WESTERBEKE MARINE DIESEL GEN.ERATOR 4.0KW BCD/4.0KW BCDA 612-60HZ OPERATORS MANUAL PUBLICATION NO.045305 SECOND EDITION MARCH 2008 l~ rWESTERBEKE , member ~ _ . j • WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD· TAUNTON MA 02780-7319· TEL. 1-508-823-7677 FAX 1-508-884-9688· WEBSITE: www.WESTERBEKE.
CALIFORNIA PROPOSITION . 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. A WARNING: Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide Is poisonous and t:an t:ause unconsciousness and death.
SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne4 and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. • Prevent flash fires.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES A WARNING: Accidental starting can cause injury A WARNING: Carbon monoxide (CO) is a deadly gas! or death! • Make certain all personnel are clear of the engine before staIting. Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifold! water-injected elbow is securely attached.
SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts. • Make sure all attaching hardware is properly tightened. Keep protective shields and guards in their respective places at all times. • Do not check fluid levels or the drive belt's tension while the engine is operating.
INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
TABLE OF CONTENTS Introduction ......................... '" .............................................2 Fuel Additives ............................................................. 17 Spares ......................................................................... 17 Engine Oil Change ............................................................ .18 Engine Oil Change ..................................................... 18 Oil Pressure ................................................................
INTRODUCTION PRODUCT SOFTWARE This WESTERBEKE Diesel Generator is a product of WESTERBEKE's long years of experience and advanced technology. We take great pride in the superior durability and dependable performance of our engines and generators. Thank you for selecting WESTERBEKE. Product software, (tech data, parts lists, manuals, brochures and catalogs), provided from sources other than WESTERBEKE are not within WESTERBEKE's control.
INTRODUCTION NOTE: A carbon monoxide warning decal has been provided by WESTERBEKE. Affix this decal in a visible position in the SERIAL NUMBER LOCATION The engine and generator serial numbers and model numbers are located on a decal on the generator housing. Take the time to enter the information on the blank decal provided below as this will provide a quick reference when seeking technical information and/or ordering repair parts. SPECIFICATION 50 HZ. engine room.
GENERATOR CONTROL PANELS DESCRIPTION OF SWITCHES EMERGENCY STOP: The EMERGENCY This manually controlled series ofWESTERBEKE marine diesel generators is equipped with toggle switches on the engine control panel and, optionally, at remote panels. stop switch on the rear of the control box is normally closed. When depressed, it will open the DC circuit to the control panel and shut the engine down. As the switch is not toggled it can be used when performing maintenance.
DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT Use fuel that meets the requirements or specification of Class 2-D (ASTM), and has a cetane rating of #45 or better. WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces. Care Of The Fuel Supply The antifreeze performs double duty.
PREPARATIONS FOR INITIAL START-UP PRESTARTINSPECTION A CAUTION: When starting the generator, it is This section of the manual provides the operator with preparation, initial starting, break-in, starting (warm or cold) and stopping procedures. Follow the procedures as presented for the conditions indicated and your WESTERBEKE generator set will give reliable performance and long service life.
STARTING/STOPPING PROCEDURE THE STARTING SYSTEM Should the engine not start when the START switch is depressed for 10 to 20 seconds, release both switches and wait 30 seconds; repeat the procedure above and preheat longer. Never run the starter for more than 30 seconds. Westerbeke diesel generators use electric starters assisted by glow plugs for both normal and cold weather starting. The illustration below shows a cross-sectional view of one cylinder.
STARTING/STOPPING PROCEDURE STARTING UNDER COLD CONDITIONS High Water Temperature Switch Make sure the lubricating oil conforms with the ratings for the prevailing temperature. Check the table in the ENGINE OIL section in this manual. A high water temperature switch is located on the thermostat housing.
GENERATOR BREAK-IN PROCEDURE DESCRIPTION CHECK THE FOLLOWING Although your engine has experienced a minimum of one hour of test operations at the factory 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. D Monitor the control panel gauges. D Check for leaks of fuel and engine oil.
THE DAILY ROUTINE CHECK LIST START THE GENERATOR Each day before starting your generator, take a few moments to run this check list: (See STARTING PROCEDURES on previous pages). Allow the engine to wam1 up for 5 to 10 minutes to reach operating temperatures of 140° to 150°F (60°-66°C) before applying AC loads, apply loads systematically allowing the generator to adjust to each load before applying the next. Check the gauges for proper oil pressure, operating temperature, and DC voltage.
