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5 - 6.5 MCG Operators Manual

1. 16 Raw Water Intake 5 2 00 16 RAW Water latum spe 16 Changing the Impeller 16 Engine Lubricating 17 17 Replacing Filter sedo alee 17 Engine Adjustments 18 Spark USSR ERS 18 AUT SCFOBII 18 OIL PIOSSUEB uar indita LSS 18 Battery Charging 19 Engine 1 20 PC 22 Control Box Components 22 Generator Information 22 Terminal Connections 00 0 022 24 Windings SChemauc ais 24 Shore Power Transfer Switch 25 Engine Generator Wiring Diagrams 55536 26 Ignition System 26 Control Box Components 24 Fuel System 5
2. qn e Un UP Ub Ub GP I The serial number is stamped on the top of the generator housing ENG SER NO GEN SER NO PF PHASE f f 20 The generator specifications ure printed on a decal on the side of the generator INSUL CLASS TEMP RISE Fill in the information for your own reference NOTE Technical information is provided in our Manuals for your reference and convenience Westerbeke recommends that your engine generator or climate control system is serviced and or installed only by a qualified Westerbeke distributor or dealer The 6 5 5 0 MCG Service Manual 055748 is available as a Pdf download at www westerbeke com This Service Manual can also be purchased from your WESTERBEKE DEALER as a book xv WESTEHBEKE Engines amp Generators 9 INTRODUCTION PROTECTING YOUR INVESTMENT Care at the factory during assembly and thorough testing have resulted in a WESTERBEKE generator capable of many hours of dependable service However the manufacturer cannot control how or where the generator is installed in the vessel or the manner in which the unit is operated and serviced in the field This is up to the buyer owner operator NOTE Six important steps to ensure long generator life B Proper installation An efficient well designed exhaust system that includes an anti siphon break to prevent water from entering the engine B Changing the engine
3. 22 RAW WATER PUMP CONTROL E OIL FILTER K1 2 3 REL Y OIL SUMP DRAIN HOSE EXTERNAL ALARM CONNECTIONS gt START MOTOR AIR SCREEN FUEL FILTER CONNECTION IP GROUND IN LINE FUEL FILTER ELECTRIC FUEL LIFT PUMP 002 den MODULE RIGHT SIDE Cw WESTERBEKE Engines amp Generators 2 INTRODUCTION This WESTERBEKE Generator is a product of WESTERBEKE s long years of experience and advanced technology We take great pride in the superior durability and dependable performance of our engines and generators Thank you for selecting WESTERBEKE In order to get the full use and benefit from your generator it is important that you operate and maintain it correctly This manual is designed to help you do this Please read this manual carefully and observe all the safety precautions throughout Should your generator require servicing contact your nearest WESTERBEKE dealer for assistance This is your Operators Manual Along with this manual there is an Installation Manual and Parts Information A service Manual is available and can be ordered from your local WESTERBEKE UNIVERSAL dealer WARRANTY PROCEDURES Your WESTERBEKE Warranty Statement is included in the product documentation package There is a warranty registeration card you can fill out and mail to Westerbeke Corporation or go to our website www westerbeke com and register your product s warranty on line You should receive a cu
4. 4 DC PI 12 WHT BLK BLU 20GA 4 3 85 GRN I8GA _ 11 WHT BLK ORG 20GA 4 DC PI 10 WHT BLK GRY 20GA DC PT 9 WHT BLK YEL 20GA BLK 16GA BATT GND D GRY 16GA K3 86 D WHT BLK ORG 20GA 2 6 D IWBO2 2 WHT BLK VIO 20GA WHT BLK RED 18GA 3 IWBO2 5 BLK WHT 18GA 24802 1 GRN YEL 20GA WHT BRN 20GA gt qd OP SENDER SENS GND WHT BLK 18GA qECT 1 WHT GRN 20GA WHT ORG 20GA MAP 4D IAIR TEMP I WHT BLU 20GA WHT VIO 18GA CAM 2 ICRANK 2 WHT YEL 20GA JDC PjI 8 WHT BLK GRN 18GA JUNC 2 RED VIO 18GA qEX TEMP I WHT GRY 18GA WHT GRY 18GA FIRE ALARM 2 D PNK 18GA DC_PI 7 t ECU CONNECTIONS xw WESTERBEKE Engines amp Generators 30 DC AUXILLIARY POWER ADAPTER DESCRIPTION NOTE This auxilliary connection provides DC power only This auxilliary power adapter is designed to plug in the when the engine is running or the fuel system is being engine wiring harness where the electric fuel pump is primed The maximum DC power available is 400 milliamps connected Simply turn off the DC power using the breaker on the control panel Unplug the electric fuel pump connect the adapter and connect the fuel pump to one of the adapter plugs Cut off the other plug and strip back the wires and maintaining polarity violet and black connect to the relay that will be supplying DC power to the auxilliary component Re set the DC
5. Exhaust Elbow Exhaust System Check the structual integrity of the water injected exhaust elbow casting Check the integrity of the exhaust system attached to the elbow All hose connections should be secure No chafing No exhaust leaks Hoses and muffler are in good serviceable condition NOTE An exhaust leak will cause exposure to carbon monoxide Fuel Filter and O Rings Remove and replace fuel filter and all sealing O rings Inlet Fuel Filter Remove and replace inlet fuel filter Generator Check that AC connections are clean and secure Ensure wires have no chafing see GENERATOR INFORMATION Hoses Engine hoses should be firm and tight Replace if hoses become spongy brittle or delaminated Check and tighten all hose clamps as needed Vibration Isolators Engine Mounts Check vibration isolators brackets and mounting hardware Replace as needed Heat Exchanger Open heat exchanger end cap s and clean out debris Replace gasket and O rings if needed EVERY 500 OPERATING HOURS OR YEARLY Water Pump Remove the pump cover and inspect the pump assembly for wear especially cam and wear plates Replace the impeller and gasket Lubricate the impeller when re assembling Exhaust System Catalyst Inspect for proper operation Replace at 2000 operating hours EVERY 500 OPERATING HOURS OR EVERY TWO YEARS Ignition System Inspect for deterioration Test resistance Coolant System Drain flush and re fill the cooling system wit
6. Intake Manifold Clean the filter screen in the flame arrester and place a clean cloth lightly soaked in lube oil around the flame arrester to block any opening Also place an oil soaked cloth in the through hull exhaust port Make a note to remove cloths prior to start up CYLINDER LUBRICATION After engine shutdown remove the spark plugs and spray a small amount of fogging oil into each cylinder Rotate the crankshaft manually two complete revolutions Re install the spark plugs loosely for winter lay up NOTE A spring commissioning remove the plugs and rotate the crankshaft two full revolutions Re install the spark plugs tighten each properly and connect the high tension leads fulky onto each spark plug Fuel System Top off your fuel tanks with unleaded gasoline of 89 octane or higher A fuel conditioner such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up any spilled fuel Gasoline with an ETHANOL content higher than 10 E10 is not allowed and may void warranty STARTER MOTOR Lubrication and cleaning of the starter drive pinion is advis able if access to the starter permits its easy removal Make sure the battery connections are shut off before attempting to remove the starter Take care in properly replacing any elec trical connections removed from the starter Raw Water
7. ml OPERATORS MANUAL 4 MCG 50HZ Multi port MARINE GASOLINE GENERATOR 6 5 MCG 60HZ 5 0 MCG 60HZ 2 MCG 50HZ 4 o gt e Im QAM e 2 ESS S X Ve T LLI UOI Wein z rr m AUGUST 2013 N E amp i Low Carbon Monoxide Em i CALIFORNIA PROPOSITION 65 WARNING Exhaust gas from diesel and gasoline engines and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A WARNING Exhaust gasses contain Carbon Monoxide an odorless and colorless gas Carbon Monoxide is poisonous and can cause unconsciousness and death Symptoms of Carbon Monoxide exposure can include e Dizziness e Throbbing in Temples e Nausea e Muscular Twitching e Headache e Vomiting e Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTUMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the unit and do not restart until it has been inspected and repaired A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living sleeping quarters of your vessel They are cost
8. 2 28 Battery Charging etie Sans 28 Exhaust System Components 29 Throttle Body Components eene 20 ECU COmponme mts dba idit test 30 Remote Panel Wiring Diagram 31 DC Auxillary Power Adapter 31 MCG Generator Specifications 32 Lay Up and 33 Remote Oil 34 Tightening Torque Specifications 35 Suggested Spare Parts 36 xv WESTEHBEKE Muir amp Generators PARTS IDENTIFICATION WIRING HARNESS TO ECU CONNECTIONS IGNITION COIL BATTERY CHARGER FUSE SIPHON BREAK BATTERY CHARGER CONNECTION REAR EXHAUST TEMPERATURE SWITCH AC CIRCUIT BREAKER TEST PORT OXYGEN SENSOR EXHAUST BACK PRESURE EXHAUST MANIFOLD BELT f RAW WATER COVER Ns DISCHARGE FRONT ISOLATOR MOUNT EXHAUST HOSE CONNECTION HEAT SUMP LEFT EXCHANGER ie SIDE ANODE THROTTLE BODY AIR BLEED PETCOCK OIL FILL CAP THERMOSTAT ASSEMBLY OIL DIPSTICK CONTROL BOX e FUEL RAIL uu om FUEL INJECTOR HEAT SINK GENERATOR
9. AMPS FOR STARTING AMPERES 1 6 1 4 3 2 4 6 6 4 to 22 4 9 2 to 32 2 1 3 1 2 7 2 3 4 10 2 1 13 9 2 10 4 to 72 8 14 4 to 29 2 20 4 to 40 8 26 to 52 NOTE the above table the maximum Amps for Starting is more for some small motors than for larger ones The reason for this is that the hardest starting types split phase are not made in larger sizes Because the heavy surge of current needed for starting motors is required for only a brief period the generator will not be damaged if it can bring the motor up to speed quickly If difficulty is experienced in starting motors turn off all other electrical loads and if possible reduce the load on the electric motor Some motor controllers can be configured to reduce the peak starting current These are called Soft Start controls LOAD TEST Run the generator first with no load applied then at half the generator s capacity and finally loaded to its full capacity 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 To monitor voltagr and load check it with a portable meter and amp probe Generator Maintenance Maintaining reasonable cleanliness is important Connections of terminal boards and rectifiers may become corroded and insulation surfaces may start conducting if salts dust e
10. COVER O RING AND THE IMPELLER RSS WESTERBEKE 6 J INCOMING RAW Engines amp Generators N 7 WATER 1 6 FROM FUEL MODULE CAM PLATE ENGINE LUBRICATING OIL ENGINE OIL Use a good brand of engine oil with an API and SAE designations as listed in the SPECIFICATION Section of this manual Change the engine oil and filter after an initial 50 hours of engine break in operation Then follow the oil and filter change interval as specified in the MAINTENANCE SCHEDULE in this manual Westerbeke Corporation does not approve or disapprove the use of synthetic oils If synthetic oils are used engine break in must be performed using conventional oil Oil change intervals must be as listed in the MAINTENANCE SCHEDULE section of this manual and not be extended if synthetic oils are used NOTE The information above supersedes all previous statements regarding synthetic oil CHANGING THE ENGINE OIL 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 or attach a pump to the end of the drain hose and pump the old oil out Make sure the oil drain hose is properly secured in its holder after all of the old oil has been drained Always observe the old oil as it is removed A yellow gray emulsion indicates the presence of water in the oil Although this condition is rare it does require prompt attention to prevent serious damage Call a competent mecha
