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Read this safety manual carefully to understand fundamental rules and precautions.
Guidelines to prevent injury or death from electrical hazards.
Precautions to avoid burns from hot engine parts or exhaust.
Safety measures to prevent flash fires and burns.
Safety precautions to prevent injury or death from fuel vapor explosions.
Precautions to prevent injury or death from accidental engine starts.
Safety guidelines to prevent battery explosions and related hazards.
Warnings and precautions for handling sulfuric acid in batteries.
Information on carbon monoxide hazards and symptoms.
Safety advice to prevent injury from rotating engine components.
Warnings about high noise levels and potential hearing loss.
References for safety codes and standards for engine installations.
Compliance requirements for marine engine and generator installations.
Provisions for installing a siphon-break in raw water supply hoses.
Requirements for marine exhaust hoses and system design.
Identifying symptoms indicating the need for engine overhaul.
Information for marine engine service and rebuilding facilities.
Instructions for proper disassembly and part handling.
Guidance on locating engine and generator serial numbers.
Probable causes and remedies for starting issues.
Diagnosing engine issues based on exhaust smoke color.
Identifying causes of high oil usage in the engine.
Troubleshooting causes for engine backfiring or misfiring.
Common causes and solutions for engine oil leaks.
Troubleshooting reasons for an increasing oil level.
Diagnosing engine problems based on unusual sounds.
Identifying causes and remedies for low cylinder compression.
Troubleshooting factors contributing to high fuel usage.
Diagnosing and resolving engine knocking issues.
Causes and solutions for low engine oil pressure.
Overview of the BC generator engine component and disassembly process.
Key considerations for engine assembly, including parts and tools.
Proper procedures for tightening engine hardware to specified torques.
Recommended sealants and lubricants for engine assembly.
Guidelines for installing bolts and fasteners during assembly.
Procedure for timing belt maintenance and replacement.
Steps for removing the engine timing belt.
Procedure for removing the crankshaft bolt.
Criteria for replacing the timing belt due to wear or damage.
Steps to remove the camshaft sprocket.
Procedure for removing the oil pump sprocket flange nut.
How to inspect the timing belt tensioner for wear.
Instructions for mounting the flange correctly.
Procedure for installing and torquing the crankshaft bolt.
Steps for installing the oil pump sprocket flange nut.
Procedure for installing and torquing the camshaft sprocket bolt.
Installing the tensioner spring and timing belt tensioner.
Detailed steps for installing the engine timing belt.
Procedure for removing the cylinder head assembly.
Inspection of valve stem, seat, and spring components.
Instructions for measuring and inspecting valve springs.
General installation guidelines for cylinder head components.
Procedure for installing new valve stem seals.
Procedure for tightening cylinder head bolts.
Instructions for installing the rocker cover and gasket.
Guidelines for inspecting camshaft for wear and damage.
Inspection of individual rocker arms and their components.
Checking clearance between rocker arm and shaft.
Inspection and measurement of the rocker shaft.
Steps for installing the camshaft and rocker arm assembly.
Procedure for removing connecting rods and pistons.
Steps for removing piston rings and pins.
Instructions for safely removing piston pins.
Checking piston pin for proper fit and alignment.
Inspection of piston surfaces for damage and wear.
Procedure for measuring piston ring gap and side clearance.
Inspection and measurement of connecting rod bearings.
Steps for assembling the piston oil ring.
General guidelines for assembling piston and connecting rod.
Detailed steps for assembling piston to connecting rod.
Procedure for installing the piston and connecting rod into the cylinder.
Selecting and assembling crankshaft and connecting rod bearings.
Procedure for torquing connecting rod bearing caps.
Steps for removing the engine oil pan.
Procedure for removing the counterbalance shaft.
Checking the front case for cracks and clogged oil holes.
Inspecting the crankshaft front oil seal for wear.
Checking oil pump assembly clearances and wear.
Inspecting the counterbalance shaft for clogging and damage.
Guidelines for installing front case, bearings, and oil pump.
Procedure for installing the counterbalance rear bearing.
Instructions for installing the crankshaft front oil seal.
Steps for assembling the front case.
Procedure for installing the counterbalance front bearing.
Instructions for installing the oil pump driven gear.
Aligning timing marks and installing the oil pump drive gear.
Installing the oil pump cover gasket.
Procedure for installing the oil pump seal.
Cleaning and preparing the oil pan and block mating surfaces.
Checking crankshaft journals and pins for damage and wear.
