Westerbeke 4.0KW BCD Operator'S Manual Download

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Summary of Contents for 4.0KW BCD

Page 1: ...S 5 0Kw BCD 5 0Kw BCDA 60Hz 4 0Kw BCD 4 0Kw BCDA 50Hz 5 5Kw BCD 5 0Kw BCDB 60Hz 5 0Kw BCD 4 BCDB 50Hz PUBLICATION NO 042871 FOURTH EDITION APRIL 2008 member WESTERBEKE CORPORATION MYLES STANDISH INDUS...

Page 2: ...e Throbbing In Temples Muscular TWitching Vomiting Weakness andSleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESH AIR IMMEDIATELY Ifsymp...

Page 3: ...e 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 n...

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

Page 5: ...ith other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTALLATIONS Preparations to install an engin...

Page 6: ...waterline Failure to use a siphon break when the exhaust manifold injection pori is at or below the load waterline will result in raw water damage to the engine andpossible flooding ofthe boat If you...

Page 7: ...t 15 Thermostat 16 Wiring Diagram 45633 36 Wiring Schematic 45633 37 Wiring Diagram 038124 38 Wiring Schematic 038124 39 Wiring Diagram 038124 40 Raw Water Intake Strainer 16 Wiring Schematic 038124 4...

Page 8: ...ATE X L r START SOLENOID P J1J r STARTER MOTOR DRIP TRAY COOLANT FILL FLEXIBLE ISOLATED MOUNTS LEFT SIDE REAR COOLANT PRESSURE CAP r EMERGENCY STOP CONNECTION SIPHON BREAK EXHAUST ELBOW START STOP SWI...

Page 9: ...s manuals brochures and catalogs provided from sources other than WESTERBEKE are not within WESTERBEKE s control WESTERBEKE CANNOTBE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WAR RANTIES O...

Page 10: ...most important factors are proper ventilation and proper maintenance of the fuel lubricating and cooling systems Replacement of fuel and lubricating filter elements at the time periods specified is a...

Page 11: ...produce properties harmful to your engine ENGINE COOLANT Engine coolant is a 50150 mixture of antifreeze and distilled water This coolant allows the engine to run at its proper temperature by transfe...

Page 12: ...tached hoses and check threaded connections Search for any gasoline leaks WAITFOR THE ENGINE TO COOL BEFORE REMOVING THE RADIATOR CAP MANIFOLD PRESSURE CAP PRESS DOWN AND TURN TO LIFTOFF FROM COOLANT...

Page 13: ...he START switch engages the strut solenoid When the engine begins to fire the START switch should be released The PREHEAT switch should not be released until the oil pressure reaches 5 10 psi Should t...

Page 14: ...ly stopped Now release the STOP switch REMOTE PANEL The remote panel uses the same three toggle switches with an LED light to indicate the generator is running STARTING PREHEAT Depress the PREHEAT swi...

Page 15: ...urrent drawn from the generator NOTE Be aware ofmotor starting loads and the high current draw requiredfor starting motors This starting amperage draw can be 3 to 5 times normal running amperage See G...

Page 16: ...ARM High Exhaust Temperature Switch An exhaust temperature switch is located on the exhaust elbow Nonnally closed tins switch will open and interrupt the DC voltage shutting off the engine should the...

Page 17: ...bolts nuts tight remain cool Check for loose belt tension Fuel Filter 0 0 0 0 0 0 Initial change at 50 hrs then change every 250 hrs Starting Batteries 0 Every 50 operating hours check electrolyte lev...

Page 18: ...and adjust injection opening pressure and spray condition see ENGINE ADJUSTMENTS Starter Motor 0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pi...

Page 19: ...and repair it The only adjustment the servicing mechanic should make to the fuel injection pump is the adjustment for the engine idle speed see IDLE SPEED ADJUSTMENTunder ENGINE ADJUSTMENTS FUEL LIFT...

Page 20: ...the raw water which is then pumped into the EXHAUST J COOLING CIRCUIT DIAGRAM FRESH WATER RAWWATER _ exhaust system where finally it is discharged overboard In other words the engine is cooled by fre...

Page 21: ...provided with fresh water cooled models and with the fresh water coolant conversion kit and must be installed before operating the engine NOTE This tank with its short run ofplastic hose is best locat...

Page 22: ...OR PUSHING AIR FROM THE COOLING SYSTEM RAW WATER INTAKE STRAINER NOTE Always install the strainer at or below the waterline so the strainer will always be self priming Aclean raw water intake strainer...

Page 23: ...he threads ofthe Zinc anodes are pipe threads and do not require sealant Sealant should not be used as it may insulate the zincfrom the metal ofthe heat exchanger housing preventing electrolysis actio...