11. Cooling Circuit Close the through hull seacock Remove the raw water intake hose from the seacock Place the end of this hose into a five gallon bucket of clean fresh water Before starting the engine check the zinc anode found in the primary heat exchanger on the engine and clean or replace it as required and also clean any zinc debris from inside the heat exchanger where the zinc anode is located Clean the raw water strainer Start the engine and allow the raw water pump to draw the fresh water through the system When the bucket is empty stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for winter freeze protection in your area Start the engine and allow all of this mixture to be drawn through the raw water system Once the bucket is empty stop the engine This antifreeze mixture should protect the raw water circuit from freezing during the winter lay up as well as providing corrosion protection Remove the impeller from your raw water pump some antifreeze mixture will accompany it so catch it in a bucket Examine the impeller Acquire a replacement if needed and a cover gasket Do not replace the impeller into the pump until recommissioning but replace the cover and gasket BATTERIES If batteries are to be left on board during the lay up period make sure that they are fully charged and will remain that way to prevent them from freezing If there is any doubt that the ba
12. affective and easily obtainable at your local marine store WESTERBEKE FF GENERATORS Low CO Low Carbon Monoxide Emissions Gasoline with an ETHANOL higher than 10 E10 is not allowed and may void warranty Engines amp Generators SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully Most accidents are caused by failure to follow fundamental rules and precautions Know when dangerous conditions exist and take the necessary precautions to protect yourself your personnel and your machinery The following safety instructions are in compliance with the American Boat and Yacht Council ABYC standards PREVENT ELECTRIC SHOCK WARNING Do not touch AC electrical connections while engine is running Lethal voltage is present at these connections Do not operate this machinery without electrical enclosures and covers place Shut off electrical power before accessing electrical equipment W Useinsulated mats whenever working on electrical equipment Make sure your clothing and skin are dry not damp particularly shoes when handling electrical equipment Remove wristwatch and all jewelry when working on electrical equipment Do noit connect utility shore power to vessel s AC circuits except through a ship to shore double throw transfer switch Damage to vessel s AC generator may result if this procedure is not followed W Electric
13. crankshaft rotation It sends a voltage signal to the ECU that is interpreted as engine speed If a speed threshold is reached either overspeed or underspeed the ECU will shut the generator down If both speed LED S are illuminated it indicates overspeed If both LED S are flashing it indicates underspeed OIL PRESSURE SWITCH An oil pressure switch is located on the right side of the oil filter mounting bracket This is a normally open contact switch It functions with the time relay circuit to ensure DC voltage to the circuit is terminated when the unit shuts down OIL GALLERY OIL PRESSURE SWITCH OIL PRESSURE SENDER OIL PRESSURE SENDER An oil pressure sender to the left of the oil filter sends DC voltage to the ECU that it interprets as oil pressure Should this voltage fall below a certain level the ECU will shut the generator down and illuminate the low oil pressure LED Should this occur refer to ENGINE TROUBLESHOOTING in this manual EXHAUST TEMPERATURE SWITCH A temperature switch is mounted on the exhaust elbow to monitor the temperature of the exhaust coolant and gases Should the switch sense an excessive exhaust temperature the ECU will shut the generator down and the exhaust temperature LED will illuminate on the control panel EXHAUST TEMPERATURE SWITCH EXHAUST COOLANT TEMPERATURE SENSOR This sensor is located on the underside of the intake manifold to monitor the
14. designed to dramatically reduce normal levels of CO in the engine exhaust Several standards for CO have been published expressed in parts per million ppm and hours of exposure Exposure Hours Regulator EPA ACGIH EP NIOSH ACGIH oF 20 00 NIOSH 1200 IDLH 1200 ppm is the so called IDLH concentration IMMEDIATELY DANGEROUS TO LIFE AND HEALTH A city in California characterizes the effect of CO concentration this way Parts per Million Permissible exposure level no apparent toxic symptoms No poisoning for long period Allowable for several hours CO ppm Should not be exposed above this level for any period of time A possible mild frontal headache in two to three hours Even though the generator normally produces very low levels of CO an exhaust leak of untreated exhaust would be extremely dangerous For this reason it is extremely impor tant to install a CO detector near the generator and to be sure it is always turned on and functioning properly If this detec tor sounds do not turn it off assuming it is a false signal You can not taste smell or otherwise detect CO Leave the detector on turn off all engines and generators evacuate the boat leaving ports and hatches open and seek professional help As soon as CO leaves the exhaust outlet the level 15 subject to dilution in the open air The closer a person is to the exhaust outlet the higher the concentration
15. engines coolant temperature The sensor is sending DC voltage to the ECU that interprets this as engine coolant temperature Should the temperature reach an over heat threshold the ECU will shut the engine down and will illuminate the engine temperature fault LED light on the con trol panel y COOLANT TEMPERATURE 224 SENSOR DC CIRCUIT BREAKER The engines electrical system is protected by a 15 amp manual reset circuit breaker An electrical overload in the wiring harness or the 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 uc FUSE PROTECTION Three fuses protect the engine s DC electrical system A 30 amp spade type fuse in a holder adjacent to the starter motor An 8 amp fuse and 30 amp buss type mounted on the control box ww WESTERBEKE Engines amp Generators 10 MAINTENANCE SCHEDULE WARNING Never attempt to perform any service while the engine is running Wear the proper safety equipment such as goggles and gloves and use the correct tools for each job When servicing replacing DC components turn off the DC circuit breaker on the control panel or turn off the battery switch SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE DAILY CHECK BEFORE START UP Coolant Level Check at recovery tank if vooanitevel Checkat recov
16. especially in marinas CO level at the exhaust will be influenced upwards by the ambient level Whenever taking the time to verify proper CO concentration from the exhaust with a CO analyzer always take the opportunity to use the analyzer to sniff around the engine looking for CO from exhaust leaks Pay close attention to the connection of the cylinder head to the exhaust manifold the exhaust manifold to the water injected exhaust elbow and all subsequent downstream exhaust components and hoses Remember exhaust gas that has not yet passed through the catalyst is raw untreated exhaust and is very high in CO content Analyzers usually require periodic calibration Follow the instructions that come with the analyzer very carefully regarding calibration The following are manufacturers that offer CO analyzers Extech TIE Testo TSI Bacharach Fluke Monoxor Fyrite Zellwgwer Analytics Industrial Scientific Corp GFG TPI Teledyne and others Westerbeke recommends analyzers with a probe connected to the analyzer by a length of transparent tubing They are slightly more expensive than those with the sensor built into one end of the analyzer but they allow you to sample the exhaust coming out of the boat s exhaust outlet xv WESTERBEKE Engines amp Generators vi EMISSIONS This genset meets the requirements of California s Exhaust You should carefully review operator Owner Installation Emissions Standards
17. in the generator 5 DENM AX CAUTION Damage to the generator can result if 2 utility shore power and generator output are connected veg at the same time This type of generator damage is not 2 covered under the warranty it is the installer s m T responsibility to make sure all AC connections are VU correct D Neutral 5 SHIPS LOAD 4 240V equipment E Ground j GRN S2 SIN j terminal block to the generator case Shore Power Notice the repositioning of the white wire ground load on the WESTERBEKE Engines amp Generators 29 90 sauiDu3 RED WET 14GA DC_P1 30 1HM Q03M 1 2 ECU J2 32 WHT RED 18GAD J m m ECU J2 i19 186 D RELAY CRANK 991 49 991 49 OPTIONAL BATTERY SWITCH BY CUSTOMER qDC PI 5 GRY 16GA DS ERTAN f YEL RED 1 46 ON H rn BATTERY LEAD WIRE FROM 5 qQECU Jj2 8 ORG 186A 30A FUSE HOLDER CUSTOMER RED 14GA DC PI 2P oF QAM BATT_GND qBATT CHARGER 14 SEMI SHIELD BLK 18GA qECU J2 2 BLK 166GA qLIFT PUMP 2 BLK 16GA q DC PI 1RED VIO 18GA SFUELL MODULE 2 BLK IGGA 4 TIME RELAY INITIATE VIO 16GA IAES DECAT PRD SENSOR JUNC 1 a RED VIO 16G6A RED WHT 16GA DIST 2 72 1 GRY 16
18. include a complete part description and part number for each part needed see the separately furnished Parts Catalog Also insist upon WESTERBEKE genuine parts because will fit or generic parts are frequently not made to the same specifications as original equipment SPARES AND ACCESSORIES Certain spares will be needed to support and maintain your WESTERBEKE generator Your local WESTERBEKE dealer will assist you in preparing an inventory of spare parts Suggested Spares are shown in the last page of this manual For additional parts and accessories contact your WESTERBEKE DEALER INSTALLATION MANUAL Publication 043268 provides detailed information for installing generators CARBON MONOXIDE DETECTOR WESTERBEKE recommends mounting a carbon monoxide detector in the vessels living quarters Carbon monoxide even in small amounts is deadly The presence of carbon monoxide could indicate an exhaust leak from the engine or generator or from the exhaust elbow exhaust hose or exhaust system If carbon monoxide is present ventilate the area with clean air and correct the problem immediately xx WESTERBEKE Engines amp Generators 4 FUEL ENGINE OIL AND ENGINE COOLANT GASOLINE A CAUTION Use unleaded 89 Octane gasoline or higher Ethanol gasoline must not exceed E10 10 Gasoline with higher percentages of Ethanol are not acceptable for use in these models and may void the Warranty Care Of The Fue
19. occurs first Verification involves actual sampling of exhaust gas with an appropriate CO analyzer There are two locations where exhaust gas can be sampled Dry but hot exhaust can be sampled at the plugged tapped hole in the exhaust elbow intended for back pressure measurements Measurements at this location may not be practical in all instances due to the high exhaust ternperature temperature limits of the analyzer safety concerns over temperatures involved or the possibility of high levels of CO The other location is the boat s exhaust outlet which contains entrained cooling water except dry stack exhaust systems Only analyzers with probes should be used at this location and it is critical that the probe not ingest water Probe type analyzers have an air pump drawing a gas sample through the probe As a result they tend to ingest water when it is present Be sure to aim the probe downwards with the opening pointed in the direction of the water flow and just out of the flow Position the analyzer as high as possible with the tubing leading to the probe running continuously down hill Observe the usually translucent tubing between the probe and the analyzer and be sure no water is being ingested If any water is ingested into the analyzer it must Be repaired or replaced and recalibrated When measuring CO at the exhaust outlet be aware of the ambient CO level by also measuring CO away from and upwind of the exhaust outlet
