Page 1 7.0 KW BCG ·60 Hz 7.0 KW BCGA· 60 Hz MARINE GASOLINE GENERATOR SETS Publication #038747 Edition One March 1990 l·v#'WESTERBEKE WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A. TEL; (508)823-7877. FAX: (508)B84-9688 • WEBSITE: www.WESTERBEKE.COM...
Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
Page 3 SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous sure the unit and its surroundings are well-ventilated. operator. • Use Extreme Care When Handling Engine Fuel IWARNINGI (A constant danger of explosion or fire exists) The above symbol is used in the manual to warn of possible Do not fill fuel tank(s) while the engine is running.
Page 5 It not only makes good sense but is imperative that appropriate representatives of Westerbeke or the supplier in question be consulted to determine the accuracy and currency of the product software being consulted by the customer.
Page 6: Table Of Contents
SPECIAL SERVICE TOOLS ..........61 CYLINDER HEAD AND ENGINE BLOCK INSPECTION AND REPAIR ..........63 ENGINE INSPECTION AND REPAIR ....... 64 SUBASSEMBLY INSPECTION, REPAIR AND ASSEMBLY ..........81 ENGINE ASSEMBL Y ............101 CYLINDER BLOCK ASSEMBLY ........1 02 Westerbeke Generators...
Page 7 AND MODEL RATING ............ 130 TROUBLESHOOTING AND ADJUSTMENTS FOR THE BC GENERATOR ........... 131 COMPONENT RESISTANCE VALUES ......134 GENERATOR TROUBLESHOOTING ......143 GENERATOR HERTZ (CYCLE) AND VOLTAGE CHANGES ..........145 FIELD FABRICATED TOOLS ......... 147 INDEX ................151 Westerbeke Generators...
Page 8 4.5 KW BeG Marine Gasoline Generator Fresh Water Coolant Fill 20 Amp DC Circuit Breaker Exhaust Temperature Switch Lube Oil Dipstick ---..;~...i;.;._ Oil Pressure ,,- DC Battery Ground Switch Connection lube Oii >::ill'oy·-- Zinc Anode Starter with Solenoid Heat Exchanger Westerbeke Generators...
Page 9 4.5 KW BeG Marine Gasoline Generator Fuel Shut - off Air Intake Flame Arrester Snl.:llnnlf1 Governor Unit Data T lube Oil Drain Hose Westerbeke Generators...
Page 10 7.0 KW BCG BCGA Marine Gasoline Generator & Exhaust Temperature Switch 20 Amp DC Circuit Breaker Lube Oil Dipstick Oil Pressure Switch DC Battery Ground Connection . with Solenoid -Rt~rt_ Heat Exchanger. Westerbeke Generators...
Page 11 7.0 KW BCG & BCGA Marine Gasoline Generator Intake Flame Arrester Control Pane! Governor ---'--Water Temperature Switch ·AC Connections - - - Outlet Sea \(Vater Pump Anooe Zinc Lube Oil Drain Hose Westerbeke Generators...
Page 12 These 1.0. plate illustrations are provided for the owner/operator"to fill in the unit serial number and gener- ator serial number for future service and needs. part NOTE: Output rating for 50 hertz units are reduced. Refer to System $pecifications. Westerbeke Generators...
Page 13: Kw Bcg General Specifications
Width: 18.34 inches (465.8 mm) Height: 23.44 inches (595.4 mm) Dry Weight Approx. 3031bs (137.4 kgs) Fuel Consumption 0.9 U.S. gph (3.41 Iph) at full rated output (approximate). Inclination (all directions) Continuous 14° Temporary 20° (not to exceed 20 min.) Westerbeke Generators...
Page 14: 4.5 Kw Bcg System Specifications
Distributor Conventional, contact-points and condenser. Spark Plug Thread Size 14 mm x 1.25 pitch (0.55 x 0.05 in.) Spark Plug Type Westerbeke part number 33805 (Always identify the generator model when ordering parts.) FUEL SYSTEM General Conventional carburetor type with fuel pump.
Page 15 90 amp (max.) at 11.5 volts. DC Cranking Current 100 -125 amps (engine cold). OUTPUT LOSS BY ALTITUDE 8% at 3,281 ft (1,000 m) 16% at 6,562 ft (2,000 m) 25% at 9,843 ft (3,000 m) 35% at 13,124 ft (4,000 m) Westerbeke Generators...
Page 16 Air Requirements, (60 hertz), at 1800 rpm 225 - 240 cfm (6.4 - 6.6 cmm) NQIE: Increase air supply 15% for 50 hertz operation (1500 rpm). Engine Combustion Air Requirements, (60 hertz), at 1800 rpm 18 cfm (0.509 cmm) Westerbeke Generators...
Page 17: Kw Bcg & Bcga
Width: 18.34 inches (465.8 mm) Height: 23.44 inches (595.4mm) Dry Weight Approx. 3281bs (148.8 kgs) Fuel Consumption 1.3 U.S. gph (4.92 Iph) at full rated output (approximate). Inclination (all directions) Continuous 14 Temporary 20 (not to exceed 20 min.) Westerbeke Generators...
Page 18: 7.0 Kw Bcg & Bcga System Specifications
Distributor Conventional, contact-points and condenser type. Spark Plug Thread Size 14 mm x 1.25 pitch (0.55 x 0.05 in.) Spark Plug Type Westerbeke part number 33805 (Always identify the generator model when ordering parts.) FUEL SYSTEM General Conventional carburetor type with fuel pump.
Page 19 (max.) at 11.5 volts. DC Cranking Current 100 -125 amps (engine cold). OUTPUT LOSS BY ALTITUDE 8% at 3,281 ft (1,000 m) 6,562 ft (2,000 m) 25% at 9,843 ft (3,000 m) 35% at 13,124 ft (4,000 m) Westerbeke Generators...
Page 20 Generator Cooling Air Requirements, (60 hertz), at 1800 rpm 250 cfm (7.0 cmm) NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm). Engine Combustion Air Requirements, (60 hertz), at 1800 rpm 26.8 cfm (0.758 cmm) Westerbeke Generators...
