Westerbeke 6.5 MCG, 5.2 MCG, 5.0 MCG, 4.2 MCG Operator's Manual

OPERATORS

MANUAL

6.5

.

5.0

MCG MCG

60HZ 60HZ

Multi-port

MARINE

GASOLINE

SINGLE

PHASE

5.2

4.2

MCG MCG

50HZ 50HZ

GENERATOR

CALIFORNIA

Exhaust gasoline

its

constituents)·

the

State cancer, reproductive

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

Weakness

IF

YOU

GET

OUT

seek

medical

until

it

PROPOSITION

WARNING

gas

from

engines

of

California

birth

defects,

harm.

gasses

gas.

Carbon

can

include:

and

OR

ANYONE

INTO

THE

attention.

has

been

diesel

and

(and

some

are

known

to

cause

and

A

WARNING:

contain

Carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

Shut

inspected

65

of

to

other

Monoxide,

is

poisonous

Symptoms

•

Throbbing

•

Muscular

•

Vomiting

•Inability

ANY

AIR

IMMEDIATELY. down

the

and

repaired.

an

of

Carbon

in

Twitching

to

Think

OF

If

unit

and

.

odorlesS

and

Temples

THESE

symptoms

and

can

cause

Monoxide

Coherently

SYMPTOMS,

do

not

persist,

restart

A

WARNING should generator.

WESTERBEKE MONOXIDE quarters easily

DECAL

be

fixed

also

DETECTORS

of

your

obtainable

is

provided

to a bulkhead

recommends

in

the

vessel.

at

your

They

local

by

WESTERBEKE

near

your

engine

installing living/sleeping are

cosl

marine

CARBON

affective store.

and or

and

Gasoline

with

an ETHANOL

content

higher

than

and

10°/o (E10)

may

void

is

not

allowed

warranty.

Jr~

rWESTERBEKE™

~

Engines &

Generators

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this caused

precautions.

take the

personne~

The the American Boat and

PREVENT

A

while

power.

• Do not operate this machinery without electrical

• Shut off electrical power before accessing electrical

• Use insulated mats whenever working on electrical

• Make sure your clothing and skin are

• Remove wristwatch and all jewelry when working on

PREVENT

A

exhaust hot!

• Monitor engine antifreeze coolant level at the plastic

A

• In case

safety

manual

by

failure

Know

necessary

and your

foUowing

safety

ELECTRIC

WARNING:

engine

is

Lethal

voltage

enclosures and covers in place.

equipment.

(particularly shoes) when handling electrical equipment.

electrical equipment.

BURNS -HOT

WARNING:

system

coolant recovery tank and periodically at the filler cap location on the water jacketed exhaust manifold, but only when the engine

WARNING:

of

an engine overheat, allow the engine

before touching the engine or checking the coolant.

carefuUy.

to

foUow

fundamental

when

dangerous

precautions

Most

accidents rules

conditions exist and

to

protect yourself, your

machinery.

instructions

Yacht

are

Council

in

compliance

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

or

when

is

present

connected

at

these

dry,

ENGINE

Do

not

touch

hot

engine

components. A running

is

COLD.

Steam

can

cause

injury

are

and

with

standards.

connections

to

shore

connections!

not damp

parts

or

engine

gets

or

death!

to

cool

very

PREVENT

A

• Prevent sparks pump, or other potential sources vapors. Use a suitable container to catch all fuel when removing the fuel line, carburetor, or fuel

•

Do Backfire can cause severe injury or death.

• Do not smoke or permit flames or sparks the fuel system. Keep the compartment and the engine/generator clean and free chances

• Be aware - diesel fuel will burn.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. Open and ventilate cabin after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine.

•

All when ventilated area away from spark-producing equipment and out of the reach

• Do not

• Shut off the the fuel system. spill. sources

servicing. the

• Do not alter or modify the fuel system.

• Be sure all fuel supplies have a positive shutoff

• Be certain fuel line fittings are adequately tightened free

• Make sure a properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the for all applications encountered in this environment.

BURNS -FIRE

WARNING:

flash

to

not operate with the air cleaner/silencer removed.

Fire

can

cause

injury

or

death!

fires.

Do not smoke or permit

occur near the carburetor, fuel line,

of

spilled fuel or

of

debris

of

fire.

Wipe up all spilled fuel and engine

flames

filter,

filters.

to

occur near

to

minimize the

BURNS -EXPLOSION

WARNING:

or

death!

fuel

handling and storing fuels. Store fuel in a well-

fill

DO

fuel

of

leaks.

Explosions

vapors

are highly explosive.

the fuel tank(s) while the engine

fuel

service

Take

Nar

allow any smoking, open

of

fire

near

the

Ensure proper ventilation exists when servicing

system.

fire

extinguisher

from

fuel

of

children.

valve

at the engine when servicing

care in catching

fuel

system or

is

installed nearby and

NFPA

vapors

can

Use

extreme

is

any

fuel that might

flames,

engine

when

are appropriate

running.

valve.

or

fuel

oil.

cause

care

or other

and

is

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

•

Thm

unit's engine.

•

Make starting.

•

Make re-installed before starting the

BAfiERY

A

WARNING:

or

death!

•

Do

not smoke or being serviced. Lead acid batteries highly explosive arcing equipment in the during

• Never connect the negative(-) battery cable positive ( +) connection terminal of the starter Do

not together. Ventilate accumulation disturb the battery charger connections is

being charged.

•

Avoid burns

wristwatch, the

battery.

•

Always the

battery connections.

and

STARTING

Accidental

OFF

the

DC

breaker

battery

selector

certain all personnel

certain

all

covers, guards, and hatches

on

switch

starting

to

are

can

the control panel or tum

OFF

before servicing

clear of

engine.

cause

the

EXPLOSION

Battery

or

by lit tobacco products. Shut

servicing.

test the battery condition by shorting

Sparks could ignite

any

compartment contammg battenes

of

contacting the terminals with tools, etc.,

or sparks that could cause

rings,

turn

the battery charger off before

reconnect it last

explosion

allow

an

gas,

which can be tgmted by

vicinity

explosive

and

to

any

Remove

when

can

open

flame

prevent electncal

batt~I?'

gases.

To

an

other jewelry before handling

the

servicing the

cause

near the battery

~mi~

hydrogen,

o~

gases avoid

while

explosion.

negative

battery.

BAfiERYACID

A

WARNING:

severe

injury

•

When

servicing the battery

level,

wear rubber protection. Batteries contain sulfuric acid which destructive. it off

at into the caps.

Sulfuric

or

death!

If

it

once with

eyes

inadvertently

gloves,

comes

water.

acid

In

batteries

or

checking the electrolyte

a rubber

in contact

Acid

when

apron,

with

your

may

splash

removing electrolyte

can

injury

the

the.

engine before

are

Injury

~

elec~cal

all

ele~trical

arcmg

to

the

solenoi~.

the

termmals

o~

fuel

vapors.

to

prevent

sparks,

do

not

the

battery

to

prevent

Remove

.disconnecting

lead

first

cause

and

eye

is

skin,

wash

on

the

skin

or

TOXIC

• Ensure that the exhaust system

• Be sure the unit and its surroundings

•

• For additional information, refer

•

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and water-injected

Run blowers Do

not run the generator set or engine equipped with a functioning marine carbon detector that complies with boat builder or dealer for installation of detectors.

(educational information

A

WARNING:

odorless nausea

AVOID

A

or

•

gas.

or

death!

Do

not

use

Diesel

fumes systems. copper tubing resulting in exhaust/water

Do

not install exhaust outlet where exhaust through portholes, exhaust discharge outlet enter

the

flow

of exhaust.

Although exhaust gas

symptoms

poisoning

Vomiting Dizziness Headache Nausea

fumes

is

present in diesel exhaust

MOVING

WARNING:

death!

Do

not service the engine situation arises in which it make

operating adjustments, use extreme care touching moving parts and hot exhaust system components.

GASES

carbon

monoxide

make

elbow

is

securely

when

nmning the generator set or

on

Carbon

Inhalation

copper tubing in diesel exhaust

can

Exhaust sulfur causes rapid deterioration of

exhaust

diesel engine exhaust

from gasoline

or

signs

are:

monoxide

produces

rapidly

destroy

vents,

or air conditioners.

is

discharge

Avoid

overloading the

of carbon monoxide inhalation

Inability Throbbing in Muscular twitching Weakness

(CO)

is a deadly

is

adequate

sure

the

attached.

ABYC

A-24.

to

ABYC

Carbon

(CO)

nu-llke

copper

near the waterline, outlet and

gases

engines,

fumes.

to

and

to

exhaust

are

well

unless

monoxide

Consult

approved

TH-22

Monoxide).

is

an symptoms,

systems.

tubing

leakage.

can

close

or

craft.

are

not

carbon

Some

think coherently

temples

sleepiness

expel

manifold/

the boat

invisible

If

restrict

as monoxide

of

PARTS

Rotating

parts

can

cause

while

it

is

running.

is

absolutely necessary

injury

gas!

gases

ventilated.

engine.

is

your

in

exhaust

be

drawn

the engine

water

could

the

toxic

as

the

or

If

a

to

avoid

Engines & Generators

ii

•

Do

not

wear

loose

equipment; jackets, could

•

Make

Keep

places

•

Do

the

•

Do

the

generator

death

HAZARDOUS

A

WARNING:

shirts,

be

caught

sure

protective

at

all

not

check

engine not

allow

exhaust

can

tie

back

sleeves,

in

all

attaching

shields

times.

fluid

is

operating.

any

discharge

is

operating.

occur.

NOISE

High

loss!

•

Never

operate

an

•

Do

not

run

the

engine

flame

arrester

•

Do

not

open

(when

A

WARNING:

mentally

removed.

run

engines

installed).

Do

or

physically

SAFETY

clothing

moving

levels

swimming

engine

not

or jewelry when servicing

long

hair

and

avoid wearing loose

rings, necklaces or bracelets that

parts.

hardware and

or

opening

Carbon Monoxide poisoning or

noise

without its muffler installed.

with

for

long

work

incapacitated

is

properly tightened.

guards in their respective

the

drive belt's tension while

or activity around or near

for the generator while

levels

can

cause

the

air intake (silencer) or

periods with their enclosures

on

machinery

by

fatigue!

when

hearing

you

INSTRUCTIONS

ABYC,

INSTAtLING

Read for safety codes and standards. Follow their recommendations

ABYC (American Boat and "Standards and Technical Craft"

Order

the

NFPA (National Fire Protection Association)

"Fire Protection Standard for Motor Craft" Order

USCG (United States Coast Guard) "USCG 33CFR183" .

Order

are

NFPA

AND

ENGINES

the

following ABYC,

when

installing your engine.

from:

ABYC 613

Third Street, Suite

Annapolis, www.abycinc.org

from:

NFPA

11

Tracy Avon Avon,

from:

U.S. Washington,

MD

21403

Drive

Industrial Park

MA

02322

Government Printing Office

D.C. 20404

USCG

PUBLICATIONS

AND

GENERATORS

NFPA

and USCG publications

Yacht

Council)

~nforrnation

10

Reports for

FOR

Small

OPERATORS

Many

of

in

your

notes

to

carefully,

procedures.

GASOLINE

Preparations begin

with a thorough

Yacht

Council's

a

combination

Sections

H-2

Ventilation

H-24

Gasoline

P-1

Installation for

P-4

Marine

E-llAC

All

installations

Regulations

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

install

(ABYC)

of

the

ABYC

for

Fuel

of Exhaust Systems

Propulsion

Inboard

and

DC

Electrical Systems

must

(FCR).

Manual critical

your

sources

Boats

and

safety

tips

and

warnings are repeated

along

with other cautions

information. Read your manual

equipment, and follow all safety

AND

GENERATOR

a gasoline engine or generator should

examination of the American Boat

standards. These standards are including

standards

Systems

Auxiliary

Engines

comply

of particular interest

using

Gasoline

Engines

and

Transmissions

with

the

INSTALLATIONS

the

USCG and

on

Boats Federal Code of

and

the

NFPA.

are:

and

from

Engines & Generators

iii

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information:

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

AND

REGULATIONS

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow is close to or

will be below the vessel's waterline, provisions must be made to install a siphon-

break in the raw water supply hose to the exhaust elbow. This hose must

minimum

the exhaust manifold injection porl raw

If

you have any doubt about the position

to the vessel's waterline under the vessel's various operating conditions,

water

of

20" above the vessel's waterline.

is

damage

to

the engine and

possible

Failure

at or

below

flooding

of

the water-injected exhaust elbow relative

to

use

the load

of

a siphon-break

waterline

the

boat.

siphon-break.

NOTE:

A siphon-break operation. engine

EXHAUST

The Exhaust Hose is recommended. The use and turns without the and turns. In this regard, a single length

system

under any sea conditions and at any angle

Failure

damage.

SYSTEM

exhaust system's hose MUST be certified for marine use. Corrugated Marine

MUST be designed to prevent the entry

requires

to

properly maintain a siphon-break

Consult

rieed

periodic inspection

the

siphon-break manufacturer for proper maintenance.

of

this type

of

additional fitting and clamps to accomplish these bends

of

corrugated exhaust hose can be used. The

of

and

cleaning

can

of

hose allows for extreme bends

of

water into the exhaust system

vessels heel.

to

result

be looped a

will

install a

ensure

proper

in

catastrophic

when

result

in

AVAILABLE YOUR DEALER

siPiiorUfiiEAK-

LOOP'

FROM

WESTERBEKE

WiTH

STAINLESS

A

detailed engines to

and

download

Marine

Installation

generators,

from

our

Manual

is

supplied

website

at

Engines & Generators

covering

with

www.westerbeke.com.

iv

each

gasoline

and

unit. A pdf

diesel,

is

available

CARBON

MONOXIDE

"CO"JLOW·CO

GENERATORS

IMPORTANT

DESCRIPTION

Carbon monoxide is a colorless, tasteless, odorless, lighter than air poisonous gas that can kill you without any warning. one

of

the major safety risks associated with boating.

threat that must not be underestimated. Westerbeke

reduce normal levels Several standards for

parts per million

Regulator

EPA

ACGIH

EPA

NIOSH OSHA

ACGIH

NIOSH NIOSH

(IDLH)

1200

ppm

is

IMMEDIATELY

A city in California characterizes the effect concentration this way:

Parts

per

25

100

200

Even though the generator normally produces very low levels of

CO, an exhaust leak extremely dangerous. For this reason it is extremely important to install a it is always turned on and functioning properly. tor sounds, do not turn it off, assuming You can not taste, smell, detector on, turn off all engines and generators, evacuate the boat leaving ports and hatches open, and seek professional

help.

As soon as to dilution in the open air. The closer a person is to the

exhaust outlet, the higher the concentration

"CO"

is a component

Low-CO generators are designed to dramatically

of

CO

in the engine exhaust.

CO

have been published, expressed in

"ppm" and hours

CO

ppm

9 8

25 35 35 50 125 200 1200

the

so-called

DANGEROUS

Million

CO

leaves the exhaust outlet, the level is subject

IDLH

concentration·

TO

LIFE

Responses

Permissible exposure level, no apparent

No poisoning for long period. Allowable for several hours.

Should

this level for any period

time. A possible mild frontal headache

of

untreated exhaust would

detector near the generator and to

or

otherwise detect CO. Leave the

of

engine exhaust.

CO

poisoning is

of

exposure:

Exposure

Hours

8

1

8 8

0.5

0.0

AND

HEALTH.

of

CO

toxic symptoms.

not

be

exposed above

in

two to three hours.

it

is a false signal.

of

CO.

It

of

be

If

this detec-

is a

sure

It

INFORMATION

In

a closed space, such as the engine compartment, the boat,

or

underneath a stem swim platform, concentrations will potentially rise to the undiluted level emanating from the exhaust system due to a lack gas. Therefore, one should never rely exhaust to provide a margin

Westerbeke by precise control control coupled with after treatment in a special catalyst. emissions are not the same for every model because each

engine is different. Also, certain fuel system components are commonized across several engine models being adequate

for some and extra-adequate for others, thus producing

different

The fuel system which accomplishes the required precise

air/fuel ratio control is comprised components: purchased sub-assemblies, machined castings, sensors, electronics and others. Because of

CO these components can and will cause variability output.

CO

concentration also varies with load. Usually, but not always, the worst case load.

Low-CO generators achieve reduction

CO

levels for different models.

reduction, any variability in the functioning

INSPECTION

The catalyst is critical to optimizing intrusion into the exhaust system will likely quickly compromise the proper operation Westerbeke's exhaust system installation instructions must be adhered to.

NOTE:

Water

intrusion ered under product warranty nor mandated by various regulating authorities andCARB.

Maintenance the flow fuel filters and air filters

Inspection

critically important. The exhaust elbow is removed loosening the metal clamp to provide a view surface flush, honeycomb appearance is most likely a result intrusion. The cause addressed.

be

replaced. Upon careful reassembly elbow gasket, and exhaust elbow, check for the presence CO a

CO

warranty,

of

any components affecting the flow

of

fuel to the engine is critically important, such as

of

the catalyst at the prescribed intervals is

of

the catalyst. Any visual irregularity

of

If

there is irregularity, the catalyst and gasket must

while the engine is running. This must be performed with

analyzer.

of

fresh air to dilute the exhaust

on

dilution

of

safety.

of

the engine's air/fuel ration

of

many different

of

CO

concentration occurs at maximum

CO

levels. Any water

of

the catalyst.

is

not a product defect and

neither

Westerbeke ~ normal

the

emissions specific

(if

any).

the irregularity must be identified and

of

the catalyst, exhaust

of

CO

the extreme level

of

the CO

is

warranty

such

as

of

the output

of

the normal

the

CO

any

not

EPA

of

by

of

cov-

air

or

water

of

v

CARBON·•MONOXIDE.

..

iMPORTANT

"CO''/

LOW·CO

INFORMATION

GENERATORS

Catalyst generator will

hours of Verlficadon·of

seasonally

Verification appropriate

There Dry, hole measurements. practical

temperature temperatures The contains systems).

Probe-type

perfonnance

accumulates

increase.

but in

other

loca~on

through it

is

present. opening out

of

the

tubing

hill.

Observe probe ingested. repaired

The catalyst must be replaced every

engine

or each

involves

CO

are

two

hot,

exhaust

the

exhaust

in

all

limits

involved

location

entrained

Only

and

it

analyzers

the

probe.

Be

pointed

the

flow.

leading

the

and

the

If

any

or

replaced

will

degrade

operating

operation.

satisfactory CO levels must be done

1,000

hours (which ever occurs first).

actual

analyzer.

locations

Measurements

instances

analyzers

is

Position

analyzer

can

elbow

of

the

or

is

the

cooling

critical

have

As a result,

sure

to

in

the

direction

to

the

usually

and

water

is

and

where

be

intended for back pressure

due

analyzer,

the

boat's exhaust outlet, which

water (except

with

that

aim

the probe

translucent

ingested

recalibrated.

over

time.

A13

the

hours,

CO

concentrations

sampling of exhaust

· exhaust

sampled at

at

to

possibility of high levels of

probes

the

an

air

they

the

analyzer

be sure no,water

gas

the

this

location

the

high exhaust

safety concerns over

dry

should be used at

probe not ingest

pump

drawing a

tend

to ingest water

probe downwards

of the water

as

high

running

continu~usly

tubing between

into

the

gas

can

be

sampled.

plugged

may

temperature,

stack exhaust

water.

gas

with flow as

possible

is

being

analyzer,

2,000

with

tapped

not

and

do_wn-

the

it

must

an

be

CO.

this

sample

when

the

just

with

be

Whenever

from opportunity looking connection ofthe cylinder head to the exhaust exhaust manifold subsequent Remember, catalyst is content.

Analyzers instructions that come with the analyzer

·

regarding

The Extech, Zellwgwer Teledyne a probe connected to the analyzer tubing.

sensor built into one end

to

sample

taking the time

the

exhaust with a co

to use the analyzer

for

CO

from exhaust leaks.

to

downstream exhaust components

exhaust

raw,

untreated exhaust

usually require periodic calibration.

calibration.

following

are manufacturers

TIP;

Testo, TSI, Bacharach,

Analytics, Industrial Scientific

and

others. Westerbeke

They

are

slightly more expensive

the

exhaust coming out of

to

verify proper

analyzer,

to

_the

water injected exhaust

gas

that

has

of

the

analyzer,

always

"sniff''

around

Pay

close

not yet

passed

and

is

very

that

offer CO

Fluke,

recommends

by

a length of

than but

the

boat's

co

concentration

take

the

attention

manifold,

elbow,

and

hoses.

through

high

Follow

carefully

analyzers:

Monoxor,

Corp,

GPo,

analyzers

transparent

those

they

exhaust

the

engine

in

CO

Pyrite,

with

allow

to

·the

and

the

TPI,

with

you

outlet.

the

all

the

·

When

measuring ambient upwind level,at ambient

CO

of

the

exhaust

level..

CO

level

exhaust

by

at

also

outlet,

will

the

exhaust outlet be

measuring

especially

be

influenced

co· away

in

marinas.

upwards

aware

from

by

of the

the

and

CO

Engines & Generators

vi

This

genset

meets

the

Emissions California

unauthorized air engine removal

Federal

Emissions indicates has

Q~tagory

intake,

emissions

been

·standards users

of

modifications

or

speed

or

replacement

Emissions

Compliance

the

number

shown

to

C=

250

are

hrs,

requirements

as

stated

this

genset

or replacement of

control

system components that affect

prohibited.

of the engine label is prohibited.

Compliance

Period referred

of operating

meet

Federal Emissions requirements.

B=500

of California's Exhaust

on

the

nameplate.

should

be aware that

Unauthorized modification,

Period:

hrs,

The Federal

to

on

the

hours

for

which

A =1000 hrs.

fuel,

exhaust,

nameplate

the

EMISSIONS

You

should

and

pther manuals

genset.

Tf

you maintenance or service should

seek

dealer. California genset users

locating information re\iited

Board

requirements for emissions control.

engine

carefully review operator (Qwner Installation

and

information

are

unsure that the installation,

of

your genset

assistance from

may

you

receive

with

use,

is

authorized,

an

approved WESlERBEKE

use

the

table

below

as

to

the California

Air

Resources

an

your

you

aid

in

EMISSIO~S

Emissions

Engine Fuel Requirements

Engine Engine Ignition Timing Engine Lubricating Engine Adjustments

Engine Emission Control System

Catalyst See MAINTENANCE Oxygen Back Pressure

Warranty

Valve

Adjustment

Sensor

Information

OU

Requirements

EXHAUST

CONTROL

The California emissions control warranty statement packet,

if

information

factory. The engine

RECOMMENDATIONS.

See MAINTENANCE See MAINTENANCE See ENGINE ECU.

The engine emission control system consists of engine design manufacture.

MAINTENANCE

See See MAINTENANCE

SYSTEM

DESCRIPTION

The

catalyst

CO.

Any

likely

Inspection

critically

loosening surface

flush,

intrusion.

addressed. gasket

casting

needed.

gasket,

wl:iile CO

analyzer.

is

critical

water

inf!:Usion

quickly

compromise

of

the

important.

the

metal

of

the

catalyst

honeycomb

The

cause

If

there

must

be

replaced.

must

be inspected

Upon

careful reassembly

and

exhaust

the

engine

to

minimizing

into

the

engine's exhaust system

the

proper

catalyst at

The exhaust elbow clamp

appearance is

is

elbow,

is

running.

the

prescribed intervals is

to

provide a view of the output

Any

visual irregularity of the normal

most

of

the.

irregularity must be identified

irreguJ.arlty,

The water injected exhaust

the

al4o

for corrosion

of

check for the presence of

This must be performed

exhaust emissions like

operation

likely a result of

catalyst

the

of

is

removed by

and

catalyst,

the

catalyst

water

sealing

elbow

replaced

new

sealipg CO with

will

and

as

'

a

INFORMATION

as

is

certified

SCHEDULE. SCHEDULE.

OIL

RECOMMENDATIONS.

SCHEDULE. SCHEDULE. SCHEDULE.

TABLE

this

manual

to

operate on unleaded gasoline. See

when

MAINTENANCE

NOTE:

For

information

refer to WESTERBEKE'S INSTALLATION

available

Refer also to

manual.

POSITfON

THE

ANOTIGH1EN

SECURELY

TWO

THE

FLANGES

at www.westerbeke.com.

CLAMP

OVER

(AND

the genset is shipped

on

installing

TESTING

GASKET}

THE BACK

is

located in

from

FUEL

and

Exhaust

PRESU~

INSTALLING A NEW

CATALYST

the

same

the

precision

Systems,

MANUAL

in

this

Engines & Generators

vii

TABLE

Parts

Identification

Introduction

Fuel,

Engine Preparations Bleeding Control

.........................................................

Oil

for

the

Fuel

Panel -Starting/Stopping Remote-Stop/Start Break-In Safety Maintenance Fuel

Cooling

Engine

Procedure

Shutdown

Schedule

System

Gasoline/Water Separator/Filter ..................

Fuel Pump ....................................................

Fuel Filter ....................................................

.......................................................

System

Changing Coolant ........................................

Thermostat ...................................................

Zinc Anode ..................................................

Heat Exchanger ........................................... 16

Raw Water Intake Strainer .......................... 16

Raw Water Pump ......................................... 16

Changing the Impeller .................................

Lubricating

Changing the Oil ........................................

Replacing the Filter ....................................

Adjustments

Spark Plugs ..................................................

Air Screen ........... : ........................................

Oil Pressure .................................................

.............................................

and

Engine

Initial

System

Coolant

Start-Up

..................

.........................

................................

Procedure

(Daily

Sensors/Switches

.............................

Operation)

................... 9

..................

......................................

..................................................

Oil..

.....................................

...........................................

OF

CONTENTS

6A

.....

2 3 5 6

7

Battery Engine

PC Control Generator

Charging

Troubleshooting

Monitoring

Box

Information

AC Terminal Connections ........................... 24

Circuit

...................................

.....................................

...................................................

Components

...................................

.......................................

8 Windings Schematic .................................... 24

10

11

13

13 13 14 14

15 15

16

17

Shore Engine/Generator

Remote DC MCG Lay-up Remote Tightening Suggested

Power

Ignition System Components ......................

Control Box Components ............................

Fuel System Components ....................... : ....

Battery Charging Circuit .............................

Exhaust System Components ......................

Throttle Body Components .........................

ECU Components .......................................

Auxiliary

Generator

Transfer

Wiring

Panel

Wiring

Power

Adapter

Specifications

and

Recommissioning

Oil

Filter

...............................................

Torque

Spare

Specifications

Parts

Switch

Diagram

............................

Diagrams

(#55536)

.........................

..............................

..........................

..............

::

...........

...................

......................................

17 17

l8

18

l8

18

....

19 20 22 22 23

25 26 26

27 28 28 29 29

.30 .31

31 32 33 34

.35

36

Engines & Generators

1

PARTS

IDENTIFICATION

WIRING

HARNESS

TO

ECU

CONNECTIONS

SIPHON CONNECTION

FRONT

I

BREAK

--fP

THERMOSTAT

ANODE.

LEFT

SIDE

AIR

BLEED

yttROmE

BODY

FILL

CHARGER

.

AC·CIRCUIT

CAP

FUSE

BREAKER

DIPSTICK

CONTROL

HEAT

BOX

ELECTRIC

FUEL

UFT

PUMP,

FUEL MODULE

2

FUEl:

FILTER

RIGHT

SIDE

SUMP

CONNECTION

GROUND

DRAIN

HOSE

This

WESTERBEKE WESTERBEKE's technology. dependable Thank

In

order

is

important manual manual throughout your

This

is

an Manual WESTERBEKFJUNIVERSAL

We performance

you

for

to

get

that

is

designed

carefully

Should

nearest

WESTERBEKE

is

your

Operators

Installation

is

available

long

take

great pride

selecting

the

full

you

operate

to

and

observe all

your

Manual

and

Generator

years

of experience

of our engines

WESTERBEKE.

use

and

help

you

generator require servicing, contact

dealer for assistance.

Manual.

and

can

be

INTRODUCTION

is

a product of

and

advanced

in

the

superior durability

and

generators.

benefit

from

your

generator,

maintain it

do

this. Please read this

the

safety precautions

Along with this manual there

Parts

Information. A service

ordered

dealer.

from

correctly.

your local

and

This

MANUALS/SOFTWARE

Westerbeke insure your www.westerbeke.com

it

frequently

that

you

will

have

WESTERBEKE

updates manuais

the

latest information

representative or visit our

and-software.

by

consulting

website

Please

at

WARRANTY

Your

WESTERBEKE product registeration Corporation register customer days

of

and

have

service

Customer

PROCEDURES

Wap-anty

documentation

card

or

go

your

product's warranty

warranty

registering.

your

product model

date

available.

ldentlfic~tion

package. There

you

can

fill

to

our website www.westerbeke.com

identification card in

If

you

do

L...,.,.IWI!STI!IlBEKE.

I Engines & Generators

~Identtfication

WES'l'ERBBKB

MAIN~

HOME'i'bWN,

Model' Expires

NOTES,

As maintenance information and

NOTE:

A

CAUTIONS

this

manual

WARNINGS.

An

operating procedure essential

CAUTION:

observed, engine.

OWNER

USA

Ser.#

AND.

takes

you

through the operating procedures,

schedules,

will

can

and

be highlighted

An explanation follows:

Procedures,

result

In

the

Statement

out

and

on

not,

please contact

number,

is

a warranty .

mail

to

line.

You

the

serial number

Card

WARNINGS

troubleshooting.

by

NOTES, CAliTIONS,

to

note.

which

if

not

damage

or

destruction

included

Westerbeke

should receive a

mail within

Criti~l)].

the

in

the,

and

60

factory

and

in

strictly

of

your

Fill in the information

NOTE:

Technical information is provided your reference that your serviced and/or installed only by a qualified distributor or

The 6.5/5.0 MCG Service Manual (#055743)

· a

pdf

download at www.westerbeke.com. This Service

Manual can also be purchased

Westerbeke Dealer.

and convenience. Westerbeke

engi11e,

dealer.

for

your own reference.

in

generator or climate control system

in

hard copy

our

Manuals

recommends

Westerbeke

is

available

from

your

for

is

as

A

WARNING:

followed,

can

result

Procedures,

In

personal

which

injury

If

not or

loss

properly

of life.

Engines & Generators

3

INTRODUCTION

PROTECTING

Care at the have resulted in a WESTERBEKE generator capable of

many

hours manufacturer cannot control installed in the vessel or the manner operated and serviced in the buyer/owner-operator.

NOTE:

Six important steps

•

Proper

• An efficient

an

anti-siphon break

YOUR

factory

during assembly and thorough testing

of dependable

installation.

well-designed

INVESTMENT

service.

to

prevent

However,

how

or where the generator

in

which the unit

field.

This

is

up

ensure long generator life:

exhaust

system

water

from entering the

the

is

to

the

that includes

engine.

• Changing the engine oil and oil filters

Maintenance

•

Proper components according

Schedule.

maintenance

of

aU

engine and generator

to

the Maintenance Schedule

as

outlined

in

this manual.

•

Use

clean,

filtered

unleadedfue~

maximum

10%

ethenol.

•

Winterize

RECOMMISSIONING

UNDERSTANDING

The gasoline engine driving ways are

vertical in-line, and overhead camshaft which solid-state distributor which camshaft-driven. The engine incorporates a pressure type lubrication system and a fresh water-cooled engine which generator's engine requires the same preventative maintenance that most important ventilation, maintenance of cooling system

your engine according

section

THE

GASOLINE

an

similar to a gasoline automobile engine.

the

engine's cylinder head

is

belt driven.

is

thermostatically controlled.

is

required of a gasoline automobile

factors

to

the generator's longevity

the

and

the generator back-end.

to

the lAY-UP AND

in this manual.

ENGINE

AC

generator

The

horizontally mounted

To

a large

fuel

system, ignition

is

in

many

The

cylinders

has

an

engine utilizes a

and

block,

degree,

engine.

are

system,

is

the

in

the

The

proper

ORDERING

Whenever replacement/service parts provide the generator model and

generator serial number black provide your generator description and part number separately furnished Parts Catalog). Also insist WESTERBEKE genuine parts because will fit or parts original equipment.

SPARES

Certain spares WESTERBEKE dealer

Suggested Spares For additional parts and accessories, contact WESTERBEKE

INSTALLATION

Publication #043268 provides detailed information installing generators.

CARBON

WESTERBEKE recommends mounting a carbon detector in even

The

presence of carbon monoxide could indicate leak from the engine or generator or from the exhaust elbow/exhaust hose or exhaust system.

If

carbon monoxide

air

and

AMPERAGE DRAIN

There the unit's starting battery by the electronics on the unit when

the generator the starting battery charge. Turn breaker or the starting battery switch when the unit will not be operated for a period

PARTS

number,

as

they appear

name

plate located on the generator

us

with this information

set.

In

are

frequently not made

AND

ACCESSORIES

will

be

generator.

will

assist

you

are

DEALER.

addition, include a complete

needed

in

preparing

shown in the last page of

so

for

each part needed

to

the same specifications

to

support and maintain your

Your

local WESTERBEKE

an

MANUAL

MONOXIDE

the

vessels living quarters. Carbon monoxide,

in

small amounts, is deadly.

correct the problem immediately!

is

a very small amount

is

not in use. To prevent this and draw down

DETECTOR

is

present, ventilate the area

of

amperage being drawn from

OFF

of

time.

are

needed,

engine serial

we

may

inventory of

either the panel DC

always

on

the

end.

You

properly identify

(see

upon

generic

this

your

an

with

number,

silver

and

must

part

the

as

spare

parts.

manual.

for

monoxide

exhaust

clean

of

4

FUEL,

ENGINE

OIL

AND

ENGINE

COOLANT

GASOLINE

A

CAUTION:

higher. Gasoline

Ethanol

:"muse

Care

Of

The

Use only clean properly filtered fuel! some components in the unit's fuel system are very critical;

dirt particles which might pass through the filter can damage

these finely finished parts. and keep it clean. unsatisfactory facilities. To assure that the fuel going into the tank for your engine's daily use is clean and pure, the following practice is

advisable: Purchase a well-known brand Install and regularly service a good, Coast Guard approved

metal bowl and the engine.

ENGINE

Use a good brand designations as listed in the SPECIFICATION Section this manual.

Change the engine oil and filter after an initial engine break-in operation. Then follow the oil and filter change intervals as specified in the

SCHEDULE

Westerbeke Corporation does not approve the use break-in change intervals must

SCHEDULE

if

NOTE:

statements

OIL

of

synthetic oils.

MUST

synthetic oils are used.

The

Use

with

unleaded

gasoline

higher

percentages

must

89

Octane

not

gasoline exceed of

Ethanol

E10

are

or

(10%}.

not

llltlreseiJJIJI/elsamlma,a

Fuel

Supply

It

is important to buy clean fuel,

The

best fuel can

by

careless handling

type filter/water separator between the fuel tank

of

engine oil with

in this manual.

If

synthetic oils are used, engine

be

performed using conventional oil. Oil

be

as listed in the

section in this manual and not to

information above supercedes all previous regarding

synthetic oil

be or

of

fuel.

an

MAINTENANCE

usage.

0

The

fit and tolerance

rendered

improper storage

API and

MAINTENANCE

SAE

50

or

disapprove

be

hours

extended

of

ENGINE

WESTERBEKE recommends a mixture and chemicals that can corrode internal engine surfaces.

The antifreeze performs double duty. to run at proper tempemtures the engine to the coolant. It also lubricates and protects the cooling circuit from rust and corrosion. Look for a good quality antifreeze that contains Supplemental Cooling Additives (SCAs') that keep the antifreeze chemically

balanced, crucial to long term protection.

The distilled water and antifreeze should ben pre-mixed

before being poured into the cooling circuit.

NOTE:

antifreeze that

A proper 50/50 mixture as recommended will protect the engine coolant to tempemtures

COOLANT

A coolant recovery tank kit is supplied with each genemtor. The purpose coolant expansion and contraction during engine opemtion, without the loss the cooling system.

COOLANT

of

50% antifreeze

50% distilled water. Distilled water is free from the

It

allows the engine

by

transferring heat away from

Use

the

new environmentally-friendly, is

now available.

of

-40"F.

RECOVERY

of

this recovery tank is to allow for engine

of

TANK

coolant and without introducing air into

long

lasting,

NOTE:

This located at or above manifold.

Engines & Generators

5

tank,

with

the

its

level

short

run

of

plastic

of

the

engines exhaust

hose,

is

best

PREPARATIONS

PRESTARTINSPECTION

Before

longed

•

Check the

•

Check bowls

•

Check and

NOTE:

generator alternator and

•

Check

and

NOTE:

air bleed petcock

purge

bubbles, After

coolant engine's

Before manifold should tank coolant

AIR

BlEED

PETCOCK

starting layoff,

full

battery

at

your

generator

check

the

engine

oil

mark

on

the

fuel

supply

for

contaminants.

the

DC

electrical

cable

connections.

The

starting battery must be totally dedicated

and maintained by

no

other

the

coolant

the

manifold.

During

air from

flows

shutdown

from

cooling system

subsequent operation

may

need

loss

the

from

the

will

on

and

recovery

be

to

have

occur.

level

initial filling

engine

topped

for

following

level:

add

dipstick.

and

examine

system.

source.

in

both

the

manifold should be opened

block.

the

petcock - close

after

the

tank will be drawn into

to

replace

off,

coolant

the first time or after a

items:

oil

to

maintain

the

Inspect

the

generator's DC charging

the

plastic recovery

of

the cooling

Once

cooled,

engine has

the purged

of

the

generator;

and

the

added.

Do

MAX.

FULL

the

fuel

filter/separator

wire

connections

system,

free

the

petcock.

cooled,

coolant recovery

the

air.

the

not overfill

FOR

pro-

level

at

to

the

tank

the

to

of

air

the

engine's ·

as.

INITIAL

•

Visually parts, threaded connections. Search for

•

Check the

• Inspect exhaust system connections.

•

Be the

• Confirm that systems with a neutral line properly grounded (or ungrounded)

and load open voltage

•

Make

A

recommended motors, up

to

This unanticipated prevent a cold

START-UP

examine the unit. Look for loose or

disconnected wires, unattached

AC

wiring for correct connections

wiring diagrams.

sure

no

other generator or utility power

load lines.

that generator neutral neutral.

neutral

CAUTION:

speed

precaution

In single phase

can supply

on

unbalanced loads.

certain

the

raw

When

that

be

switched

and,

in

will

all

cold

operation

engine

is

properly connected

systems

the

wrong line-to-neutral

water thru-hull

starting

AC

loads,

OFF

until

the

climates,

prevent

of

from

damage

the

stalling.

AC

any

gasoline

as

an

is

the

generator,

especially

engine

starts

caused

machinery

missing

hoses,

and

as

specified

is

are·

the

system

fucomplete

open.

large

has

to

warm_

check

leaks.

connected

requires,

to

the

or

it

is

come

up.

by

and

will

in

to

MANIFOLD PRESSURE CAP

THERMOSTAT HOUSING

.

COOLANT RECOVERY

TANK

...-t-~n:"'l'---

RAW

WATER

COOLANT

FILL

DRAIN

.

ROCKER

COVER

HEAT

FRESH

WATER

DRAIN

EXCHANGER

Engln~s_&

Genera~ors

6

.BLEEDING

THE

FUEL

SYSTEM

DESCRIPTION

1.

Disconnect the fuel module from the engine wiring harness.

2. Attach your fuel pressure gauge set

OTC 7211) module. Direct the bleed hose from the pressure gauge

into a proper container.

3. Open the bleed valve STOP switch and hold

pressure fuel bleed hose and when no air bubbles are seen, close the bleed valve and observe the fuel pressure. Typically about

3-5

psi

4. Remove the pressue gauge from the fuel . connect it to the

5. Re-connect the fuel module to the engine harness.

or

equivalent to the Schrader valve

on

the pressure gauge, Depress the

it

depressed. This activates the low

puQ1p.

Observe the

Schrader valve

(Snap On #MT337B,

on

:(uel

flow through the

mod1:1le

on

the fuel rail.

and

the fuel

6. Open the bleed valve on the fuel pressure gauge. Depress the

STOP switch and hold it depressed. This activates

both the low pressure and high pressure fuel pumps. Observe the fuel flow through the bleed hose and when

air bubbles are seen, close the bleed valve and observe the

fuel pressure.

7. Remove the pressure gauge set and replace the caps on

the two

8.

Insure that all harness connections are secure, operate the

generator and check that there are no fuel leaks.

NOTE:

The

filters are serviced.

A

WARNING:

No

smoking

and

properly

The

pressure should be in the 40 psi range.

Schrader valves.

fuel

system will need to be bled any time the fuel

The

fuel

is

under

and

no

discard

open

of

cloths

«ames!

and

extreme

Clean

towels.·

pressure!

up

spilled

fuel

no

.

VALVE

·

"SNAP-ON· EXCELLENT FOR BLEEDING

TOOL • PROVIDES

PRESSURE

SCHRADER

GAUGE

TESTING

AND

TEST

AN

KIT

PORTS

.

..y----

-;.~FUEL

RAIL

,

___

I

----

J I

: i

__.

.-----.

FROM

PRESSURE PUMP

I

HtGH

MODULE

t

I

i.

i

)

........

--

COOLANT

DRAIN

-/Ni'JON.TING

Engines & Generators

6a

FUEL

TO

START:

Simply

press

(the

switch

will START indicate

NOTE:

before

TO

Press The

shutdown.

electronically. A GREEN

the

engine

There

the

start switch

STOP

the

rocker switch to the

GREEN LED will

CONTROL

(DC

CIRCUIT

the rocker switch

revert

is

afew second delay while the ECU self-tests

BREAKER

to

its center posttion) the engme will

is

running.

responds.

go

out indicating the engine has

ON)

to

the

LED

STOP

position and release.

PANEL • START/STOP

~~

position

on the switch will

~d

re!ease

PROCEDURE

DC

CIRCUIT

BREAKER

GREEN

THIS

WHEN RUNNING BREAKER

LED

ILLUMINATES

THE

ENGINE (DC ON).

FAINTLY

IS

NOT

CIRCUIT

CONTROL

GENERATOR

The start/stop rocker switch on the generator control panel used generator.

The start/stop rocker switch momentary contacts in the (START) and a stationary contact in the center (NORMAL). This position allows the generator enables the remote start/stop panel(s) to control functions of

The (START) position starts the generator and once released reverts

to engine in normal operation situation. This position

necessary.

when

CONTROL

the

generator.

the

center position. The (STOP) position stops

PANEL

is

the only functional component

to

is

a three position switch with

to

run

once started

as

well

as

is

also used

to

PANEL • OPERATING

DC

CIRCUIT

TLIRN PERFORMING

.

MAINTENANCE PREVENT STARTING

start

and

stop the

(STOP) position

and

the

in an emergency

prime the

fuel

BREAKER

OFF

WHEN

ACCIDENTAL

also

start/stop

the

system

TO

and

INSTRUCTIONS

Failure

The start cycle will automatically terminate after of ECU initiates a SPEED fault and prevents further crank

attempts. Investigate the cause

reset the ECU.

The. combinations that indicate to the operator engines automatic shut-down. The LED displays ENGINE, OIL PRESSURE, ENGINE 1EMPERATURE, EXTERNAL ALARM, SPEED (flashes).

Should the generator shut down from one of these LED will remain illuminated. on

NOTE:

emissions control to

The the circuit be closed when the circuit

The

Amperage or Short Circuit.

The relays (closed circuit) ftom high amperage or short circuit.

BLEEDING

NOTE: Bleeding

the

previous page.

to

Start

cranking.

A

exhaust

the

your

the control box must be turned

troubleshoot

Three

crank cycles can be attempted before

of

this

no-start, correct it

CAUTION:

nlling

engine.

Prolonged

with

This

could

water

cause

cranking

and

the

catastrophic

can

water

result

backing

generator/engine.

LED fault shut-down display has six LED light

the

EXHAUST 1EMPERATURE

To

reset the LED,

OFF

and

The

CHECK ENGINE LIGHT indicates a possible

problem.

and

Ext.

Alarm indicates a faulty

to

deteimine the fault (the

8

Amp

Fuse

protects the Control Panel

15

Amp

DC

Circuit

THE

FUEL

of

initial commissioning

Immediate action should

correct this

problem.

is

running).

Breaker

fire

protects

SYSTEM

air from

of

the

fuel system

generator.

suppression circuit.

fire

suppression circuit

the

Refer

6-8

in

damage

cause of

are:

faults,

the

then

back

from

High

Kl,

is

required

to

seconds

the

into

the

CHECK

DC

be

K2,

the

cycle

and

to

and

the

breaker

ON.

taken

By-pass

K3

at

fault

must

Engines & Generators

7

REMOTE

STOP/START

DESCRIPTION

1\vo remote start/stop panels are available that allow for the engine/generator to

boat.

The remote panels connect to the main panel using a 15'

30' wiring haness (or a combined length installed, the engine/generator can be started and stopped from either the remote

REMOTE

The components on the panel are:

1.

2. A green LED run indicator light

3. A four position LED fault shutdown display.

The start/stop rocker switch functions the same as the start/stop rocker switch on the generator's control panel as previously explained.

The green LED run indicator light illuminate when the start circuit is energized. as the engine cranks and will brighten as the engine starts, indicating the generator is running.

The LED fault shutdown display has combinations that indicate to the operator the cause engine's automatic shutdown. The Engine,

Exhaust Temperature, and Speed

Underspeed-LEDs) flashing.

Should the generator shutdown from one

fault LED will remain illuminated. To reset the LED, the

panel DC breaker must

START/STOP

A three position start/stop rocker switch.

Oil Pressure, Engine Temperature, External Alarm,

be

contolled from any location on the

of

45'). Once

or

the main panel.

PANEL

be

cycled OFF then ON.

(with

LED

Fault

on

the rocker switch.

on

the rocker switch will

It

will go dim

six separate LED

LED

displays are: Check

(Overspeed -LEDs and

of

these faults, the

or

Display)

of

the

PART

PANELS

NO

1+------4"

N0.055345

(101.6mm) -..

4"

(101.6 mm)

-------'l~IOol-

:ug

(81.03mm)

NOTE:

For connecting these

Wiring

Diagram section

in

remote

this

manual.

panels,

refer

to

the

Engines & Generators

8

BREAK-IN

PROCEDURE/THE

DAILY

OPERATION

BREAK·IN

After the generator has been started, check for proper operation and then allow the generator to warm up a few minutes before applying a load 20% and 60%

A

generator

After the first 10 hours

be

can periodically vary the load.

Avoid overload at all times. reduced output voltage and/or frequency. illuminate a warning Monitor the current being drawn from the generator and keep

it within the generators rating.

NOTE:

drawn

GENERATOR

A

periods

PROCEDURE

..

Run the generator between

of

full-load for the first 10 hours.

CAUTION:

increased to the full-load rated output, then

Be

aware required can

CAUTION:

of

Do

not

by

running

LED

of

motor starting loads and

for starting

be 3 to

5 times normal

INFORMATION

Do

not

time

without a load

attempt

to

break-in

your

without a load.

of

the generators operation, the load

An

overload is signaled

MCG

when the generator is overloaded.

the

motors.

operate

The starting amperage

running

in

this

the

being

amperage.

manual.

generator

placed

by

models will

high

current

See

for

long

on

the

generator.

CHECK

Follow this check list each day before starting your generator.

• Record the hourmeter reading in your log (engine hours

• Visually inspect the generator for fuel, oil, or water leaks.

• Check the oil level (dipstick).

• Check the coolant level in the coolant recovery tank.

• Check your fuel supply.

• Check drive belts for proper tension.

• Check for abnormal noise such as knocking, vibration and

• Inspect the exhaust system.

NOTE:

This

temperature

LIST

relate to the maintenance schedule).

blow-back sounds.

Some

unstable running may occur

condition should lessen as normal operating

is

reached and loads

are

in

applied.

a cold

engine.

Engines & Generators

g

SAFETY

SHUTDOWN

SWITCHES

SENSORS

DESCRIPTION

The engine/generator is protected by switches and sensors that send signals to the,ECU that it interprets as a fault and automatically shuts dowri the generator's engine. When

of

an automatic shutdown occurs, one LED lights will illuminate indicating what fault caused the engine

to

shutdown. This

correct the fault, refer to ENGINE TROUBLESHOOTING in

this manual.

before correcting

SPEED

A speed sensor is mounted

engine and positioned to monitor crankshaft rotation.

a voltage signal to the

speed.

underspeed, the ECU will shut the generator down. speed LED'S are illuminated, it indicates overs peed. LED'S are flashing, it indicates underspeed.

OIL

An oil pressure switch is located filter mounting bracket. This is a normally open contact switch. voltage to the circuit is terminated when the unit shuts down.

Do

not

SENSOR

If

a speed threshold is reached, either overspeed

PRESSURE

It

functions with the time relay circuit to ensure

LED

attempt

the

to

fault.

(CRANKSHAFT)

on

ECU

that is interpreted.as engine

SWITCH

the control panel fault

will stay illuminated. To ·

re-start

a bracket at the front

the

on

the right side

generator

of

If

of

the oil

the

It

sends

or

both

DC

AND

SENDERS

EXHAUST

A temperature switch is mounted monitor the temperature Should the switch sense an excessive exhaust temperature, the temperature

COOLANT

This sensor is located to monitor the engines coolant temperature. The sensor is sending coolant temperature. Should the temperature reach an overheat threshold, the illuminate the engine temperature fault LED light on the control panel.

TEMPERATURE

ECU

will shut the generator down and the exhaust

LED

will illuminate

EXHAUST TEMPERATURE'

SWITCH

TEMPERATURE

on

DC

voltage to the

ECU

SWITCH

on

the exhaust elbow to

of

the exhaust coolant and gases.

on

the control panel.

SENSOR

the underside

ECU

will shut the engine down and will

of

that interprets this

EXHAUST

the intake manifold

as

engine

OIL

GALLERY

OIL

PRESSURE

An oil pressure sender (to the left

voltage to the ECU that it interprets as oil pressure. Should this voltage fall below a certain level, the generator down and illuminate the low oil pressure LED. Should this occur, refer to in

this manual.

SENDER

ENGINE TROUBLESHOOTING

of

the oil filter) sends

ECU

will shut the

DC

~)

DC

CIRCUIT

The engines electrical system is protected

15

by a

An electrical overload in the wiring harness or

tlie instrument panel will trip the breaker and shut down the engine/generator. Should this occur, inspect and repair the problem. Then reset the breaker and re-start the engine.

FUSE

PROTECTION

Four DC circuit protectors are found in the engines electrical circuit. A control panel. A

30 amp spade fuse circuit.

BREAKER

amp manual reset circuit breaker.

15

amp

DC

breaker and an 8 amp buss fuse

30 amp buss fuse in the control panel and a

by

the starter motor for the battery charge

on

the

Engines

10

& Generators

A

WARNING:

and

gloves,

control

panel,

and

or

Never use

the

tum

off

attempt

correct

the

battery

to

perform

tools

MAINTENANCE

any

service

while

the

engine

for

each

job.

When

switch.

servicing/replacing

SCHEDULE

Is

running.

Wear

DC

components,

the

proper

tum

safety

off

the

equipment

DC

circuit

such

as

breaker

goggles

on

the

SCHEDULED

I

DAILY

Coolant

Engine Fuel/Water

Fuel

*Visual

I

INITIAL

*Spark

Engine

*Exhaust

*Air

*Valve

*Inlet

*Fuel

MAINTENANCE

CHECK

Level

Oil

Level

Separator

Supply

Inspection

50

HOURS

Plugs

Oil

and

System

Screen/Flame

Adjustment

Fuel

Filter

and

BEFORE

START-UP

(owner

of

Engine

OF

Filter

Arrestor

"0"

Rings

installed)

OPERATION

EXPLANATION

Check Oil

level

Check hours

Fresh engine

Check securing and

electrical

Clean/re-gap. Initial

Initial Check Check

Remove, necessary,

Check Initial

Initial

OF

at

recovery

should

indicate

for

water

and

or

once a year.

unleaded

gasoline

performance.

for

fuel,

oil

and

v-clamp

is

connections.

engine

oil

and

check

at

50

that

the

exhaust

the

integrity/mounting

clean

and

then

once a year.

adjustment

change,

then

change,

then

SCHEDULED

tank,

if

empty,

check

between

MAX

dirt

in

fuel.

Drain

with

an

ethanol

and

Insure

Look

change

then

hoses

250 250

octane

exhaust there for

every

are

security

screen

Check

hours hours

10%

water

tight.

filter

hours,

re-install

of

valves.

every every

MAINTENANCE

at

manifold.

Add

and

LOW

on

dipstick.

filter

if

necessary.

rating

of

89

Check

no

exhaust

then

or

once a year.

attached

water

injected

Inspect

rubber

500

hours.

or

change

and

maximum.

leaks.

are

loose

bolts/hardware

at

50

hours,

250

hours

properly

of

the

pack.

again

at

or

once a year.

or

once a year.

coolant

Replace

higher.

that

the

leaks

and

that

exhaust

sealing

if

Do

not

filter

Lower

water

around

possible

both

every

Carefully

the

securing

ring

needed.

overfill!

every

octane

injected

the

elbow.

corrosion.

100

inspect

clamps

elbow.

and

250

operating

will

affect

exhaust

Inspect

hours.

for

replace

leaks.

are

if

elbow

wiring

·tight.

I

EVERY

50

OPERATING

*Drive

Belts

(Fresh

Water/Raw

Starting

Batteries

Electric

Fuel

Pump

Zinc

Anode

EVERY

100

OPERATING

Engine

Oil

and

Filter

*Air

Screen/Flame

*WESTERBEKE

AMPERAGE

HOURS

Water

Pumps)

HOURS

Arrestor

recommends

this

DRAIN

OR

service

There is a very small amount the unit's starting battery the generator is not in use.

by

the electronics

To

the starting battery charge. Turn

breaker be

or

the starting battery switch when the unit will not

operated for a period

of

time.

MONTHLY

Inspect

for

slipping,

Check off

corrosion Inspect Inspect

our

YEARLY

Change Remove,

necessary.

be

performed

of

amperage being drawn from

by a knowledgeable

on

the unit when

prevent this and draw down

OFF

either the panel

DC

for

proper

cracking

electrolyte

if

for

leaks,

and

clean

own

ins

engine

clean

of

tension

and

levels

Make

needed.

Apply

ensure

zinc

anode.

action

schedule.

oil

and

filter.

and

re-install

mechanic.

(3/8"

wear.

fuel

screen

sure

and

to

112'

deflection)

Adjust

tension

cables

petroleum

electrical

Replace

if

pack.

and

or

replace

and

connections

jelly

to

terminals

connections

necessary.

Inspect

rubber

adjust

Note

as

needed.

are

for

are

clean

the

condition,

sealing

if

needed.

Replace

in

good

corrosion

and

tight.

ring

and

Check

belt

cover.

order.

Clean

protection.

then

determine

replace

if

Engines & Generators

11

NOTE:

Use

the

engine hourmeter

MAINTENANCE

to

log

your

engine

SCHEDULE

hours

or

record

your engine hours

running

time.

SCHEDULED

I

EVERY

*Exhaust

*Fuel

*Inlet *Generator

*Hoses

Vibration

*Heat

I

EVERY

*Raw

*Exhaust

I

EVERY

MAINTENANCE

250

OPERATING

Elbow/Exhaust

Filter

and

Fuel

Filter

Isolators/Engine

Exchanger

500

OPERATING

Water

Pump

System

500

OPERATING

0-Rings

Catalyst

HOURS

System

Mounts

HOURS

OR

YEARLY

OR

YEARLY

OR

EVERY

TWO

YEARS

EXPLANATION

Check of

the

exhaust chafing. NOTE:

Remove Remove Check

See

GENERATOR

Engine delaminated.

Check

Open

heat

Replace

Remove plates.

Inspect

the

structual

No

exhaust

An

exhaust

and

replace

and

replace

that

AC

hoses

should

Check

vibration

exchanger

gasket

the

pump

Replace

for

proper

OF

system

connections

INFORMATION.

isolators,

and

the

SCHEDULED

integrity

of

the

attached

to

leaks.

Hoses

leak

will

cause

fuel

filter

and

inlet

fuel

filter.

are

clean

be

firm

and

tighten

all

brackets

end

cap(s)

if

and

needed.

inspect

gasket.

Replace

0-rings

cover

impeller

operation.

MAINTENANCE

water

injected

exhaust

the

elbow.

All

hose

and

muffler

are

in

exposure

to

carbon

all

sealing

0-rings.

and

secure.

Ensure

tight.

Replace

if

clamps

as

out

debris.

pump

assembly

Lubricate 2000

operating

hoses

needed.

hardware.

the

hose and

mounting

clean

the

at

elbow

connections

good

serviceable

monoxide!

wires

become

Replace

for

wear,

impeller

hours.

casting.

should

condition.

have

no

chafing.

spongy,

as

needed.

especially

when

re-assembling.

Check

be

secure.

brittle

cam

the

or

and

integrity

No

wear

*Ignition

System

*Coolant

System

*Valve

Clearances

*Starter

Motor

EVERY

1000

OPERATING

*Engine

Timing

Belt

*Heat

Exchanger

*Oiverter

I

*Oxygen

*Catalyst

*WESTERBEKE

Valve

EVERY

2000

Sensor

A

WARNING:

such

as

goggles

the

DC

circuit

OPERATING

recommends

Never

and

gloves,

breaker

HOURS

attempt

on

the

this

service

OR OR

to

and

use

control

EVERY

perform

the

correct

panel.

be

performed

Inspect Drain,

thermostat Adjust Check

motor

FIVE

YEARS

Remove

recommended to

the

Remove Remove

any

service

tools

while

for

by a knowledgeable

for

deterioration.

flush

and

valves.

(Incorrect

solenoid pinion

drive

and

replace

engine.

the

heat

and

replace.

and

replace

and

replace

the

each

Test

re-fill

the

cooling

coolant

pressure

valve

and

motor

the

timing

interval

could

exchanger

exhaust exhaust

engine

job.

When

mechanic.

resistance.

system

with

appropriate

cap.

clearance

for

corrosion.

result

for

oxygen catalyst.

is

running.

will

Remove

belt.

NOTE:

in

timing

professional

sensor.

Wear

result

Failure

belt

failure

cleaning

the

servicing/rep/acing

in

and

to

poor

and

proper

lubricate.

replace

resulting

DC

antifreeze

engine

pressure

mix.

performance.)

Clean

and

the

timing

in

major

testing.

safety

equipment

belt

components,

Replace

lubricate

at

the

damage

tum

the

ott

starter

The 6.5/5.0

pdf

a Manual can also be purchased Westerbeke

MCG

Service

Manual

(#055743) is available as

download at www.westerbeke.com. This Service

in hard copy from your

Dealer.

FUEL

SYSTEM

Incoming fuel (from the owner installed

Separator/Filter)

Fuel

Module

as it circulates through the the

Electric

and to the

Rail

and is delivered (under pressure) to the

COMPONENTS

is pumped

by the

Electric

Fuel

Pump

to the

Secondary

Fuel

thru

the Inlet

Fuel

Pump.

Fuel

Module

High

Pressure

Filter.

The fuel passes to the

FUEL

Gasoline

Fuel

The fuel is cooled

and then is pumped by

Water

Filter into the

Pump

Module

Fuel

Injectors.

Fuel

SYSTEM

I.

I I

:

!__.-~-

------

"_A:·--

)

_.

...

l·

j

'

I

t

!

I

'

I

-··

...

-·-:~:-~

.

~.-:.

FUEL

:::-:.:

RAIL

SCHRADE~

VALVE

INCOMING

GASOLINE/WATER

A primary fuel filter installed between the fuel water and other contaminants froni the fuel before they can be carried to the fuel system

Most installers include a type

the genemtor installation package as they are aware problems that contaminants in the fuel can cause.

These gasoline filters must have metal bowls (not seethrough) to meet bowls have drain valves to use when checking the water and contaminants.

FUEL

PUMP

Periodically check the fuel connections pump and

fittings are tight and secure. is maintenance free.

make sure that no leakage is present and that the

SEPARATOR

of

the water separating type must be

tank

on

U.S. Coast Guard requirements. The metal

OWNER

INSTALLED

FUEL

WATER SEPARATOR PN.049602

AND

FILTER

and the engine to remove

the engine.

of

filter/water separator with

of

to

and out

The

engine mounted fuel pump

of

·

the

FUEL

FILTER

FUEL IOILTER

ENGINE

Periodically check the fuel connections and the bowl for

leakage. Replace the filter element after the first then follow the

Changing

1.

2. Bleed the fuel system to reduce the fuel pressure to zero.

3.

4. Replace the

5. Open the fuel supply to the· generator and start the unit.

6. Bleed the fuel system again to remove trapped air from

BLEEDING

The commissioning serviced and once a season to ensure any air that may have accumulated are found in the model's SERVICE MANUAL.

FUEL

FILTER

50 hours

MAINTENANCE

the

Engine

Shut the fuel supply

Refer to Unscrew the fuel bowl from the housing and pull the

filter element down and off. that

element and thread

Ensure that there are

the system. Refer to

BLEEDING THE FUEL

may

be

present. two

THE

engine's fuel system should

of

in

the system is removed. Bleeding instructions

to

sealing

on

no

BLEEDING

FUEL

SYSTEM

the unit, each time the fuel system is

SCHEDULE.

Mounted

the genemtor off.

"0"

the fuel bowl then tighten by hand

leaks.

Filter

Element

SYSTEM.

Use

care to catch any fuel

rings. Install the new filter

THE

FUEL

SYSTEM.

be

bled

of

air at the initial

13

COOLING

SYSTEM

FRESH

An

driven circulating pump, absorbing heat from the engine. The coolant then passes through the thermostat, into the heat exchanger, then into the jacketed exhaust manifold into the

suction side

engine.

When the engine is started cold, external coolant flow is prevented by the closed thermostat (although some coolant flow manifold from overheating). As the engine warms up, the thermostat gradually opens, allowing full flow coolant to flow unrestricted to the external portion.of the cooling system.

CHANGING

The engine's coolant must

MAINTENANCE

become contaminated, it can lead to overheating problems. Drain the 'engine coolant by removing the block drain adjacent to the oil filter, remove the in-board drain plug on heat exchanger and remove the pressure cap from the water jacketed exhaust manifold.

WATER

antifreeze mixture is pumped through the engine by a belt

is

bypassed around the thermostat to prevent the exhaust

A

CAUTION:

critical; a substantial traced

back

COOLING

of

the circulating pump and then through the

Proper

to

cooling

CIRCUIT

cooling

number

of

system

maintenance

engine

failurl!s

corrosion.

of

the engine's

can

is

be

COOLANT

be

changed according to the

SCHEDULE.

If

the coolant is allowed to

the

Refilling

After re-installing the coolant drain plugs, open the air bleed petcock on the water jacketed exhaust manifold and slowly pour new pre-mixed coolant into the open filler neck until coolant is visable in the filler neck.

Start the engine and monitor coolant in the filler neck and add as needed. Check the flows from the petcock, close it.

Allow the engine to run and monitor coolant in the filler neck and add as needed. When the coolant level is stable, fill to the brim and install the pressure cap.

Remove the cap on the coolant recovery tank and fill with coolant mix to halfway between the cap. Run the engine and observe the coolant expansion flow into the recovery tank.

After checking for leaks, stop the engine and allow it to cool. Coolant should draw back into the cooling system as the engine cools down. Add coolant to the recovery tank needed and make certain the coolant is topped off at the pressure cap. Clean up any spilled coolant.

MAKE

CERTAIN

PASSAGES

ARE

the

THESE

KEPT

CLEAR

Coolant

air bleed petcock and when coolant

LOW

and

MAX

and replace

if

A

CAUTION:

down

before

the

surface

can

be

at

COOLANT DRAIN

The

attempting

of

the

engine

1911'

F.

engine

must

these

hot

LOCATED THE

INTAKE

be

allowed

procedures.

but

coolant

JUST

BELOW

MANIFOLD

to

cool

·

Not

only

is

temperatures

COOLANT

DRAIN

NOTE:

Periodically check Ensure condition and check that tightly.

PLUG

that

Carry

1he

upper and lower rubber seals

a spare

cap.

the

vacuum

COOLANT

condition

valve

RETRACTION

of

the

pressure

are

in

opens

and

·

cap.

good

closes

14

COOLING

HEAT

EXCHANGER

Cool raw water flows through the inner tubes

exchanger. the heat which discharged. The engine coolant (now cooled) flows back through the engine and the cycle repeats itself.

The engine coolant and raw water are independent other; this keeps the engine's water passages clean from the hannful deposits found in raw water.

As

the engine coolant passes around these tubes,

of

the internal engine is conducted to the raw water

is

then pumped into the exhaust system and

~TO

SIPHON

AND

of

the heat

of

BREAK

EXHAUST

CLEAN

each

UTDEBRIS

° · checked, cleaned,

SYSTEM

If

the zinc pencil needs replacement, hold the hex boss into

whjch the zinc pencil is threaded with a wrench while

loosening the anode with another wrench. This prevents the

off

hex boss from possibly tearing removing the zinc, note the condition poor condition, there are probably zinc flakes within the

exchanger. Remove the end

of

the inside exchanger end gasket in case the present one becomes damaged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part number), o-ring, cover, and install a new zinc anode.

NOTE:

not require sealant. insulate the zinc from the metal housing preventing electrolysis action on the zinc.

all zinc debris. Always have a spare heat

The threads

of

the zinc anodes are pipe threads and do

Sealant should not be used as it may

THERMOSTAT

The thermostate controls the coolant temperature as the coolant continuously flows through the closed cooling circuit. When the engine is first started, the closed thermostat prevents coolant from flowing (some coolant around the thermostat to prevent the exhaust manifold from overheating). As the engine warms up, the thermostat gradually opens. The thermostat

and gasket.

If

you suspect a faulty thermostat, place it in a pan

and bring to a boil: A working thermostate should open about

or

replaced easily. Carry a spare thermostat

the exchanger shell. After

of

it.

If

the zinc

of

the heat exchanger and clean

of

the heat exchanger

is

by-passed

is

accessible and can be

of

is

water

in

1/2".

END

GASKET

Heat

Exchanger

Remove, clean and pressure test the engine's heat exchanger according to the interval listed in the Maintenence Schedule.

(A

local automotive radiator shop should be able to clean and

test the heat exchanger.)

NOTE:

Operating

that a heat exchanger cleaning be

ZINC

ANODE

A zinc anode (or pencil) is located in the raw water cooling

circuit within the heat exchanger. The purpose

is

anode in of condition the anode cleaned or replaced as required. Spare anodes

.should be

ZINC

to sacrifice itself to electrolysis action taking place

the raw water cooling circuit, thereby reducing the effects

electrolysis on other components

of

c;arried

ANODES

Service

in

silty and/or tropical waters may require

peifonned

of

the zinc anode should be checked monthly and

on board.

.

I

.

l.

more often.

of

the zinc

the system. The

· .

1

GASKET

TO

COOLANT

RECOVERY

l'f'

TANK

NEW

REPLACE

Engines & Generators

15

COOLING

RAW

WATER

NOTE:

Always install the strainer at

the strainer will always be self-priming.

A clean raw water intake strainer is a vital component engine's cooling system. Include a visual inspection

strainer when making your periodic engine check. The water in the glass should be clear.

Perform the following maintenance after every 100 hours operation:

1.

Close

2. Remove and clean the strainer filter.

3. Clean the glass.

4.

Replace the washer

5. Reassemble and install the strainer. Open

6.

7. Run the engine and check for leaks.

NOTE:

Also follow the above procedure after having run hard

aground.

the

raw

seacock.

INTAKE

STRAINER

water

if

seacock.

necessary.

or

below the waterline so

of

this

the

of

SYSTEM

If

the engine temperature warning light cause may up in the strainer, slowing the flow cooling system.

NOTE:

type with a clear opening. No perforated opening. Let all the filtering be accomplished on the inside the hull where there is easy access to

be

that silt, leaves

TYPICAL

RAW

(OWNER

INCOMING RAW

WATER

SEACOCK

The external thru-hull opening should be

+

or

WATER

INTAKE

INSTALLED)

LED

illuminates, the

grass may have been caught

of

raw water through the

STRAINER

INSPECT GLEAN

AND

EVERY

100HOURS

or

slot type external

t~e

st~ainer.

of

the flush

of

RAW

WATER

The raw water pump is a self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller has flexible blades which wipe against a curved within the impeller housing, producing the pumping action.

Never allow a spare impeller and impeller cover gasket aboard (an impeller kit). Raw water pump impeller failures occur when raw water is not present during engine operation. failures are not warrantable, and operators are cautioned make sure raw water flow is present water pump should tom impeller blades.

NOTE:

Should a failure occur with the pumps internal parts

(seals

and

purchase a new pump and rebuild the original pump as a spare.

NOTE:

Never allow

of

dry running may destroy the impeller.

INSPECTION:

.

EACH

BLADE

REPLACE

ARE

ANY

CRACKS.

WHEN

INSTALLING:

THE

IMPELLER

KEY.

FOLD

EITHER

DIRECTION

THE

CORRECT

IMPELLER

PUMP

the

pump

to

run

dry. There should always be

at

start-up.

be

inspected periodically for broken or

See MAINTENANCE SCHEDULE.

bearings), it may be more cost efficient to

the.

IMPELLER

CHECK

BY

BENDING

THE

IMPELLER

KEYWAY

THE

IMPELLER

POSITION

STARTS

pump to run

AT

THE

VIGOROUSLY.

IF

TAKE

CARE

WITH

BLADES

(THEY

WILL

WHEN

TO

ROTATE).

BASE

THERE

TO

THE

TURN THE

Of

ALIGN SHAFT

IN

dry.

Even a short period

cam

Such

The

RAW

WATER PUMP PN

042026

plate

raw

to

Changing

Close and, using an carefully pry the impeller out impeller and curved cam plate and push the impeller into the pumps housing. When assembling, apply a thin coating the impeller and gasket.

NOTE:

(seals purchase a new a spare.

NOTE:

must They often can be found in the heat exchanger.

the

Raw

Water

the

raw

water

intake

ilppeller puller, screw drivers, or pliers,

gasket..

Should a failure occur with the pumps inte

and

If

any

be

found to prevent blockage in the cooling circuit.

Move

bearings), it

pump

of

the vanes have broken

Pump

Impeller

valve. Remove the pump cover

of

the pump. Install the new

the blades to conform to the

of

lubricant to

Open

the

raw

water

intake

may

be more cost efficient to

and

rebuild the original pump as

off

the impeller they

valve.

mal

parts

WHEN

ASSEMBliNG:

GLYCERIN COVER

TO

()-RING,

THE

AND

INSIDE

APPLY A THIN

OF

THE

COVER,

THE

IMPELLER

COAT

OF

THE

~

WESTERBEKE

Engines & Generators

·16

ENGINE

LUBRICATING

OIL

ENGINE

Use a good brand designations as listed in the SPECIFICATION Section this manual.

Change the engine oil and filter after an initial engine break-in operation. Then follow the oil and filter change interval as specified in the

SCHEDULE

Westerbeke Corporation does not approve use

in must be performed using conventional oil. intervals must be as listed in the

SCHEDULE

synthetic oils are used.

NOTE:

statements regarding synthetic oil.

CHANGING

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil to drain, hose and pump the old oil out. Make sure the oil drain hose

is properly secured in its holder after all been drained.

Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence this condition is rare, it does require prompt attention to prevent serious damage. Call a competent mechanic is present in the oil. Raw water present in the oil can be the result engine and/or a siphoning through the raw water cooling circuit into the exhaust, filling into the engine.

OIL

of

engine oil with an API and SAE

MAINTENANCE

in this manual.

or

disapprove the

of

synthetic oils.

The information above supersedes all previous

of

If

synthetic oils are used, engine break-

Oil change

MAINTENANCE

section

of

this manual and not be extended

THE

ENGINE

a fault in the exhaust system attached to the

OIL

or

attach a pump to the end

of

water in the oil. Although

the old oil has

50 hours

of

the drain

if

of

if

water

APPLY A THIN FILTER FILTER

OIL

PRESSURE

SENDER

When removing the used oil filter, you may find it helpful to punch a hole in the upper and lower portion

to drain the oil into a container before removing it. This helps to lessen spillage. An automotive filter wrench should be helpful in removing the old oil filter. Place some paper towels and a plastic bag around the filter when unscrewing it to catch any oil that's in the filter. Inspect the old oil filter as it removed to make sure that the rubber sealing gasket comes off with the old oil filter. sealed against the oil filter adapter, gently remove it. When installing the new oil filter element, wipe the filter gasket's

sealing surface on the oil filter adapter free

thin coat

the oil filter. and tighten the filter firmly

NOTE:

are not recommended.

of

clean engine oil to the rubber sealing gasket on

Screw the filter onto the threaded oil filter stub,

Use genuine WESTERBEKE oil filters. Generic filters

If

COAT

OF

CLEAN

OIL

TO

GASKET

WHEN

CONTACTS

INSTALLING.

THE

BASE

OIL

of

this rubber sealing gasket remains

of

by

hand.

THE

AFTER

TIGHTEN

FILTER

the old filter

oil and apply a

THE

FIRMLY

ASSEMBLY

.is

BY

HAND

~REMOVE

Wi!/

.

OIL

DRAIN

HOSE

A

WARNING:

contaminants. and

nails

thoroughly

discard

used

clothing

oil

properly.

TO

DRAIN

OIL

UP

DIPSTICK

TUBE

Used

Avoid

or

rags

USING

AN

OIL

THE

HOSt.

soap

BMM

OR

oil

skin

THE

THRU

engine prolonged using

containing

(11/16")

PUMP

contains

contact.

and

water.

used

SOCKET

THE

WARMED

harmful

Launder

oil.

.

Clean

skin

or

Recycle

REFILLING

Add fresh oil through the valve cover. After refilling the oil, run the engine for a few moments. Make sure there is no leakage around the new oil filter or from the oil drain system, and then stop the engine. Then check the quantity the lube oil dipstick. Fill to, but not over, the FULL mark on the dipstick.

ROCKER COVER··

THE

OIL

SUMP

of

oil with

Engines & Generators

17

ENGINE

ADJUSTMENTS

SPARK

The first schedule

SPARK SPARK

NOTE:

the of

PLUGS

spark

plugs

should be cleaned and re-gapped after the

50

hour break-in period, then follow the maintenance

in

this manual.

A

WARNING:

the

engine

removing

PLUG PLUG

Loctite

spark

plugs

the

spark

INSPECT WEAR & CARBON

INSPECTING THE

SPARK

PLUGS

Do

not

remove

is

hot.

Allow

the

them.

GAP:

0.028-0.031

TORQUE:

Anti-Seize applied

plugs

will

easier.

FOR

11·151b-H

retard

.corrosion,

the

engine

in

(0.7-0.08 (1.5·2.31

to

the

spark

to

cool

kg-m)

threaded portion

making future

plugs

while

before

mm)

removal

INSPECT

DAMAGE

CHECK

FOR DETERIORATION ANDOAMAGE

of

FOR

AIR

SCREEN/FLAME

The air screen/ flame arrester should be 50 hours Schedule in this manual. Clean using a good dish washing

solution, rinse and air

INSPECTTHE IF AIR

of

operation. Then refer

SEALING

WORN

.....

JNSTALL A NEW

SCREEN.

A

WARNING:

started/operated properly

installed.

ARRESTER

dry.

EDGES,

The

generator

without

the

clean~d

to

the Maintenance

should

air

never

screen/flame

after the

be

a~rester

first

NOTE:

It

is

important operating ignition

OIL

The engine oil pressure is continually monitored by the ECU in Should the oil pressure fall below a safe operating level, the generator will shut-down and the control panel's low oil pressure fault LED will illuminate. Should this attempt to re-start the generator. Check the oil level and the condition of the for leaks. Inspect the wire connections (pressure sender).

A

pressure

condition.

system

PRESSURE

the generator control panel when the engine

WARNING:

but

the

engine

warning.

to

maintain spark plugs

They

are

an

important component

in

lowering carbon monoxide

oil.

If

there is a loss

If

the

does

not

oil

pressure

shut

of

down,

in

a proper

in

levels.

OIL

PRESSURE

is

running.

occur,

do

oil, inspect the engine

at

the oil gallery

light

illuminates

this

is a low

oil

the

not

18

3D

AMP

.

BATTERY

FUSE

CHARGING

CIRCUIT

BAITERY.

The

minimum recommended capacity the engine's MUST be a dedicated battery.

12

volt DC control circuit

of

the battery used

is

800-1000

CCA.

in

This

The

battery

charger supplies a DC battery

while

NOTE:

The battery charging circuit is totally separate from

AC

output

the the circuits output, but not the reverse.

A

separate

bridge rectifier

charging

battery

30AFUSE

This spade type wiring harness behind

group

unit.

and

is

an

encapsulated, solid-state unit

charging

the

of

which

The

supplies a DC

voltage

generator

the generator. The generator output affects

of stator

converts

unit

senses

fuse

is located in

the

to

is

operating.

windings

the

charge

the

fuel

filter.

the generator's starting

supplies

AC

current

needs

of

when

one

AC

the

is

voltage

to

supply

starting

needed.

that

the

to

Battery

Review

. establish a systematic maintenance schedule

engine's starting batteries

• Monitor your voltmeter

• Check the electrolyte level

•

• Make certain that battery cable connections

•

a

There is a small battery when the generator is not in use. draw, panel (or

A

Maintenance

the manufacturer's recommendations

and

house batteries.

for

proper

operation~

and

hydrometer. Use

only distilled water

level.

tight

to

the battery posts (and

·Keep

your batteries clean

tum

off

tum

CAUTION:

circuit,

th~

engine

never

is

to

avoid

electrical

however, engine's

DC

the

DC

off

the

To

shut

running.

electrical

to

bnng electrolytes

and

amperage drain from the starting

breaker

DC

battery switch to the generator).

avoid

damage

off

the

engine

Shut

off

shorts

circuit.

and

for

your

charging

specific

·

to

your

free of

on

the generators control

to

the

battery

the

engine

when

during

gravity

to a proper

are

engine).

corrosion.

To

prevent this

battery

switch

battery

working

then

engine

with

a

clean

and

charging

while

switch, on

the

NOTE:

When the generator is first started, the charger will

produce a low charging rate. This charging rate will rise as

the generator

is

operated.

Engines & Generators

19

The

following

and

causes

Diagnostic

ENGINE

TROUBLESHOOTING

troubleshooting chart describes certain problems

relating

to

engine service.

Also

note there

is

Troubleshooting section that follows.

Note:

When

a

breaker (control panel) disconnects all A C power and switched

servicing the engine/generator,

off

and reset manually.

the

main

circuit

can

be

Engine

does

Engine

cranks,

(engine

will

(3

crank

cycles

Engine

starts,

Engine

hunts.

Engine

misfires/back

Engine

overheats/engine

Exhaust

temp

Low

oil

pressure/oil

Problem

not

crank.

does

not

start

crank 8 seconds)

before

underspeed

runs

and

the

shuts

firing.

temp

LED

is

illuminated.

pressure

down.

LED

fault

occurs)

is

illuminated.

is

illuminated.

Possible

1.DC

2.DC

3.K2

4.Starter

5.DC &.Water

7.DC

1.Fuel

2.Air

3.Fouled

4Jaulty

1.Fuel

2.Air

3.Faulty

4.Faulty

1.Air

2.Faulty

3.Low

4.Faulty

1.Low

2.Dirty

3.Hign

4.Exhaust

5.Wom/fouled &.Faulty

7.Low

1.Raw

2.Coolant

3.Faulty

4.Pump

5.Stuck &.Air

1.Loss

2.Faulty

1.0illevellow.

2.Faulty

3.0il

Cause

panel

breaker

battery

OFF.

relay

faulty.

solenoid

battery

low/dead.

filled

panel 8 amp

starvation.

in

fuel

system.

spark

ignition

starvation.

in

fuel

system. shutdown fuel

pump.

in

fuel

system. fuel

pump.

octane

speed

octane

air

intake

tension

restriction.

ignition

or

no

fuel

water

coolant

level impeller. belt

loose/broken.

thermostat.

in

cooling

of

coolant

exhaust

oil

pressure

viscosity

OFF.

faulty.

cylinder.

buss

plugs.

coil.

switch/sensor.

fuel

(lower

sensor

(crankshaft).

fuel

(lower

screen

ignition

spark

plug.

coil.

pressure.

flow

low.

system

flow/faulty

temperature

sendor.

incorrect.

fuse

is

faulty.

.

than

89).

than

89).

screen.

wires.

Poor

obstruction.

(fresh

water).

pump.

switch.

quality

..

fuel.

20

ENGINE

TROUBLESHOOTING

No

DC

High

DC

Starter

Poor

performance

Black

exhaust

Blue

exhaust

Check

engine

Speed

Pair

of

External

charge

Charge

stays

LED's

Speed

alarm

Problem

to

starting

to

battery.

energized

at

generator

smoke.

LED's

are

illuminated-no

LED's

are

LED

is

illuminated.

battery.

after

start.

speed.

illuminated.

flashing.

illuminated-flashing.

Possible

1.Circuit

fuse

2.Faulty

circuit

3.Faulty

regulator/battery

4.Bridge

rectifier.

1.Battery

charger

2.Faulty

starter

1.Faulty

K1

2.Faulty

starter

1.Low

octane

2.1ncorrect

3.Fuel

4.High

1.Dirty

2.Faulty

1.Lube

2.Crankcase

3.High

1.Diagnostic

1.Faulty

2.1ntake

1.AC

2.Fuel

1.Loose

2.Faulty

ignition

supply

engine

air

screen.

injector.

oil

is

lube

speed

manifold

generator

starvation.

connection.

fire

Cause

faulty/blown

connection.

misadjusted.

solenoid.

relay.

solenoid.

fuel.

timing.

issue.

compartment

diluted. breather

tube

oil

level.

software

required.

sensor.

vacuum

overload.

suppression

(two

fuses).

charger.

temperature.

is

clogged.

leak.

shutdown

devise.

The 6.5/5_0

as

a pdf download at www. westerbeke.com. This Service

Manual can also be purchased in hard copy from your

MCG

Service

Manual

(#055743) is available

Westerbeke Dealer.

21

SOFTWARE

DIAGNOSTICS

PCINTERFACESOFnNARE

Diagnostic through

It

contains

Programmed

your

CABLE PART

Your www.westerbeke.com

The Diagnostic Software (EC technician ECU (Electronic Control Unit) functions.

·

Once

diagnostics, to

EXCEL.

Software

your

Westerbeke

a

PC

USB

laptop

and

AND

DIAGNOSTIC

#055410

areas

(USB

distributor

in

monitoring the engine's operation and the

downloaded,

FAILURE

Kit

#05541

0 is available for purchase

Dealer or Distributor.

Interface Software

Interconnect Cable

the

unit's Electronic Control Board

SOFlWARE

to

ECU)

SEE

can

be

this

software provides IDLE

Record

CD

for your laptop

to

connect between

KIT

BELOW.

found on our

II)

is designed to aide the

and

Run

Time

CONTROL

website:

and

(ECU).

Mode

Data Logging

BOX

TYPICAL

TiiE

COMMUNICATIONS

FOR'

DIAGNOSTIC

OPERATION

USING

The Diagnostic Software will run on

Vista

and

megabytes of

a

communications cable plugs into a serial

to adapter Diagnostic Software.

Westerbeke

The Diagnostic Software and MUST be used or damage is substituted. The Diagnostic Software multiple screens, tabs and pull down

in

the

diagnostic process. ·

The Diagnostic Software

the

engine/generator and

target frequency between 50Hz

Refer to WESTERBEKE'S

Software Diagnostic

INTERNAL

COMPONENTS

ASSEMBLY

CABLE

IS

MONITORING

PC

SOFIWARE.

AVAILABLE

OF

Windows

Wmdows

7. These MUST have a

RAM

(Random Access Memory).

USB

adapters, the communication port that

is

using MUST be known in order

communication cable

to

the

ECU

will occur

if

any

communications

menues

is

for monitoring

is

also

used

to

and

60Hz.

MCG

Service Manual for the

THE

~

Monitoring

ENGINES

...

and

98,

XP,

minimum

of 128

The

port.

When

using

the

to

configure

is

unique

to

this

otherwise

cable

is

designed

the

change

'Iroubleshooting

with

to

aid

the

operation

the

ECU

the

user

of '

Data.

FOR

WIRING

THESE

COMPONENTS

TO

THE

IN

CONNECTIONS

WIRING

THIS

MANUAL

TO REFER DIAGRAMS

Engines & Generators

22

1

CONTROL

PANEL

GENERATOR

USE

OF

ELECTRIC

The power required to start more than Some motors require much more current to start them than others. Split-phase (AC) motors require more current

under similar circumstances, than other types. They

commonly used on easy-starting loads, such

machines, or where loads are applied after the motor started, such to 7 times hould be avoided, whenever possible, to be driven by a small generator. Capacitor and repulsioninduction motors require from 2 to 4 times to

start varies with the load connected connected more current than a motor

In

general, to

medium

is

required to keep it running after it

as

much current

as

to run. The current required to start any motor

to

an air compressor, for example, will require

the

current

starting

MOTOR

SIZE

(HP)

1/6 1/4 1/3 1/2 3/4

1

MOTORS

an

electric motor

small power tools. Because they require 5

to

start

as

to run, their use

to

it.

An electric motor

to

which

no

required

loads

to

start

will

be

approximately

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

115-

is

considerably

is

started.

are

as

washing

is

if

the electric motor

as

much current

load is connected.

Volt

motors

connected

as

follows:

AMPS

FOR

STARTING

(AMPERES)

6.4

to

22.4*

9.2

to

32.2*

1

0.4

to

72.8

14.4

to

29.2*

20.4

to

40.8

26

to

52

to

•

start,

INFORMATION

LOAD

TEST

Run

is

the generator generator's capacity, and finally loaded to its as

indicted on the generator's data plate. The output voltage should be checked periodically to ensure proper operation of the generating plant and the appliances it supplies. monitor voltagr and load, check it with a portable meter and amp

probe.

Generator

Maintaining reasonable cleanliness of

terminal boards and rectifiers may become corroded, and insulation surfaces may start conducting exhaust, carbon, etc. are allowed to build

ventilation openings may cause excessive heating and reduced life

In addition to periodic cleaning, the generator should be inspected for tightness overheated terminals and loose or damaged

first

Maintenance

of

windings.

with

no

load applied, then at half the

is

of

all

connections, evidence

full

capacity

To

important. Connections

if

salts, dust, engine

up.

Clogged

of

wires.

*NOTE:

more

for

made

Because the heavy surge of current needed for starting motors not be damaged if it can bring the motor

If

other electrical loads and, electric reduce the peak starting current. These are called Soft-Start controls.

In

the

above

table

the

maximum Amps for Starting

for

some

small motors

this

is

that

the

hardest starting types (split-phase)

in

larger

sizes.

is

required for only a brief period, the generator will

difficulty

is

experienced in starting motors, turn off

motor.

Some motor controllers can be configured

than

for larger

up

if

possible, reduce the load on the

ones.

The

to speed

reason

are

quickly.

all

is

not

to

23

BC

GENERATOR

SINGLE

PHASE

DESCRIPTION

The

BC

generator requires only the driving force of AC

output. The stator houses stator windings is

started, residual magnetism in induces a current larger current of current windings quickly reaches capacitor(s) and a regulated energy in the a steady voltage drawn off the generator's equipment. The generator is a single-phase, reconnectable

120

230

SPECIFICATIONS

ratings. The generator's data plate gives the voltage, current

and affixed end. provided on inside the generator and supplies a continuous the

Circuit

A circuit breaker WESTERBEKE generators. This circuit breaker will matically disconnect generator power in case of overload. The circuit breaker can be manually shut off servicing into

in

stator.

volt

AC

volt or

frequency rating of

to

the

A diagram of

generators starting battery when

Breaker ( AC

the

boat.

is

a brushless, self-excited generator which

the

engine to produce

two

sets of windings; the

and

the exciter windings. When

the

four rotating poles

in

the

stator which then generates

in

the exciter windings. This mutual build

the

four rotating poles and

the

At

the

same

time,

in

the

stator windings which can then be

AC

two-wire

AC

inside of

the

at

60

two-wire, at

section of

the

louvered cover at

the

various

decal.

An Integral Controller

saturation point of

this

terminals

hertz or

50

hertz. Refer

this

generator.

AC

in

the

field

is

then maintained

regulated

to

operate

115

volt

manual for generator

An

AC

voltage connections

the

generator

l

is

installed on

generator

to

all

single phase

ensure that

qo

power

the

generator an

exciter

the

field

produces

AC

two-wire or

to

the

wiring decal

the

generator

(IC)

is

DC

charge

is

running.

an

electrical

is

coming

an

main

even

up

is

mounted

auto-

when

to

is

AC

NOTE:

Correctly

onto

TERMINAL

1.

CIRCUIT.

BREAKER

CONNECTIONS

4

1 6

CIRCUIT

BREAKER

ISOLATED POST

N

l1

position

the

neutraVground

the

case

terminal.

2 5

N

4 3

ground

wire

120V/60Hz

230V~OHz

(white/green)

r

-------

I

-.;..

1

3DA

FUSE

BATTERY

CHARGING

CIRCUIT

R~W.+01

I .

~-

1

I I

I

I ,

STATOR

~OOW.Dil

9

WINDING

GENERATOR

-sCHEMATIC

WINDING

l~-----'

EXCITER

WINDING·

CAPACFrOR

.

AMP

FUSE

Located

In

the

refer

diagram

wiring

to

the

in

harness,

wiring

this

manual.

WINDINGS

.

24

SHORE

POWER

TRANSFER

SWITCH

SINGLE

Generator

~

If

the circuit, Transfer

diagrams simultaneous

LINE

120

VOLT

SYSTEM

installer connects shore power

this

must

be

done

by

means

Switch.

to

the

connection.

Set

OFF

the

transfer switch shown in

position.

This

of shore power

to

the

vessel's

of the Shore Power

switch prevents

to

genemtor

AC

the

output.

Notice

the

repositioning of the white wire

terminal block

!ill.

:I

0

.a;.

"·

SHORE

Switching

to

the

genemtor case.

GENERATOR

~

N

w

!::

::c

:r:

,----.---~~--~~-(,3

L.--~----f.-{15

r-.:__--'-lrf7

~

POWER

Shore

Power

L1

~

g GENERATOR/SHORE

::l SWITCH

ca

(NEUTRAL)! I -

-=

to

ground

,..-

......

-

/ '

1

~·

I · I

2 I

.....

_

.....

' /

......

-

......

/ '

~

6 I

.....

_

....

' /

SHORE

GROUND

Generator

load

L1

- SHIP'S

-GROUND

Power

on

the

SHIP'S

LOAD

N

Generator

~

f

..

:I

•

z

L...---+-+--

~

Shore Power

NOTE:

This

diagram

wire,

120V

__

system

-120V

I

/

z

a:

~

,.,

Notice the repositioning tenninal block to the genemtor case.

two a three wire

/..---....,

--~~,@llD

- /

1

1 Ground

z (GRN)

shows

connections for a

from the generator with

boat

system.

120

VOLT/60

WIRE

CONFIGURATION

~=~~~.!...-.N

HZ

THREE

L2

L1

SHIPS

LOAD

(no

240V

equipment) !

II•

of

the wlute wire ground load on the

A

CAUTION:

before

switching vice-versa with

cause

because

heavy

AC

'damage

generator.

A

CAUTION:

utility

shore

at

the

same

covered

under

responsibility

co"ect.

HeartY

shore

loads

to

the

Damage power time.

the

to

make

motor

power

voltage

on

the

exciter

to

and

generatiJt

This

type

warranty;

sure

leads

should

to

generator

surges

Induced

vessel

being

circuit

the

generator

output

of

ge11erator

it

is

the

all

AC

connections

be

shut

power

by

switching

operated

components

can

result

are

connected

damage

installer's

are

off

or

may

in

Is

the

If

not

Engines & Generators

25

~

~-

IQ

5'

Na

i

c:nQD

~

s

B1

0

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iii

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FUSE

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IGNITION

SYSTEM

COMPONENTS

I

OPTIONAL

BATTERY

SWITCH

!BT

CUSTOMER

I

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...

FIRE

ALARM

ID

WHT/BLK/BLU-20GA

LED

OUT -LOW

OIL

PRESS

LED

OUT -COOLANT

TEMP

ID

WHT/BLK/ORG-20JA

LEO

OUT -EXH

TEMP

FAIL

LED

OUT -OVERSPEED

STOP

SWITCH

OUTPUT

I D

WHT

/BLK /GRY-

20GA

START

SWITCH

OUTPUT

LED

OUT -RUN I NO

ICATOR

ID

WHT/BLK/YEL-20GA

ECU,

REM

SWITCH & RELAY

COIL

POWER

RELAY

LOAD

POWER

SUPPLY

BATTERY + INPUT

RUN

RELAY

INPUT

-

;:::

~

<

..

"'

0

:;

~

"'

..

.

"'

>

..

RED/WHT-

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J.

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(15A)

·,

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>

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I

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4=

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HOUR

METER

r-

r-r--

REMOVE

JUMPER

FOR

FIRE

SUPPRESSION

SYSTEM

CONNECTION

-<IF

ECU_JI-2

WHTIGRY·I8GA

DC

CONTROL

PANEL

BOX

COMPONENTS

<SEE

NOTE

I>

OP.SENDER·SENS_GNO WHT/BLK-18GA

0

NOTES:

I.

FIRE

SUPPRESSION

SYSTEM

CONNECTION

IS

NOT A POWER

SOURCE.

THIS

CIRCUIT

MUST

BE

CLOSED

TO

RUN.

AN

OPEN

CIRCUIT

WILL

STOP

THE

GENSET.

0/C

BOX

CON\ECTOR

IDC.PII

,---11-

---

I

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0

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3

START

2

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PANEL

E

GROUND

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ECU.J2·31

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ECU.J2·30

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ECU.J2·29

WHT/BLKIGRY·ZOGA

ECU.JZ-28

WHT/BLK/YEL-ZOGA

ECU.JI-11

WHT/8LK/GRN·I8GA

ECU.JI-1

PNK-18GA

ECU.J2·21

WHT

iBLK/R£0-

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RE

0 /WHT- I

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PANEL

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LED

NT

TEMP

LED

ST

TEMP

LED

UNDER

SPEED

LED

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SWITCH)

INPUT

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SWITCH)

NDICATOR

LED

SUPPLY

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STR I BLK

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-

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WHT/BLK/GRN-I&GA

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I

WHT/8LK/8RN-16GA

ECU_J2-23

VIO/WHT-I&GA

~

VIO/WHT-16GA

aL

PRESSURE

SWITCH

(OP

_SWITCH)

WHT/8LK/BLU-16GA

ECU-J2-22

BATT_GND

D

12

<<

ZIDLft ! !

BLK-I&GA

I

1'---!---<1

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-8 7

VI 0-16GA

I

BATT

_GND

BLK-18GA

I I

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I I

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I

21

l.-..!1

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TIME

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FUEL

SYSTEM

COMPONENTS

FUEL

IN.ECTCR

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PNJ_2J

FUEL

I\IJECTCR

•1

INJJ

,.

I •

BLK-I.GA

BATT

_GNO

BLK/WHT-12GA

....-----}

AC

-~

WHT

I RED- I

2GA

RED/WHT

-12GA

BATTERY

CHARGER

BATTERY

CHARGING

CIRCUIT

LEAD

WIRE

FROM

FUSE

HOLDER

30A

FUSE

LEAD

WIRE

FROM

FUSE

HOLDER

BATT•CSTRl

There is a small

DC

amperage drain from the starting

battery when the generator is not in use.

To

prevent this

draw,

tum

off

the

DC

breaker on the generators control

panel (or

tum

off

the

DC

battery switch to the generator).

:e

-

:a

-

z

G')

~

i

~

CJ"1 CJ"1 CJ"1

w

0)

~~

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1'111

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WHT/BLK·ZOGA

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WHli8LK-ZOGA OP.SEHDER·$ENS.GND

t<

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ENilN!

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ECTI

IITAICE

AIR

TEM'

SENSOR

IAILTEM'J

COMPONENTS

LOCATED

ON

THE

INTAKE

THROTTLE

BODY

~

EXHAUST

WHTIGRY·I&GA

ECU.JI-16

TaiiP

SWITCH

WHT

IBLK

·18GA

OP

.SENDER.SEHS.GND

tEX.TEMPJ

WHTIBLK·

18GA

F IRE.ALARM·GHD

WHT

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WHT/BLK·20GA

AIR.T[MP·Z WHT/BLK·ZOGA ECT·Z WHT/BLK·18GA EXH.TEMP-2 WHT/BLK·18GA

ECU.JI-21

~SENS_GND

WHTIBLK •

ZOGA

CAll· 3

WHT/8LK·20GA" CRANK-3 WHT/BRN-ZOGA

ECU.JI·&

-=1

CL

I'RESSI.IIE

SENJER

IQP_SEMSJ

WHTIYEL-20GA

ECU

JI-JDO-t-<.<

'I

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~II

WHTIBLK-20GA

OP.SEHDER-SENS.GND~<

•1

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Jl-9

R[D/VIO-IBGA

WHT/VI0·18GA

ECU

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3

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ENGINE

BLOCK

COMPONENTS

GRN/YEL·ZOGA

ECU

Jl-14

WHT

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ECU

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18GA

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Jl-22

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ECU

Jl-8

EXHAUST

SYSTEM

COMPONENTS

<WIRING

DIAGRAM

ECU_J2

#55536

BLU-18GA

WHT/BLK/GRN-16GA

TAN-16GA

ORG-18GA

RELAY

BLK-16GA

GRY-

16GA

WHT/BLK/ORG-20GA WHT/BLK/RED-18GA

WHT/BRN-20GA

OP_SENDER-1

WHT/ORG-20GA

WHT/VI0-18GA

WHT/GRY·ISGA

FIRE.ALARM-2

PNK-18GA

STEPPER-I

INJECTOR.!

WB02-4

Kl-85

BATT

.GND

K3-86

WB02-6

MAP-3

MAP-4

CAM-2

DC.PI-7

....,.12

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......

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130

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WHT/YEL·20GA

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BLK/WHT·I8GA

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DC.P

1-8

WHT/BLK/GRN-18GA

EX.TEMP.I

WHT/GRY-18GA

WHT/BLK-18GA

ECU

CONNECTIONS

30

DC

AUXILLIARY

POWER

ADAPTER

DESCRIPTION

This auxilliary power adapter is designed to plug-in the engine wiring harness where the electric fuel pump is connected. Simply tum on the control panel. Unplug the electric fuel pump, connect

the adapter and connect the fuel pump to one plugs. Cut

off the other plug and strip back the wires and

maintaining polarity relay that will be supplying component. Re-set the DC panel.

off

the

(violet+

DC

powe~

ADAPTER

DC

power using the breaker

of

the adapter

and black -), connect to the

power to the auxilliary

breaker

PN.

on

052274

the control

REMOTE

PANELS

NOTE:

This auxilliary connection provides when the engine is running primed. The maximum

DC

WIRING

DC

or

the fuel system is being

power

available is 400 milliamps.

power only

:0

...,

0

'

Q)

.REMOTE

CONNECTOR

r--~

I

POWER

r L!b

'

START

•

STOP

t

LED

1

LED

·

~ED

a

LED

OUT • RUN

SWITCH

OUT • OVERSPEED

OUT • EXH OUT OUT • LOW

INDIGATOR

OUTPUT

TEMP

COOLANT

OIL

PNK·I8GA

WHTIBLK IGRN

f"

A.l

L

TEMP

PRESS

·I

BGA WHTIBLKIYEL·20GA WHTIBLKIGRY·20GA WHT

IBLK

IORG • 20GA·

!NI:ITIBLK

IBLU

• 20GA

Gl

>

STOP/START WITH

EXTENSION

15'

PN.

30'

PN.

FAULT

DISPLAY

HARNESS'

054931 054932

PANEL

REMOTE

CONNECTOR

~~:~~~~P~OW~E~A---~---------~---------------~R~ED~·~IB~G~·A

II

~..,.

I-~~.~~~RU~.N~·~I~D~I~C~A~T~OR~----------------~~WH~T~/~B~L~Kf~R~E~D-·~18~G~A~----------~

tl

• ,

lr-:;;...

I ....

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1_~:::~

IS

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·

'r-:;;~,

'I ....

I i" -.

L--~

J

...

::-::>...,1,..(-S-T-O-P

•':::-""

S

·'

.•

:::-......

:;

'!.--- I

START

_S_W_I-TC_H

N

SWITCH

OUTPUT

__

O_U_T_P

U..-.T---------,

. PNK··I8GA

WHT

_________________________

/BLK

/GRN··I8GA

STOP/START

PANEL

~R~OC~K~E~RSWITCHONLY

Engines

31

& Generators

MCG

GENERATOR

SPECIFICATIONS

Engine

Type

Bore & Stroke

Total

Displacement Bearings Compression Compression Hp@1800/1500 Firing Aspiration Direction Inclination Dry Governor

General Fuel

Fuel (full

Fuel (supply

Fuel Fuel Air

Cleaner

(flame

Start

Battery

Starter DC

Charging

DC

Cold

Generator

Engine (all

Engine

Note:

compartment

Chamber Ratio

rpm

Order

of

Rotation

weight

Consumption

load)

approx.

Hose

Size

and

return) Pump Riter

(on

engine)

arrester)

Battery

Capacity

Cranking

Cooling

Combustion

models)

Cooling

Forced

ventilation

temperature

ENGINE

SPECIFICATIONS

3-cylinder. w/counterbalance

gasoline

engine

2.56 x 2.61

40.3

cubic

Four

main

Semi-spherical

9.8:1

10.0 1-3-2 Naturally

Counterclockwise

25°

continuous,

Refer

to

the

Electronic

FUEL

SYSTEM

Multi-port Unleaded

or

higher

5.0

MCG

4.2

MCD

6.5

MCG

5.2

MCG

1/4"

I.D.

12

volt

electric Replaceable Metal

screen

ELECTRICAL

12-Volt,

(-)negative

Battery

must generator charge

controller

BOO

-1

ODD

(minimum) 120

Volt,

Solid

state

Amps

150-176

AIR

REQUIREMENTS

225

-2

50

21

CFM

(0.6

100

CFM

should

be

provided

below

122"F

4-cycle, , overhead

shaft,

water

inches

(65.0 x 66.3

inches

(0.661iters)

bearings

aspirated

viewed

from

all

directions

sales

brochure

fuel

injection

gasoline

with

an

octane

(.74

gph)

(.63

gph)

(.76

gph)

(.71

gph)

minimum -3/8"

(high/low

cartridge-canister

type -cleanable

I.D.

pressure)

SYSTEM

ground

be

totally

and

Cold

reduction-solenoid

controller,

Amps

CFM

cmm)

(2.8

(50"C).

dedicated

maintained

system

Cranking

12

Amp

(6.3 -7.0

cmm)

to

maintain

only

in

the

Amps

cmm)

qenemtors

camshaft cooled

mm)

the

back

rating

maximum

type

to

the

by

the

AC

generator

rated

mounted

rated

end

of

DC

(CCA)

89

General

Fresh

Water

Raw

Water

Raw

Water

Cooling

Water

Operating

General Oil

Riter

Oil

Capacity Operating Oil

Grade

Single

Phase

Ratings:

4.2KW

5.0KW

5.2KW

6.5KW

General

Distributor

Spark

Plug

Spark

Plug

Ignition

Timing

Spark

Plugs

Ignition

Coil

Distributor

COOLING

Pump

Row,

Capacity

Temperature

-LUBRICATION

Oil

Pressure

AC

GENERATOR

IGNITION

Thread

Gap

SYSTEM

Fresh

water-cooled

water-cooled Centrifugal Positive

belt-driven.

