Westerbeke BCD 4.4KW User manual

OPERATOR'S MANUAL
l,WESTERBEKE
BCD 4.4KW and BCD 6.0KW
MARINE DIESEL
GENERATOR SETS
Publication # 37144
Edition
Two
May 1988
j'-.v- 'WESTERBEKE
WESTERBEKECORPORATION
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319

SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention
to and emphasize conditions potentially dangerous
to the
operator.
IWARNINGI
The above symbol is used in the manual to warn of possible
serious personal injury
or loss of life.
CAUTION
The above symbol is used in the manual to caution personnel
of possible damage to equipment.
Read the manual carefully and thoroughly before attempting
to operate the equipment. Know when dangerous conditions
can exist and take necessary precautions
to protect personnel
and equipment.
Fuels, exhaust gases, batteries, electrical equipment, and
moving and
hot parts are potential hazards that could result in
serious personal injury
or death. Follow recommended proce-
dures carefully.
Always operate bilge blowers for at least five minutes before
startingagasoline-fueledengine;ensure nogaSOline fumesare
present before starting.
• prevent Electric Shock
Shut off electric power before accessing electrical equip-
ment.
Use insulated matswheneverworking on electrical equip-
ment.
Make sure
your clothing is dry, not damp (particularly
shoes), and keep
your skin surfaces dry when handling
electrical equipment.
Remove wristwatch and jewelrywhen working on electri-
cal equipment.
Do not connect utilityshore power to vessel's AC circuits,
except through a ship-to-shore double-throw transfer
switch. Damage
to vessel'sACgenerator may result if this
is
not done.
Be extremely careful when working on electrical com-
ponents. High voltage can cause injury or death.
• Exhaust Gases Are Toxic
Ensure thatthe exhaustsystem isadequate to expel gases
discharged from the engine. Check exhaust system
regularly
for leaks and make sure the exhaust manifolds
are securely attached and
no warping exists.
Be sure the unit and its surroundings are well-ventilated.
• Use Extreme Care When Handling Engine Fuel
(A constant dangerof explosion orfire exists)
Do notfill fuel tank(s) while the engine is running.
Do not smoke or use an open flame neartheengine or the
fuel tank.
• DQ Not Alter or ModifY the Fuel System
Be sure all fuel supplies have a positive shut-offvalve.
•
Be certain fuel line fittings are adequatelytightened and
.free
of leaks.
Make sure a fire extinguisher is installed nearby and
is
• properly maintained. Be familiar with its proper use. Ex-
tinguishers rated ABC by the NFPA are appropriate for all
applications encountered in this environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection
when servicing batteries.
Leadacidbatteries
emit hydrogen,a highly-explosivegas,
which can be ignited
by electrical arcing or by a lighted
cigarette, cigar, or pipe. Do not smoke or allow an open
flame near the battery being serviced. Shut off all electri-
cal
equipment in the viCinity to prevent electrical arcing
during serviCing.
• Avoid Moving parts
Do notservice the unitwhile the unit is running; if a situa-
tion arises
in which it is absolutely necessary to make
operating adjustments, use extremecare
to avoid moving
parts and
hot exhaust system components.
Do
not wear loose clothing or jewelry when servicing
equipment; avoidwearing loosejackets, shirts
or sleeves,
rings, necklaces,
or bracelets that might be caught in
moving parts.
Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
place at all times.
Do not check fluid levels
or the drive-belt's tension while
the unit is operating.
Do notworkonthe equipmentwhen mentally
or physical-
ly incapacitated by fatigue.
CALIFORNIA
Proposition 65. Warning
Diesel qine exhaust and some of its
constituents are known te,~e State
of California·to cause can~birth
defects, and other reprodu«t~
harm.
,

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Productsoftwareof all kinds, such as brochures,drawings,technical data, operator's and workshop manuals,
parts lists and parts price lists, and other information, instructions and specifications provided from sources
otherthan
Westerbeke, is notwithin Westerbeke's control and, accordingly, is provided to Westerbeke cus-
tomers only as a courtesy and service. Westerbeke cannot be responsible for the content of such
software, makes nowarranties
or representations with respectthereto, including the accuracy, timeli-
ness
or completenessthereof, and will in noevent be liablefor anytype of damages or injuryincurred
in connection with,
or ariSing out of, the furnishing or use of such software.
For
example, components and subassembliesincorporated in Westerbeke'sproducts and supplied byothers
(such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and
other products) are generally supported by their manufacturers with their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software. Such software may
be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, of which Wester-
beke rarely has notice in advance, are frequently notreflected in the supplier'ssoftware until after such chan-
ges take place.
Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software,
and the unavoidable existence of earlier, non-current Westerbeke softwareeditions in the field. Ad-
ditionally, most Westerbeke products include customer-requested special features that frequently donot in-
clude complete documentation.
In summation, product software provided with Westerbeke products, whetherfrom Westerbeke orother sup-
pliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.
It not only makes good sense but is imperative that appropriate representatives of Westerbeke orthe sup-
plier in question be consulted to determine the accuracy and currency of the product software being con-
sulted bythe customer.
1 Westerbeke Generators

