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

Westerbeke BCD 4.4KW Operator's Manual

Marine diesel generator sets
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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

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  • Page 1 OPERATOR'S MANUAL l,WESTERBEKE BCD 4.4KW and BCD 6.0KW MARINE DIESEL GENERATOR SETS Publication # 37144 Edition Two May 1988 'WESTERBEKE j'-.v- WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 2 SAFETY PRECAUTIONS The following symbols appear in this manual to call attention • Use Extreme Care When Handling Engine Fuel to and emphasize conditions potentially dangerous to the (A constant danger of explosion or fire exists) operator. Do not fill fuel tank(s) while the engine is running. IWARNINGI Do not smoke or use an open flame near the engine or the fuel tank.
  • Page 4 It not only makes good sense but is imperative that appropriate representatives of Westerbeke or the sup- plier in question be consulted to determine the accuracy and currency of the product software being con- sulted by the customer.
  • Page 5 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 adjust- ment procedures are 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.

  • Page 6: Table Of Contents

    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 ........

  • Page 7: Westerbeke Generators

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

  • Page 8: General

    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 of many thousands of hours of dependable service. However, what the manufacturer can- not control is the treatment the unit receives in the field.
  • Page 9 BCD 4.4KW Marine Diesel Generator Fresh Water Fill Cap Exhaust Elbow Fuel Run Solenoid .Fr~shJII(~ter Block Drain Zinc Anode Lube Oil Drain Hose Lube Oil Pressure Sender Oil Pressure Switch Exchanger Fresh Water Drain. Westerbeke Generators...
  • Page 10 BCD 4.4KW Marine Diesel Generator Emergency Shut-off Switch : Fuel Lift Pump E"~h~ust Temperature SWitch 45° Exhaust Elbow: Westerbeke Generators...
  • Page 11 BCD 6.0KW Marine Diesel Generator ,20 Amp DC Circuit Breake Exhaust Temperature" 'SwItch Emergency Stop Switc 45° Exhaust Elbow Westerbeke Generators...
  • Page 12 6~OKW Marine Diesel Generator ~AirBleea Fresh Water FreshWater ·c i rcufaiIn9~f:i~iiii?"' Sea Water ~eat Exc::hanger. rter with Solenoid, Westerbeke Generators...

  • Page 13: Bcd 4.4Kw General Specifications

    BCD 4.4KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Diesel, four-cycle, two-cylinder, fresh water-cooled Engine Type Vertical, in-line overhead valve mechanism (8.6 hp at 1800 rpm, maximum). Swirl type Combustion Chamber Bore & Stroke 2.68 x 3.07 inches (68 x 78 mm) Piston Displacement 37 cubic inches (0.606 liters)

  • Page 14: Bcd 4.4Kw System Specifications

    BCD 4.4KW SYSTEM SPECIFICATIONS FUEL SYSTEM Open flow - totally self-bleeding General Fuel No.2 Diesel (cetane # 45 or better) In-line plunger type (Bosch M type) Injector Pump Pintle type Injectors Lift Pump 12-Volt DC; lift capacity 6 (1.8 m)
  • Page 15 BCD 4.4KW SYSTEM SPECIFICATIONS ELECTRICAL SYSTEM 12-Volt, 30 A-H, (-) negative ground Starting Battery (recommended) (45 A-H in cold areas) 90 - 125 (Ampere-Hours) Battery Capacity ' r <YV, Starter 12-Volt, 1.2 reduction type, solenoid-mounted DC No-Load Current 90 Amp (max.) at 11.5 Volts.
  • Page 16 BCD 4.4KW SYSTEM SPECIFICATIONS NQIE.: Increase air supply 15% for 50 Hertz operation (1500 rpm). Engine Combustion Air Requirements, (60 Hertz), at 1800 rpm 19.2 cfm (0.544 cmm) TUNE-UP SPECIFICATIONS Injector Pressure 2275 psi +142 psi -0 psi (120 kg/cm...

  • Page 17: Bcd 6.0Kw General Specifications

    Height: 23.38 inches (593.85 mm) Width: 18.69 inches (474.73 mm) Length: 26.75 inches (679.45 mm) Weight 440 Ibs (199.6 kgs) Fuel Consumption 0.7 U.S. gph (2.65lph) at full rated output (approximate) Inclination Continuous 15 Temporary 20 (not to exceed 20 min.) Westerbeke Generators...

