Westerbeke BCD 4.4KW, BCD 6.0KW Operator's Manual

OPERATOR'S MANUAL

l,WESTERBEKE

BCD 4.4KW and BCD 6.0KW

MARINE DIESEL

GENERATOR SETS

j'-.v-

Publication # 37144

May

Two

1988

Edition

'WESTERBEKE

WESTERBEKECORPORATION MYLES 150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

SAFETY PRECAUTIONS

The following symbols appear in this manual to and emphasize conditions operator.

potentially dangerous

to

call attention

to

the

IWARNINGI

The above symbol serious personal injury

is

used in the manual

or

loss

of

life.

to

warn

of

possible

CAUTION

The above symbol of

possible damage

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

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

Always operate bilge blowers for starting a present before starting.

manual carefully and thoroughly before attempting

carefully.

gasoline-fueled engine; ensure no gaSOline fumes are

is

used in the manual

to

equipment.

hot

parts are potential hazards

or

death. Follow recommended proce-

to

caution personnel

to

protect personnel

that

could result in

at

least five minutes before

• prevent Electric Shock

Shut

off

ment.

electric power before accessing electrical equip-

•

Use

Extreme

(A

constant danger of explosion or fire

Do not fill fuel tank(s) while the engine Do

not

smoke

fuel tank.

•

DQ

Not Alter or

Be

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

Care

When

Handling Engine

is

running.

or

use an open flame near the engine

ModifY

the

Fuel

System

•

Be certain fuel line fittings are adequately tightened and

.free

of

leaks.

Make sure a fire extinguisher is

• properly maintained. tinguishers rated ABC

applications

•

Use

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

Lead acid batteries which can be ignited cigarette, cigar,

flame near the battery being serviced. Shut

equipment

cal during

encountered in this environment.

Extreme

serviCing.

Be

by

Care

When

emit

hydrogen, a highly-explosive gas,

by

or

pipe. Do

in the viCinity to prevent electrical arcing

installed nearby and familiar with its proper use. the NFPA are appropriate for all

Servicing Batteries

electrical arcing

not

smoke

or

by

or

allow an open

off all electri-

Fuel

exists)

or

the

Ex-

a lighted

is

Use insulated mats whenever working on electrical equipment.

Make sure shoes), and keep electrical equipment.

Remove wristwatch and jewelry when working on electrical equipment.

Do

not except switch. Damage is

not

Be

ponents. High voltage can cause injury

• Exhaust

Ensure

discharged

regularly

are securely attached and

Be

sure the

your

clothing is dry, not

your

skin surfaces

connect utility shore power

through

done.

extremely careful when working on electrical

thatthe

a ship-to-shore double-throw transfer

to

vessel's AC generator

Gases

for

Are

Toxic

exhaust system is adequate

from

the engine. Check exhaust system

leaks and make sure

unit

and its surroundings are well-ventilated.

no

warping exists.

damp

(particularly

dry

when handling

to

vessel's AC circuits,

may

result

or

death.

to

expel gases

the

exhaust manifolds

if

this

com-

•

Avoid

Moving parts

Do

not service the unit while the

in

which

it

or

by

is

bracelets

fatigue.

tion arises

operating adjustments, use extreme care parts and

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

Make sure Keep protective shields and guards in their respective place

Do not check

the unit is operating.

Do not work on the equipment when ly

hot

exhaust system components.

not

wear loose clothing

all attaching hardware is properly tightened.

at

all times.

fluid levels

incapacitated

unit

absolutely necessary

or

is running; if a situa-

to

avoid moving

or

jewelry when servicing

that

might

be

the drive-belt's tension while

mentally

or

CALIFORNIA

Proposition

Diesel

qine

constituents of

California·to

defects,

harm.

and

65.

Warning

exhaust

are

cause

other

and

known

te,~e

can~birth

reprodu«t~

some

State

of

to

make

or

sleeves,

caught in

physical-

its

,

IMPORTANT

PRODUCT

Product software of parts lists other than

and

Westerbeke, tomers only software, makes no warranties

or

ness

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

in connection with,

example,

For

(such

as

engine blocks, other products) must depend

be

outdated

beke

rarely

has

ges

take

place.

Westerbeke

software,

and ditionally, most

all

kinds,

such

as

brochures, drawings, technical data, operator's

parts price

as

a courtesy

components

are

on

such

and

no longer accurate.

notice

customers should also

lists,

and

other information, instructions

is

not within Westerbeke's control

and

service. or

representations with respect thereto, including the accuracy, timeli-

or

ariSing out of, the furnishing

and

subassemblies incorporated

fuel

systems

and

generally supported by their manufacturers with their own software,

software for the design of Westerbeke's

Routine

in

advance,

are

frequently not reflected

keep

the unavoidable existence of

Westerbeke

products include customer-requested special features that frequently do not

clude complete documentation. In

summation, product software provided with

pliers,

must not It not only plier

in

question

makes

and

cannot

good

be

consulted to determine the accuracy

be

sense

relied

upon exclusively

but

is

imperative that appropriate representatives of Westerbeke or the

sulted by the customer.

SOFTWARE

Westerbeke cannot be responsible for the content

DISCLAIMER

and

and,

accordingly,

or

use

of

such software.

in

Westerbeke's products

and

workshop

manuals,

specifications provided from sources

is

provided to

Westerbeke

of

damages

or

injury incurred

and

supplied by others

components, transmissions, electrical components, pumps

and

Westerbeke

own

changes

in

mind

earlier,

Westerbeke

made

the time

span

non-current

products, whether from

as

the definitive authority

and

product software.

by Westerbeke's suppliers, of which

in

the supplier's software until after

between

Westerbeke

printings of Westerbeke product

software editions

on

currency of the product software

Such

software

Wester-

such

in

the

field.

Westerbeke

or other

the respective product.

being

cus-

such

and

may

chan-

Ad-

in-

supsup-

con-

1

Westerbeke Generators

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 carefully and observe all safety precautions included throughout. Operating procedures, periodic preventive maintenance procedures, installation checks, system descriptions and minor adjustment procedures are included herein so you can operate your equipment safely and properly, maintain the

at

equipment

Should

a high level

your

unit require special attention, contact your Westerbeke dealer

Service Organization is trained

of

efficiency, and expect dependable performance and long service life in return.

for

assistance. The Westerbeke

to

provide the support necessary

to

ensure long-term dependable perfor-

mance.

If,

within 60 days

tomer

Identification Card (see below) registering your warranty, please contact the factory in writing with

of

submitting the Warranty Registration Form

for

your unit, you have

not

received a Cus-

Model information, including the unit's serial number and commission date.

from:

WESTERBEKE

AVON AVON,

CORPORATION

INDUSTRIAL

MA

02322

PARK

Mall To:

--

r,~.

CUSTOMER

Adam

Silith

85

Maple

Alden, Model

Expires

Street

IN

BCD

717/89

.....

WESTERBEKE

• IIUOfII

......,..~

,

....

II"''''

.,.

...

x:

,1.-

......

IDENTIFICATION

12234

4.4

KW

Ser

...

11;

CUP)

.•

n_

"'-'.23· C ••

1234C786

.1II:1z:;r:

..,

•

1'&"

..

,7J

•••

-yy_

La:

••

an:OIJ'

~

Westerbeke

Generators

2

TABLE

OF

CONTENTS

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

GENERAL BCD BCD BCD BCD INSTALLATION DESCRIPTION

INSTRUMENT PREPARATIONS STARTING STOPPING FUEL

........................................................................... 5

4.4KW

6.0KW

GENERAL

SYSTEM GENERAL SYSTEM

CHECKS

SPECiFiCATIONS

SPECIFICATIONS

SPECiFiCATIONS

SPECIFICATIONS

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

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

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

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

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

OF

PANEL

PROCEDURE

SYSTEM

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

FOR

STARTING

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

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

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

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

Page

10 11 14 15 18

29 32

33 34 36

DC

ELECTRICAL

BCD

4.4KW

WIRING

BCD

WIRING

DIAGRAM # 35951

6.0KW DIAGRAM # 35773

COOLING LUBRICATION BC

GENERATOR

GENERAL OF

THE

GENERATOR

ENGINE

TROUBLESHOOTING

SYSTEM

DC

CONTROL

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

CIRCUIT

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

DC

CONTROL

CIRCUIT

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

SySTEM

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

SYSTEM

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

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

INFORMATION

AND

CARE

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

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

MAINTENANCE & ADJUSTMENTS

42 & 43

44 & 45

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

39

46 51 54

61 63 66

3

Westerbeke Generators

TABLE

OF

(CONTINUED)

CONTENTS

LAY-UP & RECOMMISSIONING

TABLE TIGHTENING

TABLE

SPARE

INDEX

OF

STANDARD

TORQUES

OF

TIGHTENING

PARTS

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

HARDWARE

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

TORQUES

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

...................................... 75

79

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

81

82

Westerbeke Generators

4

Introduction

GENERAL

This manual contains the equipment operating procedures as well as additional information needed the

operator keep the marine equipment in proper working order. Study and follow ly. A planned maintenance program is included in this manual; adhering equipment performance and longer equipment life. Proper diagnosis to

satisfactory repair; therefore, a troubleshooting table is included.

Understanding

The diesel engine closely resembles the gasoline engine, since the mechanism is essentially the same. The cylinders are arranged above a closed crankcase; the crankshaft is gasoline engine; and the diesel engine has the same lubricating system.

Therefore, The most important factors are proper ventilation and proper maintenance

ing systems. Replacement frequent checking Another important factor is the use

cally

for

diesel engines. Be careful not

same lubricating qualities as diesel fuel; consequently, gasoline in the fuel lines will damage components in the fuel lift

The diesel engine

buretor and ignition systems are done away with and in their place are

pump

and

the

Diesel

to

a great extent, a diesel engine requires the same preventive maintenance as a gasoline engine.

for

pump

assembly, fuel injection

does

the

fuel injectors.

Engine-Driven

of

fuel and lubricating filter elements at the time periods specified is a must, and

contamination (that

of

differ from the gasoline engine, however, in its handling and firing

Generator

type

of

valves, camshaft, pistons, connecting rods, and

is,

water, sediment,

the same brand

to

put gasoline in the diesel fuel tank(s). Gasoline does not have the

pump

of

high detergent diesel lubricating oil designed specifi-

and injectors.

or

algae) in the fuel system is also essential.

to

the program will result in better

of

a problem is

of

the same general

of

two

components - the fuel injection

the

instructions careful-

the

most important step

type

the fuel, lubricating and cool-

of

to

help

as that

fuel. The car-

of

a

Ordering

Whenever replacement parts are needed, always provide the generator model number, engine serial num-

ber, and generator serial number as they appear

ator

addition, include a complete part description and part number for each part needed (see the separately fur-

nished Parts List). Also, be sure

parts are frequently

Note that component locations in the manual are referenced from the front ley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined engine; imagine straddling the engine and facing in the same direction as the front

is at

Westerbeke generators sets are thoroughly checked and given a final run under various load conditions

before leaving the factory. Test running the generator ensures dependable operation, long service, and a

satisfied owner.

Care at the factory during assembly and thorough testing have resulted in a Westerbeke diesel engine-driven

generator capable

not control is the treatment the unit receives in the field. That part is

Parts

on

end. You must provide us with this information

to

insist upon Westerbeke factory packaged parts because "will

not

made

to

the same specifications as original equipment.

your

left, the right side at your right.

of

many thousands

of

hours

of

dependable service. However, what

the scarlet and gold name plate located

so

we

may properly identify

of

up

to

the

your

generator set. In

the engine which is the pul-

of

the engine: the left side

the

manufacturer can-

owner/operator.

on

the gener-

fit"

or

generiC

by

the

5

Westerbeke

Generators

BCD

4.4KW

Marine Diesel Generator

450 Exhaust

i Fuel Run

Elbow

Solenoid

AC

.Fr~shJII(~ter

Block

Drain

Fresh

Water

Fill

Cap

Zinc

Anode

Lube

Oil

Pressure

Sender

Westerbeke Generators

Oil Pressure

6

Switch

Exchanger

Lube

Fresh

Oil Drain

Water

Hose

Drain.

i

BCD 4.4KW Marine Diesel Generator

: Fuel

Lift

Pump

Emergency

E"~h~ust

Shut-off

Switch

Temperature

45°

Exhaust

SWitch

Elbow:

f

7

Westerbeke Generators

,20

Amp

DC

Circuit

Breake

BCD

6.0KW

Marine Diesel Generator

Exhaust

Emergency

45°

Exhaust

AC

Temperature"

'SwItch

Stop

Switc

Elbow

Westerbeke Generators

8

BCD

6~OKW

Marine Diesel Generator

Fresh

Water

~AirBleea

FreshWater

·c

i

rcufaiIn9~f:i~iiii?"'

Sea Water

~eat

Exc::hanger.

rter

with

Solenoid,

9

Westerbeke Generators

BCD

4.4KW MARINE DIESEL GENERATOR SET

GENERAL SPECIFICATIONS

Engine Type

Combustion

Chamber

Bore & Stroke

Piston

Displacement

Order

Firing Direction of Rotation Maximum Torque Compression Compression Valve

Timing

(at Ratio Pressure

1800

rpm)

Diesel, Vertical,

(8.6

Swirl

four-cycle, two-cylinder, fresh water-cooled

in-line

hp

at

type

2.68 x 3.07 37

cubic inches 1-2 Clockwise,

33

Ib-ft

(4.91 23:1 455

psi

(32

Intake

Opens

Intake

Closes

Exhaust Exhaust

Opens Closes 1 SO

1800

inches

when

kg-m)

kg/cm

overhead

rpm,

(0.606

valve

maximum).

(68 x 78

liters)

mm)

viewed from the front

2

)

at

280

rpm

18°

BTDC

4SO

ABDC

46"

BBDC ATDC

mechanism

Valve

Seat

Valve

Clearance

(engine

Engine

cold)

Speed

Dimensions

Weight

Fuel

Consumption

Inclination

Angle

Intake

45°

Exhaust

Intake Exhaust

1800 1500

Height:

Width:

Length:

410

0.5

45°

0.010

rpm rpm

23.25

17.00

27.25

Ibs

(186

U.S.

gph (1.89lph) at

Continuous

Temporary

60 50

15°

20°

inches

Hertz Hertz

inches

kgs)

(not to

(0.25

mm)

(0.25

(590.55

(431.18

(692.15

full

exceed

mm)

rated

20

output (approximate)

min.)

Westerbeke Generators

10

FUEL SYSTEM

BCD

4.4KW SYSTEM SPECIFICATIONS

General

Fuel

Injector Pump

Injectors

Lift Pump

Air cleaner

Air Flow (engine combustion)

COOLING SYSTEM

General

Operating Temperature

Fresh Water Pump

Open flow -totally self-bleeding

No.2

Diesel (cetane #

45

or

better)

In-line plunger type (Bosch M type)

Pintle type

12-Volt DC; lift capacity 6

ft

(1.8 m)

Metal screen type - cleanable

19.2 cfm (0.544 cmm)

Fresh water-cooled

block, thermostatically-controlled with heat exchanger.

170

-1900 F (77 - 88

0

C)

Centrifugal type, metal impeller, belt-driven

Sea Water Pump

Sea Water Flow, at 1800 rpm (measured before discharging into exhaust

System

elbow)

Capacity (fresh water)

LUBRICATION SYSTEM

General

Oil Filter

Sump Capacity (not including filter)

Operating Oil Pressure (engine hot)

Oil Grade

Positive displacement, rubber impeller, belt-driven.

3.50 - 3.75 U.S. gpm (13.24 - 14.19 Ipm)

6.0 qts (5.68 liters)

Pressure type

by

Trochoid pump,

gear-driven, with external pressure relief valve

Full flow, paper element, spin-on type

2.5 U.S. qts (2.36 liters)

2

OR

)

CG-4

35

- 55 psi (2.5 - 3.8 kglcm

API

specification

of

CF

11

Westerbeke Generators

ELECTRICAL SYSTEM

BCD

4.4KW SYSTEM SPECIFICATIONS

Starting Battery

Battery Capacity

Starter

DC

No-Load Current

DC Cranking Current (engine cold)

Charging

DC

AC

GENERATOR

General

12-Volt, 30 A-H,

(recommended)

90 - 125 (Ampere-Hours)

12-Volt, 1.2 solenoid-mounted

90 Amp (max.) at 11.5 Volts.

175 - 200 Amps (engine cold)

Integral controller 0 13

-14

Volts DC

Brushless, four-pole, revolving field. Self

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

(-)

negative ground

(45

A-H in cold areas)

'r<YV,

reduction type,

-

120 Volts

10

Amps

or

120/240 Volts,

Voltage

Rating (Volts AC)

60 Hertz (1800 rpm)

50 Hertz (1500 rpm)

AC Circuit Breaker

Generator

Air Requirements,

at

1800 rpm

Cooling

(60

Hertz),

120

or

120/240 Volts -60 Hertz

220 Volts - 50 Hertz.

Voltage regulation: full load.

Frequency regulation: ± 3 Hertz (5%) no-load

120 Volts 120/240 Volts

220 Volts

To

amperage and voltage output.

175 -

to

full-load.

be rated at 120%

200 cfm (4.95 - 5.66 cmm)

±5%

no load

36 Amps 36/18 Amps

15

Amps

of

the generator's rated

to

Westerbeke

Generators

12

BCD

4.4KW SYSTEM SPECIFICATIONS

NQIE.:

Increase air supply 15%

Engine Combustion Air Requirements, at

1800 rpm

TUNE-UP

SPECIFICATIONS

Injector

Pressure

Engine Timing

(60

Hertz),

for

50 Hertz operation (1500 rpm).

19.2 cfm

2275 psi (120 kg/cm2 + 10kg/cm

190 BTDC at 1800 rpm

(0.544 cmm)

+142

psi

-0

psi .

2

Okg/cm

-

2

)

13

Westerbeke

Generators

BCD

6.0KW

MARINE DIESEL GENERATOR

GENERAL SPECIFICATIONS

SET

Engine Type

Combustion Chamber

Bore &

Stroke

Piston Displacement

Order

Firing

Direction

of

Rotation

Maximum Torque (at

Compression Ratio

Compression Pressure

Valve Timing

1800 rpm)

Diesel, four-cycle, three-cylinder, fresh water-cooled Vertical,

(12

in-line overhead valve mechanism

hp

at 1800 rpm, maximum).

Swirl type

2.56 x

3.07 inches (65 x 78 mm)

47.4 cubic inches

(0.776 liters)

1-3-2

the

Clockwise, when viewed from

Ib-ft (6.2 kg-m)

42

front

9.2:1

2

19

51

0

51

go

)

at 280 rpm

BTDC

ABDC

0

BBDC ATDC

455 psi (32 kg/cm

Intake Opens Intake

Closes

Exhaust Opens Exhaust Closes 1

Valve Seat Angle

Valve Clearance

(engine cold)

Engine

Speed

Dimensions

Weight

Fuel Consumption

Inclination

0

45

Intake Exhaust 45

0

Intake 0.0071 inches (0.18 mm) Exhaust

0.0017 inches (0.18 mm)

1800 rpm 60 Hertz

1500 rpm 50 Hertz

Height: 23.38 inches (593.85 mm) Width: 18.69 inches (474.73 mm)

Length: 26.75 inches (679.45 mm)

440

Ibs (199.6 kgs)

0.7 U.S.

Continuous Temporary 200 (not

gph

(2.65lph) at full rated output (approximate)

0

15

to

exceed 20 min.)

Westerbeke

Generators

14

FUEL SYSTEM

BCD

6.0KW SYSTEM SPECIFICATIONS

General

Fuel

Injector Pump

Injectors

Lift Pump

Air cleaner

Flow (engine combustion)

Air

COOLING SYSTEM

General

Operating Temperature

Fresh Water Pump

Open flow -totally self-bleeding

No.2

Diesel (cetane # 45

In-line plunger type (Bosch M type)

Pintle type

12-Volt DC; lift capacity 6 ft (1.8

Metal screen type - cleanable

24.6 cfm (0.697 cmm)

Fresh water-cooled block, thermostatically-controlled with heat exchanger.

