Westerbeke 5.0KW BCG-60Hz Service Manual
  1. Manuals
  2. Brands
  3. Westerbeke Manuals
  4. Portable Generator
  5. 5.0KW BCG-60Hz
  6. Service manual
Westerbeke 5.0KW BCG-60Hz Service Manual

Westerbeke 5.0KW BCG-60Hz Service Manual

Gasoline generators single phase
Hide thumbs Also See for 5.0KW BCG-60Hz:
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual , Technical Manual
~
.....
SERVICE MANUAL
5.0KW BCG-60Hz', 4.2 KW BCG-50Hz
5.0KW BCGA-60Hz , 4.2KW BCGA-50Hz
7.0KW BCGC-60Hz '5.9KW BCGC-50Hz
7.0KW BCGD-60Hz , 5.9KW BCGD-50Hz
GASOLINE GENERl{
R~
:
Single Phase'
,
NO. 052020
FIRST EDITION
MARCH 2005
~r~
rWESTERBEKE
member
J
WESTERBEKE CORPORATION· 150 JOHN HANCOCK ROAD
~'lTr
•
MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02780
~~~~
~~B
SITE:
WWW.WE~~ERBEKE.COM

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 5.0KW BCG-60Hz and is the answer not in the manual?

Questions and answers

Related Manuals for Westerbeke 5.0KW BCG-60Hz

Summary of Contents for Westerbeke 5.0KW BCG-60Hz

  • Page 1 ..SERVICE MANUAL 5.0KW BCG-60Hz', 4.2 KW BCG-50Hz 5.0KW BCGA-60Hz , 4.2KW BCGA-50Hz 7.0KW BCGC-60Hz '5.9KW BCGC-50Hz 7.0KW BCGD-60Hz , 5.9KW BCGD-50Hz GASOLINE GENERl{ Single Phase' NO. 052020 FIRST EDITION MARCH 2005 rWESTERBEKE member • WESTERBEKE CORPORATION· 150 JOHN HANCOCK ROAD ~'lTr MYLES STANDISH INDUSTRIAL PARK •...
  • 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. A WARNING DECAL is provided by to a WESTERBEKE and should be fixed bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters your vessel.
  • Page 4 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are WARNING: caused by failure to follow fundamental rules and Fire can cause injury or death! precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your •...
  • Page 5 SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) is a deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine! discharged from the engine.
  • Page 6 SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR • Do not wear loose clothing or jewelry when servicing 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 WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS Parts Identi'fication ............ Testing for Overhaul ........... Troubleshooting Chart ..........Generator/Engine Disassembly ........Engine Assembly ............7 Timing Belt Disassembly ..........Engine Disassembly (p.12-p.31) ........ 12 Service Data/Standards and Limits ......Engine Hardware Torques ........Special Tools - Engine ..........Exhaust Manifoldmeat Exchanger ......

  • Page 9: Parts Identification

    PARTS IDENTIFICATION EXHAUST MANI COOLANT FI FILL THERMOSTAT CONTROL PANEL DISTRIBUTOR __ - - - - THROTTLE CONTROL \\~,----- OIL DRAIN HOSE FLAME SCREEN WATER FILTER PUMP REAR RIGHT SIDE FUEL FILTER FUEL FILTER FUEL CHARGER AIR BLEED PETCOCK FUSE ~"u AC CIRCUIT BREAKER...

  • 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 detennined by various conditions such as lowered engine guidance of suitable equipped and staffed marine engine ser-...

  • Page 11: Troubleshooting Chart

    2. Displaced or twisted connecting rod. 3. Worn piston ring. 3. Replace ring. ENGINE BACKFIRES, MISFIRES 1. Incorrect valve clearances. 1. Adjust valves and clearances. 2. Valves are out of adjustment. 2. Adjust valves and clearances. I~/WESTERBEKE Engines & Generators...
  • Page 12 BCG ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATIO N/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. Replace bearing and check lubrication systern. 3.