Page 21: 4.5 Kwbcg
Inner diameter (IN & 0.2756 - 0.2764 0.2n4 (7.000 - 7.020 mm) (7.045 mm) Projection height 0.5984 - 0.6220 (15.2 - 15.8 mm) Valves & Seat width 0.0472 - 0.0630 0.0906 (1.2 - 1.6 mm) (2.3 mm) Seat angle 44°30' Westerbeke Generators...
Page 22 0.6299 - 0.6306 0.6313 (16.000 -16.018 mm) (16.035 mm) Valve rocker shaft outer diameter 0.6287 - 0.6294 0.6281 (15.968 - 15.988 mm) (15.955 mm) Shaft to arm oil clearance 0.0005 - 0.0020 0.0031 (0.012 - 0.050 mm) (0.08 mm) Westerbeke Generators...
Page 23 Piston inner diameter for piston pin 0.6299 - 0.6302 (15.999 - 16.008 mm) Piston pin outer diameter 0.6296 - 0.6299 (15.991 - 16.000 mm) Piston to piston pin clearance 0.0002 - 0.0004 0.0020 (0.005 - 0.011 mm) (0.050 mm) Westerbeke Generators...
Page 24 0.0008 - 0.0017 (0.020 - 0.044 mm) (0.07mm) Side clearance 0.0008 - 0.0087 0.0118 (0.02 - 0.22 mm) (0.30 mm) Camshaft Camshaft thrust clearance 0.0020 - 0.0118 0.0177 (0.45 mm) (0.05 - 0.30 mm) Camshaft bend 0.0012 (0.03 mm) Westerbeke Generators...
Page 25 0.0047 (0.030 - 0.071 mm) (0.12 mm) Timing Belt Pulley Camshaft pulley outer diameter 4.3556 - 4.3627 4.3531 (110.633 - 110.813 mm) (110.57 mm) Crankshaft pulley outer diameter 2.1536 - 2.1575 2.1512 (54.701 - 54.801 mm) (54.64 mm) Westerbeke Generators...
Page 26 0.0039 (0.100 mm) Valve guide bush Oversize 0.0012 (0.03 mm) Crankshaft thrust washer None Crankshaft bearing Oversize 0.0098 (0.25 mm) Connecting rod bearing Oversize 0.0098 (0.25 mm) Piston with pin None Piston ring None Valve guide bush None Westerbeke Generators...
Page 27 Crank journal DIA 1.6430 - 1.6434 (41.733 -41.743 mm) Bearing center thickness U/S 0.0197 0.0685 - 0.0687 (0.50 mm) (1.74O -1.744 mm) Cylinder block journal section DIA None Crank journal DIA 1.3969 - 1.3973 (35.482 - 35.492 mm) Westerbeke Generators...
Page 28 Piston outer diameter 2.4592 - 2.4596 (0.50 mm) (62.465 - 62.475 mm) 0.0295 Piston outer diameter 2.4691 - 2.4695 (0.75 mm) (62.715 - 62.725 mm) 0.0394 Piston outer diameter 2.4789 - 2.4793 (1.00 mm) (62.965 - 62.975 mm) Westerbeke Generators...
Page 29 (3.5 -4.3 kg/crn2) Ignition Coil Primary resistance Q 1.2 ±0.12Q Secondary resistance KQ 26 ±3.9KQ External resistance Q 1.7 ±0.17Q Distributor Heel gap 0.018 (0.45 mm) Dwell angle Condenser capacity pF 0.25pF Resistive Cord Cord resistance KQ/m 10 -22 KQ/m Westerbeke Generators...
Page 30 Specified Value Allowable Limit V Belt Belt deflection - inches (mm) 0.37 - 0.45/22.05 Ib (9.5 - 11.5/10 kg) Westerbeke Generators...
Page 31: 7.0 Kw Bcg & Bcga
0.2n4 Inner diameter (IN 0.2756 - 0.2764 (7.000 - 7.020 mm) (7.045 mm) Projection height 0.5984 - 0.6220 (15.2 - 15.8 mm) Valves & EX) Seat width 0.0472 - 0.0630 0.0906 (1.2 -1.6 mm) (2.3 mm) Seat angle Westerbeke Generators...
Page 32 0.6299 - 0.6306 0.6313 (16.000 -16.018 mm) (16.035 mm) Valve rocker shaft outer diameter 0.6287 - 0.6294 0.6281 (15.968 - 15.988 mm) (15.955 mm) Shaft to arm oil clearance 0.0005 - 0.0020 0.0031 (0.012 - 0.050 mm) (0.08 mm) Westerbeke Generators...
Page 33 Piston inner diameter for piston pin 0.7086 - 0.7090 (17.999 - 18.008 mm) Piston pin outer diameter 0.7083 - 0.7087 (17.991 - 18.000 mm) 0.0020 Piston to piston pin clearance 0.0002 - 0.0004 (0.005 - 0.011 mm) (0.050 mm) Westerbeke Generators...
Page 34 Crankshaft bearing oil clearance (0.020 - 0.044 mm) (0.07 mm) Side clearance 0.0008 - 0.0087 0.0118 (0.02 - 0.22 mm) (0.30 mm) Camshaft 0.0177 Camshaft thrust clearance 0.0020 - 0.0118 (0.05 - 0.30 mm) (0.45 mm) 0.0012 Camshaft bend (0.03 mm) Westerbeke Generators...
Page 35 0.0047 (0.030 - 0.071 mm) (0.12 mm) TIming Belt Pulley Camshaft pulley outer diameter 4.3556 - 4.3627 .4.3531 (110.633 - 110.813 mm) (110.57 mm) Crankshaft pulley outer diameter 2.1536 - 2.1575 2.1512 (54.701 - 54.801 mm) (54.54 mm) Westerbeke Generators...
Page 36 0.0039 (0.100 mm) Valve guide bush Oversize 0.0012 (0.03 mm) Crankshaft thrust washer None Crankshaft bearing Oversize 0.0098 (0.25 mm) Connecting rod bearing Oversize 0.0098 (0.25 mm) Piston with pin None Piston ring None Valve guide bush None Westerbeke Generators...
Page 37 (50.000 - 50.024 Crank journal OIA 1.8101-1.8110 (45.976 - 46.000 mm) 0.0098 Bearing center thickness 0.0833 - 0.0834 (0.25 (2.115 - 2.119 mm) Cylinder block journal section OIA None Crank journal OIA 1.8005 - 1.8009 (45.732 - 45.742 Westerbeke Generators...