170 - 190° F (77 - 88°

Centrifugal type, metal impeller, belt-driven

C)

or

better)

m)

Sea Water Pump

Sea Water Flow, at 1800 rpm

(measured before discharging

into exhaust elbow)

System Capacity (fresh water)

LUBRICATION SYSTEM

General

Oil Filter

Sump Capacity (including filter)

Operating Oil Pressure (engine hot)

Oil Grade

Positive displacement, rubber

3.50 - 3.75 U.S.

5.0

qts (4.73 liters)

Pressure type gear-driven, with external pressure relief valve

Full flow, paper element, spin-on type

3.3

U.S. qts (3.2 liters)

35 - 55 psi (2.5 - 3.8 kg/cm

API

specification of

gpm

(13.24 - 14.19 Ipm)

by

Trochoid pump,

CF

impeller, belt-driven.

2

)

OR

CG-4

15 Westerbeke Generators

ELECTRICAL SYSTEM

BCD

6.0KW SYSTEM SPECIFICATIONS

Starting

Battery

Battery Capacity

Starter

DC No-Load Current

DC Cranking Current

(engine cold)

DC Charger

AC

GENERATOR

General

12-Volt, 26 A-H, (recommended)

(-)

negative ground

(35

A-H in cold areas)

90 - 125 (Ampere-Hours)

12-Volt,

1.2KW, reduction type,

solenoid-mounted

90 Amp (max.) at 11.5 Volts.

175 - 200 Amps (engine cold)

Integral controller 0 - 10 Amps 13

-14

Volts DC

Brushless, four-pole, revolving field.

Self exciting, capacitor saturated field excitation. Pre-lubricated, single-bearing design. Reconnectable

120 Volts

or

120/240 Volts,

single-phase

Voltage

Rating (Volts AC)

60 Hertz

(1800 rpm)

50 Hertz (1500 rpm)

AC Circuit Breaker

Generator Cooling Air Requirements, (60 Hertz),

1800 rpm

at

120

or

120/240 Volts - 60 Hertz 220 Volts - 50 Hertz. Voltage regulation:

±5%

no load

to

full load.

Frequency regulation: ± 3 Hertz (5%) no-load

120 Volts 120/240 Volts

220 Volts

To be rated at

to

full-load.

120%

50 Amps

50/25 Amps

20.4 Amps

ofthe

generator's rated

amperage and voltage output.

175 -

200 cfm (4.95 - 5.66 cmm)

Westerbeke

Generators

16

MITE:

Engine Combustion Air

Requirements, (60 Hertz),

Increase air supply 15%

at 1800 rpm

for

50 Hertz operation (1500 rpm).

24.6 cfm

(0.697 cmm)

TUNE-UP

SPECIFICATIONS

Injector Pressure

Engine Timing

2275 psi

(120 kg/cm

19° BTDC at 1800 rpm

+ 142 psi - 0 psi

2

+ 1 Okg/cm

2

- Okg/cm

2

)

17

Westerbeke

Generators

INSTALLATION

CHECKS

General

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

to

your

craft's specific design. The intent

of

this section is

not

to

advise boatyards

or

installers on procedures already well-developed and well-understood. However, the owner/operator must realize there are details equipment and safe operating conditions diesel generator in the vessel are

Factors in the installation that must be considered are ventilation,

provide air

system,

of

the installation which require periodic checks

for

the personnel on board. Proper location and installation

of

prime importance.

for

engine combustion and

to

properly discharge raw cooling water (sea water),

to

remove heat produced

to

ensure the best operating conditions

to

aid in cooling the generator end;

by

the engine while operating; the exhaust

to

quiet the exhaust, and

to

expel exhaust gas;

for

of

the

to

the cooling water supply; and the electrical connections.

CAUTION

For safety reasons, the generator's engine is NOTfilied with lubricating oil

for

shipment. Before leaving the factory, however, each generator set is thoroughly tested with oil in its engine. This testing, as a preservative, providing reliable protection against corrosion

among

other things, provides all internal parts with a coating

for

at least one year if the

of

oil. This oil acts

generator is properly stored.

Inspection

of

Equipment

The generator is shipped from the factory securely mounted and properly crated. Accessory equipment is

shipped in a separate small box, usually packed within the generator's crate.

of

Before accepting shipment and the contents inspected require the delivery agent sign "Received in damaged condition" on the proper delivery receipt. Also

the contents

of

the shipment against the packing list and make sure that the proper notation is made if any discrepancies exist. These noted discrepancies are cerning loss

or

damage must be made

the generator set from the transportation company, the crate should be opened

for

concealed damage. If either visible

or

concealed damage is noted,

you

should

check

your

to

the carrier,

protection against loss

not

to

the Westerbeke Corporation.

or

damage. Claims con-

Westerbeke

Generators

18

Rigging and Lifting

The generator is fitted with lifting eyes. Rope

should be attached ing eyes have been designed quired

or

desired.

Slings must not be so short as

to

the eyes and the generator lifted

to

carry the full weight

to

place significant stress on the generator's lifting eyes. Strain placed on the generator's lifting eyes sible

by

using longer lifting slings when possible.

or

chain slings capable of supporting the generator's weight

by

means

of

the generator; therefore, auxiliary slings are not re-

of

tackle attached

to

these slings. The lift-

CAUTION

by

the lifting sling should be reduced as much as pos-

SLING

ANGLE AS

LIFTING

SHOULD

SMALL

LIFTING

EYE

AS

POSSIBLE

BE

ENGINE

The general rule in moving generators is

to

see that all equipment used is amply strong and firmly fixed

in

place. Move the engine a little at a time and see that it is firmly supported. Eliminate the possibility of acci-

dents

by

necessary

avoiding haste. Do not lift the generator

to

lift the engine

in

positions other than the horizontal position. Certain situations exist

by

its crankshaft pulley. In certain situations it may be

by

which

the engine must be lowered endwise through a small hatchway which cannot be made larger. Under these

conditions, If the opening of the hatchway is extremely small, it is possible outside dimensions of the generator

by

removing external components such as the cooling system's piping,

to

reduce,

to

some extent, the

the heat exchanger, certain filters, the mounting rails and other obstructive equipment. This accessory equip-

should be removed

ment any exposed parts. In addition, be careful not of equipment. Removed parts should be returned stallation area. Replace gaskets as needed

In case it becomes necessary tachment weight of the

in

handling heavy machinery.

of

lifting slings must be done carefully

slings may bear. Special rigging

by

a competent mechanic and special care should be taken

to

allow dirt from entering any opening created

to

their respective position once the generator is in its

for

the parts that were removed.

to

hoist the generator front-end upwards

to

avoid the possibility

work

is best done

by

or

generator-end upwards, the at-

of

damaging the parts on which the

someone experienced and competent

to

avoid damage

by

the removal

to

in~

19

Westerbeke Generators

Generator Mounting - Location The

complete generator unit

help

prevent the transfer of vibration from the generator to the 1/2-inch bolt holes so bolts These

holes

are

on

15

inch mounting

is

mounted

can

be

on

lightweight

employed to properly

centers.

rails

by

means

rails.

secure

of four flexible isolator mounts that

Each

generator mounting

rail

has

several

the generator to its mounting platform.

The

location should

above cannot

and

repairs.

Access for major repairs should ly ventilated to provide heat

produced by the engine while operating.

in

the

vessel

form

on

erator during

it

which the generator

all

be

dry,

above

low-lying vapor

splash

is

on

the generator. It

fresh

cooling air for the generator

installed. Hot generator discharge air must

and

its mounting

angles of

vessel

operation.

Westerbeke Generators

should

be

The

rails

areas,

and

be

properly ventilated

given

consideration

end,

generator

are

located

20

in

for

set

be

removed

should

an

area

as

engine

needs

be

where

and

well.

combustion fresh from the generator

bilge water

and

water from

accessible for minor servicing

The

location

cool air

should

needs,

in

whatever location

and

be

to

area.

properremove

The

strong enough to support the gen-

plat-

Exhaust

System

IWARNINGI

Although diesel fuel is not as dangerous as gasoline, precautions should be taken

to

against CARBON MONOXIDE GAS. Carbon monoxide is a dangerous gas that can cause un-

consciousness and is potentially lethal. Some inhalation

or

poisoning are listed below.

of

the symptoms

or

signs

of

carbon monoxide

o Dizziness o Vomiting o Intense Headache o Muscular Twitching

o Weakness and Sleepiness o Throbbing in Temples

All exhaust systems should be such that the entry cylinders is prevented while the engine is not running, the vessel may experience heeling tention must be taken supply through-hull sea

be used, as they tend

to

make certain the exhaust system is secure, tight and free

cock

to

encourage siphoning.

or

backing down from following seas

fittings must be

of

sea water into the engine's exhaust manifold and

or

while the vessel is under sail

or

any other conditions. Special at-

the flush-hull type. High-speed

or

power in which case

of

leaks. The sea water

scoop

type fittings must not

When a water lift type exhaust system is used, the exhaust muffler should be mounted as close

as practical. The exhaust discharge

drop

should always

downward into the exhaust muffler. Loops in the exhaust hose between the water-injected ex-

haust elbow and the water lift muffler

should be avoided, as these will trap and

hold water.

guard

to

the engine

For

installations

where

the

exhaust

manifold/Water-injected exhaust elbow

or

is at

provisions must be made siphon-break supply hose

haust elbow. This stops the flow

below the vessel's water line,

to

install a

or

a vent in the sea water

to

the water-injected ex-

of

sea

water that runs through the sea water

cooling system from filling the exhaust

and engine cylinders when the engine is

shut down. This sea water supply hose

must be looped above the water line and the siphon-break

high point

line. This siphon-break

of

or

vent installed in the

the

loop

above the water

or

vent must always be above the water line during all angles

of

vessel operation

to

prevent

siphoning. The vent, when used, must

have its vent hose can remain above the water empty

of

water when the engine is shut

down. This allows air

to

this vent

prevent siphoning.

or

tube routed so it

line and

to

enter through

GElUIIOI

!EIUITOR

Rlon

BElOW

WITEI

WilER

LIIE

SEI

VRTER

PUNP

21

Westerbeke Generators

Exhaust Back-Pressure

of

The exhaust discharge hose must be

to

minimal run

prevent excessive exhaust back-pressure.

adequate size and

Exhaust back-pressure should be checked before a gener-

to

ator is put into service. (Refer

the illustration.) Excessive back-pressure will affect the engine's performance and the generator's power output.

To measure for back-pressure, use a mercury manometer, a

or

pressure gauge, mechanic should have a manometer

a water column. A boatyard or marine

or

a pressure gauge.

Exhaust

Elbow

Measure the engine's back-pressure while the generator is under a

to

Refer

the pressure specifications listed below.

A water column can be made

of

and taping one end the other end

of

the tube along a yardstick and fitting

the tube with a 1/4 inch NPT (National Pipe

full load.

by

at

the exhaust elbow

taking a clear plastic tube

Tap) pipe fitting.

Measure the engine's back-pressure at the exhaust elbow

while the generator is under a

Dimension A cannot exceed 39 inches

Back pressure, as measured

full load.

of

water.

by

a gauge instrument, should

not exceed the following specifications:

Specifications:

Exhaust

of

2 inches 27

inches

15.6 ounces

1.0

PSI

mercury

of

water in a water column

PSI

Excessive back-pressure can be caused the exhaust hose, improper fittings, water pockets, and a high volume to

the length

routing should be

of

the exhaust discharge hose. The use

limited since these will create flow restrictions and contribute The generator's exhaust system must be separate from any other engine's exhaust system. Dry portions the exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be

to

insulated

hold in the heat.

Westerbeke Generators

by

a small diameter exhaust hose, a small muffler, sharp bends in

of

water in the exhaust system due

of

elbows and fittings in the exhaust discharge hose's

to

exhaust back-pressure.

22

of

Dry stack-type exhaust systems

be

must

at-

ex-

be

to

(shown to the right) must

tached to the generator engine's

haust

manifold by

connector

pipe.

properly supported

means

This

of a flexible

system

and

insulated prevent water from entering into the engine's cylinders. be made engine's cooling

for

discharging

sea

Provisions

water.

must

the

Exhaust System Failures

When

the engine's

face,

erosion

jacketed or water injected

positioned

so of the entering as

big

in

diameter

sea

water

takes

place.

This

''Wet''

that the entering

sea

water

stream

as

possible.

is

fed

erosion

exhaust

stream

should

into

of

P"L"PP~R

CDVE"

an

exhaust

may

system

sea

water does not directly strike a

be

as

cause

to

low

as

system

premature

prevent

so

that the

failures.

this problem requires that the

possible, which

~

i I

DRY

can

STACK

EXHAUST

full

stream

The

be

of this water strikes a

proper design of either a

surface.

achieved

In

addition, the velocity

by

having

sea

water inlet

sur-

water

be

inlet fittings

The

best

protection against carbon monoxide poisoning

tem.

Check for rounding change

in

tem inspected Make

sure weight could tions of the

NOTE: A maximum

areas

the

sound

there

cause

exhaust

leaks

around

excessively.

manifolds,

If

excessive

or appearance of

and

repaired

are

no

at

once

unnecessary objects

deflection or distortion of the

system

to

of 8

make

Ibs

Prolonged cranking intervals without

exhaust

pumping

system

sea

with

water through the

sea

enter the engine's cylinders by way of

Prevent

exhaust

start.

owner/operator

this from happening by closing the

muffler,

Engine

and

damage

should

correct the

resulting

keep

gaskets,

heat

the

exhaust

by

a qualified

sure

there

can

be

attached to the

the

water coolant.

sea

water cooling

cause

from

this type of

this

in

mind.

and

welds.

is

present,

system,

mechanic.

suspended

lines,

is

no

deterioration of

CAUTION

engine

the

for the

starting

This

may

exhaust

sea

water supply through-hull shut-off, drain the

excessive

sea

is

a daily inspection of the complete

Make

sure

exhaust lines

are

correct the situation immediately. If

shut

down

the

unit immediately

from any portion of the exhaust

resulting

exhaust

system

in

damage or

the

leaks.

insulation.

manifold without support.

can

result

in

filling the engine-mounted

happen

because

the

during cranking.

sea

This

manifold once the exhaust

engine

water entry

cranking

is

not a warrantable

needed

Inspect

water pump

sea

system

to obtain a

exhaust

not heating

you

and

have

lines.

Excessive

insulated

water

can

fills.

issue;

the

notice a

the

is

sys-

sur-

sys-

por-

23

Westerbeke Generators

Exhaust Elbow Installation

The

Westerbeke

elbow

as

propulsion

well

engine.

Corporation offers a

as

an

exhaust riser you Refer

to

the instructions below

45°and can

90

install

0

exhaust

on

your

when

installing the exhaust elbow purchased for your generator.

1.

Coat only one

Tack"

adhesive against the exhaust manifold's gasket should stick to the flange without falling

2.

Place

the clamp over the elbow's

haust

elbow against the exhaust manifold's flange

the exhaust manifold's flange

haust

elbow's flange with the gasket

the two. Now slip the exhaust clamp over both

3.

A.

Tighten the clamp just enough

can

remain

side

of the exhaust gasket with *"High

sealant.

Place

this coated surface

exhaust

port flange

flange.

rests

snug

Place

against the

centered

so

the exhaust elbow

attached to the manifold

and

(the

off).

your

ex-

so

ex-

between

flanges.

still

be

rotated.

B.

The

exhaust elbow discharge must

so

must

There

connected

muffler,

the mixture of

be

positioned below the exhaust

should

be

as

these would trap water

downward gases

will flowlfall downward into the exhaust muf-

fler which

elbow. haust

hose

and

the

allow water to flow back into the engine during

sibly

sea

no

loops or

between

water

rises

the

exhaust

be

and

directed

exhaust

in

the

elbow

and

pos-

ex-

starting or at shut down.

45°

ELBOW

4.

Adjust the elbow by rotating it until the desired alignment

with the exhaust piping

5.

Carefully tighten the clamp

to 35Ib-in, or

0.27

to

0.41

is

between

kg-m.

acquired.

2 to 3Ib-ft, or

CAUTION

Approach the 3 Ib-ft torque limit with caution. clamp's threads will break if more than 3 Ib-ft plied to the

If a

leak

exists,

* Manufactured by

clamp.

correct it immediately.

Permatex

Company,

Brooklyn,

The

is

ap-

N.Y.

24

CLRMP

90°

ELBOW

EXHAUST

RISER

Westerbeke Generators

24

Fuel

System

The fuel system should be installed in such a manner as to

maintain a positive inlet pressure

to

the injection pump under

to

allow the engine-mounted fuel lift pump

all

operating conditions. The minimum size

to

pump

of the fuel supply line and fuel return line is 1/4 inch, inside diameter, and there should be a primary fuel filter installed between the fuel tank and the fuel lift pump. Only one fuel filter is installed on the engine, between the mechanical fuel lift pump and the injection pump; this filter has a replaceable filter element.

The fuel tank's fuel pickup tube should be clear and unobstructed.

screens

or

gauze strainers should be

No

incorporated in the fuel pickup tube.

Make sure that the fuel supply and return

are sufficiently tightened

know its location and

to

prevent leaking. Also make sure your fuel system has a positive shut-off valve;

how

it operates.

lines are securely anchored

to

prevent chafing and that all fittings

NOTE: DO NOT use spring-loaded check valves in the fuel supply line in lieu of mechanical shut-off valves. This type valve can create fuel starvation problems

for

the engine's fuel sys-

tem.

Fuel tanks that are located below the engine's fuel system level must have its fuel return at the tank extending down into the tank in the same manner as the pickup tube, otherwise fuel siphoning out

of

the engine's

fuel system through the return will take place.

Make sure the fuel tank filler is properly tank's vent should be routed so as

sealed

to

prevent water entry as well.

to

prevent water entry should it become awash. The fuel

Be sure there is a fire extinguisher installed near the unit and that it is properly maintained. Be familiar with its use. An extinguisher with the NFPA rating of

Oil

Drain

Hose

ABC is appropriate

An oil sump drain hose is installed on the engine with the discharge end secured the engine.

Oil may be drained from this hose

by

removing the cap and the discharge end of the hose from

for

all applications in this environment.

by

a bracket at the front of

the support bracket and lowering the hose into a container. The hose cap fitting is 1/4 inch NPT (National

or

Pipe Tap) and can be extended,

Connecting

Pressure Sensing Devices

have a pump added,

to

Oil Galleries

Oil pressure sensing devices, such as senders and switches, must not be connected lery with the use

of

fatigue

the fittings used

of

extended nipples

to

make such a connection. If these fittings fail during engine operation, lubricat-

or

tees. The reason is simply that continued engine vibration causes

for

easier removal

of

the old oil, if desired.

to

an engine's oil gal-

ing oil will be lost and internal engine damage will result.

When additional sensing devices such as switches

oil pressure, these devices must be bulkhead-mounted and connected grade

of

lubricating oil hose. Any fittings used

able iron composition. Brass must not be used

or

sensors need

to

connect the hose

for

this application.

to

be installed that function on engine

to

the oil gallery using an appropriate

to

the gallery must be of steel

or

malle-

25 Westerbeke Generators

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 strainer are unobstructed. Sea cocks and strainers should be at least one size greater than the inlet thread of the sea water pump. The strainer should be of the type that may be withdrawn for cleaning while the vessel is at sea and should be mounted below the water line

to

sea water lines

make sure there are no collapsed sections, which would restrict water flow. Make sure

to

ensure self-priming. Inspect the

there are no air leaks at any of the connections.