20. of CO In a closed space such as the engine compartment the boat or underneath a stern swim platform concentrations will potentially rise to the undiluted level emanating from the exhaust system due to a lack of fresh air to dilute the exhaust gas Therefore one should never rely on dilution of the exhaust to provide a margin of safety Westerbeke Low CO generators achieve reduction of CO by precise control control of the engine s air fuel ration coupled with after treatment in a special catalyst CO 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 CO levels for different models The fuel system which accomplishes the required precise air fuel ratio control is comprised of many different components purchased sub assemblies machined castings sensors electronics and others Because of the extreme level of CO reduction any variability in the functioning of any these components can and will cause variability of the CO output CO concentration also varies with load Usually but not always the worst case CO concentration occurs at maximum load INSPECTION The catalyst is critical to optimizing CO levels Any water intrusion into the exhaust system will likely quickly compromise the proper operation of the catalyst Westerbeke s exhaust system
21. oil and oil filters as outlined in the Maintenance Schedule B Proper maintenance of all engine and generator components according to the Maintenance Schedule in this manual BW Use clean filtered unleaded fuel maximum 10 ethenol Winterize your engine according to the LAY UP AND RECOMMISSIONING section in this manual UNDERSTANDING THE GASOLINE ENGINE The gasoline engine driving an AC generator is in many ways similar to a gasoline automobile engine The cylinders are vertical in line and the engine s cylinder head has an overhead camshaft which is belt driven The engine utilizes a solid state distributor which is horizontally mounted and camshaft driven The engine incorporates a pressure type lubrication system and a fresh water cooled engine block which is thermostatically controlled To a large degree the generator s engine requires the same preventative mainte nance that is required of a gasoline automobile engine The most important factors to the generator s longevity are proper ventilation maintenance of the fuel system ignition system cooling system and the generator back end ORDERING PARTS Whenever replacement service parts are needed always provide the generator model number engine serial number and generator serial number as they appear on the silver and black name plate located on the generator end You must provide us with this information so we may properly identify your generator set In addition
22. proper tightness gasoline 5 Start the engine in accordance with procedures described in the PREPARATIONS FOR STARTING section of this manual Cs id lt a piel swf ee 4 7 2 7 ODO ett to LHP ED 4 47 e pre li PER FASTEN SECURELY TO BULKHEAD SCREWS ARE OWNER SUPPLIED APPLY A THIN COAT OF CLEAN OIL TO THE FILTER GASKET WHEN INSTALLING AFTER THE i suis FILTER CONTACTS THE BASE tighten it firmly by hand A CAUTION It is vital to install the oil lines correctly If the oil flows in the reverse direction the by pass valve in the filter asembly will prevent the oil from reaching the engine causing an internal engine failure If there is no oil pressure reading shutdown immediately and check the hose connections WESTEHBEKE Engines amp Generators 94 Timing Belt Flywheel bolt Timing belt cover bolts Camshaft sprocket bolts Oil pump sprocket nuts Timing tensioner nuts Timing belt rear cover bolts Rocker Arms and Rocker Shaft Rocker cover shaft Camshaft thrust plate bolt Rocker arm adjust nut Cylinder Head Valve Cylinder head bolt cold engine Spark plug Rocket cover Miscellaneous Coolant temperature sender Coolant temperature switch Generator mounts Exhaust manifold Thermostat housing Front Crankshaft bolt Nm 135 145 10 1
23. the coolant continuously flows through the closed cooling circuit When the engine is first started the closed thermostat prevents coolant from flowing some coolant is by passed around the thermostat to prevent the exhaust manifold from overheating As the engine warms up the thermostat gradually opens The thermostat is accessible and can be checked cleaned or replaced easily Carry a spare thermostat and gasket If you suspect a faulty thermostat place it in a pan of water and bring to a boil working thermostate should open about 1 2 MAMIFOLD N TO COOLANT RECOVERY TANK PRESSURE 4 D dtm THERMOSTAT HOUSING COIL BRA GASKET ic APPLY SEALANT TO GASKETS WHEN INSTALLING THERMOSTAT zx WESTERBEKE Engines amp Generators 15 ARE ANY CRACKS COOLING SYSTEM RAW WATER INTAKE STRAINER If the engine temperature warning light LED illuminates the cause may be that silt leaves or grass may have been caught up in the strainer slowing the flow of raw water through the cooling system NOTE Always install the strainer at or below the waterline so the strainer will always be self priming clean raw water intake strainer is a vital component of the engine s cooling system Include a visual inspection of this TYPICAL RAW WATER INTAKE STRAINER strainer when making your periodic engine check The water OWNER INSTALLED in the glass should be clear Perform th
24. 2 80 100 50 57 22 30 10 12 29 85 10 12 8 10 60 70 15 2 12 13 12 18 12 18 34 47 16 23 8 11 11 15 Ib ft 135 145 Front Case Counterbalance Shaft Front case bolts Oil pump cover bolts Oil pan bolts Oil drain plug Oil screen bolts Oil pump driven gear bolt Rear cover bolts Piston and Connecting Rod Connecting rod cap nut Crankshaft Bearing Oil seal case bolts Bearing cap bolts Cylinder Block Taper plug 1 16 NPT Taper plug 1 8 NPT Water drain plug Taper plug 1 4 NPT Oil pressure switch Oil pressure sender Water Pump Water pump vv WESTERBEKE Engines amp Generators 39 TIGHTENING TORQUE SPECIFICATIONS Nm 8 10 8 10 10 12 35 45 15 22 34 40 10 12 15 4 90 turn 10 12 50 55 8 12 15 22 35 45 35 45 12 18 12 18 8 10 ft Ibs 67 6 7 7 9 25 33 11 16 25 29 7 9 11 4 90 tum 7 9 36 40 6 9 11 16 25 33 25 93 9 13 9 13 6 7 SUGGESTED SPARE PARTS WESTERBEKE MARINE GASOLINE GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION EZS PRESSURE CAP FUEL FILTERS f i FILTER FUEL WATER FILTERS 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 cruising p 9 km Kit A Impeller Kit Heat Exchanger Gasket Oil Filter oo EE M Dr
25. FER SWITCH SINGLE LINE 120 VOLT SYSTEM Generator N Gt an Neutral N Ship s Load Note NO 240 Volt equipment GRN 120 volt system Shore Power If the installer connects shore power to the vessel s AC circuit this must be done by means of the Shore Power Transfer Switch Set the transfer switch shown in the diagrams to the OFF position This switch prevents simultaneous connection of shore power to generator output Generator N Gi NOTE This diagram shows connections for a two wire 120V system from the generator with a three wire 120V boat system Neutral WHT NOTE Diagram shows connections for a two wire NOTE Ship to shore switches are available at your WESTERBEKE dealer Notice the repositioning of the white wire ground load on the terminal block to the generator case GENERATOR o N L1 a J GENERATOR SHORE lt SWITCH gt oars L N 4 L1 3 2 I SHIP S LOAD p N O NEUTRAL 6 SHIP S L SHORE GROUND 11 7 GROUND SHORE POWER Switching Shore Power to Generator Power CAUTION Heavy motor leads should be shut off before switching shore power to generator power or vice versa because voltage surges induced by switching 120 VOLT 60 HZ THREE with heavy AC loads on the vessel being operated may WIRE CONFIGURATION cause damage to the exciter circuit components
26. GA E d 11 23 DISTRIBUTOR a a 4 COILS DIST RED VIO 166GA SPARK PLUGS RED VIO 16GA 3 87 4 WBO2 3 RED VIO 166A a RED VIO 16GA DIST 1 j COIL RED VIO 16CA COIL RED WHT 16GA IGNITION SYSTEM COMPONENTS 9556567 SNIHIM 10 10 seujDui RED 18GA zi SECU_J2 29 WHT BLK GRY 20GA LED OUT OVERSPEED mim 9 q4ECU J2 28 WHT BLK YEL 20GA STOP SWITCH OUTPUT E 3ECU JI 17 WHT BLK GRN 18GA START SWITCH OUTPUT BESE D C BOX CONNECTOR DC WHT BLK BLU 20GA LED OUT LOW OIL PRESS us 3ECU J2 31 WHT BLK BLU 20GA r LED OUT COOLANT TEMP H me 3ECU J2 30 WHT BLK ORG 20GA LED OUT EXH TEMP FAIL E Q WHT BLK ORG 20GA T lt WHT BLK GRY 20GA 3 1 2 1 1 186 LED OUT RUN INDICATOR Trt D TITT q4ECU J2 21 WHT BLK RED 18GA ECU REM SWITCH amp RELAY COIL POWER ES WHT BLK YEL 20GA a iets 4K1 86 GRY 16GA RELAY LOAD POWER SUPPLY 3 9 1 30 RED WHT 14GA BATTERY INPUT RUN RELAY INPUT qBATT CSTR 1 46 4 2 81 RED VIO 18GA TO OPTIONAL REMOTE SWITCH PANEL 9 a OIL PRESSURE LED m COOLANT TEMP LED T EXHAUST TEMP LED lt 5 OVER UNDER SPEED LED a STOP INPUT FROM SWITCH 3 START INPUT FROM SWITCH UOIVOIQNI NANY HOLIMS dOLS LYVLS zo D m m e 2 2 z 5 5 2 RUN INDICATOR LED 5 o 1 lt 1 2v SUPPLY ie 2 c
27. NESS CONNECTIONS REMOTE PANEL CONNECTIONS BRIDGE RECTIFIER HEAT SINK FOR WIRING CONNECTIONS TO THESE COMPONENTS CAPACITOR REFER TO THE WIRING DIAGRAMS IN THIS MANUAL pw WESTERBEKE Engines amp Generators 22 Software Diagnostic Monitoring and Troubleshooting Data GENERATOR INFORMATION USE OF ELECTRIC MOTORS The power required to start an electric motor is considerably more than is required to keep it running after it is started Some motors require much more current to start them than others Split phase AC motors require more current to start under similar circumstances than other types They are commonly used on easy starting loads such as washing machines or where loads are applied after the motor is started such as small power tools Because they require 5 to 7 times as much current to start as to run their use hould be avoided whenever possible if the electric motor is to be driven by a small generator Capacitor and repulsion induction motors require from 2 to 4 times as much current to start as to run The current required to start any motor varies with the load connected to it An electric motor connected to an air compressor for example will require more current than a motor to which no load is connected In general the current required to start 115 Volt motors connected to medium starting loads will be approximately as follows MOTOR SIZE HP AMPS FOR RUNNING AMPERES
28. Not only is the surface of the engine hot but coolant temperatures can at 190 F AIR BLEED 5 COOLANT DRAIN LOCATED JUST BELOW THE INTAKE MANIFOLD MAKE CERTAIN THESE PASSAGES ARE KEPT CLEAR xa WWESTERBEKE Engines amp Generators Refilling the Coolant 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 air bleed petcock and when coolant 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 LOW and MAX and replace 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 if needed and make certain the coolant is topped off at the pressure cap Clean up any spilled coolant TO COOLANT RECOVERY TANK i r 7 222200 FROM COOLANT COOLANT EXPANSION RECOVERY TANK P
29. PECT THE SEALING EDGES IF WORN INSTALL A NEW AIR SCREEN removing them SPARK PLUG GAP 0 028 0 031 in 0 7 0 08 mm SPARK PLUG TORQUE 11 15 Ib ft 1 5 2 31 kg m NOTE Loctite Anti Seize applied to the threaded portion of M the spark plugs will retard corrosion making future removal S of the spark plugs easier INSPECT FOR INSPECT FOR DAMAGE WEAR amp CARBON A WARNING The generator should never be started operated without the air screen flame arrester properly installed INSPECTING THE SPARK PLUGS CHECK FOR DETERIORATION AND DAMAGE NOTE Jt is important to maintain spark plugs in a proper operating condition They are an important component in the ignition system in lowering carbon monoxide levels OIL PRESSURE OIL PRESSURE The engine oil pressure is continually monitored by the ECU in the generator control panel when the engine is running 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 occur do not attempt to re start the generator Check the oil level and the condition of the oil If there is a loss of oil inspect the engine SEDE TE for leaks Inspect the wire connections at the oil gallery J pressure sender OIL PRESSURE SWITCH WARNING f the oil pressure light illuminates but the engine does not shut down thi
30. RESSURE CAP d wo 222 2 COOLANT RETRACTION NOTE Periodically check the condition of the pressure cap Ensure that the upper and lower rubber seals are in good condition and check that the vacuum valve opens and closes tightly Carry a spare cap RUBBER COOLING SYSTEM HEAT EXCHANGER Cool raw water flows through the inner tubes of the heat exchanger As the engine coolant passes around these tubes the heat of the internal engine is conducted to the raw water which is then pumped into the exhaust system and discharged The engine coolant now cooled flows back through the engine and the cycle repeats itself The engine coolant and raw water are independent of each other this keeps the engine s water passages clean from the harmful deposits found in raw water FROM THERMOSTAT y ss TO SIPHON BREAK psu AND EXHAUST TO EXHAUST SERE Er MANIFOLD V ue 22 ZINC ANODE COOLANT DRAIN LE S E EST hd INSPECT BOTH ENDS 4 lt eS S Oo cae tts Vi O RIN COMI END COVER END GASKET Heat Exchanger Service 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 in silty and or tropical waters may require that a heat exchanger cleaning be performed more often ZINC ANODE A zinc anode or pen