FOREWORD
Thank you for selecting a Westerbeke marine product for your use. We atWesterbeke are pleased to have
you as a customer.
Read this manual carefullyand observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures, installation checks, system descriptions and minor adjust-
ment proceduresare included herein so you can operate your equipment safely and properly, maintain the
equipment
at a high level of efficiency, and expect dependable performance and long service life in return.
Should your unit require special attention, contactyourWesterbeke dealer for assistance. TheWesterbeke
Service Organization is trained to provide the support necessary to ensure long-term dependable perfor-
mance.
If, within 60 days of submitting the Warranty Registration Form for your unit, you have not received a Cus-
tomer Identification Card (see below) registering your warranty, please contact the factory in writing with
Model information, including the unit's serial numberand commission date.
from:
WESTERBEKE CORPORATION
AVON INDUSTRIAL PARK
AVON, MA 02322
--
..,
r,~. WESTERBEKE
• IIUOfII ......,..~ , .... II"'''' n_ .1II:1z:;r: • 1'&" .. ,7J ••• -yy_
.,. ... x: ,1.- ...... ... 11; CUP) "'-'.23· C •• La: •• an:OIJ'
CUSTOMER IDENTIFICATION
Adam Silith
Mall To:
85 Maple Street
Alden, IN 12234
Model BCD 4.4 KW Ser .• 1234C786
Expires 717/89
.....
~
Westerbeke Generators
2

TABLE OF CONTENTS
Section ......................................................................... Page
GENERAL ...........................................................................5
BCD 4.4KW GENERAL SPECiFiCATIONS ...................... 10
BCD 4.4KW SYSTEM SPECIFICATIONS ........................ 11
BCD 6.0KW GENERAL SPECiFiCATIONS ...................... 14
BCD 6.0KW SYSTEM SPECIFICATIONS ........................ 15
INSTALLATION CHECKS ................................................. 18
DESCRIPTION OF
INSTRUMENT PANEL ...................................................... 29
PREPARATIONS FOR STARTING ................................... 32
STARTING PROCEDURE ................................................. 33
STOPPING PROCEDURE ................................................ 34
FUEL SYSTEM ................................................................. 36
DC ELECTRICAL SYSTEM .............................................. 39
BCD 4.4KW DC CONTROL CIRCUIT
WIRING DIAGRAM # 35951 .................................... 42 & 43
BCD 6.0KW DC CONTROL CIRCUIT
WIRING DIAGRAM # 35773 .................................... 44 & 45
COOLING SySTEM .......................................................... 46
LUBRICATION SYSTEM .................................................. 51
BC GENERATOR .............................................................. 54
GENERAL INFORMATION AND CARE
OF THE GENERATOR ..................................................... 61
ENGINE TROUBLESHOOTING ....................................... 63
MAINTENANCE & ADJUSTMENTS ................................. 66
3 Westerbeke Generators

TABLE OF CONTENTS
(CONTINUED)
LAY-UP & RECOMMISSIONING ......................................75
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES .................................................. 79
TABLE OF TIGHTENING TORQUES ...............................80
SPARE PARTS .................................................................. 81
INDEX ................................................................................ 82
Westerbeke Generators 4

GENERAL
Introduction
This manual containsthe equipment operating procedures as well as additional information needed to help
the operatorkeep the marine equipment in properworking order. Studyand follow the instructions careful-
ly. A planned maintenance program is included in this manual; adhering
to the program will result in better
equipmentperformanceand longerequipmentlife. Properdiagnosis
of a problem is the mostimportantstep
to satisfactory repair; therefore, a troubleshooting table is included.
Understanding the Diesel Engine-Driven Generator
The diesel engine closely resemblesthe gasoline engine, since the mechanism is essentiallythe same. The
cylinders are arranged above a closed crankcase; the crankshaft is
of the same general type as that of a
gasolineengine; and the diesel engine hasthesame
type of valves, camshaft, pistons, connecting rods, and
lubricating system.
Therefore,
to a great extent, a diesel engine requires thesame preventive maintenanceas a gasoline engine.
The most important factors are properventilation and proper maintenance
of thefuel, lubricating and cool-
ing systems. Replacement
of fuel and lubricating filter elements atthe time periods specified is a must, and
frequent checking
for contamination (that is, water, sediment, or algae) in the fuel system is also essential.
Anotherimportantfactoristhe use
of thesame brand of highdetergentdiesel lubricating oil designed specifi-
cally
for diesel engines. Be careful not to put gasoline in the diesel fuel tank(s). Gasoline does not have the
same lubricating qualitiesas diesel fuel; consequently, gasoline in the fuel lines will damage components in
thefuel lift
pump assembly, fuel injection pump and injectors.
The diesel engine
does differfrom the gasoline engine, however, in its handling and firing of fuel. The car-
buretor and ignition systems are done awaywith and in their place are
two components -the fuel injection
pump and the fuel injectors.
Ordering Parts
Whenever replacement parts are needed, always provide the generator model number, engine serial num-
ber, and generator serial number as they appear
on the scarlet and gold name plate located on the gener-
ator end. You must provide us with this information so we may properly identify your generator set. In
addition, includea complete part description and part number for each part needed (see the separately fur-
nished PartsList). Also, besure
to insist uponWesterbekefactorypackaged parts because"will fit" or generiC
parts are frequently
not made to the same specifications as original equipment.
Note that component locations in the manual are referenced from the front
of the engine which is the pul-
ley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined
by the
engine; imagine straddlingthe engine and facing in the same directionasthefront
of the engine: theleft side
is at
your left, the right side at your right.
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.
Careatthefactoryduringassemblyand thoroughtesting have resulted in aWesterbeke diesel engine-driven
generatorcapable
of manythousands of hours of dependableservice. However, what the manufacturercan-
not control isthe treatment the unit receives in the field. That part is
up to the owner/operator.
5
Westerbeke Generators

45
0
Exhaust Elbow
i Fuel Run Solenoid
AC
.Fr~shJII(~ter
Block Drain
Lube
Oil Pressure Sender
Westerbeke Generators
BCD 4.4KW Marine Diesel Generator
Fresh Water Fill Cap
Zinc Anode
Lube Oil Drain Hose i
Oil Pressure Switch
Exchanger Fresh Water Drain.
6

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

BCD 6.0KW Marine Diesel Generator
,20 Amp DC Circuit Breake
Exhaust Temperature"
'SwItch
Emergency Stop Switc
45° Exhaust Elbow
AC
Westerbeke Generators 8

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

BCD 4.4KW MARINE DIESEL GENERATOR SET
Engine Type
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque
(at 1800 rpm)
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
Westerbeke Generators
GENERAL SPECIFICATIONS
Diesel, four-cycle, two-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(8.6 hp at 1800 rpm, maximum).
Swirl type
2.68 x 3.07 inches (68 x 78 mm)
37 cubic inches (0.606 liters)
1-2
Clockwise, when viewed from the front
33 Ib-ft (4.91 kg-m)
23:1
455 psi (32 kg/cm2) at 280 rpm
Intake Opens 18° BTDC
Intake Closes 4SO ABDC
Exhaust Opens 46" BBDC
Exhaust Closes 1 SO ATDC
Intake 45°
Exhaust 45°
Intake 0.010 inches (0.25 mm)
Exhaust 0.010 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height:
23.25 inches (590.55 mm)
Width: 17.00 inches (431.18 mm)
Length: 27.25 inches (692.15 mm)
410 Ibs (186 kgs)
0.5 U.S. gph (1.89lph) at full rated output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)
10

BCD 4.4KW SYSTEM SPECIFICATIONS
FUEL SYSTEM
General
Fuel
Injector Pump
Injectors
Lift Pump
Air cleaner
Air Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
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 (not including filter)
Operating Oil Pressure (engine hot)
Oil Grade
Open flow -totally self-bleeding
No.2 Diesel (cetane # 45 or better)
In-line plungertype (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 -190
0 F (77 -880
C)
Centrifugal type, metal impeller, belt-driven
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)
35 -55 psi (2.5 -3.8 kglcm2)
API specification of CF OR CG-4
11 Westerbeke Generators

BCD 4.4KW SYSTEM SPECIFICATIONS
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
Starter
DC No-Load Current
DC Cranking Current (engine cold)
DC Charging
AC GENERATOR
General
Voltage
Rating (Volts AC)
60 Hertz (1800 rpm)
50 Hertz (1500 rpm)
AC Circuit Breaker
Generator Cooling
Air Requirements, (60 Hertz),
at 1800 rpm
Westerbeke Generators
12-Volt, 30 A-H, (-) negative ground
(recommended)
(45 A-H in cold areas)
90 -125 (Ampere-Hours)
12-Volt, 1.2
'r<YV, reduction type,
solenoid-mounted
90 Amp (max.) at 11.5 Volts.
175 -200 Amps (engine cold)
Integral controller0 -
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
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
to full-load.
120 Volts
120/240 Volts
220 Volts
36 Amps
36/18 Amps
15 Amps
To be rated at 120% of the generator's rated
amperage and voltage output.
175 -200 cfm (4.95 -5.66 cmm)
12

BCD 4.4KWSYSTEM SPECIFICATIONS
NQIE.: Increase airsupply 15% for 50 Hertz operation (1500 rpm).
Engine Combustion Air
Requirements,
(60 Hertz),
at 1800 rpm
TUNE-UP SPECIFICATIONS
InjectorPressure
EngineTiming
19.2 cfm (0.544 cmm)
2275 psi
+142 psi -0 psi .
(120 kg/cm2 + 10kg/cm2 -Okg/cm2)
190 BTDC at 1800 rpm
13
Westerbeke Generators

BCD 6.0KW MARINE DIESEL GENERATOR SET
EngineType
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing
Order
Direction of Rotation
Maximum Torque (at 1800 rpm)
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
Westerbeke Generators
GENERAL SPECIFICATIONS
Diesel, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(12
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
Clockwise, when viewed from
the front
42 Ib-ft (6.2 kg-m)
9.2:1
455 psi (32 kg/cm2) at 280 rpm
Intake Opens 19
0 BTDC
Intake Closes
51
0 ABDC
Exhaust Opens 51
0 BBDC
Exhaust Closes 1 go ATDC
Intake 450
Exhaust 450
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. gph (2.65lph) atfull rated output (approximate)
Continuous 150
Temporary200 (not to exceed 20 min.)
14

BCD 6.0KW SYSTEM SPECIFICATIONS
FUEL SYSTEM
General
Fuel
Injector Pump
Injectors
Lift Pump
Air cleaner
Air Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
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
Open flow -totally self-bleeding
No.2 Diesel (cetane # 45 or better)
In-line plungertype (Bosch M type)
Pintle type
12-Volt DC; lift capacity 6 ft (1.8 m)
Metal screen type -cleanable
24.6 cfm (0.697 cmm)
Fresh water-cooled block,
thermostatically-controlled
with heat exchanger.
170 -190° F (77 -88° C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven.
3.50 -3.75 U.S. gpm (13.24 -14.19Ipm)
5.0 qts (4.73 liters)
Pressure type
by Trochoid pump,
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/cm2)
API specification of CF OR CG-4
15 Westerbeke Generators

BCD 6.0KW SYSTEM SPECIFICATIONS
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
Starter
DC No-Load Current
DC Cranking Current
(engine cold)
DC Charger
AC GENERATOR
General
Voltage
Rating (Volts AC)
60 Hertz (1800 rpm)
50 Hertz (1500 rpm)
AC Circuit Breaker
Generator Cooling
Air Requirements, (60 Hertz),
at 1800 rpm
Westerbeke
Generators
12-Volt, 26 A-H, (-) negative ground
(recommended)
(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
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
to full-load.
120 Volts
120/240 Volts
220 Volts
50 Amps
50/25 Amps
20.4 Amps
To be rated at 120%
ofthe generator's rated
amperage and voltage output.
175 -200 cfm (4.95 -5.66 cmm)
16

MITE: Increase air supply 15% for 50 Hertz operation (1500 rpm).
Engine Combustion Air
Requirements, (60 Hertz),
at 1800 rpm
TUNE-UP SPECIFICATIONS
InjectorPressure
EngineTiming
24.6 cfm (0.697 cmm)
2275 psi +142 psi - 0 psi
(120 kg/cm2 + 1Okg/cm2 -Okg/cm2)
19° BTDC at 1800 rpm
17
Westerbeke Generators