Page 38 Piston outer diameter 2.6398 - 2.6409 (0.50 mm) (67.05 - 67.08 mm) 0.0295 Piston outer diameter 2.6496 - 2.6508 (0.75 mm) (67.30 - 67.33 mm) 0.0394 Piston outer diameter 2.6594 - 2.6606 (1.00 mm) (67.55 - 67.58 mm) Westerbeke Generators...
Page 39 (3.5 - 4.3 kg/cm2) Ignition Coil Primary resistance 1.2 ±0.12 Q Secondary resistance 26 ±3.9KQ External resistance 1.7 ±0.17 Q Distributor Heel gap 0.018 (0.45 Owellangle Condenser capacity 0.25JlF Resistive Cord KQ/m 10 - 22 KQ/m Cord resistance Westerbeke Generators...
Page 40 Specified Value Allowable Limit VBeH Belt deflection - inches (mm) 0.37 - 0.45/22.05 Ib (9.5 - 11.5/10 kg) Westerbeke Generators...
Page 41: Engine Description
1. With a view to obtaining a uniform and strong intake swirl, the valve (for No.2 and No.3 cylinders) has been arranged symmetrically. 2. The combustion chamber has been made compact. In addition, the compression ratio has been increased to 10.0. No.2 Intake valve No.3 Intake valve Symmetrical valve arrangement (for No.2. 3 cylinders) Combustion chamber Westerbeke Generators...
Page 42 To cylinder head ~C-~ ~ ~JlJJ',. o/)f~ O/~~, ,r:: From water, p,um p ~~ V!'. , _ J "IY;,;;~rl~~ '(fJ.J ~r>, J"---~~/~\~~/ Water pump installing portion To ventilation hose ID~( L {I:: • separa~/ c~~~ Westerbeke Generators...
Page 43 Compression ring No.1 Compression ring No.2 Oil ring Connecting Rods The connecting rod has an I-shaped sectional view. The connecting rod is assembled to the piston pin, using a press-fit method. Front Mark Front Mark Westerbeke Generators...
Page 44 The crankshaft has employed a total balance type. counter weight. Futhermore. for reduced metal-tapping noise level. the crankshaft bearing has adopted a bearing having no oil groove at the lower surface. Thrust washer Crankshaft bearing lower side (oil groove less) Westerbeke Generators...
Page 45 No.2 and No.3 cylinders are arranged symmetrically, and the intake valves have been enlarged. In orderto cope with higher-speed rotation of the engine, unequally pitched valve springs and aluminum rocker arms have been employed. In addition, the valve rocker shafts are mounted directly to the cylinder head by means of bolts. Westerbeke Generators...
Page 46 99Y16 _._-_._-------- Core cord Pitch peripheral length mm (inch) 792 (31.18) oooJo ,._--------_.--- 0 0 001 ._--_ - - - - - - _ . ------10 Pitch mm (inch) 8 (0.31) Tooth numher Belt width mm (inch) 16.0 Westerbeke Generators...
Page 47 Timing belt The timing belt tensioner has employed a tensioner method in which no tensioner spring is used. Because this design, the tension adjustment can be performed easily by means of general bolts (MS) during disassembly and reassembly. Westerbeke Generators...
Page 48 (inch) (1.18) (1.02) Effective winding number 5.75 112.34 112.64 Overall length mm (inch) (4.42) (4.43) mm(inch) 27.5 (1.08) Coil outer diameter 3.67/4.3 Diameter or valve stem section Spring constant kg/mm (\b/inch) <- (central section) mm (inch) (0.28) (8.09210.169) Westerbeke Generators...
Page 49 (inch) (0.0098) (0.0118) Exhaust side Intake side Valve Guide Bushes and Stem Oil Seals The valve guide bushes differ in their material and overall length between the intake and exhaust valve sides. 48mm 50mm Heat-resistant steel Chamfer Westerbeke Generators...
Page 50: Generator Overhaul
SPECIAL SERVICE TOOLS ..........61 NOTE: Special Service Tools are available to help in the removal or installation of engine parts. Refer to the "SPECIAL SERVICE TOOLS" section of this manual for illustrations and part numbers for each tool. Westerbeke Generators...
Page 51: Preparations For Overhaul
IIll' l W;\;i;H' . 1\llill\I' , 11III Il'~ ,o! : . " , 11'1 • '. il : :; .: : : . ',' \1:\ , . :.:!; J." , " :c~~ .. ' ..Oil Sump Drain Heat Exchanger Drains Westerbeke Generators...
Page 52: Disassembly For Overhaul
4. When clear of the bearing and/or shaft, manually slide the generator housing carefully off the rotor. Back Plate Control Panel BC STYLE GENERATOR END Westerbeke Generators...
Page 53 7. Remove the rotor from the drive disks and store both the rotor and the drive disks in a safe place. 8. Remove the engine's flywheel. Now that the generator end has been removed, the engine can be disassembled. Westerbeke Generators...
Page 54: Engine Disassembly
14. Remove the oil pressure switch, the oil pressure sender (if installed), the oil filter, and the oil filter bracket. 15. Remove the thermostat housing and the thermostat. 16. Remove the crankshaft pulley from the crankshaft. 17. Remove the spark plugs from the cylinder head. 18. Remove the distributor assembly from the right rear of the engine. Westerbeke Generators...
Page 55: Timing Belt Removal
2. Remove the rocker cover and gasket from the cylinder head. Inspect the gasket for cuts and breaks. Replace the gasket if necessary, or keep it for reinstallation. 3. Remove the upper and lower timing belt covers along with their associated dust covers. Westerbeke Generators...
Page 56 NOTE: When removing the camshaft timing belt pulley, insert a screwdriver between the spokes of the pulley to prevent the camshaft rotating while loosening the pulley's screw. 9. Remove the crankshaft timing belt pulley. 10. Remove the timing belt cover No.2. Westerbeke Generators...
Page 57: Removing The Cylinder Head From The Cylinder Block
NOTE: Discard the cylinder head gasket when it is removed. When reassembling the cylinder head to the cylinder block, install a new cylinder head gasket. ® ® ® 4.5 KW BCG and 7.0 KW BCG & BCGA Loosening Sequence Westerbeke Generators...