Cooling

The generator's engine is fresh water-cooled

engine-mounted heat exchanger.

as the heat exchange's cooling medium.

is pumped into the exchanger and

System

Sea water is used

Sea water

by

a sea water pump

is

then injected into the exhaust discharge, car-

by

an

rying with it the heat removed from the engine's fresh

water cooling system.

Sea water should be supplied

to

the sea water pump through a flush-type through-hull fitting using a wirereinforced hose between the through-hull fitting and the sea water pump. This sea water should be directed through a visual-type sea water strainer and then delivered through-hull fitting

pump should be wire-reinforced

to

the pump. Hoses routed from the

to

the strainer and

to

the sea water

to

prevent the hose from collapsing during the generator's operation (suction from the pump may collapse a non-reinforced

hose).

Sea water strainers should be mounted at

below the water line

to

make sure the sea water line

or

remains primed.

DEflECTION LONGEST

AT

SPAN

CAUTION

DO NOT

use a scoop-type through-hull fitting as a means

of

supplying sea water

to

the generator. Water pressure against this type fitting, while the vessel is under way, can push sea water past the sea water pump's impeller into the generator's exhaust system, filling it and the engine as well. Flush-type, clear, through-hull fittings are recommended and should be lo-

to

cated on the hull so as

be below the waterline during all angles of boat operation.

The use of common-type street elbows is not recommended for plumbing the sea water circuit. These

generally have very restrictive inside diameters. Machined fittings are preferred.

Electrical

The electrical system should be checked

clamps

from vibration. Check

System

to

make sure all wiring harnesses are properly tied down with

or

plastic ties and that all wiring harnesses are spaced at intervals close enough

to

make sure all engine harness connections are tight and that they are made

to

prevent chafing

to

the

appropriate terminals.

Westerbeke Generators

26

DC

Electrical

A

common

the starter, in the form

this stud.

Connections

ground

for

the negative

of

a threaded grounding stud. The battery ground should be connected at

(-)

DC terminal connection is found at the bell housing

of

the generator,

Connect the battery's positive (

+)

connection

to

the starter solenoid tagged

for

this connection.

CAUTION

To avoid an overcharging condition, and a possible equipment failure,

DO

NOT

disconnect

the DC battery source while the engine is running.

Automatic

Shutdown

High Exhaust Temperature Shutdown Switch (normally closed)

An exhaust temperature switch is located on the exhaust elbow. Should the switch's sensor indicate an excessive exhaust temperature, the switch will open and shut the generator water coolant causes high exhaust temperatures). This switch opens at 260 - 2700 F (127 - 1320 C)

resets at approximately

2250 F

(1

O~

C).

OFF (an inadequate supply of sea

and

High Water Temperature Shutdown Switch (normally closed)

A high water temperature switch is located on the thermostat housing. Should the fresh water coolant's

operating temperature reach approximately 2050 F (96

This switch resets at 1950 F

(10~

C).

0

C), the switch will open and shut the generator OFF.

Low

Oil

Pressure Shutdown Switch (normally open)

A

low

oil pressure shutdown switch is located off the engine's oil gallery. The switch's sensor monitors the engine's oil pressure. Should the engine's oil pressure fall generator

Generator

OFF.

(AC

Output)

Make sure that the AC output connections within the generator's distribution

to

10 - 15 psi, the switch will open and turn the

box

are tight and

in

accordance with the specific AC Load Connections diagram found later in this manual. (See the "BC GENERATOR" section

of

this manual, page 54.)

Do

not

smoke

or

allow an open flame near batteries. Lead acid batteries emit hydrogen, a

highly-explosive gas.

27 Westerbeke Generators

Batteries Make sure the positive ( + ) battery connection is connected

The negative

When servicing the battery

(-)

battery connection should be connected

or

checking the electrolyte level, wear rubber gloves, a rubber

to

the battery connection

to

the system ground (the engine block).

apron, and eye protection. Battery acid may splash on the skin ly

when removing the electrolyte caps.

Check the battery's electrolyte level and specific gravity

to

ensure maximum engine starting efficiency. Make

sure the battery's terminals are clean and tight.

Ventilation

The ventilation requirements

engine cylinders; cooling air is required

of

the generator sets include the following: combustion air is required for the

for

the generator end and also the generator's engine during operation; and ventilating air is required ator, as well as the compartment in which the generator is located,

of

vapors.

Keep

in

mind that hot air rises, so heated air should be removed from the upper area

partment and cool fresh air should be directed

of

be accomplished with the aid SPECIFICATIONS" section

BCD 4.4KW, and page 15

blowers especially when the vessel is not underway. Refer

of

this manual

for

the BCD 6.0KW.

to

the lower areas of the compartment. Ventilation should

for

the airflow requirements

of

the starting solenoid.

or

into the eyes inadvertent-

for

removing the heat produced

to

clear the bilges below the gener-

by

potentially toxic and flammable diesel

of

the generator com-

to

the "SYSTEM

of

the generator sets, page

11

for the

Westerbeke Generators

28

DESCRIPTION OF INSTRUMENT PANEL

o

PREHEAT

....

1

~

.~'.

STOP

,\

@

\.

....

o

_

."'

.....

o

.

.:

.

o

General

The manually-operated series

remote panels. The

temperature

panel is also equipped with ator's running time (ELAPSED TIME) in HOURS and gauges and the

1.

PREHEAT: The PREHEAT switch energizes the engine's glow plugs, activates the electric fuel pump, bypasses the engine's oil pressure switch, and activates the fuel run solenoid. In addition, this switch energizes the

2.

START: The START switch, when pressed, energizes the starter's solenoid which cranks the engine. This switch will not operate electrically unless the PREHEAT switch is pressed and held at the same time.

3.

SIOE.:.

tivates the fuel solenoid and shuts

in

Through the STOP switch power is provided

NOTE: When the engine is manually shut down, the water temperature gauge and oil pressure gauge will continue by

the gauge before electrical power was turned OFF. The temperature gauge and oil pres-

sure gauge will return

Standard Instrument Panel (shown above) includes

degrees Fahrenheit

DC volt meter are illuminated; the ELAPSED TIME meter is not illuminated.

START

of

Westerbeke generators is equipped with toggle switches and, optionally,

two

gauges which indicate water

(WATER

two

meters which indicate DC control circuit voltage (VOLTS) and the gener-

switch.

to

register the last temperature reading and oil pressure reading indicated

to

zero once electrical power is restored

oF)

OFF fuel

and oil pressure in pounds per square inch (OIL PSI). This

in

1/10 hours. The water temperature and oil pressure

to

the fuel solenoid. Opening this switch deac-

to

the engine, thereby stopping the engine.

to

these gauges.

29 Westerbeke Generators

Remote

Operation

For starting and stopping the generator at a remote location, the same three switches are used. The PREHEAT and START switches are connected in parallel with the local panel's switches and serve the same

functions as in the local panel. The STOP switch is connected in series with the local panel's STOP switch

and serves the same function as in the local panel. The generator may be stopped from local

or

remote

positions

to

Refer

the remote panel wiring diagram when installing a remote instrument panel.

PANEL

REMOTE

r----------------

I

r

I

CONTROL

STOP

#~4RED

1118

PANEL

BLK

(REAR

~-#-~4-C-R-N_+_(=____.J=:::J_

;R~~E~Trl

SWITCH

#~4RED

VIEW)

I

______

-------------

I

i

RED

~R~!!..

_

...!:.u....!!p...!:':....

RED

L--~-------------l------~~~-

P.

N.

24943

CONNECTIONS

BCD

4.4KW

BCD

6.DKW

TO

STOP

sw.

TO

PANEL

GND

TO

PREHEAT

sw.

TO

PREHEAT

SW.

TO

PREHEAT

sw.

TO

START

SW.

Westerbeke Generators

30

Description

of

Starting System

Westerbeke diesel engines use electric starters assisted starting. The figure below shows a cross-sectional view of one cylinder. The glow plug is located in the com-

bustion chamber so that its tip is in the injector nozzle's spray path. When the PREHEAT button, the plug glows red at the less wear on the starter.

This system is common

must be depressed PREHEAT button engaged, the START button is depressed

to

Westerbeke Diesels. The start circuitry is designed so that the PREHEAT button

for

the time specified in the "Preheat" chart shown on page 33. Then, while keeping the

tip

and assists in igniting the fuel. The result is a rapid start with

by

glow plugs

to

crank the engine.

for

both normal and cold weather

glow

plug is energized

by

the

NOTE: The START switch will not energize unless the PREHEAT button is depressed. When depressing the preheat switch, the preheat intermittently so as not

Combustion

we

are activating the

to

overheat the glow plugs.

31

Chamber

glow

plugs in the cylinder head,

Westerbeke Generators

so

use

PREPARATION

This

section of the

warm),

and

your Westerbeke engine Fill

your engine with oil up to or near the upper limit

on

the dipstick

effect

on

the dipstick reading). Select readily

able

lubricating oil with

or

CD

and temperature For the quantity of

"SYSTEM

to the manual, for the

page

BCD

manual

provides the operator with preparation, initial starting, break-in, starting (cold or

stopping procedures. Follow the procedures

set

will give you reliable performance

(the

installation angle

an

SAE

number suitable for the

in

your operating

oil

needed

SPECIFICATION"

11

for the

BCD

API

in

4.4KW,

may

specification of

area

(see

page

your

engine,

section of this

and

page

6.0KW.

have

avail-

refer

an

CC

51).

15

FOR

STARTING

as

presented, for the conditions indicated,

and

long service

life.

UPPER

(NORMAL

LIMIT

LEUEL)

and

Fill

the

fuel

tank with a good grade of No.2 diesel

fuel

and

page

37).

engine's

prime the

fuel

When

system

fuel

returning

to start.

Each

unit

is

supplied with a coolant recovery kit (#24977)

plies:

A.

Remove

the pressure cap from the engine's tem with a mixture of water TEM"

section of this

Maintain this

0

-

190

system

B.

Make

level

F),

make

and

install the pressure

sure

the plastic recovery tank location where it level

or

above.

exhaust manifold's

C.

Add

coolant to the plastic tank after the engine

temperature

system.

ing

Monitor daily

has

With the manifold filled

and

system up

is

bled

manual,

to the

sure there

to

fuel

and

the engine

and

base

the engine

is

free

of

air,

is

ready

(see

antifreeze suitable for your temperature

page

46.)

Operate the engine

of the filler

is

no problem with coolant flow through the manifold. Top off the

neck.

cap.

is

properly mounted

can

be

monitored

In

these installations that require

and

filled

level.

been

reached

add coolant

to

make

as

needed.

sure

and

the pressure

the

exhaust

Once the engine

easily.

it,

the plastic recovery tank

has

all

air

is

LOWER

as

standard equipment, to which the following ap-

manifold

The

been

expelled from the manifold

cap

and

slowly fill the engine's

zone.

(See

the

and

observe the coolant

reaches

near

the unit (with the bracket provided),

its operating temperature

recovery tank should

started

and

after the engine's operating

level

be

mounted at manifold

can

be

and

installed, fill the plastic recovery tank half

LIMIT

COOling

"COOLING

in

the manifold.

mounted below the

the engine's cool-

sys-

SYS-

(170

COOling

in

a

full.

Make

sure the Installation Checks

TION

CHECKS"

section of this

manual

Westerbeke Generators

have

been

(refer to

made

page

in

accordance with those specified

18).

32

in

the

"INSTALLA-

1.

Depress and hold the

PREHEAT

STARTING PROCEDURE

switch. Preheat according

to

the following chart:

2. While still depressing the

the

START This the engine to continue to

NOTE:

release

starter motor for more than

3. Check

haust discharge.

Once the engine starts, allow it to

and stabilize while the engine's instruments are checked for proper

oil pressure and battery charging engage the starter while the engine

switch but continue

allows the engine to build

Should the engine not start when the

both switches and wait

all

the instruments on the

PREHEAT

run.

Atmospheric Temperature

+

41°

+

41°

+

23° F (-

Limit of continuous

switch, depress the

to

hold the

up

enough oil pressure to close the oil pressure shutdown switch and allow

30

seconds at a time.

panel

F

(+

5°

F

(+

5°

C)

run

for a few minutes to warm up

Voltage.

is

running.

PREHEAT

seconds; repeat the previous procedure. Never

for proper operation.

C)

or higher

C)

to +

23° F (-

or lower

use

Never attempt to

START

switch depressed for

START

switch is depressed for

Make

5°

C)

switch.

As

soon as the engine runs,

sure

sea

Preheating Time

Approx. Approx. Approx. 30

before cranking

10 20 30

seconds

release

an

additional 2 to 3 seconds.

10

to

12

seconds,

run

the

water discharges with the

sec. sec. sec.

ex-

NOTE: this condition should smooth out 130 -150° F (55 -66"

Proper glow plug function the cernible.

plugs or a faulty preheat circuit (check for loose connections).

Some unstable running may occur in a cold engine, but

as

the operating temperature of

C)

is

reached.

is

indicated by a voltmeter drop when

PREHEAT

Prolonged cranking intervals without the engine starting can result exhaust system with

pumping enter the engine's cylinder's by way of the exhaust manifold once the exhaust system fills.

Prevent this from happening by closing the

exhaust muffler, and correct the cause for the excessive engine cranking needed start. Engine damage resulting from this type of

the owner/operator should

switch is depressed. This drop will

If no voltage drop

sea

water through the

is

noted, it may indicate defective glow

sea

water coolant.

sea

keep

be

slight but dis-

CAUTION

in

filling the engine-mounted

This

may happen because the

water cooling system during cranking. This

sea

water supply through-hull shut-off, drain the

sea

water entry is not a warrantable issue;

this

in

mind.

sea

water pump is

sea

water can

to

obtain a

33

Westerbeke Generators

STOPPING PROCEDURES

1.

Remove the AC electrical load from the generator and allow the generator

engine can stabilize its operating temperatures.

2.

Depress the STOP switch and hold it until

the

generator comes

to

switch.

to

run

for 3 to

a complete stop.

5 minutes

Now

release this

so

the

Engine

Although

Break-In

your

Procedures

engine has experienced a minimum

of

one

hour

of

test operations

to

make sure accurate assembly procedures were followed and that the engine operated properly, a break-in time is required. The service life

of

your

engine is dependent upon

how

the engine is operated and serviced during its initial hours

of use.

Your

new engine requires approximately 50 hours

part in order

to

maximize the performance and service life

of

initial conditioning operation

of

the engine. Perform this conditioning careful-

to

break in each moving

ly, keeping in mind the following:

1.

Start the engine according

to

the "STARTING PROCEDURE" section found on page 33; run the engine

while checking that all systems (sea water pump, oil pressure, battery charging) are functioning.

2.

Start the generator and allow the engine

to

warm

up

until the water temperature gauge moves into

the

130-140° F range.

3.

Use caution not

rpm (Hertz) are signs

4.

Run the generator at 1/2 rated capacity.

to

overload the generator. The presence

of

a possible overload.

of

For

the remainder

its rated capacity

of

the break-in period, the generator

for

the first 10 hours then increase

of

a gray

or

black exhaust with loss of engine

the

load

to

3/4

may

be run at different load in-

of

its

tervals.

Breaking-in a sumption and

new

engine basically involves seating the piston rings

smoky

operation indicate that the cylinder walls are scored, which is caused

to

the cylinder walls. Excessive oil con-

the generator during the break-in period

As indicated above, operate the generator with a moderate load during one hand

Westerbeke

don't

baby

Generators

the

engine, but on the other hand, however,

34

don't

by

overloading

the

50-hour break-in period. (On

abuse it.)

Starting Under Normal Conditions Follow the procedure below for

1.

Make

sure

there

is

sufficient

and

water separators for the presence of contaminants and/or

3.

Check the coolant

NOTE:

leak.

Excessive loss of coolant from the plastic recovery tank indicates a cooling system

Check the entire cooling

level

of excessive coolant FOR

STARTING"

4.

Check the are

found

oil

on

Start the generator

section of this

level

in

the bottom of the engine or below the

in

accordance with the

allow the engine's operating temperature to

normal

in

the plastic recovery

starting of the generator:

fuel

on

board.

system

loss,

the

system

manual,

the engine sump

Keep

fuel

tank.

Add

and

pressurize the system to locate the

must

be

refilled

page

32.

and

look for any

engine.

"STARTING

reach

PROCEDURE"

140 -1500 F before placing load

Starting Under Cold Conditions

Under extremely cold temperatures, the following conditions

when operating your engine

in

cold

weather.

tank(s)

as

full

as

possible. Check the

water.

coolant solution

as

outlined under the

and

fuel

can

occur. Follow the instructions listed below

Drain

and

as

leaks,

particularly if signs of

instructions found

clean

them

needed.

leak.

In

cases

"PREPARATION

on

page

on

it.

fuel

as

needed.

such

33,

filters

leaks

and

LUBRICATING

OIL

TURNS

VISCOUS -Make

for the prevailing atmospheric temperature.

page

51

for

an

atmospheric/oil viscosity specification table.

VOLTAGE minimize

THE

RISE ever the temperature of the intake air Refer

ACROSS

THE

BATTERY

TERMINALS

voltage drop across the battery terminals.

TEMPERATURE

ENOUGH

to the preheat chart found

OF

THE

INTAKE

AIR

-Allow the glow plugs to operate sufficiently to is

low

in

the

"STARTING

certain that the lubricating oil

Refer

to the

"LUBRICATION

DROPS -Make

IS

LOW

and

when

AND

THE

the compression temperature does not

PROCEDURE"

certain that the battery

COMPRESSION aid

in

starting during the preheat period

section,

used

conforms with the ratings

SYSTEM"

section of this

TEMPERATURE

page

33.

manual,

is

fully charged to

DOES

when-

rise

enough.

NOT

35

Westerbeke Generators

Diesel Fuel

FUEL SYSTEM

Use No. 2 diesel fuel with a cetane rating

do

not

these fuels

have the same lubricating properties as

In cold weather particularly, water vapor is produced Keep fuel tank(s)

full and completely free

of

45

or

higher. Never use kerosene

of

dirt and water.

or

home heating oil since

No.2

diesel fuel.

by

condensation when air is present in the fuel tank.

Fuel Filters

primary

A entrapment type must be installed between the fuel tank and the engine. A primary available from

representative

This filter, adapted

use, comes complete with fittings either hose in

an accessible place, inspect it often and drain off water accumulation frequently.

If a water trap type filter is between the fuel tank and the enginemounted fuel system, any water in the fuel system will tend tom

of

metal parts

Particles will pass on eventually

fuel

filter

of

the

water

fuel filter, shown here, is

your

local Westerbeke

or

your

boatbuilder.

for

boatbuilder

for

or

metal tubing. Mount it

not

installed

to

lay in the bot-

the electric lift pump. Internal

of

the lift pump will rust.

to

filters and

to

the injection

pump

and

XNSTALLATXON

1.

BOLT

SEDIKENlIlATEI

AN

ACCESSIBLE THAT A RECEPTICLE CAM

BE

PLACED

2.