31. SYSTEM Fresh water cooled block through raw water cooled heat exchanger circuit Centrifugal type metal impeller belt driven Positive displacement rubber impeller belt driven 4 9 US gpm 18 5 liters 1800 rpm approx measure before discharging into exhaust elbow 3 5 qts 3 3 liters 150 170 F 65 77 C LUBRICATION SYSTEM General Oil Filter Oil Capacity Operating Oil Pressure Oil Grade Forced lubrication by gear pump Full flow paper element spin on disposals 3 0 qts 2 8 liters 30 45 psi 2 1 3 1 kg cm API Service Category SJ SL SM or SN SAE 40W ONLY No Mutli Weight oils AC GENERATOR Single Phase Single Phase Ratings 4 2KW 5 0KW 9 2KW 6 5KW General Distributor Spark Plug Thread Gap Spark Plug Gap Ignition Timing Spark Plugs Ignition Coil Distributor xv WESTERBEKE Engines amp Generators Brushless four pole capacitor regulated 1800 rpm 60Hz 1500 rpm 50Hz 230 volts 18 2 amps 50Hz single phase 4 wire 1 0 power factor 120 volts 41 6 amps 60Hz single phase 4 wire 1 0 power factor 230 volts 22 6 amps 50Hz single phase 4 wire 1 0 power factor 120 volts 54 amps 60Hz single phase 4 wire 1 0 power factor IGNITION SYSTEM Battery Ignition 12 volts negative ground Distributor with ignition module and ignitor Ignition coil and spark plugs Solid state type with signal generator and ignitor 11mm x 1 25 p
32. Standards and Technical Information Reports for Small Craft Order from ABYC 613 Third Street Suite 10 Annapolis MD 21403 www abycinc org NFPA National Fire Protection Association Fire Protection Standard for Motor Craft Order from NFPA 11 Tracy Drive Avon Industrial Park Avon MA 02322 USCG United States Coast Guard USCG 33CFR183 Order from U S Government Printing Office Washington D C 20404 Cv WESTERBEKE Engines amp Generators INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information CODES AND REGULATIONS Strict federal regulations ABYC guidelines and safety codes must be complied with when installing engines and generators in a marine environment 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 be looped a minimum of 20 above the vessel s waterline Failure to use a siphon break when the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine and possible flooding of the boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under the vessel s various operating conditions install a si
33. T STOP ROCKER SWITCH DC CIRCUIT BREAKER GREEN LED THIS LED ILLUMINATES FAINTLY WHEN THE ENGINE IS NOT RUNNING DC CIRCUIT BREAKER ON T PANEL OPERATING INSTRUCTIONS HOUR METER CONTROL PANEL FUSE O LED FAULT INDICATOR LIGHTS DC CIRCUIT BREAKER TURN OFF WHEN PERFORMING MAINTENANCE TO PREVENT ACCIDENTAL STARTING SEEN rg START SWITCH ENGINE STOP START SWITCH WITH GREEN LED o ERE K RELAYS GENERATOR CONTROL PANEL The start stop rocker switch is the only functional component on the generator control panel used to start and stop the generator The start stop rocker switch is a three position switch with momentary contacts in the START and STOP position and a stationary contact in the center NORMAL This position allows the generator to run once started and also enables the remote start stop panel s to control the start stop functions of the generator The START position starts the generator and once released reverts to the center position The STOP position stops the engine in normal operation as well as in an emergency situation This position is also used to prime the fuel system when necessary Failure to Start The start cycle will automatically terminate after 6 8 seconds of cranking Three crank cycles can be attempted before the ECU initiates a SPEED fault and prevents further crank cycle attempts Investigate the cause of this no start c
34. ains 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 of oil and apply a thin coat of clean engine oil to the rubber sealing gasket on the oil filter Screw the filter onto the threaded oil filter stub and tighten the filter firmly by hand NOTE Use genuine WESTERBEKE oil filters Generic filters are not recommended REFILLING THE OIL SUMP 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 of oil with the lube oil dipstick Fill to but not over the FULL mark on the dipstick ROCKER COVER PE Ref 2 8 JO CAM SENSOR vw WESTERBEKE Engines amp Generators 17 ENGINE ADJUSTMENTS SPARK PLUGS AIR SCREEN FLAME ARRESTER The spark plugs should be cleaned and re gapped after the air screen flame arrester should be cleaned after the first first 50 hour break in period then follow the maintenance 50 hours of operation Then refer to the Maintenance schedule in this manual Schedule in this manual Clean using a good dish washing solution rinse and air dry S NC AX WARNING Do not remove the spark plugs while ON the engine is hot Allow the engine to cool before z a S Lu INS
35. al shock results from handling a charged capacitor Discharge capacitor by shorting terminals together PREVENT BURNS HOT ENGINE WARNING Do not touch hot engine parts or exhaust system components A running engine gets very hot W Always check the engine coolant level at the coolant recovery tank WARNING Steam can cause injury or death Incase of an engine overheat allow the engine to cool before touching the engine or checking the coolant PREVENT BURNS FIRE A WARNING Fire can cause injury or death W Prevent flash fires Do not smoke or permit flames or sparks to occur near the fuel injector fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel lines injectors or fuel filters W Do not operate with the Coast Guard Approved flame arrester removed Backfire can cause severe injury Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the engine generator clean and free of debris to minimize the chances of fire Wipe up all spilled fuel and engine oil Beaware gasoline is highly flammable PREVENT BURNS EXPLOSION WARNING Explosions from fuel vapors can cause injury or death W Follow re fueling safety instructions Keep the vessel s hatches closed when fueling Open and ventilate cabin after fueling Check below
36. arger misadjusted 2 Faulty starter solenoid Starter stays energized after start 1 Faulty K1 relay 2 Faulty starter solenoid Poor performance at generator speed 1 Low octane fuel 2 Incorrect ignition timing 3 Fuel supply issue 4 High engine compartment temperature Black exhaust smoke 1 Dirty air screen 2 Faulty injector Blue exhaust smoke 1 Lube oil is diluted 2 Crankcase breather tube is clogged 3 High lube oil level Check engine LED s are illuminated 1 Diagnostic software required Speed LED s are illuminated no flashing 1 Throttle shaft sticking 2 Intake manifold vacuum leak Pair of Speed LED s are illuminated flashing 1 AC generator overload 2 Fuel starvation Exterior alarm LED is illuminated 1 Loose connection 2 Faulty fire suppression shutdown devise The 6 5 5 0 Service Manual 055748 is available as a Pdf download at www westerbeke com This Service Manual can also be purchased from your WESTERBEKE DEALER as a book WESTERBEKE Engines amp Generators 21 SOFTWARE DIAGNOSTICS PC INTERFACE SOFTWARE The Diagnostic Software will run on Windows 98 XP Diagnostic Software Kit 055410 is available for purchase through your Westerbeke Dealer or Distributor It contains a PC Interface Software CD for your laptop and a Programmed USB Interconnect Cable to connect between your laptop and the unit s Electronic Control Board ECU me
37. as stated on the nameplate and other manuals and information you receive with your California users of this genset should be aware that genset If you are unsure that the installation use unauthorized modifications or replacement of fuel exhaust maintenance or service of your genset is authorized you air intake or speed control system components that affect should seek assistance from an approved WESTERBEKE engine emissions are prohibited Unauthorized modification dealer removal or replacement of the engine label is prohibited California genset users may use the table below as an aid in Federal Emissions Compliance Period The Federal locating information related to the California Air Resources Emissions Compliance Period referred to on the nameplate Board requirements for emissions control indicates the number of operating hours for which the engine has been shown to meet Federal Emissions requirements Catagory C 250 hrs B 500 hrs A 21000 hrs EMISSIONS CONTROL INFORMATION TABLE The California emissions control warranty statement is located in the same packet if information as this manual when the genset is shipped from the factory Emissions Warranty Information Engine Fuel Requirements The engine is certified to operate on unleaded gasoline See FUEL RECOMMENDATIONS Engine Valve Adjustment See MAINTENANCE SCHEDULE Engine Ignition Timing See MAINTENANCE SCHEDULE Engine Lubricating Oil Requirements Se
38. ault LED will remain illuminated To reset the LED the panel DC breaker must be cycled OFF then ON NOTE For connecting these remote panels refer to the Wiring Diagram section in this manual 4 101 6 mm SSS nl 414 _ START Ra ca a DP ER PE TS LEAT d 4 101 6mm MEN 3 19 81 03mm PART NO 055345 vw WESTERBEKE Engines amp Generators 8 BREAK IN PROCEDURE THE DAILY OPERATION BREAK IN PROCEDURE 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 Run the generator between 20 and 60 of full load for the first 10 hours CAUTION Do not attempt to break in your generator by running without a load After the first 10 hours of the generators operation the load can be increased to the full load rated output then periodically vary the load Avoid overload at all times An overload is signaled by reduced output voltage and or frequency MCG models will illuminate a warning LED when the generator 15 overloaded Monitor the current being drawn from the generator and keep it within the generators rating NOTE Be aware of motor starting loads and the high current drawn required for starting motors The starting amperage drawn can be 3 to 5 times normal running amperage See GENERATOR INFORMATION in this manual A CAUTION Do not operate the generator for lon
39. cil is located in the raw water cooling circuit within the heat exchanger The purpose of the zinc anode is to sacrifice itself to electrolysis action taking place in the raw water cooling circuit thereby reducing the effects of electrolysis on other components of the system The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required Spare anodes should be carried on board ZINC ANODES REPLACE CLEAN amp REUSE If the zinc pencil needs replacement hold the hex boss into which the zinc pencil is threaded with a wrench while loosening the anode with another wrench This prevents the hex boss from possibly tearing off the exchanger shell After removing the zinc note the condition of it If the zinc is in poor condition there are probably zinc flakes within the exchanger Remove the end of the heat exchanger and clean the inside of all zinc debris Always have a spare heat 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 The threads of the zinc anodes are pipe threads and do not require sealant Sealant should not be used as it may insulate the zinc from the metal of the heat exchanger housing preventing electrolysis action on the zinc THERMOSTAT The thermostate controls the coolant temperature as
40. e 2 J 2 PANEL BOX BLK 18GA GROUND STUD RED WHT 16GA PB STUD EXT O STR 18 m SE E c HOUR METER REMOVE JUMPER FOR FIRE SUPPRESSION SYSTEM CONNECTION SEE NOTE 1 b c UR MEO NEAR DC CONTROL PANEL BOX COMPONENTS 4O0P SENDER SENS GND WHT BLK 18GA NOTES 1 FIRE SUPP CIRCUIT MUST GENSET RESSION SYSTEM CONNECTION 15 NOT POWER SOURCE THIS BE CLOSED TO RUN AN OPEN CIRCUIT WILL STOP THE 95550 NVUDVIG 9NISIM 86 siojesauar seuibu3 WHT BLK GRN 16GA ECU J2 II b WHT BLK BRN 16GA ECU_J2 230 JUNC 1 K2 87 RED VIO 16GA D WHT BLK BLU 16GA ECU J2 22 OIL GN age PRESSURE SWITCH OP SWITCH 2 VIO WHT 16GA 1 LIRED BATT_GND 2 2 BLK VIO WHT 16GA BLK 16GA K2 87 VIO 16GA VIO 16GA 2 BATT GND BLK 18GA BATT GND 2 BLK 16GA TIME RELAY FUEL SYSTEM COMPONENTS FUSE HL BLK 4GA BATT GND RECTIFIER WHT RED 12GA j BLK WHT 12GA RED 12GA BATTERY CHARGER BATTERY CHARGING CIRCUIT FUEL INJECTOR 3 FUEL INJECTOR 2 FUEL INJECTOR INJ 3 2 INJ 1 AC GENERATOR LEAD WIRE FROM FUSE HOLDER BATT STR There is a small DC amperage drain from the starting battery when the generator is not in use To prevent this draw turn off the DC breaker on the generators control panel or turn off the DC battery switch t
41. e ENGINE OIL RECOMMENDATIONS Engine Adjustments Engine Emission Control System The engine emission control system consists of engine design and precision manufacture Catalyst See MAINTENANCE SCHEDULE Oxygen Sensor See MAINTENANCE SCHEDULE Back Pressure See MAINTENANCE SCHEDULE ww WESTERBEKE Engines amp Generators vil TABLE OF CONTENTS Parts Identification 2 2 3 Fuel Engine Oil and Engine Coolant 5 Preparations for Initial Start Up 6 Control Panel Starting Stopping Procedure 7 Remote Stop Start Procedure 8 Break In Procedure Daily Operation 9 Safety Shutdown Sensors Switches 10 Maintenance Schedule 11 Fuel System nu EN CE 13 Gasoline Water Separator Filter 13 Fuel devas 13 Fuel a Ed N CAELO pels Cooling E 14 Chaneing Coolant a mettre iie 14 The EHOSLab euo be socero mM E 15 Heat Exchan Ger
42. e a year Valve Adjustment Check adjustment of valves Check again at 500 hours Inlet Fuel Filter Initial change then every 250 hours or once a year Fuel Filter and 0 Rings Initial change then every 250 hours or once a year EVERY 50 OPERATING HOURS OR MONTHLY Drive Belts Inspect for proper tension 3 8 to 1 2 deflection and adjust if needed Check belt Fresh Water Raw Water Pumps for slipping cracking and wear Adjust tension or replace as needed Replace cover Starting Batteries Check electrolyte levels Make sure cables and connections are in good order Clean off corrosion if needed Apply petroleum jelly to terminals for corrosion protection Electric Fuel Pump Inspect for leaks ensure fuel and electrical connections are clean and tight Zinc Anode Inspect and clean zinc anode Replace if necessary Note the condition then determine your own inspection schedule EVERY 100 OPERATING HOURS OR YEARLY Engine Oil and Filter Change engine oil and filter Air Screen Flame Arrestor Remove clean and re install screen pack Inspect rubber sealing ring and replace if necessary WESTERBEKE recommends this service be performed by a knowledgeable mechanic xv WESTERBEKE Engines amp Generators 11 MAINTENANCE SCHEDULE NOTE Use the engine hourmeter to log your engine hours or record your engine hours running time SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE EVERY 250 OPERATING HOURS OR YEARLY
43. e following maintenance after every 100 hours of INCOMING operation RAW WATER Close the raw water seacock Remove and clean the strainer filter Clean the glass INSPECT AND CLEAN EVERY 100 HOURS Replace the washer if necessary Reassemble and install the strainer Open the seacock 4 Run the engine and check for leaks NOTE The external thru hull opening should be of the flush type with a clear opening No perforated or slot type external opening Let all the filtering be accomplished on the inside of NSS D dm ce NOTE Also follow the above procedure after having run hard the hull where there is easy access to the strainer RAW WATER PUMP Changing the Raw Water Pump Impeller The raw water pump is a self priming rotary pump with a Close the raw water intake valve Remove the pump cover non ferrous housing and a Neoprene impeller The impeller and using an impeller puller screw drivers or pliers has flexible blades which wipe against a curved cam plate carefully pry the impeller out of the pump Install the new within the impeller housing producing the pumping action impeller and gasket Move the blades to conform to the Never allow the pump to run dry There should always be curved cam plate and push the impeller into the pumps hous a spare impeller and impeller cover gasket aboard an ing When assembling apply a thin coating of lubricant to impeller kit Raw water pump impeller fail
44. e will crank 8 seconds 2 Air in fuel system 3 crank cycles before underspeed fault occurs 3 Fouled spark plugs 4 Faulty ignition coil 5 Stuck throttle body 1 Fuel starvation 2 Air in fuel system 3 Faulty shutdown switch sensor 4 Faulty fuel pump Engine starts runs and the shuts down Engine hunts 1 Air in fuel system 2 Faulty fuel pump 3 Low octane fuel lower than 89 4 Faulty speed sensor crankshaft Engine misfires back firing 1 Low octane fuel lower than 89 2 Dirty air intake screen 3 High tension ignition wires 4 Exhaust restriction 5 Worn fouled spark plug 6 Faulty ignition coil 7 Low or no fuel pressure Poor quality fuel Engine overheats engine temp LED is illuminated 1 Raw water coolant flow obstruction 2 Coolant level low 3 Faulty impeller 4 Pump belt loose broken 5 Stuck thermostat 6 Air in cooling system fresh water Exhaust temp LED is illuminated 1 Loss of coolant flow faulty pump 2 Faulty exhaust temperature switch Low oil pressure oil pressure LED is illuminated 1 01 level low 2 Faulty oil pressure sendor 3 011 viscosity incorrect wi WESTERBEKE Engines amp Generators 20 ENGINE TROUBLESHOOTING possible No DC charge to starting battery 1 Circuit fuse faulty blown two fuses 2 Faulty circuit connection 3 Faulty regulator battery charger 4 Bridge rectifier High DC Charge to battery 1 Battery ch
45. ecommended that all AC loads especially large motors be switched OFF until the engine has come up to speed and in cold climates starts to warm up This precaution will prevent damage caused by unanticipated operation of the AC machinery and will prevent a cold engine from stalling After shutdown and after the engine has cooled the coolant from the recovery tank will be drawn into the engine s cooling system to replace the purged air Before subsequent operation of the generator the engine s manifold should be topped off and the coolant recovery tank may need to have coolant added Do not overfill as coolant loss will occur AIR BLEED PETCOCK MAX FULL COOLANT RECOVERY TANK MANIFOLD PRESSURE CAP CS COOLANT FILL THERMOSTAT HOUSING MAX FULL MINIMUM OIL PAN OIL DRAIN HOSE 5 vv WESTERBEKE FRESH WATER Engines amp Generators DRAIN 6 CONTROL PANEL START STOP PROCEDURE TO START DC CIRCUIT BREAKER ON Simply press the rocker switch to the start position and release the switch will revert to its center position the engine will START electronically A GREEN LED on the switch will indicate the engine is running NOTE There is a few second delay while the ECU self tests before the start switch responds TO STOP Press the rocker switch to the STOP position and release The GREEN LED will go out indicating the engine has shut down STAR
46. ery tank if empty check at manifold Add coolant if needed check at manifold Add coolant if needed Engine Engine Oil Lev 8 Qileve should indicate between MAX and LOW dipstick Do not overfill Level Oil level should indicate between MAX and LOW on dipstick Do not overfill Fuel Water Separator owner installed Check for water and dirt in fuel Drain filter if necessary Replace filter every 250 operating hours or once a year Fuel Supply Fresh unleaded gasoline with an octane rating of 89 or higher Lower octane will affect engine performance 10 ethanol maximum Visual Inspection of Engine Check for fuel oil and water and exhaust leaks Check that the water injected exhaust elbow securing v clamp is tight Insure there are no exhaust leaks around the elbow Inspect wiring and electrical connections Look for loose bolts hardware and possible corrosion INITIAL 50 HOURS OF OPERATION Spark Plugs Clean re gap Engine Oil and Filter Initial engine oil and filter change at 50 hours then change both every 100 hours Exhaust System Initial check at 50 hours then every 250 hours or once a year Carefully inspect for leaks Check that the exhaust hoses are properly attached and that the securing clamps are tight Check the integrity mounting security of the water injected exhaust elbow Air Screen Flame Arrestor Remove clean and re install screen pack Inspect rubber sealing ring and replace if necessary then onc
47. fer to the BLEEDING THE FUEL in YOUR SERVICE MANUAL CANWEST ERBEKE Engines amp Generators 1 REMOTE STOP START PANELS DESCRIPTION Two remote start stop panels are available that allow for the engine generator to be contolled from any location on the boat The remote panels connect to the main panel using a 15 or 30 wiring haness or a combined length of 45 Once installed the engine generator can be started and stopped from either the remote or the main panel REMOTE START STOP PANEL with LED Fault Display The components on the panel are 1 Athree position start stop rocker switch 2 A green LED run indicator light on the rocker switch 3 Afour 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 on the rocker switch will illuminate when the start circuit is energized It will go dim as the engine cranks and will brighten as the engine starts indicating the generator is running The LED fault shutdown display has six separate LED combinations that indicate to the operator the cause of the engine s automatic shutdown The LED displays are Check Engine Oil Pressure Engine Temperature External Alarm Exhaust Temperature and Speed Overspeed LEDs and Underspeed LEDs flashing Should the generator shutdown from one of these faults the f
48. for fumes vapor before running the blower Run the blower per boat builders recommendations W All fuel vapors are highly explosive Use extreme care when handling and storing fuels Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children m Do not fill the fuel tank s while the generator is running m Shut off the fuel service valve at the engine when servicing the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other sources of fire near the fuel system or engine when servicing Ensure proper ventilation exists when servicing the fuel system W Do not alter or modify the fuel system Be sure all fuel supplies have a positive shutoff valve m Be certain fuel line fittings are adequately tightened and free of leaks m Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use Extinguishers rated ABC by the are appropriate for all applications encountered in this environment vv WESTEHBEKE Engines amp Generators SAFETY INSTRUCTIONS ACCIDENTAL STARTING WARNING Accidental starting can cause injury or death W Turn OFF the DC breaker on the control panel or turn the unit s battery selector switch to OFF before servicing the engine m Disconnect the battery cables before servicing the engine generator Remove the negative lead first and reco
49. g periods of time without a load being placed on the generator CHECK LIST Follow this check list each day before starting your generator Record the hourmeter reading in your log engine hours relate to the maintenance schedule Visually inspect the generator for fuel oil or water leaks Bl 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 blow back sounds lll Inspect the exhaust system NOTE Some unstable running may occur in a cold engine This condition should lessen as normal operating temperature is reached and loads are applied vv WESTERBEKE Engines amp Generators 9 SAFETY SHUTDOWN SWITCHES SENSORS AND SENDERS 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 down the generator s engine When an automatic shutdown occurs one of the control panel fault LED lights will illuminate indicating what fault caused the engine to shutdown This LED will stay illuminated To correct the fault refer to ENGINE TROUBLESHOOTING in this manual Do not attempt to re start the generator before correcting the fault SPEED SENSOR CRANKSHAFT A speed sensor is mounted on a bracket at the front of the engine and positioned to monitor
50. g of the generator An AC wiring decal is affixed to the inside of the louvered cover at the generator end A diagram of the various AC voltage connections is provided on the decal An Integral Controller IC is mounted inside the generator and supplies a continuous DC charge to the generators starting battery when the generator is running Circuit Breaker AC circuit breaker is installed on all single phase WESTERBEKE generators This circuit breaker will auto matically disconnect generator power in case of an electrical overload The circuit breaker can be manually shut off when servicing the generator to ensure that no power is coming into the boat AC TERMINAL CONNECTIONS CIRCUIT BREAKER ISOLATED NEUTRAL 120V 60Hz CIRCUIT BREAKER ISOLATED POST 230V 50Hz NOTE Correctly position the case ground wire white green onto the neutral ground terminal INTEGRAL dE CONTROLLER i ES E ja 7 30 AMP FUSE CHARGER Located in the wiring harness refer to th ROTOR WINDING 50hz BATTERY CHARGING CIRCUIT wing ciagramin 1 this manual STATOR WINDING e 5 GENERATOR WINDINGS 4 SCHEMATIC STATOR WINDING EN i 9 5 n EXCITER WINDING 987 Pr CAPACITOR 6 bbb bd Ud CAPACITOR WESTERBEKE Engines amp Generators 24 SHORE POWER TRANS
51. gabytes of RAM Random Access Memory The serial to USB adapters the communication port that the Diagnostic Software CABLE AND DIAGNOSTIC SOFTWARE KIT The Westerbeke communication cable is unique to this PART 4055410 USB to ECU SEE BELOW Diagnostic Software and MUST be used or otherwise damage to the ECU will occur if any communications cable Your ateas distributor can be found on our website is substituted The Diagnostic Software is designed with www westerbeke com multiple screens tabs and pull down menues to aid the user pies uns in the diagnostic process This Diagnostic Software is designed to aide the technician Vista and Windows 7 These MUST have a minimum of 128 communications cable plugs into a USB port When using adapter 15 using MUST be known in order to configure the in monitoring the engine s operation and the ECU Electronic The Diagnostic Software is for monitoring the operation of Control Unit functions the engine generator and is also used to change the ECU Hz Once downloaded this software provides IDLE Mode target frequency between 50Hz and 60Hz diagnostics FAILURE Record and Run Time Data Logging Refer to WESTERBEKE S MCG Service Manual for the to EXCEL CONTROL BOX INTERNAL COMPONENTS TYPICAL ASSEMBLY THE COMMUNICATIONS CABLE IS AVAILABLE FOR DIAGNOSTIC MONITORING OF THE ENGINES OPERATION USING PC SOFTWARE J COMMUNICATIONS J CABLE WIRING HAR
52. h appropriate antifreeze mix Replace the thermostat and coolant pressure cap Valve Clearances Adjust valves Incorrect valve clearance will result in poor engine performance Starter Motor Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pinion drive EVERY 1000 OPERATING HOURS OR OR EVERY FIVE YEARS Engine Timing Belt Remove and replace the timing belt NOTE Failure to replace the timing belt at the recommended interval could result in timing belt failure resulting in major damage to the engine Heat Exchanger Remove the heat exchanger for professional cleaning and pressure testing Diverter Valve Remove and replace EVERY 2000 OPERATING HOURS Sensor Remove and replace exhaust oxygen sensor Catalyst Remove and replace exhaust catalyst WARNING attempt to perform any service while the engine is running Wear the proper safety equipment such as goggles and gloves and use the correct tools for each job When servicing replacing DC components turn off the DC circuit breaker on the control panel WESTERBEKE recommends this service be performed by a knowledgeable mechanic The 6 5 5 0 MCG Service Manual 055748 is available as a Pdf download at www westerbeke com This Service Manual can also be purchased from your WESTERBEKE DEALER as a book y WESTERBEKE Engines amp Generators 12 FUEL SYSTEM COMPONENTS Incoming fuel from
53. head camshaft w counterbalance shaft water cooled gasoline engine 2 96 x 2 61 inches 65 0 x 66 3 mm 40 3 cubic inches 0 66 liters Four main bearings Semi spherical 984 10 0 1 3 2 Naturally aspirated Counterclockwise viewed from the back end 25 continuous all directions 334 Ibs 151 5 Kgs Electronic FUEL SYSTEM Multi port fuel injection Unleaded gasoline with an octane rating of 89 or higher 5 0 MCG 74 gph 4 2 MCD 63 gph 6 5 MCG 76 gph 9 2 MCG 71 gph 1 4 1 0 minimum 3 8 maximum 12 volt electric high tow pressure Replaceable cartridge canister type Metal screen type cleanable ELECTRICAL SYSTEM Start Battery Starting Capacity Starter DC Charging DC Cold Cranking Amps 12 Volt negative ground Battery must be totally dedicated to the generator and maintained only by the DC charge controller system in the AC generator 800 1000 Cold Cranking Amps CCA minimum 12 Volt reduction solenoid mounted Solid state controller 12 amp rated 150 176 amps AIR REQUIREMENTS Generator Cooling Engine Combustion all models Engine Cooling 225 250 CFM 6 3 7 0 cmm 22 9 CFM 0 6 cmm 100 CFM 2 8 cmm OTE Forced ventilation should be provided to maintain the generators ompartment temperature below 122 F 50 C General Fresh Water Pump Raw Water Pump Raw Water Flow Cooling Water Capacity Operating Temperature COOLING
54. installation instructions must be adhered to NOTE Water intrusion is not a product defect and is not cov ered under warranty neither Westerbeke s normal product warranty nor the emissions specific warranty mandated by various regulating authorities such as EPA and CARB Maintenance of any components affecting the flow of air or the flow of fuel to the engine is critically important such as fuel filters and air filters if any Inspection of the catalyst at the prescribed intervals is critically important The exhaust elbow is removed by loosening the metal clamp to provide a view of the output surface of the catalyst Any visual irregularity of the normal flush honeycomb appearance is most likely a result of water intrusion The cause of the irregularity must be identified and addressed If there is irregularity the catalyst and gasket must be replaced Upon careful reassembly of the catalyst exhaust elbow gasket and exhaust elbow check for the presence of CO while the engine is running This must be performed with a CO analyzer xv WESTERBEKE Engines amp Generators V CARBON MONOXIDE LOW CO GENERATORS IMPORTANT INFORMATION Catalyst performance will degrade over time As the generator accumulates operating hours CO concentrations will increase The catalyst must be replaced every 2 000 hours of engine operation Verification of satisfactory CO levels must be done seasonally or each 1 000 hours which ever
55. itch 0 028 0 031 inches 0 7 0 8mm_ 15 BTDC at 1800 RPM 1 Vacuum advance hose connected 14mm 12 volt Breakerless with ignitor and pick up assembly LAY UP amp RECOMMISSIONING GENERAL Many owners rely on their boatyards to prepare their craft including engines and generators for lay up during the off season or for long periods of inactivity Others prefer to accomplish lay up preparation themselves The procedures which follow will allow you to perform your own lay up and recommissioning or you may use them as a check list if others do the procedures These procedures should afford your engine protection during a lay up and also help familiarize you with the maintenance needs of your engine If you have any questions regarding lay up procedures call your local servicing dealer he will be more than willing to provide assistance Lubrication System With the engine warm drain all the engine oil from the oil sump Remove and replace the oil filter and fill the sump with new oil Use the correct grade of oil Refer to the ENGINE LUBRICATING OIL pages in this manual for the oil changing procedure Run the engine and check for proper oil pressure and make sure there are no leaks A CAUTION Do not leave the engine s old engine oil in the sump over the lay up period Lubricating oil and combustion deposits combine to produce harmful chemicals which can reduce the life of your engine s internal parts
56. ive Belt amp ic 4 p us A d d 2 Se 22 4 Zinc Anodes Spark Plugs Fuel Filters T WESTERBEKE Engines amp Generators 36 RAW WATER PUMP GASKET AND IMPELLERS ZINC ANODES OIL FILTERS WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL YOUR BRAND FOR AN OIL CHANGE AND ALSO A GALLON OF PREMIXED COOLANT FOR THE COOLING SYSTEM 2 HEAT EXCHANGER END GASKET AND O RING 2 an Kit B Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc Anodes Complete Gasket Kit Heat Exchanger Gasket Fuel Filter with Gasket Filter Drive Belt Spark Plugs Fuel Filters WESTERBEKE avatar 5 CORPORATION MYLES STANDISH INDUSTRIAL PARK YA 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 TEL 508 823 7677 FAX 508 884 9688 WEBSITE WWW WESTERBEKE COM 1182 7 2013
57. l Supply N Use only clean properly filtered fuel The fit and tolerance of 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 It is important to buy clean fuel and keep it clean The best fuel can be rendered unsatisfactory by careless handling or improper storage 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 of fuel Install and regularly service a good Coast Guard approved metal bowl type filter water separator between the fuel tank and the engine ENGINE OIL Use a good brand of engine oil with an API and SAE designations as listed in the SPECIFICATION Section of this manual Change the engine oil and filter after an initial 50 hours of engine break in operation Then follow the oil and filter change intervals as specified in the MAINTENANCE SCHEDULE in this manual Westerbeke Corporation does not approve or disapprove the use of synthetic oils If synthetic oils are used engine break in MUST be performed using conventional oil Oil change intervals must be as listed in the MAINTENANCE SCHEDULE section in this manual and not to be extended if synthetic oils are used NOTE The information above supercedes all previous statements regarding synthetic oil usage ENGINE COOLANT WESTERBEKE recommends a mixt
58. lay up or a replacement if required Install the raw water pump cover with a new cover gasket REMOTE OIL FILTER OPTIONAL PN 040078 APPLY A THIN COAT OF CLEAN OIL TO THE O RING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN ADDITIONAL 3 4 TURN AFTER THE O RING CONTACTS THE BASE E aA CONNECTION AT THE y NE REMOTE OIL FILTER THE OUT CONNECTION HOSE MUST ATTACH TO THE IN CONNECTION AT THE ee ON REMOTE OIL FILTER NOTE The in and out markings gt on the kit if the hoses are removed for installation so they can be reconnected correctly INSTALLATION This popular accessory is used to relocate the engine s oil fil ter from the engine to a more convenient location such as an engine room bulkhead NOTE Refer to ENGINE OIL CHANGE in this manual for instructions on removing the oil filter To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filter kit as shown Always install this kit with the oil filter facing down as illustrated Contact your WESTERBEKE dealer for more information THE IN CONNECTION HOSE MUST ATTACH TO THE OUT 3 Reinstall the batteries that were removed during the lay up and reconnect the battery cables making sure the terminals are clean and that the connections are tight Check to make sure that the batteries are fully charged 4 Remove the spark plugs wipe clean re gap and install to
59. ngine exhaust carbon etc are allowed to build up Clogged ventilation openings may cause excessive heating and reduced life of windings In addition to periodic cleaning the generator should be inspected for tightness of all connections evidence of overheated terminals and loose or damaged wires xv WESTERBEKE Engines amp Generators 23 BC GENERATOR SINGLE PHASE DESCRIPTION The BC generator is a brushless self excited generator which requires only the driving force of the engine to produce an AC output The stator houses two sets of windings the main stator windings and the exciter windings When the generator is started residual magnetism in the four rotating poles induces a current in the stator which then generates an even larger current in the exciter windings This mutual build up of current in the four rotating poles and in the exciter windings quickly reaches the saturation point of the capacitor s and a regulated energy field is then maintained in the stator At the same time this regulated field produces a steady voltage in the stator windings which can then be drawn off the generator s AC terminals to operate AC equipment The generator is a single phase reconnectable 120 volt AC two wire at 60 hertz or 115 volt AC two wire or 230 volt or AC two wire at 50 hertz Refer to the SPECIFICATIONS section of this manual for generator ratings The generator s data plate gives the voltage current and frequency ratin
60. nic if water is present in the oil Raw water present in the oil can be the result of a fault in the exhaust system attached to the engine and or a siphoning through the raw water cooling circuit into the exhaust filling into the engine 5 22 REMOVE USING AN 8MM 11 16 SOCKET TO DRAIN THE OIL OR PUMP THE WARMED gt OIL UP THRU THE HOSE DIPSTICK TUBE OIL PAN OIL DRAIN HOSE a WARNING Used engine oil contains harmful contaminants Avoid prolonged skin contact Clean skin and nails thoroughly using soap and water Launder or discard clothing or rags containing used oil Recycle used oil properly APPLY A THIN COAT OF CLEAN OIL TO THE FILTER GASKET WHEN INSTALLING AFTER THE FILTER CONTACTS THE BASE TIGHTEN FIRMLY BY HAND OIL FILTER ASSEMBLY WIPE SURFACE CLEAN BEFORE INSTALLING TE OIL PRESSURE SWITCH When removing the used oil filter you may find it helpful to punch a hole in the upper and lower portion of the old filter 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 is removed to make sure that the rubber sealing gasket comes off with the old oil filter If this rubber sealing gasket rem
61. nnect it last W Make certain all personnel are clear of the engine before starting W Make certain all covers guards and hatches are re installed before starting the engine BATTERY EXPLOSION WARNING Battery explosion can cause injury or death Do not smoke or allow an open flame near the battery being serviced Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing or by lit tobacco products Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing W Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Sparks could ignite battery gases or fuel vapors Ventilate any compartment containing batteries to prevent accumulation of explosive gases To avoid sparks do not disturb the battery charger connections while the battery is being charged W Avoid contacting the terminals with tools etc to prevent burns or sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling the battery W Always tum the battery charger off before disconnecting the battery connections Remove the negative lead first and reconnect it last when disconnecting the battery BATTERY ACID WARNING Sulfuric acid in batteries can cause severe Injury or death m When servicing the ba
62. nstalled Do not run the engine with the air intake silencer or flame arrester removed Do not run engines for long periods with their enclosures open when installed WARNING Do not work on machinery when you are mentally or physically incapacitated by fatigue OPERATORS MANUAL Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasoline engine or generator should begin with a thorough examination of the American Boat and Yacht Council s ABYC standards These standards are from a combination of sources including the USCG and the NFPA Sections of the ABYC standards of particular interest are H 2 Ventilation for Boats using Gasoline H 24 Gasoline Fuel Systems P 1 Installation of Exhaust Systems for Propulsion and Auxiliary Engines P 4 Marine Inboard Engines and Transmissions 11 and DC Electrical Systems on Boats installations must comply with the Federal Code of Regulations FCR ABYC NFPA AND USCG PUBLICATIONS FOR INSTALLING ENGINES AND GENERATORS Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their recommenda tions when installing your engine ABYC American Boat and Yacht Council
63. o the generator 955509 NVUDVIG INIGIM 66 1 seujBu3 WHT BLK 18GA FIRE ALARM GND D WHT BLK 20GA D WHT BLK 20GA AIR_TEMP 2 D WHT BLK 20GA ECT 2 D WHT BLK 18GA 2 D WHT BLK 18GA ECULJI 21 P WHT BLK 20GA CAM 3D WHT BLK 20GA CRANK 3D WHT BRN 20GA ECU JI 6D WHT GRN 20GA ECU JI 13 WHT B8LK 20GA OP SENDER SENS GND 8LU 18GA 02 12 BRN 18GA ECU J2 35 WHT YEL 20GA ECU 10 YEL 18GA ECU J2 33 WHT i8GA ECU J2 34 WHT BLK 20GA OP_SENDER SENS_GND P 11 9 RED VIO 18GA WHT ORG 20GA ECU JI 5 WHT BLK RED 18GA ECU JI T WHT BLK 20GA OP_SENDER SENS_GND WHT YIO 186A ECU 1 3 WHT BLK 20GA OP SENDER SENS GND P WHT BLU 20GA ECU JI II WHT BLK 20GA OP_SENDER SENS GND ENGINE BLOCK COMPONENTS COMPONENTS LOCATED ON THE INTAKE THROTTLE BODY 966667 INVd9vId 9NIUIM GRN YEL 20GA ECU J 14 EXHAUST WHT BLK VIO 20GA ECU JI 15 WHT GRY 18GA ECU JI 16D TEMP SWITCH RED VIO 16GA K3 87 WHT BLK 18GA OP SENDER SENS GND EX TEMP TAN 16GA ECU J2 10 BLK WHT 18GA ECU JI 22 WHT BLK ORG 20GA ECU JI 8 EXHAUST SYSTEM COMPONENTS WIRING DIAGRAM 55536 BLU 18GA STEPPER p ISTEPPER 2 BRN 18GA JINJECTOR_2 WHT BLK BRN 16GA 2 4 STEPPER 4 WHT 18GA 11 _ 3 WHT BLK BLU 16GA 4 STEPPER 3 YEL 18GA qDC Pl 6 WHT BLK RED 18GA 4 K2 85 WHT RED 18GA WHT BLK GRN 166A INJECTOR I P TAN 16GA WBO2 4 D ORG 18GA RELAY K1 850
64. ometer W Use only distilled water to bring electrolytes to a proper level Make certain that battery cable connections are clean and tight to the battery posts and to your engine W Keep your batteries clean and free of corrosion There is a small DC amperage drain from the starting battery when the generator is not in use To prevent this draw turn off the DC breaker on the generators control panel or turn off the DC battery switch to the generator CAUTION To avoid damage to the battery charging circuit never shut off the engine battery switch while the engine is running Shut off the engine battery switch however to avoid electrical shorts when working on the engine s electrical circuit wi WESTERBEKE Engines amp Generators 19 ENGINE TROUBLESHOOTING The following troubleshooting chart describes certain problems Note When servicing the engine generator the main circuit and causes relating to engine service Also note there is a breaker control panel disconnects all AC power and can be Diagnostic Troubleshooting section that follows switched off and reset manually Possible Cause Engine does not crank 1 DC panel breaker OFF 2 DC battery OFF 3 K2 relay faulty 4 Starter solenoid faulty 5 DC battery low dead or LOOSE BATTERY CABLE 6 Faulty starter solenoid 7 Water filled cylinder 8 DC panel 8 amp buss fuse is faulty Engine cranks does not start 1 Fuel starvation engin
65. orrect it and reset the ECU A CAUTION Prolonged cranking can result in the exhaust filling with water and the water backing into the engine This could cause catastrophic damage to your generator engine The LED fault shut down display has six LED light combinations that indicate to the operator the cause of the engines automatic shut down The LED displays are CHECK ENGINE OIL PRESSURE ENGINE TEMPERATURE EXTERNAL ALARM EXHAUST TEMPERATURE and SPEED flashes Should the generator shut down from one of these faults the fault LED will remain illuminated To reset the LED the DC breaker on the control box must be turned OFF and then back ON NOTE The CHECK ENGINE LIGHT indicates a possible emissions control problem Immediate action should be taken to troubleshoot and correct this problem The Ext Alarm indicates a faulty fire suppression circuit By pass the circuit to determine the fault the fire suppression circuit must be closed when the circuit is running The 8 Amp Fuse protects the Control Panel from High Amperage or Short Circuit The 15 Amp DC Circuit Breaker protects the K1 K2 K3 relays closed circuit ftom high amperage or short circuit Sometimes after servicing the fuel system or changing the fuel filter air can accumulate in the fuel lines or the fuel module and prevent starting Schrader valves located on the high pres sure pump module and the fuel rail are used to remove this trapped air Re
66. phon break NOTE A siphon break requires periodic inspection and cleaning to ensure proper ABLE FROM operation Failure to properly maintain a siphon break can result in catastrophic YOUR WESTERBEKE engine damage Consult the siphon break manufacturer for proper maintenance DEALER SIPHON BREAK WITH STAINLESS EXHAUST SYSTEM 100 The exhaust system s hose MUST be certified for marine use Corrugated Marine Exhaust Hose is recommended The use of this type of hose allows for extreme bends and turns without the need of additional fitting and clamps to accomplish these bends and turns In this regard a single length of corrugated exhaust hose can be used The system MUST be designed to prevent the entry of water into the exhaust system under any sea conditions and at any angle of vessels heel A detailed Marine Installation Manual covering gasoline and diesel engines and generators is supplied with each unit A pdf is available to download from our website at www westerbeke com ww WESTERBEKE Engines amp Generators iV CARBON MONOXIDE CO LOW CO GENERATORS IMPORTANT INFORMATION DESCRIPTION Carbon monoxide is a component of engine exhaust It is a colorless tasteless odorless lighter than air poisonous gas that can kill you without any warning CO poisoning is one of the major safety risks associated with boating It is a threat that must not be underestimated Westerbeke Low CO generators are
67. power breaker on control Ee al panel 4 it porn ADAPTER PN 052274 00 SSS ea n E d x IL DLL LI a REMOTE B CONNECTOR Q STOP START PANEL pond WITH FAULT DISPLAY TT POWER 7Z i ED OUT RUN INDICATOR BOT 3 START SWITCH OUTPUT PNK 18GA iridis STOP SWITCH OUTPUT WHT BLK GRN 18GA IF TT S LED OUT OVERSPEED WHT BLK YEL 206A LED OUT EXH TEMP FAIL WHT BLK GRY 206A EXTENSION HARNESS IT 57777 T LED OUT COOLANT TEMP WHT BLK ORG 20GA 15 PN 054931 p FILED OUT LOW OIL PRESS WHT BLK BLU 20GA 30 PN 054932 REMOTE SON i dd STOP START PANEL ROCKER SWITCH ONLY RUN INDICATOR WHT BLK REO 18GA bs MZ UE M MA UI M 1 START SWITCH OUTPUT STOP SWITCH OUTPUT Rv upiCATOR gt PNK 18GA cb 1 an t m l WHT BLK GRN 18GA X WESTERBEKE Engines amp Generators 31 5 5 SWITCH Engine Bore amp Stroke Total Displacement Bearings Compression Chamber Compression Ratio Hp 1800 1500 rpm Firing Order Aspiration Direction of Rotation Inclination Dry weight Governor General Fuel Fuel Consumption full load approximate Fuel Hose Size supply and return Fuel Pump Fuel Filter on engine Air Cleaner flame arrester MCG GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS 3 cylinder 4 cycle over
68. re that no leakage is present and that the fittings are tight and secure The engine mounted fuel pump is maintenance free INCOMING FUEL 13 FUEL FILTER FROM HIGH PRESSURE PUMP MODULE TO FUEL RAIL eA Y orn E p 2 III NNU Uy O RING 2 Sey GF FUEL ELEMENT FUEL FILTER ENGINE FUEL FILTER Periodically check the fuel connections and the bowl for leakage Replace the filter element after the first 50 hours then follow the MAINTENANCE SCHEDULE Changing the Engine Mounted Filter Element 1 Shut the fuel supply to the generator off 2 Bleed the fuel system to reduce the fuel pressure to zero Refer to BLEEDING THE FUEL SYSTEM 3 Unscrew the fuel bowl from the housing and pull the filter element down and off Use care to catch any fuel that may be present 4 Replace the two sealing O rings Install the new filter element and thread on the fuel bowl then tighten by hand 5 Open the fuel supply to the generator and start the unit Ensure that there are no leaks 6 Bleed the fuel system again to remove trapped air from the system Refer to BLEEDING THE FUEL SYSTEM BLEEDING THE FUEL SYSTEM The engine s fuel system should be bled of air at the initial commissioning of the unit each time the fuel system 15 serviced and once a season to ensure any air that may have accumulated in the system is removed Bleeding ins
69. s is a low oil pressure warning Cw WESTERBEKE Engines amp Generators 18 BATTERY CHARGING CIRCUIT 30 FUSE THE CHARGING SYSTEM The battery charger is an encapsulated solid state unit that supplies a DC charging voltage to the generator s starting battery while the generator is operating NOTE battery charging circuit is totally separate from the AC output of the generator The generator output affects the circuits output but not the reverse separate group of stator windings supplies AC voltage to a bridge rectifier which converts the AC current to supply the charging unit The unit senses the needs of the starting battery and supplies a DC charge when one is needed 30A FUSE This spade type fuse is located in the 5 wiring harness behind the fuel filter d QA d 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 BATTERY The minimum recommended capacity of the battery used in the engine s 12 volt DC control circuit is 800 1000 CCA This MUST be a dedicated battery Battery Maintenance Review the manufacturer s recommendations and then establish a systematic maintenance schedule for your engine s starting batteries and house batteries Monitor your voltmeter for proper charging during engine operation W Check the electrolyte level and specific gravity with a hydr
70. stomer warranty identification card in the mail within 60 days of registering If you do not please contact the factory and have your product model number serial number and in service date available Customer Identification Card Engines amp Generators Customer Identification WESTERBEKE OWNER MAIN STREET HOMETOWN USA Model Expires NOTES CAUTIONS AND WARNINGS As this manual takes you through the operating procedures maintenance schedules and troubleshooting Critical information will be highlighted by NOTES CAUTIONS and WARNINGS An explanation follows NOTE An operating procedure essential to note Ser 1 CAUTION Procedures which if not strictly observed can result in the damage or destruction of your engine WARNING Procedures which if not properly followed can result in personal injury or loss of life MANUALS SOFTWARE Westerbeke frequently updates manuals and software Please insure that you will have the latest information by consulting your WESTERBEKE representative or visit our website at WWw westerbeke com SERIAL NUMBER LOCATION AS N see The engine serial 2 is stamped into the engine block WESTERBEKE MODEL Fill in the information below for reference p SPEC USA SER NO 4 5 0 co The engine model number and serial number are printed on a decal on the engine manifold
71. the owner installed Gasoline Water Separator Filter is pumped thru the nlet Fuel Filter into the Fuel Module by the Electric Fuel Pump The fuel is cooled as it circulates through the Fuel Module and then is pumped by the Electric Fuel Pump to the High Pressure Pump Module and to the Secondary Fuel Filter The fuel passes to the Fuel Rail and is delivered under pressure to the Fuel Injectors HIGH PRESSURE 7 PUMP MODULE NW ae 7 DIVERTER 3 2 VALVE 1 eee 7 ELECTRIC FUEL b PUMP COOLING WATER INLET FUEL FILTER COOLING WATER DOLANT DRAIN TE INCOMING FUEL DRAIN GASOLINE WATER SEPARATOR AND FILTER A primary fuel filter of the water separating type must be installed between the fuel tank and the engine to remove water and other contaminants from the fuel before they can be carried to the fuel system on the engine Most installers include a type of filter water separator with the generator installation package as they are aware of the problems that contaminants in the fuel can cause These gasoline filters must have metal bowls not see through to meet U S Coast Guard requirements The metal bowls have drain valves to use when checking the water and contaminants OWNER INSTALLED MP FUEL WATER SEPARATOR PN 049602 FUEL PUMP CF Periodically check the fuel connections to and out of the pump and make su
72. ting your generator for the first time or after a pro threaded connections Search for any gasoline leaks longed layoff check the following items m Check AC wiring for correct connections as specified in Check the engine oil level add oil to maintain the level at the wiring diagrams the full mark on the dipstick Check the fuel supply and examine the fuel filter separator m Inspect east sy bowls for contaminants Be sure no other generator or utility power is connected to is the load lines Check the DC electrical system Inspect wire connections and battery cable connections B Confirm that systems with a neutral line are NOTE The starting battery must be totally dedicated to the properly grounded or ungrounded as the system requires generator and maintained by the generator s DC charging and that generator neutral is properly connected to the alero and load neutral In single phase systems an incomplete or open neutral can supply the wrong line to neutral Check the coolant level in both the plastic recovery tank voltage on unbalanced loads and at the manifold l y Make certain the raw water thru hull is open NOTE During the initial filling of the cooling system the air bleed petcock on the manifold should be opened to purge air from the engine block Once cooled free of air bubbles flows from the petcock close the petcock A CAUTION When starting the generator it is r
73. tructions are found in the model s SERVICE MANUAL GS MESTERBEKE Engines amp Generators COOLING SYSTEM FRESH WATER COOLING CIRCUIT An antifreeze mixture is pumped through the engine by a belt 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 of the circulating pump and then through the engine When the engine is started cold external coolant flow 18 prevented by the closed thermostat although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheating As the engine warms up the thermostat gradually opens allowing full flow of the engine s coolant to flow unrestricted to the external portion of the cooling system AX CAUTION Proper cooling system maintenance is critical a substantial number of engine failures can be traced back to cooling system corrosion CHANGING COOLANT The engine s coolant must be changed according to the MAINTENANCE SCHEDULE If the coolant is allowed to become contaminated it can lead to overheating problems Drain the engine coolant by removing the block drain adja cent to the oil filter remove the in board drain plug on the heat exchanger and remove the pressure cap from the water jacketed exhaust manifold A CAUTION The engine must be allowed to cool down before attempting these procedures
74. tteries will not remain fully charged or that they will be subjected to severe environmental conditions remove the batteries and store them in a warmer more compatible environment A WARNING Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing or a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing xv WESTERBEKE Engines amp Generators LAY UP amp RECOMMISSIONING Spare Parts Lay up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand or replace those items used during the lay up such as filters and zinc anodes Refer to the SPARE PARTS section of this manual Recommissioning The recommissioning of your Westerbeke engine after a seasonal lay up generally follows the same procedures as those described in the PREPARATIONS FOR STARTING section regarding preparation for starting and normal starts However some of the lay up procedures will need to be counteracted before starting the engine 1 Remove the oil soaked cloths from the intake manifold 2 Remove the raw water pump cover and gasket and discard the old gasket Install the raw water pump impeller removed during
75. ttery or checking the electrolyte level wear rubber gloves a rubber apron and eye protection Batteries contain sulfuric acid which is destructive If it comes in contact with your skin wash it off at once with water Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps AX WARNING Carbon monoxide CO is a deadly gas m Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Pay close attention to the manifold water injection elbow and exhaust pipe fittings W Be sure the unit and its surroundings are well ventilated In addition to routine inspection of the exhaust system install a carbon monoxide detector Consult your boat builder or dealer for installation of approved detectors For additional information refer to ABYC HT 22 educational information on Carbon Monoxide AX WARNING Carbon monoxide CO is an invisible odorless gas Inhalation produces flu like symptoms nausea or death W Do not use copper tubing in exhaust systems Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust water leakage Do not install exhaust outlet where exhaust can be drawn through portholes vents or air conditioners If the engine exhaust discharge outlet is near the waterline water could enter the e
76. ure of 50 antifreeze and 50 distilled water Distilled water is free from the chemicals that can corrode internal engine surfaces The antifreeze performs double duty It allows the engine to run at proper temperatures by transferring heat away from 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 Use the new environmentally friendly long lasting antifreeze that is now available A proper 50 50 mixture as recommended will protect the engine coolant to temperatures of 40 F COOLANT RECOVERY TANK A coolant recovery tank kit is supplied with each generator The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and without introducing air into the cooling system NOTE This tank with its short run of plastic hose is best located at or above the level of the engine s exhaust manifold WESTERBEKE Engines amp Generators PREPARATIONS FOR INITIAL START UP PRESTART INSPECTION B Visually examine the unit Look for loose or missing parts disconnected wires unattached hoses and check Before star
77. ures occur when the impeller and gasket Open the raw water intake valve raw water 15 not present during engine operation Such failures are not warrantable and operators are cautioned to make sure raw water flow is present at start up The raw water pump should be inspected periodically for broken or NOTE Should a failure occur with the pumps internal parts torn impeller blades See MAINTENANCE SCHEDULE seals and bearings it may be more cost efficient to NOTE Should a failure occur with the pumps internal parts purchase a new pump and rebuild the original pump as seals and bearings it may be more cost efficient to Ce hs purchase a new pump and rebuild the original pump as NOTE If any of the vanes ney E Tac must be found to prevent blockage in the cooling circuit NOTE Never allow the pump to run dry Even a short period They often can be found in the heat exchanger of dry running may destroy the impeller TO HEAT EXCHANGER IMPELLER THE SCREW MUST gt LINE UP WITH THE INSPECTION CHECK AT THE BASE OF _ EACH BLADE BY BENDING VIGOROUSLY PN 042026 REPLACE THE IMPELLER IF THERE WHEN INSTALLING TAKE CARE TO ALIGN THE IMPELLER KEYWAY WITH THE SHAFT KEY FOLD THE IMPELLER BLADES IN EITHER DIRECTION THEY WILL TURN IN THE CORRECT POSITION WHEN THE IMPELLER STARTS TO ROTATE IMPELLER OR WHEN ASSEMBLING APPLY A THIN COAT OF GLYCERIN TO THE INSIDE OF THE COVER THE
78. xhaust discharge outlet and close or restrict the flow of exhaust Avoid overloading the craft W Carbon monoxide gas is present in exhaust fumes Some of the symptoms or signs of carbon monoxide inhalation or poisoning are Vomiting Muscular twitching Dizziness Intense headache Throbbing in temples Weakness and sleepiness AVOID MOVING PARTS WARNING Rotating parts cause injury or deatli Do not service the engine while it is running If a situation arises in which it is absolutely necessary to make operating adjustments use extreme care to avoid touching moving parts and hot exhaust system components i 57 Engines amp Generators SAFETY INSTRUCTIONS W Do not wear loose clothing or Jewelry when servicing equipment tie back long hair and avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that could be caught in moving parts W Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective places at all times Do not check fluid levels or the drive belt s tension while the engine is operating W Do not allow any swimming or activity around or near the exhaust discharge opening for the generator while the generator is operating Carbon Monoxide poisoning or death can occur HAZARDOUS NOISE WARNING High noise levels can cause hearing loss W Never operate an engine without its muffler i

5 - 6.5 MCG Operators Manual

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