Westerbeke 7.0 KW BCDT 50Hz Owner'S Manual Download Page 1

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Summary of Contents for 7.0 KW BCDT 50Hz

Page 1: ...ERATORS PUBL ATION NO 46294 FIRST EDITION JULY2001 WESTERBEKE WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 TEL 1 508 823 7677 FAX 1 508 884 9688 WE...

Page 2: ...Headache Weakness andSleepiness Throbbing in Temples Muscular TWitching Vomiting Inability to Think Coherently IF YOU ORANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIR IMMEDIATELY I...

Page 3: ...carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not...

Page 4: ...in or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is adeadlygas Ensure that the exhaust system is adequate to expel gases discharged fro...

Page 5: ...nual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTALLATIONS Preparations to inst...

Page 6: ...is at or below the load waterline will result in raw water damage to the engine andpossibleflooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to...

Page 7: ...l Change 22 Fuel System 23 Fuel Lift Pump 23 Glow Plugs 24 Starter Motor 25 Control Box 27 12V DC Control Circuit 28 Battery Specifications 28 Wiring Diagram 41990 29 Wiring Schematic 41990 30 Engine...

Page 8: ...IVE BELT VIBRATION MOUNTS OIL FILL I COOLANT FILL PREHEAT SOLENOID ZINC EXHAUST MAN FOlD THERMOSTAT HOUSING AIR INTAKE FILTER ft I r l7 H I FUEL LIFT PUMP CONTROL BOX SIDE OIL FILL CONTROL BOX t l TI...

Page 9: ...E CANNOTBE RESPONSIBLE FOR THE CONTENT OFSUCHSOFTWARE MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO INCLUDING ACCURACY TIMELINESS OR COMPLETENESS THEREOF AND WIU IN NO EVENT BELIABLE FOR...

Page 10: ...essentially the same The cylinder is arranged above a closed crankcase The crankshaft is ofthe same general type as on a gasoline engine and the diesel engine has the same type ofvalves camshaft pisto...

Page 11: ...CTION SUPPLIED 3 Ventilation 4 Exhaust system S Fuel supply and return 6 Raw water inlet and outlet 7 Oil fill and oil drain hose 8 Electrical connections 9 Maintenance and service accessibility 10 Ac...

Page 12: ...n Mount the plate to the boat s platform then mount the generator to the plate VENTILATION Allow for the sufficient intake ofcool air for proper engine combustion and the discharge ofthe heated air wh...

Page 13: ...n 25 4 mm 1 0 EXHAUST SYSTEM DIAGRAMS CONTACT YOUR WESTERBEKE DEALER FOR 12 in 30 em ABOVE ELBOW MINIIV UM ADDITIONAL INFORMATION For more information about exhaust system design see Westerbeke s INST...

Page 14: ...to ensureproper operation Failure to properly maintain a siphon breakcan result in severe engine damage Consult the siphon breakmanufacturerfor aproper maintenance schedule Raw Water Intake A flush ty...

Page 15: ...is available ifmore cable length is required When installing pass the cable though bulkheads by disconnecting the cable at the control panel Refer to the following illustration for control panel dimen...

Page 16: ...dicator to a normal position LED PROPORTIONAL LOAD INDICATOR r The oil pressure coolant temperature warning light red lights up when either the oil pressure is too low or the engine is overheated The...

Page 17: ...COOLANT Westerbeke recommends a mixture of 50 antifreeze and 50 distilled water Distilled water is free from the chemicals that can corrode internal engine surfaces The antifreeze performs double duty...

Page 18: ...y tank may need to be filled to the MAX level Visually examine the unit Look for loose or missing parts disconnected wires unattached hoses and check threaded connections Search for any gasoline leaks...

Page 19: ...up may occur which can cause severe damage to the engine STOPPING THE GENERATOR Remove the AC loads from the generator one at a time and allow the generator to run for an additional 3 to 5minutes this...

Page 20: ...n your log engine hours relate to the maintenance schedule Visually inspect the engil e for fuel oil or water leaks Check the oil level dipstick Check the coolant level in the coolant recovery tank Ch...

Page 21: ...r s engine is protected by an engine mounted I manual reset circuit breaker 20 amps DC Excessive current draw or electrical overload anywhere in the instrument panel wiring or engine wiring will cause...

Page 22: ...ld be between the full and low indicating marks on the dipstick Top up if necessary Change the oil see LUBRICATION SYSTEM Check the fuel supply Top up if necessary Check for water and dirt in the fuel...

Page 23: ...k for oil fuel and water leaks Hardware fastenings Inspect and tighten all fastenings and and electrical accessible screws bolts and nuts Inspect connections all wiring and electrical connections Gene...

Page 24: ...ull flow of the engine s coolant to flow unrestricted to the external portion of the cooling system Coolant Recovery Tank A coolant recovery tank allows for engine coolant expansion and contraction du...

Page 25: ...e are no leaks at the thermostat housing HIGH WATER TEMPERATURE lS SWITCH THERMOSTAT ASSEMBLY COOLANT TEMPERATURE SWITCH The coolant temperature switch is located near the thermostat housing see illus...

Page 26: ...t to the impeller and gasket Open the raw water intake valve NOTE Never allow the pump tOntil dry Even a inortperiod I ofdry running may destroy the impeller IMPELLER BLADES i SHOULD BE INSPECTED BEND...

Page 27: ...et refer to your engine model s heat exchanger end gasket part num ber O ring and cover and install a new zinc anode NOTE The threads ofthe zinc anodes are pipe threads and do not require sealant Seal...