  • Page 18: Bcd 6.0Kw System Specifications

    Oil Filter Full flow, paper element, spin-on type Sump Capacity (including filter) 3.3 U.S. qts (3.2 liters) Operating Oil Pressure (engine hot) 35 - 55 psi (2.5 - 3.8 kg/cm CF OR CG-4 Oil Grade API specification of Westerbeke Generators...
  • Page 19 50 Hertz (1500 rpm) 220 Volts 20.4 Amps AC Circuit Breaker To be rated at 120% ofthe generator's rated amperage and voltage output. Generator Cooling Air Requirements, (60 Hertz), at 1800 rpm 175 - 200 cfm (4.95 - 5.66 cmm) Westerbeke Generators...
  • Page 20 Increase air supply 15% for 50 Hertz operation (1500 rpm). Engine Combustion Air Requirements, (60 Hertz), at 1800 rpm 24.6 cfm (0.697 cmm) TUNE-UP SPECIFICATIONS Injector Pressure 2275 psi 142 psi - 0 psi (120 kg/cm 1 Okg/cm Okg/cm Engine Timing 19° BTDC at 1800 rpm Westerbeke Generators...

  • Page 21: Installation Checks

    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 of the installation which require periodic checks to ensure the best operating conditions for the equipment and safe operating conditions for the personnel on board.
  • Page 22 Special rigging work is best done by someone experienced and competent in handling heavy machinery. Westerbeke Generators...
  • Page 23 Hot generator discharge air be removed from the generator area. The plat- form on which the generator and its mounting rails are located should be strong enough to support the gen- erator during all angles of vessel operation. Westerbeke Generators...
  • Page 24 This allows air to enter through this vent to prevent siphoning. !EIUITOR BElOW WilER LIIE Westerbeke Generators...
  • Page 25 The generator's exhaust system must be separate from any other engine's exhaust system. Dry portions of the exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be insulated to hold in the heat. Westerbeke Generators...
  • Page 26 Engine damage resulting from this type of sea water entry is not a warrantable issue; the owner/operator should keep this in mind. Westerbeke Generators...
  • Page 27 Exhaust Elbow Installation The Westerbeke Corporation offers a 45°and 90 exhaust elbow as well as an exhaust riser you can install on your propulsion engine. Refer to the instructions below when installing the exhaust elbow purchased for your generator. 1. Coat only one side of the exhaust gasket with *"High Tack"...
  • Page 28 Any fittings used to connect the hose to the gallery must be of steel or malle- able iron composition. Brass must not be used for this application. Westerbeke Generators...
  • Page 29 Check to make sure all engine harness connections are tight and that they are made to the appropriate terminals. Westerbeke Generators...
  • Page 30 AC Load Connections diagram found later in this manual. (See the "BC GENERATOR" sec- tion of this manual, page 54.) Do not smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a highly-explosive gas. Westerbeke Generators...
  • Page 31 Refer to the "SYSTEM SPECIFICATIONS" section of this manual for the airflow requirements of the generator sets, page 11 for the BCD 4.4KW, and page 15 for the BCD 6.0KW. Westerbeke Generators...

  • Page 32: Description Of Instrument Panel

    ..General The manually-operated series of Westerbeke generators is equipped with toggle switches and, optionally, remote panels. The Standard Instrument Panel (shown above) includes two gauges which indicate water temperature in degrees Fahrenheit (WATER and oil pressure in pounds per square inch (OIL PSI). This panel is also equipped with two meters which indicate DC control circuit voltage (VOLTS) and the gener- ator's running time (ELAPSED TIME) in HOURS and in 1/10 hours.
  • Page 33 REMOTE CONTROL PANEL (REAR VIEW) r---------------- STOP STOP ~-#-~4-C-R-N_+_(=____.J=:::J_ ~R~!!.. PANEL GND PREHEAT ;R~~E~Trl 1118 ______ PREHEAT ...!:.u..!!p...!:' : ..SWITCH - - - - - - - - - - - - - PREHEAT #~4RED #~4RED L--~-------------l------~~~- START P. N. 24943 Westerbeke Generators...
  • Page 34 This system is common to Westerbeke Diesels. The start circuitry is designed so that the PREHEAT button must be depressed for the time specified in the "Preheat" chart shown on page 33. Then, while keeping the PREHEAT button engaged, the START button is depressed to crank the engine.

  • Page 35: Preparations For Starting

    This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and stopping procedures. Follow the procedures as presented, for the conditions indicated, and your Westerbeke engine set will give you reliable performance and long service life. Fill your engine with oil up to or near the upper limit on the dipstick (the installation angle may have an effect on the dipstick reading).

  • Page 36: Starting Procedure

    Engine damage resulting from this type of sea water entry is not a warrantable issue; the owner/operator should keep this in mind. Westerbeke Generators...

  • Page 37: Stopping Procedure

    As indicated above, operate the generator with a moderate load during the 50-hour break-in period. (On one hand don't baby the engine, but on the other hand, however, don't abuse it.) Westerbeke Generators...
  • Page 38 RISE ENOUGH - Allow the glow plugs to operate sufficiently to aid in starting during the preheat period when- ever the temperature of the intake air is low and when the compression temperature does not rise enough. Refer to the preheat chart found in the "STARTING PROCEDURE" section, page 33. Westerbeke Generators...

  • Page 39: Fuel System

    Remember, water damage to the fuel system is not covered under the Westerbeke warranty. The owner/operator is responsible in making sure that fuel reaching the engine's in- jection equipment is free impurities. This process is accomplished by installing a proper filtration/separa- tion system and maintaining this system.
  • Page 40 Priming the Fuel System The Westerbeke self-bleeding fuel system is semiautomatic in operation. The self-bleeding feature of the fuel system allows for easy servicing of the fuel filters. Simply remove the and replace the filter elements (take care in catching any fuel that may drain out of the fuel filtering assemblies) as described in the "Replacing the Fuel Filter Elements"...
  • Page 41 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 to the right, is one of the most important components of the diesel engine and, therefore, calls for the utmost caution in handling.

  • Page 42: 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.
  • Page 43 (-) lead; momentarily touch points #1, #2, and #3. The Ohmmeter's needle should deflect when each point is touched. D. Leaving the negative (-) lead on point #4, touch point #5 with the positive lead. No deflection should take place. Westerbeke Generator...
  • Page 44 I.C. unit. NOTE: When the generator is first started, the I.C. unit will produce a low charging rate. This charging rate will rise as the generator is operated for awhile. Westerbeke Generator...

  • Page 45: Bcd 4.4Kw Dc Control Circuit Wiring Diagram #35951

    BCD 4.4KW DC Control Circuit Wiring Diagram #35951 page 1 of 2 DIAGRAM WATER TEMP. • SENC';R ,,.~ ¥ ~~Lp .- .- OIL PRESSURE SENDER PRESSU~E EMERGENCY STOP SWITCH CIRCUIT BREAKER Rt:.O"14 ALTERN~TOR EXHAUST TEMP. SWITCH NOTE 2 ~OUND TO 8L..OCK [1..1...

  • Page 46: Wiring Diagram # 35951

    BCD 4.4KW DC Control Circuit Wiring Diagram #35951 page 2 of 2 SCHEMATIC DIAGRAM -: seE NOTE 2 START SOL. STARTER ~--------~..., I----{M}--~ Q.OWPLUGS :( : C.B. p.H.SOL. EXM.r.sw, O.P. sw. W.T.SW. "---J ~--+o-~ -r' __ , START 1 ____ ..: p.t;,SW.

  • Page 47: Bcd 6.0Kw Dc Control Circuit Wiring Diagram #35773

    BCD 6.0KW DC Control Circuit Wiring Diagram #35773 page 1 of2 WIRING DIAGRAM EU!2 ,...-----'c---:;I;T llQe EXHAUST TEMP, SWITCH ..POWER ALTERNATOR r---' fir, GND. '10 ILOCK '\-! SEE NOTE 2 l---a BATTERY STANDARD "iNS'i'RuME (REAR VIEW) ~---~ Westerbeke Generator...

  • Page 48: Wiring Diagram # 35773

    A SWITCH WITH A CQNrlNUQlJS RATING OF 175 AMPS AT IZVOC WILL NORMALLY SERVE THESE FUNCTIONS BUT SWITCH ,",USTNEVER BE USED :o-1AKE THE CIRCUIT. 5TARTER BATTERV CHARGER CAUSES 9.-DRAIN WHEN GENERATOR NOT OP€RATING.WMEN LEAVING BOAT FOR AN EXTENDED PERIOD DISCONNECT BATTERY. Westerbeke Generator...

  • Page 49: Cooling System

    COOLING SYSTEM 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 which circulates throughout the engine. This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred ex- ternally from the fresh water to sea water by means of a heat exchanger, similar in function to an automo- tive radiator.
  • Page 50 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 to allow for engine coolant expansion and contraction, during engine operation, without the loss of coolant and without introducing air into the cooling system.
  • Page 51 Since 1980, each type of thermostat has a hole punched through 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...
  • Page 52 1/2 inch (10 mm, 12 mm) as the belt is depressed with the thumb at the midpoint between the two pul- leys on the longest span of the belt. A spare drive belt should be carried on board. Westerbeke Generators...
  • Page 53 Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow through their independent cooling circuits. Refer to your generator's Parts List for part numbers and part descriptions if you need to order cooling system parts for your engine.

  • Page 54: Lubrication System

    NOTE: A newly started, cold engine can have an oil pressure reading upwards of 60 psi. A warmed engine can have an oil pressure reading as low as 35 psi. These readings will vary depending upon the temperature of the engine and the load placed on the generator. Westerbeke Generators...
  • Page 55 Immediately after an oil filter change and oil fill, run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil filter. Westerbeke Generators...
  • Page 56 Add fresh oil through the oil filler cap on the valve cover (refer to the photographs on pages 6 and 7 for Oil Filler Cap the BCD 4.4KW, and pages 8 and 9 for the BCD 6.0KW Rocker Cover forthe location of the oil filler cap and lube oil dipstick).

  • Page 57: Bc Generator

    D. Bridge Rectifier and Intergral Controller Generator Frequency Frequency is a direct result of engine/generator speed: 1800 RPM -60 Hertz, 1500 RPM -50 Hertz To change the generator's frequency, refer to the "MAINTENANCE AND ADJUSTMENTS" section of this manual, page Westerbeke Generators...
  • Page 58 Ask your local Westerbeke dealer for a BC GENERAL TROUBLESHOOTING GUIDE before performing the steps listed at the bottom of the next page.
  • Page 59 IF THESE PLues TOUCH HOUSING OR OTHER WIRES .. Check the resistance of the exciter windings B. Check the capacitor. BCD 4.4KW : 1.9 Ohm BCD 4.4KW: 31.0 uF 5° ± C. Check the engine's speed. 60 Hertz: 60.5 - 61.5 50 Hertz: 50.5 - 51.5...
  • Page 60 Ask your local Westerbeke dealer for a Be GENERAL TROUBLESHOOTING GUIDE before performing the steps listed at the bottom of the next page.
  • Page 61 60 Hertz: 60.5 - 61.5 50 Hertz: 50.5 - 51.5 Adjust the engine's speed by use of the governor/fuel solenoid linkage adjustment, page 73, to obtain the correct Hertz. NOTE: Refer to the "NOTE" at the bottom of page 59. Westerbeke Generators...
  • Page 62 Hertz; or 110 Volts AC two-wire, 110/220 Volts AC three-wire, or 220 Volts AC two-wire, at 50 Hertz. Refer to the "SYSTEM SPECIFICATIONS" section of this manual for generator ratings, page 11 for the BCD 4.4KW, and page 15 for the BCD 6.0KW.
  • Page 63 ' - - - - ' - L l " 32B~a r>---+---,;;N~9U,:,;lra","i_'-N (~2S AMPS/POLE) Ship'sLoad (WHT) Note --'" PH 32133 NO 24Q.Vott (299 AMPS/POLe) 1r • ."G""'o="un""d_ .._ _ _ --l equipment (GRN) Shore Power Shore Power Switch Connection Diagrams Westerbeke Generators...

  • Page 64: General Information And Care Of The Generator

    Run the generator at first with no load applied, then at half the generator's capacity, and finally loaded to its full capacity as indicated on the generator's data plate. See the rpm/Hertz/frequency chart on the next page. Westerbeke Generators...
  • Page 65 3. The rear armature bearing is lubricated and sealed; therefore, no maintenance is required. If the bearing becomes rough or noisy, replace it. Generator Troubleshooting 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. Westerbeke Generators...

  • Page 66: Engine Troubleshooting

    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 or voltage loss in small electrical wiring or corroded connections. Westerbeke Generators...
  • Page 67 4. Fuel pump is not 4. Check pump operation. operating. Check for 12-Volts at pump. 5. Fuel filters are clogged. 5. Clean/replace filters. Failure to stop. 1. Solenoid linkage 1. Stop engine by man- is disconnected. ually shutting OFF fuel and air. Westerbeke Generators...
  • Page 68 2. Check fuel filters. Make sure incorrect fuel. you are using #2 diesel fuel. 3. Faulty injector(s). 3. Remove and test injectors. 4. Lack of air. 4. Check air intake for restrictions. Make sure adequate combustion air is present. Westerbeke Generators...

  • Page 69: Maintenance & Adjustments

    2. 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. *3. Torque the cylinder head bolts. Westerbeke Generators...
  • Page 70 7. CHECK TIlE INTERNAL CONDITION OF TIlE WATER INJECTED EXHAUST ELBOW. INSPECT TIlE EXHAUST AND WATER PASSAGES. REMOVE ANY CARBON AND/OR CORROSION BUILD UP. REPLACE TIlE ELBOW IF CORROSION IS EXTENSIVE. Westerbeke Generators...
  • Page 71 1. Remove, clean, and pressure test the primary heat exchanger. (A local automotive radiator shop should be able to clean and test the heat exchanger.) 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...
  • Page 72 Torquing Cylinder Head Bolts: BCD 4.4KW Tighten the cylinder head bolts according to the sequence shown in the illustration shown Front of Engine to the right. Make sure the engine is cold when ¢::o this is done. Before applying the specified torque to the bolt, loosen it 1/4 to 1/2 of a turn and then apply the torque.
  • Page 73 Valve Clearance Adjustment: BCD 4.4KW CAUTION Adjust the valve clearance when the engine is cold. Valves are adjusted by cylinder in the firing order of the engine. Tighten the cylinder head bolts to the specified torque before adjusting the valves. (See page 69.) 1.
  • Page 74 No.2. Be sure to check the valves for this 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. Westerbeke Generators...
  • Page 75 Changing the shim thickness by 0.004 inch (0.01 mm) changes the injection timing by approximately one degree. To advance the timing, decrease the shim thickness, as required. To retard the timing, increase the shim thickness, as required. Refer to your generator's Parts List for shim part numbers. Westerbeke Generators...
  • Page 76 2. Adjust the engine's speed to obtain the frequency corresponding to the voltage selected by extending or shortening the Throttle Adjustment Linkage. Make sure the solenoid's plunger is completely bot- tomed in the solenoid. (See figure below.) 60Hz ~SOHz Westerbeke Generators...
  • Page 77 Make sure 10 - 12 volts DC is present at the solenoid's positive harness connection during PREHEAT and START. Loss of voltage will affect the solenoid's operation and cause a solenoid failure. Westerbeke Generators...

  • Page 78: Lay-Up & Recommissioning

    Fill the sump with the correct amount of oil for your engine. (Refer to the"SYSTEM SPECIFICATIONS" section of this manual, page 11 for the BCD 4.4KW, and page 15 for the BCD 6.0KW.) Use an oil with an API speCification of CC or CD. Run the generator and check for proper oil pressure and make sure there are no leaks.
  • Page 79 Make sure all AC leads are properly cleaned and reconnected. Make sure all AC leads are properly supported and not chaf- ing as they exit the generator housing. Westerbeke Generators...
  • Page 80 Spares Lay-up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement. Check your basic spares kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes.
  • Page 81 When the engine is put into operation, the system will self-flush in a short period of time with no ad- verse affects. 5. Start the engine in accordance with procedures in the "PREPARATIONS FOR STARTING" section of this manual, page 32. Westerbeke Generators...

  • Page 82: Table Of Standard Hardware Tightening Torques

    3/8 UNF 30 - 35 4.1 - 4.8 7/16 UNC 44 - 49 6.1 - 6.8 7/16 UNF 50 - 55 6.9 - 7.6 1/2 UNC 68 - 73 9.4 -10.1 1/2 UNF 73 - 80 10.1 -11.1 Westerbeke Generators...