MAINTENANCE SCHEDULE 2. A WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. NOTE: Many of the following maintenance jobs are simple but others are more difficult and may require the expert knowledge of a service mechanic.
MAINTENANCE SCHEDULE NOTE: Use the engine hour meter gauge to log your engine hours or record your engine hours by running time. SCHEDULED MAINTENANCE CHECK EACH DAY HOURS OF OPERATION 50 100 250 500 750 1000 1250 EXPLANATION OF SCHEDULED MAINTENANCE *Starter Motor 0 0 Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter motor pinion drive. *Preheat Circuit D 0 Check operation of preheat solenoid.
ENGINE COOLING CIRCUIT DESCRIPTION Westerbeke marine diesel generators are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water coolant which circulates throughout the engine. This circulating fresh water coolant cools the engine block and its internal moving parts. The heat is transferred externally from the fresh water coolant to raw water by means of a heat exchanger; similar in function to an automotive radiator.
ENGINE COOLING CIRCUIT Fresh Water Circuit After checking for leaks, stop the engine and allow it to cool. Coolant should draw back into the cooling system as the engine cools down. Add coolant to the recovery tank if needed. Clean up any spilled coolant. Fresh water coolant is pumped through the engine by a beItdriven circulating pump, absorbing heat from the engine.
ENGINE COOLING CIRCUIT RAW WATER COOLING CIRCUIT Heat Exchanger The raw water flow is created by a positive displacement impeller pump. This pump draws water directly from the ocean, lake, or river through a hose to the water strainer. The raw water passes from the strainer through the heat exchanger (through the heat exchanger tubes) where it cools the engine circulating fresh water coolant.
FUEL SYSTEM DIESEL FUEL FUEL INJECTION PUMP Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not use kerosene or home heating fuel. The fuel injection pump is the most important component of the diesel engine and, therefore, calls for the utmost caution in handling. The fuel injection pump has been thoroughly bench-tested and should not be tampered with.
FUEL SYSTEM FUEL FILTERS Fuel Additives The fuel injection pump and the fuel injectors are precisely manufactured and they must receive clean diesel fuel, free from water and dirt. To ensure this flow of clean fuel, the fuel must pass through at least two fuel filters, a fuel water separator and the engine's spin-on fuel filter. Visually inspect, clean, and change these filters according to the maintenance schedule in this manual.
ENGINE OIL CHANGE Engine Oil Change 1. Draining the Oil Sump. Discharge the used oil through the sump drain hose (attached to the front of the engine) while the engine is warm. Drain the used oil completely, replace the hose in its bracket, and replace the end cap securely. OIL FILTER NOTE: Thread size for the lube oil drain hose capped end is 1/4NPT. Always observe the used oil as it is removed. A yellow/gray emulsion indicates the presence of water in the oil.
REMOTE OIL FILTER (OPTIONAL) INSTALLATION To install, simply remove the engine oil filter and thread on WESTERBEKE's remote oil filter kit as shown. Always install this kit with the oil filter facing down as illustrated. This popular accessory is used to relocate the engine's oil filter from the engine to a more convenient location such as an engine room bulkhead. Contact your WESTERBEKE dealer for more information.
DC ELECTRICAL SYSTEM DESCRIPTION GLOW PLUGS The DC Circuit on the 4.0 KW BCD functions to start, operate and stop the generator engine. The circuit is best understood by reviewing the DC WIRING SCHEMATICS. The engine's DC wiring is designed with three simple basic circuits: preheat, start, and stop. . The glow plug is a small heater installed in each pre-combustion chamber. They run off the engine starting battery and become red hot when activated. The glow plugs are wired through the preheat solenoid.
4.0 KW BCD WIRING SCHEMATIC #44732 ,. ' e I RCU I f BREAKER ; BATTERY ISWlfCH 1-;:..,..-, Ion r ~ .. BATTERY I Z voe Sf ARTER '----1 CI, I STARTER I ISOLENOI DI I I l.. ___ ! , ,---, 1 EMERGENCY GLOWPLUGS I PREHEAT! I STOP , SWI TeH :SOLENOID: l.. ___ J 30A KI-START K2-RUN ~T~B~I_~I-----------*----~----------~JO~~8~1-------------. FUEL SOL. I r r I I ! WATEA TEMP. EXN_ TENP. SWI TeH ~8A FUEL PUMP OIL PRESS. SWI TCH SWITCH '.
4.0 KW BCD WIRING DIAGRAM #44732 WATfR TEMPERATURE SWITCH C~bJ GENERATOR 8AJT[Rf "ARG£R OUTPU1 81.T.C~ rOSEJD" ; BATTERY SWITCH r e£} -- -- --- [u_ (fll------. :-4""h. il I . In 1£0 ' " RED .. tlZrE1I8£O l.flUIfIIT SWITCH ~ ~ ~ Jl"WW/# ~ S SWI H ;; .4 vIe L~ 114 RED GROUND TO ENG INE BLOCK != tUILK 116 BRN "41£D 1.1 TEL 116 REO , .16wt1T ~~lv---""""'''''''-----' NOTE: L REMOVE JIIlWER WHEN CONNECTING A SECOND R£ftOn PANEl. ~~ r"-"-"-"-"-"-"-"-"-"-"-"l ~T .
REMOTE INSTRUMENT PANEL SCHEMATIC #44329 STOP SWI TCH AVAILABLE CONNECTIONS D 15 Ft. Extension Harness #044347 D 30 Ft. Extension Harness #044799 D "Y" Connection (for two remote panels) #046028 2 PREHEAT SWI TCH REMOTE CONTROL PANEL (REAR VIEW) r"-"-"-"-"-"-"-"-"-"-"-"-"-"-"-"-"-; : I I . .
STARTER MOTOR DESCRIPTION The starting system includes the battery, starter motor, solenoid, and starter button. ~ When the starter button on the instrument panel is depressed, current flows and energizes the starter's solenoid coil. The energized coil becomes an electromagnet, which pulls the plunger into the coil, and closes a set of contacts which allow high current to reach the starter motor.
STARTER MOTOR SERVICE Westerbeke uses a standard marine starter motor wInch can be serviced or rebuilt at any starter motor automotive service center. If replacing fue starter motor, make certalll fue new motor is certified for marine use. Automotive starters do not meet USCG standards. If in doubt, contact your WESTERBEKE dealer. (+) POSITIVE TERMINAL ~/--- ~....,---(M) TERMINAL TO REMOVE FOR SERVICE IGNITION TERMINAL TO CONTROL PANEL 1. Discomlect tile negative battery cable. 2.
ENGINE TROUBLESHOOTING Note: The engine's electrical system is protected by a 25 amp manual reset circuit breaker located on a bracket at the rear of the engine. The preheat solenoid is close by, as is the emergency STOP switch, which may be mounted on the same bracket or on the back of the instrument panel, depending upon the generator model.
ENGINE TROUBLESHOOTING Problem Verification/Remedy Probable Cause Generator engine overheats/shuts down. 1. Raw water not circulating. 1. Raw water pump failure. Check impeller - replace. 2. Coolant not circulating. 2. Obstruction at raw water intake or raw water filter. 2a. Thermostat - remove and test in hot water. Replace thermostat. 2b. Loss of cooiant - check hoses, hose clamps, drain plug, etc. for leaks. 2c. Broken or loose belts - tighten/replace. 2d.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The info77fUltion below is provided to assist the mechanic. GENERATOR FREQUENCY ADJUSTMENT (HERTZ) FUEL RUN SOLENOID Once the diesel generator set has been placed in operation, there may be adjustments required for engine speed (Hertz) during the engine's break-in period (first 50 hours) or after this period.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. DRIVE BELT ADJUSTMENT TORQUING THE CYLINDER HEAD BOLTS For your safety, WESTERBEKE generator models come equipped with belt guards that cover over the belt(s) on the front of the engine. ("Out of sight - out of mind." The belt guard is NOT installed for that purpose.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. Injection Pump Timing Adjustment (Spill Timing) If your engine's fuel injection timing is not properly adjusted, the engine will not operate properly, and may be difficult to start. Have the injection pump delivery rate checked by a weB-established fuel injection shop.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT Re-install the glow plugs (use anti-seize compound on the threads) and assemble the rocker cover and rocker cover belts. See the TIGHTENING TORQUE SCHEDULE in this manual. NOTE: Retorque the cylinder head bolts before adjusting the engine's valves. See TORQUING THE CYLINDER HEAD BOLTS.
GENERATOR INFORMATION USE OF ELECTRIC MOTORS GENERATOR FREQUENCY ADJUSTMENT The power required to start an electric motor is considerably more than is required to keep it running after it is started. Some motors require much more current to start them than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types.
BC GENERATOR SINGLE PHASE NOTE: WESTERBEKE recommends that the following generator tests and adjustments be peiformed by a qualified technician. DESCRIPTION Circuit Breaker The BC generator is a brushless, self-excited generator which requires only the driving force of the engine to produce an AC output. The stator houses two sets of windings; the main stator windings and the exciter windings.