Page 28: ...d against the filter bracket gently remove it When installing the new oil filter element wipe the filter gasket s sealing surface on the bracket free of oil and apply a thin coat of clean engine oil t...

Page 29: ...f fire near the fuel sys tem when servic ng Ensure proper ventilation exists when servicing the fuel system t t1 11 FUEL LIFT PUMP Q i r i DRAIN TO FUEL i FILTER The fuel injection pump is a very impo...

Page 30: ...tion and the other to the body of the glow plug as shown A good glow plug will have a 1 0 1 5 ohm resistance This method can be used with the plug in or out of the engine You can also use an ammeter t...

Page 31: ...ake certain the ships batteries are at full charge and that the starting system wiring connections terminals are clean and tight Pay particular attention to the ground wire connections on the engine b...

Page 32: ...astarter will run the motor without engaging theflywheel TUrn the starter switch on to provide thepower to the solenoid Hopefolly it will create enough magneticfieldfor the arm to move even though the...

Page 33: ...NOTE Ll lnd L2 lW t pll f tm rellt NOTE W chen froto 0 H tl 50 H t tOe opel1ltDl smanulI1 TERMINAL BOARD K3 RELAY RESET BUTTON 20A FUSE PROTECTS THE BATTERY CHARGER AGAINSTEXCESSIVE CURRENT K2 RELAY B...

Page 34: ...charging rate will rise as the generator is operated The IC is mounted inside the generator control box There is a voltage output adjustment on the controller that will allow a DC voltage output adju...

Page 35: ...1 t l j t tJ I IC3 181 l I VI O __ J VIO 114 RED L ___ I R EO re E 5 n CURRENT 4 1S __ JIIW 6 B l K _ _ _ 112 YEL RED TRANSFORMER 116 BlK I m BlK W j rr I BRIDGE 114 JAN w ii 1 4 RED WHT i1Q ECTlfIER...

Page 36: ...HEAT RELAY RED BATTERY BROWN 2 fUEL 2 0 f 0 rUSE 3A futi A 1_____ __ SAFETY GREY START I 0 GENERATOR L I CO ECTOR CIRCUIT BRUMEI GREEN OILIT NP r BLACK GROUND S _ _ Zj 1_____ SAFElY FUEL r ______ 8 6...

Page 37: ...e throttle arm against these stop bolts to either increase or decrease engine no load speed to adjust the Hertz produced 3 To arrive at the appropriate frequency either monitor the spt ed of the engin...

Page 38: ...torque Follow this pro cedure according to the numbered sequence shown in the illustration to the right Bolts 1 and 2 12rnm socket 14 22 ft Ib Bolts 3 4 5 6 7 8 l4mm socket 54 61 ft Ib Rockershaft Hol...

Page 39: ...rom the engine fuel will flow from this line during the timing check Rotate the engine s crankshaft in its normal direction of rotation to position piston the No 1 at the beginning of its compression...

Page 40: ...y with the timing marker on the front gear case cover when positioning the 1 Piston at TDC of it s compression stroke Confirm this by rotating the crankshaft approximately 20 degrees before and after...

Page 41: ...ng system 1 Check that fuel valves are open start fuel solenoid energized 1a Switch to combine house and start batteries 1b Check batteries 1c Fuel lift pump at injection pump may be clogged 2 Preheat...

Page 42: ...il 1 Check dipstick look for oil leaks at oil filter and at Low oil pressure oil drain hose connection 2 Oil pressure switch 2 Replace oil pressure switch Exhaust smoking problems 1 Blue smoke 1 Incor...

Page 43: ...ore Power to Generator Power Y1 Ll I I 7 3 2 I A CAUTION Heavy motor leads should be shut off before switching shore power to generatorpower or vice versa because voltage surges induced byswitch ing w...

Page 44: ...ted on the generator s data plate The output voltage should be checked periodically to ensure proper operation ofthe generating plant and the appliances it supplies Ifan AC voltmeter or amp meter is n...

Page 45: ...tor Low no load voltage 1 Engine speed too low 1 Check and adjust rpm under 110V 2 Faulty rotating diodes 2 Check replace 3 Break down in windings 3 Check windings resistance as follows 4 Capacitor ra...

Page 46: ...s needed Start the engine and allow it to run for 5 10 minutes to make sure there is no air left in the fuel system Check for any leaks that may have been reated in the fuel system during this servici...

Page 47: ...they will be subjected to severe enviromnental conditions remove the batteries and store them in a warmer more compatible enviromnent STORAGE Thoroughly clean the outside ofthe generator then store t...

Page 48: ...rature Raw Water Pump Raw Water Flow at 3600 rpm Raw Water Connection Capacity Fresh water cooled block thermostatically controlled 170 190 F 77 88 C Positive displacement rubber impeller gear driven...

Page 49: ...s Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg...

Page 50: ...6168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHER VA...

Page 51: ...605 820 14 435 590 675 915 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2...

Page 52: ...ing to engine M20 21 36 15 43 38 5 0 6 0 Nozzle Union Color Fixing Nut M12 17 18 08 21 69 2 5 3 0 Nozzle Retaining Nut M16 21 25 31 28 92 3 5 4 0 Fuel Injection Pipe Nut M12 17 18 08 25 31 2 5 3 5 Del...

Page 53: ...E COOLING SYSTEM PARTS KITS IiAWWATER PUMP IMPELLER lAND GASKET WESTERBEKE also offers engine spares in t fwo sparep artskits Each kit 1 dfferediH tlie same rdflgedrusfproof hiifg dtoOI bok KIT i f1as...

Page 54: ......

Page 55: ...Engines Generators 1054 WMJDW 7 2001...

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