  • Page 13: Generator/Engine Disassembly

    GENERATOR/ENGINE DISASSEMBLY DESCRIPTION Unfasten the generator from its mounting rails or the mounting rails from the platform and remove the generator The engine component of the BC generator is not as bulky or from the boat. heavy as most engines (approx. 75 lbs) so it can be Once the generator is securely mounted on the work bench, disassembled and repaired on a sturdy work bench.

  • Page 14: Engine Assembly

    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: Timing Belt Disassembly

    In [65 mm] INSTRUCTIONS FOR INSPECTING AND REPLACING THE TIMING BELT WESTERBEKE requires as normal maintenance, replacing ROD 0.3110 [8 mm] the timing belt after 1000 engine operating hours. The timing belt should always be replaced during an engine overhaul.
  • Page 16 TIMING BELT DISASSEMBLY 5. Remove the timing belt. Crankshaft Bolt Removal NOTE: the timing belt is to be reused, draw an arrow on 1. Lock the crankshaft in position. the belt to indicate the direction of rotation (clockwise). NOTE: Do not turn the crankshaft. 2.
  • Page 17 ENGINE TIMING BELT Flange Installation Tensioner Spring/Timing Tensioner Installation 1. Mount the flange so that its side shown by the heavy 1. Install the tensioner spring and timing belt tensioner. arrow in the illustration faces toward the sprocket. 2. Hook the tensioner spring onto the bend of the timing belt tensioner bracket and the stopper pin on the cylinder block.
  • Page 18 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: 410 5 teeth in forward direction.

  • Page 19: Engine Disassembly

    Refer to DISTRIBUTOR DISASSEMBLY in this manual. THERMOSTAT See ENGINE ADJUSTMENTS for information on ignition wires and spark plugs. Loosen the raw water pump, remove the drive belt and then remove the raw water pump. RAWWATEfi PUMP SPWFtU~· • ..-v- WESTERBEKE Engines Generators &...
  • Page 20 4CYLINDER HEAD BOLTS. TORQUE 43 - 51 FT-LI3S 60-10Nm 7RETAlNINGLOCK~ S:~RIN:~~ VALVE R E T A I N / NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY 9 VALVE SPRING SEAL VALVE SPRING CYLINDER HEAD INTAKE VALVE SEAT 19VALVEGUIDE- EXHAUST VALVE----4 CYLINDER HEAD BOLTS LOOSENING SEQUENCE REMOVING THE CYLINDER HEAD...
  • Page 21 CYLINDER HEAD AND VALVES VALVE ASSEMBLY INSPECTION Use pliers to remove the valve stem seals. Do not reuse the stem seals. Valve SteroNalve 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 22 CYLINDER HEAD AND VALVES Valve Stem and Guides VALVE STEM SEAL INSTALLER VALVE STEM SEAL Valve Springs MEASUR;NG VALVE Install the valve spring with it's enamel coated side toward STEM DIAMETER the rocker arm side. ~~~~ ~;---SPIRINIi RETAINER VALVE STEM SEAL TO VALVE GUIDE CLEARANCE ENAMel Standard Intake...
  • Page 23 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-lbs (20 - 30 Nm). 2.
  • Page 24 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 1 ROCKER ARM, ROCKER SHAFT ASSEMBLY 14 CAMSHAFT ®...
  • Page 25 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.
  • Page 26 PISTONS AND CONNECTING RODS 111 PISTON RING 112 PISTON RING gOIL RING ARROW FRONT MARK BOLT STOPPER CYLINDER NOTCH NUMBER NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY REMOVING THE CONNECTING RODS/PISTONS Tum 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 27 PISTONS AND CONNECTING RODS PISTON PIN INSPECTION Check the piston ring for damage, wear, seizure and bends replacing the rings 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·...
  • Page 28 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 29 PISTONS AND CONNECTING RODS Installing the Piston Assembly Apply an ample amount of oil to the outside surfaces of the NO.3 piston and the piston rings. Position the piston rings and oil ring (side rail spacer) end gaps as shown. NO.2 NO.'1 SlDERAIL...