4.9 (approx. exhaust

3.5

170°-190° F

heat

type,

displacement,

US

gpm

(18.51iters)@

measure

elbow).

qts

(3.31iters).

metal

(n•-

SYSTEM

Forced

lubrication

Full

flow,

paper

element.

3.0

qts.

(2.8

liters).

30 -45

psi

(2.1 -3.1

API

Service

40.

Catagory

ONLY

(No

SAE

(Single

Brushless, 1800

230 single

120 single

230 single

120 single

four-pole

rpm/60Hz,

volts,

18.2

phase, 4 wire,

volts,

41.6

phase, 4 wire,

volts,

22.6

phase, 4 wire,

volts,

54

amps,

phase, 4 wire,

1500

amps,

SYSTEM

Battery

ignition

coil

state

advance

with

and

type

with

12

ignition

spark

with

pitch inches

ignitor

Distributor Ignition

Solid ignitor.

11mm x 1.25

0.028 -0.031 15"BTDCat1800

(Vacuum 14mm 12

volt

Breakerless assembly

block

through

exchanger

before

by

circuit impeller, rubber

1800

discharging

as·

C)

gear

pump.

spin-on

kg/em').

SJ,

SL,

Multi-Weight

SM

Phase)

capacitor,

rpm/50Hz

50Hz

1.0

power

60Hz

1.0

power

50Hz

1.0

power

60Hz

1.0

power

volts

negative

module

plugs.

signal

generator

(0.7-

O.Bmm)

RPM± 1• hose

disconnected)

and

pick

raw

belt-driven.

impeller,

rpm

into

disposals.

or

SN

Oils).

regulated.

factor

ground.

and

ignitor.

and

up

Engines & Generators

32

LAY-UP & RECOMMISSIONING

GENERAL

Many

owners rely including engines and generators, for lay-up during off-season to

accomplish lay-up preparation themselves.

The own check list if others

These procedures should afford your engine protection during a lay-up and

maintenance

If

you your local servicing provide assistance.

or

procedures which

lay-up and recommissioning, or

have

Lubrication

With

the

engine

sump.

Remove and replace

with

new

oil.

ENGINE LUBRICATING

oil changing procedure. oil pressure

A

CAUTION:

oil

in

the

and

combustion chemicals intemal

parts.

on

their boatyards

for

long

periods of

follow

do

the procedures.

also

help familiarize

needs

of your

any

questions regarding lay-up procedures, call

dealer;

engine.

he

inactivity.

will

allow

will

to

prepare their

you

be

more

Others prefer

to

perform

may

use

with

than willing

System

warm,

Use

and

make

sump

which

drain all

the

correct grade of

Run

sure

Do

not

over

the

deposits

can

reduce

the

oil filter and

OIL

pages

the engine

there

are

leave

the

lay-up

combine

the

engine oil

oil.

in

this manual for

and

no

leaks.

engine's

period.

to

produce

life

of

from

fill

the

Refer

check

old

Lubricating

your

engine's

the

them

the

the oil

sump

to

the

for

engine

harmful

craft,

your as

to

the

proper

oil

STARTER

Lubrication and cleaning of the starter drive pinion able, sure remove

trical connections removed

a

Raw

Close hose

gallon

check

the

engine and clean or replace it any zinc

Start fresh stop solution slightly stronger than needed protection in your

Start through the water circuit as

providing corrosion protection.

Remove antifreeze mixture will accompany Examine the a cover gasket. until recommissioning, but replace the cover

MOTOR

if

access

to

the starter permits its

the

battery connections

the

starter.

Take

Water

the

from

zinc

anode

the

water through the system. When

the

engine.

Cooling

through-hull seacock. Remove the

the seacock. Place the end of

bucket of clean fresh

the

zinc

anode

debris

from

is

located. Clean the raw water

engine and allow the raw water pump

engine and refill the bucket with

area.

engine and allow all of this mixture

the

raw

water system.

This antifreeze mixture should protect

from

freezing during the winter

the impeller from your

impeller.

Do

not replace the impeller

are

shut off before

care in properly replacing

from

the

Circuit

water.

found

in the primary heat exchanger

as

inside the heat exchanger

Once

raw

Acquire a replacement,

easy

removal.

attempting

starter.

raw

this

hose

Before starting

required,

for

the bucket

water

it,

so

the

an

winter

catch it

and

where

strainer.

to

bucket

antifreeze

to

be is

lay-up,

pump

if

(into

and

is

advis-

Make

to

any

elec-

water intake

into a

five

the

engine,

on

also

clean

the

draw

the

is

empty,

freeze

drawn

empty,

stop

the_raw

as

well

(some in a bucket). needed,

the

pump)

gasket.

and

Intake

Clean cloth lightly soaked

block

through-hull exhaust port, Make a note prior

CYLINDER

After engine shutdown, remove small amount of crankshaft manually spark plugs loosely

NOTE:

the

·

plugs,

leads fulky onto

Fuel

Top or

stabilizer should be gasoline/water and fuel.

Manifold

the

filter screen in

any

opening.

to

start-up!

the

flame

in

lube oil around

Also

place

an

LUBRICATION

fogging

At

spring commissioning,

crankshaft

tighten each properly and connect

two

each

oil into each

two

complete revolutions. Re-install

for

winter lay-up.

full

revolutions.

spark

plug.

System

off your

higher. A fuel

make

fuel

tanks with unleaded gasoline

conditioner such ~ Sta-Bil

added.

Change the·etement in your

separator and clean the metal bowl. Re-install

certain there are

Gasoline

higher

no

leaks. Clean

with

than

and may

oil-soaked cloth in

the

remove

10"/o

arrester, and place a clean

the

flame

arrester

to

remove cloths

spark plugs

cylinder.

Re-install

an ETHANOL content

IE10) is not allowed .

void waiTIInty.

and

Rotate

the

plugs and

the

high tension

of

gasoli~e

up

any

the

spray a

spark

89

spilled

to

the

rotate

octane

BAnERIES

If

batteries make way, the be

subjected batteries environment.

A

a electrical Do being vicinity

are

to

be

sure that they

to

prevent them from freezing.

batteries

will

not

to

severe environmental conditions,

and

store them in a

WARNING:

highly-explosive

arcing

not

smoke

or

serviced.

to

Shut

prevent

left

on

board during

are

fully

charged,

remain fully charged, or that

warmer,

Lead

acid

batteries

gas,

which

can

or a lighted

allow

off

electrical

an

open

all

cigarette,

electrical

arcing

the

and

will

If

there

more compatible

emit

be

ignited

cigar,

flame

near

equipment

during

lay-up period,

remain that

is

any

doubt

they

will

remove

hydrogen,

by

or

pipe.

the

battery

in

the

servicing.

that the

33

Spare

Parts

Lay-up

time Westerbeke or

coolant

kit

and

order items not

during

the

SPARE

PARTS

LAY-UP

provides a good opportunity to inspect

engine

to

see if external items such

hoses

need

replacement. Check your basic

on

hand, or replace those

lay-up, such

section of this manual.

as

filters and zinc anodes. Refer

your

as

drive pelts

spares

items

&

Recommissioning

The recommissioning of your Westerbeke engine after a

seasonal those section However, counteracted before starting

1.

2.

lay-up generally follows the same procedures

described

regarding preparation for starting

in

the

PREPARATIONS

FOR

and

some of the lay-up procedures will need

the

engine. Remove Remove

discard removed Install

the oil-soaked cloths from the intake the

raw

the

water pump cover

old

gasket.

Install the

during

lay-up (or a replacement, if required).

raw

water pump cover with a

and

raw

water pump

STARTING

normai

to

manifold.

gasket

and

new

cover

starts.

be

i,mpeller

RECOMMISSIONING

3.

Reinstall the batteries that lay-up, and reconnect the battery

used

to

the

as

gasket.

terminals are clean Check to make sure that

. .

4.

Remove

the

proper tightness

5.

; Start

the

engine in accordance

in

the

PREPARATIONS

manual.

and

spark plugs, wipe clean,

[gasoline].

were

that

the

FOR

removed

cables,

the

connections

batteries

with

procedures

STARTING

during

making

are

fully

re-gap,

section

the

sure

are

tight.

charged.

and

described

the

install

of

this

to

APPLY A THIN INSTALLING TIGHTEN CONTACTS

THE MUST CONNECTION REMOTE

THIS

AN

ADDITIONAL

THE

"OUT"

CONNECTION

ATTACH

OIL

COAT

OF

KIT.

BASE.

TO

THE

AT

THE

FILTER.

CLEAN

THREAD

3/4

TURN

.

"IN"

NOTE;

on

the

for

Installation}

reconnected

INSTALLATION

This

popular

ter

from

engine

NOTE:

in.Structions

To

install, WESTBRBEKE's install

Contact

accessory

the

engine

room

bulkhead.

Refer

to

ENGINE

on

simply

this

kit

with

your

WESTBRBEKE

to a more

removing

remove

remote

the

REMOTE

OIL

TO

THE

O·RING

THE

KIT

ON,

The

"/ll"and

kit

(If

the

correctly.

'is.

used

OIL

the

oil

filter facing down

WHEN

THEN

HAND

THE

O·RING

hoses

are

so

to

tel'rn~WiJr.~~

they

can

relocate the engine's

convenient location such

CHANGE

oil

filter.

engine oil filter and thread

filter kit

as

dealer for more information.

OIL

PN:

be

in

this manual for

shown.

Always

as

illustrated.

FI~TER

(OPTI

............

040078

oil

fil-

as

an

A

CAUTION:

on

_

correctly. by-pass from

reaching failure. Immediately

:r::;·,·:iif":':,,,._

APPLY A THIN FILTER FILTER

tighten

If

the

valve

In

the

If

there

and

GASKET CONTACTS

It

f1rmly

It

is vital

o/1

Bolfls

the

filter

engine.

Is

no

oil

check

COAT

OF

CLEAN

WHEN

INSTALLING.

THE

BASE;

by

hand

to

Install

In

the

asembly

causing

pressure

the

hose.

,,

FASTEN

SECURELY

ARE

OIL

TO

THE

AFTER

·

the

o/11/nes

reverse

direction.

will

prevent

an

Internal

reading.

connections.

TO A BULKHEAD

OWNER

SUPPLIED)

THE

the

oil

engine

shutdown

34

Timing

Bell

Flywheel

bolt

Timing

belt

Camshaft Oil Timing Timing

Rocker

Rocker Camshaft Rocker

Cylinder

_cylinder Spark Rocket

Miscellaneous

Coolant Coolant Generator Exhaust Thermostat

Front

sprocket

pump

sprocket tensloner belt

rear

.Anns

and

cover

tl:lrust

arm

Head,

head

plug

cover

temperature temperature

mounts

manifold_

'

Crankshaft

-.

cover

bolls

bolts

nuts

cover

Rocker

shaft

plate

adjust

nut

Valve

bolt

(cold

____

housing

bolt

______

_ . _

bolls

Shaft

bolt

engine)

sender. switch

.

__

IJIGHTENING

ft.lbs.

98-105

58-72 36-41 16-22

--

21-25

··-

43-51

11-15/b-ft

.9-10

-

----_9-13 23-34 12-17

___

Nm

135-145

10-12

80-100

-

50-57"·

.

22~30

10-12

29-35 10-12.

8-10.

60-70

15.2_

12-13

12-18 12-18---

34-47

16-23

8-11

135-145

-

__

---

·-·

TORQUE

·Front

7~9

7-9

Piston 7-9 6-7

9-13

6-8

98-105

Crankshaft,

Cylinder

Water

SPECIFICATIONS

Case,

Front

ease

011

pump

Oil

pan

Oil

drain

011

screen

Oil

pump

Rear

cover

and

Connecting

011

seal

Bearing

Block

Taper

plug

Taper

plug

Water

drain

Taper

plug

Oil

pressure

Oil

pressure

Pump

Water

pump.

Counterbalance

bolls

__

cover

bolts.

bolts

_

plug

bolts--~----------

driven

gear

bolts

Connecting

rod

cap

Bearing·

case

bolts

cap

bolls

1n6

NPT

1/8

NPT

plug

1/4

NPl

switch sender

bolt

Rod

nut

_.

Shalt

.

Nm 8-10 8-10.

10-12 35-45

.

15-22.

- ------34-40 10-12

- .

J5+90"tum_

10-12 50·

55

8-12

-15-22 35-45 35-45 12-18 12-18

8-10.

lt.lbs.

.6-7

25-33

11-16

25-29

______

11 + 90"

36-40

-11-16

25-33

...

25-33

-~13

6-7 7-9

7-9

tum

7-9

6·9

9-13

6-7.

35

CONTACT

YOUR

SUGGESTED

.

WESTERBEKE

MARINE

DEALER

SPARE

GASOLINE

FOR

SUGGESTIONS

PARTS

GENERATORS

AND

ADDITIONAL

"'

.

INFORMATION

RAW

GASKET

.

ZINC

AND

IMPELLERS

ANODES

WESTERBEKE also· offers two Spare Parts Kits, each packaged in a rugged, rust free toolbox.

KIT

A includes the basic spares.

KIT

B is for more extensive off-shore cmising.

Kit

A

Impeller Kit Heat Exchanger Gasket

Oil Filter Drive Belt Zinc Anodes

Plugs

Spark Fuel Filters

HARDWARE

•

PARTS

KITS

KIT

Kit

8

Impeller Kit

Pump Repair Kit

Water Thermostat Kit

Zinc Anodes Complete Gasket Kit Heat Exchanger Gasket Fuel Filter with Gasket Oil Filter Drive Belt

Spark

Plugs

Fuel Filters

Engines. & Generators

36

.itt&lr--

§Jf.tf{l'

WESTERBEKE

150

JOHN

FAX

(508)884-9688 • WEBSITE:

CORPORATION • MYLES

HANCOCK

ROAD • TAUNTON

WWW.

WESTERBEKE.COM

STANDISH

MA

INDUSTRIAL

0278()..7319 • TEL.

PARK

(508)823·7677

1221·2/2016

Westerbeke 6.5 MCG, 5.2 MCG, 5.0 MCG, 4.2 MCG Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual