Bmw D7 Owners Manual

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1 Owners Manual D7 BMW Marine Engines This copy of the BMW D7 Owners Manual has been recreated using images computer scanned from a manual rather than original artwork It has also been reformatted in 223portrait224 style to display andor print better on computer systems 2 This manual was written on your behalf in an effort to help you enjoy your new BMW Marine Engine to the maximum No marine engine be it the best in the world will perform at it222s best during a long life without proper care and maintenance Please read this manual carefully before you set out on the first trip with your new BMW Marine Engine For the practical boat owner some maintenance procedures are described in this manual Next to some jobs you will find this marking which indicates that the work will require special tools as well as certain special knowledge It is therefore recommended that your authorized BMW Marine Dealer complete these operations 3 INDEX ENGINE DESCRIPTION 4 INSTRUMENTS AND CONTROLS 6 STARTING AND OPERATING 7 SERVICE MAINTENANCE 12 FUEL SYSTEM 13 LUBRICATION SYSTEM 16 COOLING SYSTEM 17 VALVE SYSTEM 19 ELECTRICAL SYSTEM 20 WINTER LAY UP AND RECOMISSION 21 4 ENGINE DESCRIPTION The BMW D7 is a singlecylinder fourstroke diesel engine The engine is equipped with a rawwater cooling system fed by an impeller type pump driven by the crankshaft Electrical starting and charging systems are standard as is an automatic air bleeder device in the fuel system Technical Data Displacement 280cc 170 cu in Stroke Bore 67 x 73 mm 263 x 287 in Max output at min1 RPM 45 kW 3600 6 HP 3600 Max torque at min1 RPM 117 Nm 3300 12 kpm 3300 87 lb ft 3300 Compression Ratio 191 Weight dry engine incl Gearbox 68 kg 150 lb Gearbox reduction 27 Maximum engine inclination 15 deg 5 Specifications Engine Gearbox Fuel Diesel Oil DIN 51601 USA 2 Fuel Filter BMW 13 32 1 329 270 Lubrication oil Type Capacity 226 Litre US gal HDAPI CCCD SAE 30 1 litre 026 US Gal ATF Dexron 04 litre 01 US Gal Air Filter BMW 13 71 1 329 269 Injector make Bosch Injection pressure 135 8 bar Injection pump Bosch PFE 1 Q 5519 Starter motor make Bosch Alternator charging capacity 14v 350w Battery rec capacity 12v 60 Ah Polarity Negative ground Rawwater pump Johnson Gearbox Hurth HBW 5 Adjustment Data Injection ends 115 226 125 deg BTDC Tappet clearance 015 mm 006 in Torque Nm lbft Injector retainer 10 72 Cylinder head bolts 35 25 6 INSTRUMENTS CONTROLS Instruments The BMW D7 is equipped with an instrument panel as shown 1 Starter Switch 226 with three positions 224O224 226 the circuit is switched off and the key can be removed 224II224 226 the current is switched on and the alternator charging control lamp lights 224S224 226 the started is engaged When the engine fires the key should be released and will automatically return to position 223II224 2 Alternator Charging Control Lamp 226 is normally out when the engine is running above idle speed 3 Engine Temperature Control Light 226 should be out at all times except if engine temperature exceeds 70oC or 160oF In such cases the engine must be stopped at once or severe damage may occur Find the trouble before the engine is restarted 4 The panel also has a reserve lamp marked 223OIL224 which is not connected Controls Throttle and gearshift are both operated by singlelever remote control which works as shown N Neutral F1 Forward gear engaged F2 The RPM increases B1 Reverse gear engaged B2 RPM increases To disengage the gearshift mechanism push the knob 226 2 226 fully in for instance when starting the engine Aloha Owners Association note 226 the control fitted to Aloha 27s is not always the same as this and in some cases you pull the knob OUT to disengage 7 STARTING AND OPERATING The Decompression Valve The automatic decompression valve makes starting easier particularly manual starting The valve is operated by a twist grip In the 223O224 position the valve is closed while in the 2231224 sector it is open but the automatic control device is not engaged Turning the grip further 226 always clockwise 226 will engage the automatic control When the engine is cranked the valve will automatically return notch by notch to the 2230224 position This takes four full turns of the crank handle and the speed gained thereby should make the engine fire at the first following compression stroke Use of the decompression valve is also helpful when the battery is too low for sufficient cranking speed NOTE 226 never use the decompression valve to stop the engine 8 Cold Starting Device Situated next to the injection pump on the starboard side just forward of the dipstickWhen starting a cold engine the knob is pulled out fully and the RPM control pushed to the 223full224 position with the gear disengaged Cold Weather Starting Aid A cold start primer is located on top of the cylinder head Fill with diesel or lubricating oil with the cover removed and press the cover fully down prior to starting Engine ShutOff Control Pull the handle and hold it in this position until the engine has completely stopped 9 Air Bleeding The BMW D7 fuel system incorporates a fully automatic airbleed device Prior to starting up after a long rest period or when the fuel system has been worked on operate the primer pump some 30 226 50 strokes which will save the battery and starter For location of primer pump see diagrams on pages 13 15 Starting A Cold Engine 247 Check that the gearshift is in neutral 247 Set the throttle at the 223full224 position 247 Turn the starter switch key to the 223II224 position ans check that the alternator charging control lamp comes on 247 Turn the key to the 223S224 position which will engage the starter motor When the engine fires evenly release the starter switch key 247 Set the throttle at normal idling Important 226 see NOTES on next pageA runningin period of approximately 10 hours when the maximum RPM should not exceed 3000 min1 will prolong engine and gearbox life After these 10 hours the engine should be checked by a BMW Marine Dealer in accordance with the instructions in the service section Always check the engine oil level prior to the first starting of the day 10 NOTE If outside temperature is extremely low the primer device on top of the cylinder head see diagram on page 8pressed down to inject the oil into the intake manifold NOTE Since a diesel engine is dependent on a certain compression pressure heat to ignite the fule one may have to operate the starter for longer periods than is the case with a gasoline engine Under no circumstances should the starter be engaged for more than thirty seconds at a time A battery too low for sufficient cranking speed will doom the starting from the beginning and the battery will drain very rapidly In such a case try the decompression valve or crank the engine manually Starting A Warm Engine 247 Check that the gearshift is in neutral 247 Set the throttle at the 223full224 position 247 Turn the starter switch key to the 223II224 position ans check that the alternator charging control lamp comes on 247 Turn the key to the 223S224 position which will engage the starter motor 247 Release the key as soon as the engine fires 247 Decrease the RPM to normal idling 247 Check that the alternator charging control lamp is out and the gearshift is reengaged 11 Manual Starting 247 Prepare the starting according to the instructions for a cold engine on page 9 247 Insert the crank handle and make sure it is properly engaged 247 Turn the decompression valve twist grip almost 180o clockwise 247 Hold the crank handle as shown ie with fingers and thumb on the same side of the handle thus avoiding spraining the hands should the engine rotate backwards 247 Crank the engine as rapidly and vigorously as possible After four crank handle revolutions the decompression valve will close and the engine will fire normally 247 Remove the crank handle and decrease RPM to normal idling Aloha Owners Association note 226 owners of some Aloha 27s advise that due to the close proximity of the bulkhead there may be insufficient clearance to allow insertion of the crank handle for manual starting Stopping the engine 247 Set the control in neutral and allow the engine a few minutes idling in order to even out any thermal stresses 247 Pull the shutoff handle fully until the engine has completely stopped NOTE 226 never use the decompression valve to stop the engine 12 SERVICE AND MAINTENANCE Periodical service and maintenance procedures are listed below The marking indicates that the procedure in question requires special tools and certain knowledge and should be left to your authorized BMW Marine Dealer Jobs to be done Engine hours Page Oil level check Daily 16 Oil change engine 50 or once yearly First change after 10 hours 16 Oil change gearbox 150 or once yearly 16 Fuel primary filter draining Every two weeks 13 Fuel primary filter cartridge replacement 100 or once yearly 13 Fuel screen cleaning inside the feed pump 100 or once yearly 13 Air filter replacement 100 or once yearly 15 Tappet clearance 100 or once yearly 19 Injector cleaning When necessary 14 Sacrificing anodes Replaced once yearly 18 Impeller raw water pump 100 or once yearly 17 Decompression valve adjusting 100 or whenever tappet clearance is altered 19 13 FUEL SYSTEM Fuel flow circuit Number markings refer to corresponding paragraph 1 The fuel tank 226 consult the tank manufacturers or boat builders instructions for proper draining cleaning and other maintenance procedures NOTE 226 diesel fuel should not be left in the tank during the layup period due to rust sludge or wax deposits forming 2 The fuel pump 226 located on the port side of the engineoperated by the camshaft Underneath the pump housing cover there is a screen type pump which needs cleaning at regular intervals The filter sealing ring as well as the gasket at the cover centre should be renewed whenever the parts are dismantled Apart from this the pump needs no maintenance and is replaced as a complete unit if there are any doubts about it222s functioning 3 The primary fuel filter 226 with water trap Water and dirt deposits are drained by removing the knurled plud with a suitable container underneath to catch the spill The spinon type filter cartridge Type BMW 13 321 329 270is replaced at regular intervals 226 see maintenance schedule on page 12 NOTE 226 the filter cartridge cannot be cleaned and used again 14 4 The injection pump 226 of Bosch make must not be dealt or tampered with by anyone other than an authorised BMW Marine Engine or Bosch diesel dealer Should the pump need to be removed it is very important that all openings fuel line connectors etc are properly sealed to prevent contamination 5 The injector 226 of Bosch manufacture will normally need no maintenance except for cleaning of the area nect to the atomizer The injector must not be dismantled since the set injection pressure then could be altered inadvertedly When installing the injector make sure that the cylinder head seal is clean and the nuts evenly tightened to 10 kpm 72 lbft WARNING 226 when the injector is tested outside the cylinder the jet must not be directed towards unprotected skin eyes etc as it is powerful enough to penetrate the skin causing nasty wounds and possible infection 15 6 The return pipes 226 direct surplus fuel to the tank and evacuate any air locks NOTE 226 whenever the fuel system has been serviced bleeding it by operating the primer pump some 30 226 50 strokes is worthwhile Any air locks trapped in the system will otherwise cause trouble or make starting impossible NOTE 226 handling the fuel system requires total cleanliness The injection pump and injector tolerances are very fine and any fragment of dirst or the tiniest amount of water could ruin the injector operation Air filter replacement 226 is easily carried out by undoing the filter housing clasps The filter paper element is discarded and cannot be used again Clean out the filter housing and install a new element Type BMW 13 321 329 269 16 LUBRICATION SYSTEM The BMW D7 is equiped with a simple and relaible splash lubrication system Oil level check 226 is done daily with aid of the dipstick Engine oil change 226 normally every 50 hours A brand new engine however will require it222s first oil change after ten or fifteen hours running Pump out the oil oil via the dipstick opening while the engine is warm Refill via the crankcase filler plug Gearbox oil change 226 is carried out at 150 hour intervals and when the gearbox is still warm Remove the drain plug 226 1 226 and the filling opening plug 226 2 Allow the oil enough time to drain completely Check that the drain plug seal is undamaged prior to reinstallation Top up the gearbox slowly with 04 litres 01 US galLeave the filling opening open for some minutes until any possible air locks have escaped Check the plug seal and install the plug 17 COOLING SYSTEM The engine has a rawwater direct cooling system fed by an impeller type pump located on the front of the engine and driven by the crankshaft The water is circulated through the cylinder block and cylinder head jackets and finally discarded via a thermostat controlled outlet into the exhaust manifold Pump impeller change 226 is possible when the pump housing front cover is removed Pry the impeller off its shaft using two scredrivers Lubricate the shaft and the impeller vanes with a few drops of oil prior to installation Bend the vanes opposite to the direction of rotation in order to avoid distortion Renew the pump housing gasket and install the cover NOTE 226 the impeller should be removed prior to layup 226 see instructions on page 21 18 The engine temprature warning light sensor 226 1 226 and anodes 226 2 226 are situated next to the thermostat housing 226 3 226 The anodes resist internal corrosion in the cooling system The anodes 226 are checked regularly and replaced if more than 50 has been eaten away by corrosion Undo the anodes 226 2 226 and replace them with new ones including new gaskets The thermostat 226 will open at 55oC 130oFremoved 226 3 226 Check the thermostat by submerging it in hot water Always use a new gasket when reinstalling the manifold Draining the cooling system 226 is done by removing the lower sacrificial anode 19 VALVE SYSTEM The overhead valves are operated by the camshaft via pushrods and rocker arms Tappet Clearance 247 to be checked and adjusted while the engine is cold 247 set the decompression valve twist grip in the 2230224 position 247 remove the rocker arm cover attached with two studs and nuts 247 crank the engine until the compression resistance is clearly noticeable 247 use a feeler gauge to check the clearance between rocker arm and valve Correct clearance 015mm 006 in 247 adjust if necessary by loosening the adjustment screw lock nut at the rocker arm pushrod end 226 1 226 247 turn the adjustment screw either way until the correct clearance is achieved 247 hold the screw in position while the lock nut is tightened 247 check the clearance once more 247 repeat the same procedure at the remaining valve 247 reinstall the cover with a new gasket The Decompression Valve 247 is checked and adjusted when the valve mechanism has been worked on or if the proper setting has been altered for other reasons affecting the correct functioning of the valve 247 remove the rocker arm cover 247 check and adjust the tappet clearance 247 turn the decompression handle to position 2231224 247 undo the decompression valve adjusting screw locknut 226 2 226 247 turn the adjustment screw until the rocker arm clearance is clearly noticeable 247 turn the adjustment screw clockwise until the rocker arm is just in touch with the valve and then another half turn 226 180o 226 in the same direction 247 hold the screw in position while the locknut is tightened 247 install the rocker arm cover and a new gasket 247 set the decompression valve twist grip in 2230224 position 20 ELECTRICAL SYSTEM The BMW D7 is equipped with a 12 volt electrical system consisting of a starter motor operating on the flywheel ring gear and an internal alternator with static charging coils inside the flywheel The maximum charging capacity is 14 V 350 W at 2000 RPM A panel with rectifier regulator and fuses completes the installation The alternator charging control light in the instrument panel will light up when the starter switch key is turned to 223II224 position but should go out when the engine runs indicating that everything is in order If not consult your BMW Marine Dealer as in case of any starter motor malfunctioning Apart from replacing any burned fuses make sure that the correct type of replacement is used the electrical system should need no maintenance Check however that all visible connections are clean and tightened Wiring Diagram 1 Charge Control Lamp 6 Water Temp Switch 11 Flywheel Generator BL Blue RT Red 2 Water Temp Lamp 7 Regulator 12 Fuse box 25A BR Brown SW Black 3 Spare Oil 8 Impulse Transmitter 13 Starter GE Yellow WS White 4 Keyswitch 9 Plug 226 1 Pin 14 Battery GN Green 5 Plug 226 9 Pin 10 Plug 226 4 Pin 21 WINTER LAYUP AND RECOMISSION Prior to winter layup or any long periods of rest the engine should he prepared for storage mainly to fend off corrosion Either leave this job to the authorized BMW Marine Dealer or do it you according to the following instructions Before the boat is taken out of the water 247 warm up the engine and remove the oil see page 16 247 use preservation oil level with the dipstick lower marking 247 drain the gearbox oil and refill with ATE Dexron oil NOTE before the engine is recomissioned the preservation oil must be removed and replaced by recommended engine oil Some kind of marking is useful as a reminder 247 Mix 2 litres 05 US gal025 US gal in a suitable container Connect a hose to the ordinary fuel tank line or directly to the primary filter inlet while the other end is inserted into the container 247 Start the engine and let it run for approximately 15 minutes On dry land 247 Drain the engine cooling system but without removing the cooling water pump impeller 247 Shut off the raw water inlet and disconnect the raw water pipe at the pump 247 Mix approximately 12 litres of fresh water with 12 litres of emulsifying preservation oil in a container Always mix the oil with water not the other way round and stir vigorously 247 Connect a hose to the rawwater pump and put the open end in the container 247 Start the engine and let it idle until the oilwater mixture is nearly gone Stop the engine Make sure that no liquid remains in the system since it has no antifreeze qualities 247 Remove the injector and pour approximately 1 teaspoonful of oil into the cylinder Crank the engine a couple of turns and reinstall the injector 247 Give the engine and gearbox a good cleaning and a coat of oil to prevent rust 247 Lubricate control cables and linkage Recomission before launching 247 Remove all preservation oil in the engine and replace with recommended oil 247 Install the rawwater pump impeller 247 Remove the injector and crank the engine a few turns to get rid of surplus oil in the combustion chamber 247 Change fuel filters 247 Refuel with fresh diesel fuel Fuel left in the tank during winter storage should never be used Check lines and connectors 247 Start the engine after launching do not forget to reopen the rawwater inlet Warm up the engine and check that there are no leaks in fuel or cooling systems 578743210

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