Westerbeke 7.0 KW BGC, 4.5 KW BGC, 7.0 KW BCGA, 3.5 KW BCG, 5.0 KW BCG Technical Manual

TECHNICAL MANUAL

4.5 KW BCG

7.0

KW BCG

7.0

KW

BCGA·

WESTERBEKE

··60

·60
60

Hz
Hz

Hz

MARINE GASOLINE

GENERATOR SETS

3.5

KW BCG •

5.0

KW BCG •

50
50

Hz
Hz

Publication

Edition One

March

#038747

1990

l·v#'WESTERBEKE

~

WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK

.

150

JOHN

HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.

TEL; [phone]. 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
to

and

operator.

symbols

emphasize conditions potentially dangerous to

appear in this manual

to

call attention

IWARNINGI

The above
serious personal injury

The above

of

possible

Read

to

operate the equipment. Know when dangerous conditions
can exist and take necessary precautions
and equipment.

Fuels, exhaust gases, batteries, electrical equipment,
moving and
serious personal injury
dures carefully.

I>Jways

starting a gasoline-fueled engine; ensure
present before starting.

• Prevent Electric

symbol

is used in

or

loss

the

of

manual

life.

to

warn

of

possible

CAUTION

symbol

is used in the manual

damage

the

manual carefully

operate bilge blowers

to equipment.

hot

parts are potential hazards that could result in

or

and

thoroughly before attempting

death. Follow recommended proce-

for

to

caution personnel

to

protect personnel

at

least five minutes before

no

gasoline

fumes

Shock

Shut

off

ment.

Use insulated mats whenever working on electrical
ment.

electric power before accessing electrical equip-

the

and

are

equip-

Be

sure the unit

and

its

surroundings are well-ventilated.

• Use Extreme Care When Handling Engine Fuel
(A

constant danger

Do

not

fill fuel tank(s) while

Do

not

smoke

Alter

leaks.

or

or

fuel tank.

•

Do

Not

Be

sure all fuel supplies have a positive shut-off valve.

Be

certain fuel line fittings are adequately tightened and

free

of

Make sure a fire extinguisher
properly maintained.
tinguishers rated ABC
applications encountered in this environment.

of

explosion

the

engine

use an open flame near

Modify

the

Fuel System

is

Be

by

installed nearby and is

familiar with

the NFPA are appropriate

or

fire exists)

is

running.

the

engine or the

its

proper use.

for

Ex-

all

• Use Extreme Care When Servicing Batteries

Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.

emit

Lead acid batteries
which can be ignited
cigarette, cigar,
flame near the battery being serviced.
equipment
during servicing.

in

the

hydrogen, a highly-explosive gas,

by

or

electrical arcing

pipe. Do

vicinity

not

smoke

or

to

Shut

prevent electrical arCing

or

by

a lighted

allow an open

off

all electrical

Make sure
shoes), and keep
electrical equipment.

Remove wristwatch and jewelry when working on
cal equipment.

Do
except
switch. Damage
is

not

Be

ponents. High voltage can cause injury

your

clothing is dry,

your

skin surfaces

not

connect utility shore power

through

done.

extremely careful when working on electrical

a ship-to-shore double-throw transfer

to

vessel's AC generator

not

damp
dry

to

vessel's AC circuits,

• Exhaust Gases Are Toxic

Ensure

that
discharged
regularly
are securely attached and

the exhaust system

from

for

the

leaks and make sure the exhaust manifolds

is

engine. Check exhaust system

adequate to expel gases

no

warping exists.

(particularly

when handling

electri-

may

result

or

death.

if

this

com-

• Avoid Moving parts

Do

not

service the unit while the
situation arises in which
operating adjustments, use extreme care

and

hot

parts

not

Do
equipment; avoid wearing loose jackets, shirts
rings, necklaces,
moving parts.

Make sure all attaching hardware

Keep protective shields and guards in their respective
place

Do

not

the unit is operating.

not

Do
incapacitated

exhaust system components.

wear loose clothing

at

all times.

check fluid levels or the drive-belt's tension while

work on the

by

it

is absolutely necessary to make

or

bracelets that

equipment

fatigue.

unit

is running;
to

avoid moving

or

jewelry when servicing

might

is

properly tightened.

when mentally

or

be caught in

or

if

sleeves,

physically

a

IMPORTANT

PRODUCT

Product software of
parts lists
other

and

than

Westerbeke,

customers only

all

kinds,

such

parts price lists,

is

not within Westerbeke's control and; accordingly,

as

a courtesy

as

brochures, drawings, technical

and

other information, instructions

and

service.

software, makes no warranties or representations with respect thereto,

SOFTWARE

DISCLAIMER

data,

and

specifications provided from

operator's

is

provided to

Westerbeke cannot be responsible for the content

including the accuracy,

timeliness or completeness thereof, and will in no event be liable for any type

or

use

of

incurred in connection with, or arising out of, the furnishing
For

example,

(such
other products)
must depend
be

outdated

rarely
take

place.

Westerbeke
software
Additionally, most

components

as

engine

has

blocks,

are

generally supported by their manufacturers with their

on

such software for the design of Westerbeke's

and

no longer accurate.

notice

in

advance,

customers should also

and

the unavoidable existence of

Westerbeke

and

subassemblies

fuel

systems

are

and

Routine

frequently not reflected

keep

incorporated

in

Westerbeke's products

components, transmissions, electrical components, pumps

changes

in

mind

earlier,

made

by Westerbeke's suppliers, ofwhich

in

the supplier's software until after

the time

span

non-current,

products include customer-requested special features that frequently do not

own

between

Westerbeke

such software.

own

product

software.

printings of

software,

software editions

include complete documentation.

and

workshop

Westerbeke

of

damages or injury

and

supplied by others

and

Westerbeke

Such

software

Westerbeke

such

Westerbeke

in

manuals,

sources

of

such

and

may

changes

product

the

field.

In

summation, product software provided with

and

suppliers, must not

It not only

in

question

by

the

makes

be

consulted to determine the accuracy

customer.

good

cannot

sense

be

relied

upon exclusively

but

is

imperative that appropriate representatives of

Westerbeke

as

and

currency of the product software being consulted

products, whether from

the definitive authority

Westerbeke

on

the respective product.

Westerbeke

or the supplier

or other

1

Westerbeke Generators

TABLE

OF

CONTENTS

Section .........................................................................

4.5

KW

BCG

GENERAL

4.5

KW

BCG

SYSTEM

7.0

KW

BCG & BCGA

GENERAL

7.0

KW

SYSTEM

4.5

KWBCG

ENGINE

7.0

KW

ENGINE

ENGINE
GENERATOR

SPECiFiCATIONS

BCG & BCGA

SPECIFICATIONS

SERVICE

BCG & BCGA

SERVICE
DESCRIPTION

OVERHAUL..

PREPARATIONS

SPECIFICATIONS

SPECIFICATIONS

...........................................

.............................................

SPECIFICATIONS

SPECIFICATIONS

...................................................

............................................

FOR

OVERHAUL..

....................... 9

........................

.............................

.............................

................................

Page

10

13

14

17

27
37

..46

47
DISASSEMBLY
ENGINE
REMOVING

FROM
CYLINDER
CYLINDER
SPECIAL
CYLINDER

INSPECTION

ENGINE

DISASSEMBL

THE

THE

CYLINDER
HEAD
BLOCK

SERVICE

HEAD

AND

INSPECTION

SUBASSEMBLY

REPAIR
ENGINE

CYLINDER

AND

ASSEMBLY

ASSEMBL

BLOCK

FOR

OVERHAUL

....................................

Y ...................................................

CYLINDER

DISASSEMBLY

DISASSEMBLY
TOOLS

AND

REPAIR

HEAD

BLOCK

........................................

...................................

.................................

..............................................

ENGINE

BLOCK

..............................................

AND

REPAIR

...............................

INSPECTION,

.................................................

Y .......................................................

ASSEMBLY

..................................... 1

48
50

53
54
57
61

63
64

81

101

02

Westerbeke Generators

2

TABLE

OF

(CONTINUED)

CONTENTS

CYUNDER
LUBRICATION
GENERATOR

AND

HEAD

MODEL

ASSEMBLY

SYSTEM

DESCRIPTION

RATING

TROUBLESHOOTING
FOR

THE

BC

GENERATOR
COMPONENT
GENERATOR
GENERATOR

AND

VOLTAGE
FIELD
INDEX

FABRICATED

.............................................................................

RESISTANCE

TROUBLESHOOTING

HERTZ

CHANGES

TOOLS

.......................................

................................................

....................................................

AND

ADJUSTMENTS

...........................................

VALUES

..........................

............................

(CYCLE)

............................................

.........................................

109
119

130

131
134
143

145
147
151

3

Westerbeke Generators

20 Amp DC
Circuit Breaker

Lube

Oil

Dipstick

4.5 KW

BeG

Marine Gasoline Generator

Fresh Water Coolant Fill

Exhaust Temperature
Switch

Oil Pressure

,,-

---..;~...i;.;._

Switch

lube

Oii

>::ill'oy·--

Zinc Anode

Heat Exchanger

DC

Battery Ground

Connection

Starter with Solenoid

Westerbeke Generators

4

4.5

KW

BeG

Marine

Gasoline

Generator

AC

Unit Data T

Fuel Shut - off

Snl.:llnnlf1

Air Intake Flame Arrester

Governor

lube

Oil Drain Hose

5

Westerbeke Generators

7.0

KW

BCG & BCGA

Marine

Gasoline Generator

20

Amp

DC

Circuit Breaker
Lube

Oil

Dipstick
Oil

Pressure

Switch

Heat

Exchanger.

Exhaust Temperature

DC

Battery Ground

Connection

-Rt~rt_

with Solenoid

Switch

.

Westerbeke Generators

6

7.0

KW

BCG & BCGA

Marine

Gasoline

Generator

Intake

Flame

Arrester

Control

·AC

Connections

Pane!

Outlet

---

Lube

Oil

Drain

Hose

---'--Water

Switch

Governor

Temperature

Sea

\(Vater

Zinc

Anooe

Pump

7

Westerbeke Generators

4.5

KW

UNIT 1.0.

BeG -

614

PLATES

(3.5

KW

BeG -

514)

These

serial

ator

1.0.

plate illustrations

number for future service

7.0

KW

BeG &

are

provided for the owner/operator"to fill

and

BCGA -614

part

needs.

(5.0

KW

BeG -

in

514)

the unit

serial

number

and

gener-

NOTE:

Output rating for

Westerbeke Generators

50

hertz units are reduced.

8

Refer

to

System

$pecifications.

4.5

KW

BCG

MARINE

GENERAL

GASOLINE

GENERATOR

SPECIFICATIONS

SET

Engine

Type

Governor
Combustion
Bore

& Stroke

Piston
Firing
Direction of
Maximum
Compression
Compression

Chamber

Displacement

Order

Rotation

Torque (at

Ratio
Pressure

(Limit of difference

Valve

Timing

1800

between

rpm)

cylinders)

Gasoline,
Vertical,

(6.0

Hoof,

four-cycle, three-cylinder,

in-line

bhp

at

flybail

Multi-sphere

2.44 x 2.38

33.4

cubic inches
1-2-3
Oockwise,

13.5Ibf-ft

10.0:1

198.1

psi

(14.0

(28

psi

[2.0

Intake

Opens

Intake

Ooses

overhead

1800

type,

type.

inches

when

kg/cm

kg/cm

32°

52°

valve

rpm,

maximum).

5%

speed

(62.0 x 60.5

(.547

liter)

viewed

2

at

)

2

])

from the front.

BTDC
ABDC

mechanism

regulation.

mm)

400

rpm

fresh

water-cooled

Valve

Seat

Valve

Oearance

(engine
Engine

warm)

Speed

Dimensions

Dry

Weight

Fuel

Consumption

Inclination

Angle

(all

directions)

Exhaust
Exhaust

Intake
Exhaust

Intake
Exhaust

1800
1500

Length:
Width:
Height:

Approx.

0.9

45°

0.010

rpm
rpm

U.S.

Opens

Ooses

45°

0.012
60

50

26.50

18.34

23.44

3031bs

gph

Continuous
Temporary

5SO

inches

inches

hertz.

hertz.

inches

inches

inches

(3.41

14°

20°

(not

BBDC

2SO

ATDC

(0.25

(137.4

Iph)

to

mm)

(0.30

(673.1

(465.8

(595.4

kgs)

at full

exceed

mm)

mm)

mm)

mm)

rated

20

output

min.)

(approximate).

9 Westerbeke Generators

INTAKE SYSTEM

4.5

KW

BCG SYSTEM SPECIFICATIONS

Carburetor (STD type)

PN

037832

Manifold

IGNITION SYSTEM

General

Distributor

Spark Plug Thread Size

Spark Plug Type

SYSTEM

FUEL

General

Manual with butterfly shaped valve, single barrel

with

U.S.C.G. approved flame arrester.

Naturally aspirated.

Battery ignition, 12-volts (negative ground),
distributor with points condenser, ignition coil
and spark plugs.

Conventional, contact-points and condenser.

14

mm

x 1.25 pitch (0.55 x 0.05 in.)

Westerbeke part number 33805

(Always identify the generator model

when ordering parts.)

Conventional carburetor type with fuel pump.

Fuel

Fuel Pump
PN

037818

Fuel Screens (on engine)

Air cleaner

Air Flow (engine combustion)

COOLING SYSTEM

General

Operating Temperature

Fresh Water Pump
PN

037919

Regular
of 89

12-volt DC; lift capacity 5

Reusable screen type (located at inlet

Metal screen type - cleanable.

18 cfm

Fresh water-cooled block, thermostatically-controlled

with a heat exchanger.

130 - 150°F (55 -

Centrifugal type, belt-driven, 1.13:1.

or

unleaded gasoline with an octane rating

or

higher.

ft

(1.5

m)

to

(0.509 cmm) at 1800 rpm.

66"C)

carburetor).

Westerbeke

Generators

10

4.5

KW

BCG SYSTEM SPECIFICATIONS

Raw Water Pump
PN

032617

Raw Water Row, at 1800 rpm

(measured before discharging

into exhaust elbow)

System Capacity (fresh water)

LUBRICATION SYSTEM

General

Oil Filter
PN 036918

Sump Capacity (not including filter)

Operating

Oil Grade

Oil Pressure (engine hot)

Positive displacement, rubber impeller, belt-driven.

3.75 - 4.0 U.S.

4.2 U.S. qts (3.9 liters)

Fully - Force fed type

crankshaft -driven.

Full flow, paper element, spin-on type.

3.0 qts (2.8 liters)

50 -

70 psi (3.5 - 4.9 kg/cm

API SPECIFICATION

gpm

(14.19

-15.14Ipm)

by

Trochoid pump,

2

)

OF

SE; SF;

SG

OR

SJ.

ELECTRICAL SYSTEM

Starting Battery

Battery Capacity

DC Battery Charger

Starter
PN 034552

DC No-Load Current

DC Cranking Current

OUTPUT LOSS

BY

ALTITUDE

12-volt, 24 A-H, (-) negative ground
(recommended) (28 A-H in cold areas).

24 - 28 (ampere-hours)

Integral controller 13-volt, 10
Oocated in the AC alternator).

12-volt, 1.2

90

amp

100

-125

8%

16% at 6,562 ft (2,000 m)
25% at 9,843 ft
35% at 13,124 ft

KW,

Magneto engaging type.

(max.) at 11.5 volts.

amps (engine cold).

at

3,281

ft (1,000 m)

(3,000 m)

(4,000 m)

amp

11

Westerbeke Generators

4.5

KW

BCG

SYSTEM

SPECIFICATIONS

TUNE-UP

AC

SPECIFICATIONS
Plug

Spark
Contact Point Clearance
Timing

OweliAngle

GENERATOR

General

Voltage

Gap

0.028 -0.031

0.017 -0.018
11° ± .5°

58

-SSO

Brushless,
Self

exciting. Capacitor saturated field excitation.
Pre-lubricated, single-bearing design.
Reconnectable
single-phase.

120

or
220

volts ­Voltage regulation: ±5% no-load to
full-load.

Frequency regulation: ± 3 hertz
no-load to full-load.

inches
inches

BTDC

four-pole, revolving field.

120/240

50

at

120

volts -

hertz.

(0.70 -0.80
(0.4 -0.5

1800

rpm

volts or

60

hertz

mm)

mm)

120/240

(5%)

volts,

Rating
60

50
AC

Generator

Air

at

(volts

AC)

Hertz

(1800

rpm)

Hertz

(1500

rpm)

Circuit Breaker

Cooling

Requirements,

1800

rpm

(60

hertz),

NQIE: Increase air supply

Engine
Requirements,
at

Combustion Air

1800

rpm

(60

hertz),

15%

for

50

hertz operation

120

volts

120/240
220

To

amperage

225 -240

18

volts

be

(1500

cfm

volts

rated

(0.509

at

120%

and

voltage output.

cfm

(6.4 -6.6

rpm).

cmm)

37.5

amps

37.5/18.7
16
of the generator's

amps

amps

cmm)

rated

Westerbeke Generators

12

7.0 KW BCG & BCGA MARINE GASOUNE GENERATOR SET

GENERAL SPECIFICATIONS

Engine Type

Governor
Combustion Chamber

& Stroke

Bore
Piston Displacement

Firing

Order

Direction of Rotation

(at

1800

Maximum Torque

rpm)
Compression Ratio
Compression Pressure

(Umit of difference between cylinders)
Valve

Timing

Gasoline, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism

(9.5

bhp at
Hoof,
Multi-sphere

2.62

51.6

1800

rpm, maximum).

flyball type,

type.
x 3.19 inches
cubic inches

5%

speed regulation.

(66.6 x 81

(.846

mm)

liter)
1-2-3
Clockwise, when viewed from the front.

13.5Ibf-ft

9.5:1

213.3

psi

(15.0

(28

psi [2.0 kg/cm

Intake Opens
Intake Closes

200

620 ABDC

kg/cm

2

])

BTDC

2

at 400 rpm

)

Valve

Seat

Angle

Valve

Oearance

(engine warm)

Engine

Speed

Dimensions

Dry Weight
Fuel

Consumption

Inclination

(all

directions)

Exhaust Opens
Exhaust Ooses

Intake

45

Exhaust
Intake

Exhaust
1800

1500
Length:

45

0.010

0.012

rpm 60 hertz.
rpm

26.50 inches

0

0

50

620 BBDC

200

inches

inches

hertz.

Width: 18.34 inches
Height:

Approx.

1.3

Continuous
Temporary

23.44
3281bs (148.8

U.S.

gph

inches (595.4mm)

(4.92

Iph) at full rated output (approximate).

0

14

200 (not to exceed

ATDC

(0.25

(0.30

(673.1

(465.8

kgs)

mm)

mm)

mm)

mm)

20

min.)

13

Westerbeke Generators

7.0

KW

BCG

& BCGA

SYSTEM

SPECIFICATIONS

INTAKE

Carburetor
PN037832

Manifold

IGNITION

General

Distributor
Spark
Spark

FUEL

SYSTEM

SYSTEM

(STD

SYSTEM

Plug

Thread

Plug

Type

type)

Size

Manual
with

Naturally aspirated.

Battery ignition, 12-volts
distributor with points condenser, ignition coil
and

Conventional, contact-points

14

Westerbeke

(Always

when

with butterfly

U.S.C.G.

spark

mm x 1.25

ordering

approved

plugs.

pitch

part number

identify the generator

parts.)

shaped

(0.55 x 0.05

valve,

flame

arrester.

(negative

and

33805

single

ground),

condenser type.

in.)

model

barrel

General
Fuel

Fuel

Pump

PN037818
Fuel

Screens
Air cleaner
Air

Flow

COOLING

General

Operating Temperature
Fresh

Water

PN

037919

(on

(engine

SYSTEM

Pump

engine)

combustion)

Conventional carburetor type with
Regular

of
12-volt

Reusable
Metal

26.8

Fresh
with a

130 -150°F
Centrifugal

or

unleaded

89

or

higher.

DC;

lift capacity 5 ft

screen

screen

cfm

water-cooled block, thermostatically-controlled

heat

type -

(0.758

exchanger.

(55 -66"C)

type,

gasoline with

type

Oocated

cleanable.

cmm)

at

belt-driven,

(1.5

1800

fuel

pump.

an

octane rating

m)

at inlet to carburetor).

rpm.

1.13:

1 to crankshaft.

Westerbeke Generators

14

Raw

Water

PN

032617

Raw

Water

(measured

exhaust

into

Pump

Flow,
before

elbow)

7.0

KW

at

1800

rpm

discharging

BCG

& BCGA

SYSTEM

Positive

3.75 -4.0

SPECIFICATIONS

displacement, rubber

U.S.

gpm

(14.19

impeller,

-15.14Ipm)

belt-driven.

System

Capacity

LUBRICATION

General

Oil

FAter

PN

036918

Sump

Capacity (not including filter)

Operating

on

Grade

ELECTRICAL

Starting Battery

Battery Capacity

(fresh

SYSTEM

Oil

Pressure

SYSTEM

water)

(engine

hot)

4.2

U.S.

qts

(3.9

liters)

Fully

- Force

fed

type by Trochoid

crankshaft-driven.
Full

flow,

paper

element,

3.0

qts

(2.8

liters)

50 -70

API SPECIFICATION OF

12-volt,
(recommended)

24 -28

psi

(3.5 -4.9

24

A-H,

kg/cm

(-)

negative

(28

A-H

(ampere-hours)

spin-on

2

)

S~

SF;

ground

in

cold

pump,

type.

SG

OR 81.

areas).

DC

Battery

Starter
PN

034552

DC

No-Load

DC

Cranking

OUTPUT

LOSS

Charger

Current

Current

BY

ALTITUDE

Integral controller

~ocated

12-volt,

in

1.2

the

KW,

90 amp (max.) at

100

-125

amps

8%

at

3,281

16%

at

6,562

25%

at

9,843

35%

at

13,124

15

13-volt,

AC

alternator).

10

amp

Magneto engaging

11.5

volts.

(engine

ft

(1,000

ft

(2,000

ft

(3,000

ft

(4,000

cold).

m)
m)
m)
m)

Westerbeke Generators

type.

7.0

TUNE-UP SPECIFICATIONS

KW

BCG &

BCGA

SYSTEM SPECIFICATIONS

Spark Plug

Contact Point

Timing

OweliAngle

AC

GENERATOR

General

Voltage

Gap

Oearance

0.028

-

0.031

inches (0.70 - 0.80 mm)

0.017 - 0.018 inches (0.4 -0.5 mm)

10° ± .5°

58 - 66"

Brushless, four-pole, revolving field.
Self

Pre-lubricated, single-bearing design.
Reconnectable 120 volts
single-phase.

120
220 volts - 50 hertz.
Voltage regulation:
full-load.

Frequency regulation: ± 3 hertz

no-load

BTDC at 1800 rpm

exciting. Capacitor saturated field excitation.

or

120/240 volts,

or

120/240 volts - 60 hertz

±5%

to

full-load.

no-load

to

(5%)

NOTE: BCGA models

Rating (volts

60 Hertz (1800 rpm)

50 Hertz (1500 rpm)

AC Circuit Breaker

Generator Cooling
Air Requirements, (60 hertz),
at 1800 rpm

NOTE: Increase air supply 15% for

Engine Combustion Air
Requirements, (60 hertz),
at 1800 rpm

AC)

are 60 hertz only. This model cannot be converted

120 volts

120/240 volts

220 volts

To be rated at 120%

amperage and voltage output.

250 cfm (7.0 cmm)

50

hertz operation (1500 rpm).

26.8 cfm (0.758 cmm)

to

50 hertz.

58 amps
58/29 amps

23 amps

ofthe

generator's rated

Westerbeke Generators

16

4.5

KWBCG

ENGINE SERVICE SPECIFICATIONS

NOTE: All
millimeters unless otherwise stated. For example, 0.002 (0.5 mm).

Cylinder

Lower gasket surface distortion

Lower surface grinding tolerance

Manifold gasket surface distortion

Valve

Width

Angle (IN)

Head

Seat

dimensions and specifications contained in this section are given In inches then

Specified

(IN &

EX)

(OUT)

0.0472 - 0.0630

Value

9.9370

(100 mm)

(1.2

-1.6

mm)

30° - 45° - 70°

- 45° - 70°

25°

Allowable

0.0039

(0.10 mm)

3.9291

(99.8 mm)

0.0039

(0.10 mm)

0.0906

(2.3 mm)

Umit

Recession (IN)

(EX)

Valve

Guide

Inner diameter (IN &

Projection height

Valves

Seat width (IN &

Seat angle

Bush

EX)

EX)

0.0591

0.0748 - 0.0945

0.2756 - 0.2764

(7.000

0.5984 - 0.6220

(15.2 - 15.8 mm)

0.0472 - 0.0630

- 0.0787

(1.5 - 2.0 mm)

(1.9 - 2.4 mm)

- 7.020 mm)

(1.2 - 1.6 mm)

44°30'

0.0984

(2.5 mm)

0.1142

(2.9 mm)

0.2n4

(7.045 mm)

0.0906

(2.3 mm)

17

Westerbeke Generators

Valves

(continued)

Specified

Value

Allowable

Limit

Valve head stock thickness (IN)

(EX)

Valve stem outer diameter (IN)

(EX)

Overall length (IN)

(EX)

Stem head recession

Valve

Spring

0.0394

0.0512 - 0.0669 0.0433

0.2740

(6.96 - 6.975 mm)

0.2738 - 0.2744 0.2730

(6.955 - 6.970 mm)

- 0.0551

(1.0

-1.4

mm) (0.9 mm)

(1.3

-1.7

mm)

- 0.2746

4.4228

(112.34 mm)

4.4346

(112.64 mm)

0.0354

(1.1

0.2732

(6.94 mm)

(6.935 mm)

0.008

(0.2

mm)

mm)

Free length 1.7795 -1.8110

46.0 mm) (44.3 mm)

(45.2 -

Length as

Tension as

Squareness

Valve

Rocker arm inner diameter 0.6299 - 0.6306

Valve rocker shaft outer diameter 0.6287 - 0.6294

Shaft

installed 1.4961

(38.0 mm)

installed

Rocker

to

Shaft

and

Rocker

arm oil clearance 0.0005 - 0.0020 0.0031

Arm

58.2 - 64.8 Ib 50.71b

(26.4 - 29.4 kg) (23.0 kg)

0.0630

(1.6 mm)

(16.000 -16.018

(15.968 - 15.988 mm) (15.955 mm)

- 0.050 mm) (0.08 mm)

(0.012

1.7441

0.6313

mm) (16.035 mm)

0.6281

Westerbeke

Generators

18

Cylinder

Block

Specified

Value

Allowable

Umit

Upper gasket surface distortion

Cylinder block height

Cylinder bore

Cylinder

Piston,

Piston

Piston ring end

Piston ring end

out

of

roundness and taper

Piston

to

Pin,

and

Piston

cylinder clearance 0.0014 - 0.0022 0.0039

gap

compression No. 1 0.0098 - 0.0157

gap

compression

Ring

No.2

0.0020 0.0031

(0.05

mm) (0.08 mm)

8.6575 - 8.6653 8.6535

(219.9 -

(62.00

(0.035

220.1

mm) (219.8 mm)

2.4409 - 2.4421

- 62.03 mm)

- 0.055 mm)

- 0.40 mm)

(0.25

0.0079 - 0.0138 0.0256

(0.20

- 0.35 mm) (0.65 mm)

0.0039

(0.1

0.0012

(0.03

(0.10 mm)

0.0256

(0.65 mm)

mm)

mm)

gap

Piston ring end

Piston ring side

Piston ring side

Piston outer diameter

Piston inner diameter

Piston pin outer diameter

Piston

to

piston pin clearance 0.0002 - 0.0004 0.0020

oil 0.0079 - 0.0276 0.0394

clearance compression No. 1 0.0012 - 0.0028 0.0047

clearance compression NO.2 0.0008 - 0.0024

for

(0.20

- 0.70 mm) (1.00 mm)

- 0.07 mm)

(0.03

(0.02

- 0.06 mm)

2.4392 - 2.4403

(61.955 -61.985 mm)

piston pin 0.6299 - 0.6302

(15.999 - 16.008 mm)

0.6296 - 0.6299

(15.991 - 16.000 mm)

(0.005

- 0.011 mm) (0.050 mm)

(0.12 mm)

0.0043

(0.11

mm)

19

Westerbeke

Generators

Connecting

Rod

Specified

Value

Allowable

UrnH

Rod bend

Rod twist

Pin portion width

Rod width

Big end thrust clearance 0.0059 - 0.0098

Connecting rod bearing oil clearance 0.0008 - 0.0017 0.0028

Crankshaft

Crankshaft bend 0.0012

0.7874 - 0.7894

(20.00

- 20.05 mm)

0.7795 - 0.7815

(19.80 -19.85 mm)

(0.15 - 0.25 mm) (0.30 mm)

(0.020

- 0.044 mm) (0.07mm)

0.0020

(0.05 mm)

0.0020
mm)

(0.05

0.0118

(0.03

mm)

Uneven wear

Main journal diameter 1.6526 - 1.6535

Crank pin diameter 1.4557 - 1.4567

Crankshaft bearing oil clearance

Side clearance

Camshaft

Camshaft thrust clearance 0.0020 - 0.0118 0.0177

Camshaft bend

of journal and pin section

0.0008

(0.02 mm)

(41.976 -

(36.976 - 37.000 mm)

(0.020 - 0.044 mm) (0.07mm)

(0.02 - 0.22 mm) (0.30 mm)

42.000 mm)

0.0008 - 0.0017

0.0008 - 0.0087

(0.05

- 0.30 mm)

0.0028

0.0118

(0.45 mm)

0.0012

(0.03 mm)

Westerbeke

Generators

20

Camshaft (continued)
Cam

lobe height

(IN)

Specified Value Allowable

1.3858 -1.3913

(35.20 -35.34

mm)

1.3819

(35.10

Umit

mm)

(EX)

Camshaft journal diameter

Front

Center

Rear

Cylinder

head

journal diameter

Front

Center

Rear

1.3835 -1.3890

(35.14 -35.28

1.6709 -1.6717

(42.44 -42.46

1.6512

(41.94 -41.96

1.1791

(29.95 -29.97

1.6732 -1.6742

(42.500 -42.525

1.6535 -1.6545

(42.000 -42.025

1.1811

(30.000 -30.021

-1.6520

-1.1799

-1.1819

mm)

mm)

mm)

mm)

mm)

mm)

mm)

1.3799

(35.05

mm)

Uneven

Camshaft journal section oil clearance

Timing Belt Pulley
Camshaft pulley outer diameter

Crankshaft pulley outer diameter

wear of camshaft journal

Front

and

Center

Rear

0.0016 -0.0033

(0.040 -0.085

0.0012 -0.0028

(0.030 -0.071

4.3556 -4.3627

(110.633 -110.813

2.1536 -2.1575 2.1512

(54.701 -54.801

mm)

mm)

mm)

mm)

(110.57

0.0016

(0.04

0.0051

(0.13

0.0047

(0.12

4.3531

(54.64

mm)

mm)

mm)

mm)

mm)

21

Westerbeke Generators

Flywheel

Specified

Value

Allowable

Umit

Runout

STD

Piston

STO

OIS

&

OIS,

U/S

Parts

Ust

Crankshaft thrust washer Oversize
Crankshaft bearing Oversize
Connecting rod bearing Oversize
Piston with pin Oversize
Piston ring Oversize
Valve guide bush None

Crankshaft thrust washer Oversize

0.0049 (0.125 mm)

0.0098 (0.25 mm)

Crankshaft bearing None
Connecting rod bearing None
Piston with pin Oversize

0.0098 (0.25 mm)

0.0197 (0.50 mm)

0.0394 (0.75 mm)

0.0039 (0.100 mm)

0.0039

(0.10

mm)

UlS

Piston ring Oversize

0.0098 (0.25 mm)

0.0197 (0.50 mm)

0.0394 (0.75 mm)

0.0039 (0.100 mm)

Valve guide bush Oversize

0.0012 (0.03 mm)

Crankshaft thrust washer

Crankshaft bearing Oversize

Connecting rod bearing Oversize

Piston with pin
Piston ring None
Valve guide bush None

None

0.0098 (0.25 mm)

0.0098 (0.25 mm)

None

Westerbeke Generators

22

Crankshaft

Thrust

Washer

Specified

Value

Allowable

Umit

STD Thrust washer thickness

No.3

crank journal width

O/S 0.0049 Thrust washer thickness

(0.125 mm)

No.3

crank journal width

O/S 0.0098 Thrust washer thickness

(0.250 mm)

No.3

crank journal width

Crankshaft

STD Bearing center thickness

Bearing

0.0764 - 0.0783

(1.94O

- 1.990 mm)

0.8661

- 0.8681

(22.oo - 22.05 mm)

0.0813 - 0.0833

(2.065 - 2.115 mm)

0.8760 - 0.8780

(22.25 - 22.30 mm)

0.0862 - 0.0882

(2.190 - 2.240 mm)

0.8858 - 0.8878

- 22.55 mm)

(22.50

0.0783 - 0.0785

(1.990 - 1.994 mm)

U/S 0.0098

(0.25 mm)

U/S 0.0197

(0.50 mm)

Cylinder block journal section

Crank journal DIA

Bearing center thickness

Cylinder block journal section DIA

Crank journal DIA

Bearing center thickness

Cylinder block journal section

Crank journal DIA

DIA

DIA

1.8110 -1.8120

(46.000 - 46.024 mm)

1.6526 - 1.6535

(41.976 - 42.000 mm)

0.0636 - 0.0637

(1.615

(41.733 -41.743 mm)

(35.482 - 35.492 mm)

-1.619

None

1.6430 - 1.6434

0.0685 - 0.0687

(1.74O

-1.744

None

1.3969 - 1.3973

mm)

mm)

23

Westerbeke Generators

Connecting

Rod

Specified

Value

Allowable

Limit

STD

U/S

U/S

Bearing center thickness 0.0587 - 0.0588

Big end inner diameter 1.5748 - 1.5757

Crank pin diameter 1.4557 - 1.4567

0.0098

(0.25

0.0197

(0.50

Bearing center thickness 0.0636 - 0.0637

mm)

Big end inner diameter None

Crankpin diameter

Bearing center thickness

mm) (1.740

Big end inner diameter None

Crank pin diameter

(1.490 - 1.494 mm)

(40.000 - 40.024 mm)

(36.976 -

(1.615

(36.732 - 36.742 mm)

(35.482 - 35.492 mm)

37.000 mm)

-1.619

1.4461 - 1.4465

0.0685 - 0.0687

-1.744

1.3969 - 1.3973

mm)

mm)

Piston

For each kind listed below, the cylinder bore finishing DIA =

0.0014 in. [0.035

STD

0.0098 Piston outer diameter 2.4494 - 2.4498
(0.25 mm) (62.215 - 62.225)

0.0197 Piston outer diameter 2.4592 - 2.4596
(0.50 mm) (62.465 - 62.475 mm)

0.0295 Piston outer diameter
(0.75 mm) (62.715 - 62.725 mm)

0.0394
(1.00 mm)

mm]

- 0.0022 in. [0.055 mm])

Piston outer diameter 2.4396 - 2.4400

Piston outer diameter 2.4789 - 2.4793

(O/S

piston outer DIA) + (Oil clearance

(61.965 - 61.975 mm)

2.4691

(62.965 - 62.975 mm)

- 2.4695

Westerbeke

Generators

24

Valve

Guide

Bush

Specified

Value

Allowable

Umit

STD Bush outer diameter

OIS

Oil

Pump

Side clearance

Tip clearance

Drive

to

gear body clearance

Relief valve opening pressure

Ignition

Coil

Bush outer diameter

0.4742 - 0.4748

(12.045 -

(12.075 -

(0.035

(0.17 - 0.24 mm)

(0.06

49.77 ­(3.5

12.060 mm)

0.4754 - 0.4760

12.090 mm)

0.0014 - 0.0028

- 0.070 mm)

0.0067 - 0.0094

0.0024 - 0.0047

- 0.12 mm)

61.46lbs/in

-4.3

kg/crn2)

0.0059
mm)

(0.15

0.0138

(0.35 mm)

0.0098

(0.25 mm)

2

Primary resistance Q

Secondary resistance KQ

External

Distributor

Heel gap

Dwell angle

Condenser capacity

Resistive

Cord resistance KQ/m

resistance Q

pF

Cord

1.2

±0.12Q

26

±3.9KQ

1.7

±0.17Q

0.018

(0.45 mm)

0.25pF

10

-22

KQ/m

25

Westerbeke Generators

V Belt

Specified Value

Allowable

Limit

Belt deflection - inches (mm)

0.37 - 0.45/22.05
(9.5 - 11.5/10 kg)

Ib

Westerbeke Generators

26

7.0

KW

BCG &

BCGA

ENGINE SERVICE SPECIFICATIONS

NOTE: All dimensions and specifications contained in this section are given in inches then
millimeters unless otherwise stated. For example, 0.002 (0.5 mm).

Cylinder Head

Lower gasket surface distortion

Lower surface grinding tolerance

Manifold gasket surface distortion

Valve Seat
Width (IN &

EX)

Angle (IN)

(OUT)

Recession (IN)

Specified

Value

9.9370

(100 mm)

0.0472 - 0.0630
(1.2

-1.6

mm)

0

0

- 45

45

-

0

70

-

0

70

-

30
25

0.0787 - 0.0984
(2.0 -2.5 mm)

Allowable

Umit

0.0039

(0.10 mm)

3.9291

(99.8 mm)

0.0039

(0.10 mm)

0.0906

(2.3 mm)

0

0

0.1181

(3.0 mm)

(EX)

Valve

Guide

Inner diameter (IN &

Projection height

Valves
Seat width (IN &

Seat angle

Bush

EX)

EX)

0.1437 - 0.1634

(3.65 - 4.15 mm)

0.2756 - 0.2764

(7.000 - 7.020 mm)

0.5984 - 0.6220

(15.2 - 15.8 mm)

0.0472 - 0.0630
(1.2

-1.6

mm)

0

44

30'

0.1831

(4.65 mm)

0.2n4

(7.045 mm)

0.0906

(2.3 mm)

27

Westerbeke Generators

Valves

(continued)

Specified

Value

Allowable

Limit

Valve head

Valve stem outer diameter (IN) 0.2740 - 0.2746 0.2732

Overa" length

Stem head recession

Valve

stock

Spring

thickness (IN) 0.0394 - 0.0551 0.0354

(1.0

-1.4

mm) (0.9 mm)

(EX)

(EX)

(IN) 4.3756

(EX)

0.0512 - 0.0669 0.0433
(1.3

-1.7

mm)

(6.96 - 6.975 mm) (6.94 mm)

0.2738 - 0.2744 0.2730

(6.955 - 6.970 mm) (6.935 mm)

(111.14 mm)

4.3480

(110.44 mm)

(1.1

0.008

(0.2

mm)

mm)

Free length

Length as installed 1.4961

Tension as installed 58.2 -

Squareness

Valve

Rocker

Rocker arm inner diameter

Valve rocker shaft outer diameter 0.6287 -0.6294

Shaft

to

Shaft

and

arm oil clearance

Rocker

Arm

1.7795

(45.2 -

(26.4 - 29.4 kg) (23.0 kg)

0.6299 - 0.6306 0.6313

(16.000 -16.018

(15.968 - 15.988 mm) (15.955 mm)

0.0005 - 0.0020 0.0031

(0.012

-1.8110 1.7441

46.0 mm) (44.3 mm)

(38.0 mm)

64.8Ib

0.0630

(1.6 mm)

mm) (16.035 mm)

- 0.050 mm) (0.08 mm)

SO.71b

0.6281

Westerbeke

Generators

28

Cylinder

Block

Specified

Value

Allowable

Umit

Upper gasket surface distortion

Cylinder

Cylinder bore

Cylinder out

Piston,

Piston

Piston ring end

Piston ring end

block

height

of

roundness and taper

Piston

to

Pin,

and

cylinder clearance

gap

compression No. 1

gap

compression

Piston

Ring

No.2

0.0020 0.0031

(0.05

mm) (0.08 mm)

9.2874 - 9.2953

236.1

(235.9 -

2.6220 - 2.6232 0.0039

(66.60 -66.63 mm)

0.0016

(0.040

- 0.060 mm)

0.0098 - 0.0157

(0.25

- 0.40 mm) (0.65 mm)

0.0079 - 0.0138

- 0.35 mm) (0.65 mm)

(0.20

mm)

- 0.0024

9.2834

(235.8 mm)

(0.1

0.0012

(0.03

0.004

(0.11

0.0256

0.0256

mm)

mm)

mm)

Piston ring end

Piston ring side

Piston ring side

Piston outer diameter

Piston inner diameter

Piston pin outer diameter

Piston

to

gap

oil 0.0079 - 0.0276 0.0394

clearance compression No. 1

clearance compression

for

piston pin clearance 0.0002 - 0.0004

(0.20

- 0.70 mm) (1.00 mm)

0.0012 - 0.0028 0.0047

(0.03

- 0.07 mm) (0.12 mm)

No.2

piston pin 0.7086 - 0.7090

0.0008 - 0.0024 0.0043

(0.02

- 0.06 mm)

2.6201 - 2.6213

(66.550 - 66.580 mm)

(17.999 - 18.008 mm)

0.7083 - 0.7087

(17.991

(0.005

- 18.000 mm)

- 0.011 mm)

(0.11

mm)

0.0020

(0.050 mm)

29

Westerbeke

Generators

Connecting

Rod

Specified

Value

Allowable

UmH

Rod bend

Rod twist

Pin portion width

Rod width

Big end thrust clearance

Connecting rod bearing oil clearance

Crankshaft

Crankshaft bend

0.0020

(0.05

0.0020

(0.05

0.7874 - 0.7894

(20.00

- 20.05 mm)

0.7795 - 0.7815

(19.80 - 19.85 mm)

0.0059 - 0.0098

- 0.25 mm)

(0.15

0.0008 - 0.0017 0.0028

(0.020

- 0.044 mm) (0.07 mm)

0.0118

(0.30 mm)

0.0012

(0.03

mm)

mm)

mm)

of

Uneven wear

Main

journal diameter

Crank pin diameter

Crankshaft bearing oil clearance

Side clearance

Camshaft

Camshaft thrust clearance 0.0020 - 0.0118

Camshaft bend

journal and pin section

1.8101

(45.976 - 46.000 mm)

1.5739 - 1.5748

(39.976 -

0.0008 - 0.0017 0.0028

(0.020

0.0008 - 0.0087 0.0118

(0.02

(0.05

- 1.8110

40.000 mm)

- 0.044 mm) (0.07 mm)

- 0.22 mm) (0.30 mm)

- 0.30 mm) (0.45 mm)

0.0008

(0.02

0.0177

0.0012

(0.03

mm)

mm)

Westerbeke

Generators

30

Camshaft (continued)

Specified Value

Allowable

Umit

Cam

lobe height

(IN)

(EX)

Camshaft journal diameter

Front

Center

Rear

Cylinder

head

journal diameter

Front

Center

1.3752 -1.3807

(34.93 -35.07

1.3728 -1.3783

(34.87 -35.01

1.6709 -1.6717

(42.44 -42.46

1.6512

(41.94 -41.96

1.1791

(29.95 -29.97

1.6732 -1.6742

(42.500 -42.525

1.6535 -1.6545

(42.000 -42.025

-1.6520

- 1

.1799

mm)

mm)

mm)

mm)

mm)

mm)

mm)

1.3701

(34.80

1.3681

(34.75

mm)

mm)

Rear

Uneven

Camshaft journal section oil clearance

TIming Belt Pulley
Camshaft pulley outer diameter

Crankshaft pulley outer diameter

wear of camshaft journal

Front

and

Center

Rear

1.1811

(30.000 -30.021

0.0016 -0.0033

(0.040 -0.085

0.0012 -0.0028 0.0047

(0.030 -0.071

4.3556 -4.3627

(110.633 -110.813

2.1536 -2.1575 2.1512

(54.701 -54.801

-1.1819
mm)

mm)

mm)

mm)

mm)

(110.57

0.0016

(0.04

0.0051

(0.13

(0.12

.4.3531

(54.54

mm)

mm)

mm)

mm)

mm)

31

Westerbeke Generators

Flywheel

Specified Value Allowable Limit

Runout

STD

Piston & OIS,

STO

OIS

U/S

Parts List

Crankshaft thrust

washer
Crankshaft bearing
Connecting

rod

bearing
Piston with pin
Piston ring
Valve

guide

bush

Crankshaft thrust washer

Crankshaft bearing
Connecting
Piston

rod

with pin

bearing

Oversize
Oversize
Oversize
Oversize
Oversize

None

Oversize

0.0049 (0.125

0.0098 (0.25

None
None

Oversize

0.0098 (0.25

0.0197 (0.50

0.0394 (0.75

0.0039 (0.100

mm)

mm)

mm)
mm)
mm)

mm)

0.0039

(0.10

mm)

U/S

Piston

Valve

Crankshaft thrust
Crankshaft bearing

Connecting

ring

guide

bush

rod

washer

bearing

Oversize

0.0098 (0.25

0.0197 (0.50

0.0394 (0.75

0.0039 (0.100

Oversize

0.0012 (0.03

None

Oversize

0.0098 (0.25

Oversize

0.0098 (0.25

Piston with pin None
Piston

Valve

ring

guide

bush

None
None

mm)
mm)
mm)

mm)

mm)

mm)

mm)

Westerbeke Generators

32

Crankshaft Thrust Washer

Specified Value

Allowable

Umit

STO

OIS

0.0049 Thrust washer thickness

(0.125 mm)

OIS

0.0098 Thrust washer thickness

(0.250 mm)

Thrust washer thickness

No.3

crank journal width

No.3

crank journal width

No.3

crank journal width

Crankshaft Bearing

STO

Bearing center thickness

0.0764 -0.0783

(1.940 - 1.990

0.8661 -0.8681

(22.00 - 22.05

0.0813 - 0.0833

- 2.115

(2.065

0.8760 - 0.8780

(22.25 -22.30 mm)

0.0862 - 0.0882

(2.190 -2.240

0.8858 - 0.8878

(22.50

- 22.55

0.0783 - 0.0785

mm)

mm)

mm)

mm)

mm)

(1.990 - 1.994 mm)

Cylinder block

Crank journal

U/S

0.0098 Bearing center thickness

(0.25

mm)

Cylinder block

Crank journal

journal section

OIA

journal section

OIA

OIA

OIA

1.9685 - 1.9694

(50.000 - 50.024

1.8101-1.8110

(45.976 - 46.000 mm)

0.0833 -0.0834

(2.115 -2.119 mm)

None

1.8005 - 1.8009

(45.732 - 45.742

mm)

mm)

33

Westerbeke Generators

Connecting Rod

Specified Value Allowable

Umit

STO

U/S

0.0098

(0.25

Piston

each

For

0.0014
STO

In.

Bearing center thickness

Big

end

inner diameter

Crank pin diameter

Bearing center thickness

mm)

Big

end

inner diameter None

Crankpin diameter

kind

listed below, the cylinder bore finishing

[0.035

mm] -

0.0022

in.

[0.055

mm])

Piston outer diameter

0.0587 -0.0588

(1.490 -1.494

1.6929 -1.6939

(43.000 -43.024

1.5739 -1.5748

(39.976 -40.000

0.0636 -0.0637

(1.615

-1.619

1.5642 -1.5646

(38.732 -39.742

OIA

=

(O/S

piston outer

2.6201 -2.6213

(66.55 -66.58

mm)

mm)

mm)

mm)

mm)

mm)

OIA) + (Oil

clearance

0.0098
(0.25

0.0197
(0.50

0.0295
(0.75

0.0394
(1.00

mm)

mm)

mm)

mm)

Piston outer diameter

Piston outer diameter

Piston outer diameter

Piston outer diameter

2.6299 -2.6311

(66.80 -66.83

2.6398 -2.6409

(67.05 -67.08

2.6496 -2.6508

(67.30 -67.33

2.6594 -2.6606

(67.55 -67.58

mm)

mm)

mm)

mm)

Westerbeke Generators

34

Valve Guide

Bush

Specified Value

Allowable

Umit

STD

OIS

Oil

Pump

Side clearance

Tip clearance

Drive

to

gear body clearance

Relief valve

Ignition

opening pressure

Coil

Bush outer diameter

Bush outer diameter

0.4742 - 0.4748

(12.045

- 12.060 mm)

0.4754 -0.4760

(12.075

- 12.090 mm)

0.0014 -0.0028

- 0.070 mm)

(0.035

0.0067 - 0.0094

- 0.24 mm)

(0.17

0.0024 - 0.0047

- 0.12 mm)

(0.06

49.77 - 61.46 Ibs/in2
(3.5 - 4.3 kg/cm2)

0.0059

(0.15

0.0138

(0.35

0.0098

(0.25

mm)

mm)

mm)

Primary resistance Q

Secondary resistance

External resistance Q

Distributor

Heel gap

Owellangle

Condenser capacity JlF

Resistive Cord

Cord resistance

KQ/m

KQ

1.2

26

1.7

(0.45

0.25JlF

- 22

10

±0.12

Q

±3.9KQ

±0.17

Q

0.018

mm)

KQ/m

35

Westerbeke Generators

VBeH

Specified Value

Allowable Limit

Belt deflection - inches (mm)

0.37 -0.45/22.05
(9.5 - 11.5/10 kg)

Ib

Westerbeke Generators

36

ENGINE

Cylinder Head and Combustion Chamber

DESCRIPTION

For improved
have

been

designed to incorporate the following constructional

1.

With

a view to obtaining a uniform

been

arranged symmetrically.

2.

The

combustion chamber

10.0.

to

fuel

efficiency

and

increased engine output, the cylinder

and

has

been

strong intake

made

compact.

No.2 Intake valve No.3 Intake valve

swirl,

In

addition, the compression ratio

head

and

features.

the valve (for No.2

combustion chamber

and

No.3

cylinders)

has

been

increased

has

Symmetrical valve
(for No.2. 3

cylinders)

Combustion chamber

arrangement

37

Westerbeke Generators

Cylinder

Head

Cover

The cylinder head cover is made
thereby, reducing the noise

Cylinder

The skirt section

Block

of

the cylinder block has employed a deep skirt type. The water jacket has adopted a full

of

sheet metal. In addition, the entire head cover has dual construction;

level. It also serves as an oil separator.

jacket which ensures good cooling performance. The water pump
the cylinder block. Furthermore, the upper section
cooling water directly flows
combustion chamber.
of

the cylinder block.

to

the cylinder head; thus, enhancing the cooling performance around the

Also, the oil separator and the passage

of

the cylinder block has been so constructed that the

of

blow-by gas has been provided at the front

is

located at the

top

gasket surface

of

~C-~

~

~JlJJ',.

From water,

Water

To ventilation hose

Oil

p

p,um

,_

J

"IY;,;;~rl~~

\l

~r>,

pump

separa~/

c~~~

To cylinder head

o/)f~

,r::

O/~~,

v

~~

V!'.

'(fJ.J

J"---https://manualmachine.com/~\https://manualmachine.com/

installing portion

~.

( f'

it

ID~(

~ . ~

::

L

{I::

•

i

Westerbeke Generators

38

Pistons

The piston rings have adopted steel rings. Moreover, the sliding surface with the cylinder has undergone a
tufftriding treatment. The second ring is a tapered ring made

addition, the oil ring has employed a combination type.

and

Piston

Rings

of

a special cast Iron and has an undercut. In

)

Compression ring

Compression ring No.2

Oil ring

Connecting

The connecting rod has an I-shaped sectional view. The connecting rod is assembled

using a press-fit method.

Rods

No.1

to

the piston pin,

Front Mark

Front Mark

39 Westerbeke Generators

Crankshaft and Bearings
The

crankshaft

noise

level.

has

employed

the crankshaft

a total

bearing

balance

has

adopted a

type. counter

bearing

weight.

having

Futhermore.

no

oil

groove

for

reduced

at

the lower

metal-tapping

surface.

Thrust washer

Crankshaft bearing lower side
(oil groove less)

Westerbeke Generators

40

Valve Actuating Mechanism
The

valve

actuating

for the No.2

and

orderto cope with

have

arms
means

been

of bolts.

mechanism

No.3

cylinders

higher-speed

employed.

In

is

of a single

are

arranged

rotation of the

addition, the

overhead

symmetrically,

engine,

valve

unequally pitched

rocker

camshaft.

and

shafts

are

For increased engine output, the

the intake

valves

valve

have

springs

been

enlarged.

and

aluminum rocker

mounted directly to the cylinder

valves

head

In

by

41

Westerbeke Generators

Camshaft

The

improved

speed

Dog

force

operation

clutch

of

the

cam

of

grooves

camshaft

profile,

the

camshaft.

for

driving

has

in

combination

the

been

sustained

with

distributor

by a camshaft

have

an

appropriate

been

provided

thrust

valve

at

ring.

the

timing,

rear

end

has

of

made

the

camshaft.

possible

The

mm

the

(inch)

high

thrust

Camshaft journal No.1
Camshaft journal No.2
Camshaft journal No.3
Cam lift (intake)
Cam lift (exhaust)
Fuel pump cam lift

IN

open

IN

close

TOC

BOC

EX

close

EX

open

EX

0

42.5 (1.67)

42.0 (1.65)

30.0 (1.18)
(0.207)

5.27

5.31 (0.209)

2.0

0

IN

Timing Belt

For

improved

timing

belt

Nominal name

_._-_._--------

Pitch peripheral length mm (inch)

._--_

...

,._--------_.---

Pitch

_.

Tooth numher

Belt width

Westerbeke Generators

reliability, a round

has

been

installed.

of

helt 99Y16

mm

_

..

mm (inch)

toothed

792

------_.

(inch) 8 (0.31)

(31.18)

99

16.0

42

~

Core cord

------10

00

oooJo

Core cord

0 0

001

Timing Belt Pulley

For reduced weight, the timing belt pulley at the camshaft side has been made using sheet metal.

F mark

Crankshaft

pulley

,

Camshaft pulley

(Upper)

~

Flange bolt

(Lower)

Timing Belt Tensioner

The

timing

belt tensioner has employed a
method in which no tensioner spring is used.
Because
can be performed
bolts

of this design, the tension adjustment

easily

by

means of general

(MS)

during disassembly and reassembly.

Timing

43

belt

tensioner

Westerbeke Generators

Timing

The timing belt cover consists

Belt

Cover

of

No.1 and No.2 sections.
Rubber bushes have been provided at all the mating
sections with the engine proper; thereby, preventing
vibration from transmitting from the engine proper.

Timing

belt

cover No.2

Valves

and

Valve

Springs

Both intake and exhaust valves have adopted heat-resis­tant steel. In addition, the valve springs have employed
an unequally pitched type with an unconventional cross-

of

section; thus, preventing the occurrence

surging.

Valve Specifications

Item

__ .

_.

__

.-

- --

Diameter
section

Overall length mm (inch)

Diameter
(central section) mm (inch) (0.28)

or

valve head

or

valve stem section 7.0

H._.

mm (inch)

IN

30 26

(1.18)

112.34
(4.42) (4.43)

EX

(1.02)

112.64

<-

Valve Spring Specifications

Free length mm (inch)
Wire diameter mm (inch)
Effective winding
Coil

outer

Spring constant kg/mm (\b/inch)

diameter

number

mm(inch)

45.6 (4.35)

4.0 (0.16)

5.75

27.5

(1.08)

3.67/4.3

(8.09210.169)

Westerbeke

Generators

44

Valve

Rocker

The

valve
bolts.
rocker
side.

Valve

Rocker

For

reduced

of

aluminum.

contact

Shafts

rocker

The

positions

arm

differ

Arms

weight,

High-chromium

section

shafts

of

between

the

with

the

have

been

the

oil-lubricating

the

intake

valve

rocker

iron

camshaft.

installed

and

arm

has

been

by

means

holes

exhaust

has

been

casted

for

valve

made

on

of

the

the

(Q

COJ

Lubricating hole

for

o

(OJ

Direct installation

W"h"',

l,~

Intake side shaft

CO)

rocker arm

o (OJ 0

Exhaust side shaft

4

~

'f .

~

0

COJ·

Valve

The

valve

length

~on

Item
Valve clearance (during hot)

Guide

Bushes

guide

between

bushes

the

intake

and

Stem

differ

and

mm (inch)

Oil

in

their

exhaust

IN

0.25

(0.0098) (0.0118)

Seals

material

valve

and

sides.

EX

0.30

overall

High-chromium iron

Exhaust side Intake side

48mm

Heat-resistant steel Chamfer

~

50mm

tip

45

Westerbeke

Generators

GENERATOR

OVERHAUL

Section .........................................................................

PREPARATIONS
DISASSEMBLY

Removing
ENGINE
Removal

Timing Belt

REMOVING
FROM

CYUNDER
CYUNDER
SPECIAL

DiSASSEMBLy

of

THE

SERVICE

FOR

OVERHAUL..

FOR

OVERHAUL

the Generator

External
Removal

THE

CYUNDER
HEAD
BLOCK

Parts

.........................................................

CYUNDER

DISASSEMBLY

DISASSEMBLY
TOOLS

................................

....................................

End

from the

...................................................

and

Subassemblies ...............

HEAD

BLOCK.

.......................................

..............................................

Engine

...................................

.................................

.............

Page

47
48

..48

50
50
51

53
54
57

61

NOTE:
parts.
part numbers for

Special

Refer

to the

Service

"SPECIAL

each

Tools

tool.

are

available to help

SERVICE

TOOLS"

in

the

removal

section of this

or installation of engine

manual

for illustrations

and

Westerbeke Generators

46

1.

Remove

2.

Shut off

3.

Unbolt the unit

4.

Once

5.

Clean

and

at

the overhaul shop, drain

the exterior of the generator of

all

AC

disconnect

PREPARATIONS

and

DC

power connections from the

all

fuel

lines,

raw

water

and

carefully move it to the overhaul shop.

all

lubricating

all

oil

and

FOR

OVERHAUL

unit.

and

exhaust connections.

oil

and

coolant from the engine

dirt deposits.

and

exchanger system.

~lltll

'.

Il'~

','

, .

:c~~

1\llill\I',11III

I

I 11'1 I • ,

I

il : :;

\1:\

:.:!; ~ :

~

..

'

.......

I

ill!

.",

,o!

.:

: : .

IIll'lW;\;i;H'

: 0

~.

I

'

Oil

Sump

..

J."

,-.

./

,"

Drain

.

Heat Exchanger Drains

47 Westerbeke Generators

DISASSEMBLY

Removing the Generator End from the Engine

1.

Disconnect
connections,
connections. Unbolt the control
generator housing

2.

Supporting the rear of the

generator housing from the back plate
mounting

NOTE:
the
of this

harness

rails.

The

"FIELD

manual

leads from the engine

and

tag

and

as

one

Housing Puller

FABRICATED

will help

mark

all
panel

assembly.

engine,

unbolt the

Tool

TOOLS"

make

the

harness

from

and

listed

in

section

removal
of the generator's stator housing much
easier.

3.

Take

off the removable cover

and

support web
cases,

the rear support bearing may be pulled off the rotor shaft along with the generator housing.

rotor

shaft,

and,

with the

aid

carefully draw the generator housing off the

FOR

OVERHAUL

~<~~~i

....

,,~)v

" ,

I

."

I

.~.

I

..

' I

,r·

I

, ( I

I i

" I

" I I

of the Housing Puller Tool attached to the

rear

support bearing.

I

,

end

bearing

In

some

4.

When

clear of the bearing and/or

shaft,

Back

manually

Plate

slide

the generator housing carefully off the rotor.

Control

Panel

Westerbeke Generators

BC

STYLE

GENERATOR

END

48

5.

For

6.

Remove

7.

Remove

8.

Remove

all

generator models,

remove

the
the drive disks with the rotor attached.
the rotor from the drive disks
the engine's

flywheel.

fan

assembly.

and

store both the rotor

and

the drive disks

in a safe

place.

Now that the generator

end

has

been

removed,

the engine

can

be

disassembled.

49

Westerbeke Generators

ENGINE DISASSEMBLY

This section describes the disassembly

procedures which
repair

or

replacement

Removal

1.

Loosen the belt guard's thumbscrews and remove the engine's belt

of

follow include the disassembly of subassemblies, inspection

of

these parts (if necessary), and the reassembly

External Parts

and

guard from its brackets at the front

motor

2. Remove the starter
starter and have it repaired

3.

Remove the heat exchanger and its related hoses and mounts from the

and circuit breaker assembly. Examine the

or

front of the engine. Have the heat exchanger
local automotive radiator repair shop,

4. Remove the exhaust

manifold and related hoses as a unit. Disassemble

of

the engine when performing a complete overhaul

Subassemblies

of

the engine.

replaced if necessary.

cleaned and tested at a

or

replace it if necessary.

and inspect these parts.

5.

Remove the raw water pump, the drive belt, and the raw water pump's

mounting brackets.

6.

Set the raw water

pump

to

one side

for

inspection and overhaul as needed.

of

their components parts,

of

the subassemblies.

of

the unit. The

BElT

GUARD

7.

Disconnect the linkage arm between the governor and the carburetor at the ball joint (carburetor end

of

arm); remove the governor and its mounting bracket.

8.

Remove the fresh water circulating pump's pulley.

9.

Remove the fresh water circulating pump.

10. Remove the fuel line, the carburetor, the fuel pump, gasdenser assembly, and the intake manifold.

11. Remove the ignition coil/ballast resistor and its mounting bracket.

12. Remove the engine's

13.

Remove the water temperature switch and the water temperature sender (if installed).

backplate.

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

18.

Remove the distributor assembly from the right rear

plugs from the cylinder head.

of

the engine.

Westerbeke

Generators

50

The

basic engine assembly

is

now

ready

for

disassembly,

cleaning,

inspection,

and

repair if

necessary.

Since the
they
while they

Timing Beh Removal

1.

Remove

4.5

KW

BCG

are

not

as

bulky or

are

disassembled

the crankshaft pulley from the

and

as

the

heavy

and

7.0

KW

as

some

repaired.

BCG & BCGA

automobile

crankshaft.

generator engines
engines,

the engines may

are

small,

Pulley

Crankshaft

Securing

three cylinder engines

be

laid

on

a sturdy

to

Bolt

bench

2.

Remove

cylinder
breaks.
keep

3.

Remove

along with their associated dust

the rocker cover
head.

Inspect the gasket for cuts

Replace

it for reinstallation.

the upper

the gasket if

and

lower timing belt covers

4.5

and

gasket from the

necessary,

covers.

KW

BCG,

7.0

KW

Crankshaft

and

or

51

BCG & BCGA

Pulley

.

l'

J\

Westerbeke Generators

4.

Remove the tension spring from the timing

and the tension spring bracket, and remove the timing
belt tensioner.

CAUTION

belt

tensioner

When removing the timing belt, be sure

the belt sharply (that is,

small radius). The cablecord contained in the timing
belt is extremely durable against tensile forces.
However, the cablecord is susceptible
when the
belt's overall strength.

5.

Carefully remove the timing belt from its pulleys.

The timing belt
or
deteriorate

6. Inspect the timing belt
ing, and peeling
is found
service. Refer

7.

Inspect the timing belt tensioner
and/or damage
belt tensioner is excessively worn, replace it.

belt is sharply bent. Bending reduces the

CAUTION

IIJ1JS1

other substances which may cause the belt

or

swell.

or

deformed teeth; replace the belt if it

to

be faulty

to

the pictures below.

at

the belt contact point.

do

not

bend the belt into a

be kept free

for

deterioration, swelling, crack-

or

after 1000 hours

of

oil, grease, water

for

abnormal noise

not

to

to

breakage

of

operating

If

the timing

bend

to

8.

Remove the camshaft timing belt pulley.

NOTE:
pulley, insert a screwdriver between the spokes
the pulley
loosening the pulley's screw.

9. Remove the crankshaft timing

When removing the camshaft timing belt

to

prevent the camshaft rotating while

belt pulley.

of

10.

Remove the timing belt cover

No.2.

Westerbeke

Generators

52

REMOVING

THE

CYLINDER

HEAD

FROM

THE

CYLINDER BLOCK

To avoid the possibility of distorting the cylinder

in

time,

Remove

NOTE:
head

the sequence shown

the cylinder

Discard the cylinder

to the cylinder block, install a new cylinder

head

below.

and

cylinder head's

head

@

Repeat

gasket

this sequence

gasket.

when

®

head,

it

loosen

is

removed.

head

®

each

several

gasket.

of the cylinder

times until the bolts are unfastened.

When

reassembling the cylinder

head

bolts, a little at a

®

4.5

KW

BCG

and

7.0

Loosening Sequence

KW

BCG & BCGA

53

Westerbeke Generators

CYLINDER

HEAD

DISASSEMBLY

Disassemble
relationship of parts for the

the cylinder

®~

®l®

~®

teD

~

<D

head

by removing parts

4.5

KW

BCG

@

,.

,

,

I

I

and

7.0

in

the order indicated.

KW

BCG & BCGA

The

figure below presents the

engine's cylinder

<D

Cylinder head Ay

® Cylinder head gasket

@ Water outlet (with thermostat)

® Valve spring retainer lock

@ Valve

® Compression spring

eD

Valve

@ Valve spring seat

® Valve stem oil seal

@>

Valve guide bushing

head.

spring retainer

4.5

KW

BCG

and

7.0

KW

BCG & BCGA

1.

Cylinder

2.

Cylinder

3.

Water

4.

Valve

5.

Valve

6.

Compression Spring

7.

Valve

8.

Valve

9.

Valve

10.

Valve

*Denotes that disassembly instructions for these parts follow

Head
Head

Outlet

(with
Spring
Spring

Spring
Stem

Retainer

Retainer

Seat

Oil

Guide Bushing

DISASSEMBLY

Ay
Gasket

thermostat)

Lock

Seal

ORDER

on

the indicated

pages.

Westerbeke Generators

54

1.

Mount the cylinder

head,
appropriate holder, to allow for the
springs,

valves

and

guides

while supporting it

as

needed.

removal

ofthe

in

an

valve

2.

Be

remove

3.

Remove

sure

to fully

the

valve

the flange bolt for

slacken

rocker

the adjusting

shaft.

camshaft

screws

thrust

first.

ring.

Then,

Fig. 3-34 SST Installation

Fig. 3-35 Valve Rocker Shaft Removal

Wl-03038

WI·03039

4.

Remove

at the
by tapping it with a

the

rear

camshaft.

end

of the

Using

camshaft,

hammer.

a wooden dowel

CAUTION

Exercise care

when

removing the camshaft to
avoid damaging the bearing journals or
surfaces of the

camshaft.

drive out the

placed

camshaft

cam

lobe

55

Fig.3-36 Flange Bolt Removal WI·03040

Westerbeke Generators

5. Remove the oil seal and camshaft thrust ring. Place
the wooden pole
Then, tap the handle
time, make sure that the flange

removed.

to

the rear surface

to

drive out the oil seal. At this

of

bolt has been

the camshaft.

I

,~~

~~

PN

6. Using the valve spring compressor tool
or

equivalent (snap-on, Craftsman

following parts:

1)

Valve spring retainer lock.

2)

Compression spring.

3)

IN and

NOTE: As the valves and their associated parts are removed, keep valve sets together and
in correct order with respect
are replaced, they must be returned

EX

valve.

SK),

to

their placement in the cylinder head. Unless any of the parts

37728

remove the

to

the same locations from which they were removed.

~

Oil seal

7.

Remove the spark plug.

Westerbeke Generators

56

CYUNDER

BLOCK

DISASSEMBLY

Disassemble
relationship of parts for the

the cylinder block by removing parts

4.5

KW

BCG

and

7.0

in

the order indicated.

KW

BCG & BCGA

The

figure below presents

engine's cylinder block.

the

ut:

·I~

@

4.5

KW

BCG

and

7.0

KW

BCG & BCGA

1.

Crank

shaft

timing belt

2.

Water

pump.

3.

Oil

pan.

4.

Oil

strainer.

*Denotes that disassembly instructions for

pulley.

57

these

(j) Crank shaft timing belt pulley

® Water pump

@ Oil pan

@ Oil strainer

® Oil pump

@ Oil seal retainer

<2l

Piston and connecting rod

@ Crank shaft and bearing

DISASSEMBLY

5.

Oil

pump.

6.

Oil

seal

7.

Piston

8.

Crank

parts follow

on

ORDER

retainer.

and

connecting

shaft

and

the indicated

Westerbeke Generators

rod.

bearing.

pages.

1.

Remove the cylinder head, IN &

flywheel related parts.

2.

Remove the oil filter element.

3.

Remove the water

gauge guide (2).

(#1,2, and 3 may have been removed earlier.)

4.

Remove the oil pan.

a.

Loosen the oil pan attaching bolts.

pump

(1) together with the oil level

EX

manifold and

b.

Using a putty knife
the oil pan from the cylinder block.

5.

Remove the oil strainer.

or

firm gasket scraper, separate

Westerbeke

Generators

58

6.

Remove the oil pump

7.

Remove the connecting rod cap bolts. Detach the
connecting rod cap. Push the connecting rod and

piston

block.

assembly upward out the top of the cylinder

(1)

and oil seal retainer

(2).

NOTE:
and cap so as not
tion.

8.

Remove the crankshaft bearing cap.

9.

Remove the crankshaft.

Temporarily assemble the connecting rod

to

disturb the correct combina-

59

Westerbeke

Generators

10.

Remove the crankshaft bearing & thrust washer.

11. Remove the
required.

stud bolt, oil pressure switch etc. as

Westerbeke

Generators

60

SPECIAL SERVICE TOOLS

NOTE:

Illustration

Special

n

Service

Tools

are

listed

in

the

same

Tool No.

order

as

#37729

4.5KWBCG

7.0KWBCG

& BCGA

#37728

#37731

#37732

they appear

Tool Name

Valve

Valve

Piston

in

the

manual.

rocker

spring replacer

pin

shaft

remover

puller

and

replacer

(~.

-~(~

#37725

4.5

KW

BCG

#37727

7.0KWBCG

& BCGA

#37726

#37730

Valve

guide

Valve

stem

Balance
remover

oil

shaft

and

remover

seal

replacer

gear

bearing

replacer

and

replacer

61

Westerbeke Generators

NOTES

Westerbeke Generators

62

CYLINDER HEAD AND ENGINE BLOCK

INSPECTION

AND REPAIR

Section

ENGINE

..........................................................................

INSPECTION

Checking

Checking

Replacing

Checking

Refacing

Checking

Checking

Checking

Checking

Checking

the

Cylinder

the

Valve

the

Valve

Valves

the

Valve

Rocker

Valve

the

Cylinder

the

Pistons

Piston

AND

REPAIR

Head

............................................ 64

..............................

Guides ..............................................

Guides

.............................................

...............................................................

and

Valve

Seat

..................................

Arms

and

the

Springs

Block

Rocker

................................................... 69

........................................... 69

Shaft

................

.......................................................

Rings

.................................................

Page

64

65
65

66

68

68

71

....

71

Checking

Checking

Checking

Checking

Checking

Checking

Replacing

Checking

the

Connecting

the

Piston

the

Connecting

the

Crankshaft

the

Camshaft ....................................................

the

Crankshaft

Front

and

the

Flywheel

Rods

.......................................

Pins

.................................................

Rod

Bearings .........................

................................................. 74

Timing

Rear

and

Belt

Crankshaft

Ring

Gear

Pulleys

Oil

.................

Seals

............................ 80

.............

72

73

73

76

78

79

63

Westerbeke

Generators

ENGINE INSPECTION AND REPAIR

NOTE:
gas leaks, damage or cracks. After checking these components, wash each part to remove
any adhered matter such
head,
handle them carefully to ensure against damage. Do not
harmful to the aluminum.

Checking

1. Replace the cylinder

2. Measure the extent of warping (flatness) on the lower surface that mates with the cylinder block. If the

warping exceeds the
tolerance.

Before washing the cylinder

as

pieces of gasket, dust, oil, carbon, and scale. Since the cylinder

cylinder

the

If the warping exceeds the allowable grinding tolerance, then replace the cylinder head.

head

cover, timing chain cover and other engine parts are made of aluminum,

Cylinder Head

head

allowable limit of distortion, grind the surface

if it shows signs of water

head

and block, check them for indications of water leaks,

use

cleaning solutions that will

leaks,

gas leaks or cracks.

to

within the specified grinding

be

Specified Cylinder

Allowable Limit of Distortion:

Grinding Limit:

Head

(warpage)

~--~----~----~-~-

Westerbeke Generators

Height:

1

i

i

:

!

I

64

4.5 KW

3.9370

4.5 KW

0.0039

4.5 KW

3.9291

BCG

in.

(100

BCG

in.

BCG

in.

(0.1

(99.8

and 7.0 KW

mm)

and 7.0 KW

mm)

and 7.0 KW

mm)

BCG & BCGA

BCG & BCGA

BCG & BCGA

Checking
Measure the clearance between the valve and guide bushing. If the clearance exceeds the specified limit,

replace those parts that have worn beyond the allowable limit.

Valve

Guides

Allowable Umit:

#1:

Measuring Method

with a mounted dial indicator

to

from side

Measuring Method

the

inner diameter

diameter

side.

NOTE: Separate the valve from the valve seat
before measuring. Measure
to

the valve guide bushing.

of

the valve stem.

Check each valve's deflection

by

moving the valve stem

at a position closest

#2:

Check the difference between

of

the

guide bushing and

Intake 0.2774
Exhaust

the

in.

(7.045 mm)

0.2774 in. (7.045 mm)

the

Valve

Replacing

1.

Remove the valve

2.

Knock the guide out toward the opposite side

combustion chamber with a valve guide installer.
(Special

Service Tool # 37725)

Guides

Seal

from the valve guide.

of

65

#37725

the

Westerbeke Generators

3.

Place a clip on the new valve guide and drive it in from the opposite side of the combustion chamber with

the valve guide installer.

NOTE: The shape
side.

of

the intake valve guides differ from that

of

the guides

4. Install the valve seal on the valve guide with a valve

seal pusher
BCG &BCGA.

5. Check the clearance

ing.

Projection Height

0.5984 -0.6220 in. (15.2

Checking

or

Valves

tool

#37727

-

4.51<Y1

for

each new valve guide bush-

-15.8

BCG and 7.0

mm)

I<YI

1. Check the contact surface of the valve face and valve seat for damage. Minor

repaired with a valve grinder.

Contact width

0.0472 - 0.0630 in.

(1.2

-1.6

mm)

on

the exhaust

or

rough surface may be

NOTE: Check the valve's contact area and position

or

red lead
enough pressure
cylinder head. Perform this operation
be accurately measured.

Check if the valve seat's contact face contacts the center position
Do

not

2.

If the valve stem is worn, damaged, bent

Westerbeke Generators 66

to

the valve's seat and push the valve upward into cylinder head's seat (apply only

to

assure a press

rotate the valve.

fit).

Under its own weight, let the valve

two

or

three times until the valve's contact surface can

or

the end surface of the stem is dented, replace the valve.

by

applying a thin coat

of

the valve's contact face.

of

Prussian Blue

drop

away from the

3.

Check the valve stem's diameter with a micrometer;

if the stem is worn beyond the allowable limit,

replace the valve.

Valve stem outer diameter limit:

Specified value:

(6.955 -

- 0.2746 in.

6.970 mm)

Intake: 0.2740

(6.96 - 6.975 mm)

Exhaust: 0.2738 - 0.2744 in.

Allowable Limit

Intake: 0.2732 in.

(6.940 mm)

Exhaust: 0.2730 in.

(6.935 mm)

4.

Check

Replace the

Valve Head Stock Thickness Limit

of

each valve's head

valve if it is beyond the allowable limit.

stock

thickness.

Specified Value

Specified Limit

5.

Check

for

stem.

-

-1.4

-1.7

mm)

0.0551
mm)

mm)

Intake: 0.0394

(1.0

Exhaust:

Intake: 0.0354 in.

Exhaust: 0.0433 in.

0.0512 - 0.0669 in.

(1.3

(0.9 mm)

(1.1

excessive grooves at the end of the valve

in.

67

Westerbeke

Generators

Refacing

To

reface the valve and cylinder head valve seats, follow

the steps below.

1.

For

cutter
use a

face.

2.

For the exhaust port in the cylinder head, use a 20°

cutter
use a
face.

the

Valve and Valve Seat

the intake port in the cylinder head, use a 30°

to

bring back the valve seat's shoulder. Then

45° cutter

to

45° cutter

to

recondition the valve seat contact

bring back the valve seat's shoulder. Then

to

recondition the valve seat contact

3. Grind each valve's contact face

to

ensure that both the cylinder's contact face and the valve's contact face are perfectly matched.

4. After each valve is reconditioned, hand lap each valve onto its seat with a

5. Remeasure the contact width

conform

to

the specifications.

to

45°. Match each valve

of

both the valves and each cylinder head valve seat and ensure that

to

its respective cylinder head port and check

good

brand of lapping compound.

they

Checking Rocker Arms and the Rocker Shaft

1. Check each component

a

new

one.

2. Check

them

to

see that the oil passages of the rocker arm and shaft are open. If

or

replace the unit.

of

the rocker arm assembly

for

damage

or

cracks.

If

necessary, replace it with

any

clogs are found, remove

3. Measure the clearance between each rocker arm's bore and the shaft. If this measurement exceeds the

allowable limit, replace the worn rocker arm bushings and shaft.

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

68

Checking

Valve

Springs

1. Check the valve spring for corrosion
replace it, if necessary.

2.

Check each spring

replace the spring if the free length is

free length limit specified below.

Free Length

1.779 ­(45.2 -

Free Length Limit

1.7441

3.

Check the squareness

exceeds the limit, replace it with a new one.

Squareness Limit

0.063 in. (1.6 mm)

4.

Using a spring tester, measure each spring's tension

at

the specified installed length. Replace the springs

if they prove

for

free length and squareness;

Standard

1.S11

46.0 mm)

in. (44.3 mm)

to

be weakened.

in.

of

the valve spring. If it

or

damage and

less than the

Fig.3-52 Valve Spring Check

WI-03056

Installed Length:

Installed Load

Standard:

Allowable Limit:

Checking

1.

Check the cylinder block for damage

necessary, repair

2.

Check
passages
remove with compressed air

3.

Check the cylinder block

the allowable limit

cylinder block.

the

Cylinder

to

see that the oil passages and coolant

of

Allowable Limit

1.4961

or

the cylinder block are open. If clogged,

of

of Distortion:

in.

(3S.0

5S.2

- 64.Slbs (26.4 - 29.4 kgs)

so.

71bs (23.0 kgs)

Block

replace the cylinder block.

or

for

distortion. If it exceeds

distortion, repair

0.0031

(O.OS

mm)

or

cracks. If

a wire probe.

or

replace the

in.

mm)

69

Westerbeke Generators

Grinding tolerance

for

cylinder block upper surface.

Cylinder Block Height 4.5

STO: 8.6575 - 8.6653 in.

(219.9 -

Umit: 8.6535 in. (219.8 mm)

Cylinder

4.

Check

If

necessary, repair

replace the cylinder block.

5.

Measure the wear on the cylinder bores at the six
positions shown in the figure
inside micrometer. (The wear is the difference be­tween the maximum and minimum diameters.)
cylinder bores have worn beyond the specified wear
limit, the cylinder block requires boring
each cylinder's true

Block Height 7.0

STO:

9.2874 - 9.2953 in.

(235.9 -

Umit: 9.2834 in. (235.8 mm)

for

scratches

wall surface.

KW

BCG

220.1

mm)

KW

BCG & BCGA

236.1

mm)

or

burns on the cylinder walls.

by

boring each cylinder

to

the right with an

to

restore

or

Ifthe

Front

+-

8

V

:

m

c ' :

,fr)

\~~

'

Jr

'~

,

Standard Bore Diameter

4.5

KW

BCG: 2.4409 -

(62.00 - 62.03 mm)

7.0KWBCG:
& BCGA

Wear limit: 0.0039

Out-of-Roundness, Taper Umit:

0.0012 in. (0.03 mm)

6.

Check the ridge in the cylinder. If the engine has a large number

likely will be present. If a ridge exists, have the cylinders reamed
ridges in the cylinder can break piston rings when the pistons are installed in the engine. In addition, if
new piston rings are
properly.

2.6220 - 2.6232 in.
(66.60 -66.63 mm)

to

be installed, have the cylinder walls deglazed (roughed up) so the rings may seat

in.

(0.10 mm)

2.4421

in.

of

hours on it, a large cylinder ridge most

to

remove these ridges. Leaving these

Westerbeke Generators

70

Checking

1.

Check all pistons carefully, and replace those that exhibit
circumference of the piston.

2.

Measure each piston's diameter 0.0016 -

angles to the piston pin's location (that

3.

Check the clearance between the piston and the cylinder wall.

the

Pistons

0.0024

is,

in the thrust direction) without the pin in place.

in.

(0.04

severe

- 0.06

bums or scratches on the external

mm)

under the oil ring groove, at right

Piston Diameter: 4.5KWBCG

7.0KWBCG

&

BCGA

Standard Cylinder-ta-Piston Oearance: 4.5KWBCG

7.0KWBCG

&

BCGA

Allowable Cylinder-to-Piston Limit:

it)M

E:fi

E

.::

•

it)

M .

~~

4.5KWBCG

7.0

KW

BCG

&

BCGA

Front

2.4392 - 2.4403
(61.955 -61.985

2.6201
(66.550

0.0014 - 0.0022
(0.035 -0.055

0.0016
(0.040 -0.060

0.0039
(0.10

mm)

0.0043
(0.11

mm)

~

..

c

-2.6213

-66.580

- 0.0024

In.

in.

in.

mm)

in.

mm)

in.

mm)

in.

mm)

@

E'

Checking

1.

Check the piston rings for cracks, burning or wear and

replace them, if necessary.

2.

Measure each piston ring's end gap. Replace the ring

if the gap exceeds the allowable

Piston Rings

end

gap limit.

NOTE:
until it is about 2 inches from the block's top surface.

Push

a ring into the cylinder with a piston

71

:

,~I-

...

'~

Ef

c :

Westerbeke Generators

..

.

" ,

, ,

, ,

, ,

'

·f

'.

Standard End Gap Clearance

Compression ring

Compression ring

Oil ring:

3.

Measure the side clearance between the piston ring

No.1:

No.2:

0.0098 -0.0157

0.0079 - 0.0138 in. (0.20 -0.35 mm)

0.0079 - 0.0276

and ring groove.

NOTE: Measure the clearance around the total

circumference

Standard

Side Oearance

Compression ring

Compression ring

of

the ring groove.

No.1:

No.2:

0.0012 - 0.0028 in. (0.03 - 0.07 mm)

0.0008 -0.0024

in.

(0.25 -0.40 mm)

in.

(0.20 -0.70 mm)

in.

(0.02 -0.06 mm)

limit: 0.0256 in. (0.65 mm)

limit: 0.0256 in. (0.65 mm)

limit: 0.0394 In. (1.00 mm)

limit: 0.0047

limit: 0.0043 in.

In.

(0.12 mm)

(0.11

mm)

Checking

1.

Check the side

the

Connecting

Rods

of

each connecting rod's small end and large end for cracks

replace damaged 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
rod.

Twist

limit: 0.0020 in. (0.05 mm)

Bend

limit: 0.0020 in. (0.05 mm)

to

the rod

or

damage. If necessary,

or

replace the connecting

Westerbeke Generators 72

Checking

1.

Check
A.

Measure

Standard

4.5 KWBCG
Standard

7.0

B.

Measure

the

each

KW

Piston

piston pin's

each

each

Pins

oil

clearance.

piston pin's bore diameter.

Bore

Diameter:

0.6299 - 0.6302
(15.999 - 16.008

Bore

Diameter:

BCG & BCGA

0.7086 - 0.7090
(17.999 -18.008

piston pin's diameter.

in.

mm)

mm)

Standard

4.5

Standard

7.0

Standard

Pin

KW

BCG

Pin

KW

BCG & BCGA

Oil

Diameter:

Diameter:

Clearance:

0.6296 - 0.6299
(15.991 -16.000

0.7083 - 0.7087
(17.991 - 18.000

0.0002 - 0.0004

(0.005 - 0.011

2.

Replace

Allowable

Checking

1.

Check

2.

Check

exceed

the piston

Limit:

the

each

each

connecting

and

0.0020

Connecting

connecting

piston

pin

in.

(0.050

Rod

Bearings

rod

bearing carefully

rod

bearing's

the allowable limit, replace

if

the pin's
mm)

oil

clearance with a "plastigauge." If the clearance for

all

the connecting

scored or flaked, grind the crankshaft's connecting

Oil

Bearing

Clearance:

in.

mm)

in.

mm)

in.

mm)
oil

clearance exceeds the allowable limit specified

and

replace it if it

rod

rod

journals

is

worn, scored or flaked.

bearings. If the connecting

and

install

an

undersize bearing.

these

rod

below.

bearings

journals

are

Kinds

of Connecting

Specified Limit: 0.0008 - 0.0017

Allowable

(0.020 - 0.044

Limit:

0.0028

Rod

Bearings:

in.

mm)

(0.07

Standard

Undersize

0.0098

Undersize 0.0197

in.
in.

(0.25

(0.50

mm)
mm)

in.

mm)

73

Westerbeke

Generators

3.

Check

each

connecting rod's thrust clearance.

Specified Umit:

Allowable Umit:

4. Check

each

Journal Width

STO

U/S

U/S

Journal Width

STO

U\S

0.0059 -0.0098
(0.15 -0.25

0.0118

connecting rod's journal width.

4.5

KW

BCG:

1.4557 -1.4567

(36.976 -37.000

0.0098

(0.25

0.0197

(0.50

0.0098

(0.25

in.

mm)

in.

mm)

7.0

BCG & 7.0

in.

mm)

1.4461 -1.4465
(36.732 -36.742

1.3969 -1.3973
(35.482 -35.492

1.5739 -1.5748
(39.976

1.5642 -1.5646
(38.732 -39.742

in.

(0.30

BCGA:

mm)

-40.000

in.

mm)

in.

mm)

in.

mm)

in.

mm)

in.

mm)

in.

mm)

5.

Measure

Standard

Checking the Crankshaft

1.

Check the crankshaft for cracks or other

2.

Check to

compressed air or a suitable

3.

Check the crankshaft for eccentric

if the journals

it exceeds the allowable limit, compensate for this
wear by grinding the bearing
the bearings with undersized bearings.

the connecting

Rod

see

NOTE:
crankpins
front
crankshaft

Measure

and

rod

width.

Width:

that the oil

have

become elliptical or tapered. If

and

main

rear portions) at

axis,

0.n95

(19.80 -19.85

passages

the diameter of

journals at two points

as

shown

-

0.7815

of the crankshaft

wire.

wear;

journals

90

degrees

in

the figure.

in.

mm)

damage.

that

and

each

is,

see

replace

of the

(the

to

the

If

necessary,

are

open.

replace the crankshaft.

If any clogs

are

found,

remove

them with

Westerbeke Generators

74

Allowable elliptical or tapered

Limit:

0.0008

in.

(0.02

mm)
Specified
Allowable

4.

If the journals must

OU

Oearance:

Limit:

be

ground

crankshaft bearings with undersized

4.5KWBCG:
Main

Crankpin

7.0

KW

Main

Crankpin

NOTE:
journals

Journal

BCG & BCGA:

Journal

When

D1.lm1.

DIA.

DIA.

DIA.

DIA.

grinding the crankshaft,
be

ground to a

done by a qualified machine

because

of

severe

bearings.

1.6526 -1.6535
(41.976 -42.000

1.4557 -1.4567
(36.976 -37.000

1.8101

-1.8110

(45.976 -46.000

1.5739

-1.5748

(39.976 -40.000

the

radius

of

0.25

shop.

0.0008 -0.0017

0.0028

in.

(0.07

in.

(0.020 -0.044

mm)

burning or scoring, grind the crankshaft

in.

mm)

in.

mm)

in.

mm)

in.

R,·O.I46/0./~7"(.1.

R,

-0./26/0./42"(3.20/3,61

"!/J.99mm)

mm}

mm)

corner sections of the

(R1

and

R2).

Any

main

journals

crankshaft grinding should

mm)

and

and

replace

crank pin

be

the

5.

Measure

Runout

6.

Measure

the crankshaft's runout

Limit:

0.0008

in.

(0.02

the crankshaft for

gauge at the center bearing journal

as

crankshaft

Bend

Limit:

shown

0.0012

in

the illustration to the right.

in.

(0.03

(uneven

mm)

bend

by placing a dial

and

mm)

wear).

turning the

75

Westerbeke Generators

7.

Check the crankshaft's thrust clearance with a feeler gauge

as shown in the figure.
replace the thrust washer.

Specified Limit

0.0008 - 0.0087

Allowable Limit

0.0118

Kinds of Thrust Washers:

in.

If it exceeds the allowable limit,

in.

(0.30

(0.02 -0.22

mm)

mm)

Standard Repair

Oversize

Oversize 0.0098

Checking the Camshaft

1.

Check the camshaft for cracks, wear or damage and replace it if necessary.

2.

Measure the runout. If it exceeds the allowable limit, replace the camshaft.

Allowable Limit of Runout:

3.

Measure the camshaft's lobe height. Replace the camshaft

if the wear

Cam

limit

Lobe Height, Specified Limit:

4.5KWBCG IN: 1.3858 -1.3913

0.0049

is

exceeded.

in.
in.

(0.125

mm)

(0.250

mm)

0.0012

EX:

(0.03

(35.20 -35.34

1.3835 -1.3890

(35.14 -35.28

mm)

0.0764 -0.0783

0.0813 -0.0833

0.0862 -0.0882

in.

mm)

in.

mm)

in.
in.
in.

(1.940 -1.990
(2.065 -2.115
(2.190 -2.240

mm)
mm)
mm)

7.0

KW

BCG & BCGA

Allowable Limit:

4.5

KW

BCG

7.0

KW

BCG & BCGA

Westerbeke Generators 76

IN:

1.3752
(34.93

EX:

1.3728 -1.3783

(34.87 -35.01

IN: 1.3819

EX:

1.3799

IN:

1.3701

EX:

1.3681

- 1.3807

-35.07

in.

(35.10

in.

(35.05

in.

(34.80

in.

(34.75

in.

mm)

mm)

in.

mm)

mm)

mm)

mm)

4.

Measure the camshaft journal-to-cylinder head journal

clearance. Replace the

Camshaft Journal Diameter:

part that exhibits the most wear.

Specified

Cylinder Head Journal Diameter:

Specified

Uneven Wear

Valve

Front: 1.6709 - 1.6717 in.

(42.44 - 42.46 mm)

Center: 1.6512 -1.6520 in.

(41.94 - 41.96 mm)

Rear: 1.1791 - 1.1799 in.

(29.95 - 29.97 mm)

Valve

Front: 1.6732 -1.6742 in.

(42.500 - 42.525 mm)

Center: 1.6535 - 1.6545 in.

(42.000 - 42.025 mm)

Rear: 1.1811 -1.1819 in.

(30.000 -

of

0.0016 in. (0.04 mm)

30.021

Camshaft Journal

mm)

5. Measure the crankshaft oil clearance.

a.

Lay

a strip

of

plastigauge across the journal

pin, but

b. Tighten the crankshaft bearing

rod bearing cap bolts

Tightening Torque:

not

over the oil hole.

cap

to

the specified torque.

Crankshaft Bearing Cap

Connecting Rod Bearing Cap

or

crank

and connecting

39.1

- 47.7 ft-Ib

(5.4 - 6.6 kg-m)

15.2 -

21.0 ft-Ib

(2.1

- 2.9 kg-m)

Oil clearance measurement (1)

Oil clearance measurement (2)

77

Westerbeke Generators

c.

Remove the bearing cap. Measure the plastigauge

at its widest point.
specification, replace the bearings.

If the clearance is not within

Crankshaft Main Journal

STD 0.0008 - 0.0017

(0.020 -0.044 mm)

Limit

d.Check the crankshaft thrust clearance.

clearance exceeds the
washer.

Thrust Clearance:

STD

Limit

Checking

0.0028 in. (0.07 mm)

0.0008 - 0.0087
(0.02 -0.22 mm)

0.0118

the

Crankshaft

& Crank Pin Oil Oearance:

in.

limit, replace the thrust

in.

in.

(0.30 mm)

Timing

Belt Pulleys

Oil clearance measurement (3)

If the

Measure the outside diameter
and camshaft

worn beyond the

Crankshaft Pulley:

Pulley

Allowable Limit

Camshaft

Pulley

Allowable Limit

pulleys. Replace those pulleys that have

allowable limit.

Diameter 2.154 - 2.158 in.

(54.701 -54.801

2.151

in. (54.64 mm)

Pulley:

Diameter 4.3556 - 4.3627

(110.633 - 110.813 mm)

4.3531

in.

of

both the crankshaft

mm)

in.

(110.57 mm)

Westerbeke Generators

78

Replacing

Replace the oil seal and O-ring.

1.

Type T oil seal. (Crankshaft front

appropriate
oil seal. Apply engine oil
seal.

Front

seal

and

Rear

Crankshaft

tool (snap-on, Craftsman), install the

to

Oil

Seals

aU

seal.) Using an

the lip portion

of

the oil

2.

Install the oil pump O-ring

ensure the seating

of

the position

as indicated in the figure.

3.

Type T oil seal (crankshaft rear oil seal). Using an

appropriate
to

the lip portion of the oil seal.

the 3 embossed marks on the cover

tool, install the oil seal. Apply engine oil

to

the oil pump cover. To

of

the O-ring, push the O-ring at

Embossed mark

4.

Assemble the oil pump assembly and rear oil

retainer.

Tightening torque:

Rear oil

Oil pump assembly

seal retainer

7.2 - 11.6
(1.0

(1.56 -2.34 kg-m)

ft-Ib

- 1.6 kg-m)

11.3 - 16.9

ft-Ib

79

seal

Westerbeke

®

Generators

5.

Assemble

Tightening torque bolt,

Checking the Flywheel and Ring Gear

1.

Checktheflywheelfordamage or

gear's teeth for
badly worn.

2.

Check the runout limit

the oil strainer.

wear.

on

nut:

4.62 -6.93
(0.64 -0.96

Replace

the

flywheel.

wear.

the ring gear if it

ft-Ib

kg-m)

Check the

ring

is

Runout

2.

Replace

a.
b.
c.

Umit:

0.0039

the

ring

Heat

the ring with a torch.
Remove
Heat

the

NOTE:
of the ring

the ring gear by striking its circumference.

the

new

flywheel,

make

Excessive

gear.

in.

(0.10

mm)

gear by the following procedure:

ring gear to

sure

heat

250 -3000 C

that the

may

chamfered

destroy the original

(480 -5700 F)

side

on

of the

heat

a hot plate or

ring

gear

is

treatment

and

in

an

oven.

Before

directed toward the

cause

premature failure

Slipping

engine.

it onto

Westerbeke Generators

80

SUBASSEMBLY INSPECTION, REPAIR, AND ASSEMBLY

Section ..........................................................................

Disassembling
Assembling
Fresh

Water
Thermostat
Disassembling

Raw

Water

Electric

Fuel

Disassembling

and

Inspecting the

the

Oil

Pump

................................................

Pump

...........................................................

Removal

Pump

Pump

and

Inspection ..............................

and

Inspecting the

..............................................................

...........................................................

and

Rebuilding

Oil

Pump

..................

Page

the Carburetor ..................................................................

Inspecting the Distributor

and

its Components ................................................................

Testing the Ignition
Inspecting the Spark

Coil

...................................................

Plugs

..............................................

82
84
84
85

86
87

88

94
95
95

Testing the Starter ............................................................

96

81

Westerbeke Generators

Disassembling and Inspecting the

Oil

Pump

<D

"T"

type oil seal

®

OilpumpAy

@ Compression spring

@)

Cotter pin

® Oil pump relief valve
® Oil pump relief valve retainer

Q)

Gasket

® Oil pump drive gear
® Oil pump driven gear

pump cover

@ Oil

@

Oring

1.

Remove
a.
b.

2.

Remove
a.
b.

the relief

Using

pliers,

Remove

the drive

Remove

Remove

valve.

remove

the

retainer,

and

the 5 bolts

the drive

the cotter

spring

driven
and

and

driven

oil

and

gear.

pump

gear.

pin.

relief

cover.

valve.

Westerbeke Generators

82

3.

Using a feeler gauge, measure the tip clearance

of the drive and driven gears.

Tip

Clearance:

STO

Limit

4.

Using a feeler gauge and flat block, measure the

side

Side

STO

Limit

5.

Using a feeler gauge, measure the clearance
between the drive gear and body.

0.0067 - 0.0094

0.0138 in.

clearance as shown.

Clearance:

0.0014 - 0.0028 in. (0.035 -0.07 mm)

0.0059

in.

(0.35

(0.15

in.

(0.17 - 0.24 mm)

mm)

mm)

STO

Limit

6.

Using a screw driver, pry out the oil seal.

0.0024 - 0.0047 in. (0.06 - 0.12 mm)

0.0098 in. (0.25 mm)

83

Westerbeke Generators

7.

Install the new oil seal using an appropriate service
tool.

a.

Using the tool, install the new oil seal.

NOTE: Be careful not
slanted.

b. Coat the oil seal lightly with engine oil.

Assembling

1.

Install the relief valve.

the

Oil

Pump

to

install the new oil seal

a.

Install the relief valve, spring and retainer

pump body.

b.lnstall the cotter pin.

2.

Install the drive and driven gears.

a.

Insert the drive and driven gear

b.

Install the pump cover, tighten the 5 screws.

Tightening Torque: 5.8 - 9.4

3.

Install the a-ring.

Fresh Water

No

rebuilding kit is offered for the fresh water circulating
pumps on the 4.5
RemOVal
is,

therefore, necessary.

Pump

KW

and replacement

BCG, 7.0

of

the defective

to

the body.

ft-Ib (0.8 - 1.3 mm)

KW

BCG

& BCGA.

or

worn pump

to

the

Westerbeke Generators

84

Thermostat

The thermostat is located toward the rear of the intake

manifold within the thermostat housing.

1.

Remove the thermostat from its housing.

2.

To testthe thermostat, immerse it in water and gradual-

ly

heat the water. The thermostat should start

when the water temperature reaches

- 600 C).

0.31

reaches

Removal

The thermostat should open

inches (8 mm) when the water temperature

1500 F

(64

and

0

C).

Inspection

130

to

to

1400 F (55

by

more than

open

3. Replace the thermostat if the valve remains open at

or

normal temperatures

is

valve

fully closed.

When replacing
Westerbeke thermostats. These thermostats are
designed specifically for the engines covered
this manual. Other, generic thermostats will not
work in these engines and may seriously damage
the engine should they be installed.

if the valve is loose when the

CAUTION

the

thermostat, use genuine

in

• ! ! • H ,

J7

Thermostat Inspection (1)

Thermostat Inspection (2)

'~

'"

85

Westerbeke Generators

Disassembling and Inspecting the
When

disassembling the

can

be

replaced along with a new gasket at the time of inspection

small

part,

it plays

raw

of the
new impeller
See

water pump's inspection

the note below.

is

accompanied with a new

raw

water pump for inspection,

an

important role in the proper operation of the

Raw

Water Pump

can

only improve the

gasket,

an

an

impeller kit should

raw

water pump's pumping ability.

item

that

is

as

engine.

needed

be

purchased

needed.

Replacing the in:'peller at the time

to assemble the

Although the impeller

so

the impeller

In

addition, a

raw

water pump.

is

a

1.

To disassemble the

2.

Remove

3.

Remove

4.

Remove

5.

Remove
Now the
Inspect the

is

rough or frozen, replace the entire

Since rebuilding a damaged or worn pump from individually purchased pieces would almost match the price
of a new pump,

the cover
the rubber impeller
the rubber a-ring.
the

cam

raw

water pump

raw

NOTE:
jelly around the impeller. This
dry until

When

raw

raw

water

pump,

and

the

gasket.

and

screw,

water pump by rotating the pump's drive

we

recommend that a new pump

reassembling the

water

washer

is

stripped far enough to

reaches

remove

the wear

and

the

cam.

pump.

raw

water pump with a

ensures

the impeller

the four cover

plate.

be

inspected.

be

purchased instead of rebuilding

that when the engine

as

it draws a

screws.

shaft.

If excessive play exists

new

impeller

is

started the impeller will not

prime.

in

one.

kit,

wipe a little petroleum

it,

or if its sound

run

Westerbeke Generators

86

Electric Fuel
Later models are equipped with a Solid State interrupter type fuel pump that operates well under high ambient

temperature condition; however, it does not incorporate any fuel filter/screen in its construction.

Installers/operators must ensure that fuel being supplied
contaminants that will hinder the pumps operation

The fuel pump and Gasdenser are replaceable components; but not overhaulable.

Periodically, check the fuel connections
and that the fittings are tight and secure. Also, check that the
DC

to

the pump is clean, tight, and secure. The

should be clean and well secured by the mounting bolt

Pump

to

and out

to

this pump is free

or

affect the carburetor further down stream.

of

the pump and make sure that no leakage is present

DC

electrical connection supplying

DC

ground connection at one of the pumps mounting bolts

to

ensure proper pump operation.

of

water

or

other types

12

of

volts

(Installers

12 Volt DC

Male

Bayonet

Compression

DC Ground Wire

Fuel

(+)

Connection

Connector

Fuel

Connection

Fuel

Fuel Pump

Supply

(In)

Connection)

Fitting

Connection

Connection

Outlet

(To Carburetor)

Fuel

Connection

Pump

IWARNINGI

Fuel leakage at the fuel pump
Make sure proper ventilation exists whenever servicing fuel system components.

or

its

connections is a fire hazard and should be corrected.

87

Mounting

Bolt

Westerbeke Generators

Disassembling and Rebuilding the Carburetor

rebuild the carburetor, first purchase a carburetor rebuilding kit

To

all

kit contains

of the following rebuild parts.

Two

(2)

copper accelerator

pump gaskets
One

(1)

main

body gasket

One

(1)

choke lever spring

One

(1)

rotary throttle shaft valve

One

(1)

fuel

filter element

One

(1)

manifold gasket

Refer

to the illustration below the list.

One
(two pieces to the

One
One
One
One

00

COPPER

ACCELERATOR

PUMP

GASKETS

NEEDLE

VALVE

PN

036450.

(1)

needle

(1)

aluminum

(1)

idle mixture screw O-ring

(1)

throttle shaft

(1)

aluminum shutoff solenoid gasket

valve

set)
seat

and

gasket

valve

Make

seat

spring

sure that the rebuild

o

ALUMINUM

SHUTOFF

IDLE

CHOKE

ROTARY

SOLENOIO

GASK

ET

o

MIXTURE

O-RING

CIlllllJJ1IlmlO

LEVER

THROTTLE

VALVE

SCREW

SPRING

SHAFT

o

UI(

__

FUEL

FILTER

THROTTLE

VALVE

VALVE

SEAT

ALUMINUM

VALVE

SEAT

GASKET

B.Ji~

ELEMENT

SHAFT

SPRING

MAIN

BODY

MANIFOLD

GASKET

GASKET

Westerbeke Generators

88

1. Loosen the flame arrester's
clamp and remove the arrester

followed by the clamp.

2.

Disconnect the fuel supply line,

fuel

solenoid

wire,

electric
choke wire, and the throttle con­trollinkage (not shown).

the

two

3. Remove

nuts

washers that secure the car-

to

buretor

the intake manifold.

Lift the carburetor from the in-

manifold.

take

and

Flame Arrester Clamp

Carburetor Top Cover

Ball Joint
(To

Throttle

Control Unkage)

Fuel Solenoid Wire

Cover Screw

-_~.II'

Vacuum Hose

Electric

: Choke

Wire

4.

Remove the electric choke's
stabilizing screw and the indi­cated (one
and

of four) cover screw

washer.

Remove

electric choke.

5.

Replace the choke lever spring,

if necessary.

the

Stabilizing Screw

89

Westerbeke Generators

6.

Remove the remaining three cover screws and their washers.

Lift

the carburetor's

and away from the carburetor's base.

7.

In the carburetor

side

of

the pivot bracket and remove the float.

the

float

retaining

8.

Remove all

9.

Shake the float. If you can hear any sand-like particles moving inside the float, replace it.

Cover Screws & Washers

(Remaining

top

cover, gently punch out the float retaining pin in the opposite direction

hook

under

the

float's

of

the old cover gasket from both halves

3

Of

4)

pivot

Make

arm

sure

you

catch

and

place

of

the carburetor.

Roat

Roat

Pivot

Arm

the

needle

it

aside.

Retaining Hook

valve

top

cover straight

that

of

the split

hangs

up

from

Wire Retaining
Loop

Pin

Needle Valve
Seat

Pivot

Carburetor
Top Cover

Westerbeke Generators

90

10.

Remove the needle valve's seat with a

10

mm wrench. Make sure that the seat's aluminum gasket

removed at this time. Screw in the new seat along with a new gasket.

11.

Place a new carburetor cover gasket on the carburetor

top

cover.

Do

not

use any gasket sealer on this

gasket.

12.

Gently place the needle valve in the needle valve seat. Replace the float and float retaining pin so that
the needle valve's wire retaining loop hooks onto the float's retaining hook.

distance from the housing mating surface with the

housing

held vertically.

Now

check the float level

is

Distance

Carburetor

.

Top

Cover

"A"

from mating surface: 3/16 in. (4.76 mm) .

.

Wire

Loop

,

Float
Hook

Retaining

Retaining

Needle

Valve

Seat

'''.''"'~~

8/

Needle

V Carburetor

.

AlUmin~m'~

Gasket

Screw

Valve

Seat

Top

Cover

13.

On the carburetor base, remove the retaining screw
to

the accelerator pump nozzle, the nozzle, and the

two

copper gaskets placed above and below the

nozzle.

14.

Replace the

two

copper gaskets and reinstall the
accelerator pump nozzle. Snug down the nozzle's
retaining screw.

Do

not

overtighten the screw.

91

Accelerator

Carburetor

Copper

Gaskets

Westerbeke Generators

15.

Place

the carburetor top cover straight down

on

the carburetor.

sure

to replace the

Replace

Do

16.

Unscrew the idle mixture screw

the remaining three cover screw's

not

overtighten the cover

Hand

old

washer.

on

the carburetor

tighten the cover screw that

Then,

replace

screws.

and

replace the idle mixture screw's

stabilizing screw's washer

This

washers

can

and

strip the threads

base

and

reposition the electric choke

secures

the electric choke to the carburetor.

and

tighten the stabilizing

tighten the cover screws

in

the carburetor.

O-ring.

screw.

in

the indicated order.

Be

Westerbeke Generators

92

17.

Replace

18.

Remove

19.

Unscrew the

the rotary throttle

the

fuel

filter

element

fuel

solenoid

shaft

and

valve

plug

and

replace

and

the throttle shaft

replace the

the aluminum

fuel

filter

gasket.

valve

element.

Screw

spring.

in

the solenoid.

Now the carburetor
the carburetor

is

rebuilt.

on

the intake manifold

Make
the carburetor to the intake manifold.
Reconnect the

Reattach

the

fuel

flame

supply

arrester

line,

and

tighten the

fuel

sure

all

the

using a new

solenoid

flame

screws

manifold

wire,

electric choke

arrester's

on

the carburetor

are

gasket along with a gasket

wire,

and

clamp.

properly tightened

sealant.

the throttle control

and

replace

Resecure

linkage.

Fuel Filter

Fuel Filter

8ement

Fuel

Solenoid Wire

8ectric
Choke

Wire

Aluminum Gasket

93

Westerbeke Generators

Inspecting the Distributor and its Components

1.

Inspect the rotor

2.

Check the cap with
lustrated

in

Prior to testing the distributor
breath
the

inside the cap to dampen the interior of

cap.
INSULATION M
less

that

20M
detergent. After drying the
insulation
is

still

less

3.

Check

the distributor

Replace

4.

Measure

all

the condenser capacity with a circuit tester. If

and

cap for cracks,
an

electronic tester,

the diagram to the right.

cap,

Set

the

Ohm.

ohm,

range
clean

of the

If the cap's resistance

the cap

cap,

resistance.

than

damaged

If the insulation resistance

20M

ohm,

replace the

shaft

for

wear

parts.

wear,

rust,

as

apply your

ohm

tester to

using a neutral

remeasure

the

cap.

or

damage.

replace the condenser.

dirt or

il-

is

salt

deposits.

(V)OO

Insulation

00

®

,..

8:

Measuring

<D

Between
No.1

0Between

No.3

reading

000

~

•

o -

Q.

o "

~U)

the

00

M n

CJ

t:J

CJ

00

'f!lOO.

=--

POints

center

through

each

does not

00

---":::::.:.==:: -

electrode

No.3

segment

fall

~

'~r

1

,

,

)'

,

,

,

1--

I

,

~

::do

I

,

, I
' I

-..!-

----@-----:

and

segments

of

No.1

through

_~J

::'12

.....

j:

r-l

""

!

I

I
I

within the specified

range,

Specified

range:

(Condenser Capacity)

5.

Test

each

spark plug wire

and
Connect the leads of a circuit tester to
of the spark plug
the spark plug wire while gently
portion of the spark plug

wire.

Check the continuity of

waving

wire.

the tester deflects while the wires

are

the wires

satisfactory.

Specified

resistance:

the coil

wire.

each

the center

If the pointer

are

waved,

then

end

on

0.25

microfarads

10 -22

(uF)

ohm/m

Westerbeke Generators

94

Testing

the

Ignition

Coil

Measure
if

any

the

test fails

Ignition coil's primary and secondary resistance and capacitance as follows. Replace the coil

to

meet the resistance value given.

Primary Coil Resistance:

Secondary Coil Resistance:

Resistor Resistance:

only

(Replace

the resistor

fails this test.)

Inspecting

the

Spark

Plugs

Inspect each spark plug

fouling.

Make sure
before

Oean

or

replace the spark plugs if necessary.

that

new

they

are installed in the engine.

Spark Plug Gap:

or

used spark plugs are gapped

0.028 - 0.036 in. (0.7 - 0.9 mm)

if it

for

cracks, chips,

or

for

1.2

26

1. 7

±0.12

±3.9

±0.17

PLUG

ohm

ohm

ohm

GAP

WEAR

AND

ADHESION

CONDITION

Of

CARBON

DAMAGE

DETERIORATION

AND

DAMAGE

95

Westerbeke

Generators

Testing

The

the

Starter

starter motor is a reduction gear type with activation solenoid mounted on

it.

Performance

No-load Performance

Loaded

Stall Performance 4 V
Rated Output

If

an
problem. The cause of the problem may
cylinders causing a hydraulic lock or a faulty starter switch in the panel.

fails to turn the engine over, check the engine and starter circuit.
the starter and test

1.

Starter Circuit
a.

Charged condition of battery

b.

Tightened condition of battery terminals

c.

Tightened condition of starter terminals

d.

Condition of wiring (grounded or broken)

e.

Grounded condition of starter

Performance

engine fails

Specifications

Voltage Current

11.5

V

V

7.7

to

turn over when the starter circuit is energized, it's not always a starter

it.

Max

90

A

300

A

Max

570

CAUTION

be

related to something

Torque

------

Min.

0.93

Min.

2.5

A

12
435

kw

kg

kg-m

(12

V)

else,

In the event the starter

If no fault is found, remove

Speed
Min.

3300

rpm

kg-II

Min.

850

rpm

--------

such

as

water in the

Switch

2. No-load Test

Connect the starter with the battery

turn lightly at the current and speed shown above when the battery voltage

has been found, make the following inspections.

Westerbeke Generators

Description

No-load
characteristics
of starter
(Battery
voltage:

11.5

volts).

as

illustrated and close the switch to turn the starter.

96

1.2KW

Standard Value

Current

100Aorless

is

11.5

volts. If any abnormality

The

starter must

Speed

3,000

rpm

or more