Be GENERATOR SINGLE PHASE NOTE: WESTERBEKE recommends that the following generator tests and adjustments be peiformed by a qualified technician. AC TERMINAL cCONNECTION @ DIAGRAM ® 120V/60Hz ~~IJ l1 '~\ GENERATOR BACK END A WARNING: Make certain the insulating covers on the unused leads are in place and are NOT in contact with each other or in contact with the generator's housing.
Be GENERATOR SINGLE PHASE NOTE: WESTERBEKE recommends that the following generator tests and adjustments be performed by a qualified technician. INTEGRAL CONTROLLER (I.C.) Testing the Battery Charging Circuit The Integral Controller (I.C) is an encapsulated, solid-state unit that supplies a DC charging voltage to the generator's starting battery while the generator is opening. Charging Voltage: 13.0 - 14.
LAY-UP AND RECOMMISSIONING General Fuel System Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the offseason or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves. The procedures which follow will allow you to perform your own lay-up and recommissioning, or to use as a check list if others do the procedures.
LAY-UP AND RECOMMISSIONING Generator End Recommissioning Remove the louvered cover on the generator end. Check all wire connections on the AC terminal block and those running to the bridge rectifier making sure they are secure. Should 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.
SPECIFICATIONS 4.0 KW BC GENERATORS LUBRICATION SYSTEM ENGINE SPECIFICATIONS Engine Type Combustion Chamber General Oil Filter Full flow, spin-on replaceable type Swirl type Sump Capacity (nat including filter) 3.2 U.S. qts (3.03 liters) 2.76 x 2.76 inches (70 x 70 mm) 2.99 x 2.76 inches (76 x x70mm) Operating Oil Pressure (engine hot) 35 - 55 psi (2.5 - 3.
SPECIFICATIONS 4.0 KW BCD GENERATORS DESCRIPTION AC GENERATOR (Single Phase) If the installer connects shore power to the vessel's AC circuit, this must be done by means of the Shore Power Transfer Switch. Set the transfer switch shown in the diagrams to the OFF position. This switch prevents simultaneous connection of shore power to generator output. Single Phase Brushless, four-pole, revolving field. Self-exciting, capaCitor saturated field excitation. Pre-lubricated, single-bearing design.
WESTERBEKE 4.
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Pilch Ib-It kg-m 6mm bolt head/nut 1 5.8-8.7 0.8-1.2 1.0-1.6 8mm bolt head/nut 1.25 14.5-21.7 2.0-3.0 13.7-22.4 1.9-3.1 10mm bolt head/nut 1.25 28.9-39.8 4.0-5.5 13.0-21.7 1.8-3.0 10mm bolt head/nut 1.5 26.8-37.6 3.7-5.2 7.5-10.5 Pilch Ib-It kg-m 6rnrn bolt head/nut 1 2.9-5.1 0.4-0.7 8rnm bolt head/nut 1.25 7.2-11.
STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches Feet (tt) x .305 = Meters (m) x 3.281 = Feet Miles x 1.609 = Kilometers (km) x .0621 = Miles VOLUME Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =in 3 Imperial Pints (IMP pt) x .568 =Liters (L) x 1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt Imperial Gallons (IMP gal) x 4.546 =Liters (L) x .22 =IMP gal Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .
METRIC CONVERSIONS MILLIMETERS TO INCHES INCHES TO MILLIMETERS Inches mm 1 2 3 4 5 10 25.40 50.80 76.20 101.60 127.00 254.00 mm Inches 15 20 25 30 35 40 381.00 508.00 635.00 762.00 889.00 1016.00 mm Inches mm Inches 1 2 3 4 5 10 0.0394 0.0787 0.1181 0.1575 0.1969 0.3937 15 20 25 30 35 40 0.5906 0.7874 0.9843 1.1811 1.3780 1.5748 10 MILLIMETERS =1 CENTIMETER, 100 CENTIMETERS =1 METER = 39.37 INCHES (3.
SUGGESTED SPARE PARTS ''''''''''''''--_'!~I'.WESTERBEKE MARINE DIESEL G~NERATO~~~.• "",,, ~' i Zinc Anodes Heat Exchanger and Gasket Carry several. Spin-On Fuel Filters Raw Water Impeller and Gasket Always carry a spare. Check annually. Check annually. Oil Filter Have several aboard Change every 100 hours. Fuel Lift Pumps Solid State Model have a spare on board. """,,~'I!I Always carry a spare aboard. Drive Belts Fuel Hardware Kits Fuel line banjo fittings and washers.
Engines & Generators 1062Wri1DW-8/2002
