Westerbeke Carbureted Gasoline Generators 3.5 KW BCG-50 Hz Marine Gasoline*Factory Service / Repair/ Workshop Manual Instant Dow

TECHNICAL MANUAL WESTERBEKE 4.5 KW BCG ··60 Hz 7.0 KW BCG ·60 Hz 7.0 KW BCGA· 60 Hz 3.5 KW BCG • 50 Hz 5.0 KW BCG • 50 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

Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators

SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator. IWARNINGI The above symbol is used in the manual to warn of possible serious personal injury or loss of life. CAUTION The above symbol is used in the manual to caution personnel of possible damage to equipment. Read the manual carefully and thoroughly before attempting to operate the equipment. Know when dangerous conditions can exist and take necessary precautions to protect personnel and equipment. Fuels, exhaust gases, batteries, electrical equipment, and moving and hot parts are potential hazards that could result in serious personal injury or death. Follow recommended proce- dures carefully. I>Jways operate bilge blowers for at least five minutes before starting a gasoline-fueled engine; ensure no gasoline fumes are present before starting. • Prevent Electric Shock Shut off electric power before accessing electrical equipment. Use insulated mats whenever working on electrical equipment. Make sure your clothing is dry, not damp (particularly shoes), and keep your skin surfaces dry when handling electrical equipment. Remove wristwatch and jewelry when working on electrical equipment. Do not connect utility shore power to vessel's AC circuits, except through a ship-to-shore double-throw transfer switch. Damage to vessel's AC generator may result if this is not done. Be extremely careful when working on electrical components. High voltage can cause injury or death. • Exhaust Gases Are Toxic Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Be sure the unit and its surroundings are well-ventilated. • Use Extreme Care When Handling Engine Fuel (A constant danger of explosion or fire exists) Do not fill fuel tank(s) while the engine is running. Do not smoke or use an open flame near the engine or the fuel tank. • Do Not Alter or Modify the Fuel System Be sure all fuel supplies have a positive shut-off valve. Be certain fuel line fittings are adequately tightened and free of leaks. Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its proper use. Ex- tinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment. • Use Extreme Care When Servicing Batteries Wear rubber gloves, a rubber apron, and eye protection when servicing batteries. Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical arcing or by a lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the battery being serviced. Shut off all electrical equipment in the vicinity to prevent electrical arCing during servicing. • Avoid Moving parts Do not service the unit while the unit is running; if a situation arises in which it is absolutely necessary to make operating adjustments, use extreme care to avoid moving parts and hot exhaust system components. Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts or sleeves, rings, necklaces, or bracelets that might be caught in moving parts. Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective place at all times. Do not check fluid levels or the drive-belt's tension while the unit is operating. Do not work on the equipment when mentally or physically incapacitated by fatigue.

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals, parts lists and parts price lists, and other information, instructions and specifications provided from sources other than Westerbeke, is not within Westerbeke's control and; accordingly, is provided to Westerbeke customers only as a courtesy and service. Westerbeke cannot be responsible for the content of such software, makes no warranties or representations with respect thereto, including the accuracy, timeliness or completeness thereof, and will in no event be liable for any type of damages or injury incurred in connection with, or arising out of, the furnishing or use of such software. For example, components and subassemblies incorporated in Westerbeke's products and supplied by others (such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and other products) are generally supported by their manufacturers with their own software, and Westerbeke must depend on such software for the design of Westerbeke's own product software. Such software may be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, ofwhich Westerbeke rarely has notice in advance, are frequently not reflected in the supplier's software until after such changes take place. Westerbeke customers should also keep in mind the time span between printings of Westerbeke product software and the unavoidable existence of earlier, non-current, Westerbeke software editions in the field. Additionally, most Westerbeke products include customer-requested special features that frequently do not include complete documentation. In summation, product software provided with Westerbeke products, whether from Westerbeke or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product. 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. 1 Westerbeke Generators

TABLE OF CONTENTS Section ......................................................................... Page 4.5 KW BCG GENERAL SPECIFICATIONS .......................9 4.5 KW BCG SYSTEM SPECIFICATIONS ........................ 10 7.0 KW BCG & BCGA GENERAL SPECiFiCATIONS ........................................... 13 7.0 KW BCG & BCGA SYSTEM SPECIFICATIONS ............................................. 14 4.5 KWBCG ENGINE SERVICE SPECIFICATIONS ............................. 17 7.0 KW BCG & BCGA ENGINE SERVICE SPECIFICATIONS ............................. 27 ENGINE DESCRIPTION ................................................... 37 GENERATOR OVERHAUL.. ............................................ ..46 PREPARATIONS FOR OVERHAUL.. ................................ 47 DISASSEMBLY FOR OVERHAUL .................................... 48 ENGINE DISASSEMBL Y................................................... 50 REMOVING THE CYLINDER HEAD FROM THE CYLINDER BLOCK ........................................ 53 CYLINDER HEAD DISASSEMBLY ................................... 54 CYLINDER BLOCK DISASSEMBLY ................................. 57 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 2

TABLE OF CONTENTS (CONTINUED) CYUNDER HEAD ASSEMBLY ....................................... 109 LUBRICATION SYSTEM ................................................ 119 GENERATOR DESCRIPTION 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 3 Westerbeke Generators

20 Amp DC Circuit Breaker Lube Oil Dipstick 4.5 KW BeG Marine Gasoline Generator Fresh Water Coolant Fill Oil Pressure ,,----..;~...i;.;._ Switch lube Oii >::ill'oy·-- Zinc Anode Heat Exchanger Westerbeke Generators 4 Exhaust Temperature Switch DC Battery Ground Connection Starter with Solenoid

4.5 KW BeG Marine Gasoline Generator Fuel Shut - off Snl.:llnnlf1 Air Intake Flame Arrester Governor AC Unit Data T lube Oil Drain Hose 5 Westerbeke Generators

20 Amp DC Circuit Breaker Lube Oil Dipstick Oil Pressure Switch Heat Exchanger. Westerbeke Generators 7.0 KW BCG & BCGA Marine Gasoline Generator Exhaust Temperature Switch 6 DC Battery Ground Connection . -Rt~rt_ with Solenoid

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Westerbeke Carbureted Gasoline Generators 3.5 KW BCG-50 Hz Marine Gasoline*Factory Service / Repair/ Workshop Manual Instant Dow

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