  • Page 30 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. 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.
  • Page 31 FRONT CASE COUNTERBALANCE SHAFT AND OIL PAN GASKET ENGINE BLOCK ' - 1 TORQUE 6 -7 R-Lbs NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY FRONT OIL SEAl. OIL PUMP COVER CONFIGURAnON OF FRONT CASE ASSEMBLY " ----------------------------~---------~---;~--------~ OIL PAN REMOVAL 2.
  • Page 32 FRONT CASE I 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. If the oil holes clogged, use compressed or solvent to clean them out EARING REMOVER TOOL...
  • Page 33 FRONT CASE 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. ~()r---., OILHOL BEARING Front Case Assembly Mate the ratchet ball of the bearing in the oil hole of the rear bearing and install the bearing in the bearing Install the front case assembly through the gasket and tighten to the...
  • Page 34 FRONT CASE lOlL PUMP AND OIL PAN 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 fiat side of the gasket is positioned against the pump cover.
  • Page 35 CRANKSHAFT BEARINGS AND OIL SEAL NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY CYLINDER BLOCK ' = "' __ ----. THRUST BEARING CRANKSHAFT BEARING (UPPER) INSPECT THE JOURNALS FOR UNEVEN WEAR. CHECK FOR CRACKS, BENDS, TORQUE 105 FT-LBS 98 - AND CLOGGED OIL HOLES. [135 - 145 CRANKSHAFT TORQUE...
  • Page 36 CRANKSHAFT, BEARING AND OIL SEAL R • 0.059 IN {1.5MM] 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 37 CRANKSHAFTI BEARING AND OIL SEAL MEASURING END PLAY Push the crankshaft 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: 0.0020 - 0.0009in (0.05 - 0.02Smm) CRANKSHAFT BEARINGS CRANKSHAFT CRANKSHAFT REAR OIL SEAL...
  • Page 38 CYLINDER BLOCK INSPECTION AND PISTON CLEARANCE NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY CYLINDER BLOCK 1/4'~ 1 OllU'EH PlUG D O W E l - - - - . o • 6STUDS8X5D-7T/ KNOCK BUSHINGS 6 X CYLINDER BLOCK INSPECTION 1. Before inspecting, clean the cylinder block to ensure that the water and oil holes are not plugged.

  • Page 39: Service Data/Standards And Limits

    SERVICE DATA / STANDARDS AND LIMITS BCG ENGINE/GENERATOR Component Specified Value Standard Repair Limit Component Specified Value I Standard Repair limit inches(mm) inches(mm) inches(mm) inches(mm) VAlVES FRONTCAS~COUNTERBAlANCESHAFT Valve Guide Service Size 0.05, 0.25, 0.50 oversize Oil Pump Side Clearance Driven Gear......0.0024-0.0047 (0.06-0.12) Valve Seat Width of Drive Gear ......
  • Page 40 SERVICE DATA / STANDARDS AND LIMITS • BeG ENGINE/GENERATOR! Component Specified Value Standard Repair Limit Component Specified Value Standard 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) ....

  • Page 41: Engine Hardware Torques

    ENGINE HARDWARE TORQUES Front Case, Counterbalance Shaft ft.lbs. Timing Belt ft.lbs. Front case bolts 8-10 Crankshaft bolt 135-145 98-105 Timing belt cover bolts 10-12 Oil pump cover bolts 8-10 Oil pan bolts 10-12 Camshaft sprocket bolts 80-100 58-72 Oil drain plug 25-33 Oil pump sprocket nuts 50-57...

  • Page 42: Special Tools - Engine

    SPECIAL TOOLS • ENGINE NOTE: These special tools are available from your local Mitsubishi Automotive Dealer VALVE STEM SEAL INSTALLER CAMSHAFT OIL SEAL INSTALLER MD 998302 MD 999569 OIL PAN GASKET CUrrER PISTON PIN SETTING BASE For removing the oil pan to Used to pUll-out and press in break the oil pan seal.
  • Page 43 They will also service transmission and engine oil coolers. 6. Repaint the assembled heat exchanger with WESTERBEKE heat resistant spray enamel HEAT EXCHANGER ASSEMBLY Reinstall the heat exchanger. Tighten down the holdown brackets and once the engine is running, check the heat exchanger and hose connections for leaks.

  • Page 44: Coolant Circulating Pump

    COOLANT CIRCULATING PUMP REMOVING THE COOLANT PUMP 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 45: Raw Water Pump

    RAW WATER PUMP PN.46120 13C1RClIP(EXTl'RNAL).~ ",. 17'""",, " . D-RiNG - ' > Ii':. 18 DUTBl BEARING ·;::v. :..: ... ;:-:'. :',' SCREW WEAR PLATE INSPECT THE a-RING AND IMPELLER. REPLACE IF THEY SHOW SIGNS OF WEAR. LIGHTLY GREASE THE PUMP CHAMBER, O-RING, AND IMPELLER WITH GLYCERIN.

  • Page 46: Carburetor

    CARBURETOR • LOW PROFILE CARBURETOR ADJUSTMENT: THE IDLE MIXTURE CAN BE The carburetor is a single barrel, side-draft type with a ADJUSTED BY PRYING OFF THE PLASnC CAP. cleanable metal screen air intake filter/spark arrester. TURN THE SCREW ALL THE WAY DOWN - THEN BACK THE SCREW OUT 112 TURNS.

  • Page 47: Distributor

    DISTRIBUTOR COVER VACUUM CONTROL CHECK THE DISmlBUTER CAP FOR CRACKS, WEAR AND EVIDENCE OF OR BURNING. IF ANY OF THESE CONDmONS EXIST. REPLACE THE DlSmlBUTER CAP. PICK·UP ASSEMBLY NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY WIRE SET TESTING THE PICK UP COIL STANDARD RESISTANCE VALUE;.420 ;540 Cheek that when a screwdriver is passed near the iron core Adjust the point 'gap of the pick-up assembly between the...

  • Page 48: Starter Motor

    STARTER MOTOR NOTE: To oider spare parts, contact your WESTERBEKE dealer. COVER RETAINER /'" :----------------y ~ BUSHIN~ : WGEAR ~----------------: STATIONARY GEAR ASSEMBLY ~TW_ RETAINER . D.E. HOUSING SCREW /" SCREW C.E. FRAME (COVER) BRUSH HOLDER ASSEMBLY STARTER DISASSEMBLY Use this exploded view drawing to disassemble and reassemble the starter motor.
  • Page 49 STARTER MOTOR No-Load Test DESCRIPTION The starter Connect the ammeter, voltmeter, and battery to the starter can be roughly divided into the following sections: as illustrated. • A motor section which generates a drive power. • An overrunning clutch section which transmits an arma- 2.
  • Page 50 STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and body. M and between tenninals S and No continuity should be found between S and M. Continuity should be found between S and the body and M and the body. Brush and Brush Holder Inspection Check the brushes.
  • Page 51 STARTER MOTOR 2. Greasing. Whenever the starter has been overhauled, Field Coil Inspection apply grease to the following parts: Check for insulation between one end (brush) of the a. Armature shaft gear and reduction gear. coil and yoke. h. All bearings. 2.

  • Page 52: Wiring Diagram

    GENERATOR WIRING DIAGRAM CHOKE SOLENOID BATTERY 12 VDC FUEL PUMP - · l ==,=;~Pl FUEL i .. i . . . , . SOLENOID ----.----.------~ OlL PRESS )i\SWiTCH 'IwO) 12 8LK '"'16 GRA '-Il· InI-- EXHAUST TEMPERATURE SWITCH (N/C) IGNITI~Nf\ WATER TEMPERATURE SWITCH IN/C) COIL...

  • Page 53: Wiring Schematic

    GENERATOR WIRING SCHEMATIC 12 VDC BA_T_T_ER_V_D~~>-:-W-' . . : : - j A I ~ I : ; ~I~II--------~o----------~ ).j ___________ T_C_" _____ STARTER )~----------.---- > - - - - - ! '}.t rUSE 30A F.W. RECTIFIER 1 20 AMP ~l"r I C I RCU I T GENERA TOR...

  • Page 54: Remote Panel Wiring

    REMOTE PANEL WIRING SCHEMATIC #043912 REMOTE PANEL #14 WHT/RED L-------+---l{'. C KT 1 ON SW #14 VEl/RED WHITE #14 WHT WHITE #14 RED/VIO VIEWED FROM MATING END Engines & Generators...

  • Page 55: Testing Relays

    TESTING RELAYS 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. RELAY SHOULD test measurements, make sure that a good ground for the ____ "CLICK"...

  • Page 56: Testing The Igniter

    TESTING THE IGNITER DESCRIPTION Unplug the two connector's at the distributor plug. Take care In one direction the ohm reading will be 100 ohms less. In the other direction there should be no ohm reading. Any to note the two separate connections as they must be reconnected in the exact same position.

  • Page 57: Governor System Components And Operation

    GOVERNOR SYSTEM COMPONENTS and OPERATION DESCRIPTION MAGNETIC PICK-UP [MPU] INSTALLATION The Electronic Governor consists of three components, the The MPU is installed in the threaded opening on the side CONTROLLER, a pc board installed in the control panel. A of the flywheel bellhousing. This positions the MPU over MAGNETIC PICK·UP (MPU) installed in the bellhousing over the teeth of the flywheel ring gear.
  • Page 58 PANEL COMPONENT,S/WIRING OVERS PEED PC ELECTRONIC SPEED .BOARD PN 046732 CONTROllER PN 046945 NOTE: For wiring connection :/' refer to the diagram below., MAGNETIC PICK-UP (MPU) PN 046874 [~t:,~c,~~~~p WIRING SCHEMATIC NOMINAL VOLTAGES at IDLE and 1800 RPM ...--,--,.1-..iH-}- OVERSPEED PC .

  • Page 59: Electronic Governor Troubleshooting

    ELECTRONIC GOVERNOR TROUBLESHOOTING PROBLEM CORRECTION TEST/CHECK Unit starts, then overspeeds 1. Check DC voltage between terminal 1. Charge starting battery. Start unit, troubleshoot and shuts down. #12 and connection on hourmeter battery, charge circuit. when ON switch is depressed. NOTE: When troubleshooting, manually operate the throttle to prevent an overspeed or disconnect the throttle from the actuator and...

  • Page 60: Electronic Governor (Models Prior To June 2004)

    THE ELECTRONIC GOVERNOR GENERATOR MODELS UP TO JUNE 2004 DESCRIPTION A generators engine must run at a constant speed to enable the generator to produce the stable AC power (hertz) required. The Electronic Governor consists of three components, the CONTROLLER, a pc board installed in the control panel.
  • Page 61 THE ELECTRONIC GOVERNOR GOVERNOR CIRCUIT VOLTAGES MAGNETIC PICK-UP [MPU] INSTALLATION Below are the voltages normally found in the governor The MPU is installed in the threaded opening on the side circuit when the system is functioning normally. These of the flywheel bellhousing. This positions the MPU over voltages are an approximate and should be of help in the teeth of the flywheel ring gear.

  • Page 62: Electronic Governor Troubleshooting

    NOTE: Reconnect the actuator leads properly after completing this test. e. MPU pOSitioned marginally too far away from flywheel e. Check the position of the MPU. teeth giving erratic AC input to controller. problems continue to perSist, contact your WESTERBEKE dealer for additional assistance. Engines & Generators...

  • Page 63: Engine Adjustments

    ENGINE ADJUSTMENTS ENGINE COMPRESSION TEST TESTING OIL PRESSURE 1. To check the engine's compression pressure, warm up the To test oil pressure, remove the hex head plug from the oil engine then shut it down. gallery and install a mechanical oil pressure gauge in its place.
  • Page 64 ENGINE ADJUSTMENTS TORQUING THE CYLINDER HEAD BOLTS VALVE CLEARANCE ADJUSTMENT NOTE: Retorque the cylinder head bolts before adjusting the After the initial breal<-in period (approximately hours), the cylinder head bolts should be re-torqued. engine's valves (see TORQUING THE CYliNDER HEAD BOLTS).
  • Page 65 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 thereafter and replaced as needed.

  • Page 66: Battery Charge Controller

    BATTERY CHARGE CONTROLLER THE CHARGING SYSTEM Testing the Battery Charger Westerbeke's low profile generators are equipped with a To test the battery charger, put a multimeter between the battery charge controller that is powered from a separate positive and negative (") leads. to the battery. It should winding in the generator.
  • Page 67 7.0 KW BCGC/BCGD GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3-cylinder, 4-cycle, , overhead camshaft w/counterbalance shaft, water cooled gasoline engine Bore & Stroke 2.56 x 2.61 inches (65.0 x 66.3 rnm) General Fresh water-cooled block through raw water- Total Displacement 40.3 cubic inches (0.66 liters) cooled heat exchanger circuit Bearings...
  • Page 68 5.0 KW BCG\BCGA GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type 3 cylinder, 4 cycle, overhead camshaft w/counterbalance shaft, water cooled gasoline engine Bore & Stroke 2.56 2.61 inches (65.0 66.3 mm) General Fresh water-cooled block through raw water- cooled heat exchanger circuit Total Displacement 40.3 cubic inches (.66Uter) Fresh Water Pump...

  • Page 69: Generator Information

    Run the generator first with no load applied, then at half the Carbon Monoxide Detector generator's capacity, and finally loaded to its full capacity as WESTERBEKE recommends mounting a carbon indicted on the generator's data plate. The output voltage monoxide detector in the vesssel's living quarters. Carbon should be checked periodically to ensure proper operation of Monoxide, even in small amounts, is deadly.
  • Page 70 DESCRIPTION The following test procedures can be used to troubleshoot The BC generator is a brushless, self-excited generator which WESTERBEKE'S POLE DUAL EXCITER CIRCUIT requires only the driving force of the engine to produce an Due to the simplicity of the BRUSHLESS GENERATORS.
  • Page 71 MECC ALTE BC GENERATORS TROUBLESHOOTING CHART (REFER TO THE WIRING SCHEMATIC BELOW) WINDING RESISTANCE VALUES (OHMS) A,B,C,&D refer to the components of the INTERNAL WIRING DIAGRAM and their test procedures in the following pages. 5.0KW 7.0KW NOTE: This fault finding chatt is compiled assuming the engine is operating at MAIN STATOR: the correct speedlhertz.
  • Page 72 TESTING THE Be ROTOR (MECC ALTE MODEL) TESTING THE ROTOR FIELD WINDINGS Unsolder the winding connection from the diode and care- THE MfCC ALTtE MODEL GENERATOR fully remove the diode from its isolated heat sink using a thin IS IDENTIFIED BY ITS LOUVERED .
  • Page 73 COLISEUM MODEL BC GENERATORS TROUBLESHOOTING CHART (REFER TO THE WIRING SCHEMATIC) POTENTIAL Be PROBLEMS FAULT CAUSE TEST Diodes NO AC VOLTAGE OUTPUT 1. Shorted stator 1. W1 & W2 2. Open stator 2. W1 & open diode will cause the loss of any rotating field. 3.
  • Page 74 TESTING THE BC ROTOR COLISEUM MODEL COLISEUM MODEL DIODE "COVER PLATE SCREWS COVER PULLING BOLTS POWER DCV~.A TESTING FOR A WINDING SHORTED ACV~+t TO GROUND REMOVE THE COVER PLATE Remove the four cover plate screws. y.n.A © 2. Insert two 8mm x 35mm-1.25 pitch bolts into the two left and right vacant holes as shown.
  • Page 75 TESTING THE DIODES/CONTROL PANEL TESTING THE DIODES· ALL MODELS A low resistance should be found with the leads in one direc- tion and infinite resistance (blocking) in the other direction. Carefully unsolder the winding connection to the diode and remove the diode using a thin walled, deep well 7/16" DIODES: 1.4 •...
  • Page 76 Be GENERATORS TROUBLESHOOTING NO AC VOLTAGE OUTPUT EXCITING THE GENERATOR To quickly detennine a short or an open in the main stator Ellr.iJ21 winding, excite the generator with 12 VDC using one exciter winding group to accomplish this. DUEL EXCITER The AC voltage that the generator will produce measured (COLISEUM) between the line and neutral during excitation will be very...
  • Page 77 Be GENERATORS TROUBLESHOOTING REACTION DURING EXCITATION No Continuity between Isolated Stator Windings and Ground (Unit running-12VDC applied to winding) 1. A very low AC outout and loading of the drive engine and a growling noise from the generator end. This indicates a shorted stator winding to ground or the stator windings are shorted to each other.
  • Page 78 Be GENERATORS TROUBLESHOOTING TESTING THE EXCITER WINDINGS MEASURING VOLTAGE AC voltage can be measured across the capacitor electrical GENERATOR RUNNING" connections while the generator is operating. This voltage may be as high as 350 to 400 volts AC. This AC voltage build-up is accomplished as the exciter winding for each capacitor charges the capacitor and the capacitor discharges back into the winding.
  • Page 79 Be GENERATORS TROUBLESHOOTING TESTING CONTINUITY Quick field check (no capacitance scale on meter). Connect a digital ohm meter or analog ohm meter (high scale) to the capacitor terminals. The meter will register and arbitrary ohm value for the material in the capacitor.
  • Page 80 Be GENERATOR COMPONENTS COLISEUM MODEL DIODE ASSEMBLY MECC ALTE MODEL Engines & Generators...
  • Page 81 GENERATOR WIRING DIAGRAM #46876 CHOKE SOLENOID FUEL PUMP [-1 Y ,------' ------- J D--SA TTERY 12 Gi-~~ -----C __ --~Z1 -.~- FUEL SOLENOID =-S116~'K 30 AMP rUSE ti l ® L-____ '14 REO/VIQ /1 - STARTER e!OIL PRESS SWITCH (NIDI 0"...

  • Page 82: Terminal Board Connections

    /--~'- "/ _"" ..SHIP'S LOAD ;;17' - .) &+\ ---i_N-:-:e-c-:U1..;;,ral'--...N Ships Load ~~~~:o-VOIt / ' - ..(WHTI ~----~5 Ground E'luipmenl ® " (NEUTRAL)' 7 (GRN) WESTERBEKE ~--' Engines Generators & Shore Power SHIP'S - GROUND --::- SHORE GROUND...

  • Page 83: Special Tools-Generator

    SPECIAL TOOLS - GENERATOR Lifting Eye Tool FIELD FABRICATED TOOLS This tool allows a mechanic to safely remove the generator These drawings provide a means by which simple tools can be end from the engine by attaching this Generator End Lifting made to assist in the removal of the generator end from the Eye to the four screw holes located under the control panel.
  • Page 84 ANGULAR NUT AND BOLT TIGHTENING METHOD 1. Carefully wash the nuts and bolts to remove all oil and 6. Draw another line (F-G) on the face of each of the parts grease. to be clamped. This line will be in the direction of the specified angle across the center of llle nut or...

This manual is also suitable for:

5.0kw bcga-60hz4.2kw bcga-50hz5.9kw bcgd-50hz7.0kw bcgc-60hz5.9kw bcgc-50hz7.0kw bcgd-60hz ... Show all

Table of Contents