  • Page 83: Table Of Tightening Torques

    Nozzle mounting bolt 10.8 -14.5 1.5 - 2.0 (All Models) Nozzle holder and retaining nut 43.4 -57.9 6.0 - 8.0 (All Models) Glow plug 10.8 -14.5 1.5 - 2.0 (All Models) NOTE: M8 indicates Metric, 8 mm thread diameter Westerbeke Generators...

  • Page 84: Spare Parts

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

  • Page 85: Index

    COOLING SYSTEM SPECIFICATIONS, BCD 4.4 KW ................11 COOLING SYSTEM SPECIFICATIONS, BCD 6.0 KW ................15 Cylinder Head Bolts, Torquing, BCD 4.4 KW ....................69 Cylinder Head Bolts, Torquing, BCD 6.0 KW .................., ..69 Cylinder Lubrication ............................. 77 Westerbeke Generators...
  • Page 86 Engine Oil Viscosity (SAE Number) ......................51 ENGINE TROUBLESHOOTING ......................63-65 Engine 12-Volt DC Control Circuit ......................39 Equipment Inspection ..........................18 Exhaust Back-Pressure ..........................22 Exhaust Elbow Installation .......................... 24 Exhaust System ............................21 Exhaust System Failures ..........................23 Exhaust, Through-Hull ..........................76 Westerbeke Generators...
  • Page 87 Generator Remote Operation ........................30 Generator Troubleshooting ......................... 62 Hose, Oil Drain ............................. 25 Injection Pump, Fuel ............................ 38 Injection Pump Timing Adjustment (Spill Timing) ..................72 Inspection of Equipment ..........................18 INSTALLATION CHECKS ........................18-28 Installation of Exhaust Elbow ........................24 Generators Westerbeke...
  • Page 88 Oil Galleries, Connecting Pressure Sensing Devices ................25 Oil Pressure ..........................: ....51 Oil Viscosity (SAE Number) ........................51 Operating Speed, Required ........................61-62 Ordering Parts ............................... 5 PANEL, INSTRUMENT, DESCRIPTION OF ....................29 Parts, Ordering .............................. 5 Westerbeke Generators...
  • Page 89 ....................16-17 Battery ..............................39 COOLING, BCD 4.4 ........................11 COOLING, BCD 6.0 ........................15 ELECTRICAL, BCD 4.4 ....................... 12 ELECTRICAL, BCD 6.0 ....................... 16 Exhaust Back-Pressure ........................22 FUEL, BCD 4.4 ..........................11 FUEL, BCD 6.0 ..........................15 Westerbeke Generators...
  • Page 90 Torquing Cylinder Head Bolts, BCD 4.4 'r0/V ....................69 Torquing Cylinder Head Bolts, BCD 6.0 'r0/V ....................69 TROUBLESHOOTING, ENGINE ......................63-65 Troubleshooting, Generator ........................62 TUNE-UP SYSTEM SPECIFICATIONS, BCD 4.4 'r0/V ................13 TUNE-UP SYSTEM SPECIFICATIONS, BCD 6.0 'r0/V ................17 Westerbeke Generators...
  • Page 91 Water Pump Drive Belt Tension ........................49 Water Pump, Sea ............................49 ADJUSTING THE DRIVE BELT'S TENSION ................... 49 CARBON MONOXIDE GAS ..•..•..•••.•...•......•••••••••••••••••.•••••••.••.••.••••••.•.•••••••••••.••••.•••• 21 & NO-LOAD VOLTAGE ADJUSTMENT ••.••.•.....••..••..•.•••••••••••••..•••••..•..••••••••.•••.••••••••••• 55 OPEN FLAMES NEAR BATTERIES ..•.•..••••....•..••..•••..•••..••..••..•.•..•.•••..•••••..•.••••• 27 SERVICING THE BATTERy ..•••...•••••..•••..•.•••...•..•••..••••.••••••..••..•..••••••.•.•..•••..••.•...•..28 & 77 Westerbeke Generators...
  • Page 92 YOUR NOTES Westerbeke Generators...
  • Page 93 YOUR NOTES Westerbeke Generators...

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