Westerbeke BCD 4.4KW Betreibershandbuch

OPERATOR'S MANUAL l,WESTERBEKE BCD 4.4KW and BCD 6.0KW MARINE DIESEL GENERATOR SETS Publication # 37144 Edition Two May 1988 j'-.v-'WE

: Fuel Lift Pump BCD 4.4KW Marine Diesel Generator 7 Emergency Shut-off Switch E"~h~ust Temperature SWitchf 45° Exhaust Elbow: Westerbeke Generat

BCD 6.0KW Marine Diesel Generator ,20 Amp DC Circuit Breake Exhaust Temperature" 'SwItch Emergency Stop Switc 45° Exhaust Elbow AC Westerbek

Fresh Water ~AirBleea FreshWater ·c i rcufaiIn9~f:i~iiii?"' Sea Water ~eat Exc::hanger. BCD 6~OKW Marine Diesel Generator rter with Solenoid

BCD 4.4KW MARINE DIESEL GENERATOR SET Engine Type Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Maximum

BCD 4.4KW SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Injectors Lift Pump Air cleaner Air Flow (engine combustion) COOLING SYSTEM Gen

BCD 4.4KW SYSTEM SPECIFICATIONS ELECTRICAL SYSTEM Starting Battery Battery Capacity Starter DC No-Load Current DC Cranking Current (engine cold) DC Ch

BCD 4.4KW SYSTEM SPECIFICATIONS NQIE.: Increase air supply 15% for 50 Hertz operation (1500 rpm). Engine Combustion Air Requirements, (60 Hertz), at 1

BCD 6.0KW MARINE DIESEL GENERATOR SET Engine Type Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Maximum

BCD 6.0KW SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Injectors Lift Pump Air cleaner Air Flow (engine combustion) COOLING SYSTEM Gen

BCD 6.0KW SYSTEM SPECIFICATIONS ELECTRICAL SYSTEM Starting Battery Battery Capacity Starter DC No-Load Current DC Cranking Current (engine cold) DC Ch

SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator.

MITE: Increase air supply 15% for 50 Hertz operation (1500 rpm). Engine Combustion Air Requirements, (60 Hertz), at 1800 rpm TUNE-UP SPECIFICATIONS In

INSTALLATION CHECKS General Since the crafts in which Westerbeke generators are installed vary in design, installation procedures will vary according

Rigging and Lifting The generator is fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight should be attac

Generator Mounting - Location The complete generator unit is mounted on lightweight rails by means of four flexible isolator mounts that help prevent

Exhaust System IWARNINGI Although diesel fuel is not as dangerous as gasoline, precautions should be taken to guard against CARBON MONOXIDE GAS. Car

Exhaust Back-Pressure The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust back-pressure. Exhaust back-pr

Dry stack-type exhaust systems (shown to the right) must be at-tached to the generator engine's ex-haust manifold by means of a flexible co

Exhaust Elbow Installation The Westerbeke Corporation offers a 45°and 900exhaust elbow as well as an exhaust riser you can install on your propulsion

Fuel System The fuel system should be installed in such a manner as to allow the engine-mounted fuel lift pump to pump to maintain a positive inlet pr

Sea Water Intake System Make sure the intake system (sea water cooling system) is in proper order. Check that the hull inlet, sea cock and strain

DC Electrical Connections A common ground for the negative (-) DC terminal connection is found at the bell housing of the generator, next to the start

Batteries Make sure the positive ( + ) battery connection is connected to the battery connection of the starting solenoid. The negative (-) battery co

DESCRIPTION OF INSTRUMENT PANEL o PREHEAT o ~ ... 1 ."' .~'. STOP @,\ \. . .: . ... _ ... o o General The manually-operated series

Remote Operation For starting and stopping the generator at a remote location, the same three switches are used. The PREHEAT and START switch

Description of Starting System Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold weather starting. The f

PREPARATION FOR STARTING This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and s

STARTING PROCEDURE 1. Depress and hold the PREHEAT switch. Preheat according to the following chart: 2. While still depressing the PREHEAT switch, de

STOPPING PROCEDURES 1. Remove the AC electrical load from the generator and allow the generator to run for 3 to 5 minutes so the engine can stabilize

Starting Under Normal Conditions Follow the procedure below for normal starting of the generator: 1. Make sure there is sufficient fuel on board. Keep

FUEL SYSTEM Diesel Fuel Use No. 2 diesel fuel with a cetane rating of 45 or higher. Never use kerosene or home heating oil since these fuels do not h

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals

Priming the Fuel System The Westerbeke self-bleeding fuel system is semiautomatic in operation. The self-bleeding feature of the fuel system allows fo

Fuel Injection Pump The illustration below shows the BCD 6.0KW's fuel system. The BCD 4.4KW fuel system's differs in that it has one less f

DC ELECTRICAL SYSTEM Engine 12-Volt DC Control Circuit The Westerbeke BCD 4.4KW and BCD 6.0KW generators have a 12-Volt DC electrical control circuit,

Testing the Battery Charging Circuit NOTE: This circuit is totally separate from the AC output of the generator. The AC output of the generator effec

E. Place the positive ( +) lead on point #1 and the negative (-) lead on point #3. The Ohmmeter again should not register any deflection (no deflectio

BCD 4.4KW DC Control Circuit Wiring Diagram #35951 page 1 of 2 WATER TEMP. • SENC';R ~ ,,.~ ¥ ~~Lp ~ DIAGRAM o ~ .-.-~ ~ EMERGENCY STOP SWITCH S

BCD 4.4KW DC Control Circuit Wiring Diagram #35951 page 2 of 2 SCHEMATIC DIAGRAM ~ -: seE .. ~ NOTE 2 START SOL. STARTER I ~--------~..., I----{M}--~

BCD 6.0KW DC Control Circuit Wiring Diagram #35773 page 1 of2 WIRING DIAGRAM ~ ,...-----'c---:;I;T llQe ~ ~ EU!2 Westerbeke Generator ... EXHA

BCD 6.0KW DC Control Circuit Wiring Diagram #35773 page 2 of 2 SCHEMATIC DIAGRAM 1 : :SEENOnz , , START SOL. ~--------------------------~"~---

COOLING SYSTEM Description Westerbeke marine diesel generators are designed and equipped for fresh water cooling. Heat produced in the engine by comb

FOREWORD Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have you as a customer. Read this manual c

Antifreeze Concentration Freezing Temperature ANTIFREEZE CONCENTRATION DATA % 13 23 30 35 45 50 60 ° F 23 14 5 - 4 - 22 -40 - 58 e C) (-5) (-10)

COOLANT RECOVERY TANK Coolant Recovery Tank, Recommended Installation Fill the fresh water system as follows: 1. Remove the pressure cap from the mani

Sea Water Circuit The sea water flow is created by a belt-driven, positive displacement, neoprene impeller pump. The pump draws sea water d

Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow through their independent cooling circui

LUBRICATION SYSTEM Engine Oil FOR ENGINE LUBRICATION, USE LUBRICATING OIL DESIGNATED FOR DIESEL SERVICE. THESE OILS ARE CLASSIFIED ACCORDING TO THE AP

Engine Oil Change (to include fiHer) 1. Draining the Oil Sump Remove the oil drain hose from its attachment bracket and lower it into a contain

3. Filling the Oil Sump Add fresh oil through the oil filler cap on the valve cover (refer to the photographs on pages 6 and 7 for the BCD 4.4KW

BC GENERATOR The BC generator is a brushless, self-excited generator which requires only the driving force of the engine to produce an AC output. The

No-Load Voltage Adjustment: BCD 4.4KW 1. Remove the louvered metal plate covering the terminal connections and the capacitor (see page 56). 2. Start t

SO Hertz Plug CAUTION-DO NOT ALLOW ANY OF THESE PLUGS TO TOUCH THE GENERATORoS HOUSING .. WINDINGS WILL BURN IF THESE PLues TOUCH THE HOUSING OR OTHER

TABLE OF CONTENTS Section ... Page GENERAL ...

No-Load Voltage Adjustment: BCD 6.0KW 1. Remove the louvered metal plate covering the terminal connections and the capacitor (see page 56). 2. Start t

THE 17 PlUG IS SHOWN CONNECTED TO THE CAPACITOR ONLY FOR DEMON-STRATION PURPOSES. BCD G.OKW GENERATOR 58 Hertz Plug A. Check the resistance of the exc

Load Connections The generator's data plate gives the voltage, current and frequency rating of the generator. An AC wiring decal is affb<ed t

Shore Power Connections If the installer connects shore power to the vessel's AC circuit, this must be done by means of the SHORE POWER/OFF/SHIPS

GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electric motor is considerably more than is requir

4-Pole Generator Voltage Load Speed Frequency 120V(110) 240V (220) Applied (rpm) (Hertz) Plants Plants None 1830 62 122 240 (1530) (52) (112) (

Problem Preheat is depressed: no preheat. Preheat is depressed: fuel pump does not operate. Preheat is depressed: no fuel solenoid activation. ENGINE

problem START switch is de-pressed: no starter engagement. Engine does not crank. Engine cranks, but does not start. Failure to stop. Westerbeke Gener

problem Engine Stops. Battery runs down. Black exhaust smoke. probable Cause 1. Fuel starvation. Fuel shut-off is turned OFF. 2. Fuel pump is inoperat

MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/

TABLE OF CONTENTS (CONTINUED) LAY-UP & RECOMMISSIONING ... 75 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ...

*4. Adjust valve clearances. 5. Adjust the water pump drive belt tension, if required. 6. Lubricate the ball joint linkage between the run solenoid an

Servicing After Every 800 Hours of Operation *1. Remove and check fuel injectors. Injector spray pressure: 2275 psi + 140 psi (160 kgJcm2 + 10 kg/cm2)

Torquing Cylinder Head Bolts: BCD 4.4KW Tighten the cylinder head bolts according to the sequence shown in the illustration shown to the right. Make

Valve Clearance Adjustment: BCD 4.4KW CAUTION Adjust the valve clearance when the engine is cold. Valves are adjusted by cylinder in the firing order

Valve Clearance Adjustment: BCD 6.0KW CAUTION Adjust the valve clearance when the engine is cold. Valves are adjusted by cylinder in the firing orde

Injection Pump Timing Adjustment (Spill Timing) If your engine's fuel injection timing is not properly adjusted, the engine will not operate prop

Adjustments (Generator) Once the diesel generator set has been placed in operation, there may be adjustments required for engine speed (Hertz) during

CAUTION Failure of the solenoid plunger to bottom in the solenoid will result in a failed solenoid. To avoid failure ofthe solenoid, make sure the sol

LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their· craft, including engines and generators, for lay-up during t

Fuel System Top off your fuel tanks with No.2 diesel fuel. Fuel additives should be added at this time to control algae and condition the fuel. Care

GENERAL Introduction This manual contains the equipment operating procedures as well as additional information needed to help the operator keep the ma

Starter Motor Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter permits its easy removal. Make sure the ba

3. Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the terminals are clean and that the con

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standar

Cylinder head bolt TORQUE SPECIFICATIONS (M14) (M17) 50.7 - 57.9 79.6-86.8 7.0 - 8.0 11.0 -12.0 (See the" Torquing Cylinder Head BoRs" secti

SPARE PARTS Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than your home port, certain spare

INDEX A AC GENERATOR SYSTEM SPECIFICATIONS, BCD 4.4 KW ... 12-13 AC GENERATOR SYSTEM SPECIF

CAUTIONS AC LOADS WHEN STARTING THE GENERATOR ... 73 DAMAGE TO BATTERY CHARGING

F Failures, Exhaust System ...

Installation of Fuel System ...

PARTS, SPARE ...

450 Exhaust Elbow i Fuel Run Solenoid AC .Fr~shJII(~ter Block Drain Lube Oil Pressure Sender Westerbeke Generators BCD 4.4KW Marine Diesel Generator

GENERAL, BCD 4.4 'r0/V ... 10 GE

U Understanding the Diesel Engine-Driven Generator ... 5 Use of Elect

YOUR NOTES 89 Westerbeke Generators

YOUR NOTES \ Westerbeke Generators 90