Specifications for upper and lower crankshaft bearings.
Procedure for measuring crankshaft oil clearance using Plastigauge.
Checking the crankshaft rear oil seal for wear and damage.
Procedure for measuring crankshaft end play.
Guidelines for installing crankshaft thrust bearings.
Procedure for installing the crankshaft rear oil seal.
Checking cylinder block for cracks, flatness, and bore condition.
Procedure for boring cylinders to accommodate oversize pistons.
Calculating and verifying piston to cylinder clearance.
Inspection and assembly of the exhaust manifold.
Steps for assembling the exhaust manifold to the cylinder head.
Inspection and servicing procedures for the heat exchanger.
Reinstallation steps for the heat exchanger assembly.
Procedure for removing the engine's coolant pump.
Checking the coolant pump body and impeller for damage.
Guidance on replacing the coolant pump assembly if faulty.
Steps for installing the coolant pump with a new gasket.
General overview of the raw water pump overhaul process.
Detailed steps for disassembling the raw water pump.
Inspection of raw water pump parts for wear or corrosion.
Instructions for reassembling the raw water pump.
Description of the single barrel, side-draft carburetor.
Instructions for cleaning the air screen filter.
Function and maintenance of the choke solenoid.
Proper operation confirmation for the side draft carburetor.
How to verify correct carburetor operation.
Adjusting carburetor linkage for proper choke and throttle control.
Adjusting the speed actuator for throttle control.
Procedure for testing the distributor's pickup coil resistance.
Checking spark plugs for carbon build-up, burning, and gap.
Steps for disconnecting and removing starter motor components.
Overview of the starter motor's main sections and type.
General guidance for starter adjustment and repair.
Procedure for inspecting and adjusting the pinion gap.
Testing the starter motor's performance without load.
Tests and inspection procedures for the starter solenoid.
General inspection of starter components.
Detailed inspection of the starter solenoid.
Checking the armature for shorts and insulation issues.
Inspect brushes, springs, and brush holders for wear and condition.
Checking field coils for insulation and continuity.
Guidelines for starter adjustment and reassembly.
General guidelines for DC and AC voltage measurements.
Information on relay coil polarization, rating, and testing.
Overview of the electronic governor system components.
How the electronic governor regulates engine speed.
Procedure for adjusting governor gain to dampen speed oscillation.
Description of speed controller adjustments and indicators.
Instructions for installing the magnetic pick-up (MPU).
Normal circuit voltages for governor troubleshooting.
Nominal voltages for the electronic governor at idle and 1800 RPM.
Overview of the electronic governor's function and components.
Adjustments for speed and gain on the governor controller.
Procedure for calibrating the electronic governor.
Details on adjusting the speed and gain control pods.
Steps for removing the generator rotor cover plate.
Checking rotor field windings for shorts and resistance.
Testing winding continuity to the generator case.
Procedure to check rotating field windings for ground shorts.
Instructions for testing generator diodes.
Procedure for testing diodes using an ohmmeter.
Overview of components within the control box.
Troubleshooting generator when no AC output is present.
Procedure to excite generator windings with 12 VDC.
Steps for applying 12 VDC to exciter windings.
Troubleshooting generator behavior during excitation.
Measuring AC voltage across capacitor connections.
Determining exciter winding condition via residual AC voltage.
Performing quick field checks for continuity.
Procedure for testing generator capacitors.
Exploded view of the Coliseum model generator components.
Exploded view of the Mecc Alte model generator components.
Terminal board connections for a single line 120V system.
Terminal connections for 120V/60Hz two-wire setup.
Installation guidelines for the shore power transfer switch.
Terminal connections for 230V/50Hz two-wire setup.
Description of a field-fabricated tool for removing generator housing.
Tool for safely removing the generator end from the engine.
Tool for aligning generator drive disks during removal/installation.
Tool used to pull the stator assembly from the engine.
Explanation of bolt strength class markings.
Torque values for standard SAE bolts and nuts.
Torque values for metric bolts and nuts.
Recommended sealants and lubricants for various applications.
Guidelines for oiling, sealing, and assembling bolts and fasteners.
General| Model | 4.2 KW BCG-50Hz |
|---|---|
| Power Output | 4.2 kW |
| Frequency | 50 Hz |
| Fuel Type | Diesel |
| Starting System | Electric Start |
| AC Voltage | 230V |
| Manufacturer | Westerbeke |
| Model Short | BCG-50Hz |
| Cooling System | Liquid Cooled |