IF

FUEL

IS

BUND'

TUBINS,

INCH

THROUSH

FUEL

IS

TWO

BRASS

BE

OIASONAL

IHAT

IS

~~~

lATER

IS

SLOWLY THE

LOOSEN

lATER

RUNS

DRAIN

THE

StSTEI.

THE

TD

BE

THE

TO

APPROUED.

PRESENT

DAAIN

OR PROUIDEO.

1/4

IISHTEMIIG

3.

IF THE SUPPLIED. HAS BARBl, II

4.

IF COLLECT SEDI"EMIER. REACNES BOIL, All

5.

TIGHTEM ENTER

&.

ENERGIZE BOUL.

STRUCTURE

TO

UNDER

BE

PIPED

USE

SURE

TNE

THE

HUT.

BE

PIPED

BARBED CERTAII BRAID

INSERTED

IT

IS

HEDPREHE

II

THE

WHEN

THE LIIE

THE

1UJ1l0"

OUT.

PLUC

SECURElY

FUEL

PUMP

XNSTRUCTXONS

TRAP

SECUREU

TO

SO

POSITIONED

CAICN

DRAINAGE

II.

IIiN

COPPER,

MUTS

AMD

FERRULES

TUBIIS

PROJECTS

FERRULE

BEFORE

.IIH

HOSE,

IRE

LIIED,

FUEL,

FLOAT THE

ORRII

REFILL

AID NIISE

ITO

OF

PLISTIC PLUS

SO

USE UASHERS

CLIIS

AID

IT ¥IlL

THE RINS

NO

AIR

THE

SELECTED

UIIIL

FIITIII&S

INAT

IN

TNE BOITO" RED

ON

TO

01

THAT

CAN

THE

injectors with damaging results and

of

the possibility Remember, water damage

system is

expensive repairs.

not

covered

to

the fuel

under

the

Westerbeke warranty. The owner/operator is responsible in making sure that fuel reaching the engine's in-

jection equipment is free

of impurities. This process is accomplished

by

installing a proper filtration/separa-

tion system and maintaining this system.

In addition, any gasoline in the fuel system will damage the engine's fuel injection pump assembly and injectors, as gasoline does not have the same lubricating qualities as diesel fuel.

Although most boatbuilders supply a water trap/filter, some trap/filter as an optional extra at moderate cost. The filter is supplied with fittings tubing fuel lines.

Westerbeke

Generator

36

do

not. Westerbeke offers a sedimentary/water

for

either hose

or

metal

Priming the Fuel System

The

Westerbeke system care

the

operate for proceed to start the ments,

the preheat

allows for

in

catching any

Fuel

Filter

and

self-bleeding

easy

Elements"

20

to

30

then

repeat

elements

servicing of the

fuel

seconds to prime

engine

the

(the

fuel

system

that may drain out of the

section

as

bleed

glow

below.

you

procedure

plugs)

is

semiautomatic

fuel

filters.

Energize

and

bleed

normally would. If the

as

indicated

are

energized,

Simply fuel

filtering

the

PREHEAT

air from

CAUTION

so

the

above.

take

in

operation.

remove

assemblies)

switch

system.

engine

care

The

the

and

(No

fittings should

does not

When

the

not to over

self-bleeding feature of the

replace

as

PREHEAT

the filter

described

allow the electric start,

stop

heat

them.

in

be

opened.)

and

switch

elements the

wait a

"Replacing

fuel

pump to few

is

depressed,

fuel

(take

Then

mo-

Prolonged cranking intervals without exhaust pumping enter the engine's cylinders by Prevent exhaust start. the owner/operator

ReplaCing the Fuel Filter Elements While

it Therefore, fuel

filter

purchase cludes replacement 8,

20,

21). sealing slight tightening of ter along with the O-rings supplied with

After the first

#

and

careful fuel filter assemblies.

the Similarly, new removed base by twisting it back on

washer location that cannot

23

and

install a

to

# 6 filter

# 8

off the pump's locking tabs

the

hex

system

sea

this from happening by closing

muffler,

Engine

is

unlikely that the operator will it

is

recommended

and

gasket

spares

If a leak should develop at a

50

discard filter

new

catch any fuel that

element

install a

gasket.

with the

nut cast into the

with

sea

water coolant.

water through

and

damage resulting from this type of

should

be

carried

from your local

elements

the

filter cup

hours of operation, loosen

element # 21.

filter

using a new # 20

This

in

new

# 6 filter

The

base

aid

of

an

open

on

the

locking

the

correct

may

same

the electric

of

the

keep

that banjo

on

board

Westerbeke

with

gaskets

retainer,

spill

service

element

the

electric

end

and

tabs.

base.

be

from

wrench.

sea

Clean

reinstall Place

the

engine

water cooling

way

of

the

cause

for the

this

in

mind.

be

forced to

washers,

at

all

times.

Dealer

(items

fuel

banjo or

remedied

replace

the

new

retainer

bowl # 22

gasket.

within

is

required

fuel

lift along fuel

pump

Twist

the

wrench

starting

This

may

exhaust

sea

excessive

injector

Select

or Distributor. For

#6,

by

a

the

fil-

filter.

ring

Be

these

of

pump.

with

a

is

the

base

can

result

in

filling the engine-mounted

happen

system

manifold once the exhaust

water supply through-hull shut-off, drain the

sea

service

seat

the parts for your

because

during cranking.

engine

water entry

the

cranking

system

washers,

8

the

sea

water pump

This

needed

is

not a warrantable

at

sea,

the possibility does

electric lift pump filter

engine

example,

hardware kit #33093

sea

water

system

to obtain a

from the

is

can

fills.

issue;

exist.

and

gasket,

Parts

List

and

in-

~

I

After the first 50-hour be

increased

to

change,

200

hours or once per

the

change

season.

period

may

37

23

Westerbeke Generator

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 fuel injector and injector pump plunger. The fuel injection pump, located

of

the most important components

the diesel engine and, therefore, calls

for

the utmost caution in handling.

to

the right, is one of

Furthermore, the fuel injection pump has been thoroughly bench-tested and should not be tampered with.

Speed (Hertz) and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump. Other types

of

adjustments

or

repairs must be performed

by

a qualified injection service shop.

ELECTRIC

LI

FT

PUMP

FUEL

To obtain long and satisfactory service from the injection pump, always use fuel which is free from impurities and maintain a

system regularly: the injection

Westerbeke

good

filtration and water separation system between the fuel tank and engine. Service this

Generator

pump

Fuel Injection System

it saves will be your own.

38

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, as shown on the wiring diagrams which follow on pages 42 and 45. Refer

to

these diagrams when troubleshooting

or

servicing electrical components on the engine.

CAUTION

To

avoid damage

to

the battery charging circuit, never shut off the engine battery switch while

the engine is running.

Shut off the engine battery switch, however,

to

avoid electrical shorts when working on the en-

gine electrical circuit.

Battery

The minimum recommended capacity

Specification

of

the battery used in the engine's 12-Volt DC control circuit is

90

125 Ampere-hours (minimum).

-

39

Westerbeke

Generator

Testing

the

Battery Charging

Circuit

NOTE: This circuit is totally separate from the AC output the generator effects this circuit's output but not the reverse.

1.

Bridge Rectifier

Normal AC voltage running

the two AC connections on the bridge rectifier. (See the illustration below.)

AC voltage running

No-load off the generator Full-load

Normal DC voltage running out of the rectifier of the bridge rectifier; that is,

DC voltage running from the bridge rectifier (approximate):

No-load off the generator Full-load

off the generator 17.5 Volts AC

off the generator 18.5 Volts DC

to

the rectifier (while the engine is operating at 1800 rpm) is measured across

to

the bridge rectifier (approximate):

AC

-t>I-

BRIDGE

RECTIFIER

+

(in

Volts

+ and - .

16.0 Volts AC

17.0 Volts DC

of

the generator. The AC output of

DC)

is measured across the two DC connections

DC

I.C.

INTEGRAL

CONTROLLER

2.

AC

Stator Winding: 0.14 Ohms

Lift the two AC leads off the bridge rectifier and measure with an ohmmeter the resistance between these

leads should measure 0.14 Ohm. No continuity should exist between these two leads and the ground.

two

3.

Testing the

A.

Set your Ohmmeter's scale on

B.

Connect the (

to

lead, momentarily touch points

The Ohmmeter should register

of

C.

Remove the positive connect the negative points should deflect when each point is touched.

D.

Leaving the negative point should take place.

Bridge

point

#4.

the points touched.

#1, #2,

#5

Rectifier

+)

positive lead from the Ohmmeter

Taking the Ohmmeter's negative

and

with the positive lead. No deflection

RX1

(+

DC)

#1,

#2, #3,

no

deflection for any

(+)

lead from point

(-)

lead; momentarily touch

#3.

The Ohmmeter's needle

(-)

lead on point #4, touch

and set the needle

(-)

and

#5.

#4

and

to

zero.

-.-_

Point

#3

Westerbeke Generator

40

E.

Place the positive (

should not register

+)

lead on point

any

deflection (no deflection indicated infinite resistance). Reverse these connections and the Ohmmeter should again register PREVIOUS TESTS (A -

4.

Integral Control/er (I.C.)

E),

REPLACE THE RECTIFIER BECAUSE IT IS DEFECTIVE.

#1

and the negative

no

(-)

lead on point

#3.

The Ohmmeter again

deflection. IF THE RECTIFIER FAILS ANY OF THE

The integral controller (I.C.) is an encapsulated, solid-state unit that supplies a DC charging voltage

generator's starting battery while the generator is operating.

Charging Voltage: 13.0

-14.0

Volts DC

Charging Amperage: 0 - 10 Amps DC

A separate

into

DC current

DC charge when one is needed. low), tions

NOTE: When the generator is first started, the I.C. unit will produce a

rate will rise as the generator is operated

group

of

stator windings supplies AC voltage

to

supply the I.C. unit. The I.C. unit senses the needs of the starting battery and supplies a

If

you

suspect that the I.C. unit is faulty (that

check

the charging circuit's operating and components as described in steps 1-4. Check all connec-

for

cleanliness and tightness including the ground before replacing the I.C. unit.

for

awhile.

to

a bridge rectifier which converts the AC current

is,

if the battery's charge is

low

charging rate. This charging

to

the

41

Westerbeke

Generator

BCD 4.4KW

DC

Control Circuit Wiring Diagram

page 1

of

2

#35951

WATER

~

¥

EMERGENCY

~

TEMP. •

SENC';R

,,.~

~~Lp

STOP

SWITCH

CIRCUIT

BREAKER

DIAGRAM

o

.-

~

OIL

PRESSU~E

~

Rt:.O"14

n OIL PRESSURE

T

SENDER

~

ALTERN~TOR

EXHAUST TEMP. SWITCH

SEt

~1

NOTE

2

LtJ

I

~OUND

[1.....1

TO

1

8L..OCK

PRE-HEAT

START

STOP

-l

I

Westerbeke Generator

42

BCD 4.4KW DC Control Circuit Wiring Diagram #35951

page 2 of 2

SCHEMATIC

~

-:

seE

.. ~ NOTE

2

~--------~...,

, ,

:( : C.B.

~

J

20A

p.t;,SW.

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EXM.r.sw,

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STARTER

sw.

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FUEL

W.T.SW.

__

SOL.

I

.J

STARTING

~:

~

I.

TIoiIS

AND

HJ

t~OST

THEREFORE THE BUILDER/OWNER

A~E

Z..AN

BATTERY IN AN Ef-1E!(GENCY TYPICALLY SHOWLD

'WILL NORMALLY SERVE ..

.3.~OST

EE

AND

T--tE~

AND

I.

ALWAY:

PU-:'H

2.WHILE CONTINUING

3.

WHEN

GENERr.TOw STARTS, RELEASE START SWITCH ONLY.

4.WHEN OIL

(THE

J:.~E~EAT

PUSH

ANO

PWQCUCT

I:: PROTECTED

AS

CLOSE

TO

THE INSTRuMENT

GENERATORS

INSTALLED

O:-.l-OFF

STARTER

NC GREATER THAN

8J\CI<':

A RELAY

THE

WILL SHUT

TO

PREVENT

SWITCH SHOULD

DRAW

:'00

NOT

EXCEED

~~OLENOIDS

TO

THE STANDARD

MAY

STOPPING INSTRUCTIONS

~E-HEAT

PRE:SuRE

SWITCH

HOLD THE STOP SNITCH

SouCE

PANEL

TO

500

.30 SECONDS. A SWITCH WITH A CONTINUOUS F;'I\TING

THESE FUNCTIONS, SUT A SWITCH MUST

IOlelN

BE

ADDED

SWITCH FIRST. HOLD

TO

PUSH PRE-HEAT SWITCH1 PUSH

REACHES AF-PROxIMATELY

OVEIO:IGES

THE

BY

A MANUAL

OF CUPRENT I\S

OR

ENGINE WIRING

DOW~I

BEC/,USE

f.4UST

CONTACT

BE

AND

DRAW

BE

BETwEEN ELETRICAL DEvICES

INSTALLED

WHEN

LEAVING

AMPS

WHEN

15

AMPS,

THE

PATH

FF?OM

START

SWITCH).

TO

CONTROL THE STARTER SOLENOID ITSELF".

FOR

15

TO

20

LOW

UNTil

RESET

~OSSIBLE.

WILL

11-IE

SU~E

IN

THIS CIRCUIT

CRANKING.

THEREFOI1E THE VOLTAGE JRCP IN

THE STANOARO

PSI

OIL

PRESSURE

THE GENERATOR STOPS COMPLETELy.

CIRCUIT BREI\KER LOCATED

EXCESSIVE CURRENT

CAUSE

THE

OPENED BREAKER DISCCNNECTS

THAT THE INSTRUMENT PANEL

THE BOAT. TWELVE VOLT DIESEL ENGINE STARTERS

THE DURATION

IF

TI-I15

qEOUIRES

60

SECONDS

AS

REQUIREO.

START SWITCH.

RELEASE FwE·HE/.T SWITCH

SHUT~OWN

CIRCUIT).

NEAR

BREAKER

TO

DISCO~NECT

NEvER

STAR:

DRAW

TO

TRIP.

ANO

ShLT WATER.

THE STARTER

OF

INDIVIDuAL

OF'

[75

6f

u~EO

THIS

SWITCH

IMPRACTICALLY

TO

IN

A~O

THE STARTER

ANYWHERE

THIS

EvENT

TI-IE

FUEL

SUPPLY.

ENGINE WIRING

FROM

THE

CRANKING CYCLES

AMPS AT 12VDC WILL

TO

MAKE THE STARTER CIRCUIT •

CONDUCTOR

ANY

LARGE

RE~OTE

CONDUCTORS

MUST

SWITCHES

43

Westerbeke Generator

BCD 6.0KW

DC

Control Circuit Wiring Diagram

page 1

of2

#35773

,...-----'c---:;I;T

~

llQe

~

WIRING

DIAGRAM

~

EU!2

......

EXHAUST

TEMP, SWITCH

. -

..

POWER

ALTERNATOR

r---'

I 0

I

I I

I

fir,

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L~

SEE

NOTE

GND.

'10

2 i

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l---a

BATTERY

STANDARD

"iNS'i'RuME

~

,

(REAR VIEW)

I

NT

Westerbeke Generator

~---~

44

BCD 6.0KW

:

:SEENOnz

, ,

1

~--------------------------~"~---~-~'----~M

DC

Control Circuit Wiring Diagram #35773

page 2 of 2

SCHEMATIC DIAGRAM

START SOL.

~5_T_AR_T_ffi

__

~

PRE-MEAT

SOl..

~-:j

L

~------------~:~-i~-~;------~I--~GLOWPL~u7G5~----------~

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;

):

~:~~~~R

" J

~----~---------+----~~r-----~

!,J(.11.T.SW.

""'-

___

5;..:~-("~~~

i PRE-HEAT

STARTING

~:

AND

I.

ALWAYS PUSH PRE-I-IEAT SWITCH SECONDS

2. WHILE CONTINUING START SWITCH.

3.

WHEN

GENERATOR

4.

WHEN

OIL PRESSURE RELEASE PRE-HEAT SWITCH (THE THE

LOw

PUSH AND HOLD THE

STOPS

COMPLETELY.

SW.

STOPPING INSTRUCTIONS

TO

PUSH

PRE-HEAT

~ELEASE

~EACHES

STOP

SWITCH

FIRST.

DOWN

AS

REOUIRED.

STARTS,

OILPRES5URE SHuT

1"'-,--.

EMERGENCY STOP

w.T.SENDER

HOLD

FOR 15 TO

SWlrel-l

START

SWITCH

APPROXI.~ATELY

PRE'~EAT

SWITCH

CIRCUIT)

UNTIL

THE

BATTERY

W.T.SW.

sw.

Q..P.

PUSH

I

ONLY,

20

PSI

OVERIOES

GENERATOR

POWER

AL'VERNATOR

CHARGER

FU

EL

PUMP

FUEl.

SENDER

GO

O.P.SW.

501..

~:

I.

THIS PRODUCT IS PROTECTED NEAR THE STi\RTER EXCESSIVE CUR.I1ENT

......

ILL

CAuSE

DOWN

BEC.uSE

THE~E~ORE

WIRING

AND

DEVICES

Z.AN

ON

O~

STARTER FROM

TWEl.VE

vOLT

CRANKING. THE DURATION

30

SECONDS. A SWITCH

NORMALLY

:o-1AKE

THE

~.

BATTERV

LEAVING

AND

THE

BREAI(ER

THE

BUILDER/OWNER

ENGINE ARE

AND

SALT WATER.

SWITCH SHOULD

THE

BATTERY

DIESEL

SERVE THESE FUNCTIONS BUT A SWITCH

5TARTER

CHARGER CAUSES

BOAT

FOR

AN

BY

I\.

MANUAL RESET CIRCUT BREAKER LOCATED

AS

CLOSE

TO

OJ:;AW

O~ENED

INSTALLED

ENGINE

WITH

CIRCUIT.

EXTENDED PERIOD DISCONNECT

THE SOURCE OF

ANYWKERE IN

TO

TRIP.

BREMER

BE

IN AN

STARTERS

O~

INQIVIDUAL CRANKING CYCLES

A CQNrlNUQlJS

AI

9.-DRAIN

THE

INSTRUMENT

IN

THIS EVE!'\T MOST GENERATORS

DISSCDNNECTS

~UST

BE

SURE THAT THE INSTRU,\4ENT PANEL

TO PFlEVENT CONTACT 8ET.¥e:EN ELECTRICAL

INSTALLEO

IN

THIS

E~ERGENC.Y

TYPICALLY

RATING

WHEN

45

CURRE.NT

THE

FUEL

CIRCUIT

A"O

TO

WHEN LEAVING THE

DRAW

200

OF

175 AMPS

,",USTNEVER

GENERATOR

TME

AS

PANEL

DI5CDNNET

TO

SHOUl.D

IS

NOT

BATTERY.

SUPPLY.

300

P05SIBLE.

WIRING

OR

ENGINE

WILL

SHUT

THE

BOAT.

AMPS

WHEN

NOT

EXCEED

AT

IZVOC

WILL

BE

USED

TO

OP€RATING.WMEN

Westerbeke Generator

Description

COOLING SYSTEM

Westerbeke marine diesel generators are designed and equipped in

the engine

by

combustion and friction is transferred

to

fresh water which circulates throughout the engine.

for

fresh water cooling. Heat produced

This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred externally from the fresh water tive radiator.

Sea water flows through the tubes

tubes; engine heat transferred

to

sea water

to

the fresh water is conducted through the tube walls

by

means of a heat exchanger, similar

of

the heat exchanger while fresh water flows around the

in

function

to

the sea water which

an automo-

is then pumped into the exhaust system where finally it is discharged overboard. In other words, the engine is cooled heat over the side through the exhaust system. The fresh water and sea water circuits are independent each other. Using only fresh water within the engine allows the cooling water passages free from

by

fresh water, the fresh water is cooled

harmful deposits. The

two

independent circuits and their components are discussed in the follow-

by

sea water, and the sea water carries the transferred

to

stay clean and

of

ing paragraphs.

Fresh Water

NOTE: Refer mixture

Circuit

to

paragraphs A and B in this section

to

be used as the fresh water coolant, and for information on filling the fresh water

for

the recommended antifreeze and water

system.

Fresh water is pumped through the engine

by

a belt-driven circulating pump, absorbing heat from the en-

gine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through

the thermostat into the exhaust manifold,

to

the heat exchanger

wher.e

it is cooled, and then is returned

to the engine block through the suction side of the fresh water circulating pump. When the engine is started cold, external fresh water flow is prevented

to

bypassed around the thermostat

prevent exhaust manifold from overheating). As the engine warms up,

the thermostat gradually opens, allowing full flow

by

the closed thermostat (although some fresh water flow is

of

the engine's fresh water coolant

to

flow unrestricted

to the external portion of the cooling system.

A.

Fresh Water Coolant (Antifreeze) Mixture.

A freshwater and antifreeze mixture should be used year-round

to

expands sufficiently

split the heat exchanger and crack the engine block. A water/antifreeze mixture

proper concentration will prevent freezing (see page 47

Use soft water with few impurities, such as tap water (potable water)

water. Use of hard water

or

water containing impurities will lead

in

the cooling system. Water, when it freezes,

for

an antifreeze/water mixture chart).

or

rainwater. Never use hard

to

the collection

of

scale in the engine and

or

of

foul

heat exchanger which will reduce the cooling system's efficiency.

Antifreeze of

use antifreeze which is compatible with aluminum cooling system components and is made

poor

quality

or

without rust inhibitors will cause corrosion within the cooling system. Always

by

a reliable

manufacturer. Never mix different brands of antifreeze.

Make sure that the cooling system of the engine is well cleaned before adding antifreeze. Recommended antifreeze

In order ding it

Westerbeke Generators

for

year round use is ZEREX

to

control the concentration

to

the cooling system.

or

PRESTONE with rust inhibitors.

of

the mixture, mix the antifreeze and freshwater thoroughly before ad-

46

Antifreeze

Concentration

Freezing Temperature

%

° F

e

ANTIFREEZE CONCENTRATION DATA

13

C)

23

30

23

(-

14 5 - 4 - 22 -

5)

(-10) (-15) (-20) (-30) (-40) (-50)

35

45

50

40

60

- 58

NOTE: An antifreeze concentration should be selected on the basis is about 10° F

B. Filling the Fresh Water System

A coolant recovery tank kit is supplied with each Westerbeke diesel engine. The purpose of this recovery tank is

coolant and without introducing air into the cooling system.

This coolant recovery tank should be installed at,

be easily monitored and where coolant can be easily added if needed (see the figure below). A stainless steel mounting bracket is supplied with each kit along with a 30-inch length of clear plastic hose and clamps to

to

allow

connect the hose between the engine's manifold fitting

(5°

C)

lower than the actual atmospheric temperature expected.

for

engine coolant expansion and contraction, during engine operation, without the loss of

or

above, engine manifold level,

to

the hose spud on the base of the recovery tank.

FUNCTION

From Coolant Tank

OF

MANIFOLD

PRESSURE

of

a temperature which

in

a location where it can

CAP

to

Coolant Tank

Coolant from the engine, when heated during engine operation, will expand, lifting the spring-loaded manifold pressure cap, and enter the recovery tank

When the engine is shut down and cools, a small check valve in the pressure cap is opened

ofthe

tion cooling system, free on the manifold and the filler neck in the manifold is clear so coolant can flow

engine coolant, allowing some of the coolant in the recovery tank

of

air and without loss. Periodically check that the passage

by

way

of

the hose connecting the recovery tank

to

be drawn back into the engine's

(A)

between the 90° fitting

in

either direction.

47

Westerbeke Generators

to

the manifold.

by

the contrac-

COOLANT

Coolant Recovery Tank, Recommended Installation

Fill

the fresh water system as follows:

RECOVERY TANK

1.

Remove the pressure cap from the manifold.

2.

Pour a clean, antifreeze mixture into the manifold and allow enough time

water

COOling

3.

Start the engine and allow it

and add antifreeze coolant as air is

system.

to

come

up

to

its operating temperature. Monitor the coolant in the manifold

expelled. Once all air is expelled from the system, fill the manifold

for

the coolant

to

fill the fresh

to

the filler neck and install the pressure cap.

4.

Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway between the

5.

Run the engine and observe the coolant's expansion flow into the plastic recovery tank.

6.

Check

allow it

ADD

mark and the

for

leaks between the pressure cap/filler neck and then plastic recovery tank. Stop the engine and

to

cool. Coolant should be drawn back into the cooling system as the engine's temperature comes

MAX

mark. Replace the plastic cap.

down.

7.

Add coolant

to

the recovery tank, as required,

to

top

off the fresh water coolant system.

Thermostat

Generally, thermostats are of engine's temperature rises and

the bottom of the thermostat which moves downward

head.

Since 1980, each type of thermostat has a hole punched through

two

types. One is simply a choking device which opens and closes as the

falls. The second type has a bypass mechanism. Usually this is a disc on

to

close off an internal bypass passage within the

it.

The hole is a bypass

to

prevent the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have this design characteristic.

Westerbeke Generators

48

Sea Water

Circuit

The sea water flow is created driven, positive displacement, neoprene

impeller pump. The pump draws sea

water directly from the ocean through the

cock

sea ses the water water inlet. The sea water passes through the heat exchanger's tubes, from which heat from the fresh water system is ab-

sorbed, and then the sea water charged overboard through the water-injected wet exhaust system. Be sure debris from the area inside

changer where the zinc anode is positioned.

A zinc anode,

of

the zinc anode is by should be checked monthly and the anode cleaned or replaced as required. Spare anodes should be carried on board.

and sea water strainer and pas-

to

the heat exchanger's sea

from

the

cooling

or

pencil, is located in the sea water cooling circuit within the heat exchanger. The purpose

to

sacrifice itself

reducing the effects of electrolysis on other components

by

a belt-

system

to

clean zinc

of

the heat ex-

is

dis-

NEW

ANODE

to

electrolysis action taking place

of

REPLACE REPLACE

Zinc Anode Conditions

in

the sea water cooling circuit, there-

the system. The condition

CLEAN

OR

REPLACE

of

the zinc anode

Sea Water

The sea water pump impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing, producing the pumping action. On no account should this pump be run dry. There should always be a spare impeller and impeller cover gasket aboard (an impeller kit). Sea water failures occur when lubricant water) is not present. Such failures are not warrantable and the operator's are cautioned water flow is present at start-up.

Water

The water pump drive belt than 1/2 inch leys on the longest span of the belt. A spare drive belt should be carried on board.

Pump

is

a self-priming,

Pump

Never attempt

Excessive water pump drive belt tension can cause rapid wear

vice

can cause belt

Drive Belt Tension

to

adjust the drive belt's tension while the engine is in operation.

life

of

the fresh water pump's bearings. Excessive slack

slipping, resulting in high operating temperatures.

is

properly adjusted

(10

mm,

12

mm) as the belt

gear-<:lriven

is

rotary pump with a non-ferrous housing and a neoprene

CAUTION

or

if

the belt can be deflected no less than 3/8 inch and no more

depressed with the thumb at the midpoint between the two pul-

to

make sure

of

the belt and reduce the ser-

the presence of oil on the belt

(sea

sea

49

Westerbeke Generators

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

to

descriptions if you need

order cooling system parts for your engine.

WATER

INJECTED

ELBOW

to

your generator's Parts List for part numbers and part

WATER

Westerbeke Generators

OVERHEAT

Typical Cooling System

ALARM

50

IICOMII'

f

SEA

VATER

LUBRICATION SYSTEM

Engine

FOR THESE GRADES CC, RECOMMENDED. THE OIL

Oil

ENGINE LUBRICATION, USE LUBRICATING OIL DESIGNATED

OILS ARE CLASSIFIED ACCORDING

CD

CF

AND CG-4. THE USE

YOU

SELECT SHOULD BE USED

OF

TO

THE API SPECIFICATIONS INTO SERVICE

THE

lllGHEST

GRADE AVAILABLE IS

ON

A REGULAR BASIS WHEN

POSSmLE.

Engine

Use an oil having a viscosity best suited 30

Oil Pressure

Oil

Viscosity

with minimum viscosity change under different temperatures is suggested.

NOTE: Do

(SAE

Number)

to

the atmospheric temperature. Use of an aU-season oil

Atmospheric Temperature

(20

(50

0

C)

- 68

-

or

0

lower

higher

F

(20

0

C)

SAE SAE

680 F 410 F 410 F(5°

not

use an engine lubricating oil with an SAE number greater than

FOR

DIESEL SERVICE.

Viscosity

30

or

10W-30

20

or

10W-30

SAE 10W-30

30

in the engine.

SAE

1

OW-

The engine's

During normal operation, the oil pressure will range between

NOTE: A newly started, cold engine can have an oil pressure reading upwards of warmed engine can have an oil pressure reading as low as depending upon the temperature

oil pressure, during operation, is indicated

of

the engine and the load placed on the generator.

by

the oil pressure gauge on the instrument panel

35 and

55

35

psi. These readings will vary

60

psi. A

51 Westerbeke Generators

Engine Oil Change (to

1.

Draining the Oil Sump

include

fiHer)

Remove the oil drain hose from its attachment bracket and lower it into a container and allow the

oil

to

drain, or attach a pump

to

the end of the drain

hose and pump the old oil out. Make sure the oil

drain hose

properly secured

in

its holder after all

is

of the old oil has been drained.

Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence of water in

the oil. Although this condition is rare, it does

require

prompt

damage.

water be present in the oil.

attention

to

prevent serious

Call a competent mechanic should

Sea water present in

the oil can be the result of a fault in the exhaust

system attached through the sea water haust, filling it up into the engine (refer stallation illustrations on page

to

the engine and/or a siphoning

cooling circuit into the ex-

to

21

and 22).

the in-

2.

Replacement of the Oil Filter

When removing the used oil filter, you may find it helpful and cleaner and lower portion of the old filter from it into a container before removing

to

helps

lessen spillage. A small style automotive

to

punch a hole in the upper

to

drain the oil

it.

This

filter wrench should be helpful in removing the old oil filter. Place some paper towels and a plastic

bag around the filter when unscrewing it

in

any oil left

engine reduces the engine's Please keep your engine clean.)

filter as it is removed

the filter. (Oil or any other fluid on the

cooling

Inspect the old oil

to

make sure that the rubber

to

catch

ability.

sealing gasket came off with the old oil filter. If this

rubber engine block, gently remove

sealing gasket remains sealed against the

it.

The replaceable cartridge-type oil filter requires no cleaning inside, so it may be properly disposed of.

When installing the new oil filter element, wipe the filter gasket's sealing surface on the engine block free of

oil and apply a thin coat of clean engine oil

oil

threaded

filter stub, and then tighten the filter firmly

to

the rubber gasket on the oil filter. Screw the filter onto the

by

hand.

NOTE: Generic filters are not recommended, as the material standards or diameters of important items on generic parts might be entirely different from genuine parts. after

an

oil filter change and oil fill, run the engine

that there are no oil leaks around the new oil filter.

Westerbeke Generators

to

make sure the oil pressure is normal and

52

Immediately

3.

Filling the Oil Sump

Add fresh oil through the oil filler cap on the valve

cover (refer

the BCD 4.4KW, and pages 8 and 9

forthe After refilling the oil, run the generator

to

location

the photographs on pages 6 and 7

for

the BCD 6.0KW

of

the oil filler cap and lube oil dipstick).

for

a few mo-

for

ments while checking the engine's oil pressure. Make sure there is no leakage around the new oil filter

or from the oil drain system, and then stop the generator. Then check the quantity of oil with the lube oil dipstick.

Fill to, but not over, the high mark on the dipstick, should the engine require additional oil.

Oil

lower

Oil

Rocker

Dipstick

Filler

Cover

Crankcase

Cap

53

Westerbeke Generators

BC

GENERATOR

The BC generator is a brushless, self-excited generator which requires only the driving force to

produce an AC output. The stator houses

windings. When the generator is started, residual magnetism

two

sets

of

windings: the main stator windings and the exciter

in

the four rotating poles induces a current in

of

the engine

the stator exciter windings. This flow of current then induces a greater current flow through the four rotat-

ing poles which then generates an even larger current in the exciter windings. This mutual build rent in the four rotating poles and in the exciter windings quickly reaches the saturation point

up

of

cur-

the

capacitor(s) and a regulated energy field is then maintained in the stator. At the same time, this regulated

field produces a steady voltage in the stator windings which then can be drawn off the generator's AC ter-

minals to operate AC equipment.

D

r-----------------------------------------,

I I

r---------,

I

I I

,

I

IDIDDE

A

,DIODE

I

,

--t--

I

L

_________

I

I 1

1

1 I

I

I I

I

I RECTIFIER

~

-----~Dl

____

AC

+

BRIDGE

""1

________________

T

E R

INTEGRAL

CONTROllER:

BAllAST RESISTOR

_._._

------O2~

...J

L

------<:>

_____

------05

------0

t:iPH~

____________

BC

6.5KW

and

6.0KW

-Q4

91

I

Ie

1

I

!

...I

3 =

6

__

L

B

L

o

C

K

...J

i

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BC

B

EARLIER

1

o

5

o

AC

TERMINAL

tCAPiC~

___________

4.0KW

and

4.4KW

!

...J

DC

CHARG

I.C.

60

HZ

I.

INTEGRAL

CONTROllER

MODElS

4

o

2

o

C.

3

6

BLOCK

1

·1

I

-l

DC CHARGE

Generator Internal Wiring Schematic with

A.

Rotating Field/Auxiliary

Windings with Diodes

C.

Exciter Windings and Capacitor(s)

Generator Frequency

Frequency is a direct result

the generator's frequency, refer

of

engine/generator speed: 1800

to

the "MAINTENANCE AND ADJUSTMENTS" section

72.

Westerbeke Generators

DC Battery Charging Circuit

B.

Integral Controller with Ballast Resistor

(Earlier Models)

D.

Bridge Rectifier and Intergral Controller

RPM

-60

54

Hertz, 1500

RPM

-50

Hertz To change

of

this manual, page

No-Load

1.

Remove the louvered metal plate covering the terminal connections and the capacitor (see page 56).

2.

Start the generator and allow it sure the generator is operating without any equipment drawing AC current from the generator (that

OFF all electrical appliances). Make sure the engine's speed (Hertz) is correct. Adjust the governor/fuel

solenoid linkage as needed

3.

Referring ing the voltage across the neutral lead and the ing. The generator's no-load voltage is 115 - 124 volts at 60.5 - 61.5 Hertz. If the voltage output is higher or

Voltage

lower than specified, proceed.

Adjustment:

to

the AC load connections diagram below, check the generator's no-load current

BCD

to

obtain the correct engine speed before proceeding. (See page 73.)

to

4.4KW

run

for

approximately five minutes so the engine can warm up. Make

is,

by

measur-

hot

lead with a volt meter. Make sure you record this read-

L,

shut

5

1

5.2-

143

5-

e2

6

L1

110v 50 Hz

4.

Shut off the generator. Make sure the correct Hertz lead (60 Hertz

capacitor. Refer

DO

NOT capacitor can hold a 450 -500 volt charge. Touching any wiring can result in a severe electrical shock. In addition, attempting is operating can cause fingers

to

5. Refer grouped disconnectthe lower numbered plug and connect the plug with the next higher number. no-load voltage is high, then disconnect the higher numbered plug and connect the plug with the next lower number. Note that the plug presently connected available.

the illustration on the next page before making any adjustments. Note that there are three plugs

for

to

attempt

the right capacitor terminal,

120v

60Hz

the illustration on the

to

make a no-load voltage adjustment while the generator is operating. The

to

be caught in the generator's rotor.

220v 50 Hz

top

of

the next page.

make a no-load voltage adjustment while the generator

#7, #8,

and

3

6

LI

5 2

LI

240v

#6,

#9.

If

the generator's no-load voltage is low, then

to

this terminal may be

3-

6.

N

60Hz

or

50 Hertz

#5)

anyone

is plugged into the

Ifthe

of

the three plugs

generator's

6.

If the generator's no-load voltage cannot be adjusted because the voltage needs

highest numbered plug is already connected the lowest numbered plug is connected, then follow the steps at the bottom local Westerbeke dealer

listed at the bottom

NOTE: Make sure the insulating covers on the unused leads are in place and are

tact with each other

of

the next page.

to

be increased and the

to

the right terminal,

for

a BC GENERAL TROUBLESHOOTING GUIDE before performing the steps

or

are in contact with the generator's housing.

55

or

the voltage needs

of

Westerbeke Generators

to

be lowered and

the next page. Ask your

not

in con-

N

+'

I..

Qj

:::c o

LI'I

BCD

4.4KW

GENERRTOR

THE

17

PLUG SHOWN TO ONLY STRRTION

CONNECTED

THE

CRPRCITOR

FOR

DEMON-

PURPOSES.

AC Ter.inal

IS

Load

Connection

Block

SO

Hertz

Plug

CAUTION-

ALLOW PLUGS

GENERATORoS WINDINGS

IF

THE WIRES

A.

Check the resistance

ANY TO

THESE

HOUSING

..

DO

OF

TOUCH

WILL

PLues

NOT

THESE

THE

HOUSING

BURN

TOUCH

OR

OTHER

BCD 4.4KW : 1.9 Ohm

C.

Check the engine's speed.

..

of

the exciter windings

B.

Check the capacitor.

BCD 4.4KW: 31.0 uF ±

Generator

Plate

5°

End

60 Hertz: 60.5 - 61.5

50 Hertz: 50.5 - 51.5

Adjust the engine's speed

by

use

correct Hertz.

NOTE: Refer

to

the "NOTE" at the bottom

Westerbeke Generators

of

the governor/fuel solenoid linkage adjustment, page

of

page

59.

56

73,

to

obtain the

No-Load

1.

Remove the louvered metal plate covering the terminal connections and the capacitor (see page 56).

2.

Start the generator and allow it

sure the generator is operating without any equipment drawing AC current from the generator (that

OFF all electrical appliances). Make sure the engine's speed (Hertz) is correct. Adjust the governor/fuel

solenoid linkage as needed

3.

Referring ing the voltage across the neutral lead and the hot lead with a volt meter. Make sure you record this reading. The generator's no-load voltage is 115 - 124 volts at 60.5 - 61.5 Hertz. If the voltage output is higher or

Voltage

lower than specified, proceed.

Adjustment:

to

the AC load connections diagram below, check the generator's no-load current

BCD

to

obtain the correct engine speed before proceeding. (See page 73.)

to

6.0KW

run

for

approximately five minutes so the engine can warm up. Make

is,

by

measur-

L1

4e::::a3

1 3

e2

5-

6

4e3 2e6

5e2_

4

2

36e

1

5e2e6

shut

L1

110v 50

4.

Shut off the generator. Make sure the correct Hertz lead

capacitor. Refer

DO capacitor can hold a 450 - 500 volt charge. Touching any wiring can result cal shock. is operating can cause fingers

5.

Refer

to grouped disconnect the lower numbered plug and connect the plug with the next higher number. If the generator's no-load voltage is high, then disconnect the higher numbered plug and connect the plug with the next lower number. Note that the plug presently connected available.

6.

If the generator's no-load voltage cannot be adjusted because the voltage needs highest numbered plug is already connected the lowest numbered plug is connected, then follow the steps at the bottom local Westerbeke dealer for a

listed at the bottom

Hz

to

NOT

attempt

In addition, attempting

the illustration on the next page before making any adjustments. Note that there are three plugs

for

the right capacitor terminal,

120v

60Hz

(60

the illustration on the

to

make a no-load voltage adjustment while the generator is operating. The

to

Be

of

the next page.

top

of

the next page.

to

make a no-load voltage adjustment while the generator

be caught in the generator's rotor.

#7, #8,

GENERAL TROUBLESHOOTING GUIDE before performing the steps

and

#9.

to

this terminal may be

to

the right terminal,

If the generator's no-load voltage is low, then

Hertz

LI

N

240v

60Hz

#6,

or

50 Hertz

in

anyone

or

the voltage needs

of

#5)

is plugged into the

a severe electri-

of

the three plugs

to

be increased and the

to

be lowered and

the next page. Ask your

NOTE: Make sure the insulating covers on the unused leads are tact with each other

or

are

in

contact with the generator's housing.

57

in

place and are not

Westerbeke Generators

in

con-

BCD

G.OKW

GENERATOR

THE

17

PlUG

SHOWN TO ONLY STRATION

CONNECTED

THE

CAPACITOR

FOR

DEMON-

PURPOSES.

AC Ter.inal

IS

Load

Connection

Block

Capacitor

58

Hertz

Plug

A.

Check the resistance

of

BCD 6.0KW : 2.2 Ohm

C.

Check the engine's speed.

60 Hertz: 60.5 - 61.5 50 Hertz: 50.5 - 51.5

Adjust the engine's speed

correct Hertz.

NOTE: Refer

to

the "NOTE" at the bottom

the exciter windings

by

use

of

the governor/fuel solenoid linkage adjustment, page

of

page 59.

B.

Check the capacitor.

BCD 6.0KW: 31.0 uF ±

CAUTION;

THESE THE

CENERATOR-S

WXNDING PLues OTHER

DO

PLues

WILL TOUCH WIRES.

5°

73,

NOT

TO

TOUCH

BURN

HOUSING

to

obtain the

ALLOW

HOUSING.

IF

OR

Westerbeke

Generators

58

Load

Connections

The generator's data plate gives the voltage, current and frequency rating decal is age connections is provided on the decal.

The generator is a single-phase, reconnectable 120 Volts AC two-wire

Hertz; the "SYSTEM SPECIFICATIONS" section and page 15

A circuit breaker should be installed between the generator and the

rated hig considerations.

affb<ed

or

NOTE: The frame ground wire must be moved when changing from 110 Volts, 50 Hertz Volts, 50 Hertz.

at

120%

N

to

the inside

110 Volts AC two-wire, 110/220 Volts AC three-wire,

for

the BCD 6.0KW.

of

the generator's AC output and be able

of

the louvered cover on the generator end. A diagram

of

N

this manual

L2

for

to

react quickly

N

or

220 Volts AC two-wire, at

generator ratings, page

AC load. This circuit breaker should be

of

or

120/240 Volts AC three-wire, at

to

overloads, subject

L2

the generator. An AC wiring

of

the various AC volt-

60

50

Hertz. Refer

11

for

the BCD 4.4KW,

to

Lt

r

/220

to

motor start-

to

1

~4

J:::l

3

5e2-

L1

110v

For making connections strand wire sized amperage that will be drawn through the conductor(s). (Refer ator's amperage and voltage ratings.)

50

Hz

NOTE: When changing Hertz produced governor/fuel solenoid linkage must be made. The lustrated terminal blocks must be selected for the voltage and Hertz at the capacitor must be changed connections the bridge rectifier in the Schematic" on page 54.

120v 60 Hz

to

the AC terminal block, use terminal ends

for

the number

to

the integral controller require a 50(#5)

of

conductors in the bundle, the rating

DC charging circuit. Refer

for

220v

by

the generator, an engine speed adjustment at the

50(#5)

~

6

L1

50Hz

AC output connections on the above il-

or

60(#6) Hertz use. Early models with 3 wire

or

4e::::::=-3

1 4

5 2

3-

6e

1

5.2-6

Lt N

240v

for

to

the generator's data plate

60(#6) Hertz connection change at

to

the "Generator's Internal Wiring

60Hz

#10

studs which will accept multi-

of

the conductor's insulation, and

to

be produced. A plug

220v

for

the gener-

N

50Hz

59

Westerbeke Generators

Shore

Power

Connections

If the installer connects shore power POWER/OFF/SHIPS

simultaneous connection

Damage

GEN., center position-off transfer switch shown below. Use

of

shore power

to

the generator can result

to

the vessel's AC circuit, this must be done

to

at the same time. This type of generator damage

to

installer's responsibility

~

r N

Gl

..

~

z

make sure all AC connections are correct.

G2

• 1

-'-

_______

j

t

I I

L-----HJJ

r-----\<3J

I

i

I

I I

I

:

I I

~

S1

\S2

.

ShOtePow",

NOTE: OIAGRAM

/,--,

.....

_-""

.,.--,

/ r.-. '

~

I-

0::-

-_/

--,

-:;.,

'-

--"

ri:

"'"

Ground

N

by

means

of

this switch prevents

generator output.

CAUTION

if

utility shore power and generator output are connected

is

not covered under the warranty; it is the

SHOWS

WIRE.

128-VOLT

S_Y_SI..,EM

USE

OIHER HOI LEGS.

DOTTED

CONNECTIONS

SYSTEM.

LINES

FOR

IWO-

IHREE-WIRE

IHE

,

~\

~-

--I

I

/

\

/

"

/

I

I I

I

Neutral N

~~l

Ll

Ships

LOAD

II'

SHIP-10-SHORE

(3

POL

PN

32898

(40

AMPS/POLE)

PN

32009

(88

AMPS/POLE)

PN

32818

(125

AMPS/POLE)

PH

32133

(288

AMPS/POLE)

El

SWITCH

the SHORE

( N

Generalor

Gl~

t

g

lE-

~

Shore

NOTE:

DIAGRAM WIRE, 120-VOLT

WITH

BOAT

'-

,

/

'"

4'"

o.!-

0-""

I

l

~r

4-

~

if?

Power

'/

'~

'"

J...

1

~

--,

-:;.,

"

r>---+---,;;N~9U,:,;lra","i_'-N

/

--'"

."G""'o="un""d_

(GRN)

SHOWS

CONNECTIONS

THREE-WIRE, 120-VOLT SYSTEM.

Z

0::

Q

.......

'----'-Ll

(WHT)

___

\

I

SYSTEM

--l

1r

L2

•

FROM

Ship'sLoad

Note

NO

24Q.Vott

equipment

FOR A TWO-

THE

Ship-lo-Shore Switch

Shore Power Switch Connection Diagrams

GENERATOR,

PH

3299B

(49

AMPS/POLE)

PH

32989

(89

AMPS/POLE)

PN

32B~a

(~2S

AMPS/POLE)

PH

32133

(299

AMPS/POLe)

(3

Pole)

Westerbeke Generators

60

GENERAL INFORMATION AND CARE

of

Use

The

is

Electric Motors

power required to start

an

electric motor

is

considerably more than

started. Some motors require much more current to start than others. Split-phase

OF

THE

GENERATOR

is

required to keep it running after it

more current to start, under similar circumstances, than other types. They are commonly ing loads, such

power tools. Because they require S to 7 times whenever possible, if the electric motor tion motors require from 2 to 4 times

motor varies with the load connected to

require more current than a motor to which no load

will

In

general, the current required to start

proximately

as

washing machines, or where loads are applied after the motor

as

much current to start

is

as

follows:

to be driven by a

as

much current to start

it.

An

electric motor connected to

11S-Voit

motors connected to medium starting loads will

small

is

connected.

generator. Capacitor and repulsion-induc-

as

to

is

started, such

as

to

run,

their

use

run.

The current required to start any

an

air compressor, for example,

(AC)

motors require

used

on easy-start-

should

as

be

avoided,

small

be

ap-

MOTOR

SIZE (HP)

1/6 1/4 1/3 1/2 3/4 1

* Note that than for larger made

in

the above table the maximum "Amps for Starting"

ones.

The reason for this

larger

sizes.

Because the heavy surge of current needed for starting motors

will not

ing motors, turn off

be damaged if it can bring the motor up to speed

all

other electrical loads

AMPS

FOR RUNNING (Amperes)

AMPS

FOR

STARTING

(Amperes)

3.2 6.4 to 22.4*

4.6 S.2

7.2

10.2 13

is

that the hardest starting types (split-phase)

in

a few seconds. If difficulty

and,

if possible, reduce the load on the electric motor.

9.2

to 32.2*

10.4

to 72.8*

14.4

to

20.4

to

26 toS2

is

more for some small motors

is

required for only

29.2

40.8

an

instant, the generator

is

experienced

are

not

in

start-

Required Operating Speed Although individual units may vary slightly, the normal voltage and frequency of typicaJ60-(SO-)Hertz engine-

driven generators described

in

this manual are shown on the chart on the next page.

Run

the generator at first with

full capacity as indicated

See

the rpm/Hertz/frequency chart on the next page.

on

no

load applied, then at half the generator's capacity, and finally loaded to its

the generator's data plate.

61

Westerbeke Generators

Load

Applied

4-Pole

Speed

(rpm) (Hertz)

Frequency

Generator Voltage

120V(110) 240V (220)

Plants Plants

None 1830

(1530)

Half

Full 1755 59

The output voltage should be checked periodically the appliances it supplies.

If an AC voltmeter

and amp-probe.

Preventive

Maintenance on the generator is minimal.

1.

Keep the generator clean,

2.

Make sure all connections are clean and tight and that cables carrying AC voltage are properly supported and protected against chafing.

Maintenance

or

ampmeter is not installed

(Generator)

1800

(1500) (50)

(1455)

dry

and well-ventilated.

62 122 240

(52)

60

(49)

to

ensure proper operation

to

monitor voltage and load, check it with a portable meter

(112)

120 240

(110) (220)

110 220

(100) (200)

(224)

of

the generating plant and

3.

The rear armature bearing is lubricated and sealed; therefore,

becomes rough

Generator

A complete and illustrated text on troubleshooting the BC series of generators is furnished in the Technical

Manual which is available through your local dealer.

Troubleshooting

or

noisy, replace it.

no

maintenance is required.

If

the bearing

Westerbeke Generators

62

ENGINE TROUBLESHOOTING

Problem

Preheat is depressed: no preheat.

Preheat is depressed: fuel pump does not operate.

probable Cause

1.

Connection

or

switch.

2.

Preheat solenoid.

3.

Glow plugs are

faulty.

1.

Faulty connections

or

bad pump.

Verification/Remedy

1.

Check

for

12 volts at the PREHEAT switch and at the S terminal on the preheat solenoid.

2.

No

activation with 12 volts

S terminal. Tap solenoid

at the with a mallet

to

determine if it is stuck internally. Solenoid should produce a click when activated and when deactivated.

3.

Twelve volts are present at

the glow plugs. Remove each

plug and check the resistance

by

of the plugs

applying

artificially.

1.

Check

fuel

for

12 volts at the

pump

connections. If 12 volts are present, the pump is possibly faulty.

Tap pump with a mallet.

Pump's plunger may be stuck. Remove the filter and check for contamination which will affect the pump.

12

volts

Preheat is depressed: no

fuel solenoid activation.

1.

Faulty connections

or

solenoid.

2.

Voltage problem.

63

1.

Check

for

12 volts at ( + )

positive terminal at the back of the fuel solenoid when the PREHEAT button is depressed. Twelve volts with no activation indicates a faulty solenoid.

2.

Less than

10

volts found at the

positive ( + ) terminal on the

solenoid will not properly activate the solenoid and will cause a failure. Check for low

batteries

small electrical wiring

or

voltage loss

or

corroded connections.

Westerbeke Generators

in

problem

START switch is depressed: engagement. Engine does not crank.

no

starter

probable Cause

1.

Connection

solenoid faulty.

2.

Faulty

to

START

starter

switch.

Verification/Remedy

1.

Check connection S at the

starter solenoid with the switch depressed.

2. Check switch with an ohmmeter.

for

12 volts

Engine cranks, but does not start.

3. Faulty solenoid.

4. Loose battery

connection.

5. Low batteries.

6. Sea water in

cylinders.

1.

Shut-off valve at

fuel tank.

2.

Faulty fueling system.

3. Air is in the fuel

system.

3. Twelve volts is present

at the S terminal

starter solenoid.

of

the

4. Check battery connections

at both the

+ and - ground.

5. Check battery charge state.

Low voltage at the solenoid's

S terminal with no activation.

6. Remove exhaust hose at exhaust

elbow and drain water.

1.

Return shut-off valve

its ON position. the fuel system.

2. Check for fuel to

engine.

3. Bleed the fuel system.

Locate the leak and correct it.

Now

to

bleed

Failure

Westerbeke Generators

to

stop.

4.

Fuel pump is not

operating.

5.

Fuel filters are clogged.

1.

Solenoid linkage

is disconnected.

64

4.

Check

5.

Clean/replace filters.

1.

Stop engine

pump

operation.

Check

ually shutting OFF fuel and air.

for

12-Volts at pump.

by

man-

problem

probable Cause

Verification/Remedy

Engine Stops.

1. Fuel starvation.

Fuel shut-off is turned OFF.

2.

Fuel pump is

inoperative.

3.

Water is in the

fuel.

4.

Exhaust system is

restricted.

1.

Check

to

see that the

shut-off valve at the

fuel tank is ON.

2.

Inspect the fuel pump

12 volt and

to

see if it is

for

pumping.

3.

Pump water out of the

bottom of the fuel tank(s) and change the fuel filters and

bleed the fuel system.

4.

Check exhaust system for

some type

of

blockage

such as carbon buildup at the exhaust for

a fault in the muffler.

Check

elbow. Check

for

a collapsed

exhaust hose.

Battery runs down.

Black exhaust smoke.

1.

Bad DC windings

is low.

2.

Bad battery

connections.

1.

Generator is

overloaded.

2.

Poor fuel quality

incorrect fuel.

3.

Faulty injector(s).

4.

Lack of air.

or

1.

Perform DC Voltage.

check.

2.

Connections are corroded

or

loose at the battery or/and

at the engine.

1.

Check generator data plate

for

rating and monitor the load

that is producing the black

exhaust smoke.

2.

Check fuel filters. Make sure

you are using

3.

Remove and test injectors.

4.

Check air intake for

#2

diesel fuel.

restrictions. Make sure adequate combustion air present.

is

65

Westerbeke Generators

MAINTENANCE AND ADJUSTMENTS

Introduction

This section contains a scheduled preventive maintenance program and several adjustment procedures the

owner/operator can perform without the benefit

of

sophisticated and expensive tools and instruments.

Preventive

Perform the preventive maintenance Adherence that it will perform formed

Daily

1.

2.

3.

4.

5.

6.

Maintenance

in

accordance with the schedules listed in the following paragraphs.

to

these schedules will ensure the equipment is maintained in the best possible condition and

to

expectations. Those items marked

by

an authorized dealer

(before

Check the oil sump level. Maintain the oil level at

Check the coolant level in the plastic recovery tank. Maintain this level at

ADD.

Visually inspect the unit; check for loose belts, chafed

damaged hoses, loose clamps, and other equipment not properly secured.

Check the fuel supply. Fill tank(s) with a good grade of

Check the primary filter/water separator. Drain and service as required.

is optional, but strongly recommended.)

Check the generator's gauges tery charging voltage once the engine is operating.

each

use)

or

distributor.

or

lights

for

proper oil pressure, operating temperature, and starting bat-

by

an asterisk

or

near upper level mark on dipstick.

or

broken wires, loose brackets and fittings,

No.2

diesel fuel, if required.

(*)

are recommended

or

above the level marked

(A

primaryfilter/water separator

to

be per-

7.

Check the generator's output meters (when installed) for proper AC voltage and output frequency.

Monthly

Check the condition as required. Keep the area inside the heat exchanger clean of zinc anode debris.

Servicing

1.

2.

*3. Torque the cylinder head bolts.

Westerbeke Generators

After

Change the engine's lubrication oil and oil filter.

Replace the fuel filter element in the electric fuel lift pump and in the engine-mounted secondary fuel fil-

ter. Change the fuel filter element and clean the optional filter/water sedimentor, if a separator has been

installed, and if the model type permits cleaning.

of

the zinc anode in the heat exchanger's sea water circuit. Clean

Initial

50

Hours

of

Operation

66

or

replace the anode,

*4. Adjust valve clearances.

5.

Adjust the water

6.

Lubricate the ball joint linkage between the run solenoid and the throttle arm. Make sure the fuel solenoid

operates properly when 10 - 12 volts are present at the solenoid during preheat.

7.

Adjust the engine's no-load speed, if required (hertz). Please note that this adjustment is

able adjustment during

pump

drive belt tension, if required.

or

after the generator's break-in.

not

a warrant-

Servicing

1.

2.

3. Lubricate the ball joint linkage between the run solenoid and the throttle arm.

ServiCing

1.

2.

Servicing

*1. Torque the cylinder head bolts.

*2. Adjust the valve clearances.

3.

After

Every

100

Hours

Change the engine's lubrication oil and oil filter.

Adjust the water pump drive belt tension, if required.

After

Every

250

Hours

Replace the fuel filter elements in the electric fuel lift pump and in the engine-mounted secondary fuel

filter.

Lubricate the ball joint linkage between the run solenoid and the throttle arm.

After

Every

500

Drain, flush, and refill the fresh water cooling system. The illustration on pages 6 changer and the zinc anode location. The drain

Hours

of

Operation

of

Operation

of

Operation

to

9 show the heat ex-

plug for the fresh water system is next

to

the zinc anode.

*4. Check the condition

5.

Check the resistance

NOTE: Items

6.

Check the condition impeller cover, the cam plate, and the internal housing is worn affect the service life the lives ly

7.

CHECK

or

cracked. Replace worn components as needed. Operating condition (such as sea water)

of

the pump's various components which come in contact with sea water cannot be accurate-

predicted.

TIlE

INTERNAL INSPECT TIlE CORROSION

BUILD

of

highlighted

of

EXHAUST

UP.

the starter motor drive pinion; lubricate the pinion.

the

glow

plugs. (.4

by

an asterisk

the sea water pump. Examine the pump

the sea water pump's components. Therefore, the life

CONDITION OF TIlE

AND

WATER

REPLACE

TIlE

to

.6 ohms)

(*)

should be performed

for

WATER

PASSAGES.

ELBOW

REMOVE

IF

CORROSION

by

a competent mechanic.

for

leaks and internal wear. Check the

wear. Check the impeller and replace it if it

INJECTED

EXHAUST

ANY

IS

CARBON

EXTENSIVE.

67 Westerbeke Generators

of

the sea water pump

ELBOW.

AND/OR

or

Servicing

After

Every 800

Hours

of

Operation

*1. Remove and check

fuel injectors.

Injector spray pressure:

2275 psi (160 kgJcm

+ 140 psi

2

+

10

kg/cm

2

)

Eliminate undesirable injection conditions including

after dripping.

*2.

Check

Remove each

the

engine's

compression

glow plug and check each cylinder's

pressure.

compression pressure. The engine's cranking speed is at

(32

280 rpm.

Standard

455 psi

kgJcm

Minimum

369.7 psi

2

)

(26

kgJcm

2

)

(Maximum difference between cylinders: 35.5 psi

*3. Check the DC Charging Circuit for proper operation.

*4. Check the tightness of

bolts, nuts, and clamps.

(2.5

kgJcm

2

)

Servicing

1.

After

Every 1000

Hours

of

Operation

Remove, clean, and pressure test the primary heat exchanger.

be able

to

clean and test the heat exchanger.)

(A

local automotive radiator shop should

NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours.

*2. Check the injection pump's timing.

Westerbeke Generators

68

Torquing

Cylinder

Head Bolts: BCD 4.4KW

Tighten the cylinder head bolts according the sequence shown in the illustration shown to

the right. Make sure the engine

this is done. Before applying the specified

to

torque

and then apply the torque. Follow this procedure according shown in the illustration

Bolts

50.6

Torquing

the bolt, loosen it 1/4

to

# 1 ,

2,

3,

4,

5 and 6 are tightened between

to

57.8 Ib-ft

(7

Cylinder

to

the numbered sequence

to

8 kg-m).

Head BoRs: BCD 6.0KW

is

to

1/2 of a turn

the right.

cold when

to

Front

¢::o

of

Engine

Tighten the cylinder head bolts according

the sequence shown to

the right. Make sure the engine this is done. Before applying the specified torque and then apply the torque. Follow this procedure according

shown

Bolts

tween 79.5

Bolts to

to

the bolt, loosen it 1/4

in

the illustration

# 4,5,6,7,8,9,10 and

to

86.8Ib-ft

# 1,2 and 3 are tightened between 50.6

57.8 Ib-ft

(7

to

in

the illustration shown

is

cold when

to

1/2 of a turn

to

the numbered sequence

to

the right.

11

are tightened be-

(11

to

12

kg-m).

8 kg-m).

to

FRONT

¢:o

OF

ENGINE

02

0 0 0

7

4

0 0

01

5

6

11

0

03

8

69

Westerbeke Generators

Valve

Clearance

Adjustment:

BCD

4.4KW

CAUTION

Adjust order

Tighten torque

1.

Pull off

take off

2. Adjust for

each cylinder when

stroke (see below). Remember order crankshaft is engine's crankshaft is rotated.

A.

Align the timing cylinder at its valve clearances justing screws. Remember the piston, depending they

the

valve clearance when

of

the

engine.

the

cylinder head bolts

before adjusting the valves. (See page 69.)

the

air breather pipe

the

rocker

the

valve clearances

is 1-2.

glow

No.1

top

both

cover

bolts and

they

You

may

find that turning the engine's

more

easily accomplished when

plugs

(the

Timing Mark while dead center on its compression stroke.

should

are

mark

on the gear case with

one

for

this cylinder. If the valves have

on

be

closed.

the

engine is cold. Valves are adjusted

to

the

specified

from

the rocker cover, and

the

rocker cover.

at

TDC (Top Dead Center)

are

on

their compression

the

engine's firing

the

removed

the three injection timing marks). In this position,

to

align the timing marks properly; if not,

the

position

before

of

the

timing

no

cam

lobe. Be sure

by

cylinder in

mark

on the crankshaft pulley indicated

Check

specified clearance, adjust

the

to

check

both

valve

the

valves

may

the

firing

for

the

NO.1 cylinder is

intake and exhaust

by

means

be

for

of

the

ad-

pushed

this cylinder -

up

by

B.

the

No.2

cylinder: Turn the crankshaft clockwise 3600 to

pulley approximately

valves

Adjust each valve's clearance

0.010 inch (0.25 mm) feeler gauge between rocker arm and

for

cylinder

the

at

the

No.2.

valve stem.

position shown in

Be sure

by

inserting a

to

check

the valves

the

illustration above.

for

this cylinder -

ADJUST (0.25

position the TDC

Now

adjust

they

both

VALVES

MMJ

TO

0.010

mark

on

the

crankshaft

the

intake and exhaust

should be closed.

INCHES

Westerbeke

Generators

70

Valve Clearance Adjustment: BCD 6.0KW

CAUTION

Adjust the valve clearance when the engine is cold. Valves are adjusted cylinder

in

the firing order

of

by

the en-

..

TDC

MRRK ( Cylinder

No.ll

\

gine.

Tighten the

cylinder head bolts

to

the

specified torque before adjusting the

valves. (See page 69.)

TDC

1.

Pull off the air breather pipe from the rock-

MARK

(C

Y 1 i n d e r

er cover, and take off the rocker cover No _ 3 ) bolts and the rocker cover.

TDC

2.

Adjust the valve clearances at TOC (Top Oead Center)

on

are

for

each cylinder when they

their

compression stroke (see

MRRK

(Cylinder

No.2)

below). Remember the engine's firing order is 1-3-2. You may find that turning the engine's crankshaft more easily accomplished when the engine's glow plugs are removed before the crankshaft is rotated.

A.

Align the timing mark on the gear case with the timing mark on the crankshaft pulley indicated for cylinder

No.1

(the one next

to

the three injection timing marks). In this position, the

No.1

cylinder is at its top Timing Markwhile dead center on its compression stroke. Check both intake and exhaust valve clearances

for

this cylinder. If the valves have

Remember

to

align the timing marks properly; if not, the valve may be pushed

ing on the position

of

the cam lobe. Be sure

no

specified clearance, adjust

to

check the valves for this cylinder -they both should be

by

means

up

of

the adjusting screws.

by

the piston, depend-

closed.

is

B.

Next the

the front crankshaft

No.3

cylinder: Turn the crankshaft clockwise 2400 so the TOC mark

pulley, is approximately at the position shown in the illustration above. Now adjust

the intake and exhaust valves for cylinder

No.3. cylinder - they both

C.

crankshaft clockwise another 2400 to

Be sure

Last is

to

check the valves for this

should be closed.

the

No. 2 cylinder:

Turn

the

position the TOC mark on the crankshaft pulley approximately at the position shown the illustration shown above. the intake and exhaust valves No.2.

Be sure

to

check the valves for this

Now for

in

adjust

cylinder

cylinder - they both should be closed.

Adjust each valve's clearance

by

inserting a

0.010 inch (0.25 mm) feeler gauge between the rocker arm and the valve stem.

RDJUST

(0.25

VRLVES

MMJ

TO

for

the NO.3 cylinder, on

0.010

INCHES

71

Westerbeke Generators

Injection

If

your

difficult

Pump

Timing

Adjustment

engine's fuel injection timing is not properly adjusted, the engine will not operate properly and will be

to

start. Have the injection pump delivery rate checked

just the injection timing as

follows:

(Spill

Timing)

by

a well-established fuel injection shop. Ad-

NOTE: The fuel shut-off lever must be in the RUN position while making the adjustment

or

no

fuel will flow from the fuel injection pump.

Refer

to

the illustration below when servicing the fuel injection pump. First remove the high-pressure fuel line from between the No. 1 injector and the No. 1 fuel delivery valve holder. Remove the No. 1 fuel delivery valve holder and remove the delivery valve spring beneath the holder. Reinstall only the delivery valve holder and reattach the high pressure fuel to

the fuel injector is pointing away from the engine. Fuel will flow from this line during the timing check.

line

to

the delivery holder. Attach it so that the end that would connect

DELIVERY

VALVE

HOLDER

Rotate the engine's crankshaft in its

normal direction

tion piston No. 1 at the beginning

of

rotation

to

posi-

of

SPRING

its compression stroke

DELIVERY

Move the throttle lever

to

its full open

position and operate the electric

VALVE

lift pump. Slowly rotate the crankshaft clockwise (as viewed from the front), catching the fuel from the

No.1

fuel

line, until the instant the fuel com-

pletely stops flowing (no drips). At

this instant, the 190 BTDC timing

mark

on

the

crankshaft

pulley

FUEL

CONTROL

RACK

should be directly aligned with the timing indicator on the front of the gear case (refer on pages

70 and 71).

to

the illustrations

PLUNGER

SPRING

TAPPET

If the specified injection timing (190 BTDC) cannot be attained, adjust the timing ing the thickness

of

shim material under the injection pump's mounting flange point. Changing the shim thickness one degree. To advance the timing, decrease the shim thickness, as required. To retard the timing, increase the shim thickness, as required. Refer

Westerbeke Generators

by

0.004 inch

to

your generator's Parts List

(0.01

mm) changes the injection timing

72

by

to

change the injection timing

for

shim part numbers.

increasing

by

approximately

or

decreas-

Adjustments

(Generator)

Once the diesel generator set has been placed in operation, there may be adjustments required speed (Hertz) during the engine's break-in period (first 50 hours) justment may also be required in conjunction with the engine's speed adjustment.

CAUTION

When starting the generator, all AC loads, especially large motors, should be switched OFF until the engine has come tion will prevent damage caused a cold engine from stalling.

Generator

Frequency is a direct result

When the generator is run at 1800 rpm, the AC voltage output frequency is 60 Hertz. When the generator is

run at

Therefore, frequency change, perform the following:

1.

Frequency

1500 rpm, the AC voltage output frequency is

to

change the generator's frequency, the engine's speed must be changed. To accomplish the

Connect the AC output leads

diagram specified nections are illustrated in the

Adjustment

for

up

to

speed and, in cold climates, starts

by

unanticipated operation

(Hertz)

of

engine/generator speed, as indicated

50

Hertz.

to

the AC terminal block in accordance with the AC Voltage Connections

your

generator set, and change the Hertz connection

"BC GENERATOR" section

or

after this period. A no-load voltage ad-

to

warm up. This precau-

of

AC machinery and will prevent

by

the following:

to

the capacitor. These con-

of

this manual, page 54.

for

engine

2.

Adjust the engine's speed

or

shortening the Throttle Adjustment Linkage. Make sure the solenoid's plunger is completely bot-

tomed in the solenoid. (See figure below.)

to

obtain the frequency corresponding

to

the voltage selected

by

60Hz

~SOHz

extending

73

Westerbeke Generators

CAUTION

Failure

To avoid failure the solenoid's operation at the initial start-up. Periodically lubricated linkage joints between the solenoid plunger and the throttle arm will eliminate binding.

NOTE: The solenoid plunger must move smoothly and rapidly into the solenoid when the solenoid is electrically energized, drawing the engine's throttle arm into the Set Speed/Run position.

To arrive at the appropriate frequency, either monitor the speed or

monitor the frequency with a frequency meter, the latter method being the more precise

Make sure

and

START.

of

the solenoid plunger

ofthe

solenoid, make sure the solenoid plunger bottoms in the solenoid. Check

10 - 12 volts DC is present at the solenoid's positive

Loss

of

voltage will affect the solenoid's operation and cause a solenoid failure.

to

bottom in the solenoid will result in a failed solenoid.

of

the engine/generator with a tachometer,

(+)

harness connection during PREHEAT

of

the two.

Westerbeke Generators

74

General

LAY-UP AND RECOMMISSIONING

Many owners rely on their boatyards

or

for

during the off-season selves.

The procedures which follow will allow you a check list if others

These procedures should afford your engine protection during a lay-up and also help familiarize you with the maintenance needs

If you have any questions regarding lay-up procedures, call your local servicing dealer; he will be more than

willing

to

provide assistance.

long periods

do

the procedures.

of

your engine.

to

prepare their· craft, including engines and generators, for lay-up

of

inactivity. Others prefer

to

perform your own lay-up and recommissioning,

to

accomplish lay-up preparation them-

or

to

use as

Fresh Water Cooling System

A 50-50 solution of antifreeze and fresh water is recommended

all times. This solution may require a higher concentration of antifreeze, depending on the area's winter climate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more concentrated mixture. Operate the engine centration throughout the cooling system.

Check the solution

to

make sure the antifreeze protection is adequate.

to

ensure a complete circulation and mixture of the antifreeze con-

Now

recheck the antifreeze solution's strength.

for

use in the fresh water

COOling

system at

Lubrication System

With the engine warm, drain all the lubricating oil from the oil sump. Remove and replace the oil filter. (Place some paper towels and a plastic bag around the filter

When installing the new oil filter, be sure

of

base SPECIFICATIONS" Use an oil with an API speCification make sure there are

the filter. Fill the sump with the correct amount

section

no

DO NOT ing oil and combustion deposits combine the life of your engine's internal parts.

leave the engine's old lubricating oil in the sump over the lay-up period. Lubricat-

of

this manual, page

leaks.

of

to

apply a small amount

CC

or

CD. Run the generator and check for proper oil pressure and

to

catch the oil during its removal.)

of

oil on the rubber sealing gasket at the

of

oil

for

your engine. (Refer

11

for

the BCD 4.4KW, and page

CAUTION

to

produce harmful chemicals which can reduce

15

for

the BCD 6.0KW.)

to

the"SYSTEM

75 Westerbeke Generators

Fuel System

Top off your fuel tanks with and condition the fuel. Care should be taken that the additives used are compatible with the primary filter/water separator used in the system. Change the element fuel system contains one, and clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. allow it have been created in the fuel system during this servicing, correcting them as needed.

Sea

Close the through-hull sea cock. Remove the sea water intake hose from the sea cock. Place the end of this hose into a in the primary heat exchanger on the engine and clean debris from inside the heat exchanger where the zinc anode is located.

stalled

Start the engine and allow the sea water pump is empty, stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for

winter freeze protection in your area.

Start the engine and allow all of this mixture is empty, stop the engine. This antifreeze mixture should protect the sea water circuit from freezing during the winter lay-up, as well as providing corrosion protection.

to

run for 5 - 10 minutes

Water Circuit

5-gallon bucket

in

the inside

of

No.2

the hull.

diesel fuel. Fuel additives should be added at this time

in

your primary fuel filter/water separator, if the

to

make sure no air is left in the fuel system. Check

of

clean fresh water. Before starting the engine, check the zinc anode found

or

replace it as required, and also clean any zinc

Clean the sea strainer, if one is in-

to

draw fresh water through the system. When the bucket

to

be drawn through the sea water system. Once the bucket

to

control algae

Start the engine and

for

any leaks that may

Remove the impeller from your sea water pump (some antifreeze mixture will accompany it, so catch it bucket). Examine the impeller. Acquire a replacement, if needed, and a cover gasket. Do not replace the impeller (into the pump) until recommissioning, but replace the cover and gasket.

in

a

Intake Manifold and Through-Hull Exhaust

Place a clean cloth, lightly soaked ing. Do not shove the cloth out

start the engine, you may need the assistance of a servicing dealer.) Make a note

to

start-up. The through-hull exhaust part can be blocked in the same manner.

in

lubricating oil,

of

sight. (If it is not visible at recommissioning, and an attempt is made to

in

the opening of the intake manifold

to

block the open-

remove the cloth prior

Generator End

Remove the louvered cover on the end of the generator. Check all wire connections on the AC terminal block and those running these connections appear corroded, they should be removed, cleaned, and reconnected. Make sure all AC leads are properly cleaned and reconnected. Make sure all AC leads are properly supported and not chafing as they exit the generator housing.

to

the capacitor(s) and the bridge rectifier making sure they are secure. Should

Westerbeke Generators

76

Starter

Motor

Lubrication and cleaning removal. Make sure the battery connections are shut off before attempting

of

the starter drive pinion is advisable, if access

to

in properly replacing any electrical connections removed from the starter.

Cylinder

It is not necessary

cylinders or

more),

pistons rings from sticking

Lubrication

to

remove the fuel injectors from the cylinder head

for

the few months

we

recommended that this procedure be performed. The light oil in the cylinders will prevent the

of

normal lay-up. However, if you anticipate a longer lay-up period (12 months

to

the cylinder walls. Make sure you have replacements

to

squirt light lubricating oil into the

line sealing washers.

Spares

Lay-up time provides a good opportunity as drive belts or

replace those items used during the lay-up, such as filters and zinc anodes. Refer

section

or

coolant hoses need replacement. Check your basic spares kit and order items not on hand,

of

this manual, page

81.

to

inspect your Westerbeke engine

Batteries

the starter permits its easy

remove the starter. Take care

for

the injector and return

to

see if external items such

to

the "SPARE

PARTS"

If batteries are

that way,

charged,

to

be left on board during the lay-up period, make sure they are fully charged, and will remain

to

prevent them from freezing.

or

that they will be subjected

If

there exists any

to

severe environmental conditions, remove the batteries and store

doubt

that the batteries will not remain fully

them in a warmer, more compatible environment.

Recommissioning

The recommissioning

dures as those presented in the

for

starting and normal starts. However, some

of

your Westerbeke engine after a seasonal lay-up generally follows the same proce-

"PREPARATIONS

FOR

STARTING" section, page 32, regarding preparation

of

the lay-up procedures will need

to

be counteracted before

starting the engine.

1.

Remove the oil-soaked cloths from the intake manifold and from the through-hull exhaust port.

2.

Remove the sea water pump cover and gasket and discard the old gasket. Install the sea water pump impeller removed during lay-up (or a replacement, if required).

Install the sea water pump cover with a

new cover gasket.

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

batteries emit hydrogen, a highly-explosive gas, which can be ignited

a lighted cigarette, cigar,

serviced. Shut off all electrical equipment in the vicinity

or

pipe.

Do

not smoke

or

allow an open flame near the battery being

to

prevent electrical arcing during

by

electrical arcing

or

servicing.

77

Westerbeke Generators

3.

Reinstall

sure

the batteries that

the terminals

are

clean

were

and

fully-charged.

4.

Check the condition of the zinc anode

Note that it

tem.

When

is

not necessary to flush the antifreeze/fresh water solution from the

the engine

is

put into operation, the

verse affects.

5.

Start the engine

manual,

page

in

accordance with procedures

32.

removed

during the

that the connections

in

the

sea

water circuit

system

in

the

lay-up,

are

and

reconnect the battery

tight. Check to

and

clean or replace the anode

will self-flush

in

"PREPARATIONS

make

cables,

sure

that the batteries

sea

water coolant

making

as

needed.

are

sys-

a short period of time with no ad-

FOR

STARTING"

section of this

Westerbeke Generators

78

TABLE

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.

Grade4T

6mm bolt head/nut

8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 1.5 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

OF

STANDARD HARDWARE TIGHTENING TORQUES

Pitch

1

1.25

1.5

1.25

1.5

1.75

1.5

2

1.5 2

(ISO)

Ib-ft

5.1

2.9 -

7.2 - 11.6

13.7 - 22.4

13.0-21.7

25.3 - 39.8

21.7 - 36.2

50.6

32.5 -

36.2 - 57.9

34.0 - 55.7

54.2 - 79.6

51.4 - 76.7

kg-m

0.4 - 0.7

1.0 - 1.6

3.1

1.9 -

1.8 - 3.0

3.5 - 5.5

3.0 - 5.0

4.5 -

7.0

5.0 -

8.0

4.7 - 7.7

7.5-11.0

7.1

-10.6

Grade

Grade ?T,

Grade 5 capscrew

6T 6mm bolt head/nut 8mm bolt head/nut

10mm

bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 1.75

8I

and

8.8

6mm bolt head/nut

8mm bolt head/nut 10mm 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

bolt head/nut

1/4 UNC 1/4 UNF

UNC

5/16 5/16 UNF

UNC

3/8 3/8 UNF

UNC

7/16 7/16 UNF

UNC

1/2 1/2 UNF

1.25

1.5

1.25

1.5

1.25

1.5

1.25

1.5

1.75

1.5

2

1.5 2

(ISO)

4.3 - 6.5

10.8 - 15.9

21.7-

32.5

30.4

19.5 -

36.2 - 57.9

50.6

36.2 -

34.7 - 49.2

5.8 - 8.7

14.5-

21.7

28.9 - 39.8

26.8 - 37.6

54.2 - 75.9

50.6 -

65.1

43.4 - 61.5

57.9 - 86.8

72.3

-108.5

68.7

-101.3

108.5 - 166.4

101.3 -159.1

9 -

11

- 13

18 -

20

21

-

23

28 -

33 3.7 - 4.6

30 -

35

44 -

49 50 -55 68 -

73 73

-

80

0.6 - 0.9

1.5 - 2.2

3.0 - 4.5

2.7 - 4.2

5.0 - 8.0

5.0

- 7.0

4.8 - 6.8

0.8 - 1.2

2.0 - 3.0

4.0 - 5.5

3.7 - 5.2

-10.5

7.5

7.0 - 9.0

6.0 -

8.5

8.0 -12.0

10.0 -15.0

9.5 - 14.0

15.0 - 23.0

14.0 - 22.0

1.2 - 1.5

1.5 - 1.8

2.5 - 2.8

2.9 - 3.2

4.1

- 4.8

6.1

- 6.8

6.9 - 7.6

9.4

-10.1

10.1

-11.1

79

Westerbeke Generators

TORQUE

SPECIFICATIONS

Cylinder head bolt

(M14)

(M17)

(See

the"

Torquing

Crankshaft pulley nut BCD4.4KW BCD6.0KW

Oil

pan drain plug

(All Models)

Oil filter

(All Models)

Delivery valve holder (injection pump) 28.9 - 36.2

(All Models)

Nozzle mounting bolt

(All Models)

Nozzle holder and retaining nut 43.4

(All Models)

Cylinder

Head BoRs" section

(or tighten firmly

50.7 - 57.9

79.6-86.8

of

108.5

-144.6

-180.8

108.5

-43.4

36.2

8.0

-9.4

10.8

-14.5

-57.9

this manual on page 69.)

by

hand)

7.0 - 8.0

-12.0

11.0

15.0 - 20.0

20.0 - 25.0

5.0

-6.0

1.1

- 1.3

4.0

-5.0

1.5 - 2.0

6.0 - 8.0

Glow plug (All Models)

* NOTE: M8 indicates Metric, 8

mm

thread diameter

10.8

-14.5

1.5 - 2.0

Westerbeke

Generators

80

SPARE PARTS

Since a possibility exists in which the engine may need your home port, certain spare parts should be kept on board

refer

to

your engine's Parts List

for

part numbers when ordering spare parts. Listed below are those spare

to

be serviced at sea to

help minimize delays in your voyage. Please

or

while in a port other than

parts that should be carried on board at all times.

1.

An Impeller Kit

2.

A Fuel System hardware Kit

3.

An Electric Fuel Lift Pump Filter and a Secondary Fuel Filter.

4.

An Alternator/Sea Water Pump Belt

5.

Hose Clamps

6. A Spare Oil Filter with a Spare Quart

of

Diesel Service Engine Oil along with a Gallon of Premixed An-

tifreeze.

7.

A few Zinc Anodes and Heat Exchanger End Plate Gaskets

8.

An Oil Pressure Switch

Other

parts, whose life expectancy cannot be accurately predetermined, should be carried on board (in ad-

to

dition

those listed above) especially if the vessel is

to

be taken on long ocean voyages. These parts are

listed below.

1.

Fuel Injectors

2.

Glow Plugs

3.

Cooling System Hoses

4.

A Starter

5.

A 20 Amp DC Circuit Breaker

6.

An Electric Fuel Lift Pump

7.

A Sea Water Pump

8.

Battery Terminal Connectors

9.

A Fuel Run Solenoid

The spare parts listed directly above are those voyages. You may wish

ocean voyages as of

the voyage. From the list provided directly above and from these inquiries, you can determine what spare

to

ask other boat owners

to

what spare parts they carried on board and what parts were needed at specific times

we

recommend be carried on board during long ocean

who

have similar crafts and who have completed long

parts may be needed. In addition, if you are planning a long ocean voyage, consult your local Westerbeke

dealer

for

a listing of the Westerbeke dealers located on your route.

81

Westerbeke Generators

INDEX

A

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

AC GENERATOR SYSTEM SPECIFICATIONS, BCD 6.0 KW .............................................................. 16-17

AC Output, Generator .................................................................................................................................. 27

Adjustment, No-Load Adjustment, No-Load

Adjustments, Generator ............................................................................................................................... 73

ADJUSTMENTS AND MAINTENANCE ................................................................................................. 66-74

Automatic Shutdown ................................................................................................................................... 27

B

Back-Pressure, Exhaust .............................................................................................................................. 22

Batteries ....................................................................................................................................................... 28

Batteries, Lay-Up and Recommissioning .................................................................................................... 77

Battery Charging Circuit, Testing the .................................................................................................... 40-41

Battery Specification .................................................................................................................................... 39

BC GENERATOR ................................................................................................................................... 54-60

Belt Tension, Water Pump Drive ................................................................................................................. 49

Break-In Procedures

Voltage, BCD 4.4 KW ......................................................................................... 55-56

Voltage, BCD 6.0 KW ......................................................................................... 57-58

for

Engine .................................................................................................................. 34

c

CARE OF THE GENERATOR AND GENERAL INFORMATION ........................................................... 61-62

CHECKS, INSTALLATION ..................................................................................................................... 18-28

Circuit, Fresh Water ............................................................................................................................... 46-48

Circuit, Circuit, Clearance Adjustment,

Clearance Adjustment, Valve, BCD 6.0 KW ................................................................................................

Cold Conditions, Starting Under ................................................................................................................. 35

Control Circuit, Engine 12 Connecting Pressure Sensing Devices

Connections, Load ....................................................................................................................................... 59

Connections, Shore Power .........................................................................................................................

Cooling System ............................................................................................................................................ 26

COOLING SYSTEM, CARE OF ............................................................................................................. 46-50

Cooling

COOLING SYSTEM SPECIFICATIONS, BCD 4.4 KW ................................................................................

COOLING SYSTEM SPECIFICATIONS, BCD 6.0 KW ................................................................................ 15

Cylinder Head Bolts, Torquing, Cylinder Head Bolts, Torquing,

Cylinder Lubrication ..................................................................................................................................... 77

Sea Water ........................................................................................................................................ 49

Sea Water, Lay-Up and Recommissioning .................................................................................... 76

Valve, BCD 4.4 KW ................................................................................................ 70

71

Volt DC .............................................................................................................. 39

to

Oil Galleries ............................................................................. 25

60

System, Fresh Water, Lay-up and Recommissioning ..................................................................

BCD 4.4 KW .............................................................................................. 69

BCD 6.0 KW ..................................................................................... , ........ 69

75

11

Westerbeke Generators

82

CAUTIONS

AC

LOADS WHEN STARTING THE GENERATOR .......................................................................... 73

DAMAGE TO BATTERY CHARGING CIRCUIT ............................................................................... 39

ENGINE NOT SHIPPED WITH OIL .................................................................................................. 18

ENGINE

OIL

LEFT IN SUMP ........................................................................................................... 75

FAILURE OF SOLENOID PLUNGER ................................................................................................ 74

LIFTING SLINGS ............................................................................................................................. 19

OVERCHARGING THE ALTERNATOR ........................................................................................... 27

PROLONGED CRANKING INTERVALS ......................................................................... 33 & 37 & 23

SCOOP-TYPE FITTINGS ................................................................................................................. 85

TORQUE

UMIT

............................................................................................................................... 24

UTILITY SHORE POWER AND GENERATOR OUTPUT .................................................................. 60

VALVE CLEARANCE

WHEN THE ENGINE IS COLD .............................................................. 70 &

71

WATER PUMP DRIVE BELT TENSION ........................................................................................... 49

D

DC Electrical Connections .......................................................................................................................... 27

DC ELECTRICAL SYSTEM .................................................................................................................... 39-45

DC Engine Control Circuit, 12-Volt ............................................................................................................. 39

DESCRIPTION OF INSTRUMENT PANEL ................................................................................................. 29

DESCRIPTION OF STARTING SYSTEM ....................................................................................................

Diesel Engine-Driven Generator, Understanding the ................................................................................. 5

Diesel Fuel ................................................................................................................................................... 36

DISCLAIMER, PRODUCT SOFTWARE ......................................................................................................... 1

Drive Belt Tension, Water Pump ................................................................................................................. 49

31

E

Elbow Installation, Exhaust ......................................................................................................................... 24

Electric Motors, Use

Electrical Connections, DC ......................................................................................................................... 27

Electrical

ELECTRICAL SYSTEM, DC ................................................................................................................... 39-45

ELECTRICAL SYSTEM SPECIFICATIONS, BCD 4.4 ELECTRICAL SYSTEM SPECIFICATIONS, BCD 6.0 Engine

Engine-Driven Generator, Understanding the Diesel .................................................................................. 5

Engine

Engine Oil Change (to include filter) ..................................................................................................... 52-53

Engine

ENGINE TROUBLESHOOTING ............................................................................................................. 63-65

Engine 12-Volt

Equipment Inspection ................................................................................................................................. 18

Exhaust Back-Pressure ............................................................................................................................... 22

Exhaust Exhaust

Exhaust System Failures ............................................................................................................................. 23

Exhaust, Through-Hull ................................................................................................................................

System .................................................................................................................................... 26-28

Break-In Procedures ....................................................................................................................... 34

Oil ....................................................................................................................................................

Oil Viscosity (SAE Number) ...........................................................................................................

Elbow

System ...........................................................................................................................................

of

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

'rWJ

.......................................................................... 12

'rWJ

.......................................................................... 16

DC Control Circuit .............................................................................................................. 39

Installation .......................................................................................................................... 24

61

51

21

76

83

Westerbeke Generators

F

Failures, Exhaust System ............................................................................................................................ 23

Filter Elements, Fuel, Replacing the ............................................................................................................ 37

Filters, Fuel ................................................................................................................................................... 36

FOREWORD ................................................................................................................................................... 2

Frequency Adjustment Generator (Hertz) ............................................................................................ 73-74

Frequency, Generator ................................................................................................................................. 54

Fresh Water Circuit ................................................................................................................................ 46-48

Fresh Water Cooling System, Lay-Up and Recommissioning ................................................................... 75

Fuel, Diesel ................................................................................................................................................... 36

Fuel Filter Elements, Replacing the ............................................................................................................. 37

Fuel Filters .................................................................................................................................................... 36

Injection Pump ..................................................................................................................................... 38

Fuel FUEL

SYSTEM, CARE OF ..................................................................................................................... 36-38

Fuel System, Lay-up and Recommissioning .............................................................................................. 76

Fuel System, FUEL

SYSTEM SPECIFICATIONS, BCD 4.4 KW ........................................................................................

FUEL SYSTEM SPECIFICATIONS, BCD 6.0 KW ........................................................................................ 15

Fuel

System Installation ............................................................................................................................... 25

Priming the ............................................................................................................................. 37

11

G

GENERAL INFORMATION AND CARE OF THE GENERATOR ........................................................... 61-62

GENERAL GENERAL Generator

Generator Adjustments ................................................................................................................................ 73

GENERATOR,

Generator End .............................................................................................................................................. 76

Generator Frequency .................................................................................................................................. 54

Generator Frequency Adjustment (Hertz) ............................................................................................ 73-74

GENERATOR, GENERAL

Generator Mounting-Location ..................................................................................................................... 20

Generator,

Generator Remote Operation ...................................................................................................................... 30

Generator Troubleshooting ......................................................................................................................... 62

SPECIFICATIONS, BCD 4.4 KW ............................................................................................... 10

SPECIFICATIONS, BCD 6.0 KW ............................................................................................... 14

AC output ................................................................................................................................... 27

BC

.................................................................................................................................. 54-60

INFORMATION AND CARE OF ................................................................. 61-62

Preventive Maintenance ............................................................................................................ 62

H

Hose, Oil Drain ............................................................................................................................................. 25

Injection Pump, Fuel .................................................................................................................................... 38

Injection Inspection

INSTALLATION CHECKS ...................................................................................................................... 18-28

Installation

Pump

Timing Adjustment (Spill Timing) ......................................................................................

of

Equipment ............................................................................................................................. 18

of

Exhaust

Elbow

...................................................................................................................... 24

72

Westerbeke

Generators

84

Installation of INSTRUMENT Intake Manifold Intake

System,

Introduction ................................................................................................................................................... 5

L

Fuel

System

PANEL,

and

Sea

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

DESCRIPTION

Through-Hull Exhaust ................................................................................................

Water ...........................................................................................................................

OF

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

25 29 76 26

LAY-UP Lifting Load

Lubrication, Cylinder ...................................................................................................................................

LUBRICATION Lubrication LUBRICATION LUBRICATION

MAINTENANCE

Maintenance, preventive ................................................................................

Maintenance, preventive

Manifold, Intake ...........................................................................................................................................

Motor Starter ...............................................................................................................................................

Mounting-Location, Generator ...................................................................................................................

No-Load Voltage Adjustment, No-Load Voltage Adjustment,

Normal Conditions, Starting Under ............................................................................................................

AND

RECOMMISSIONING

and

Rigging ......................................................................................................................................

Connections .......................................................................................................................................

SYSTEM,

System,

SYSTEM SYSTEM

M

AND

N

CARE

Lay-Up

and SPECIFICATIONS, SPECIFICATIONS,

ADJUSTMENTS

(Generator)

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

OF

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

Recommissioning ..................................................................................

BCD

4.4

KW

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

BCD

6.0

KW

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

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

(see

Preventive

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

BCD

4.4

KW

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

BCD

6.0

KW

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

Maintenance)

75-78

51-53

66-74

55-56

57-58

19 59 77

75

11 15

62 76 77

20

35

o

Oil

Change (to include filter) ..................................................................................................................

Oil

Drain

Hose .............................................................................................................................................

Oil,

Engine ...................................................................................................................................................

Oil

Galleries,

Oil

Pressure

Oil

Viscosity Operating Ordering

p

PANEL, Parts,

Ordering .............................................................................................................................................. 5

Connecting

.............................................................................................................................. : ..................

(SAE

Number) ........................................................................................................................

Speed,

Parts

INSTRUMENT,

Required

............................................................................................................................................... 5

Pressure

DESCRIPTION

Sensing

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

Devices

OF

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

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

85

Westerbeke Generators

52-53

25 51 25 51 51

61-62

29

PARTS,

Power Connections, Shore .........................................................................................................................

PREPARATION

Pressure, Exhaust-Back ..............................................................................................................................

Pressure, Oil .................................................................................................................................................

Pressure Sensing Devices, Connecting

Preventive Maintenance ..............................................................................................................................

Preventive Maintenance, Generator ............................................................................................................

Procedures for Engine Break-In ..................................................................................................................

PROCEDURES PROCEDURES PRODUCT

Pump, Pump,

SPARE

Daily ....................................................................................................................................................

Monthly ..............................................................................................................................................

Servicing Intervals ....................................................................................................................... 66-68

Fuel Sea

R

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

FOR

STARTING

FOR

STARTING

FOR

STOPPiNG

SOFTWARE

Injection ....................................................................................................................................

Water .........................................................................................................................................

DISCLAIMER

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

to

Oil

Galleries ............................................................................

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

................................................................................................. : ........ 1

81 60 32

22

51

25

66

62 34 33 34

38

49

RECOMMISSIONING

Recommissioning Procedure ................................................................................................................

Remote Operation of Generator ..................................................................................................................

Replacing the

Required Operating Speed ....................................................................................................................

Rigging and Lifting .......................................................................................................................................

Fuel

AND

LAy-UP ......................................................................................................

Filter Elements ..............................................................................................................

75-78 77-78

61-62

s

Sea

Water Circuit .........................................................................................................................................

Sea

Water Circuit, Lay-Up and Recommissioning .....................................................................................

Sea

Water Intake System ............................................................................................................................

Sea

Water Pump ..........................................................................................................................................

Shore Power Connections ..........................................................................................................................

Shutdown, Automatic ..................................................................................................................................

SOFTWARE, SPARE

Spares, Lay-Up and Recommissioning ......................................................................................................

SPECIFICATIONS

AC AC

Battery ................................................................................................................................................

COOLING, COOLING, ELECTRICAL, ELECTRICAL,

Exhaust Back-Pressure .....................................................................................................................

FUEL,

PRODUCT

PARTS

............................... : .............................................................................................................

GENERATOR, GENERATOR,

BCD BCD

BCD

4.4 ~ ............................................................................................................................

BCD

6.0 ~ ............................................................................................................................

DISCLAIMER

BCD

4.4 ~ ...................................................................................................

BCD

6.0 ~ ...................................................................................................

4.4 ~ ....................................................................................................................

6.0 ~ ....................................................................................................................

BCD

4.4 ~ ...............................................................................................................

BCD

6.0 ~ ...............................................................................................................

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

12-13

16-17

30 37

19

49 76 26 49 60 27

81 77

39 11 15 12 16 22

11 15

Westerbeke Generators

86

GENERAL, BCD 4.4 GENERAL, BCD 6.0 LUBRICATION, BCD 4.4 LUBRICATION, BCD 6.0 SYSTEM, BCD 4.4 SYSTEM, BCD 6.0

TORQUE ............................................................................................................................................

TUNE-UP, BCD 4.4 TUNE-UP, BCD 6.0

'r0/V

.................................................................................................................... 10

'r0/V

....................................................................................•............................... 14

'r0/V

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

'r0/V

............................................................................................................ 15

'r0/V

................................................................................................................. 11-13

'r0/V

................................................................................................................. 15-17

'r0/V

..................................................................................................................... 13

'r0/V

..................................................................................................................... 17

11

80

Starter,

STARTING, PREPARATION FOR ............................................................................................................... 32

STARTING PROCEDURES ......................................................................................................................... 33

STARTING SYSTEM, DESCRIPTION OF ...................................................................................................

Starting Under Normal Conditions ............................................................................................................. 35

Starting Under

STOPPING PROCEDURES ........................................................................................................................ 34

SYSTEM

Motor

............................................................................................................................................... 77

31

Cold Conditions ................................................................................................................. 35

Cooling

COOLING, CARE OF ................................................................................................................... 46-50

DC ELECTRiCAL .......................................................................................................................... 39-45

DESCRIPTION OF STARTING ..........................................................................................................

Electrical ....................................................................................................................................... 26-28

Exhaust ..............................................................................................................................................

Failures, Exhaust ............................................................................................................................... 23

Fresh Water

FUEL, CARE OF ........................................................................................................................... 36-38

Fuel Installation ................................................................................................................................. 25

Fuel, Lay-Up and Recommissioning ................................................................................................ 76

Fuel, Priming the ............................................................................................................................... 37

LUBRICATION, CARE OF ............................................................................................................ 51-53

Lubrication, Lay-Up and Recommissioning .....................................................................................

SPECIFICATIONS, BCD 4.4 SPECIFICATIONS, BCD 6.0

.............................................................................................................................................. 26

31

21

Cooling, Lay-Up and Recommissioning .....................................................................

'r0/V

........................................................................... (see Specifications)

'r0/V

........................................................................... (see Specifications)

75

T

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ............................................................... 79

Testing the Battery Charging Circuit ..................................................................................................... 40-45

Thermostat .................................................................................................................................................. 48

Through-Hull Exhaust and Intake Manifold ................................................................................................ 76

Timing Adjustment,

TORQUE SPECiFiCATIONS .......................................................................................................................

TORQUES, TABLE OF STANDARD HARDWARE TIGHTENING ..............................................................

Torquing Cylinder Head Bolts, BCD 4.4 Torquing

TROUBLESHOOTING, ENGINE ............................................................................................................ 63-65

Troubleshooting, Generator ....................................................................................................................... 62

TUNE-UP TUNE-UP SYSTEM SPECIFICATIONS, BCD 6.0

Cylinder Head Bolts, BCD 6.0

SYSTEM SPECIFICATIONS, BCD 4.4

Injection Pump (Spill Timing) .....................................................................................

'r0/V

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

'r0/V

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

'r0/V

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

'r0/V

................................................................................ 17

87

Westerbeke Generators

72 80 79

13

U

Understanding Use

of

Electric Motors .................................................................................................................................

the

Diesel Engine-Driven Generator .................................................................................... 5

61

v

Valve Clearance Adjustment, BCD 4.4 Valve Clearance Adjustment, BCD 6.0

Ventilation ..................................................................................................................................................... 28

Viscosity, Engine

Oil (SAE Number) ...........................................................................................................

Voltage Adjustment, No-Load, BCD 4.4 Voltage Adjustment, No-Load,

BCD 6.0

W

Water Circuit, Fresh ............................................................................................................................... 46-48

Water Circuit,

Water Pump Drive Belt Tension .................................................................................................................. 49

Water Pump,

Sea ........................................................................................................................................ 49

Sea ......................................................................................................................................... 49

'f(J/I/

••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 70

'f(J/I/

•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

'f(J/I/

••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 55-56

'f(J/I/

••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 57-58

71

51

ADJUSTING THE DRIVE BELT'S TENSION ................................................................................... 49

CARBON MONOXIDE GAS ....•....•..•••.•...•.........................•••••••••••••••••.•••••••.••.••.••••••.•.•••••••••••.••••.••••

21

NO-LOAD VOLTAGE ADJUSTMENT ••.••.•.............••.....••......•.•••••••••••••..•••••..•..••••••••.•••.••••••••••• 55 & 57

OPEN FLAMES NEAR BATTERIES .....•.•..••••................•.....••....•••....•••.....••.....••....•.•..•.•••..•••••..•.•••••

SERVICING THE BATTERy ....•••...•••••....•••..•.•••...•......•••..••••.••••••..••..•..••••••.•.•....•••....••.•...•....... 28 &

27

77

Westerbeke Generators

88

YOUR NOTES

89

Westerbeke Generators

YOUR NOTES

\

Westerbeke Generators

90

Westerbeke BCD 4.4KW, BCD 6.0KW Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual