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Page 52: Engine Adjustments
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine ,mechanic. The information below is provided to assist the mechanic. Governor Maintenance ENGINE SPEED (HERTZ) ADJUSTMENT Governor 1. Periodically lubricate the linkage arm attaching points at the governor arm and throttle lever. -
Page 53: Spark Plugs
ENGINE ADJUSTMENTS DRIVE BELT ADJUSTMENT SPARK PLUGS The drive belt must be properly tensioned. Excessive drive The spark plugs should be cleaned and regapped after the belt tension can cause rapid wear of the belt and reduce the first 50 hour break-in period, then inspected every 250 hours service life of the fresh water pump's bearing. -
Page 54: Valve Clearance Adjustment
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT IGNITION TIMING NOTE: Retorque the cylinder head bolts before adjusting the... -
Page 55: Component Testing
COMPONENT TESTING NOTE: WESTERBEKE recommends that the following engine testing adjustments be performed by a competent technician. GENERAL TAP THE GROUND All DC voltage measurements are made to the engine battery CONNECTION TO negative ground point unless specified otherwise. In making THE TERMINAL. -
Page 56: Wiring Diagram
4.SKW /7 .OKW BeGB GENERATOR WIRING DIAGRAM #43864 OIICE IIlLSaI rMTTBn' IZ VDC $Cl!II:lII MIX. CL PIIESS sma! Il1O CL PIIESS II1II RItCH ~I!F--+----' VIO/lIMT T i l l 114 RED/VIO 114 RED 114 RED IIC REHIHT I" = lIS ORG liS ,"T IIC BLI IIC RFOIVIO... -
Page 57: Wiring Schematic
4.SKW /7 .OKW BeGB GENERATOR WIRING SCHEMATIC #43864 12 VOC I I 8A HERY SWITCH STARTER STARTER SOLENOID r--, .-------------------~------~~~------~ l 20 AMP ICIRCUIT I BREAKER FUEL PUMP FUEL SOL. l, .. STOP SW CHltNC) HOUR METER .--+ ______ ~~ ~L-------------------------+_--~ L.. -
Page 58: Wiring Schematic
REMOTE PANEL WIRING SCHEMATIC #043912 REMOTE PANEL r-------------------------------. S TA RT / STOP SW NI---+'_..::#,-,-1...:..4 -=B:..::L..:.;.K _ _ _ _ -, #14 WHT/RED L--------i~--K~ CKT I ON SW YEL/RED WHITE WHITE *14 RED/VIO WHITE L_ -: L ______________ .:_. ____________ , VIEWED FROM MATING END Engines... -
Page 59: Service Data/Standards And Limits
I STJ'NDARDS AND LIMITS • BCGB ENGINEiGENERJ'TOR SERVICE DATA Component Specified Value Standard Repair Limit Component Specified Value Standard Repair Limit inches(mm) inches(mm) inches(mm) inches(mm) VALVES FRONT CASE/COUNTERBALANCE SHAFT Valve Guide Service Size 0.05, 0.25, 0.50 oversize Oil Pump Side Clearance Driven Gear ...... - Page 60 SERVICE DATA / STANDARDS AND LIMITS • BCGB ENGINE/GENERATOR Component Specified Value I Standard Repair limit Specified Value I Standard Component Repair Limit inches(mm) inches(mm) inches(mm) inches(mm) CRANKSHAFT, BEARING PISTON AND CONNECTING ROD Piston Pin Press-in temperature Crankshaft End Play ..0.0020 - 0.0098 (0.05 - 0.25) ....
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Page 61: Hardware Torques
ENGINE HARDWARE TORQUES Timing Belt ft.lbs. Front Case, Counterbalance Shaft ft.lbs. Crankshaft bolt 135-145 98-105 Front case bolts 8-10 liming belt cover bolts 10-12 Oil pump cover bolts 8-10 80-100 Camshaft sprocket bolts 58-72 Oil pan bolts 10-12 Oil pump sprocket nuts SO-57 36-41 Oil drain plug... -
Page 62: Standard Hardware
STANDARD HARDWARE BOLT HEAD MARKINGS Metric bolt class numbers identify bolts by their strength with 10.9 the strongest NOTES: 1. Use the torque values listed below when specific torque values are not available. 2. These torques are based on clean, dry threads. Reduce torque by 10% when engine oil is used. 3. -
Page 63: Specifications
BCGB ENGINE/GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3 cylinder, 4 cycle, overhead camshaft w/counterbalance shaft, carbureted, water cooled gasoline engine Bore and Stroke 2.56 x 2.61 in. (65 mm x 66.3 mm) General Fresh water-cooled block through raw water-cooled heat exchanger circuit Total Displacement . -
Page 64: Special Tools - Engine
SPECIAL TOOLS • ENGINE NOTE: Tht:se special tools are available from your local Mitsubishi Automotive Dealer CAMSHAFT OIL SEAL INSTALLER VALVE STEM SEAL INSTALLER MD 998302 MD 999569 OIL PAN GASKET CUTTER PISTON PIN SETTING BASE For removing the oil pan to Used to pull-out and press in break the oil pan seal. -
Page 65: Bc Generator Electrical Testing
The following field tests should be performed by a qualified technician. Proper safety precautions must be followed as most of these tests are executed with the generator operating or connected to ships power. AC voltage is lethal. If generator problems persist, contact your Westerbeke dealer. Engines & Generators... - Page 66 BC GENERATOR ELECTRICAL TESTING DESCRIPTION GENERATOR TROUBLESHOOTING CHART A, B, C, D refer to the components of the INTERNAL WIRING & The BC generator is a brushless, self-excited generator which DIAGRAM and their test procedures in the following pages. requires only the driving force of the engine to produce an AC output.
- Page 67 INTERNAL WIRING SCHEMATIC DC BAnERY CHARGING CIRCUIT FUSE - INTEGRAL CONTROLLER y'" ______________________ ., A • ROTOR WINDINGS/DIODE WINDING: NO TIME DELA Pn#43634 30A • B • STATOR WINDINGS 250V MDA-30 !' : ifI r-------" C • EXCITER WINDING(S)/CAPACITOR(S) l ----- -~-:-7---- ~.~.
- Page 68 LOW VOLTAGE - ROTATING FIELD AUXILIARY WINDINGS TESTS TESTING THE DIODES WARNING: Some of the following tests require the If a distinct difference is noted in the ohm value, carefully generator to be running, make certain the front pulley unsolder the lead on the top of the diode and remove the diode from its isolated heat sink using a thin walled, deep cover and timing belt covetS are in place.
- Page 69 LOW VOLTAGE • ROTATING FIELD AUXILIARY WINDINGS TESTS Testing Continuity Testing the Rotor Field Auxiliary Windings With the diode removed, both leads for the first group of Check that no continuity exists between either of the wind- rotating field/auxiliary windings will be isolated with no ing leads and the generator shaft.
- Page 70 RESIDUAL VOLTAGE - EXCITER CIRCUIT TESTS DUAL EXCITER SINGLE CAPACITOR t.::~-~ CI--...J DUAL CAPACITOR TESTING THE EXCITER WINDINGS AC voltage can be measured across the capacitor(s) while the generator is operating. 1bis voltage may be as high as 400 to 500 volts AC.
- Page 71 NO VOLTAGE OUTPUT - MAIN STATOR WINDINGS TESTS NOTE: The studs on the AC terminaL board are identified by the six red wire that attach to them. These wires are num- bered 1 thru 6. There are no numbers on the terminaL block. TESTING RESIDUAL VOLTAGE EXCITING THE GENERATOR Test for residual voltage between terminal #1 and terminal...
- Page 72 NO VOLTAGE OUTPUT • MAIN STATOR WINDINGS TESTS Testing Continuity There should not be any continuity between these two wind- ing groups. Test between terminal #3 and tenninal #6. If con- tinuity exists, there is a short in the windings. There also should be no continuity between the terminals and the generator case (ground).
- Page 73 EXCITER CIRCUIT CAPACITOR{S) TESTS Measuring Resistance TESTING THE CAPACITORS To measure the resistance of the exciter winding locate the #9 and the #50 Hertz capacitor connections. NOTE: Three numbered capacitor connections exist: #7, #8, and two Hem connections #50 and #60. Unplug any other connections from the capacitor noting their position on the capacitor.
- Page 74 BATTERY CHARGING CIRCUIT BRIDGE RECTIFIER TESTING THE BATTERY CHARGING CIRCUIT NOTE: The battery charging circuit is totally separate from the A C output of the generator: The generator output affects the circuits output, but not the reverse. Normal AC voltage running to the rectifier (while the engine is operating at 1800 rpm) is measured across the two AC connections on the bridge rectifier (shown below).
- Page 75 The generator supplies a continuous 17 amp charge from its battery charger to the starting battery. The DC Circuit on the BCGB functions to start, operate and stop the generator's engine. The circuit is best understood by reviewing the DC WIring Diagram and WIring Schematic.
- Page 76 INTEGRAL CONTROLLER NO-LOAD VOLTAGE ADJUSTMENT TESTING THE INTEGRAL CONTROLLER WARNING: Capacitors must be discharged before To test the battery charger, put a multimeter between the handling as they store electricity and can pack a poten- positive (+) and negative (-) leads to the battery. It should indicate 13.5V to 14V with the engine running.
- Page 77 NO-LOAD VOLTAGE ADJUSTMENT DUAL EXCITER DUAL EXCITER CIRCUIT MODEL NOTE: When changing Hertz produced by the generator; an engine speed adjustment at the governor must be made. These generators have dual Hertz and no-load voltage adjust- The AC output connections on the terminal blocks must be ment connectors at each capacitor.
- Page 78 Be GENERATORS PARTS IDENTIFICATION B C GENERATORS / " ELECTRICAL COMPONENTS [DUAL EXCITER SHOWN] / " - ".r ....~",;:" ..CAPACITOR TERMINAL BOARD TO CIRCUIT BREAKER CURRENT MODEL C GENERATORS ELECTRICAL COMPONENTS [SINGLE CAPACITOR SHOWN] /' /., '; ",", ..!NTEGRAL CONTROLLER ~"'"...
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Page 79: Special Tools - Generator
SPECIAL TOOLS • GENERATOR FIELD FABRICATED TOOLS Lifting Eye Tool These drawings provide a means by which simple tools can be This tool allows a mechanic to safely remove the generator end from the engine by attaching this Generator End Lifting made to assist in the removal of the generator end from the engine and in the replacement of the generator end on the engine. -
Page 80: Engine Generator Troubleshooting
ENGINE/GENERATOR TROUBLESHOOTING OPERATING PROCEDURES The following chart is repeated from the operators manual. Before restarting the engine, the cause of the problem The problems described do not relate to problems should be determined and corrected. consistent with an engine overhaul. This chart is included The tables that follow suggest a troubleshooting procedure only as a convenience to the operator or service technician. - Page 81 ENGINE/GENERATOR TROUBLESHOOTING OPERATING PROCEDURES PROBABLE CAUSE PROBLEM PROBLEM PROBABLE CAUSE Engine misfires. Poor quality fuel. No DC charge to the 1. Faulty connections to starting battery. battery voltage regulator. Incorrect timing. 2. Faulty battery voltage regulator. Dirty flame arrester. Faulty bridge rectifier. Dirty throttle body.
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Page 82: Metric Conversions Data
STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches Feet (ft) x .305 = Meters (m) x 3.281 = Feet Miles x 1.609 = Kilometers (km) x .0621 = Miles VOLUME Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =in 3 Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal...