Westerbeke 9.6 KW BCGTC 60Hz, 7.2 KW BCGTC 60Hz, 3.75 KW BCGTC 50Hz, 6.0 KW BCGTC 50Hz, 8.0 KW BCGTC 50Hz Service Manual

~

£ R

II

SERVICE

BCGT

GASOL

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. .., 'f.

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o q

IlI."D~'

".

. . .

MANUAL

~

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GENERATORS

CARBURETOR

4.5

KW

3.75

KW

7.2

KW

6.0

KW

9.6

KW

8.0

KW

MODELS

...

BCGTC

BCGTC BCGTC BCGTC BCGTC BCGTC

60Hz

60Hz 50Hz 60Hz 50Hz

'

50Hz

"'---'::::"--

PUBLICATION NO.44518

1ST EDITION

NOVEMBER

ELECTRONIC

.. .

.

4.5

KW

,

3.75

KW

7.2

KW

6.0

KW

1999

FUEL

BCGTE

BCGTE BCGTE BCGTE

60Hz 50Hz

60Hz

WESTERBEKE

WESTERSEKE

ISO

JOHN

TEL:

NAIl'''''

• •

CORPORATION'

HANCOCK

(508)8ZJ.7677·

...

MemMr

ROAD.

FAX:

MYLES

TAUNTON.

(508)88409688 • WEBSITE:

NationDl

MariM

STANDISH·

MA

Manufacturers

INDUSTRIAL

0271JO.731S"U.s.A.

www.weSTERBEKE.COM

PARK

Association

INJECTION

50Hz

MODELS

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

A

WARNING

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

-

IF GET seek until

gasses

gas. can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

and

include:

and

Sleepiness

THE

attention.

inspected

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

This WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

They obtainable

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

IMMEDIATELY. down

repaired.

WARNING

MONOXIDE

are

inexpensive

ANY

the

near

at

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

DECAL

and

should

your

also

recommends

quarters

your

local

odorless

and

Temples

THESE

symptoms

engine

DETECTORS

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

restart

is

provided

be

fixed

or

ge.nerator.

of

your

and

easily

marine

persist,

installing vessel. store.

in

by to

a

the

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety caused by failure to follow fundamental rules tions. Know when dangerous conditions exist necessary precautions to protect yourself, your and

your machinery.

The following safety instructions are in compliance with

the American Boat

PREVENT

A

WARNING:

while

engine

power.

•

Do

not

enclosures and covers

• Shut off electrical power before accessing electrical equipment.

•

Use

insulated mats whenever working

equipment.

• Make sure your clothing and skin are (particularly shoes) when handling electrical equipment.

• Remove wristwatch and electrical equipment.

•

Do

not circuits, except through a ship-to-shore double throw transfer switch. Damage result if this procedure

• Electrical shock results from handling a charged capacitor.

Discharge capacitor

PREVENT

A

WARNING:

exhaust

very

hot!

• Always check the engine coolant level recovery

A

•

In

case of

before touching the engine or checking the coolant.

manual

ELECTRIC

is

Lethal

voltage

operate this machinery without electrical

connect utility shore power

BURNS -HOT

system

tank.

,WARNING:

an

engine overheat, allow the engine

carefully. Most accidents are

and

Yacht Council (ABYC) standards.

SHOCK

Do

not

touch

AC

electrical

running,

or

when

connected

is

present

in

is

at

these

place.

on

dry,

all

jewelry when working

to

vessel's

to

vessel's

not followed.

by

shorting terminals together.

AC

generator may

ENGINE

Do

not

touch

hot

engine

components. A running

Steam

can

cause

engine

at

injury

connections

connections!

electrical

not damp

parts

the coolant

and

precau-

and

take the

personne~

to

shore

on

AC

or

gets

or

death!

to

cool

PREVENT

A

• Prevent sparks

pump,

vapors. Use a suitable container

removing the

•

Do arrester removed. Backfire can cause severe injury or

death.

• Do

Backfire can cause severe injury or death.

• Do

the

engine/generator clean and chances

• Be aware - diesel

PREVENT

A

injury

• Follow re-fueling safety instructions. hatches closed when fueling. Open and ventilate cabin after fueling. Check below ning the starting your engine.

•

All

when tilated area away out of the reach

•

Do

• Shut off the the spill. sources ing. fuel

• Do not alter or modify the

• Be sure

• Be certain free

• Make sure a properly maintained. Extinguishers rated ABC for

BURNS -FIRE

WARNING:

to or other potential sources of spilled

not

operate with a Coast Guard Approved

not

operate with the air cleaner/silencer removed.

not

smoke or permit

fuel

Fire

can

cause

injury

or

death!

flash

fires.

Do not smoke or permit

occur near the carburetor,

fuel

line, carburetor, or

flames

system. Keep the compartment and the

free

of

fire.

Wipe

up

all

fuel

will burn.

fuel

to

catch

or sparks to occur near

of

debris

spilled

fuel

flames

line,

fuel

all

fuel

filters.

to

minimize the

and engine

BURNS -EXPLOSION

WARNING:

or

death!

fuel

handling and storing

not

fill

fuel

DO

Ensure proper ventilation exists when servicing the

system.

of leaks.

all

applications encountered

Explosions

blower.

vapors

are

the

fuel

system.

NOT allow

of

fire

near

all

fuel

line fittings are adequately tightened and

fire

from

fuel

vapors

Keep

for

fumes/vapor before

Run

the

blower

for

four minutes before

highly explosive.

fuels.

from

spark-producing equipment and

of

children. tank(s) while the engine

service

valve

Take

care

in

any

smoking, open

the

fuel

system

fuel

supplies have a

extinguisher

Be

familiar with

by

Use

Store

at the engine

catching

is

the,NFPA

any

or

engine

system.

positi..,e

installed nearby

in

this environment.

the vessel's

extreme

fuel

in

when

fuel

flames,

when

shutoff

its

proper

are

appropriate

can

is

or

filter,

fuel

or

fuel

when

flame

oil.

cause

run-

care

a well-ven-

running.

servicing

that might

or other

servic-

valve.

and

is

use.

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect generator. it

last.

• Make certain starting.

• Make certain installed before starting the engine.

BATIERY

A

WARNING:

or

death!

•

Do

not being highly explosive arcing or equipment ing

servicing.

• Never connect tive not

test together. Ventilate accumulation of explosive gases. disturb is

being charged.

•

Avoid burns wristwatch, rings, the

battery.

• Always tum the battery charger off before disconnecting the

battery connections. Remove

and

reconnect it last when disconnecting the

STARTING

Accidental

the

battery cables before servicing

Remove

the

all

personnel are clear of

all

covers, guards,

starting

negative lead

and

can

cause

first

and

the

engine before

hatches are

injury

the

reconnect

re-

EXPLOSION

Battery

smoke

or

serviced. Lead acid batteries emit hydrogen, a

by

lit tobacco products. Shut off

in

the

(+) connection terminal of the starter solenoid.

the

battery condition

Sparks could ignite battery gases or

any

compartment containing batteries

the

battery charger connections while

contacting

or sparks that could cause

explosion

allow

an

gas,

which can

vicinity

the

to

negative (-) battery cable

terminals with tools, etc.,

and

any

can

cause

open

flame

near

be

ignited

prevent electrical arcing

by

shorting the terminals

To

avoid sparks,

an

explosion. Remove

other jewelry before handling

the

negative lead

injury

the

by

electrical

all

electrical

to

fuel

the

battery.

battery

the

to

battery

to

engine!

dur-

posi-

Do

vapors.

prevent

do

not

prevent

first

BATIERYACID

A

WARNING:

severe

injury

•

When

servicing

level,

wear

tion.

Batteries contain sulfuric acid which

If

it

comes

with

water.

inadvertently

Sulfuric

or

death!

rubber gloves, a rubber apron, in

contact with your skin, wash it off

Acid

when

acid

in

batteries

the

battery or checking

may

splash

on

the skin or

removing electrolyte caps.

can

the

is

cause

electrolyte

and

eye protec-

destructive.

at

into

the eyes

once

TOXIC

• Ensure that

•

• For additional information refer

•

• Although diesel engine exhaust gases

AVOID

•

EXHAUST

A

WARNING:

discharged regularly for leaks are

securely attached attention exhaust pipe nipple.

Be

sure

the

In

addition install a carbon monoxide detector. Consult builder or dealer for installation of approved detectors.

tional

information

A

WARNING:

odorless nausea

Do

not

use

fumes

can

tems.

Exhaust sulfur causes rapid deterioration of copper

tubing resulting Do

not

install exhaust outlet where exhaust

through portholes, vents, or air conditioners. exhaust discharge outlet enter

the

flow

of exhaust.

exhaust gas toms are:

Vomiting Dizziness Throbbing Muscular twitching Intense headache Weakness

fumes

is

present

or signs of carbon monoxide inhalation or poisoning

MOVING

A

WARNING:

or

death!

Do

not service

tion

arises operating adjustments, ing

moving parts

GASES

Carbon

monoxide

the

exhaust system

from

the

engine. Check

and

make sure

and

no

to

the

manifold, water injection

unit

and

its

surroundings are

to

routine inspection of the exhaust system,

on

Carbon Monoxide).

Carbon

gas.

Inhalation

or

death!

copper tubing

rapidly

in

exhaust discharge outlet

Avoid

from

in

diesel exhaust

in

temples

and

sleepiness

in

destroy

copper

exhaust/water leakage.

is

overloading the craft.

gasoline engines, carbon monoxide

(CO)

is

adequate

the

exhaust

warping exists.

to

ABYC

monoxide

produces

diesel exhaust

near

(CO)

flu-like

tubing

the

waterline, water

and

close

fumes.

is a deadly

exhaust

elbow,

well

T-22

is

systems.

in

exhaust

or

are

not

Some of

PARTS

in

which

Rotating

the

parts

can

cause

injury

engine while

it

is

absolutely necessary

use

and

hot exhaust system components.

it

is

running.

extreme care to

to

manifolds

Pay

your boat

an

symptoms,

can

If

restrict

as

avoid

gas!

expel

gases

system

close

and

ventilated.

(educa-

invisible

Diesel

sys-

be

drawn

the

engine

could

the

toxic

as

the

symp-

If

a situa-

to

make

touch-

Engines & Generators

ii

SAFETY

INSTRUCTIONS

• Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose

jackets, shirts, sleeves, rings, necklaces or bracelets that

could be caught in moving parts.

• Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times.

• Do not check fluid levels or the drive belt's tension while the engine is operating.

• Stay clear when the engine is running; hair and clothing can easily be caught in these rotating parts.

HAZARDOUS

A

WARNING:

of

the drive shaft and the transmission coupling

NOISE

High

noise

levels

can

cause

hearing

loss!

• Never operate an engine without its muffler installed.

• Do not run an engine with the air intake (silencer)

removed.

• Do not run engines for long periods with their enclosures

open.

A

WARNING:

mentally

or

Do

not

physically

incapacitated

work

on

machinery

by

when

fatigue!

you

are

ABYC, INSTALLING

Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their recommendations when installing your engine.

ABYC "Safety Standards for Small Craft"

Order from:

NFPA (National Fire Protection Association) "Fire Protection Standard for Motor Craft"

Order from:

USCG "USCG 33CFR183"

Order from:

NFPA

AND

USCG

PUBLICATIONS

DIESEL

(American Boat and Yacht Council)

ABYC

15

East 26th Street

New York,

National Fire Protection Association 11

Tracy Drive Avon Industrial Avon,

U.S. Government Printing Office Washington, D.C.

NY

MA02322

(United States Coast Guard)

ENGINES

10010

Park

20404

FOR

OPERATORS

Many

of in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

ENGINE

Preparations to install an engine should begin with a thorough examination (ABYC) standards. These standards are a combination sources including the USCG and the NFPA.

Sections

H-2 Ventilation P-l P-4 Inboard engines E-9 DC Electrical systems

All installations must comply with the Federal Code Regulations (FCR).

MANUAL

the preceding safety tips and warnings are repeated

INSTALLATIONS

of

the American Boat and Yacht Council's

of

the ABYC standards

Exhaust systems

of

particular interest are:

of

Engines & Generators

iii

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information:

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For

installations where the exhaust manifold/water injected exhaust elbow is close to or will be below the vessel's waterline, provisions must be made to install a break in the raw water supply hose to the exhaust elbow. 'This hose must be looped a minimum

the exhaust manifold injection port raw

If

you have any doubt about the position

to the vessel's waterline under the vessel's various operating conditions,

siphon-break.

NOTE:

operation. engine

EXHAUST

The exhaust hose must be certified for marine use. The system must prevent water from entering the exhaust under any sea conditions and at any angle of

of

20" above the vessel's waterline. Failure

water damage

A siphon-break

Failure

damage.

Consult

SYSTEM

the vessels hull.

A

detailed

diesel,

engines

is

at or

below

to

the engine and possible flooding

of

the water-injected exhaust elbow relative

requires

to

properly maintain a siphon-break

40

page

periodic inspection and cleaning

the

siphon-break manufacturer for proper

Marine

and

Installation

generators,

Manual

is

available

to

use a siphon-break when

the load waterline will result in

of

the

boat.

to

ensure

can

result

in

maintenance.

covering

from

gaSOline

your

WESTERBEKE

dealer.

siphon-

instaU

proper

catastrophic

be

designed to

and

a

Engines & Generators

iv

TABLE

Specifications .............................................................. 2 Engine Adjustments ................................................. .46

Parts Identification .....................................................

Testing for Overhaul .................................................. .4 Testing the Battery Charging Circuit.. ......................

Troubleshooting Chart [Engine] ................................. 5

Engine Assembly [Methods] ...................................... 7

Generator Disassembly ............................................... 8 Wiring Schematic [BCGTC] ....................................

Engine Disassembly .................................................... 9

Timing Belt Disassembly ..........................................

Cylinder Head and Valves ........................................

Cylinder Head Installation ........................................ 18

Camshaft and Rocker Arms ......................................

Pistons and Connecting Rods ..................................

Front Case/Counterbalance Shaft and Front Case/Counterbalance Shaft and

CrankshaftlBearings and Cylinder Block Inspection and

Distributor ................................................................. 34 Special Tools ............................................................. 78

Coolant Circulation Pump ........................................ 35 Engine Hardware Torques ........................................ 79

Exhaust ManifoldlHeat Exchanger ........................... 36 Standard Hardware ...................................................

Raw Water Pump ...................................................... 37

Thermostat AssemblylFuel Pump ............................ .38 Metric Conversion [Chart] ........................................ 82

Starter Motor ............................................................. 39 Index .....................................................................

Rebuilding the Carburetor ........................................ 43

Oil Seal ............................ 30 Generator Electrical Testing ..................................... 69

Oil Pan ........ .26

Oil Pump ...... 27

Piston Clearance .... .33 Service Data/Standards and Limits .......................... 76

OF

CONTENTS

.3

11

15

19

.21

Component Testing ................................................... 50

Troubleshooting the Overspeed Switch ....................

Wiring Diagram [BCGTC] ....................................... 52

Remote

EFI [BCGTE] Troubleshooting ................................

EFI [BCGTE] Troubleshooting [Chart] .................... 58

EFI [BCGTE] Component Testing ...........................

BCGT Engine/Generator Troubleshooting [Chart]

BCGTE Wiring Schematic ....................................... 66

BCGTE Wiring Diagram .......................................... 67

Remote

Standard and Metric Conversion Data .....................

51 51

53

Panels Diagram [BCGTC] .......................... 54

55

60

..

64

Panels Wiring Diagram [BCGTE] .............. 68

80 81

83

Engines & Generators

1

BCGT

ENGINE/GENERATOR

SPECIFICATIONS

Engine

Type

Bore

and

Stroke

Total

Displacement Bearings Combustion Compression Firing Direction

Inclination

Governor

Fuel Fuel Distributor Spark Ignition

Flame

Carburetor

Start Starting

Battery Battery

Generator

Engine (all

Engine

Chamber

ratio

Order

of

Rotation

Pump

Plugs

Coil

Arrester

Motor

Battery Capacity Charging

Cooling

Combustion

models)

Cooling

ENGINE

SPECIFICATIONS

3

cylinder, 4 cycle, w/counterbalance water

cooled

2.56 x 2.61

40.3

cubic

Four

main

Semi-spherical

9.8

- 1

1 - 3 - 2

Counterclockwise end

25°

continuous,

30°

temporary,

Mechanical

FUEL

SYSTEM

Electric Unleaded Breakerless 14mm 12

volt

Metal

screen

Single-barrel

ELECTRICAL

12

volt

12

volt

300

cold

Integral

AIR

REQUIREMENTS

225-250

(6.3-7.0cmm) 42

CFM

100

CFM

gasoline

in.

(65

inches

bearings

all

fuel

pump

89

octane

distributor

type

downdraft

SYSTEM

reduction negative

cranking

electric,

CFM

(1.2

cmm)

(2.8

cmm)

ground

17

overhead

shaft,

carbureted,

engine

mm x 66.3

(.66

liter)

viewed

from

directions

or

higher

type

gear

w/solenoid

amps

(CCA)(min)

amps

camshaft

mm)

the

back

gasoline

General

Fresh

Water

Raw

Water

Raw

Water

at

3600

RPM

Cooling

Water

Type Oil

Filter

Oil

Capacity

Oil

Grade

Type

Rating

(minimum)

Spark

Plug

Spark

Plug

Valve

Clearances

Timing

Specifications

Cylinder

Pump

Pump Flow

Capacity

LUBRICATION

AC

GENERATOR

TUNE-UP

Gap Torque

Head

Fresh

water-cooled

water-cooled Centrifugal

belt-driven Positive

displacement,

7.0-7.5

gpm measured water

3.5

injected

qts.

(3.4

before

block

heat

exchanger

type,

metal

(26.4-28.3

discharge

exhaust

liters)

SYSTEM

Forced

lubrication

Fuel

flow,

disposals

2.7

qts.

(2.6

API

specification

paper

liters)

by

gear

element

SJ

class

SPECIFICATIONS

2

pole

50/60

r~m

3000 3000 3000 3600 3600 3600

Consult

capacitor

hertz-1.0

Model

3.75Kw

6.0

8.0

4.5

7.2

9.6

factory

regulated

power

Hz

50

Kw

50

Kw

50

Kw

60

Kw

60

Kw

60

for

1201240

SPECIFICATIONS

0.031 ± 0.002

10.8

-

Intake Exhaust

18° ± .5° (no

load

60 -70

15.2

Ib-ft

valves:

BTDC

on

generator)

Nm

inches

0.20

0.30

at

43-51

(0.8

mm

3600

ft-Ibs

through

circuit

impeller

rubber

impeller,

Ipm)

into

elbow

pump

spin-on

factor

KVA

3.75

6.0

8.0

4.5

7.2

9.6

volt

application

±

0.05mm)

(0.008

(.012

rpm

raw

VAC

230 230 230 120 120 120

in)

Bolt

Torque

Engines & Generators

2

see

TORQUING

BOLTS

under

THE

CYLINDER

ENGINE

ADJUSTMENTS.

HEAD

ROCKER COVER

ARM

COOLANT

Fill

PARTS

IDENTIFICATION

RELAYS

FUEL

FIlTER

ASSEMBLY

FRONT COVER

[BCGTE]

PUllEY

CARBURETOR

FRONT

ANO

TIMING COVER

BELT

GENERATOR BACK

END

ACCESS

TO

REMOVAL

CIRCUIT

BOLT

OF

BREAKER.

FOR BACKEND

REAR

CONTROL

MODEL

[FUEL

I

PANEL

BCGTE

INJECTION]

Oil Fill

HEAT EXCHANGER

IN-LINE

FRONT

RAW PUMP

FUEL

Oil

WATER

PUMP

FilTER

FRONT

PUllEY

COVER

.

EXHAUST

COOLANT

ORAIN

FUEl

ELBOW

PLUG

LIFT

PUMP

GASDENSER

Oil

PAN

MODEL

BCGTC

[CARBURETOR]

ACCESS

FOR

REMOVAL

BACK

END

EXHAUST

GENERATOR BACK

END

TO

BOLT

OF

MANIFOlO

FlYWHEEL

HOUSING

'MOUNTING

AND

BRACKET

Oil

FEET

Fill

CONTROL

PANEl

GOVERNOR

Oil

FilTER

RAW

WATER

PUMP

HEAT EXCHANGER

Engines & Generators

3

TESTING

HOW

TO

DETERMINE

Cause

Generally, the time at which an engine should be overhauled is power output, decreased compression pressure, and increased fuel and oil consumption. The lowered engine power output is sometimes caused by improper oil, clogged filters or a faulty carburetor.

The decrease in compression pressure tors. It is, therefore, necessary to determine a cause or causes on the basis maintenance. means worn cylinders or piston rings, the following symptoms will occur:

of

Low

Compression

determined by various conditions such

not necessarily due to trouble with the engine itself, but

of

data produced by periodic inspection and

Oil analysis on a seasonal basis is a good

of

monitoring engine internal wear. When caused by

1 Low engine power output 2 Increased fuel consumption 3 Increased oil consumption 4

Hard

5 Noisy engine operation

ENGINE

engine starting

OVERHAUL

is

caused by many fac-

PERIOD

as

lowered engine

FOR

is

OVERHAUL

ENGINE

The following sections contain detailed information relating to the major components and systems Included are disassembly and inspection instructions for the guidance vice and rebuilding facilities. The necessary procedures should be undertaken only by such facilities.

Additional detailed information and specifications are provided in other sections generator, alternator, starter motor, engine adjustments, cooling pumps, etc.

DISASSEMBLY

1.

2. Clean the engine exterior.

3. Perform disassembly in a proper order using proper tools.

OVERHAUL

of

the engine.

of

suitable equipped and staffed marine engine ser-

of

this manual, covering the

Before disassembly and cleaning, carefully check for defects which cannot be found after disassembly and cleaning.

Keep disassembled parts in order. Apply oil when necessary. Take special care to keep the fuel system parts

of

intrusion

dust and dirt.

from .

These symptoms often appear together. Symptoms 2 and 4 can result also from improper fuel regulation or a faulty carburetor. They are caused also by defective electrical devices such as the battery, starter or spark plugs. Therefore it desirable to judge the optimum engine overhaul time by the lowered compression pressure caused by worn cylinders and pistons plus increased oil consumption. Satisfactory combustion

is

obtained only under sufficient compression pressure.

If

an

engine lacks compression pressure, incomplete combus-

tion

of

fuel will take place even are operating properly. overhaul, it pressure regularly. At the same time, the engine speed at which the measurement should be checked because the compression pressure varies

with engine rpm. The engine rpm can be measured at the

front end

NOTE:

ADJUSTMENT

OVERHAUL

Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in. Thereafter, it decreases gradually with the progress

of these parts. When decrease

limit, the engine must be overhauled.

The engine requires overhaul when oil consumption is high,

blowby evident, and compression values are at minimum or below.

400 rpm. With a limit differ by more than 14 ENGINE

is

important to measure the engine compression

of

the crankshaft.

To

test engine compression see the

CONDITIONS

Engine compression should be 178

COMPRESSION in this manual.

To

of

section

of

compression pressure reaches the repair

137

psi

if

other parts

determine the period

compression pressure is made

this manual.

psi

(860 Kpa). Pressure should

(100 Kpa) between cylinders. See

of

ENGINE

psi

is

the engine

of

engine

of

wear

(1260 Kpa)

at

not

SERIAL

Fill below for reference.

~

The number and serial number are printed on a decal on the

engine manifold.

The generator serial

number is stamped

on the top

generator

sDl~citicatiOJ'1s

pnnted

on the side

generator.

An additional decal is located on the top of liousing.

NUMBER

in

the information

lY

~'\\\

?~

!

~I'

I 1

I.

1\

~ngin~

mo~el

nm',o",o

on a decal

of

the generator

LOCATION~'

/-~~

A'",(~

~~~"'iiijiiijiiiiiliiiiiiiiiiiiiiiiiiiijiij~

~~~~~~~

are

the

~

The

engine serial

1'~0~oo')...

.I

,?? \ mto the engzne block.

0\,

,:umber

~i

is

st~mfJed

,

Engines & Generators

4

The

following problems of these determining

relating

these

problems,

problems.This chart

the

BCGT

/ENGINE

troubleshooting chart describes certain

to

engine service,

and

the

need

for

an

recommendations

may

engine overhaul.

the

be

of assistance

probable

to

causes

overcome

in

TROUBLESHOOTING

Also

refer

to

the

manual.

See

EFI

component testing

to

refer

GENERATOR TESTING.

Troubleshooting

TROUBLESHOOTING

in

this

manual.

Guide

For back-end troubleshooting

in

for

your

operators

electrical

PROBLEM

HARD

STARTING

OR

FAILURE

TO

START

SMOKY

EXHAUST

EXCESSIVE CONSUMPTION

OIL

PROBABLE

1.

High

exhaust

pressure.

2.

Timing

belt.

3.

AC

generator

overload.

4.

Check

valve

at

fuel

5.

Defective

starter.

6.

Faulty

fuel

regulator.

7.

Raw

water

in

cylinders.

WHITISH • PURPLE

1.

Excessive

2.

3.

BLACKISH

1.

2. I mproper

3.

4. I mproper

OIL

1.

2.

3.

4.

5.

6.

7.

engine

Excessive

3.

Poor

b.

Seized

c.

Excessive

d.

Worn

e.

Low

engine

I.

Excessive

g.

Piston

Insufficient

OR

Poor

compression.

valve

Insufficient

fuel.

LEAKAGE

Defective

oil

Broken

gear

Loose

gear

Loose

drain

Loose

oil

pipe

Broken

rocker

Loose

rocker

oil.

rise

of

oil

piston

contact.

piston

piston-to-cylinder

valve

stem

oil

rings

compression.

DARK

clearance.

intake

seals. case

case

attaching

plug.

connector. cover

cover

supply.

OR

BLUE

into

combustion

ring.

and

viscosity.

pressure.

are

worn

GRAY

air

(air

gasket.

attaching

CAUSE

SMOKE

valve

or

unseated.

cleaner

bolts.

chamber.

clearance.

guide.

clogged).

1.

Install a larger

2.

Inspect

3.

Remove

4.

Repair

5.

Repair

6.

Replace

7.

Failure Engine

1.

Correct

2.

Engine

3.

Check

b.

Replace

c.

Replace

d.

Replace.

e.

Replace.

I.

Correct.

g.

Engine

3.

See

LOW

1.

See

LOW

2.

Valve

3.

Replace

4.

Replace

1.

Replace

2.

Replace

3.

Retighten

4.

Retighten

5.

Retighten

6.

Replace

7.

Retighten

VERIFICATION/REMEDY

diameter

exhaust.

timing

belt-replace.

loads

before

starting.

or

replace

..

or

replace

starter.

regulator.

of

exhaust

system

or

may

need

overhaul.

oil

level.

overhaul.

standard.

or

clean.

or

correct.

overhaul.

COMPRESSION;

COMPRESSION.

adjustment.

air

cleaner.

with

proper

oil

seals.

gasket.

bolts. plug. oil

connections.

gasket.

attaching

syphon

HARD

fuel.

bolts.

break.

Clear

STARTING.

cylinders-

ENGINE

BACKFIRES,

MISFIRES

OIL

LEVEL

1.

Incorrectly

2.

Displaced

3.

Worn

piston

4.

Worn

piston

OIL

LEVEL

1.

Defective

2.

Worn

valve

1. I ncorrect

2.

Valves

are

RISING

positioned

or

twisted ring. or

cylinder.

FALLING

valve

stem

and

valve

clearances.

out

of

adjustment.

piston

ring

connecting

seal.

guide.

gaps.

rod.

Engines

& Generators

5

1.

Correct

2.

Replace

3.

Replace

4.

Replace

1.

Replace

2.

Replace a valve

1.

Adjust

valves

2.

Adjust

valves

ring

gap

positions. connecting ring. piston

and

valve

stem

and

and and

rod.

rebore

cylinder.

seal.

valve

guide.

clearances.

BCGT

/ENGINE

TROUBLESHOOTING

PROBLEM

ABNORMAL OR

LOW

EXCESSIVE CONSUMPTION

SOUND

NOISE

COMPRESSION

FUEL

CRANKSHAFT

1.

Badly

2.

Badly

3.

Melted

CONNECTING

1.

Worn

2.

Worn

3.

Bent

PISTON,

1.

Worn

2.

Worn

3.

Piston

4.

Piston

VALVE

1.

Worn

2.

Excessive

3.

Worn

4.

Worn

MAIN

1.

Incorrect

2.

Inadequate

3.

Valve

4.

Broken

5.

Compression

6.

Piston

7.

Worn

8.

Worn

1.

Noisy

2.

Smoky

3.

Moving

4.

Poor

5.

Improper

6.

Improper

AND

worn

bearing.

worn

crankshaft.

bearing.

ROD connecting crankpin.

connecting

PISTON cylinder. piston

pin. seized. seized

MECHANISM

camshaft.

valve

timing

gear.

fan

pulley

ENGINE

TROUBLES

valve

contact

stem

seized.

valve

ring

seized.

piston

ring

engine

knocking.

exhaust.

parts

compression.

valve valve

PROBABLE

MAIN

AND rod

big

rod.

PIN,

AND

and

ring

clearance.

bearing.

clearance.

of

valve

spring.

leaks

through

and

cylinder,

bearings.

nearly

seized

timing.

clearance.

CAUSE

BEARING

CONNECTING

end

bearing.

PISTON

RING

worn

or

damaged.

seat.

cylinder

head

or

excessively

ROD

gasket.

worn.

BEARING

1.

Replace

2.

Grind

3.

Replace

1.

Replace

2.

Grind

3.

Correct

1.

Rebore

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

4.

Replace.

1.

Adjust

2.

Lap

3.

Replace

4.

Replace

5.

Replace

6.

Replace

7.

Overhaul

8.

Overhaul

1.

See

2.

See

3.

Repair

4.

See

5.

Adjust.

6.

Adjust.

VERIFICATION/REMEOY

bearing

and

grind

crankshaft.

bearing

and

check

beari

ng.

crankshaft.

bend

or

replace.

cylinder

to

oversize piston. piston

and

rebore

piston

and

rings.

valve

clearance.

valve.

valve

and

valve

guide.

valve

spring. gasket. piston

and

piston engine. engine.

KNOCKING.

SMOKY

EXHAUST.

or

replace.

LOW

COMPRESSION;

crankshaft.

lubrication

and

replace

cylinder.

ring.

HARD

STARTING.

system.

piston.

KNOCKING

LOW

OIL

PRESSURE

INSUFFICIENT

1.

Air

NOZZLE

1.

Seized

2.

Worn

ENGINE

1.

Main a.Overheated b.Carbon

KNOCKING

1.

Poor

1.

Worn

2.

Relief

3.

Clogged

4.

Diesel

INTAKE

intake

obstructed.

TROUBLES

nozzle.

KNOCKS

engine

troubles.

cylinder.

deposits

WITH

compression.

Bearings. valve

malfunction.

oil

cooler/filter.

dilution

AIR

WITHOUT

in

cylinder.

DARK

SMOKE

of

the

oil.

MUCH

SMOKE

Engines & Generators

6

1.

Remove

1.

Replace.

2.

Replace.

a.

See

OVERHEATING;

b.

Clean.

1.

See

LOW

1.

Engine

2.

Overhaul

3.

Repair

4.

Injection

obstruction.

LOW

COMPRESSION;

overhaul

replace

oil

pump.

and

replace.

pump

repair.

OUTPUT.

HARD

bearings.

STARTING.

ENGINE

ASSEMBLY

GENERAL

•

Be bolts are

• During are correct direction pistons, piston rings, bearings and bearing caps.

•

Apply Insure that moving parts, rotate or slide excessive tension.

• If there are mating marks scribed during disassembly, reference them correctly for assembly.

•

Use

• Tighten to

•

When bolts

• Most gaskets and many bolt washers are asymmetrical, make certain

Torquing

Prevent mechanical damage

three yield torqued brought center

damaged during assembly,

care.

INFORMATION

careful not

being assembled

lubricating

new

specified torques using a reliable torque wrench.

required,

and

steps-I/2, bolts

as

down

bolts

See

TORQUE

to

mix bolts

used

on

various engine assemblies.

assembly,

gaskets, lockwashers, O-rings, packings

the

gaskets. Refrain from using tape sealants.

recheck clearances

in

relation

oil

and

are not subject

bolts and

use

they

are positioned properly.

and

nuts.

in

their proper order

to

the

engine block, such

to

moving parts during

when

assembled

to

nuts

on

important parts of

liquid sealants

Metric

and

insure that

and

binding or

when

required

and

facing

assembly.

on

the

S.A.E.

Hardware

by

running fasteners

2/3,

and

111

torque. Exceptions are torque-to-

and

rocker arm shaft fasteners. The former are

indicated. The latter-rocker shaft fasteners-should

in

very

small increments, working

out.

Gaskets, especially head gaskets, might

they

should

be

SPECIFICATIONS thru out

down

from

positioned

this

parts

in

engine,

and

engine

on

in

the

with

manual.

the

as,

seals.

nuts,

be

great

When installing gaskets that seal around water (coolant) passages, coat both

Do

not

use

sealant

HIGH-COPPER ADHESIVE ing

a gasket

Specialized gasket sealers such applications requiring non-hardening properties. HYLOMAR is

particularly effective

resists

fuel,

NOTE:

TAPE

fitting that connect water coolant passages.

Bolts

and

Lightly them. should be sealed

When LOCTITE

LITHIUM based grease bearings

Antiseize compounds LOCTITE protect threaded components yet come apart locking according

be

Heavily use

oil

head bolts

Bolts

assembling

blue.

and

when

oil

all

clean engine

sides

with

WHITE SILICONE

when

installing a

SPRAYS

in

position during

oil , and

SEALANTS should

water.

assembly.

on

copper cylinder-head

Fasteners

and

other fasteners

and

other plugs that penetrate

with

PERMATEX

the

flywheel, coat

is

waterproof, ideal

stuffing boxes.

and

thread locking adhesives

necessary.

to

sliding

oil.

LOCKTITE offers levels of

the

job.

and

reciprocating components, always

new

gasket.

are

useful for

as

HYLOMAR work

be

used

on

pipe plugs and

as

you

the

#2 or

HIGH

the

bolt threads

for

allow

GREASE.

hold-

well

gaskets

water jacket

water

assemble TACK.

with

pump

such

them

to

and

in

as

Sealants

Oil excellent any coating of gaskets

LOCTITE hydraulic red sealant should be used hoses

Coat both surfaces of the SILICONE SEALER.

based

joint

and

in

and

Lubricants

PERMATEX

all

purpose sealers. They are effective

contact

oil

or

o-rings.

the

oil

#2

and

its

with

coolant,

LIQUID TEFLON

filter assembly.

oil

raw

pan gasket with high temp

HIGH

water,

can

TACK

be

used

oil,

equivalent

in

just about .

or

fuel.

A light

on

rubber

on

oil

adapter

RED

are

Engines & Generators

7

FRONT

STATOR

GENERATOR

DISASSEMBLY

BACK

COVER

STRIKE

HERE

FROM

THE

TO

LOOSEN

TAPPERED

SHAFT

FAN

BACK

END

DISASSEMBLY

TAPPER

EO

SHAFT

GENERATOR

Disconnect the AC wiring connections at the terminal block and breaker [E.EI.] and [carburetor] and remove the control panel from the side battery cable connections and the engine ground cables.

Separate the exhaust hose at the water injected elbow and disconnect the fuel supply and return lines.

NOTE:

Label

Drain the engine oil and oil lines, the fuel and the fuel lines and drain the coolant from the engine.

Be aware this is a gasoline engine. Carefully close off fuel lines, wipe up gasoline spills, and properly stow any left over gasoline.

A

CAUTION:

injury

or

death.

any

lines,

of

the generator housing. Disconnect the

hoses or cables

Explosion

from

fuel

as

you separate

vapors

can

them.

cause

FLATHD. SCREW

REMOVE

THE EXCHANGER ACCESS

The BCGT engine is not as bulky engines. [Approx.75Ibs.] repaired on a sturdy work bench. that

the

engine is securely fastened so

off

the

bench.

1. Separate the generator back-end from the engine by first removing the plastic cap covering the nut on the back

of

the generator. Loosen but do not remove the nut.

2. Unbolt and remove the complete generator from the

shaft by prying against the loosened nut and taping with a brass mallet.

If

there is no separation, remove the nut and washers and slide the casing and armature off the rotor. Then remove the rotor/fan assembly separately.

3.

Strike the rotor with a wood block and mallet in a downward motion to release the rotor from its tappered shaft [see illustration above).

HEAT

TO

THE

SCREW

or

heavy as most marine

So it can be disassembled and

Make

certain it

can

however,

not

topple

Engines & Generators

8

ENGINE

INTRODUCTION

The

following text describes the disassembly, inspection,

repair,

and reassembly of the engine

complete engine overhaul. This

manual engine adjustments, generator information and all related technical

NOTE:

inspected and adjusted adjustment and replacement removing

The

also

data.

cylinder

the

engine.

includes a breakdown of sub assemblies,

head,

rocker arms and valves

with

the

can

when

engine

also

preforming a

can

be

in

the

boat.

TIming

be

accomplished without

DISASSEMBLY

6.

belt

Disconnect inspect

OIL

FILTER

COMPONENTS

the

oil

and

drain the oil hoses.

gallery/filter

OIL

COOLER

assembly.

Remove,

clean,

and

Suggested

The

heat exchanger, having

generator back plate, should

HEAT

1.

Loosen wheel

2.

Remove cleaned, inspected, and repainted. Refer

MOTOR.

3.

Remove distributor.

4.

Disconnect the assembly aside in

5.

Remove

disassemble the thermostat

Sequence

EXCHANGER

the front crankshaft pulley bolt and remove

and

back-plate.

the

starter

the

ignition wires, ignition coil and the

the

exhaust elbow

this

manual.

the

water temperature switch

of

Disassembly

been

removed

be

set aside for servicing. See

in

this manual.

motor.

The starter motor should

exhaust temperature switch and disassemble

and

manifold

for

servicing. Refer

assembly.

to

access the

to

STARTER

from

the

engine.

to

EXHAUST SYSTEM

and

sender and

Set

the

be

fly

this

7.

Loosen the belt guard thumb screws guard sections and their gaskets.

8.

[BCGTC] governor the

CARBURETOR

9.

[BCGTC]

governor assembly and

MAINTENANCE.

GOVERNOR GOVERNOR [BCGTC

ONLy]

Disconnect

and

the carburetor at the ball joint

carburetor.

AND BELT

When

SECTION in this manual.

Release the governor belt

.

the

servicing the carburetor, refer

belt.

and

linkage

arm

between

and

See GOVERNOR

~

\\.

(jjd.

OIL

FILTER

remove the belt

the

and

remove

to

the

remove

the

THERMOSTAT

ASSEMBLY

COOLANT

PUMP

ASSEMBLY

Engines & Generators

9

ENGINE

DISASSEMBLY

10. [BGCTE] Disconnect the in-line fuel pump and the fuel filter, drain the fuel and inspect the components, their conneeting fittings, and hoses. Replace the fuel filter cartridge.

IN-LINE

FUEL

[BCGTE]

11.

[BCGTE] Remove the entire fuel

FUEL

INJECTOR

PUMP

ASSEMBLY

FUEL

FILTER

AND

AS'EMBLY"CGlE)

aSSemble

e

12. [BCGTC] Remove the gasdenser and the connecting fuel lines from the front pump.

INSPECT

HOSES

13. Loosen the raw water pump, remove the drive belt and

then remove the raw water pump.

14. Remove the engines coolant pump. For servicing, refer to

COOLANT

15. Detach and remove the ignition wires, the distributor, and

the spark plugs. Refer to See

wires and spark plugs.

DISTRIBUTOR

ENGINE

ADJUSTMENTS for information on ignition

PUMP.

of

the engine and remove the fuel lift

DISASSEMBLY in this manual.

FUEL

INJECTOR

USE

INJECTOR

CLEANER

DISTRIBUTOR COMPONENTS

IGNITION

WIRES

Engines & Generators

10

TIMING

BELT

DISASSEMBLY

12

BOLT

TORQUE

98 -105

135

-145

NUMBERS SUGGESTED DISASSEMBLY

1

TIMING

COVER

3

ACCESS

FT-LBS

Nm

INDICATE

THE

ORDER

OF

A

COVER~

9

CAMSHAFT

SPROCKET

BELT

C

TIMING TENSIONER

TIMING

BELT INSPECTION CAN ENGINE

ADJUSTMENT,

AND

BE

PERFORMED

IN

THE

BELT

REPLACEMENT

WITH

BOAT

INSTRUCTIONS THE

TIMING

WES1ERBEKE requires the

timing

belt should always The

adjustments, inspection, and replacement procedures

may

be

perfonned without removing

boat.

THE

TIMING

Timing

1.

NOTE:

TIMING

2.

NOTE:

0.31

Belt

Turn

the

camshaft sprocket

Always

MARK_=:,;;;~v~,....,

Remove and

insert a rod

Be sure to use an inserting rod with a diameter

in

(8 mm).

FOR

INSPECTING

BELT

as

nonnal maintenance, replacing

belt after

1000

be

replaced during

BELT

PART

engine operating

NUMBER

Removal

crankshaft clockwise

and

tum

the crankshaft clockwise.

the

plug

on

the

left surface of the cylinder block

with

a diameter of 0.31

the

counterbalance shaft.

AND

an

the

generator

IS

#043036

to

align the timing mark

timing belt rear

REPLACING

hours.

The timing

engine overhaul.

from

cover.

in

(8

mm)

to

of

Engines & Generators

the

on

lock

~-~~

~

Loosen the timing belt tensioner

4.

Move

the

timing belt tensioner toward

and

temporarily tighten the

that

position.

CRANKSHAFT SPROCKET

~----':2.6

ROO

In

0.31

nut.

the

nut

to

hold

the

165

mmJ

In

[8

water

tensioner

mmJ

pump,

in

11

TIMING

BELT

DISASSEMBLY

5. Remove the timing belt.

NOTE:

If

the

timing belt

the

belt

to

indicate

Camshaft

1.

Remove the camshaft sprocket bolt without turning the camshaft.

Sprocket

is

to

be

the

direction

Removal

reused,

of

rotation

draw

(clockwise).

an

arrow

on

Crankshaft

1. Lock the crankshaft in position.

NOTE:

2. Remove the crankshaft bolt.

Timing

Replace the belt

• Hardening pressed with fingernail (back side is glossy).

• Cracks on rubber back.

• Cracks or peeling

• Cracks on tooth bottom.

• Cracks on belt.

• Abnormal wear are sharp as

• Abnormal wear on teeth.

• Tooth missing

Bolt

Do

not tum

Belt

Inspection

if

of

the back rubber, leaves no indent when

if

Removal

the

crankshaft.

any

of

the following conditions exist:

of

canvas.

of

belt sides. The sides are normal

cut by a knife.

~d

canvas fiber exposed.

-,

~

CRACKS

if

~

ON

EDGE

they

SPROCKET

Oil

1.

2.

3. Remove the oil pump sprocket flange nut.

BOLT

Pump

Sprocket

Remove the plug from the left side Insert an 0.31 in

counterbalance shaft.

SPROCKET

Flange

(8

mm) diameter round bar to lock the

NUT

OIL

Nut

PUMP

SPROCKET

Removal

of

the cylinder block.

HARDENING

'v.

PEELING

~

('

00

$

CRACKS

ON

UNDERSIZE

CRACKS

ON

TOP

Tensioner

1.

Replace the tensioner when turned.

Inspection

,~\'.:",

~'"

~

..

,

ROUNDED FLUFFY

if

the pulley binds, rattles or

EDGES

STRANDS

TOOTH

MISSING

CANVAS

EXPOSED

is

noisy

Engines & Generators

12

ENGINE

TIMING

BELT

Flange

1. Mount the flange so that its side shown by the heavy

Installation

arrow in the illustration faces toward the sprocket.

FLANGE

fi

__

~NKSHAFT

-~

WASHER

Crankshaft

1. Lock the crankshaft.

NOTE:

2. Tighten the crankshaft bolt to the specified torque.

Oil

Pump

1. Insert the round bar into the plug hole in the left side the cylinder block to keep the counterbalance shaft from turning.

2. Install the oil pump sprocket.

3. Tighten the nut to the specified torque.

Bolt

Do not

tum

Sprocket

Installation

the crankshaft.

Flange

Nut

Installation

of

Tensioner

1. Install the tensioner spring and timing belt tensioner.

2. Hook the tensioner spring onto the bend tensioner bracket and the stopper pin on the cylinder block.

3. Move the timing belt tensioner as close as possible to the

water pump; temporarily tighten the tensioner nut.

Timing

1. Align the triangular marking with a marking on the timing belt rear cover.

2. Align the notch in the crankshaft sprocket flange with the marking on the front case.

3. Align the triangular marking on the oil pump sprocket with the marking on the front case, and then insert a 2.56 in. (65 mm.) or longer, the plug hole in the left side

Spring/Timing

Belt

Installation

0.31 in (Smm.) diameter round bar into

Tensioner

on

of

the cylinder block.

Installation

of

the camshaft sprocket

the timing belt

Camshaft

1. Tighten the bolt to the specified torque.

CAMSHAFT

Sprocket

BOLT

TORQUE

Bolt

Installation

58

-72

Ft-Ibs

SPROCKET

(80

-100

Nm)

BOLT

MARK

ON

BELT

REAR

-

TRIANGLE CAMSHAFT

TIMING

COVER_--"'''A

MARK

ON

SPROCKET

NOTCH

IN

SPROCKET

~d~=\=~====i"'C-..TRIANGLE

CRANKSHAFT

MARK

ON

FRONT

OIL

CASE

PUMP

MARK

ON

SPROCKET

Engines & Generators

13

ENGINE

At

this time, check that the moveable range

oil pump sprocket is according to specifications.

STANDARD

VALUE: 4 to 5 teeth

1

to 2 teeth

in

forward

in

reverse

of

direction.

teeth on the

TIMING

BELT

8. Turn the crankshaft teeth

(81°) to align the timing mark on the camshaft sprocket with the tensioner set mark on the timing belt rear cover.

A

CAUTION:

proper

tension crankshaft check

the

clockwise by nine camshaft sprocket

This

operation

to

the

timing

counterclockwise

tension.

is

belt,

and

perfonned

so

do

not

push

the

belt

to

tum

give

the

to

a

4.

If

the movable range

exceeds the specified range, correct as follows:

a. Pull out the round bar from the plug hole in the left

side

of

the cylinder block.

b. Turn the oil pump sprocket one turn at a time until the

round bar can again be inserted.

c. Check that the movable range

is in the specified value.

5.

Set the timing belt over the crankshaft sprocket and then over the oil pump sprocket and camshaft sprocket, in that order.

NOTE:

Ensure

that

slack.

Keep

the

round bar inserted until

been

placed.

6. Apply counterclockwise force to the camshaft sprocket to make the belt taut on the tension side, arid make sure that all timing marks are lined up.

After

of

the teeth on the oil pump sprocket

of

the oil pump sprocket

the

tension

side

of

the

timing belt

the

this

step,

be

sure

to

remove

is

timing belt

the

round

not

has

bar.

TENSIONER

9. Make sure that the timing belt teeth are engaged with the camshaft sprocket teeth along the portion shown by the curved arrow in the illustration below. Then tighten the tensioner nut.

IO.Pull the timing belt in the center

toward the sealing gasket line for the trated. Make sure that the clearance between the back the belt and the sealing line is the standard value.

STANDARD

VALUE:

O.47in.

SET

(12mm)

MARK

of

the sprocket

the tension side

belt

cover, as illus-

0.47

In

[12

mm]

of

CAMSHAFT

7. Loosen the temperorarily tightened tensioner nut on the

SPROCKET

water pump side use

of

the spring force.

TENSION

SIDE

1 or 2 turns, and tension the belt making

Engines & Generators

1l.Pull out the rod from the plug hole on the left surface

the cylinder block and apply the specified sealant. Then tighten the plug to the specified torque.

Specified sealant value: 3M equivalent.

TIGHTENING

TDRQUE:

11-16

fUbs.

AID

Part No. 8660 or

(15-22

Nm)

14

of

4

CYLINDER

TORQUE

60-70Nm

HEAD.

43 -51

FT-LBS

CYLINDER

HEAD

~-----14

AND

VALVES

13

8

9

VALVE SEAL

1 o

VALVE

19VAlVE

REMOVING

FROM

Disassemble the cover bolts as shown above, taking care not to lose the washer and insert. Remove the rocker cover and rocker cover gasket.

Loosen each as to avoid the possibility several times until the bolts are unfastened. Follow the sequence shown in the diagram.

GUIDE

THE

CYLINDER

of

the cylinder head bolts, a little at a time so

CYLINDER

HEAD

BLOCK

of

distorting the cylinder. Repeat

HEAD

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

THE OF

¢::I

ENGINE FRONT

8 6

CYLINDER

LOOSENING

Remove the valve retainers, valve springs and valves from the cylinder head. When removing each valve retainer, depressing the retainer against the valve spring and remove the retainer lock. Identify each valve by putting a mark

~';;:~::

numbe>-

of

the

cyfuJrler

HEAD

BOLTS

SEQUENCE

~

which

the

valve

,

Remove the cylinder head and the cylinder head gasket.

KEEP

THE

PARTS

IN

OROER

ACCOROING

TO

THE

CYLINDER

NUMBER -EXHAUST

ANOINTAKE

Engines & Generators

15

'\

CYLINDER

HEAD

AND

VALVES

Use pliers to remove the valve stem seals. Do not reuse the stem seals.

CYLINDER

Before cleaning check the cylinder head for water leaks, cracks and other possible damage.

Clean sealant. After flushing the oil passage, blow that no portion

To

check the cylinder head bottom surface for flatness and distortion, as indicated in the diagram, use a straight edge and a feeler gauge. by grinding.

HEAD

INSPECTION

by

completely removing the oil, scaling, carbon and

air

thru

of

the oil passage is clogged.

If

distortion exceeds the limit correct

CHECKING

CYLINDER

HEAD

FLATNESS

to ensure

VALVE

Valve

If

contact between the valve and valve seat by applying a thin coat face, then insert the valve into the valve guide and press-fit

the valve on the valve seat. Check

tion correct the valve seat. the valve.

THICKNESS

Intake Exhaust

VALVE

ASSEMBLY

StemNalve

the valve stem is bent or worn, replace the valve. Check

of

Prussion Blue (or Redhead) on the valve seat contact

if

the valve seat contact face contacts the center posi-

of

the valve contact face.

OF

VALVE

Standard

0.0391n

0.051in

CONTACT

wmi

SEAT

[to

be

al

cenler

of

seat)

INSPECTION

Seat

Do

not rotate the valve.

If

the margin is out

HEAD

MARGIN

(1.0mm) (1.3mm)

VALVE

HEAD

THICKNESS

it is not correct concentric,

of

the limit, replace

.

Limit

0.020in

(0.508mm)

0.031

in

(0.787mm)

-

[MARGIN)

---r--

.L

VALVE

LENGTH:

VALVE

SEAT

Standard

Valve

Measure the free height spring

VALVE

SPRING

Standard

Intake

Exhaust

WIDTH

0.035in -0.051

Spring

if

it is out

FREE

1.823in

3.60in

3.968in

OF

CONTACT

of

limit.

LENGTH

(46.3mm)

(100.6mm)

(100.8mm)

(p.9 -1.3mm)

of

the valve spring and replace the

____

Limit

1.783in

(45.3

mm)

VALVE LENGTH

CYLINDER

A

stock

See the STANDARDS

head rework dimensions

HEAD

Standard

HEAD

0.079in Total

HEAD

4.287 -4.295in

CAUTION:

may

cylinder

FLATNESS

0.020in GRINDING

(0.2mm)

resurfacing

HEIGHT

be

removed

block

mating

(0.05mm)

depth

(NEW)

(108.9

No

AND

Limit

LIMIT

of

cylinder

head

-109.1mm)

more

than

O.07Bin

from

the

cylinder

surfaces

of

in

LIMITS

the valve seat hole.

0.079

and

block

(O.2mm)

total.

CHART

(0.2mm)

of

head

and

for cylinder

Also check the spring for squareness and limit replace the spring.

VALVE

SPRING

Standard

Refer to the StandardslLimits chart for additional

Engines & Generators

16

SQUARENESS

less

than

2°

______

~~)~-b~jl

if

Limit

TESTING

SQUARENESS/ANGLE

it exceeds the

4°

CYLINDER

Valve

Stem

and

Guides

Measure the clearance between the valve guide and the valve stem and , valve guide

MEASURING

STEM

VALVE

Standard

Limit

VALVE

Standard

if

the clearance exceeds the limit, replace the

or

valve,

VALVE

DIAMETER

STEM

SEAL

TO

Intake Exhaust Intake Exhaust

STEM

OUTER

Intake Exhaust

or

replace both.

VALVE

GUIDE

DIAMETER

CLEARANCE

0.0008·

0.0020in

0.020 . 0.0033in

0.0039in

(O.10mm)

0.0059in

~0.15mm)

0.2585·

0.2591in

0.2571 . 0.2579in

(0.7·

0.05mm)

(0.50 . 0.085mm)

(6.565·

6.580mm)

(6.330 . 6.550mm)

HEAD

AND

VALVE

SEAL

Valve

Install the valve spring with it's enamel coated side toward the rocker arm side.

COATED SIDE

VALVES

STEM

INSTALLER

Springs

ENAMEL

~

1=I"~-o;PRING

'H""'i,------.-

_--.JI::::::::=:::!,.-_.JSiW:::::::::::..

STEM

..

SPRING

VALVE

SEAL

RETAINER

SEAL

SEAT

STEM

Valve

Seat

Reconditioning

Before correcting the valve seat, check for clearance between the valve guide and the valve. replace the valve guide

if

necessary.

To

recondition, use a valve and seat cutter and a pilot seat grinder, repair so that the seat width and seat angle are the specified configuration.

After correction, the valve and the valve seat should be lapped with lapping compound.

VALVE

SEAT

CONTACT

[0.9 . 1.3

WIDTH

mml

.

/----

----/

.035

..

051

in

~:.~

INSTALLATION

Valve

Stem

Seal

InstaII the valve spring seat, then using the valve stem seal installer, install a new stem seal to the valve guide.

Do not use the old valve stem seal.

NOTE:

Use

the

installation

installer tool

can

cause

oil

to

leak

insert

into

the

stem

seal,

cylinder.

improper

or

Use the valve spring compressor to compress the valve

::.;

a

::.the

vruve

"compre~'

remove

the

REMOVING RETAINER LOCKS

Cylinder

Clean the residue

surface Place a new cylinder head gasket on the cylinder block

facing its identification mark upward.

Head

Gasket

of

gasket and oil from the gasket mounting

of

the cylinder block and the cylinder head.

CYLINDER

HEAD

GASKET

Engines & Generators

17

CYLINDER

HEAD

AND

VALVES

Cylinder

Tighten the cylinder head bolts in the order shown in the diagram using a stepped-up tightening torque.

1.

2.

3.

CYLINDER

Rocker

Install the rocker cover using a new gasket (slightly coat both sides with clean oil). Gradually tighten the cover bolts to the specified torque making certain the cover gasket is positioned properly.

ROCKER

Head

Bolts

Temporarily tighten the bolts in numerical order to 22ft-Ibs (20 - 30 Nm).

Tighten the bolts again in numerical order to 29 - 36ft-Ibs

(40 - 50Nm).

Tighten the bolts in numerical order to the specified torque.

HEAD

TORQUE

43

-51H-lbs

(60 -70Nm)

14

-

Cover

COVER

BOLT

TORQUE

(6mm

BOLT)

2.9 -5.2

H-Ibs

(4 -7Nm)

ENGINE

FRONT

INTAKE

SIDE

2

7

EXHAUST

CYLINDER TIGHTENING

3

SIDE

HEAD

BOLTS

SEQUENCE

Engines & Generators

18

1

ROCKER SHAFT

NUMBERS SUGGESTED DISASSEMBLY

ARM,

ROCKER

ASSEMBLY

INDICATE

ORDER

CAMSHAFT

THE OF

TORQUE

21-35Nm

1 0

ROCKER EXHAUST

AND

ROCKER

21 -25

Ft-Lbs

ARM

~

ARMS

TORQUE

21 -25

2!

-35

Nm

,.d,...

~

FT-LBS

~

12CAMSHAFT

OILSEAL

INSPECTING

1.

Visually inspection the camshaft for cracks and damage.

If

necessary, replace the camshaft.

NOTE:

If

camshaft special

2. Inspect the camshaft journal and, limit, replace the camshaft.

CAMSHAFT STANDARD

CHECK FOR

the

damage

with

care

to

JOURNAL

1.6118

JOURNAL

WEAR

THE

an

not

DAMAGE

~

CAMSHAFT

is

slight,

oil soakedfine emery

damage

DIAMETER

·1.612410

BEARINGS

the

(40.940 -40.955mm)

you

may

original

®

be

able

to

correct

grindstone.

cam

form.

if

wearing exceeds the

Camshaft

NOTE:

If

the

journal

3. Measure the cam height and, replace the camshaft.

is

seized,

also check

if

the

cylinder

it is less than the limit,

Take

head!

the

CAMSHAFT

HEIGHT

C:r:-~D'

~.

4. Inspect the clearance between the camshaft journal and

BEARING STANDARD

HEIGHT

lotake

Exhaust

the camshaft support bore as follows:

a. Measure the camshaft journal diameter and the

camshaft support bore.

b. Calculate the clearance and replace the camshaft or

cylinder head

OIL

CLEARANCE

0.0018·0.003310

STANDARD

#1 #2

#3

#1

#2

#3

1.381510

1.380710

1.380310

1.383910

1.383110

1.385410

if

(35.09mm)

(35.07mm) (35.06mm) (35.15mm)

(35.13mm)

(35.19mm)

the clearance exceeds the limit.

(.045·

0.085mm)

LIMIT

1.361810

(34.59mm)

1.361010

(34.57mm)

1.360610

(34.56mm)

1.364210

(34.65mm)

1.363410

(34.63mm)

1.365710

(34.69mm)

MEASURING CAMSHAFT

HEIGHT

Engines & Generators

19

CAMSHAFT

AND

ROCKER

ARMS

Rocker

Check each component part carefully inspect the individual rockers where the arrows indicate.

ROCKER

INSPECTION

Inspecting

Check the clearance between the rocker arm and shaft and, it exceeds the limit, replace the rocker arm

ROCKER

Rocker

1.

2.

ROCKER ROCKER

Arm

of

the rocker arm assembly and

ARM

CLEARANCE

Standard

Limit

Clearance

0.0005 • O.0017in

0.004in

Rocker

(ROCKER

(0.1mm)

Arm

And

ARM

TO

SHAFT)

(0.012 • O.043mm)

or

Shaft

shaft.

Shaft

Inspect the rocker shaft where the rocker arms sit for water and damage. Replace the shaft

Measure the shaft length and the shaft outer diameter (O.D.).

If

the shaft fails to meet the standards, replace

the shaft.

SHAFT SHAFT

LENGTH

0.0.

Standard

16.985 • 16.988in

9.134in

if

worn.

(232mm)

(0.6687·

0.6693mm)

3. Measure the end play feeler gauge in the gap between the rear

plate and the new front camshaft journal.

VALVE

if

4. Using the oil seal installer tool, install the front oil seal in

Standard Limit

the cylinder head.

0.236·

0.118in

of

the camshaft by inserting a

0.0551

in

(0.06·

(0.3mm)

0.14mm)

of

the thrust

~

OIL

HOLES-

~~II

OIL

or]

HOLES

INSTALLATION

1.

Apply a coating and cams and insert the camshaft through the rear

cylinder head.

2.

Install the camshaft thrust plate as shown in the diagram

tighten the bolts to the specified torque. .

THRUST

PLATE

TORQUE BOLT

--.... ..

BOLT

,..,...T\

of

engine oil to the camshaft journals

TORQUE

7·

9ft·lbs

(10 • 12Nm)

of

the

5. Install the rocker armIrockershaft assembly. Install the

·35

is

FRONT

Nm)

rocker shaft so the portion shown in the diagram

located on the front.

6.

Tighten the rocker arm shaft bolts (4 bolts) uniformly and then to the specified torque.

ROCKER

ARM

SHAFT

BOLT

TORQUE

BOLT

HOLE

21 • 25ft·lbs

(29

Engines & Generators

20

ARROW

FRONT

MARK

PISTONS

golLRING

AND

CONNECTING

111

PISTON

112

~~

__

v

PISTON

RODS

RING RING

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

THE

OF

6

BEARING

STOPPER NOTCH

CYLINDER NUMBER

REMOVING

Turn the engine over and remove the connecting rod bearing caps and the connecting rod bearings, note the markings on

the bearing cap and keep the disassembled parts (connecting rod, rod cap, piston, etc. classified by cylinder.

are worn away be certain to remark them.

Disassemble

Using the ring remover, remove the piston rings. While removing the piston rings, note the order they are removed and which side

THE

CONNECTING

the

Pistons

of

the ring faces the piston crown.

RODS/PISTONS

If

the marks

Engines & Generators

.

PINSmlNG BASE

TOOL

Remove

Insert the special tool, push the rod, and guide B into the

piston pin then set the piston and connecting rod assembly

on the pin setting base. Make certain that the front (arrow) stamped on the piston top surface faces upwards. Using a

press, drive out the piston pin.

NOTE:

connecting

~GUIDEB

SPECIAL

Keep

'---'"

the

Piston

the

disassembled

rod

in

order according

Pins

piston,

to

piston pin and

the

cylinder

21

number.

PISTONS

AND

CONNECTING

RODS

PISTON

Reinsert the piston pin into the piston hole with your thumb. You the pin will click or bind as it enters. Try the pin from both sides. Replace the piston if the pin can be too easily inserted or if there

NOTE:

Measure the outside diameter

PISTON

INSPECTION

should feel a slight resistance,

is

excessive play.

The

piston pin and piston

0.0.0.6300 -0.6302in

are

of

the piston pin.

(16.001

if

the bore

replaced

-16.007mm)

is

misaligned

as

an

assembly.

Pistons

Check the piston surfaces for wear, seizure, cracks and

If

streaking.

Inspect the oil return hole in the oil ring groove and the oil

hole in the piston boss. Clean the piston

Check the piston pin hole for signs

Replace the piston

diameter at

PISTON

If

the piston diameter

the piston.

NOTE:

Piston

Insert the piston ring into the cylinder bore placing it against the top right angle, measure the piston ring gap with a feeler gauge. When the gap

PISTON

No.1 No

2'

Oil

PISTON

No.1 No.2

Oil

any damage

90° (perpendicular) to the pin bore axis.

0.0.2.5579 -2.5591in

The

piston and piston pin

Rings

of

the piston head and pressing it in. When it marks a

is

too large, replace the piston ring.

RING

GROOVE

Standard

0.0480 -0.0488in

0.0476 -0.0484in

0.1108 -0.1116in

RING

END

GAP

Standard

0.0059 -0.0118in

0.0138 -0.0197in

0.008 -0.028in

is

evident, replace the piston.

if

of

seizure or damage.

if

damage

is

evident. Measure the piston

(64.97 -65.00mm)

less then the standard replace

are

replaced

(1.22 -1.24mm)

(1.21

-1.23mm)

(2.815 -2.835mm)

(0.15 -0.30mm) (0.35 -0.50mm)

(0.2 -0.7mm)

these are clogged.

as

an

assembly.

Limit

0.8in

(0.0315mm)

0.8in

(0.0315mm)

1.Din

(0.0394mm)

Check the piston ring for damage, wear, seizure and bends replacing the rings if anything unusual replace the piston rings when installing a new piston.

RING

is

noted. Always

SIDE

FEELER

GAUGE

CLEARANCE

Check the clearance between the piston ring and the ring groove, or both.

PISTON

No.1 No.2

Connecting

Visually check the surface which are lopsided, streaked or seized. When streaks or seizure are excessive, check the crankshaft. discovered on the crankshaft, either replace it or reuse after undersize machining. severe thermal damage, replace the bearing.

Measure the inner diameter and the outer diameter clearance) exceeds the limit, replace the bearing, and, if essary, the crankshaft...or undersize machine the crankshaft and replace the bearings with

CONNECTING

if

it exceeds the limit, replace the rings, the piston

RING

SIDE

CLEARANCE

Standard

0.0012 -0.0028in

ring ring

0.0008 -0.0024in

Rod

ROD

Standard

0.009 -0.002Din

ROD

Bearing

If

the connecting rod bearing indicates

of

BEARING

OIL

(0.022 -0.052mm)

(0.03 -0.07mm) (0.02 -0.06mm)

of

the bearing. Replace those

of

the connecting rod bearing

the crankshaft pin.

an

appropriate undersize type.

CLEARANCE

Limit

0.0047in

0.0039in

If

Limit

0.004in

(0.12mm) (0.10mm)

damage

If

the gap (oil

(0.1mm)

is

nec-

%

PISTON

RING

GAP

~~~!~~~~~~~4=OILCLEARANCE

Engines & Generators

22

PISTONS

NOTE:

See

Crankshaft/Bearing section for measuring

with

clearance

Use a rod aligner to check the connecting rod for bend and twist.

CONNECTING

a Plastigauge.

ROD

BEND

ROD ROD

Standard

ROD

Standard

LIMIT

TWIST

LIMIT

BIG

END

CENTER

0.004in

TO

CRANKSHAFT

0.0039 -0.0098in

LENGTH

4.0138 -4.o178in

(o.05mm)

(o.1mm)

SIDE

CLEARANCE

(0.10 -0.25mm)

(101.95

AND

the

-102.o5mm)

ASSEMBLY

Piston

Using the special tool (pin setting base) assemble the piston install the piston pin into the special tool,

Connecting

and connecting rod and press-in the piston pin. First,

Rod,

Piston

CONNECTING

oil

Oil

Ring

Assemble the oil ring spacer into the piston ring groove. Then, after assembling the upper side rail, assemble the lower side rail.

NOTE:

There

is

no

side

rails

or

the

The chart below identifies the color coding on new spacer and side rails according to size.

SPACER

AND

SIDE

SIZE

S.T.D.

0.0098in

0.0197in

0.0295in

0.0394in

Install the three-piece oil ring in the piston. Then, make certain the side rails move smoothly in both directions. The side rail my be easily installed by pushing it in with your finger after fitting the one end over the piston groove. Do not use an expander ring on the oil ring.

(O.25mm) (o.50mm) (o.75mm) (1.oomm)

RODS

difference between

spacers.

j/'~~

/~

m

RAIL

CODING

Oversize OverSize Oversize Oversize

END

OF

SIDE

the

upper and

~~c-

'----"""'~

Color

Identification

Two

Blue

One

Two

One

RAIL

Lines

Red

Line

red

lines

Yellow

Line

lo·wer

SIDE

RAIL

SPACER

PUSH ROD

GUIDE

A

Set up the piston and connecting rod on the piston pin setting base. Make sure that the front marks are facing up. Apply

engine oil to the outer circumference

insert the pin, Guide A and the push rod (assembled) into the piston and connecting rod.

Using a press, load the push rod top end and press-fit the piston pin in the connecting rod. The piston pin is press fitted in the specified position by bottom end surface until it is seated on the bottom surface the base. replace the pin (piston assembly)

PISTON

If

the press-fitting load is out

PRESS-FITTING

LOAD

of

the piston pin and

press-fitti:ng the Guide A

of

the specification,

or

connecting rod, or both.

1102 -33071bs

(5000

-15ooNm)

of

Piston

Use a piston ring expander and install the piston rings with the marker and size marks facing up toward the piston top.

Notice the difference

Rings

~

__

in

shapes between No.1 and No.2 ring.

-,/_""'TD.RI.'

~~1I2PISTONRING

Engines & Generators

23

PISTONS

AND

CONNECTING

RODS

Installing

Apply an ample amount piston and the piston rings. Position the piston rings and oil ring (side rail spacer) end gaps as shown.

the

Piston

SIDERAIL

Assembly

of

~

oil to the outside surfaces

of

the

/I

.

FRONT

+

~

It2

SPACER

~

Insert the piston and connecting rod assembly into the cylinder, working from the arrow mark on the piston top toward the camshaft sp(ocket side.

FRONT

ARROW

MARK

Securely pressing the piston ring with the ring band, insert the piston and connecting rod assembly into the cylinder. Keep in mind that the piston ring may be damaged strongly.

PISTON

RING

BANO

INSTALLER

!J

-:::;:::?

'\SIDE

LUBRICATE

/

RAIL

WITH

OIL

if

hit too

CRANKSHAFT Identification

CONNECTING Identification

(1) (2) (3)

marks

11\

G

C

ROD

Marks

o

I

IT

CONNECTING Identification

Brown Blue

CONNECTING

Crankshaft

Identification

(1)

(2)

(3)

ROD

Color

ROD Pin

Marks

1/\

G

[

DIAMETER

1.4171 -1.4173in

1.4167

-1.4171in

1.4165

-1.4167in

BIG

END

INNER

1.5354 -1.5356in

1.5356 -1.5360in

1.5360 -1.5362in

BEARING

THICKNESS

0.0586 -0.0588in

0.0588 -0.0590in

0.0590 -0.0592in

SELECTION

Connecting

Identification

I

n

ill

I

n

m

I

][

m

F-----NO.1

Journal

Diameter

(35.995 -36.000mm) (35.985 -38.995mm) (35.980 -35.985mm)

DIAMETER

Big

End

Inner

(39.000 -39.005mm) (39.005 -39.015mm) (39.015 -39.020mm)

Bearing

Thickness

(1.488 -1.493mm) (1.493 (1.498

TABLE

Rod

Bearing

Marks

Brown Brown

Brown Blue

Blue Blue

NO.3 NO.2

NO:1

ARM

Diameter

-1.498mm)

-1.503mm)

Crankshaft/Bearing

When the bearings are to be replaced, select the appropriate bearings for assembly according to the identification marks

for the crankshaft and the connecting rod.

Assembly

CRANKSHAFT

Engines & Generators

IDENTIFICATION MARK

CONNECTING

24

0

ROD

STOPPER NOTCH

IDENTIFICATION COLOR

CYLINDER NUMBER

PISTONS

AND

CONNECTING

RODS

Installing

Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined before reuse. down",

Necking can be checked by running a nut with fingers to the full length smoothly, the bolt should be replaced.

Before installation thread portion and bearing surface

Install each nut to the bolt and tighten it with your fingers. Then tighten the nuts alternately to install the cap properly. Tighten the nuts to the proper torque.

CAP

NUT

A

before the

Make a paint mark on the head mark on the bolt end at the position paint mark made on the nut in the direction

nut. Give a

paint mark on the nut and that on the bolt are in alignment. If

the nut is turned less than 90°, proper fastening

performance may not be expected. When tightening the nut,

tum it sufficiently.

If

the nut is overtightend (exceeding 100°), loosen the nut completely and then retighten it by repeating the tightening procedure.

the

Connecting

If

the bolt should be replaced.

of

the bolt threads.

of

each nut, apply clean engine oil to the

TIGHTENING

CAUTION:

installing

spark

90° to 100° tum to the nut and make sure that the

plugs.

TORQUE

If

the

connecting

Rod

Bearing

the bolt threads are "necked

If

the nut does not run

of

the nut.

11+90·

turn

(15Nm

cylinder

head

rod

cap

of

each nut. Make a paint

90° to 100° from the

+90·

has

,been

nut,

of

the tightening

Caps

turn)

installed

remove

Engines & Generators

25

TORQUE

6

-1

Ft-Lbs

'-1

FRONT

CASE I COUNTERBALANCE

GASKET

SHAFT

AND

OIL

GASKET

PAN

5

OIL

PUMP

COVER

CONFIGURATION OF

FRONT

ASSEMBLY

CASE

1

OIL

1J"fQ.~L--"'"

DRAIN

ASSEMBLY

COOLANT

.

OIL

SCREEN

NUMBERS SUGGESTED DISASSEMBLY

DRAIN

ASSEMBLY

INDICATE

ORDER

THE

OF

OIL

PAN

REMOVAL

Remove the oil drain hose assembly. Remove the oil pan bolts and then use the special tool to break the pan seal.

--

COUNTERBALANCE

1.

Remove the plug on the cylinder block and insert an

0.32in (8mm) rod into the hole to lock the counterbalance shaft.

SHAFT

REMOVAL

2. Remove the oil pump cover and gasket. Discard the gasket.

3. Remove the oil pump driven gear tightening flange bolts to release the counterbalance shaft.

4. Remove the counterbalance shaft. Drive it from the front.

Engines & Generators

26

FLANGE OIL

PUMP

GEAR

BOLT

DRIVEN

FRONT

CASE I COUNTERBALANCE

SHAFT

AND

OIL

PUMP

4. Using a special tool drive the counterbalance shaft front bearing from the cylinder block.

EARING

REMOVER

5.

Use the same tool and drive the counterbalance shaft rear bearing from the cylinder block.

TOOL

FRONT

Check the front case for cracks or other damage also inspect the oil holes.

or solvent to clean them out.

CRANKSHAFT

Check the oil seal for wear and damage. Inspect the oil seal lip for hardening.

CASE·

CRANKSHAFT FRONT

OIL

SEAL

INSPECTION

If

the oil holes are clogged, use compressed air

FRONT

OIL

If

there any signs

SEAL·

of

INSPECTION

wear, replace the seal.

OIL

PUMP

Fit the oil pump gear into the cylinder block, then, using a feeler gauge, check the clearance with the body at the points indicated in the diagram below.

DRIVEN

DRIVE

DRIVEN DRIVE

Using a straight edge, check the side clearance at the point indicated in the illustration with a feeler gauge.

There should be no uneven wear on the contact surfaces

the cylinder block or on the pump gear side

ASSEMBLY·

GEAR

BODY

A.

B.

GEAR

BODY

C. D.

GEAR

SIDE

GEAR

SIDE

CLEARANCE

0.0161 -0.0266in

0.0051 • 0.0069in

CLEARANCE

0.0173 -0.0276in

0.0059 -0.077in

CLEARANCE

STANDARD

INSPECTION

STANDARD

(0.410 -0.675mm) (0.130 -0.175mm)

(0.44 -0.7omm)

(0.150 -0.195mm)

.0024·

0.0047in

0.0027 -0.0051in

(0.06 -0.12mm)

-C+---DRIVE

(0.07 -0.13mm)

of

the pump

GEAR

of

COUNTERBALANCE

Inspect the oil holes for clogging and clean

Inspect the shaft journal for seizure, damage and its contact with the bearing. Check the counterbalance shaft oil clearance. Replace the counterbalance shaft the standards.

COUNTERBALANCE

Front

Journal

Rear

Journal

Front

Journal

Rear

Journal

SHAFT

Diameter

Oil

Clearance

Oil

Clearance

SHAFT

SHAFT·

STANDARDS

0.7869 -0.7874in

1.7317

0.0014 -0.0027in

0.0014 -0.0028in

INSPECTION

if

necessary.

if

-1.7322in

(19.987 -2o.ooomm) (43.984 -44.ooomm) (0.035 -0.068mm) (0.035'

it fails to meet

0.071mm)

Engines & Generators

27

FRONT

CASE I COUNTERBALANCE

SHAFT

AND

OIL

PUMP

INSTALLATION

Counterbalance

. 1. Install the special tool guide pins (bearing Installer) in the

tapered hole

2. Mate the ratchet ball rear bearing and install the bearing in the bearing installer.

3. Apply clean engine oil to the outer Circumference bearing and the bearing hole in the cylinder block.

4.

GUIDE

Rear

Bearing

of

the cylinder block as shown.

,j

( )

r----..

\

~~J

~\

of

the bearing in the oil hole

-""".v

(

Gr

BEARING-

of

the

Crankshaft

1. Apply oil to the crankshaft front oil sea1lip inner circumference, and using the special tool, knock the oil

~mro~_t=,.~

Front

Install the front case assembly through the gasket and tighten

the bolts to the specified torque.

FRONT

CASE

There are two different length front case bolts. Make certain

they are positioned properly. See the diagram.

NOTE:

the

inner circumference

the

front

seal

lip

the

crankshaft.

Case

BOLTS

When

case

on

the

A

Oil

Seal

Assembly

TORQUE

installing

assembly take

stepped

A

the

of

up

~

6 -

7ft.lbs.

front

the

oil seal

care

portion

pi

(8

-10

Nm)

case

assembly,

lip.

When

not

to

damage

of

the

front end

A

BOLT

B

BOLT·

apply

oil installing the

oil

of

-18mm 30mm

to

(.71 (1.18

in)

\

Counterbalance

1. Apply engine oil to the bearing outer circumference and the bearing hole in the cylinder block.

2. Press-in the front bearing using the installer tool.

Front

Bearing

FRONT

BEARING

INSTALLATION

B

Oil

Pump

Driven

1. Apply an ample amount pump driven gear and insert it so that the timing mark is positioned as shown.

2.

Using the same hole on the side reinsert the 8mm rod to lock the counterbalance shaft. Then tighten the flange bolt to the specified torque.

~

rJ6

~VJ\

Gear

of

clean engine oil to the oil

of

the cylinder block,

;;

~'-----"""'\\""\

>b

~

OJ

SETTING

DRIVEN

TIMING

MARK

~~

ORIVEN

GEAR

FLANGE

BOLT

TORQUE

25 -29ft.lbs.

(34 • 40Nm)

B

THE

GEAR

Engines & Generators

28

FRONT

CASE

TIMING

lOlL

2.6

MARKS

PUMP

In

[65mm[

'8mm

AND

ROD

OIL

PAN

OIL

PUMP

ASSEMBLY

Oil

Pump

Cover

Fit a new oil pump cover gasket into the groove in the oil pump cover. The flat side the pump cover.

Oil

Pump

Seal

Press the seal into the oil pump cover flush with the surface using the seal installer tool.

Gasket

of

the gasket is positioned against

FRONT

CASE

CONFIGURATION

Oil

Pan

Remove the old gasket and sealant from the oil pan and cylinder block with a scraper, wire brush, solvent, etc. Make certain all residue is removed.

GASKET

INSTALLING

OIL

PUMP

THE

SEAL

OIL

PAN·

Engines & Generators

29

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

CRANKSHAFT I BEARINGS

THE

OF

AND

OIL

SEAL

1

OIL

SEAL

CASE

BOLT

!

TORQUE 1-9

1'0-'2Nm

Ft-Lbs

8

CRANKSHAFT

INSPECT FOR

UNEVEN

CHECK

FOR

AND

CLOGGED

CYLINDER

THE

JOURNALS WEAR.

CRACKS.

OIL

TORQUE

[135 -

BLOCK

BEARING

_

BENDS.

HOLES.

9

CRANKSHAFT

98

-

105

145

Nm]

THRUST

BEARING

(UPPER)

FT-LBS-_d~.

MAIN

BEARING

TORQUE

36 -

[50-56Nm]

BOLT

40

FT-LBS

,@)

~

____

-----q-

BEARING

CAP

BOLT

CRANKSHAFT

1. Check the journals and pins for damage, seizure and cracks. Check the journals contact surface for uneven wear and replace

2.

Measure the outside diameter

inside

clearance) exceeds the limit, replace the main bearing and

also the crankshaft, undersized crankshaft and replace the main bearing with an

undersized one.

Standard

0.0008 -0.0018in

3. When grinding the crankshaft to under-size, take note the "R" dimensions area.

INSPECTION

diameter

of

(0.021 -0.045mm)

if

badly damaged.

of

the journal and the

the main bearing.

if

necessary. Otherwise, fabricate an

of

the fillets

If

the clearance (oil

Limit

.004in

(0.1mm)

of

the journal and pin

MEASURING

of

POSITION

¢-w

Engines & Generators

30

MEASURING CRANKSHAFT

AND

THE

0.0.

BEARING

1.0.

MEASURING DIRECTION

R -

0.059

IN

(1.5MMJ

CRANKSHAFT,

R -

0.059

IN

{1.5MMJ

BEARING

AND

CRANKSHAFT

Upper

and

OIL

SEAL

BEARINGS

Lower

SPECIFICATIONS

When the bearings are to be replaced, select the correct ones and install them in positions according to the identification marks stamped on the crankshaft and the top surface

of

the

cylinder block.

CRANKSHAFT

Identification

JOURNAL

Marks

1

2

3

DIAMETER

1.5746

-1.5748

1.5743

-1.5746

1.5741

-1.5743

Journal

Diameter

in

139.994 -40.000mm)

in

39.988 -39.994mm)

in

39.982 -39.988mm)

MEASURE

THE

CRANKSHAFT

OIL

CLEARANCE

The crankshaft oil measured by using a plastic gauge as follows:

1. The oil and grease and other foreign matters form the crankshaft journal and bearing inner surface.

2.

InstaII the crankshaft.

3. Cut the plastic gauge to the same length as the width

of the bearing and place it on the journal in parrallel with its axis.

4. Gently place the main bearing cap over it and tighten the bolts to the specified torque.

5. Remove the bolts and gently remove the main bearing

of

cap. Measure the width

the smashed plastic gauge (at its widest section) by using the scale printed on the plastic gauge.

MAIN

BEARING

36 -

BOLT

40

FT-LBS

TORQUE [SO-S6NmJ

CRANKSHAFT Identification

CYLINDER

Identification

BEARING

Colors

brown

blue

yellow

green

BLOCK

Marks

o

I

n

THICKNESS

0.0783 -0.0784

0.0784 -0.0785

0.0785 -0.0786

0.0786 -0.0787

0.0787 -0.0789

BEARING

1.7323

1.7325

1.7328

Bearing

..

MN

0000

:z

DIAMETER

Bearing

-1.7325

-1.7328

-1.7330

CAMSHAFT

Thickness

in

(1.988 -1.991mm)

in

1.991 -1.994mm

in

1.994 in in

-1.997mm

1.997 -2.000mm

2.000 -2.003mm

CYLINDER

......

:z:z

Inner

Diameter

in

144.000 -44.006mm}

in

44.006 -44.012mm

in

44.012 -44.018mm

JOURNAL

BLOCK

PLASTIGAUGE

INSPECTING

THE

CRANKSHAFT

II!.....-'_~

REAR

OIL

SCALE

SEAL

1. Inspect the oil clearance lip for wear or damage. Check the rubber portion for deterioration and hardening. Replace the seal

2. Check the oil case for cracks and damage.

if

at all suspect.

If

here is

damage, replace the case.

CRANKSHAFT

Crankshaft

Identification

1

2

3

Engines & Generators

31

BEARING

Journal

Marks

SELECTION

Crankshaft

Identification

Bearing

brown

blue blue

yellow

blue

yellow

green

CHART

Marks

BEARING IDENTIFICATION MARKS

Cylinder

Block

Identification

][

Bearing Marks

0

I

0

I

0

I

CRANKSHAFTI

BEARING

AND

OIL

SEAL

CRANKSHAFT

INSTALLING

1.

Apply a coat

the oil groove faces outward as illustrated.

THE

THRUST

of

oil to the thrust beating and install so that

BEARINGS

MEASURING

Push the crankshaft to the rear. Then, insert a feeler gauge the gap between the crankshaftjoumal side surface and the thrust bearing

CRANKSHAFT

1. Apply engine oil to the rear cover and to the oil seal.

2.

Press the oil seal into the seal case using the special tool.

END

PLAY

end

surface to measure the end play.

END

PLAY:

0.0020 -O.OOOgin

REAR

OIL

(0.05 -0.025mm)

SEAL

in

2. Install the bearing cap paying careful attention to the cap number and the arrow mark. Apply oil to the bolt threads.

3. Tighten the bearing cap to the specified torque.

BEARING

CAP

BOLT

TORQUE

36 -40

ft-Ibs

(50 -55Nm)

3.

OIL

SEAL

NOTE:

Make

OIL

CASE

CASE--""

certain

BOLT

TORQUE:

the

lips

of

7 - g

the

Ft-Ibs

oil seal

(10

-12Nm)

are

not turned

up.

Engines & Generators

32

CYLINDER

BLOCK

INSPECTION

AND

PISTON

CLEARANCE

NUMBERS SUGGESTED DISASSEMBLY

CYLINDER

1. Before inspecting, clean the cylinder block to ensure that

2. Check for cracks and damage.

3. Inspect the mating surface.

4. Inspect the cylinder bore. Using a cylinder gauge, mea-

CHECKING

Calculate the difference between the minimum cylinder bore

in the thrust direction and the piston outer diameter shown in

. the illustration.

replace the piston or cylinder block,

PISTON

0.0008 -0.0016

INDICATE

THE

ORDER

OF

10

TAP"'

PlUG

1/'.~

2 DOWEL-

6STUDS8X5

the water and oil holes are not plugged. with compressed air.

pound as needed. Replace the block

feeler gauge measure the flatness Grind or replace

FLATNESS LIMIT:

0.004

sure the bore at six places (as shown in the diagram). Calculate the difference between the max. and min. ues.

If

CYLINDRICITY CYLINDER

TO

•.

BLOCK

STANDARD

in

(0.1

worn or damaged, rebore

STANDARD

BDRE:

MEASURING DIRECTION

THE

If

CYLINDER

in

(0.0 -0.04

~-

7T/

8

KNOCK

BUSHINGS

INSPECTION

Using a straight edge and

if

the limit is exceeded.

VALUE:

0.0020

mm)

VALUE:

2.5591 -2.5602

PISTON

the difference exceeds the specified range,

CLEARANCE

in

MEASURING

CLEARANCE

STANDARD:

mm)

6 X

9~

If

clogged, clear

Use a flaw detecting com-

if

defective.

of

the top surface.

in

(0.05

mm)

or

replace the cylinder.

0.0004

in

(0.01

mm)

or

(65.00 -65.03

POSITION

or

mm)

UPPER

CENTER

LOWER

rebore the cylinder.

.

val-

less

ltSEALING

BORING

1. Select an oversize piston based on the cylinder with the

2.

Boring (Piston

OVERSIZE (INNER

0.250.S.

0.500.S.

0.750.S.

1.000.S.

3. Bore the cylinder to obtain the calculated dimensions.

4. Hone to finish the cylinder inner diameter. S.

THE

CYLINDER

maximum bore and maximum damage depth. Using the outer diameter (at the specified measurement

point)

of

the selected oversize piston, calculate the boring

dimension.

dimension

O.D.) + (piston

DIAMETER

Size

Check again for cylindricity and piston clearance .

=

PISTON

Mark

25

50

75

100

clearance) -(honing

OUTSIDE

FINISH

DIAMETER

DIMENSION

Piston

2.5677 -2.5689in (65.22 -65.25mm)

2.5776 -2.5787in (65.47 -65.50mm)

2.5874 -2.5886in (65.72 -65.75mm)

2.5972 -2.5984in (65.97 -66.00m)

AND

(REF))

Dia.

CAPS

margin:

0.0008in

CYLINDER

Cylinder

(35)

(0.02mm))

Inner

Dia.

2.5693 -2.5697in (65.26 -65.27mm)

2.5791 -2.5795in (65.51 -65.52mm)

2.5890 -2.5894in

(65.76 -65.77mm)

2.5988 -2.5992in

(66.01 -66.02mm)

Engines & Generators

33

1

CAP

CHECK CAP AND OR

THESE

REPLACE

NUMBERS SUGGESTED

DISASSEMBLY

INDICATE

ORDER

THE

DISTRIBUTER

FOR

CRACKS,

EVIDENCE

BURNING.

IF

CONDITIONS

THE

DISTRIBUTER

THE OF

WEAR

OF

ARCHING

ANY

OF

EXIST,

CAP.

2

ROTOR

3

COVER ASSEMBLY

DISTRIBUTOR

PICK-UP

ASSEMBLY

VACUUM

CONTROL

1

O-RING

HOUSING ASSEMBLY

6

IGNITER

TESTING

STANDARD

THE

PICK

RESISTANCE

VALUE:

UP

COIL

,,420

-.540

KQ

Check that when a screwdriver is passed near the iron core

of

the pick-up assembly the needle

of

the tester deflects.

BRE

10

A'KER

PLATE

REAO

WIRE

SET

of

Adjust the point gap

the pick-up assembly between the

rotor and the pick-up,

STANDARD

INSPECTING

GAP:

0.35mm

TO

SPARK

0.40mm

PLUGS

Check the plugs for carbon build-up and burning. Check the

plug gap.

SPARK

PLUG

GAP:

0.028 -0.031

in

(0.7 -

0.8

mm)

Engines & Generators

34

DESCRIPTION

Unplug to reconnected leads meter. meter.

note

the

on

Then

the

two

the

two

connector's

separate

in

the tenninals reverse

exact

connections

same

SG

the

ohmmeter

at

the

distributor

as

position. Place

and C shown

leads

TESTING

plug.

Take

they

must be

your

ohmmeter

below

and

read

and

again

read

care

the

THE

IGNITER

In

the value value the

one

direction

other direction

above

100

found

with

igniter

is

faulty.

the

ohm

reading

there

should

ohms

indicates a

the

meter connections

will

be

no

ohm

faulty

100

reading.

igniter.

in

either

ohms

Any

direction,

less.

Any

ohm

In

. SWITCH THE OHMMETER LEADS

.

BACK

AND

FORTH BETWEEN

SG

AND

l!

TERMINALS READ THE VALUES.

AND

Engines & Generators

34a

COOLANT

CIRCULATING

PUMP

REMOVING

1. Loosen the belt guards thumbscrews and remove the engine's belt guard from its brackets at the front engine.

2. Ease the belt tension by releasing the raw water pump and remove the engine drive belt [on carburetor models it will be necessary to remove the governor belt].

Unscrew the five bolts that hold the pump to the engine

3. and remove the coolant pump and its gasket. Note that the pulley is an integral part

~

THE

COOLANT

PUMP

of

the pump assembly.

GASKET

USE

HI-

TACK

SEALANT

of

the

COOLANT

PUMP

ASSEMBLY

~THE

PULLEY

IS

PART

OF

THE

PUMP

COOLANT

PUMP

PULLEY

FLANGE

REPAIR

If

the pump does not pass inspection, replace the entire pump

assembly which includes the pulley.

INSPECTION

Carefully check the pump body and impeller for cracks and damage. Inspect the weep holes for signs and rust that would indicate a faulty seal. The pulley should tum the shaft (and impeller) smoothly, without noise or sluggish rotation.

The pulley edges should be smooth and undamaged and the

locknut should be drawn up tight.

of

water leakage

THREE

BOLTS

0.24 X 1.38

(96X35

mm)

IN

TWO

BOLTS

0.24 X 0.71

(6X18

INSTALLATION

When reinstalling the pump use a new gasket. There are five bolts in two sizes that fasten the pump in place, make certain they are positioned properly.

sealant when assembling the new gasket.

CIRCULATING

PUMP

BOLT

See the diagram above. Use

TORQUE

6 • 7 It •

Ibs

(8 • 10

Nm)

mm)

IN

Engines & Generators

35

EXHAUST

MANIFOLD I HEAT

EXCHANGER

EXHAUST

The exhaust manifold, which was disassembled from the

cylinder head, should be inspected before reassembly.

1. Remove the exhaust elbow from the manifold. Scrape off and discard the old gasket. Inspect the exhaust elbow for corrosion and damage, replace

If

2. temperature sensor and clean and re-paint the elbow with WESTERBEKE heat resistant enamel.

3. Carefully inspect the exhaust manifold, remove the hose connections noting the location alignment at reassembly. Clean the exterior and interior

manifold.

WESTERBEKE heat resistant enamel.

MANIFOLD

INSTALL

NEW

GASKETS

MANIFOLD

the exhaust elbow passes inspection, remove the high

ASSEMBLY

if

necessary.

of

each for proper

If

the manifold can be reused, repaint with

HEAT

EXCHANGER

The heat exchanger should be inspected and serviced during an engine overhaul.

1. Disconnect the hoses and remove the hose fittings, petcock, drain plugs and zinc anode. Also, remove the end fittings and gaskets.

2. Inspect the tube (casing) for wear and dents, suspect replace the heat exchanger.

3. Clean out any zinc debris and pressure test the coolant and raw water passages.

4. When reassembling, install new gaskets and O-rings. Apply some lubricant to the new gaskets and to the petcocks and fittings as you install them.

5. Install a new zinc anode.

NOTE:

All

of

the

above

can

be

accomplished

heat exchanger

They will also

6. Repaint the assembled heat exchanger with WESTERBEKE heat resistant spray enamel

to

a heat exchangerlradiator

service

transmission and

engine

?

INSPECT

HOSES

if

at all

by

sending

service

oil

~7"'

the

shop.

coolers.

'?\

",~i

ASSEMBLY

1.

If

the manifold was removed as an assembly and left intact, it can be replaced on the cylinder head in the reverse order

MANIFOLD

2. Attach the hose connections to the manifold and the exhaust elbow. running, carefully check these assemblies and hose connections for leaks.

of

removal. Install a new gasket.

MOUNTING

BOLTS

TORQUE

Once the engine has been re-installed and

12

-17

ft-Ib

(16 -23

Nm)

HEAT

EXCHANGER

ASSEMBLY

SERVICE

BOTH

~

HEAT

EXCHANGER

Reinstall the heat exchanger. Tighten down the holdown brackets and once the engine is running, check the heat exchanger and hose connections for leaks.

ASSEMBLY

REPLACE

ENDS

GASKET

Engines & Generators

36

RAW

WATER

PUMP

Inspect frozen the

NOTE:

parts would almost match

WESTERBEKE using

PUMP

The

attachment nipples threaded into

They

the

if

1.

2.

the

pump

before disassembly, if

or

rotates

with

excessive play or roughness, replace

entire

pump.

Since

rebuilding

recommends

the

old pump for

OVERHAUL

pump,

as

removed

may

be

left

in

place or removed if they interfere

pump

disassembly. Note the port location

removed.

Loosen the

Remove cover plate gasket.

the

set screw with

water

pump

pulley

the

four cover screws,

NOTE:

Replacement recommended; the

gasket well lubricated until

If

it's allowed

however,

to

dry,

a pump from individually purchased

the

cost

purchasing a new pump and

spares.

from

the

an

from

of

the

cover plate gasket

it you

the

gasket will shrink and not

reusable.

3.

Pull

out

the

impeller

a pair of screwdrivers.

with

long nose pliers or

the

drive shaft

of

a new

pump,

engine,

the shaft.

will

have hose

its

inlet

and

outlet

port.

and

positioning

allen wrench and remove

the

cover plate

and

is

are

going

to

reuse

it,

the

pump

is

reassembled.

pry

out

is

with

the

keep

be

..yith

4.

Remove

5.

Remove

6.

Remove bearing and and

NOTE:

to

7.

Inspect

8.

Use water

a. Apply a small amount of petroleum jelly

b. When positioning

c.

9.

When hose nipples. Assemble the

the

wear plate

the

cam

the

bearing

seal

seals

to

be

disassembled for inspection.

It

may

be

press

the

bearing and seal assembly from

all

parts

and

the

illustration

pump.

inner race

amount of Permatex cam screw heads; remove housing.

Apply a light inner surface of

hoses

and

the pump

and

the

and

screw,

washer,

assembly,

assembly.

necessary

replace

to

assist

to

the

impeller shaft

the

cam

#1

on

film

of silicon or petroleum jelly

the

housing for

is

assembled, reposition

the

belt.

the O-ring.

and

releasing

This

will

to

use

a drift and arbor press

those

showing

in

reassembling

in

the

the inner

any

excess

pump

cam.

allow

at

housing

the

to

the

shaft,

the

wear

the

to

reassembly.

use a small

cam

surface

from

the

impeller

and

tighten

engine

bearings

shaft.

or

erosion.

raw

the

seal's

and

impeller

to

the

and

attach

the

RAW

WATER

PUMP

PULLEY---_~

COMPONENTS

1L.t

___

I'nVFR

"lll::l~---<RI:rAIIIING

~~oo(----::':::"'BEARING

SPACER

PLUG

PLATE

SHAFT

Engines & Generators

37

THERMOSTAT

ASSEMBLY I FUEL

PUMP

COOLANT

Flush out the recovery tank and the hose that connects to the pressure cap assembly. to clear the passage where the hose connects to the casting. Also clear the by-pass hose fittings. Replace the plastic tank and hose

PRESSURE

Check the manifold pressure cap. Open the valve by pulling it and make sure it closes when released. Make certain the upper and lower seals are in good condition. replace the cap.

RECOVERY

if

it fails to pass inspection.

TANK

Use a pipe cleaner or compressed air

CAP

If

any doubt,

THERMOSTAT

1. Inspect the thermostat housing and housing gasket. Apply some sealant to the gasket when reassembling.

2. Install a new thermostat and gasket (the old thermostat can become a spare). When installing the new thermostat and gasket, apply a thin coat the gasket.

3. A thermostat can be checked for proper operation by

of

placing it in a pan perature open noticeably (with travel on the order

0.0098 - 0.0197mm) and be fully opened when the water is boiling.

of

the water to a boil. The thermostat should

cold water and then raising the tem-

of

sealant to both sides

of

114

-

1/2

of

in

FUEL

PUMP

[BCGTC]

This solid state lift pump requires no maintenance. ulate a start, the pump should produce a clicking sound indicating the piston in the pump is working. check that 12 volts are present at the pump connection and the pump is grounded.

GASDENSER

The gasdenser cools the fuel to prevent vapor lock, there is no maintenance required except making certain the fuel fittings are tight and secure.

ELECTRIC

This 12 volt DC high flow fuel pump maintains a constant stable flow pump mechanism is extremely resistant to clogging or jamming.

FUEL

If

it fails to work, replace the pump.

GASDENSER

[BCGTC]

PUMP

[BCGTE]

of

fuel through all engine loads. Its roller vane

If

no clicking is heard,

To

test: sim-

THERMOSTAT

CLEAN COOLANT TANK

AND

HOSE

ASSEMBLY

OUT

THE

RECOVERY

CONNECTING

IN·LlNE [BeGTE]

THERMOSTAT

Engines & Generators

38

FUEL

PUMP

~i

FUEL

FILTER

AND

ASSEMBLY

[BCGTE]

~

U

e

STARTER

MOTOR

DESCRIPTION

The

starter can be roughly divided into the following sections:

• A motor section which generates a drive power.

• An overrunning clutch section which transmits an arma-

ture torque, preventing motor overrun after starting.

• A switch section (solenoid) which is operated when actu-

ating the overrunning clutch through a lever and which supplies load current to the motor.

The starter is a new type. small. light-weight and is called a high-speed internal-reduction starter. arate from the motor shaft; the pinion slides only

ion shaft. A reduction gear is installed between the motor shaft and a pinion shaft. exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease. The motor shaft is supported lever mechanism. switch and overrunning clutch inner circuit are identical to conventional ones.

ADJUSTMENT

If

any abnormality is found by the following tests, the starter

should be disassembled and repaired.

Pinion

1. Connect a battery

2. Lightly push the pinion back and measure the return

3.

Gap

Inspection

and the starter body, and the pinion drive should rotate out and stop.

A

CAUTION:

seconds

stroke (called pinion gap).

If

the pinion gap is not within the standard range, 0.0197

- 0.0788in (0.5 to 2.0mm), adjust it by increasing or decreasing the number

is decreased as the number

Never

continuously.

AND

(l2V)

The

pinion sliding part is not

at

both ends

REPAIR

between the starter terminal S

apply

battery

of

The

pinion shaft is sep-

on

the pin-

on

ball bearings. The

voltage

shims on the solenoid. The gap

of

shims increases.

for

over

10

No-Load

1.

2. When the switch is closed, the pinion

A

tighten type that starter in

Test

Connect the ammeter, voltmeter. and battery to the starter as illustrated.

must

protrude and the starter must run smoothly (at the current or starter speed is semble the starter and repair it.

CAUTION:

starter

of a direct-drive

contact

Use

every

tenninal

which

rotation

with

thick

wires

securely.

makes a rotating

type

at

the

pinion

the

pinion

out

as

This

starter.

tip,

gear

when

3000 rpm

of

BAmRY

much

or

more).

specification, disas-

as

possible

is a solenoid

sound

louder

When

detecting

be

careful

not

it

protrudes.

shift-

than

to

SOLENOID

Perform the following tests.

satisfactory, replace the solenoid assembly.

1. Inspect the solenoid for continuity between terminals and (-) and between terminals S and the body and M and

the body. There should be no continuity found between terminals minals S and the body and terminal M and the body.

S and M. Continuity will be found between ter-

If

any test result is not

If

and

come

(+)

0.5-2.0

mm

PINION

GAP

NOTE:

Disconnect

2. Connect a battery to the solenoid's terminal S for (+)

and M for (-). Have a switch in the + lead and close it. The pinion drive should extend fully out.

A

CAUTION:

than

10

Engines & Generators

39

MULTIMETER

the

Do

seconds

when

not

wire

apply

testing

from

terminal

battery

the

solenoid.

M.

current

for

more

STARTER

MOTOR

STARTER

INSPECTION

Solenoid

Inspect

the

solenoid for continuity

and

between

M be

found

between

between S and

Inspecting

1.

Check circuited, between insulated,

the

The

the

armature with a growler

replace

the

replace the armature.

tenninals S

S and

body

and

M.

Continuity should

and M and

Armature

the

armature.

communicator

body.

and

between

tenninals S and

No

continuity should

be

the

body.

tester.

If

it's short

Also

check for insulation

its

shaft.

If

poorly

found

Brush

1.

and

Check

replace

BRUSH

HEIGHT

BRUSH

HEIGHT

2.

Check

spring

if

suspect.

Brush

the

Holder

brushes. If

brushes.

Inspection

worn

out beyond

the

BRUSHES

0.669

in

(17

STANDARD LIMIT

•

the

brush spring tension. A weak or defective

will

cause excessive brush

0.2363

in

mm)

(6

mm)

wear;

replace

service limit,

the

springs

..

2.

Measure Repair check

the

or

replace

the

commutator outside

roughness.

crocus

cloth.

COMMUTATOR COMMUTATOR

OUTSIDE OUTSIDE

commutator

it

if

If

rough, polish

DIAMETER DIAMETER

0.0.

the

service limit

the

STANDARD

LIMIT

ARMATURE

CHECK

and

the

d~pih

of undercut.

is

exce¢ed. Also

surface

for

dirtiness

commutator with

1.523

-0.039

in

fine

(38.7

(-1.0

and

mm)

BRUSH

HOLDER

ASSEMBLY

3.

Check for insulation between and

holder base.

assembly.

Also

'"

If

poorly insulated, replace

check

~~_

the

brush holders

.....

~tr7

positive brush holder

the

holder

for

proper staking.

COMMUTATOR

0.0.

Engines & Generators

40

ATTRACTION

3.

TEST

Holding

minal

S (+) pinion when

released

test.

fully.

With

a battery connected

and

to

the starter

The

pinion must remain at that position even

from

holding with your

body,

to

the

manually

hand.

solenoid pull

STARTER

ter-

out

the

MOTOR

4.

Return test:.

minal M pinion when

(-)

and

fully.

The

released

With

a battery connected

to

the

starter

pinion must return

from

holding

body,

manually pull out

to

by

hand.

to

the solenoid

its original position

ter-

the

HOLDING

TEST

STARTER

1.

Disconnect

2.

Loosen the

3.

Remove fastening

4.

With remove the

5.

Remove

washer.

6.

Unscrew same adjustment

DISASSEMBLY

the

solenoid

the

armature

time,

STARTER

.

MOTOR

the

wire from the solenoid terminal M

two

screws fastening the solenoid. Remove

assembly.

the

two

long through bolts and two screws

the

brush holder. Remove the rear bracket.

brushes pulled away from the armature,

yoke

and brush holder assembly. Then pull

out.

the

cover,

pry the snap ring out, and remove

the

bolts and remove the center bracket.

the

washers for the pinion shaft end play

will

come

off.

INSPECT

FOR

WEAR & CHIPPING

(-).

At

the

RETURN

7.

Pull out the reduction gear lever and lever spring front bracket.

S.

On

the pinion

pinion and pinion shaft.

9.

At each end of a bearing press-fitted off, replace

SOLENOID

'ADJUSTING

puller.

in

the

SHIMS

side,

the

armature, remove the ball bearing

It

is

the

front bracket.

front bracket

TEST

pry

the snap ring out, and pull

impossible

to

replace the

If

that bearing

assembly.

ball has

from

out

bearing

worn

the

with

PINION

LEVER

SPRING

Engines & Generators

41

..

NOTE:

---

Inspect.

if necessary

solenoid.

following

..

~

clean and

brush.

armature,

pages.

replace

commuter;

etc.

See

the

STARTER

MOTOR

Field

Coil

Inspection

1.

Check

for

insulation between one end (brush)

coil and yoke.

2.

Check for continuity between both ends (brushes) of the coil

3. Check the poles and coil for tightness.

MULTIMETER

FIELD

COIL

TEST

STARTER

ADJUSTMENT

AND

REASSEMBLY

of

the

2. Greasing. Whenever the starter has been overhauled,

apply grease to the following parts: a.

Armature shaft gear and reduction gear.

b.

All bearings.

c. Bearing shaft washers and snap rings.

d.

Bearing sleeves.

e. Pinion.

f. Sliding portion

A

CAUTION:

terminals,

3. After reassembly, check by conducting a no-load test again.

SNAP

brushes,

WASHER

RING

of

Never

lever.

smear

the

or

commutator

starter

with

fitting

grease.

surface,

A

CAUTION:

starter

paint,

and

the

quality

grade

between

to

the

terminal.

Reassemble the starter assembly in the reverse order disassembly, making sure

1.

To

adjust the pinion shaft end play, set the end play (thrust gap) to between 0.0197 - 0.0788in (0.5 to 2mm) by

inserting an adjusting washer between the center bracket and the reduction gear.

a. Fit the pinion shaft, reduction gear washer and snap

ring to the center bracket.

b. Measure end play by moving the pinion shaft in the

axial direction. (O.5mm), increase the number inserted.

flange

rust.

of

Before

and

mounting

Starter

the

wiring.

the

battery

installing,

performance

of

If

the end play exceeds 0.0788in

thoroughly

surfaces,

Use

wire

of sufficient

and

starter

the following:

of

clean

remove

largely

depends

and

fully

adjusting washers

all

size

tighten

the

oil,

of

old

on

and

0.5

PINION

mm

MAX

SHAFT

END

PLAY

Engines & Generators

42

REBUILDING

THE

FLAME

CARBURETOR

ARRESTER

ALUMINUM GASKET

VALVE SEAT

[BCGTC]

SCREW

CARBURETOR TOP

COVER

IDLE

MIXTURE

SCREW

DISASSEMBLY,

1. Release the flame arrester clamp and remove the flame arrester. Disconnect the electric choke wire, the vacuum hose attached to the manifold, the fuel supply the throttle control

2. Remove the two nuts holding the carburetor to the manifold and lift the carburetor from the manifold.

3. Disconnect the vacuum hose. Remove the cotter pin from the electric choke control lever and remove the electric choke assembly.

4. Remove the four cover screws and washers. Lift the carburetor top cover straight up and away from the carburetor base.

INSPECTION,

linkage (not shown).

AND

ASSEMBLY

line, and

____

5. In the carburetor top cover, gently punch out the float pin

retaining the pivot bracket and remove the float. Make certain you catch the needle valve that hangs from the float retaining hook under the float pivot arm. aside.

6. Remove the main body gasket.

in the opposite direction

NEEOLE VALVE

THROTTLE

LEVER

of

the split side

Place the needle valve

CONTROL

of

Engines & Generators

43

REBUILDING

THE

CARBURETOR

[BCGTC]

7. Shake the float.

If

you

hear any sand like particles

moving inside, replace the float.

Use a lOmm wrench and remove the needle valve seat.

8. Make certain the seats aluminum gasket is also removed

9. Screw in a new seat and gasket.

10. Replace the main body gasket.

Do

not use any gasket

sealer on the main body gasket.

11. Gently place the needle valve in the needle valve seat. Re-install the float and the float retaining pin so that the needle valves wire retaining loop hooks onto the floats retaining hook.

12. Check the float level distance from the housing mating surface with the housing held vertically.

DISTANCE

FROM THE

NEEDLE

VALVE

MATTING

SEAT

SURFACE

3/16

,3/16

in

FLOAT

IN

[(4.76mml

(4.76mm)

FLOAT HOOK

WIRE RETAINING LOOP

RETAINING

COPPER

NOZZLE

SCREW

WAlSHtII:S,-

REPLACE

THE

FOUR

WASHERS

RETAINING

CARBURETOR BASE

...........

'"

~""C~IV~R

18. Replace the idle mixture screw's O-ring, the rotary throttle shaft valve and the shaft valve spring.

19. Remove the fuel filter plug and replace the fuel filter element.

SCREW

,

CARBURETOR

TOP

COVER

13. On the carburetor base, remove the retaining screw to the accelerator pump nozzle, the nozzle, and the two copper washers that fit above and below the nozzle.

14. Replace the two copper washers and reinstall the

accelerator pump nozzle. Snug down the nozzles retaining screw.

Do

not

NOTE:

the

all

overtighten

With

the

carburetor

components,

replace

the

screw.

disassembly,

any

damaged or

clean

and

worn

inspect

parts.

15. Place the carburetor top cover straight down on the carburetor base. Replace the four washers with new ones and hand tighten the four cover screws in the order shown.

Do

not

overtighten.

16. Re-assemble the electric choke to the carburetor and replace the two choke assembly retaining screws and their washers. Re-attach the electric choke control lever and insert the cotter pin.

FUEL

I"HI"L.-r

PLUG

~M--

FUEL

SHUT-OFF

SOLENOID

20. Make certain all the carburetor screws are properly tightened. Fasten the assembled carburetor on the intake manifold using new gaskets (use sealant). Replace the two nuts and washers and tighten the carburetor to the manifold.

CARBURETOR

TO

MANIFOLD

TORQUE

12

-14

ft-Ibs

(16 -23

Nm)

Engines & Generators

44

REBUILDING

THE

CARBURETOR

I

CARBURETOR

ADJUSTMENTS

[BCGTC]

21. Reconnect the throttle control linkage, the fuel supply line, the vacuum hose, and the electric choke wire.

22. Replace the flame arrester on the carburetor and tighten the flame arrester clamp.

CARBURETOR

Basic Jet Adjustment is performed with the generator operat-

ing.

Screw the

1112

to 2 turns. This

rpm range to improve engine performance.

NOTE:

An

induce

a sooty exhaust discharge at

down.

NOTE:

At

idle

of

the

oil pressure

shutdown

Run Mixture Jet is presized at the factory and is not

adjustable.

ADJUSTMENT

jet

slowly in until it seats, then back it out

jet

idle

at

mixture

speed,

idle

jet adjusted

oil pressure will

switch.

speed.

adjustment can be made in the 3600

too

far off

its

seat

can

engine

start-up and shut-

be

lower

than

the

rating

Jump

this

switch

to

prevent

engine

CHOKE

The choke solenoid is a tions to close the choke plate in the carburetor when the switch is depressed during engine start-up.

The choke solenoid de-energizes once the engine starts and

the

present when the engine starts cold but should smooth out

the engine reaches operating temperature. Keep this solenoid

between the solenoid and the choke lever.

SOLENOID

12

volt DC operated unit that func-

ON

ON switch is released. Some unstable running may be

dry

and periodically lubricate the linkage

as

Engines & Generators

45

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should be cleaned and regapped after the

first thereafter and replaced as needed.

SPARK SPARK

NOTE:

the of

INSPECTING

SPARK

PLUGS

50

hour break-in period, then inspected every 250 hours

A

WARNING:

the

engine

removing

PLUG

GAP:

PLUG

TORQUE:

Loctite Anti-Seize applied

spark plugs will

the

spark plugs

PLUGS

Do

not

is

hot.

Allow

them.

0.028 -0.031 10

-15

retard

easier.

GAP~

INSPECT

FOR

CARBON & WEAR

remove

the

engine

in.

(0.7 -0.8

Ib-fl

(1.5 -2.31

to

corrosion,

+

the

spark

plugs

to

cool

mm). kg-m).

the

threaded portion

making future

INSPECT

CHECK

&

before

DAMAGE

while

removal

FOR

DAMAGE

FOR

DETERIORATION

of

DRIVE

The drive belt must be properly tensioned. Excessive drive

belt tension can cause rapid wear service life the presence resulting in high operating temperatures.

The BCGB generator has two drive belts, one drives the

governor and alternator and the other drives the raw water

,pump. The tension adjustment procedure for both belts is as

follows:

1. Remove the belt guard.

2.

3. With the belt(s) loose, inspect for wear, cracks and frayed

4. To loosen or tighten the governor drive belt, slide the

5. The drive belts are properly adjusted

BELT

ADJUSTMENT

of

the belt and reduce the

of

the fresh water pump's bearing. A slack belt or

of

oil on the belt can cause belt slipping,

To

adjust the governor drive belt, loosen the two governor

mounting bolts. To

adjust the raw water pump/fresh water pump drive

belt, loosen the two raw water pump mounting bolts.

if

edges, and replace

governor in bolts.

To

loosen or tighten the raw water pump/fresh water pump drive belt, slide the raw water pump in or out as required, then retighten its mounting bolts.

no less than (12mm) as the belt is depressed with the thumb at the

midpoint between the two pulleys

the belt.

NOTE:

or

3/&

Maintain a

for proper belt

carried

on

board.

necessary.

out as required, then retighten its mounting

if

it can be deflected

inch (IOmm) and no more than

on

the longest span

22

lb

pressure

operation.

Spare

to

the

belt's outer face

belts should

112

always

inch

of

be

HIGH

TENSION

Check the ignition wires every compartment heat can deteriorate the wires.

Check the resistance because the wire connection inside the cap may become separated or the insulator may be damaged. When removing the wires from the spark plugs, grasp and twist the molded cap, then pull the cap off the spark plug.

THE

RESISTANCE

CORDS

VALUE

IS

(IGNITION

of

each wire.

410

OHM

WIRES)

500

operating hours as engine

Do

not pull on the wire

PER

INCH

OF

WIRE.

A

WARNING:

drive

belt's

6. Operate the generator for about 5 minutes, then shut down the generator and recheck the belt(s) tension.

7. Replace the belt guard.

Never

tension

attempt

while

the

to

check

engine

is

Dr

in

adjust

a

operation.

Engines & Generators

46

ENGINE

ADJUSTMENTS

ENGINE

SPEED

(HERTZ)

ADJUSTMENT·

Governor

The

belt-driven,

the

engine's

determines

Governor

Operate perature

NOTE:

adjust before

There tion).

1.

2.

3.

the

If

the

proceeding

are

IncreaselDecrease Speed Adjustment.

sets

the between adjusted not

running.)

that

the graphite and

apply

HuntinglReguiatitJn Adjustment.

engine adjust hub.

1be increase/decrease speed bolt

adjusted

If

the move adjustment).

Bumper Screw Adjustment.

a

no-load

into

the

mechanically operated governor

rpm

under

the

hertz

various

and

load conditions. Engine

voltage output of

Adjustments

generator

before

the

governor

linkage

three

no-load speed of

the

to

ball

lube

graphite lube

speed

this

eye

as

governor surges under load, adjust this eye bolt

the

spring

surge

governor

to

bring

the

adjusting

adjusting points

governor arm

hold

Make sure

joint connectors are

for

between no-load

well.

the

governor.

is

severely out

at no-load

with

the

this

bolt

away

ONLY.

so

to

obtain a

the

adjustment.

the

and

throttle

to

full

this

purpose. Disconnect the

to

the

draw

the

from

the

This

NEVER turn

far

that it increases

on

engine.

linkage

inside of

BCGTC

maintains

the

generator.

unit

up

to

operating

of

adjustment,

safe

the

governor

This

(The

throttle lever should

open

when

moves

properly

the

If

the

variation

and

full-load

spring closer to

may

lever

hub

screw

is

the

manually

output

(see

adjusting

linkage arm

the

engine

freely

lubricated.

ball

joint.

is

too

the

need

to

(check speed

used

to

bumper

no-load

speed

tem-

voltage

illustra-

bolt

be

is

and

Use

joint

in

great,

lever

be

to

remove

screw

speed.

Governor

1.

Periodically lubricate the lubricant or equivalent.

NOTE:

proper governor/throttle

2. Governor

NOTE:

3.

Change To

remove oil. engine

4.

Periodically adjust

BELTS

stretching

action.

Maintenance

governor arm

Free

movement

oil

capacity - 3 ounces

Do

not overfill

the

governor

change

the

oil,

the

oil

fill

Reinstall

REGULATION ADJUSTMENT

on

the

oil.

Replace

ADJUSTMENT). Since belts stretch

will,

to

the

linkage arm attaching

and

throttle

the

oil

remove and

engine

the

some

lever.

of

this

linkage arm

operation.

governor.

every

250 hours of

the

governor

the

fill

level plug,

and

fill

plugs.

governor belt tension

degree,

affect the govenor's

Use a graphite

is

important for

10/30

engine

operation.

from

the

and

drain

with 3

ounces

(see

slightly,

GOVERNOR

[BCGTC

points

oil.

engine,

all

of

DRIVE

ONLY)

at

the

10/30

this

ALL

Engines & Generators

47

OIL

(UNDER)

GOVERNOR

BELT

ENGINE

ADJUSTMENTS

TESTING

To the oil manifold and install a mechanical oil pressure gauge in its place. After warming up the engine and set the engine speed at

OIL

Note:

pressure oil pressure as depending

LOW

The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3

+

0.1 worn bearings. For additional information on low oil pressure readings, see the

OIL

PRESSURE

test the oil pressure, remove the oil pressure sendor from

3600 rpm read the oil pressure gauge.

PRESSURE

kglcm2).

Between

30

and

40

psi

at

3600

rpm.

A newly started (cold) engine may have an oil

up

to

70

or 80 psi. A warmed engine can have an

low

as 30

psi.

Oil pressure will vary

on

the load placed

OIL

PRESSURE

A gradual loss

ENGINE

on

the generator.

OIL

GALLERY

of

oil pressure usually indicates

TROUBLESHOOTING

chart.

ENGINE

1.

2. Remove the three spark plug caps and remove the three

3. Install a compression adapter and gauge in the spark

4. Close

5. Crank the engine with the start motor and unplug the

6. Measure the compression pressure for all the cylinders.

7.

8. Reinstall three plugs and ignition wires.

9.

COMPRESSION 178

COMPRESSION

To check the engine's compression pressure, warm up the engine then shut

spark plugs.

plug hole.

off

the raw water intake seacock.

ignition coil and allow the compression gauge to reach a maximum reading and record.

Ensure that compression pressure differential for each cylinder is within the specified unit.

Compression 14

psi

If

a cylinder's compression or pressure differential below the limit, add a small amount through the spark plug hole and repeat steps 4 and

(a)

piston ring and/or cylinder wall may be torn or damaged.

(b) pressure suspect poor valve contact, valve seizure, or valve wear.

Open the raw

PSI

pressure

(100Kpa)

If

additional oil causes an increase

If

additional oil does not increase compression

water

PRESSURE

[1260Kpa]

AT

400

it

should

RPM

TEST

down.

not

thru

differ

by

seacock.

more

than

of

engine oil

of

pressure, the

is

5.

OIL

PRESSURE

The generator is fitted with an oil pressure shutdown switch.

Should the engine's oil pressure drop below the safe minimum, the switch will shut the engine down to prevent damage by interrupting the DC voltage to the K2 run relay.

SWITCH

NORMALLY

OPEN 5 PSI

RATED

+

~

I

BATTERY

...

PRESSURE

Engines & Generators

COMPRESSION GAUGE (TYPICAL)

ADAPTER

~

48

ENGINE

ADJUSTMENTS

VALVE

NOTE:

engine's valves (see TORQUING THE CYLINDER HEAD BOLTS).

1. Remove the rocker cover and gasket.

2. Rotate the crankshaft in the normal direction

3. Rotate the crankshaft

CLEARANCE

Retorque the cylinder head bolts before adjusting the

placing the stroke with the exhaust and intake valves completely closed. Adjust the intake valve for intake valve for

rotation. Locate the piston in No. 1 cylinder at the top its exhaust stroke. Adjust the intake valve for cylinder and the exhaust valve for (see chart).

CRANK

When

compression

When at

top

No.1

ANGLE

No. 1 piston

stroke

No. 1 piston of

exhaust

ADJUSTMENT

piston at the top

No.3

cylinder (see chart).

180° in its normal direction

is

set

at

top

of

is

positioned

stroke

IN EX

of

its compression

No.2

cylinder, and the

No.3

cylinder

CYLINDER

1

2

•

of

rotation,

No.2

#

of

•

3

of

IGNITION

1.

Attach a timing light to the #1 spark plug and mark the front timing pointer to indicate mark on the crankshaft pulley and mark it with white

chalk or a crayon.

2.

Start the engine and warm it up to its normal operating temperature. Make sure the generator is operating

a

3. Using the timing light, align the timing mark in the front crankshaft pulley so it is ing pointer. Do this by loosening and slowly rotating the distributor body. Refer to the timing specifications:

TIMING

(no

TIMING

load

on

it.

SPECIFICATIONS:

load

on

generator)

1So

18°.

just

slightly before

BTDC

at

3600

Locate the timing

without

tD.e

first tim-

rpm

IGNITION

TIMING

4. Replace the rocker cover along with a new rocker cover gasket.

ROCKER

COVER

TORQUE:

2.9-5.1Ib-ft

(0.4-0.7

Nm)

VALVE CLEARANCE

VALVE

CLEARANCE:

INTAKE EXHAUST

.00S

..

012

inches

(0.2omm)

(0.30mm)

TORQUING

After the initial break-in period (approximately 50 hours), the cylinder head bolts should be re-torqued.

Tighten the cylinder head bolts according to the sequence shown. Make sure the engine is cold when this is done, and loosen one head bolt one-half turn and then tighten it between 43 head bolt in the sequence. Tighten the securely.

ENGINE~

FRONT

ENGINE

.

The

engine timing belt should be replaced at 1000

operating hours. Refer to

INSTRUCTIONS FOR INSPECTING

THE

CYLINDER

51lb-ft

7

TIMING

BELT

HEAD

BOLTS

(60 - 70 Nm). Then proceed to the next

RS (rocker cover stud)

2

3

ENGINE

TIMING

AND

BELT

REPLACING.

Engines & Generators

49

REVISED

JULY

2004

COMPONENT

GENERAL

All DC voltage measurements are made to the engine battery negative ground point unless specified otherwise. In making test measurements, make sure that a good ground for the

is

meter battery is connected to the engine. Battery positive voltage is indicated as B+ and should measure no less than 11.5 volts.

AC voltage measurements should be made with a true AC meter to insure measurement accuracy.

ENGINE.Gnu\

established, preferably the point where the negative

lI1u

--"<ctttl

RMS

TESTING

TO

B(+)

TESTING TERMINALS

THE

.--.

RELAY

____

TAP

THE

TERMINAL.

RELAY

"CLICK"

GROUND

TO

SHOULD

ON.

CONNECTION

GROUND

AND

B(+)

CONNECTIONS

RELAYS

The relays used in the control system have coils which are

polarized by the fact that they have internal free wheeling suppression diodes across them. Relay coil terminal 86 must be maintained (+), terminal rated 12V DC, and the coil resistance is typically 85 ohms. With B+ on terminal 86, direct grounding permissible for testing purposes.

RELAYS

RELAY

TERMINALS

REMOVE RELAY

THIS

CONNECTOR

85(-).

The

relay coil is

of

terminal 85 is

TESTING

COIL

RESISTANCE

Engines & Generators

50

TESTING

THE

BATTERY

CHARGING

CIRCUIT

BAnERY

The generator supplies a continuous 17 amp charge from its battery charger to the starting battery. charger put a multimeter between the positive negative (-) leads to the battery. It should indicate 13.5V to

14V with the engine running. indicated, check that the battery charger terminal connections are tight. With the unit running, test between the (+) and (-) terminals for 13.5V to the charger.

r -

-~

I

:

30A

I I

I

L

___

CHARGER

If

only the battery voltage is

14V.

If

no charge is indicated, replace

- - - -

---

--

----

--

- ---- -

RECTIFIER

Hz

..:...

_______________________

To

test the battery

(+) and

------

- ----..,-----,

CONTROLLER.:

DC

.

CHARGE

I

t

:

....1

INTEGRAl CONTROLLER [REQUIRES

TEST

BATTERY

POWER]

""-PDT

UNDER

ADJ.

(VOLTS)

OVERSPEED CIRCUIT

BOARD

TROUBLESHOOTING

TO

EXHAUST SWITCH

BLACK

TO

TB116

SHUTDOWN

THE

OVERSPEED

The overspeed switch in the DC circuit shuts off the generators engine by interupting relay

if After correcting the problem, this switch can be reset by momentarily depressing the stop switch.

Overspeed

A fault in this switch can cause a loss

resulting in an engine (generator) shutdown or the inability to start the engine.

CIRCUIT

the engine's speed reaches 2175 rpm (approximately).

Switch

SWITCH

BOARD

DC

voltage to the K2 run

of

ignition

spark

Troubleshooting

If

the overspeed switch is suspect, remove the T3 lead from

the T3 terminal and connect it to the (vacant) T4 terminal. Try starting the engine,

switch is faulty-replace the overspeed circuit board.

If

the engine fails to start (still no ignition spark) continue

troubleshooting elsewhere.

if

the engine starts then the overspeed

Engines & Generators

51

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Engines & Generators

53

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TROUBLESHOOTING

GUIDE

FOR

EFI

COMPONENTS

[BCGTE]

ENGINE

The engine/generator is equipped with an electronic speedregulated, fuel injected control system. Engine speed is maintained constant by varying the amount past a throttle plate into the intake manifold. The throttle plate position is controlled by a rotary proportional actuator energized from a closed loop control circuit whose signal input is from a magnetic pickup-type speed sensor.

Fuel is metered to the engine intake manifold by a central port-type fuel injector system where the amount injected is primarily determined by the engine speed, the engine load, the engine temperature and the intake air temperature. Fuel is deliv.ered to the engine by a high pressure fuel pump. The fuel pressure drop across the injector is maintained constant by a fuel pressure regulator which is ported to the intake manifold to compensate for pressure variations as a result

Air-fuel management are performed by an embedded electronic control unit Engine/generator control functions (starting and stopping) are inputted from a remote control panel or from the engine START/OFF switch to the ECU. The ECU then sets the required operational parameters necessary for the running the engine.

ECU

The BCU is entirely contained on a single printed circuit board. It uses as the principal engine controlling element a micro controller integrated circuit self-contained microcomputer with an internal central processor unit access memory (RAM), an analog to digital converter

(AID), as well as programmable digital input/output ports

(I/O). The vides the required timing functions necessary for engine control (i.e., oil pressure switch, closure time delay, etc.).

OPERATING

CONTROL

CIRCUIT

(CPU), read-only memory (ROM), random

MCU

also contains an internal timer which pro-

SYSTEM

of

engine load changes.

as

well as engine operational functions

DESCRIPTION

of

air induced

of

fuel

DESCRIPTION

(MCU). The

MCU

(BCU).

of

is a

The output driver in the

(Kl,

K2) and the remote control panel indicator lamp(s) is

one which has internal current limiting capability outputs, and will tum itself off should such an over-current condition occur. Therefore, the indicator lamp(s) which are used to indicate the engine status must be type and resistance can and will (in most cases), create a current

surge which will cause an over-current condition which

will tum off these outputs.

occur, tum off the power to the the condition, then resume normal operation.

The the engine is controlled. The the status

sets accordingly the outputs which control the engine. The MCU

as well as some control position however, is determined by a proportional, integral and derivative MCU monitors the engine speed and will shut down the engine in case an overspeed condition should ever occur.

addition, the ECU has a safety backup overspeed circuit in

the unlikely event that the The following text provides a detailed description and a

troubleshooting chart

A

this

any

not

of

ROM

of

the

of

the engine through various inputs and then

has direct control

of

the throttle plate actuator for speed control

(PID) analog closed loop control circuit. The

CAUTION:

manual,

the

circuit

breaker

shore

power

the tungsten filament type whose low cold

Before

disconnect

ECU

which controls the relays

of

If

such a condition should

ECU, remove the cause

MCU

contains the program from which

MCU

measures and monitors

of

the amount

of

the throttle position. The actual

MCU

fails to respond.

of

this control circuit.

performing

the

AC

at

the

control

of

the

test

voltage

panel

the fuel injected

procedures

by

and

cords.

of

its

the

12V,

LED

In

in

thrOwing

off

unplugging

of

Engines & Generators

55

EFI

CONTROL

CIRCUIT

OPERATION

[BCGTE]

DESCRIPTION

When the remote START/STOP switch and the engine START/OFF switch are in their center positions and the generator is not running, the

cal components are in an

from the battery except for a small but negligible leakage current, typically in the order a START switch is actuated, the start is assumed. The indicator lamp (on the remote control

pan~l)

will

co~~~ce

o~

turnmg of

approXImately one second and start relay

the IgrutlOn and the fuel pump. After a time delay

which in turn energizes the starter solenoid and a crank sequence is initiated and continues until the engine runs.

If

the start switch is released before the engine starts, all power is removed and the actuation

of

the START switch will repeat the start sequence as previously described until the engine starts and runs, at which time the starter will automatically disengage (start relay

de-energized), the indicator lamp will light steadily, and circuit power to the

ECU then be released to its center position generator will come up to operating speed, and the engine is under the control

of

the ECU.

When a stop is initiated from a remote control switch, which is for .25 seconds or longer, the acknowledge it as a valid stop command. The de-energize the run relay K2 which in tum removes power to the ignition, the fuel pump and the injector. The indicator light will commence to flash. The then be released to it's center senses an engine zero speed condition, it will then release the

la~ch

which holds the circuit power on, the indicator lamp

WIll

tum off, and the

ECU

and all the engine electri-

off state and there is no current flow

of

20

nano amps (20 -9). When

ECU

is powered up and a

to flash and run relay K2 is energized

Kl

is energized,

ECU

is in an off state. Continued

is latched on. The START switch may

(run mode). The

START/STOP

ECU

will

ECU will then

START/STOP switch may

(ofJ)

position. Once the

ECU

will revert to an off state.

ECU

Kl

Should a fault condition have occurred to initiate a stop as a

of

result

tempera~re

sec?nds valId .stop

an open oil pressure, exhaust temperature or water

sw~tch,

then a time period

IS

requIred before the

co~and.

The stop sequence is as previously

descnbed, wIth the exception that the circuit power will

~e~ain

on continuously after the engine has stopped, and the mdicator lamp will continue to flash, indicating that a fault has occurred. The

ECU

fault circuit and the indicator lamp

may be turned off by a momentary actuation

switch or the on-engine off switch. This reset action must be initiated before the

ECU

will permit the engine to be started.

The stopping sequence for the on engine START/OFF switch is the same as previously described for the remote control

?~el

sto~

swit~h

with .the exception that the stopping action

I~

Imme~ate

WIthOUt

tIme delay because the offposition

dIrectly mterrupts power to the coils

is

HOURMETER

of

approximately four

ECU

will acknowledge it as a

of

relays

KI

the STOP

and

K2.

20A

CIRCUIT

BREAKER

START

RUN

OFF

START/OFFSWITCH

MUST

BE

OFF

PERFORMING

POSITION POSITION

POSITION

( ••••

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

_,

(./

Engines & Generators

MAINTENANCE

~

....

••

' "

WHEN

56

ECU

ADJUSTMENTS

[BCGTE]

DESCRIPTION

The

ECU

printed circuit board includes two user adjustments

in the fonn

1.

PI

generator speed for operation at either

2. P2 - A single tum potentiometer, which sets the optimal response time control circuit.

The specified otherwise, and is internally configured for a 2 pole or 4 pole generator. make sure it is configured by label for the generator in use.

All electrical connections to the circuit board through a single

which connects the wires and may therefore vary in number according to the generator model. For further details, consult the engine circuit wiring diagram.

of

trimmer-potentiometers:

- A 25 turn potentiometer which sets and trims the 50

or 60 Hz.

of

the integral portion

ECU

is nonnally set for operation at

If

it is necessary to replace the ECU,

to

the engine components as required,

ECU

30 pin type PCB connector

of

the closed loop

60

Hz

unless

are made to the printed

STABILITY

When changing engine speed, or condition should occur, the stability potentiometer (P2) may require adjustment. There is no specific set point for this adjustment and it is nonnally set to the middle to a point in its range which obtains optimal engine speed response without any tendency

SEnlNG

The engine speed can be set for operation at either 50 or 60 Hz. Corresponding engine speeds for a 2 pole generator would be

1. Set up whatever equipment is to be used to measure engine speed or generator output frequency.

2. Start up and run the generator at the current operating speed and frequency.

3. Tum the screw adjustment on the top potentiometer increase and counterclockwise for a decrease.

SPEED

(OR

3,000 or 3,600 rpm.

TRIM

TRIMMING)

(PI)

clockwise for a speed and frequency

ADJUSTMENT

if

an engine hunting

of

hunting.

ENGINE

SPEED

of

the speed

its range or

BCGTE

CIRCUIT

BOARD

Engines & Generators

57

EFI

CONTROL

CIRCUIT

TROUBLESHOOTING

CHART

[BCGTC]

GENERAL

If

the

engine

is

not running or not running properly

BCU

is

suspected

as

the possible cause of

the

troubleshooting for the specific PROBLEM indicator heading should

be

performed

to

help determine if the

replacement.

NOTE:

Refer

to

the

detailed testing

PROBLEM:

Preliminary

minal. If

Engine

test:

B+

is

TEST

1.

B+

atTB1-1.

B+

at

2.

3.

4.

5.

6.

TB1-2

place

or

Actuate

B+

at

terminal

B+

at

terminal

Actuate relay

K1

the

engine

ELECTRICAL

procedures.

does

actuate

present,

(YES)

ohms.should

the

- jumper

remote

start

86,

relay

85,

relay

start

control

not

the

switch.

TESTING

start.

engine ON/OFF switch

problem

across

K1. K1.

be

TB1-1,

panel

B+

Voltage

less

than 1 volt.

is

in

the starter (repair or replace); replace starter, if not present proceed

GO

TO

THE

TB1-2

installed.

at

TB

1-3.

at

terminal

and

the

problem,

BCU

then

requires

SECTION for

to

the

must

be

in

85,

start position. After 1 second, check for B+ at the starter solenoid

Before making

the cuit board connector tact,

and

that

the

tests

should

be

made

the

result of

(no),

components

go

to

the

as

adjacent

indicated.

(NO)

1.

Fuse.

2.

Engine

3.

Associated

1.

Remote

2.

Remote

3.

1.

Engine

2.

Associated

1.

Associated

1.

Replace

1.

Resistance Observe cantly

2.

If

stop

Jumper

start

less,

resistance

switch.

wiring

wiring. stop

across

switch.

wiring wiring

relay

test

meter

replace

is

switch.

tests make sure that

is

properly seated

10-24

hold-in screw

in

the sequence that

test

is

(yes),

go

no

column

CHECK

THE

connections.

remote

connections. connections.

K1.

relay

coil

polarity

relay

okay,

replace

FOLLOWING

TB-3

K1,

when

and

to

the

and

to

TB-4.

should testing.

retest.

ECU.

the

BCU

and

making

is

firmly

they

test

or

as

follows:

be

approximately

If

resistance

printed

good

tightened.

are

listed. If

If

the

replace

is

cirThe

result

those

ter-

signifi-

con-

is

85

B+

at

7.

8.

PROBLEMS:

terminal

Actuate

engine

Engine Engine Engine

TEST

1.

2.

3.

4.

(YES)

Connect temperature switch.

Connect

DC

Voltage

depending

DC

ground.

Actuate

measure 4 volts With

engine

Connect

an

lead

to

ground.

a

perceptible

30,

start

starts, starts,

hunts.

voltmeter

sensor

should

on

engine

voltmeter

the

or

cranking,

AC

voltmeter

With

AC

voltage

relay

switch.

to

ground.

measure

water

to

engine

more

observe

the

K1.

B+

at

terminal

runs

and

runs

but

(+)Iead

from

Actuate

from

temperature.

output

lead

start

switch.

while

cranking. actuator

from

the

engine

cranking,

reading.

GO

fuel

then

does

TO

the

.25V

of

MAP

Voltage

moving.

injector

87,

relay

shuts

not

THE

engine

engine to

3.5V

sensor

negative

there

should

K1.

down.

come

to

should

up

TEST

be

to

speed.

1.

20A

Circuit

2.

Associated Replace

1.

(NO)

Electrical

1. Associated

2.

1.

Electrical

2.

Associated

Electrical

1.

Associated

2.

If 1 and 2 above

3.

Electrical

1.

Associated

2.

If 1 and 2 above

3.

K1.

test

wiring

test

wiring

test

wiring

test

wiring

breaker. wiring

connections.

CHECK

engine

connections.

MAP

sensor.

connections.

actuator.

connections.

okay,

injector.

connections.

okay,

THE

water

replace

temperature

FOLLOWING

sensor.

ECU.

Engines & Generators

58

CONTROL

CIRCUIT

TROUBLESHOOTING

CHART

[BCGTC]

PROBLEM:

TEST

1.

2.

3.

4.

5.

6.

7.

8.

Engine

(YES)

B+

at

terminal

B+

at

terminal

Actuate

relay

B+

Actuate

Connect actuate during

With

Connect lead a perceptible

K2

at

terminal

cranking

engine

to

Engine

engine

start

ground.

should

an

AC

switch,

cranking,

an

AC

cranks

86, 85,

30,

but

relay relay

start

switch

be

less

relay

start switch

voltmeter

and

should

be

observe actuator

voltmeter

With

the

voltage

fails

to

start.

GO

TO

K2. K2.

voltage at terminal

than 1 volt.

K2.

B+

at

terminaI8?,

to

terminals

crank

the

engine.

1 volt

AC

or

from

the

fuel

engine

cranking there

reading.

THE

85,

relay

TB1-5,

TB1-6,

Voltage

greater.

moving.

injector negative

should

K2

be

(NO)

1.

Associated

1.

Replace

1.

Resistance

Observe

less,

replace

2.

If

resistance

1.

Associated

1.

Replace

1.

Resistance

greater.

to

spec.

1.

Electrical

2.

Associated

3.

If 1 and 2 above

1.

Electrical

2.

Associated If 1

and 2 above

3.

CHECK

THE

wiring

connections.

relay

K2.

test

relay

coil

meter polarity

relay

and

is

okay,

replace

wiring

connections.

K2.

test magnetic 1 C

If

not,

replace

test

actuator.

wire

connections.

okay,

test

injector.

wire

connections.

okay,

FOLLOWING

K2.

Should

when

testing.

retest.

ECU.

pickup.

magnetic

replace

pickup,

ECU.

be

approximately

If

resistance

Should

if

okay,

be

is

significantly

1000

ohms

readjust

85

pickup

ohms.

or

REPLACING

Remove

the

ECU,

from

its

loosen

connects the

PC

.

and

unfasten

panel.

THE

the

control

disconnect

fuse

holder.

the

10-32

to

the

ECU.

board mounted heatsink

the

two

Unscrew

the four cable connector screws completely disengage then

slide

the

ECU

INSTALLING

To

install

the

THE

new

ECU

box

cover.

Before attempting

its

power

by

removing the 2

Using a 114"

nut

driver,

cable connector hold-in screw which

Then

remove the screw that fastens.

to

the

side of the control

screws that hold

the

cable connector

up

and

out.

NEW

ECU

ECU,

reverse the above procedure.

the

ECU

from

to amp

completely

to

the

and

the

box,

remove

fuse

box

bottom

Engines & Generators

59

EFI

COMPONENT

GENERAL

All DC voltage measurements are made to the engine battery negative ground point unless specified otherwise. In making test measurements, make sure that a good ground for the

is

meter

battery is connected to the engine. Battery positive voltage

indicated as B+ and should measure no less than 11.5 volts. AC voltage measurements should be made with a true RMS

AC meter to insure measurement accuracy.

ENGINE

There are times for test purposes that it may be necessary to power up the

(i.e. testing the MAP be best accomplished by removing the wire to the starter solenoid and by removing the relay connector from the run

relay K2.

TBl-l

B+ at terminal

relay K2 active and disconnect the connector at the fuel

injector. See

previously indicated above.

established, preferably the point where the negative

GRI1UND.....:~Htlrr((f;~'!il

GROUND

AND

B(+)

CONNECTIONS

ECU without cranking

of

temperature sensors, etc.). This can

Ajumper

and TBl-3 which will power up the

may then be placed across terminals

TBl-3). For fuel pressure measurements leave

FUEL

PRESSURE.

or

running the engine

ECU

jumper at

TB

(check for

1

is

as

TESTING

is

RELAYS

The relays used in the control system have coils which are polarized by the fact that they have internal free wheeling

suppression diodes across them. Relay coil terminal 86 must be maintained (+), terminal 85(-). The relay coil is rated With permissible for testing purposes.

[BCGTE]

RElAYS

REMOVE

THIS

RELAY

CONNECTOR.

12V DC, and the coil resistance is typically 85 ohms.

B+

on terminal 86, direct grounding

of

termihal

85

is

TERMINAL

BOARD

#1

Engines & Generators

60

TESTING

THE

TERMINALS

RElAYS

EFI

COMPONENT

FUEL

INJECTOR

The fuel injector has no polarity and operates on 12 VDC. The coil resistance The positive wire to the injector is supplied power through the contacts running. and connect a ground wire to one a wire from a point input pin. When touched, a low audible click should be perceptible; may be assumed to be functioning electrically. However it could be clogged.

To

is

typically in the order

of

relay K2, which

test the injector, disconnect its cable connector

of

B+ and repeatedly touch the other

if

not, resistance test the coil.

If

in doubt, replace the injector.

is

off when the engine

of

14 to 16 ohms.

is

not

its input pins. Connect

If

okay, the injector

TESTING

[BCGTE]

ACTUATOR

The throttle plate rotary actuator has no polarity and operates on

12

VDC. The coil resistance positive wire to the actuator (see wiring diagram) continuously supplied power through the 20A circuit breaker and

is

controlled on through the negative lead to the ECD.

Testing the indicated negative lead wire. When so doing, the actuator should rotate 45 degrees from its normally closed position to the open position. position, when the a shorted output driver in the replaced.

of

the actuator may be accomplished by grounding

If

the actuator

ECU is in an

is

typically 5 ohms. The

is

continuously in the open

off

state, this would indicate

ECU and the ECU should be

FUEL

PRESSURE

Connect a fuel pressure test gauge to the throttle body (as shown).

(run) relay must be connected.

Pressure readings should indicate

TEST

33

to 35 psi. K2 .

Engines & Generators

--"~

...

,

61

EFI

COMPONENT

MAP

SENSOR

The Manifold Absolute Pressure (MAP) sensor is a solid state pressure transducer which measures the intake· manifold pressure (vacuum). (+5V,

Pin C; Gnd, Pin A) from the ECU and receives power only when the measured to ground. Typical output voltages are

ECU is in an on state. Its output (Pin B) is

It

derives its operating power

as

follows:

1.4.8 VDC, 0 inches HG (atmosphere)

2.3.0

VDC,

-10

inches

HG

3. 1.20 VDC, To

test, connect a DC voltmeter from the output (Pin B) the MAP sensor to a good ground point. Activate the ECU; output should read (engine not running) approximately VDC. Disconnect the MAP vacuum hose from the intake manifold, and withdraw perceptible drop in the output volt. sensor may be assumed to be okay. at

MAP sensor Pin C. not, disconnect Pin C and retest for +5 volts at the wire to Pin

C.

is

not present at the wire to Pin C, make sure the

powered up (voltage at

-20

inches HG

air

from the hose; there should be a

If

there is, the MAP

If

not, test for +5 volts

If

okay, replace the MAP sensor.

If

okay, replace the MAP sensor (shorted).

TBl-3);

if

it is so, replace the ECU.

If

+5 volts

ECU

of

4.8

If

is

TESTING

[RCGTE]

WATER

TEMP. & AIR

TEMP.

SENSOR

\.IJ..t/ftf,J.4r:---

REACH

UP

TO

WATER

TEMP.

THRU

TESTING

MAP

B

TEMP. & AIR

SENSOR

THE

SENSOR

ENGINE TEMPERATURE

The engine water and air temperature sensors contain as their sensing elements identical negative temperature coefficient (NTC) thermistors whose internal resistance inversely changes to a change in temperature (i.e., temperature increase, resistance decrease). The thermistors nominal resistance value at 770 F (250 C) is 10,000 ohms. When the ECU is in an on state, the thermistors to ground, and its (+) lead is connected to the then through a fixed series power source. Therefore, the voltage at the thermistors (+) lead should 770 F and decreases to a voltage 220 not linear over this range and therefore it should only serve an

Generally, the thermistor may be assumed to be good there is a perceptual voltage (or resistance) change for a corresponding temperature over the indicated range, other-

wise replace the sensor.

lead, disconnect it from the sensor.

sured at the (+) wire, replace the sensor (shorted). not present at the (+) wire, make sure the up (voltage at TB 1-3);

WATER

TEMPERATURE

SENSOR & AIR

SENSOR

(-)

lead is connected

10,000 ohm resistor to the +5V

be

approximately +2.5 volts at a temperature

of

0

F.

The voltage - temperature relationship however,

indicator that the thermistor

If

there is no voltage at the (+)

if

it is

approximately +.25V at

is

functioning.

If

+5 V is then mea-

ECU is powered

so·,

replace the ECU.

ECU and

if

If

+5V is

of

is

as

Engines & Generators

62

MAGNETIC

PICK-UP I SPEED

SENSOR

TESTING

Lift the wire leads board ohm value should be 1000+ ohms. measures less, replace the magnetic pick-up.

If

the ohm value is correct, remove and inspect the magnetic pick-up. With the wires disconnected, unscrew the magnetic pick-up from the generator housing and visually inspect the contact end. replace the unit.

NOTE:

provided with the new pick-up coil.

THE

MAGNETIC

TB

in

the control panel and check the resistance. The

Carefully follow the installation instructions

1-

5 and

PICK-UP

TB

COIL

1-6 from the terminal

If

the ohm value

If

any damage is detected,

INSPECT

THE

CONTACT

END

Engines &

63

Generators

BeGT

ENGINE I GENERATOR

OPERATING

The following chart is repeated from the operators manual. The problems described do not relate to problems consistent with an engine overhaul. This chart is included only as a convenience to the operator or service technician.

This chart combines both engine and generator.

ENGINE

If

and the remote control panel indicator lamp is flashing, this indicates that an engine operating fault has occurred as a result

1.

2. Loss

3.

TROUBLESHOOTING

the engine stops while running for no apparent reason

of

one or more

Engine overs peed

of

speed signal (magnetic pickup)

Low

oil pressure

4. High engine water temperature

5. High exhaust temperature

6. Low battery voltage

PROBLEM

Engine does not crank.

Engine starts, runs but does not come up to speed.

BCGTE

of

the following conditions:

Voltage drop at starter solenoid

1.

Engine

2. tripped.

3. Engine

blown (E.F.I.). Battery is low or dead.

4.

Loose battery connections.

5.

Faulty wire connection.

6.

Faulty start switch.

7. Faulty start relay

S.

9.

Reset ECU

10. Faulty starter solenoid. High exhaust back-pressure.

11.

Sea water filled cylinders.

12.

1.

Fuel line restriction.

2. Mechanical check valve at the fuel supply is faulty.

3. Dirty fuel filter.

4. Throttle plate binding.

5. Faulty fuel pump.

6. Faulty fuel regulator. (E.F.I.)

7. Faulty wire connection.

S.

Faulty

9. Faulty engine temperature sensor. (E.F.I.)

10. Faulty actuator. (E.EI.)

11. Faulty

12.

AC

13. High exhaust pressure.

(E.F.L)and the

PROBABLE

terminal.

20A circuit breaker has

ECU

circuit fuse has

ECU

or faulty

(E.F.I.).

MAP

sensor. (E.F.I.)

ECU

(E.EL).

generator overload.

BCGTC

CAUSE

(Kl).

TROUBLESHOOTING

PROCEDURES

Before restarting the engine, the cause should be determined and corrected. The remote control panel

START/STOP switch switch must be momentarily placed in the ojfposition to reset the

ECU

fault circuit in order for the engine to be restarted.

The tables that follow suggest a troubleshooting procedure based upon certain engine problem indicators and the most likely causes

When troubleshooting indicates an electrical problem refer to

WIRING

the reveal other possible causes listed below.

NOTE:

ECU(BCGTE), replacing it

is

the

electrical

PROBLEM

Engine starts, runs and then shuts down.

Engine hunts.

of

the problem.

DIAGRAMS in this manual, these diagrams may

If

the

cause

see

it,

in

order

ECU that

component.

.

of

the problem

or

the engine START/OFF

of

the problem which are not

of

the

problem

the

ECU TROUBLESHOOTING

to

help

is

at fault and not some associated

1.

2.

3.

4.

5.

6.

7. S.

9.

10. Faulty ECU. (E.EI.)

11. High exhaust back pressure.

12. Catalytic converter clogged.

1.

2.

3. Generator is overloaded.

4. Dirty fuel filter.

5. Damaged vacuum hose.

6. Faulty fuel regulator. (E.EI.)

7. Faulty S.

9. Cracked distributor cap.

10. Faulty high tension wires.

11. Faulty fuel pump.

12. Faulty

13. High exhaust back-pressure.

14. Valves are out

is

determined

make

a final determination

PROBABLE

Faulty shutdown switch,

(oil pressure, water

temperature). High engine water or exhaust

temperature.

Dirty fuel filters.

Mechanical check valve at the

fuel supply faulty.

Low

oil level in sump.

Faulty fuel pump.

Faulty fuel regulator. (E.EI.) Faulty

MAP

Faulty engine temperature sensor. (E.F.I.)

Throttle plate is binding. Low

battery voltage.

MAP

Faulty engine temperature sensor. (E.F.L)

ECU

CAUSE

sensor. (E.EI.)

(E.EI.).

of

adjustment.

to

or

exhaust

be

the

before

that

Engines & Generators

64

BCGT

ENGINE I GENERATOR

OPERATING

PROCEDURES

TROUBLESHOOTING

PROBLEM

Engine cranks but

fails to start.

Engine misfires.

Engine backfires.

PROBABLE

1.

Out

of

fuel.

2.

Faulty overspeed circuit board, See

TROUBLESHOOTING

THE OVERSPEED SWITCH.

Fuel pump inoperative.

3.

4. Engine is flooded (BCGTC)

a.

Carburetor float needle valve is open or damaged. Clean or replace the needle valve.

h. Float in carburetor is leaking.

Repair or replace float.

c. Float chamber gasket damaged

or

securing screws are loose. Replace gasket and/or tighten screws.

5. High tension wires grounding

(wet system). Faulty ignition coil.

6.

7. Faulty distributor.

Faulty wire connection.

s.

9. Worn or faulty spark plugs.

Faulty run relay (K2).

10.

11.

Timing belt.

12. No engine compression.

13. Faulty idle adjustment, (BCGTC)

14. High exhaust back pressure.

Faulty fuel injector (E.EI.).

15.

1. Incorrect timing.

2.

Faulty high tension wires.

3. Dirty flame arrester.

4. Dirty throttle body.

Throttle plate is binding.

5.

6. Cracked distributor cap.

7. Poor quality fuel.

Spark plugs are worn.

s.

High exhaust back-pressure.

9.

Valve clearances are incorrect.

10.

Spark plug wires are connected

1.

wrong. Incorrect timing.

2.

3. Engine is flooded.

4.

Dirty flame arrester.

5. Cracked distributor cap.

High exhaust back-pressure.

6.

CAUSE

PROBLEM

Engine overheats.

Black exhaust smoke discharge from the engine.

High oil pressure.

No DC charge to the starting battery.

Alternator excitation failure

High no-load 1. High engine speed, adjust RPM'S. voltage

Low no-load voltage

Proper no-load but low loaded voltage.

Proper no-load but high loaded voltage.

Unstable voltage.

1.

2.

3.

4.

5. Faulty thermostat.

1.

2.

3.

4. Faulty fuel injector. (E.EI.)

5.

6.

7. Faulty carburetor.

1.

2.

1.

2.

3. Faulty bridge rectifier.

4.

1.

2.

3. Faulty exciter windings, check

2.

1. Low engine speed, adjust RPM'S.

2.

3. Breakdown in windings, check

4.

1.

2.

3. Short circuit in rotary diodes,

1.

2.

PROBABLE

Coolant loss (pressure test cooling system).

Faulty raw water pump impeller. Belts are loose or broken. Raw water pump worn.

Dirty flame arrester. Faulty vacuum hose Faulty fuel regulator. (E.EI.)

Faulty

MAP

Faulty engine temperature sensor.

(E.EI.)

Dirty oil in the engine.

Relief valve is stuck. Faulty connections to

battery voltage regulator.

Faulty battery voltage regulator.

Faulty generator charger

windings. Low engine speed, check RPM'S.

Faulty capacitor, check/replace.

resistance.

Faulty capacitor, check/replace.

Faulty rotary diodes, check/replace

resistance.

Faulty capacitor, check/replace. Low

loaded speed, regulate RPM.

Load too heavy, reduce load.

check/replace. RPM too high, regulate RPM.

Loose contacts, check connections. Uneven rotation, check governor.

CAUSE

..

sensor. (E.EI.)

or

wrong SAE type oil

Noisy generator backend.

Engines & Generators

65

1.

Broken bearings, replace.

2.

Poor couplings, check/repair.

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BCGT

GENERATOR

ELECTRICAL

TESTING

INTRODUCTION

The following test procedures can be used to troubleshoot WESTERBEKES 2 POLE SINGLE

BRUSHLESS

generator, troubleshooting is relatively easy. Field testing and repairing can be accomplished with basic

tools and repair parts which should include the following: A quality multimeter [multitester] capable

less than one ohm and with a specific diode testing function.

Basic electrical tools including cutters, soldering iron,

wire strapper/crimper, terminals connectors, etc. Repair

rectifier, etc.

PRELIMINARY

Before electrical testing check for proper engine speedlhertz adjustment. Low engine speed will cause low AC voltage output, high engine speed-high AC output.

Refer to manual for engine speedlhertz adjustment or for other possible engine related problems.

Before testing, get a clear explanation exists, be certain it relates to generator components.

A

WARNING:

distributor and

shutdown

circuit

leave

GENERATORS. Due to the simplicity

parts

such as diodes suppressors, fuses, bridge

CHECKING

WESTERBEKES operators manual or service

AC

and

DC

circuits

panel.

Be

certain

DC/AC

inverters.

breakers

hot

wires

will

on

not

the

do

supply

to

the

side

unplug Simply job

CAPACITOR

of

the problem that

often

share

AC

power

swftching

since

it

will

of

the

panel.

of

reading

the

same

cords

off

still

the

GENERATOR

FAULT

No

AC

Output

Residual 7-8

Low (60-100

High Voltage

Load No

Low

Unstable (Refer Manual)

Noisy

NOTE:

operating at

A

generator

cover

Voltage

VAC

{Hot

AC

Output

VAC)

AC

Output

Drop

{or

at

No-load)

Battery

Charge

Battery

Voltage

to

Operators

Operation

This

fault finding

the

WARNING:

to

and

timing

N)

Under

Charge

correct

Some

be

mnning,

belt

TROUBLESHOOTING

CHART

CAUSE

Shorted Open Shorted Shorted

Shorted

Open Faulty

Faulty Faulty Faulty

Faulty Faulty

Check Faulty

Check

Adjust

Check AC Wiring

Check

of

Stator

Exciter

Rotor

Diode CapaCitor Suppressor

Capacitor Rotor

Bridge

Integral

Fuse

Winding

Engine Governor Capacitor

Terminal

Diagrams]

Coupling,

chczrt

is

speed.

the

following

make

covers

Stator Suppressors

Diodes

Exciter

Diode

Rectifier

Controller

Speed

Connections

Wiring

[Refer

Check

compiled

with

tests

certain

are

in

place.

the

(hertz)

to

Bearing

the

require

front

and

engine

the

pulley

TEST

C* C

A A

D D

A A

CAP

A

CAP

A

B B B B

* Letters

Components [page 7].

Engines & Generators

69

A.,

B,

C.,

& D refer to the Internal Wiring Diagram

CAP

is capacitor.

BCGT

GENERATOR

ELECTRICAL

TESTING

Assume that the diodes are OK. Test the resistance values of

the rotor windings by placing the multitester leads

across the diode as shown and compare to the data below.

Model4.5Kw Model7.2Kw Model9.6Kw

If

the data

To unsoldering the two winding leads.

Test for resistance between the two winding leads and again

compare to the

GENERATOR

ROTOR

BC,

___

BC,

___

BC,

___

is

correct, the problem in NOT in the rotor.

continue testing, remove the diode/suppressor by

data~

COMPONENTS

WINDINGS

_ _ _

Check for continuity between each rotor shaft. Continuity would

TESTING

With the diodes removed, measure the resistance (as shown) using a multitester (with a diode testing capability). If

the meter measures resistance in one direction, it should

indicate infinity in the other.

~

ALTERNATE

DIODE

Both diodes should measilre

one measures lower than the other, it is presumed faulty. Replace both.

THE

STYLE

DIODES

TESnIIG

DIIDES

of

these leads and the

inoicate a short in the rotor.

TESTING

the

same resistance value.

CONTINUITY

If

TESTING MNDING

THE

LEADS

A

CAUTION:

large

enough Excessive Also

make

windings

soldering

heat

certain

as

it

[ON

SOLDERING]

iron

will

damage

no

soldering

will

melt

the

When

soldering,

to

get

the

diodes.

splashes

insulation.

job

done

onto

use

quickly.

the

a

TESTING

Unsolder the suppressor from the diode and check for infinite resistance.

A shorted suppressor will often turn black when shorted

out.

Repeat the same test procedures to the opposite side rotor

THE

windings.

SUPPRESSOR

IF

THE

SUPPRESSOR

FAILS

TO

READ RESISTANCE. SUPPRESSOR

INFINITE

THE

IS

FAULTY

Engines & Generators

70

·

SCGT

GENERATOR

ELECTRICAL

TESTING

o

-

I-

t

TESTING

An AC voltage is induced in these windings by the

rotating field. Checking the residual voltage output from this winding can determine the condition when troubleshooting.

RESIDUAL Single

AC generator is operating. This voltage may be as high as to

500 volts AC. This voltage buildup is accomplished as the exciter windings charge the capacitor and the capacitor discharges back into the exciter windings. reading is taken between the

number connection plugged into the capacitor while the generator is operating at its rated Hertz (61.5 flow phase-imbalance type

windings: a beneficial result that produces good motor starting characteristics for this type

THE

EXCITER

VOLTAGE

Capacitor

voltage can be measured across the capacitor while the

of

saturating AC in the exciter windings produces a

Model

WINDINGS

of

the winding

16

-18

VAC

from

each

winding

This

AC

#60 Hertz connector and the

62.0). This

of

field that effects the auxillary

of

generator.

400

voltage

MEASURING

To

measure the resistance value

locate

#9 and the #50 Hertz capacitor connections.

NOTE:

Three numbered capacitor connections exist:

and #9;

Unplug any other connections from the capacitor noting their position on the capacitor. multimeter on plug connection #9 and the other lead on

plug, connection

of

the exciter windings.

WINDING Model

4.5Kw Model7.2Kw Model9.6Kw

NOTE:

Lower

resistance will confirm a faulty winding.

CHECKING

Check to make sure there is no continuity to the ground/generator case from either Also check that no continuity exists between either the

#60 Hertz plug

winding leads on the AC output (not illustrated). continuity is found winding groups.

RESISTANCE

of

the exciter windings,

and

two Hertz connections,

#50 Hertz. Measure the resistance value

RESISTANCE

BC BC BC

[OHMS]

4.550

3.960

3.710

residual voltage along with a lower winding

#50

and

#60.

Place one lead

CONTINUITY

of

the two leads.

or

the #8 plug and any

he~e,

a fault exists between

of

the main stator

#7,

of

the

If

thes~

two

#8,

.....

~

"

NOTE:

Position the meter correctly

to damage the meter.

EXCITER Model4.5Kw

Model Model

CHECKING

RESIDUAL

VOLTAGE

CIRCUIT

7.2Kw

9.6Kw

RESIDUAL

BC

16

BC

17

BC'

18

VAC VAC VAC

VOLTAGE

(±

.5)

(±

.5)

(±

.5)

for

AC

voltage so as not

TESTING VOLTAGE [GENERATOR

AC

RUNNING]

TESTING

....

A

CAUTION:

testing.

a

lethal

power

source.

Discharge the capacitor by a bridging the terminals with a screwdriver.

Capacitors

CapaCitors

punch

even

must

store

electricity

when

disconnected

be

discharged

and

can

from

before

pack

the

CONTINUITY

Engines & Generators

71

·

BCGT

GENERATOR

ELECTRICAL

TESTING

Connect a multitester (highest ohm scale) terminals. The meter should go to zero ohms and slowly return to high. Discharge the capacitor again and reverse the leads, the same results should be obtained.

If

the meter goes down and stays at zero ohms, the capaci-

tor is faulty (shorted).

If

the meter fails to go down to zero, the capacitor is faulty

(open circuited). Indications

THE

CAPACITORS

of

a defective capacitor:

to

the capacitor

o Infinite resistance, or no rise in resistance

(shorted capacitor)

o Infinite resistance (open capacitor)

NOTE:

The

capacitor

capacitor.

CAPACITOR Model

Model Model

RATINGS

4.5Kw

7.2Kw

9.6Kw

BC BC BC

rating

is

marked

25MFD

31.5

MFD

35

MFD

on

the

TESTING

CAPACITORS

housing

of

Pn#035985 Pn#035978 Pn#041199

the

Normal AC voltage running to the rectifier (while the engine is operating at two AC connections

AC

VOLTAGE

No-load Full-load

Normal DC voltage running out DC) is measured across the two bridge rectifier, that is

DC

VOLTAGE

No-load Full-load

Lift the two AC wire leads off the bridge rectifier and measure the resistance between these two leads. It should measure 0.14 ohm. No continuity should exist between there two leads and the ground

TO

off

the

off

FROM

off

the

off

3600 rpm) is measured across the

o~

the bridge rectifier.

THE

BRIDGE

generator

the

generator

THE

generator

the

generator

MAKE

CERTAIN

PROBES

+

and-.

BRIDGE

RECTIFIER

__

_

__

_

BRIDGE

THE

TOUCH

METAL

of

the rectifier (in volts

DC

RECTIFIER

17.0

18.5

or

the main stator windings.

(APPROXIMATELY):

RECTIFIER

connections

of

the

(APPROXIMATELY):

volts

DC

volts

DC

12

VOLT

EXCITATION

The generator may be excited using from the engine's starting battery. This voltage is applied across the

(unplugged) with any other numbered leads unplugged from the capacitors. The generator's reaction during flashing will help determine its fault.

12

VOLT

#50 and

EXCITATION,

#9

OUTPUT

leads

of

RANGE

o A slight rise in the output voltage with the loading

the engine and/or a growling noise from the generator end will indicate a fault in the main stator windings.

12

volts DC taken

the exciter circuit windings

IS

22

TO

26

VAC.

of

o No rise or a very slight rise in the output voltage will

indicate a fault in the excitor windings.

o Normal output voltage as specified above, check

excitor circuit.

TESTING

THE

BArrERY

CHARGING

CIRCUIT

AC

LEAD

RESISTANCE Model

Model Model

MEASUREMENT

4.5Kw

BC @ 60Hz

7.2Kw

BC @ 60Hz

9.6Kw

BC @ 60Hz

@50Hz @50Hz

.1570. .094n .116n .084n .106n

Blue

to

Blue

to

Blue

to Green Blue

to

Blue Green White

tD

Blue

White

ACTERMINAL

Engines & Generators

72

BCGT

TESTING

1. Set your multimeter's scale on needle to zero.

2. Connect the #4. Taking the multimeter's negative (-) lead, momentarily touch points #1, #2, #3, and #5. The multimeter should register

3.

Remove the positive (+) lead from point

the negative (-) lead, momentarily touch points #1, #2, and #3. The multimeter's needle should deflect when each point is touched.

THE

BRIDGE

(+) positive lead from the multimeter to point

no

deflection for any

RECTIFIER

#5

GENERATOR

RX1

(+DC) and set the

of

the points touched.

#4

and connect

#4

ELECTRICAL

INTEGRAL

VOLT

~VOLTAGE

+ -

o

:::a

>

z

C)

."

o

:::a :::a

."

c

TESTING

CONTROLLER

ADJ.

GND

WINDINGS

BRIDGE

RECTIFIER

AC

#3--"'et

#1

#2

4. Leaving the negative multimeter (-) lead on point #4, touch point #5 with the positive lead. No deflection should take place.

5. Place the positive lead (-) on point #3. The multimeter again should not register any deflection (no deflection indicates infinite resistance). Reverse these connections and the multimeter should again register no deflection.

NOTE:

Different types and/or

produce

INTEGRAL

The Integral Controller (I.C.) is an encapsulated, solid-state

unit that supplies a starting battery while the generator is opening.

A seperate group a bridge rectifier which converts the the I.C. unit. battery and supplies a you suspect that the battery's charge is low), check the charging circuit and it's components as described in the following text. Check all connections for cleanliness and tightness including the ground before replacing the I.C. unit.

opposite test

Charging Charging

CONTROLLER

Voltage Amperage

(+) lead on point

results.

DC

of

stator windings supplies

The

I.C. unit senses the needs

DC

I.e.

BRIDGE

RECTIFIER

#1

and the negative

brands

o/test meters

charging voltage to the generator's

13.0

-14.0

volts

0 •

17.0

amps

DC

AC

current to supply

charge when one is needed.

unit is faulty (that is,

DC

AC

of

the starting

if

may

voltage to

If

the

TESTING

To

positive indicate 13.5V to battery voltage is indicated, check that the battery charger terminal connections are tight. With the unit running, test between the charge is indicated, replace the charger.

~

FUSE

A 30 amp fuse protects the windings from a failure of the

bridge rectifier

short).

THE

INTEGRAL

test the battery charger,

(+) and negative (-) leads to the battery. It should

14V with the engine running.

(+) and (-) terminals for 13.5V to

GROUND

INTEGRAL

CONTROLLER

......

.........

......

@

.............. ~ ---

-......

'-

CONTROLLER

put

a multimeter between the

- - -

......

~:'I.

PROTECTION

or

integral controller (high amperage or a

If

14V

only the

If

no

NOTE:

When

the

generator

produce a low

the

generator

The

I.e. a voltage output adjustment on the controller that will allow a DC voltage output adjustment

is

mounted

charging

operated.

is

first

started,

rate.

This

inside the generator housing. There is

charging

of

the

I.

C.

rate

will

± 2 volts.

unit

rise

will

as

Engines & Generators

73

BCGT

GENERATOR

ELECTRICAL

TESTING

C

TESTING

Residual voltage measured between the hot and neutral

leads will be 7-8 volts AC. This would be an indication

that the stator windings are okay. and artificially excite the generator.

Residual

Measure between hot [#1 and #4]

Model Model Model9.6Kw

THE

Voltage

4.5Kw

7.2Kw

MAIN

BC BC BC

STATOR

Check

8

VAC

7.5 7

VAC

WINDINGS

Check

exciter windings

and

neutral [#2 and #5].

(±

.5)

VAC

(±

.5)

(±

.5)

Group

with lead #1 and terminal with lead #3. (Check that there is no continuity

#1

- Measure resistance value between terminal

of

Group #1 windings to the case ground).

Group #2 - Measure resistance value between terminal

with lead no continuity

Check

stator windings by placing one lead the terminal with the stator #3 terminal with stator between the two groups

#4

and terminal with

of

group #2 windings to the case ground).

for a possible short between the two groups

lead

GROUP

#1

#6.

of

lead

and

There

stator

#6. (Check that there is

of

the multitester

the other

should be no continuity

windings.

lead

#2

MAIN

STATOR

WINDINGS

of

on

on the

t2

FASlENS

TO

#5

AC

CIRCUIT

FASTENERS

TO

BREAKER

STUD

TESTING

BETWEEN

TESTING

Model· Between

Model Between

RESISTANCE

4.5Kw leads

7.2Kw leads

9.6Kw

leads

RESISTANCE

LEADS

BETWEEN

BC

___

BC

___

BC

___

Resistance

_

#1

#4 #4

_

#1 #1 #4 #4

_

#1

#4 #4

THE

and and and and

MAIN

Values

#2

#3

#5 #6

#2

#3 #S #6

#2 #3 #5

#6

STATOR

WINDINGS

[ohms]

5150 .5850 .5160 .5850

.2940 .3300 .2930 .3310

.1790 .2000

.. 1790

.2010

Engines & Generators

74

FUSE·

TWO

INTEGRAL

WINDING: pn#43634

ENGINE (NOT 250V

CONTROLLER NO

TIME

30A

PROTECTION

SHOWN)

MTH·8

Pn#33769

(TIME

r--------,

I I

:

fH:

: A :

I I I I I I

POLE

DELAY

250V

MDA·30

DELAY)

8A

Be

30A

B

~-....I

GENERATOR

INTERNAL

BRIDGE

RECTIFIER

A • B •

rn

•

C •

D •

WIRING

ROTOR BATTERY

MODEL

BATTERY

MODELS STATOR CAPACITOR

WINDINGS

CHARGE

4.SKw CHARGE

7.2Kw

WINDINGS

WINDING

WINDING WINDING

AND

9.6Kw

CAPACITOR Model

Model Model

MAKE HAS

THE

AND

WINDING MODEL

MODEL

RATINGS I PART

4.5Kw

BC

7.2Kw

BC

9.6Kw

BC

CERTAIN A REPLACEMENT

THE

CORRECT

BODY

OF

NUMBER.

RESISTANCE

4.5Kw

7.2Kw

9.6Kw

PART

THE

CAPACITOR

A B C

D

A

B C D

A

B C D

NUMBERS

Po#035985 Po#035978 Po#041199

CAPACITOR

NUMBER.

FOR

VALUES

IN

ROTOR CHARGER STATOR EXCITER

CHECK THE

OHMS

3.51!2

O.14!J O.58!J

2.3!J

3.51!2

O.14!J O.29!J

2.2!J

4.03!J O.14!J O.17!J

1.9!J

D

rrrn

7 8 9

6·

6

t~

RATING

r~

CONNECT REQUIRED

AND

FOR

FREQUENCY

OUTPUT

AC

CONNECTIONS

4~-------,

THE

VOLTAGE

:?t

- N

1-.------~

6,~----...,

NOTE:

When c/u;znging from 60Hz to 50Hz. make certain the ground wire is properly repositioned according to this diagram.

CIRCUIT

BREAKER

L

N

120

(CONNECT

230

(REMOVE

L

VAC

60Hz

JUMPER)

50Hz

JUMPER)

Engines & Generators

7-5

SERVICE

DATA I STANDARDS

AND

LIMITS • BCGT

GENERATOR

Component

FRONT

CASE/COUNTERBALANCE

Oil

Pump

Side Driven Drive

Counterbalance

· . .

Counterbalance

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

Counterbalance

·

Counterbalance

·

CYLINDER

Cylinder

Out-of-Roundness

Taper

Gasket

CYLINDER

Flatness Overall Cylinder

Intake Intake

Exhaust Exhaust

Cylinder

0.05

0.25

0.50 Intake Exhaust Intake Exhaust Valve

Exhaust...

Intake

Valve

(Intake) (Exhaust)

Valve

(Intake) (Exhaust)

Valve

Intake Exhaust...

Stem

Intake Exhaust

Valve

(Intake) (Exhaust)

Clearance

Gear

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

Gear

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

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

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

BLOCK

Bore

of

Cylinder

Surface

HEAD

of

Gasket

HeighL.

Head

oversize

0.3

0.6

0.3

0.6

Head

rework

O.S

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

O.S

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

O.S

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

Valve

Seat

Valve

Seat

Valve

Seat

Valve

Seat

Clearance

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

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

Head

Thickness

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

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

Length

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

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

Stem

O.D.

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

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

to

Guide

Clearance

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

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

Guide

Length

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

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

Specified

Shaft

Front

0.7869-0.7874

Shaft

Rear

1.7317-1.7322

Shaft

Front

0.0014 -0.0027

Shaft

Rear

0.0014 -0.0028

2.5591-2.5602

and

Bore

Flatness

Surface

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

rework

0.S

......

1.2323

0.S

.....

1.2441

O.S

....

1.1535 -1.1544

O.S

....

1.1653 -1.1662

of

valve

0.4744 -0.4751

0.4823 -0.4830

0.4921 -0.4928

Angle

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

Angle

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

Width

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

Width

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

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

(margin)

0.2585 -0.2591

0.2571 -0.2579

0.0020 -0.0033

Value / Standard

inches(mm)

SHAFT

0.0024-0.0047

0.0027-0.0051 Joumal

Diameter

(19.987-20.000)

Journal

Diameter

(43.984-44.000)

Journal

Oil

Clearance

Journal

Oil

Clearance

(65.00-65.03)

0.0004

(less

0.0020

(less

... 0 ..

0019

(Less

.4.287-4.295

0.0008 -0.0020

dimension

-1.2333

-1.2451

guide

hole

.45·

30·

0.079

0.D12

0.008

039 051

3.960

3.968

1.73

1.949

(108.9-109.1)

(31.300 -3.325)

(31.600 -31.625) (29.300 -29.321)

(29.600 -29.621)

(both (12.050 (12.250 (12.500

(2.0) (2.0)

.

(0.30) (0.20)

(1.0) (1.3)

(100.6) (100.8)

(0.0050 -0.0085)

(44)

(49.5)

(0.06-0.12) (0.07-0.13)

(0.035 -0.068)

(0.035 -0.071)

than

0.01)

than

0.05)

than

0.05)

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

of

valve

seat

hole

intake

and

-12.068)

-12.268)

-12.518)

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

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

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

(6.565 -6.580) (6.530 -6.550)

(0.02 -0.05)

Repair

Limit

inches(mm)

0.0039

0.0079

exhaust)

0.004

(0.1)

0.004

(0.1)

020

(.5)

031

(8)

......

0.0039

(0.10)

..

0.0059

(0.15)

(0.1)

(0.2)

Component

VALVES

Valve

Guide

Service

Valve

Seat

Valve

Valve Valve Valve

Load/Installed Ibs.lin Squareness

TIMING

ROCKER

Camshaft

Camshaft Diameter

Bearing End Rocker Rocker

PISTON

Piston Piston

Piston

Piston Piston

Piston

Piston Piston

End

Width

Contact

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

Seat

Angle

Seat

Sink

Spring

Free

Spring

(N/mm)

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

BELT

#043036

ARM

Height

No.1

(Intake)

No.2

(Intake)

No.3

(Intake)

No.1

(Exhaust)

No.2

(Exhaust)

No.3

(Exhaust)

Journal

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

Oil

Clearance

Play

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

Shaft

Length

Arm

Shaft

Outer

Diameter

Clearance

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

AND

CONNECTING

Outer

Diameter

to

Cylinder

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

Ring

Grove

No.1

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

No.2

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

Oil

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

Service Ring

End

No.1

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

No.2

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

Oil

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

Side

Clearance

No.1

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

No.2

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

O.D

Press-in

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

Play

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

Specified

Size

of

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

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

Length

Height

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

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

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

..........

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

.......

Value / Standard

inches(mm)

0.05, 0.25,

035-.051

30·/44·/65·

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

1.823

.46/1.48

.Iess

1.3815

1.3807

1.3803

1.3839

1.3831

1.3854

1.6118-1.6124(

0.0018-0.0033 0024-.0055

9.134

0.6687 -0.6692

0.0005 -0.0017

0.50

oversize

(0.9-1.3)

(46.3)

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

(210137.7)

than

2·

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

(35.09)

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

(35.07)

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

(35.06)

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

(35.15)

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

(35.13)

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

(35.190)

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

40.940-40.955) (.45-0.085) (.06-.14)

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

(232)

(16.985 -16.998)

(0.012 -0.043)

Repair

inches(mm)

0.008

1.783

1.3618

1.3610

1.3606

1.3642

1.3634

1.3657

118

......

0.004

ROD

......

Clearance

Width

Size

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

Gap

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

Load

2.5579-2.5591

0.0008 -0.0016

0.0480 -0.0488

0.0476 -0.0484

0.1108 -0.1116

0.25, 0.50, 0.75,

0.0059 -0.0118

0.0138 -0.0197

0.008 -0.028

0.0012 -0.0028

0.0008 -0.0024

0.6300 -0.6302 Ibs(N)

1102 -3307

0.0059 -0.0118

(64.97-65.00)

(0.02 -0.04)

(1.22 -1.24) (1.21 -1.23)

(2.815 -2.835

1.00

OS

(0.15 -0.30) (0.35 -0.50) (0.2 -0.7)

(0.03 -0.07) (0.02 -0.06)

(16.001

-16.007)

(5000

-15000)

(0.15 -0.28)

........

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

......

0.0315

0.0394

0.0047

0.0039

Limit

(0.2)

(45.3)

.4.

(34.59) (34.57) (34.56)

(34.65) (34.63) (34.69)

(.03)

(0.1)

(0.8) (0.8) (1.0)

(0.12) (0.10)

Engines & Generators

76

SERVICE

DATA / STANDARDS

AND

LIMITS • BCGT

ENGINE/GENERATOR

Component

PISTON

AND

CONNECTING

Piston

Press-in

·

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

Connecting

·

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

Parallelism

·

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

Connecting Connecting

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

temperature

Rod

Center

between

Rod

Twist..

Rod

Big

End

Specified

Value / Standard

inches(mm)

ROD

ordinary

length

.4.01384.0178

End

and

Small

0.004

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

to

0.004

Crankshaft

0.0039 -0.0098

temperature

(101.95

-102.05)

End

(0.05)

(0.1)

Side

Clearance

(0.10 -0.25)

Repair

inches(mm)

..........

0.16

limit

(0.4)

Component

CRANKSHAFT,

Crankshaft

Crankshaft Crankshaft Cylindericity

Concentricity

Oil

Oil Undersize

Undersize

End

Play

Journal

0.0

of

Journal

·

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

of

Journal

·

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

Clearance

of

Journal

·

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

of

rework

0.25

U.S

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

0.50

U.S

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

0.75

U.S

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

rework

0.25

U.S

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

0.50

U.S

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

0.75

U.S

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

Specified

BEARING

..........

0.0020 -0.0098

0.0

...

1.5740

.........

1.4165

and

.Less

and

Less

0.0008 -0.0018

........

0.0009 -0.0020

dimension

of

1.5644

1.5545 -1.5551

1.5447

dimension

1.4069 -1.4075

1.3970 -1.3976

1.3872 -1.3878

Value / Standard

inches(mm)

(0.05 -0.25)

-1.5748

(39.98 -40.0)

-1.4173

(35.98 -36.00)

than

0.0002

than

0.0006

(0.021 -0.045) (0.022 -0.052)

Journal

-1.5650

(39.735 -39.750) (39.485 -39.500)

-1.54539 of

(39.235 -39.250)

(35.735 -39.750) (35.485 -35.500) (35.235 -35.250)

(0.005)

(0.015)

Repair

limit

inches(mm)

......

0.0039

(0.1)

Engines & Generators

77

SPECIAL

NOTE:

These

special

your

local

Mitsubishi

TOOLS

tools

are

available

Automotive

Dealer.

from

CAMSHAFT

MD

PISTON

Used the

MD

CRANKSHAFT

MD

999569

to

pull-out

piston

999583

998376

OIL

SEAL

SETTING

pin.

REAR

INSTALLER

BASE

and

press

in

OIL

SEALINSTALLEB

OIL

PAN

For break

MD~27

BEARING

For rear

MD

FRONT

(Counterbalance

MD999591

GASKET

removing

the

oil

REMOVER

pulling

out

bearings

999593

BEARING

the

pan

seal.

the

(counterbalance

shaft).

CUTTER

oil

pan

to

front

and

shaft).

INSTALLER

For

supporting

when

the

loosened

MD

998715

END

YOKE

For

supporting

when

the

loosened

MB

990767

camshaft or

tightened.

HOLDER

the

camshaft

or

tightened.

the

sprocket

is

is_

CRANKSHAFT

MD999570

OIL

PUMP

Engines & Generators

OIL

FRONT

SEAL

INSTALLER

OIL

SEAL

INSTALLER

78

Timing

Belt Crankshaft TIming Camshaft Oil TIming TIming

Rocker

Rocker Camshaft Rocker

Cylinder

Cylinder Spark Rocket

Miscellaneous

Coolant Coolant Generator Exhaust Thermostat Carburetor

bolt

belt

sprocket

pump

sprocket tensioner belt

Arms

and

cover

thrust

arm

Head,

head

plug

cover

temperature temperature

mounts

manifold

to

cover

bolts

nuts

rear

cover

Rocker

shaft

plate

adjust

nut

Valve

bolt

(cold

housing

manifold

bolts

Shaft

bolt

sender switch

engine)

ENGINE

Nm

135-145

10-12

80-100

50-57 22-30 10-12

29-35 10-12

8-10

60-70

15.2

12-13

12-18 12-18 34-47 16-23 12-17

8-11

16-23

HARDWARE

ft.lbs.

98-105

7-9 58-72 36-41 16-22

7-9

21-25

7-9

6-7

43-51

10.8

9-10

9-13 9-13

23-34

6-8 12-17

TORQUES

Front

Case,

Counterbalance

Front

case

bolts

Oil

pump

cover

bolts

Oil

pan

bolts

Oil

drain

plug

Oil

screen

bolts

Oil

pump

driven

gear

Rear

cover

bolts

Piston

and

Connecting

Crankshaft,

Oil Bearing

Cylinder

Taper Taper Water Taper Oil Oil

Water

Bearing

seal

case

cap Block plug

1/16

plug

1/8

drain

plug

1/4

pressure pressure

Pump

pump

rod

cap

bolts

plug

NPT switch sender

bolt

Rod

nut

Shaft

Nm 8-10 8-10

10-12 35-45 15-22 11-16 34-40 10-12

15 + 90"

turn

10-12 50-55

8-12 15-22 11-16 35-45 35-45 12-18 12-18

8-10

11 + 90·

ft.

Ibs. 6-7 6-7 7-9

25-33

25-29

7-9

36-40

6-9

25·33 25-33

9-13 9-13

6-7

turn

Engines & Generators

79

BOLT

Bolt

strength

HEAD

MARKINGS

classes

are

embossed

on

the

head

STANDARD

of

each

bolt.

HARDWARE

Metric

bolt

class

numbers

strongest.

identify

bolts

by

their

strength

with

10.9

the

NOTES:

1.

2.

3.

STANDARD

Capsrew

Body

1/4

-

20

-

28

5116-18

-24

.3/8-16

-24

7/16

-14

-

20

1/2

-13

-

20

9/16-12

-18

518-11

-18

3/4

-10

-16

7/8-

9

-14

1 - 8

-14

Size

(Inches) • (Thread)

Use

the

torque

These

torques

Reduce

torques

BOLT & NUT

SAE

Torque Torque Torque

FHb(Nm)

110 120

150 170

270 295

395 435

590 660

Grade

8

(11)

10

(14)

17

(23)

19

(26)

31

(42)

35

(47)

49

(66)

55

(75)

75

(102)

85

(115) (149)

(163) (203)

(231) (366)

(400) (536)

(590) (800)

(895)

values

are

based

by

30%

TORQUE

5

listed

on

or

SAE

FHb(Nm)

below

when

specific

clean,

dry

more,

threads.

when

Reduce

threading

SPECIFICATIONS

SAE

Grade

10

(14)

19

(26)

34

(46)

55

(75)

85

(115)

120

(163)

167

(226)

280

(380)

440

(597)

660

(895)

6·7

Grade

Ft·Lb(Nm)

12

(16)

14

(19)

24 27

44 49

70 78

105 120

155

170

210 240

375 420

605 675

910 990

torque

values

torque

capscrews

8

(33) (37)

(60) (66)

(95) (106)

(142) (163)

(210) (231)

(285) (325)

(508) (569)

(820) (915)

(1234) (1342)

are

not

by

10%

into

aluminum.

METRIC

Bolt Dia.

M3 M4 M5

M8 M9

Ml0

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33 M36

available.

when

Wrench

Size

5.5mm 7mm 8mm

10mm 13mm 16mm

18mm

21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

engine

oil

is

used.

BOLT & NUT

Grade

4.6

Ft-Lb

(Nm)

0.3

(0.5)

0.8

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(SO)

59

(80)

81

(110)

118

(160)

159

(215)

203

(275)

295

(400)

402

(545)

546

(740)

700

(950)

TORQUE

Grade

Ft-Lb

0.5

85

118 166 225

288 417 568

774 992

SPECIFICATIONS

4.8

(Nm)

(0.7)

1

(1.5)

2

(3)

4

(5.5)

10

(13)

18

(25)

33

(45)

55

(75)

(115)

(160) (225) (305)

(390) (565) (770)

(1050) (1345)

Grade

Ft-Lb

1

2

4.5

7.5 18

37

63

103 159

225 321 435

553

811

1103

1500 1925

8.8 -9.8 (Nm)

(1.3)

(3)

(6)

(10) (25) (50)

(85)

(140)

(215)

(305) (435) (590)

(750)

(1100)

(1495)

(2035) (2610)

Grade Ft-Lb

1.5 3

(4.5)

6.5

11 35 55

97

(130) 151 232

321 457 620

789

(1070)

1154 1571

2139 2744

1D.9

(Nm)

(2) (9)

(15) (26) (75)

(205) (315)

(435) (620) (840)

(1565) (2130)

(2900) (3720)

NOTE:

Formula

to

convert

Ft-Lbs

to

GASKETSf,SEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

O-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper ing

assembly.

Specialized ing copper

gasket

non-hardening

cylinder-head

#2

They

are

water,

oil

or

of

OIL

or

LIQUID

red

sealant

of

the

gaskets

that

SILICONE

ADHESIVE

SPRAYS

sealers

properties.

gaskets

and

it's

effective

fuel.

should

oil

pan seal

grease.

such

as

HYLOMAR

as

TEFLON

Nm

(Newton

HIGH

TACK

in

just

about

can

be

used

gasket

with

around

water

are

useful

HYLOMAR

is

it

resists

fuel,

Meters)

multiply

Ft-Lb x 1.356.

SEALANTS & LUBRICANTS

Use

LIQUID

equivalent

any

joint

be

used

on

oil

adapter

high

temp

(coolant)

for

holding

work

well

particlarly

oil

and

are

excellent

in

contact

on

rubber

hoses

RED

SILICONE

passages,

gaskets

in

applications

effective

water.

all

with

gaskets

and

the

oil

sealer.

coat

both

in

position

dur-

requir-

on

Engines & Generators

passages.

BOLTS & FASTENERS/ASSEMBLIES

Lightly plugs HIGH

When

Anti-seize threaded LOCTITE

LITHIUM ing

Heavily use

TEFLON

Do

oil

head

that

penetrate

TACK.

assembling

compounds components offers

based

boxes.

oil

all

clean

engine

not

use

bolts

the

levels

grease

sliding

oil!

80

for

sealing

tape

sealants!

and

other

the

water

flywheel,

and

thread

yet

allows

of

locking

is

waterproof,

and

reciprocating

pipe

plugs

fasteners

jacket

should

coat

the

locking

them

to

according

ideal

and

fillings

as

you

assemble

be

sealed

bolt

threads

adhesives

came

components

to

for

apart

the

water

such

job.

when

that

connect

them.

with

PERMATEX

with

LOCTITE

as

when

necessary.

pump

bearings

assembling.

coolant

Bolts

and

blue.

LOCTITE

protect

and

Always

#2

stuff-

or

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

=

Millimeters

Feet

(ft)

x

.305

=

Meters

Miles

x

1.609

=

Kilometers

METRIC

(mm)

(m)

x

3.281

(km)

x

CONVERSION

x

.0394

=

Feet

.0621

=

Miles

=

Inches

DATA

VOLUME

Cubic

Inches

(in3) Imperial Imperial Imperial Imperial Imperial Fluid US US US

Pints Quarts Gallons Quarts Gallons

Ounces

Pints

(US Quarts Gallons

x

(US

(IMP

29.573

pt)

qt)

gal)

MASS-WEIGHT

Ounces Pounds

(oz)

(Ib)

x

28.35

x

.454

PRESSURE

Pounds

Inches Inches Inches Inches Inches

Per

Sq

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

In

x

16.387

pt)

(IMP

x

.473

x

.946 x

=

(psi)

(Hg)

(Hg) (H20) (H20)

(H20)

=

Cubic

x

.568

=

qt)

x

1.137

gal)

x

4.546

qt)

x

1.201

gal)

x

1.201

=

Milliliters

=

Liters(L)

=

Liters

3.785

=

Liters

Grams

(g)

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

Centimeters

Liters

(L)

x

1.76

=

Liters

(L)

=

Liters

(L)

=

US

Quarts

=

US

Gallons

x

.034

=

Ounces

x

2.113

=

(L)

x

1.057

(L)

x

.264

x

.035

=

Ounces

(kg)

x

2.205

='Kilopascals

=

psi

x

2.036

=

Kilopascals

=

Inches

of

Mercury

=

psi

x

27.684

Kilopascals

(kPa)

x

=

x.88

x

.22

(US

Pints =

Quarts

=

Gallons

=

Pounds

(kPa)

=

Hg

(kPa)

=

H20

.061

IMP

=

IMP

qt)

x

4.026

=in

pt

=

IMP

x

.833

gal)

.145

.2961

x

13.783

qt

x

3

gal

.833

=

IMP

psi

=

Hg

=

H20

=

IMP

H20

qt

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles

Kilometers

Miles

Kilometers

Per

(Hp)

Hour

IMP

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree Degree

Fahrenheit Celsius

(0C)

(in-Ib)

(ft-Ib)

x

1.609

x

.745

=

(MPG)

(Km/L)

US

(MPG)

(Km/L)

(OF) = (OC

=

(OF

-

x

.113

=

1.356

=

Kilometers

Kilowatts

x

.354

=

x

2.352

x

.425

x

2.352

X

1.8) + 32

Newton

(Kw)

Kilometers

=

Kilometers

=

IMP

US

Meters

Per

x

1.34

MPG

32) x .56

Engines & Generators

Hour

=

MPH

Per

(Nm)

(KPH)

Liter

x

8.85

x

.738

x

.621

(Km/L)

=in-Ib

=

ft-Ib

=

MPH

81

METRIC

CONVERSIONS

INCHES TO MILLIMETERS MILLIMETERS TO INCHES

Inches

1 25.40 15 381.00 1 0.0394 15 2 50.80 20 508.00 2 0.0787 3 4 5

10

mm

76.20

101.60

127.00

254.00

MILLIMETERS

Inches

25 30 35 40

= 1

CENTIMETER,

mm

635.00

762.00

889.00

1016.00 10 03937 40 1.5748 100

CENTIMETERS

mm

3 0.1181 25 0.9843 4 0.1575 30 1.1811 5

= 1

Inches

0.1969

MmR = 39.37

mm

20 0.7874

35 1.3780

INCHES

(3.3

Inches

0.5906

FEET)

Inches

1 2 3 4 5 6

TO

INCHES TO METERS

Meters

0.0254

0.0508 8 0.2032 0.2 7.874 0.8

0.0762

0.1016

0.1270

0.1524

CONVERT

METERS

Inches

10 11 12

TO

CENTIMETERS,

Meters Meters

0.1778

7

9 0.2286 0.3 11.811 0.9 35.433

0.2540 0.4 15.748 1.0 39.370

0.2794 0.5 19.685

0.3048 0.6 23.622

MOVE

DECIMAL

0.1

METERS

POINT

TO INCHES

Inches

3.937 0.7 27.559

TWO

Meters

1.1

1.2 47.244

PLACES

TO

THE

RIGHT

YARDS TO METERS METERS TO YARDS

Yards

1 2 3 4 5

Meters

0.91440

1.82880 7 6.40080 2 2.18723 7

2.74320

3.65760

4.57200

MOVE

DECIMAL

Yards

6

8 9

10

POINT

FOR

Meters Meters

5.48640

7.31520

8.22960

9.14400

HIGHER

VALUES -e.g.

Yards

1 1.09361 6 6.56168

3 4 4.37445 9 9.84252 5

3.28084

5.46807

6,000

MmRS = 6,561.68

Meters

8 8.74891

10

10.93614

YARDS

POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

Ib

1 0.454 6 2.722 1 2.205 6 13.228 2 3 4 1.814 9 5

kg

0.907 7 3.175 2 4.409 7 15.432

1.361 8 3.629 3 6.614

2.268

Ib

10

kg kg

4.082 4 8.818

4.536 5 11.023

Ib

kg

8 17.637 9 19.842

10 22.046

GALLONS TO LITERS LITERS TO GALLONS

Gallons

1 3.79 2 3 4 15.14 5

Liters

7.57

11.36

18.93

PINTS TO LITERS

Pints

1

2 3 1.42 8 4 1.89 9 5

Liters

0.47

0.95 7 3.31 2 4.23

2.37

Gallons

10 20 75.71 2 0.53 90 23.77 30 113.57 5 1.32 120 31.32 40 151.42 50

Liters Liters

37.86 1 0.26 60 15.66

10

189.28 20 5.28 180 47.54

Gallons

2.64 150 39.62

Liters

LITERS TO PINTS

Pints

6

10

Liters Liters

2.84 1

3.79

4.26 4 8.45 9

4.73 5

3

Pints

2.11

6.34

10.57

Liters

6 12.68 7 8

10

TEMPERATURE

32

40

I I I

50 60

I I I I I I I I I

70

75

85

I I I I I I I I

5 10 15

0

20 25

30

105 140 175 212

95

I

I I I

35

40

60

80

100

Inches

31.496

43.307

Yards

7.65529

Ib

Gallons

Pints

14.79

16.91

19.02

21.13

OF

°C

Engines & Generators

82

INDEX

AC Connection Diagrams Actuator Battery Charging Circuit BCGT Electrical Testing BCGTE Wiring Diagrams Belt Adjustment Bridge Rectifier Capacitors -Testing Carburetor - Rebuilding Carburetor Adjustment Choke Solenoid Compression Test Coolant Circulating Pump Cylinder Block Inspection Cy linder Head Torquing Diodes - Testing Distributor ECU - Adjustments ECU - Replacing/lnstalling EFI Component Testing EFI Components Troubleshooting EFI Control Circuit

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

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

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

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

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

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

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

Engine Disassembly

CamshaftIRocker Arms Crankshaft Bearing Assembly CrankshaftlBearings Cylinder BlocklPiston Clearance Cylinder Head Installation Cylinder HeadlValves

Front Case/ Counterbalance Shaft

Oil Pan Oil Pump Pistons/Connecting Rods

Timing Belt Exciter Windings - Testing Exhaust Manifold Fuel Injector Fuel Pressure Test Fuel Pump Gasdenser Generator Disassembly Generator Troubleshooting [Chart] Governor Adjustments Hardware Standards Hardware Torques

Heat Exchanger Ignition Timing

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

and

Inspection

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

& Oil Seal

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

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

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

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

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

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

.......

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

...........

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

75 Ignition Wires 61

51

&72 Internal Wiring Diagrams

69

66&67 Main Stator Windings Testing

.46

73 Metric Conversion [Chart]

72 Metric Formulas .43 .45 Oil Pressure Testing .45 .48 Piston Clearance

35 33

.49

70

.34 Sealants & Lubricants

57 59 62 Speed Hertz Adjustment 55 56 Starter Motor -Adjustment

9-33

19

24 Thermostat .31 .33

18 15

26

26,29 27,29

21

11

71

36 61 61 38 38

64

.47

7&80

79 36

.49

Integral Controller

Magnetic Pick-up Coil

Sensor

Map

Oil Pressure Switch

Parts Identification

Raw Water Pump Relays Remote Panels Wiring Diagram Rotor Windings - Testing

Spark Plugs Specifications

Standards and Limits

Starter Motor - Inspection Suppressor - Testing

Timing Belt Tools - Special

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

Troubleshooting Charts

Control Circuit Engine Generator - Electrical Generator

Valve Clearance Adjustment

Wiring Diagrams/Schematics

AC Connections BCGTC BCGTE Generator - Internal Remote Panels [BCGTC] Remote Panels [BCGTE]

8

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Operating Procedures

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

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

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

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

...........

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

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

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

.46

73 75 63 74 62 82

81 .48 .48

3 33 37

50&60

.54,68

70

7&80

.46

2

.47

76

39&42

.40

70 38

11,49

78

58

5

69 64

.49

75 52,53 66,67

75

54 68

Engines & Generators

83

Engines & Generators

1006 WMJDW 10/99