Page 24: ...d to make sure that the rubber sealing gaSket comes off with the old oil filter If this rubber sealing gasket remains sealed against the filter bracket gently remove it LUBRICATION DIAGRAM OIL PRESSUn...

Page 25: ...ore information THE OUT CONNECTION MUST ATTACH TO THE IN CONNECTION AT THE REMOTE OIL FILTER APPLY ATHIN COAT OF CLEAN OIL TO THE O RING WHEN INSTALLING THIS KIT THREAO THE KIT ON THEN HAND TIGHTEN AN...

Page 26: ...300 600 Cold Cranking Amps CCCA Battery Care Review the manufacturer s recommendations and then establish a systematic maintenance schedule for your engine s starting batteries and house batteries o M...

Page 27: ...nking the starter for a few seconds never more than 10 seconds at a time then run your hand along the wires and terminals looking for warm spots that indicate resistance Repair or replace any trouble...

Page 28: ...ntacts can cause the sporadic problem of the engine starting one time but not another If corrosion is the problem the starter will need to be rebuilt It is however sometimes possible to get started by...

Page 29: ...or decrease engine no load speed to adjust the Hertz produced 3 To arrive at the appropri te frequency either monitor the speed of the engine generator with a tachometer or mon itor the frequency wit...

Page 30: ...and the engine mounting surlace as shown ACTUATOR MEASURE FOR REFERENCE ENGINE MOUNTING SURFACE JAM NUT 4 Back offthe 17 1 jam nut and unscrew the actuator S Apply a small amount ofteflon sealant to t...

Page 31: ...grees in the normal direction of rotation and adjust the next cylinder s valves in the firing order Rotate the cranKshaft another 240 degrees and adjust the valves of the next cylinder in the firing o...

Page 32: ...ckly check for a short circuit When reinstallillg the glow plugs use anti seize compound on the threads A WARNING 00 notkeep ag owp ug on for more than 30seconds GLOW PLUG TIGHTENING TORQUE 1 0 1 5M K...

Page 33: ...that the end that would connect to the fuel injector is pointing away from the engine fuel will flow from this line during the timing check Rotate the engine s crankshaft in its normal direction of r...

Page 34: ...nd recheck the belt tension 8 Replace the guard t DEIUCTION 1 2 TO 3 8 PIVOT BOLT TORQUING THE CYLINDER HEAD BOLTS Mter the initial break in period approximately 50 hours and every 500 hours thereafte...

Page 35: ...ection on the fuel run solenoid Generator engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open start fuel solenoid energized 1a Switch to combine vehicle and start batt...

Page 36: ...rade of engine oil 1a Crankcase is over filled with engine oil oil is blowing out through the exhaust 2 White smoke 2 Engine is running cold 2a Faulty injector or incorrect injector timing 3 Black smo...

Page 37: ...sitive 0 25 amp meter in battery lines Do NOT start engine Remove connections and replace after short is located 3 Low resistance leak to ground 3 Check all wires for temperature rise to locate the fa...

Page 38: ...III GROUND TO sJI I IlliE1 II E itGo N 114 PUR WHT 116BLK WHI CD 2D UlWJ ll 6REiKER t12 REO TAN 114 RED PUR 6L EMEBGE CY II PUR WHI STOP SWITe J r r E 0 r I I E 0 It 4 PUR I It I o 4Bll II LUlIRE If...

Page 39: ...AT SWITCH OVERIDES THE LOW OIL PRESSURE SHUT DOWN CIRCUIT STOP PUSH AND HOLD THE STOP SWITCH UNTIL GENERATOR STOPS COMPLEiELY Nons IHIS PRODun IS PROTECTED BY A MANUAL RESEI IHCUIT BREAKER LOCATED NEA...

Page 40: ...ITCH NOT I REMOn JlJMPER WHEN CONNECTING A SECOND REMOTE PANEL 116 REI I l r82 1 116R DIrIlT fl6 WHT TB1 l Iii HlfRtD TBI 5 T81 3 f51 2 Te 1 10 TB1 5 Ta I fBl B HOUR METER 114 VIO 116 YEL 116 flED 16...

Page 41: ...ESS SWI TCH FUEL SOL FUEL PUMP TOP ISWI TCH I K2 RUN RELAY TBI 2 IN4002 TB1 6 1B2 7 86 85 FIRE ALARM N C CONTACTS REMOVE JUMPER KI ST ART RELAY PREHEAT START SWITCH SWITCH 86 I q r L __ I 85 1BI 3 STO...

Page 42: ...KU SWITCH 0 tl2 ED r r_ _r t I TAN Jl J STOP SW ITCH fl4 VIO l NOTE I REMOVE JUMPER WREN CONNECT ING A SECO O REVOTE p m SPEED ACTUATOR HC 9 T8281 I RU lI Hl e TB1 1 l 1 L Jlli _ A TB H r O cM TO 3 i...

Page 43: ...BI 8A lSTOP Isw ITCH I 01 L PHSS SWI TCH IN4001 FUEL PUMP K2 RUN RELAY _ 0_f0 _ _____ _ 85 r I RE ALARM START SWI TCH _ _ _ _ _ J Mov O m KI START RELAY q _ _ _ J _ _ _ __________ 8 6 85 T61 3 STOP SW...

Page 44: ...ENOO Cf CUlT Ii BREAKER SWITCH l2 YELIAEO IZV LI REI i GROlKlTO Q ENGINE It SLoe 8ATT A I 14 BLUE L 0 14 PUR LO PU i IA RED U l L EMERG eSTOP j 0i0 SWITCH GENERATOR i R M YItE THtS_ a JUMPER WHEN ro 0...

Page 45: ...fUEL SOLENO I Q r Du 114 RED 114 PUR WHT GROUND TO ENG IHE BLOCK OIL PRESSURE ill lI V OIL PRESSURE ll IiQ E B r 1 ____ _ 20A CIRCUIT I 112 RED EAK ____ __ __ _____ ____ m ___________ Q EXHAUST TEMP i...

Page 46: ...T RELAY 1 EMERG SW J START SOL t r r __1 STARTER PREHJ AT SOL ilr 1C S IIOA START SW L J r 1 r I iEMERGENCY L ___ I I JSTOP SW L r l r l I ISTOP SW I I I I IPREHEAT SW I L J L J FUEL PUMP EXHAUST TEMP...

Page 47: ...ENOID GLOWPlUGS I r 1 i 1 1 I I 1 1 __ J 10 AMP 120 AMP CIRCUIT BREAKER lCIRCUIT L _I BREAKER START SWITCH K I at 85 I EMERGENCY L L_ J 1STOP L ISWI TCH r I PREHEAT FUEL PUMP II I SWITCH L P r ISTOP 1...

Page 48: ...T w fwo Relays Terminal Blocks Terminal Blocks I r l TOTB1 1_ _ ____ 1B1 2 1 to TB1 I to Stop Switch I L 14 BLACK cO BLACK TB1 Ground to TB1 Ground to Panel Ground STOP I I 22 I I BLACK I I 22REDG I I...

Page 49: ...gine combustion FUEL SYSTEM Open How self bleeding self priming No 2 diesel oil cetane rating of 45 or higher In line plunger Bosch type 16 5 BTDC Before Top Dead Center BCD BCDA 16 5 BTDC Before Top...

Page 50: ...probe NOTE When the vessel in which the generator is installed contains AC equipment of120 volts only it is recommended that the generator s AC tenninal block be configured to pro vide one 120 volt A...

Page 51: ...red cover at the generator end A diagram of the various AC voltage connections is pro vided on the decal An Integral Controller IC is mounted inside the generator and supplies a continuous DC charge t...

Page 52: ...or s two tenninals with an insulated plastic handle screwdriver This will discharge any excess electricity A WARNING Do notattempt to make ano load volt age adjustment while the generator is operating...

Page 53: ...at the capacitor must be changed for 50 Hertz 5 or 60 Hertz 6 The frame ground wire must be moved when changingfrom 115 volts 50 Hertz to 230 volts 50 Hertz A WARNING Capacitors must be discharged be...

Page 54: ...illustrated AC voltage running to the bridge rectifier approximate No load offthe generator 16 0 volts AC Full load off the generator 17 5 volts AC Normal DC voltage running out of the rectifier in v...

Page 55: ...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 56: ...125 17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125...

Page 57: ...coating Check that the transmission vent is open For additional information refer to the TRANSMISSION SECTION Spare Parts Lay up time provides a good oppOltunity to inspect your Westerbeke engine to s...

Page 58: ...onditioner such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any...

Page 59: ...nd electrical accessories The 5 OKw BCD produces 9 2hp at a continuous 1800 rpm This horsepower can be utilized either for generator AC output or to operate the power take off Contact your WESTERBEKE...

Page 60: ...o Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising KIT A ZINC ANODES DRIVE BELTS OIL FILTER FUEL FILTER HEAT EXC...

Page 61: ...Engines Generators 1107WMDW 8 2006...

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Westerbeke 4.0KW BCD, Operator'S Manual

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