Page 58: Cylinder Head Disassembly
4. Valve Spring Retainer Lock 5. Valve Spring Retainer 6. Compression Spring 7. Valve 8. Valve Spring Seat 9. Valve Stem Oil Seal 10. Valve Guide Bushing *Denotes that disassembly instructions for these parts follow on the indicated pages. Westerbeke Generators...
Page 59 4. Remove the camshaft. Using a wooden dowel placed at the rear end of the camshaft, drive out the camshaft by tapping it with a hammer. CAUTION Exercise care when removing the camshaft to avoid damaging the bearing journals or cam lobe surfaces of the camshaft. Westerbeke Generators...
Page 60 NOTE: As the valves and their associated parts are removed, keep valve sets together and in correct order with respect to their placement in the cylinder head. Unless any of the parts are replaced, they must be returned to the same locations from which they were removed. 7. Remove the spark plug. Westerbeke Generators...
Page 61: Cylinder Block Disassembly
5. Oil pump. 2. Water pump. 6. Oil seal retainer. 3. Oil pan. 7. Piston and connecting rod. 4. Oil strainer. 8. Crank shaft and bearing. *Denotes that disassembly instructions for these parts follow on the indicated pages. Westerbeke Generators...
Page 62 (#1,2, and 3 may have been removed earlier.) 4. Remove the oil pan. a. Loosen the oil pan attaching bolts. b. Using a putty knife or firm gasket scraper, separate the oil pan from the cylinder block. 5. Remove the oil strainer. Westerbeke Generators...
Page 63 Push the connecting rod and piston assembly upward out the top of the cylinder block. NOTE: Temporarily assemble the connecting rod and cap so as not to disturb the correct combina- tion. 8. Remove the crankshaft bearing cap. 9. Remove the crankshaft. Westerbeke Generators...
Page 64 10. Remove the crankshaft bearing & thrust washer. 11. Remove the stud bolt, oil pressure switch etc. as required. Westerbeke Generators...
Page 65: Special Service Tools
& BCGA #37728 Piston pin remover and replacer #37731 #37732 Valve guide remover and replacer #37725 Valve stem oil seal replacer 4.5 KW BCG (~. -~(~ #37727 7.0KWBCG & BCGA #37726 #37730 Balance shaft gear bearing remover and replacer Westerbeke Generators...
Page 66 NOTES Westerbeke Generators...
Page 67: Cylinder Head And Engine Block Inspection And Repair
Checking the Connecting Rod Bearings ......73 Checking the Crankshaft ..........74 Checking the Camshaft ............ 76 Checking the Crankshaft Timing Belt Pulleys ....78 Replacing Front and Rear Crankshaft Oil Seals ..... 79 Checking the Flywheel and Ring Gear ......80 Westerbeke Generators...
Page 68: Engine Inspection And Repair
BCG & BCGA 4.5 KW 7.0 KW 3.9370 (100 Allowable Limit of Distortion: BCG and BCG & BCGA 4.5 KW 7.0 KW (warpage) 0.0039 (0.1 Grinding Limit: BCG and BCG & BCGA 4.5 KW 7.0 KW 3.9291 (99.8 ~--~----~----~-~- Westerbeke Generators...
Page 69: Checking The Valve Guides
Replacing the Valve Guides #37725 1. Remove the valve Seal from the valve guide. 2. Knock the guide out toward the opposite side of the combustion chamber with a valve guide installer. (Special Service Tool 37725) Westerbeke Generators...
Page 70: Checking Valves
Check if the valve seat's contact face contacts the center position of the valve's contact face. Do not rotate the valve. 2. If the valve stem is worn, damaged, bent or the end surface of the stem is dented, replace the valve. Westerbeke Generators...
Page 71 0.0394 - 0.0551 in. (1.0 -1.4 mm) Exhaust: 0.0512 - 0.0669 in. (1.3 -1.7 mm) Specified Limit Intake: 0.0354 in. (0.9 mm) Exhaust: 0.0433 in. (1.1 5. Check for excessive grooves at the end of the valve stem. Westerbeke Generators...
Page 72: Refacing The Valve And Valve Seat
Arm Inner Diameter: 0.6299 - 0.6306 in. (16.000 - 16.018 mm) limit: 0.6313 in. (16.035 mm) Shaft Outer Diameter: 0.6287 - 0.6294 in. (15.968 - 15.988 mm) limit: 0.6281 in. (15.955 mm) Westerbeke Generators...
Page 73: Checking Valve Springs
If clogged, remove with compressed air or a wire probe. 3. Check the cylinder block for distortion. If it exceeds the allowable limit of distortion, repair or replace the cylinder block. Allowable Limit Distortion: 0.0031 in. (O.OS Westerbeke Generators...
Page 74 In addition, new piston rings are to be installed, have the cylinder walls deglazed (roughed up) so the rings may seat properly. Westerbeke Generators...
Page 75: Checking The Pistons
2. Measure each piston ring's end gap. Replace the ring if the gap exceeds the allowable end gap limit. NOTE: Push a ring into the cylinder with a piston until it is about 2 inches from the block's top surface. Westerbeke Generators...
Page 76: Checking The Connecting Rods
2. Check the connecting rod for bends or twists with a suitable alignment fixture. If realignment is necessary, place the connecting rod in a press and apply a gradual pressure to the rod or replace the connecting rod. Twist limit: 0.0020 in. (0.05 mm) Bend limit: 0.0020 in. (0.05 mm) Westerbeke Generators...
Page 77: Checking The Piston Pins
Bearing Oil Clearance: Specified Limit: 0.0008 - 0.0017 in. (0.020 - 0.044 mm) Allowable Limit: 0.0028 in. (0.07 mm) Kinds of Connecting Rod Bearings: Standard Undersize 0.0098 in. (0.25 mm) Undersize 0.0197 in. (0.50 mm) Westerbeke Generators...
Page 78: Checking The Crankshaft
NOTE: Measure the diameter of each of the crankpins and main journals at two points (the front and rear portions) at 90 degrees to the crankshaft axis, as shown in the figure. Westerbeke Generators...
Page 79 Runout Limit: 0.0008 in. (0.02 mm) 6. Measure the crankshaft for bend by placing a dial gauge at the center bearing journal and turning the crankshaft as shown in the illustration to the right. Bend Limit: 0.0012 in. (0.03 mm) Westerbeke Generators...
Page 80: Checking The Camshaft
(34.93 - 35.07 mm) 1.3728 - 1.3783 in. (34.87 - 35.01 mm) Allowable Limit: 4.5 KW BCG IN: 1.3819 in. (35.10 mm) 1.3799 in. (35.05 mm) 7.0 KW BCG & BCGA IN: 1.3701 in. (34.80 mm) 1.3681 in. (34.75 mm) Westerbeke Generators...
Page 81 Tighten the crankshaft bearing cap and connecting rod bearing cap bolts to the specified torque. Tightening Torque: Crankshaft Bearing Cap 39.1 - 47.7 ft-Ib (5.4 - 6.6 kg-m) Connecting Rod Bearing Cap 15.2 - 21.0 ft-Ib (2.1 - 2.9 kg-m) Oil clearance measurement (2) Westerbeke Generators...
Page 82: Checking The Crankshaft Timing Belt Pulleys
Crankshaft Pulley: Pulley Diameter 2.154 - 2.158 in. (54.701 - 54.801 mm) Allowable Limit 2.151 in. (54.64 mm) Camshaft Pulley: Pulley Diameter 4.3556 - 4.3627 in. (110.633 - 110.813 mm) Allowable Limit 4.3531 in. (110.57 mm) Westerbeke Generators...
Page 83: Replacing Front And Rear Crankshaft Oil Seals
4. Assemble the oil pump assembly and rear oil seal ® retainer. Tightening torque: 7.2 - 11.6 ft-Ib Rear oil seal retainer (1.0 - 1.6 kg-m) Oil pump assembly 11.3 - 16.9 ft-Ib (1.56 - 2.34 kg-m) Westerbeke Generators...
Page 84: Checking The Flywheel And Ring Gear
F) on a hot plate or in an oven. Before Slipping it onto the flywheel, make sure that the chamfered side of the ring gear is directed toward the engine. NOTE: Excessive heat may destroy the original heat treatment and cause premature failure of the ring gear. Westerbeke Generators...
Page 85: Subassembly Inspection, Repair And Assembly
Raw Water Pump .............. 86 Electric Fuel Pump ............87 Disassembling and Rebuilding the Carburetor ..............88 Inspecting the Distributor and its Components ..............94 Testing the Ignition Coil ........... 95 Inspecting the Spark Plugs ..........95 Testing the Starter ............96 Westerbeke Generators...
Page 86: Disassembling And Inspecting The Oil Pump
Using pliers, remove the cotter pin. b. Remove the retainer, spring and relief valve. 2. Remove the drive and driven gear. a. Remove the 5 bolts and oil pump cover. b. Remove the drive and driven gear. Westerbeke Generators...
Page 87 0.0059 in. (0.15 mm) 5. Using a feeler gauge, measure the clearance between the drive gear and body. 0.0024 - 0.0047 in. (0.06 - 0.12 mm) Limit 0.0098 in. (0.25 mm) 6. Using a screw driver, pry out the oil seal. Westerbeke Generators...
Page 88: Assembling The Oil Pump
3. Install the a-ring. Fresh Water Pump No rebuilding kit is offered for the fresh water circulating & pumps on the 4.5 KW BCG, 7.0 KW BCG BCGA. RemOVal and replacement of the defective or worn pump is, therefore, necessary. Westerbeke Generators...
Page 89: Thermostat Removal And Inspection
CAUTION When replacing the thermostat, use genuine Westerbeke thermostats. These thermostats are designed specifically for the engines covered in this manual. Other, generic thermostats will not work in these engines and may seriously damage the engine should they be installed.
Page 90: Disassembling And Inspecting The Raw Water Pump
NOTE: When reassembling the raw water pump with a new impeller kit, wipe a little petroleum jelly around the impeller. This ensures that when the engine is started the impeller will not run dry until raw water reaches the impeller as it draws a prime. Westerbeke Generators...
Page 91: Electric Fuel Pump
Fuel Connection DC Ground Wire Connection Fuel Connection Pump Mounting Bolt IWARNINGI Fuel leakage at the fuel pump or connections is a fire hazard and should be corrected. Make sure proper ventilation exists whenever servicing fuel system components. Westerbeke Generators...
Page 92: Disassembling And Rebuilding The Carburetor
VALVE SEAT ALUMINUM SHUTOFF SOLENOIO GASK ET ALUMINUM MAIN BODY GASKET VALVE SEAT IDLE MIXTURE SCREW GASKET O-RING CIlllllJJ1IlmlO B.Ji~ UI( _ _ CHOKE LEVER SPRING FUEL FILTER ELEMENT ROTARY THROTTLE SHAFT THROTTLE SHAFT VALVE VALVE SPRING MANIFOLD GASKET Westerbeke Generators...
Page 93 : Choke Wire Fuel Solenoid Wire Cover Screw 4. Remove the electric choke's stabilizing screw and the indi- cated (one four) cover screw and washer. Remove the electric choke. 5. Replace the choke lever spring, if necessary. Stabilizing Screw Westerbeke Generators...
Page 94 9. Shake the float. If you can hear any sand-like particles moving inside the float, replace it. & Cover Screws Washers 3 Of 4) (Remaining Roat Retaining Hook Roat Pivot Carburetor Wire Retaining Top Cover Loop Needle Valve Seat Pivot Westerbeke Generators...
Page 95 Accelerator two copper gaskets placed above and below the nozzle. Carburetor 14. Replace the two copper gaskets and reinstall the accelerator pump nozzle. Snug down the nozzle's retaining screw. Do not overtighten the screw. Westerbeke Generators...
Page 96 Replace the remaining three cover screw's washers and tighten the cover screws in the indicated order. Do not overtighten the cover screws. This can strip the threads in the carburetor. 16. Unscrew the idle mixture screw and replace the idle mixture screw's O-ring. Westerbeke Generators...
Page 97 Reconnect the fuel supply line, fuel solenoid wire, electric choke wire, and the throttle control linkage. Reattach the flame arrester and tighten the flame arrester's clamp. 8ectric Choke Wire Fuel Filter 8ement Fuel Filter Aluminum Gasket Fuel Solenoid Wire Westerbeke Generators...
Page 98: Inspecting The Distributor And Its Components
If the pointer on the tester deflects while the wires are waved, then the wires are satisfactory. Specified resistance: 10 - 22 ohm/m Westerbeke Generators...
Page 99: Testing The Ignition Coil
Oean or replace the spark plugs if necessary. PLUG GAP Make sure that new or used spark plugs are gapped before they are installed in the engine. CONDITION DAMAGE AND DETERIORATION Spark Plug Gap: 0.028 - 0.036 in. (0.7 - 0.9 mm) DAMAGE Westerbeke Generators...
Page 100: Testing The Starter
Connect the starter with the battery as illustrated and close the switch to turn the starter. The starter must turn lightly at the current and speed shown above when the battery voltage is 11.5 volts. If any abnormality has been found, make the following inspections. Westerbeke Generators...
Page 101 If current is flowing, the coil is grounded. In this case, check the insulated con- dition and correct it. Replace the yoke assembly if not repairable. c. Check the staked condition of poles and check the coil and other parts for looseness. Westerbeke Generators...
Page 102 11. Pinion Shaft Thrust Gap A pinion shaft thrust gap is an axial play of the shaft. Adjust the gap to a value less than the standard value by the adjusting washer between the center bracket and the reduction gear. Westerbeke Generators...
Page 103 If the pinion returns to its original position as soon as it is released, the solenoid is good. In the above three tests, do not supply current for more than 10 seconds. Westerbeke Generators...
Page 104 NOTES Westerbeke Generators...
Page 105: Engine Assembly
(Illustration and Numerical Order) ......... 102 Assembling the Crankshaft ..........103 Piston Ring Installation and Connecting Rod Assembly ..........104 CYLINDER HEAD ASSEMBLY (Illustration and Numerical Order) ......... 109 Installation of the Generator to the Engine ....117 Westerbeke Generators...
Page 106 2. Piston and Connecting Rod Assembly 3. Oil Seal Retainer 4. Oil Pump 5. Oil Strainer 6. Oil Pan 7. Water Pump 8. Crankshaft Timing Belt Pulley *Denotes that assembly instructions for these parts follow on the indicated pages. Westerbeke Generators...
Page 107 Install the bearing cap with its front mark facing toward the front side. c. Each time one bearing cap is tightened, make sure FRONT that the crankshaft can still turn slightly. Tightening torque: 39.1 - 47.7ft-lb (5.4 - 6.6 kg-m) Westerbeke Generators...
Page 108 No.2 Side rail lower Piston Ring Installation (3) 7. Using the ring compressor, install the piston with the connecting rod into the cylinder bore, making sure that the front marks face the correct direc- tion. Westerbeke Generators...
Page 109 O-ring at the position of the embossed marks on the cover as indicated. c. Type T oil seal (crankshaft rear oil seal). Using an appropriate service tool, install the oil seal. Apply engine oil to the lip portion of the oil seal. Westerbeke Generators...
Page 110 Apply of the oil pan. FIPG 15 straight NOTE: No harmful effect will be made even Apply FIPG with a slight curvature if the excess FIPG is oozed out from the applied sections. Westerbeke Generators...
Page 111 15. Assemble the water pump ay with the oil level gauge guide. Tightening Torque: 11.3 -16.9 ft-Ib (1.56 - 2.34 kg-m) & 16. Assemble the cylinder head, IN EX manifold and flywheel related parts. Westerbeke Generators...
Page 112 NOTES Westerbeke Generators...
Page 113: Cyunder Head Assembly
3. Valve Spring Seat 4. Valves 5. Compression Spring 6. Valve Spring Retainer 7. Valve Spring Retainer Lock 8. Water Outlet 9. Cylinder Head Gasket 10. Cylinder Head Ay *Denotes that assembly instructions for these parts follow on the indicated pages. Westerbeke Generators...
Page 114 NOTE: Apply the engine oil to the sliding portion of the valve stem. 3. Using a valve spring compressor, assemble the valve spring. NOTE: Install the valve spring so that the painted portion faces the upper side. Westerbeke Generators...
Page 115 Oil Seal Installation (1) c. Remove the bolt. Hit the tool with a hammer to confirm the fitting condition of the oil seal. Oil Seal Protrusion Amount: Front ± ± 0.0078 0.0098 in. (0.2 0.25 mm) Oil Seal Installation (2) Westerbeke Generators...
Page 116 1. Install the cylinder head gasket. 2. I nstall the cylinder head assembly and tighten the FRONT cylinder head bolts, as indicated in the sequence -==::===============::::- evenly and progressively several times over. Tightening Torque: 36.2 - 33.4 ft-Ib (5.0 - 6.0 kg-m) Westerbeke Generators...
Page 117 (3.52 - 5.28 kg-m) 4. Install the crankshaft inner flange and crankshaft timing belt pulley. NOTE: Be sure to install the crankshaft timing belt pulley so that the "F" mark stamped on the pulley faces the front side. Westerbeke Generators...
Page 118 Tighten the tensioner to the specified torque. Tightening Torque: 23.1 - 34.7 ft-Ib (3.2 - 4.8 kg-m) e. Remove the M6 screw and steel plate. Install the resin cap. Adjusting Timing Belt Tension (2) Westerbeke Generators...
Page 119 Cut out section of coupling c. Apply engine oil to the "0" ring and the forward end section of the shaft. Then, proceed to insert them into place. Westerbeke Generators...
Page 120 Crankshaft pulley Tightening Torque: 36.2 - 43.4 ft-Ib (5.0 - 6.0 kg-m) d. Fresh water pump pulley Tightening Torque: 3.2 - 4.8 ft-Ib (0.44 - 0.66 kg-m) Westerbeke Generators...
Page 121 2. Assemble the stator housing to the engine using field fabricated tool). Secure to back plate. 3. Mount control panel and install wiring harness. Ensure connections are clean and secure. (Follow unit DC schematic.) Mounting Rail Be STYLE GENERATOR END Westerbeke Generators...
Page 122 NOTES Westerbeke Generators...
Page 123: Lubrication System
- - - - - - . Oil splash lubrication Valve rocker shaft Camshaft Oil capacity (whole) 2.8£ Maximum oil pan capacity 2.2£ Minimum oil pan capacity 1.6£ Oil pump relief valve opening 3.5 - 4.3 kglcm pressure (60·C. 4000 rpm) (49.8 - 61.2 psi) Oil strainer Westerbeke Generators...
Page 124 4. Remove and replace oil filter. Change oil. 5. Clogged oil pump 5. Remove and clean. strainer. 6. Worn or fatigued 6. Remove and replace. oil pressure relief valve spring. 7. Faulty electrical 7. Check circuit and circuit. repair as needed. Westerbeke Generators...
Page 125 4. Measure the oil pressure. If it is less than the specification listed below, check the engine's lubricating system. Oil pressure: 50 - 70 psi (3.5 - 4.0 kg/cm NOTE: Ensure that the engine's oil meets all temperature requirements and the SF; SG OR SJ. API SPECIFICATION OF Westerbeke Generators...
Page 126 4. Remove elbow and clean. Other causes of engine overheating may be caused from faults in the raw water circuit supplying coolant to the raw water pump on the engine. Examine the off circuit for possible contributing faults. Westerbeke Generators...
Page 127 Poor performance 1. Main jet clogged. 1. Remove and clean. at generator speed. 2. Carburetor inlet 2. Remove and clean. filter clogged. 3. Air intake filter 3. Remove and clean. screen dirty. Westerbeke Generators...
Page 128 Page 1 of2 WIRING DIAGRAM OIL PRESSURE SWITCH. WATER TEMP. SWITCH r9---~ l!d-l . - EXHAUST TOIP. S.ntH STOP SWITCH HOUA METER •• TART SWITCH '14 YELLOW/RED ON SWITCH 'I. RED PURPLE -14 RED PURPLE rUSE eAMp. PANEL Westerbeke Generators...
Page 129 BATTERY CHARGER CAUSES A 9ma DRAIN AND OVERSPEED MODULE CAUSES A 15ma DRAIN WHEN GENERATOR IS NOT OPERATING. THEREFORE. WHEN LEAVING BOAT FOR AN EXTENDED PERICXl. DISCONNECT THE BATTERY. WESTERBEKE GASOLINE MARINE GENERATORS, AS SHIPPED FROM THE FACTORY AND EXCLUSIVE 0- OPTIONAL REMOTE INSTRUMENT OR CONTROL PANELS,COMPLY WITH U.S. COAST GUARD 33CFR-183. ACCESSORY INSTRUMENT AND CONTROL PANELS DO NOT NECESSARILY SO COMPLY AND ARE INTENDED TO BE INSTALLED ABOVE DECK AND "ISOLATED FROM GASOLINE SOURCES"...
Page 130 ---------, OPT/OrvAL REMOTE START PAtVEL (REAR VIEW) P,IV. 33703 1 - - - - - - - - "/t,Z YEl/'rJ/RED STRIPE .--- I~ ~I .Y5<~ D+-- '--1'+"-121<£0 "'D STOP START /W/PUR ,STRIPE ~lli & QED/W/PUR STRIPE 539: Il.(~ TO TBI-2- j#/4RED/kl/PUR •...
Page 131 3. Lack of fuel. 3. Check for fuel to generator set. Check fuel lift pump. 4. Choke faulty. Solenoid 4. Check to see that it inoperable. is not jammed. Should close when engine is cranking over, only. Westerbeke Generators...
Page 132 3. Same as above. exhaust temperature switches open at too Iowa temperature. 4. Overspeed module. 4. Check engine speed. Check module for pro- per operation. 5. Switch and wiring. 5. Inspect all wiring for loose connections and short circuits. Westerbeke Generators...
Page 133 4. Low resistance leak 4. Check all wires for to ground. temperature rise to locate fault. 6. Overspeed circuit 6. Unit not run for drained battery. months and fuse left in circuit drawing 0.025 amp. Westerbeke Generators...
Page 134: Generator Description And Model Rating
1500 rpm at 50 hertz. M.Qd§! Hertz BCG 4.5 -614 37.5/18.7 BCG 3.5 -514 BCG 7.0 -614 58/29 BCG 5.0 -514 22.7 BCGA 7.0 - 614 60 (only) 58/29 Derating 1 percent for each 10° Fahrenheit above 85° F ambient. Westerbeke Generators...
Page 135: Troubleshooting And Adjustments For The Bc Generator
The following trouble shooting guide is designed to give insight into problems which may be encountered & with the 4.5 KW BCG and 7.0 KW BCG BCGA Westerbeke brushless generators. Owing to the simplicity of the equipment and controls, troubleshooting is relatively easy once the relationship between cause and effect is understood.
Page 136 4.5 BC (Single Capacitor) (Dual Capacitors) Components (page 134) A. Rotating Field and Diodes B. Main Stator Windings (page 135) (page 136) C. Exciter Windings and Capacitor(s) (page D. Battery Charging Circuit 138) A description of each component follows. Westerbeke Generators...
Page 137 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --, CHARGE • r---------, i>I- _ I.C. • • BRIDGE INTEGRAL' RECTIFIER CONTROLLER ..~----------I------- _________ IDIODE AC TERMINAL BLOCK .DIODE L...-+_ • L _________ 7.8 BCGA (Single Capacitor) Westerbeke Generators...
Page 138: Component Resistance Values
Diode Repeat this same check on the second group of windings. Rotate the engine's crankshaft 180° to position the second diode and connections at 12 o'clock. No continuity should be found between these two groups of windings. Westerbeke Generators...
Page 139 The numbered leads on the terminal blocks are not in any numerical order. They are as shown below. & 7.9 KW BCG 7.8 KW BCGA Terminal Blocks ~~5~ 4.5 KW BCG & 7.B KW BCG 7.9 KW BCGA Westerbeke Generators...
Page 140 To measure the resistance value of the exciter windings on the 4.5 and 7.0 BCG models, locate the #9 and the #50 hertz capacitor connections. On the 7.0 BCGA model itwould be the #60 hertz connection. Westerbeke Generators...
Page 141 Indications of a defective capacitor: 1. Zero resistance - no rise in resistance value (shorted capacity). 2. Infinite resistance - (open capacitor). 3. No continuity should found between the capacitor's connections and the capacitor's case or base. Westerbeke Generators...
Page 142 Lift the two AC leads off the bridge rectifier and measure with an ohmmeter the resistance value between these two leads. This measurement should register 0.14 ohm. No continuity should exist between either of these two leads and the ground. CHARGE i>I- I. C. BRIDGE INTEGRAL REeT IF IER CONTROllER Westerbeke Generators...
Page 143 If the rectifier fails any of the above tests (a through e), the rectifier is defective and should be replaced. NOTE: Some ohmmeter models have internally differing polarities between their red and black leads. The test results above may read the opposite to your meter when performing above tests with meter needle deflection. Westerbeke Generators...
Page 144 White/ Yellow ( .. )Positive Terminal of rectifier White/Green (- ) Negative Terminal of rectifier Voltage Output Adjustment NOTE: White / Green (-) Negative and White/ Black Ground are interchangeable. Four Wire Controller Showing its Connections Westerbeke Generators...
Page 145 Voltage 118 - 122 The Governor/Speed Adjustment may the source of no AC output, low AC output, or high AC output. Hunting/Regulation Adjustment IncreaselDecrease Speed Carburetor Throttle Lever & 4.5 KW BCG and 7.0 KW BCG BCGA Belt-Driven Governor Westerbeke Generators...
Page 146 4. Fine Adjusting Bumper Screw Fine adjust the bumper screw by slowly unscrewing it with the unit running unloaded until a surge starts. Then, slowly screw back in until the surge stops and recheck other adjustments. retor Throttle Lever 4.5 KW BCG and 7.0 KW BCG & BCGA Belt-Driven Governor Westerbeke Generators...
Page 147: Generator Troubleshooting
2. Overload on the generator. 2. Check the load (amps) that is being drawn from the gen- erator using an amp-probe. 3. Diode(s) in rotor shorting. 3. Isolate diodes, compare resistance values between diodes, and replace with new diode. Westerbeke Generators...
Page 148 2. Rear support bearing 2. Check each load as it is is faulty. taken off each 120 volt leg with an amp-probe. 3. Generator connection 3. Stop the generator to engine is loose. and check the connection. Westerbeke Generators...
Page 149: Generator Hertz (Cycle) And Voltage Changes
<1:=1> 4.5 KW BCG Generator ..The #7 plug is ..shown connected to the capacitor ' " ' " only for deDlon- strati on purposes..- - 7.0 KW BCG Generator Westerbeke Generators...
Page 150 Note that the plug presently connected to this terminal may be anyone of the three plugs available. NOTE: Voltage variation between each plug is approximately 8 - 10 volts AC. Westerbeke Generators...
Page 151: Field Fabricated Tools
A local machine shop should be able to manufacture these tools at a modest price, but first check with your local Westerbeke dealer to see if these tools are on hand for loan. The tool below helps keep the rotor from damaging the windings in the generator housing by allowing the generator housing to be removed straifght off the engine or to be placed straight on the engine.
Page 152 TO ONE SIDE OF THIS CENTER ~ 1/2 DIA DRILL-TYP. 4 HOLES 4" 112-13UNC STORE-BOUGHT MATERIAL: COLD ROLLED STEEL EYE BOLT WITH TAPERED TIP. HOUSING PULLER TOOL (FIELD FABRICATED) x 39mm LONG-3 BOLTS PROPER USE OF THE HOUSING PULLER Westerbeke Generators...
Page 153 Drive Plate Guide Pin. The Pin screws into the flywheel and acts as a guide. Also, the pin helps to support some of the rotor and drive plate's weight while removing or replacing these parts. IIIIJ!IIIII~"'IIIIIIIIIIIIIIIIIII Material: One M8 bolt with the hex head machined off and a screw driver slot cut in the machined end. Westerbeke Generators...
Page 154 NOTES Westerbeke Generators...
Page 155: Index
Checking Valve Springs ..........................69 Checking Valves ............................66 COMPONENT RESISTANCE VALUES ..................... 134 Connecting Rods ............................39 Cooling System Troubleshooting ......................122 Crankshaft and Bearings ..........................40 Cylinder Block ............................. 38 CYLINDER BLOCK ASSEMBLY ....................... 102 CYLINDER BLOCK DISASSEMBLY ......................57 Westerbeke Generators...
Page 156 GENERATOR DESCRIPTION AND MODEL RATING ................130 GENERATOR HERTZ (CYCLE) AND VOLTAGE CHANGES ..............145 Generator Internal Wiring Schematic, 4.5 KW and 7.0 KW BCG ............. 132 Generator Internal Wiring Schematic, 7.0 KW BCGA................133 GENERATOR OVERHAUL ........................... 46 GENERATOR TROUBLESHOOTING ......................143 Westerbeke Generators...
Page 157 Replacing Front and Rear Crankshaft Oil Seals ..................79 Replacing Valve Guides ..........................65 Rotating Field/Auxiliary Windings and Diodes ..................134 SPECIAL SERVICE TOOLS ........................61 SUBASSEMBLY INSPECTION, REPAIR, AND ASSEMBLy ..............81 SYSTEM SPECIFICATIONS, 4.5 BCG ....................10 SYSTEM SPECIFICATIONS, 7.0 & BCGA .................. 14 Westerbeke Generators...
Page 158 DO NOT MAKE NO-LOAD ADJUSTMENT WITH GENERATOR ON ..........146 FUEL LEAKAGE ..........................87 STOP GENERATOR BEFORE CHECKING CONNECTIONS ••••••••••••••••..••.•.•••.•••••..•••••• 143 and 144 WIRING DIAGRAM #38024, OPTIONAL REMOTE START PANEL ............126 WIRING DIAGRAM #38028, DC CONTROL CIRCUIT ................124 Westerbeke Generators...

This manual is also suitable for:

4.5 kw bgc -60hz 7.0 kw bcga 60hz 3.5 kw bcg 50hz 5.0 kw bcg 50hz 7.0 kw bcg -60hz 4.5 kw bcg -60hz

Westerbeke 7.0 KW BGC -60Hz Technical Manual

Table of Contents

Generator Overhaul

Cylinder Head and Engine Block Inspection and Repair

Subassembly Inspection, Repair and Assembly

Quick Links

Chapters

Troubleshooting

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Questions and answers

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Summary of Contents for Westerbeke 7.0 KW BGC -60Hz

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