Generator/Engine Disassembly - Westerbeke 5.0KW BCG-60Hz Service Manual

GENERATOR/ENGINE DISASSEMBLY
DESCRIPTION
The engine component of the BC generator is not as bulky or
heavy as most engines (approx. 75 lbs) so it can be
disassembled and repaired on a sturdy work bench. make
certain however that the engine is securely fastened so it can
not topple off the bench and that the bench also is secure and
can not tip over.
Set the generator breakers and panel switches in the off
position. Disconnect the AC wiring connections at the
terminal block/circuit breaker and unplug the harness at the
control pane. Disconnect the battery cable connections and
the engine ground cables.
Close off the raw water seacock and disconnect the raw
water components. Separate the exhaust at the water injection
elbow and disconnect the fuel supply.
A
CAUTION:
Make certain the fuel lines are closed
off and drained. Clean up all fuel and oil spills and
properly dispose of the rags.
STARTER
MOTOR
HOUSING
TYPICAL BC GENERATOR
BACK-END ASSEMBLY
Unfasten the generator from its mounting rails or the
mounting rails from the platform and remove the generator
from the boat.
Once the generator is securely mounted on the work bench,
drain the engine oil and coolant.
Remove the starter motor. Disconnect and remove the wiring
harness, be certain to tag all the wiring -connections so you
can separate them.
Separate the generator back-end from the engine. Once the
housing is removed, the remaining generator components can
be disassembled from the engine back-plate.
NOTE:
For servicing and testing of the back-end (generator),
refer to the GENERATOR section in this manual.
ASSEMBLY
BOLTS
GENERATOR
i:-REMOVE USING AN BMM (tt/t6') SOCKET
~ifl!(r?
TO DRAIN THE OIL OR PUMP THE WARMED
OIL UP THRU THE HOSE.
COOLANT DRAIN
LOCATED JUST BELOW
THE INTAKE MANIFOLD
Engines & Generators
6
GENERATOR BACK·END
SEE SPECIAL TOOLS FOR
DISASSEMBLING THE
GENERATOR COMPONENTS