Westerbeke 6.5 MCG 60HZ User manual

OPERATORS MANUAL
6.5 MCG 60HZ 5.2 MCG 50HZ
. 5.0 MCG 60HZ 4.2 MCG 50HZ
Multi-port
MARINE GASOLINE GENERATOR
SINGLE PHASE

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:
•Dizziness
•Nausea
•Headache
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
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 cosl affective and
easily obtainable at your local marine store.

Gasoline with an ETHANOL content
higher than 10°/o (E10) is not allowed
and may void warranty.
Jr~ rWESTERBEKE™
~ Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by failure to foUow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personne~ andyour machinery.
The foUowing safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated 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.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets very
hot!
• Monitor engine antifreeze coolant level at the plastic
coolant recovery tank and periodically at the filler cap
location on the water jacketed exhaust manifold, but only
when the engine
is COLD.
A WARNING: Steam can cause injury or death!
• In case 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!
• Prevent flash fires. Do not smoke or permit flames or
sparks
to occur near the carburetor, 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 line, carburetor, or fuel
filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• 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.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• All 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 ofthe reach
of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system.
Take care in catching any fuel that might
spill. DO
Nar 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.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the
NFPA are appropriate
for all applications encountered in this environment.

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Thm OFF the DC breaker on the control panel or tum the
unit's battery selector switch to OFF before servicing the.
engine.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BAfiERY EXPLOSION
A WARNING: Battery explosion can cause Injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries
~mi~ hydrogen, ~
highly explosive gas, which can be tgmted by elec~cal
arcing or by lit tobacco products. Shut o~ all ele~trical
equipment in the vicinity to prevent electncal arcmg
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal ofthe starter solenoi~.
Do not test the battery condition by shorting the termmals
together. Sparks could ignite batt~I?' gases o~ fuel vapors.
Ventilate any compartment contammg battenes to prevent
accumulation
of explosive gases. To avoid sparks, do not
disturb the battery charger connections
while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always turn the battery charger offbefore .disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BAfiERYACID
A WARNING: Sulfuric acid In batteries can cause
severe injury or death!
• When servicing the battery 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.
TOXIC EXHAUST GASES
A WARNING: carbon monoxide (CO) is a deadly gas!
• 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 manifold/
water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when nmning the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information, refer to ABYC TH-22
(educational information
on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces nu-llke symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy 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 exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or signs ofcarbon monoxide inhalation or
poisoning are:
Vomiting
Dizziness
Headache
Inability
to think coherently
Throbbing in
temples
Muscular twitching
Nausea
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• 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.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces orbracelets that
could be caught in moving parts.
• 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.
• 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
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• 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).
A 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 ofthe 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 ofparticular interest are:
H-2 Ventilation for Boats using Gasoline
H-24 Gasoline Fuel Systems
P-1 Installation ofExhaust Systems
for Propulsion and Auxiliary Engines
P-4 Marine Inboard Engines and Transmissions
E-llAC and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTAtLING 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)
"Standards and Technical ~nforrnation 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
Engines & Generators
iii

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 porl 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
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation.
Failure to properly maintain a siphon-break can result in catastrophic
engine
damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
AVAILABLE FROM
YOUR WESTERBEKE
DEALER
siPiiorUfiiEAK- WiTH STAINLESS
LOOP'
The exhaust system's hose MUSTbe 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
rieed 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.
Engines & Generators
iv

CARBON MONOXIDE "CO"JLOW·CO GENERATORS
IMPORTANT INFORMATION
DESCRIPTION
Carbon monoxide "CO" 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 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:
Regulator
CO ppm Exposure Hours
EPA 9 8
ACGIH 25
8
EPA
35 1
NIOSH
35 8
OSHA
50 8
ACGIH 125 0.5
NIOSH 200 0.0
NIOSH 1200 0.0
(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
Responses
25 Permissible exposure level, no
apparent toxic symptoms.
100 No poisoning for long period.
Allowable for several hours.
200 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 offall 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 is subject
to dilution in the open air. The closer a person is to the
exhaust outlet, the higher the concentration
of CO.
v
In a closed space, such as the engine compartment, the boat,
or underneath a stem swim platform, concentrations will
potentially rise to the undiluted level emanating from the
exhaust system due to a lack
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 installation instructions must be
adhered to.
NOTE: Water intrusion is not a product defect and is not cov-
ered under warranty, neither Westerbeke ~ normal
product warranty nor
the emissions specific warranty
mandated by various regulating authorities such as EPA
andCARB.
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.

CARBON·•MONOXIDE. "CO''/ LOW·CO GENERATORS
.. iMPORTANT INFORMATION
Catalyst perfonnance will degrade over time. A13 the
generator accumulates operating hours, CO concentrations
will increase. The catalyst must be replaced every 2,000
hours of engine operation.
Verlficadon·of satisfactory CO levels mustbe done
seasonally oreach 1,000 hours (which ever occurs first).
Verification involves actual sampling ofexhaust 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 temperature,
temperature limits of the analyzer, safety concerns over
temperatures involved or the possibility ofhigh 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
loca~on 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 ofthe water flow and just
out of the flow. Position the analyzer as high as possible with
the tubing leading to the probe running continu~usly do_wn-
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, especially in marinas. the 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 ofthecylinder 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, TIP; Testo, TSI, Bacharach, Fluke, Monoxor, Pyrite,
Zellwgwer Analytics, Industrial Scientific Corp, GPo, TPI,
Teledyne and others. Westerbeke recommends analyzers with
aprobe 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.
Engines & Generators
vi

EMISSIONS
This genset meets the requirements ofCalifornia's Exhaust
Emissions ·standards as stated on the nameplate.
California users of this genset should be aware that
unauthorized modifications or replacement of fuel, exhaust,
air intake, or speed control system components that affect
engine emissions are prohibited. Unauthorized modification,
removal or replacement ofthe engine label is prohibited.
Federal Emissions Compliance Period: The Federal
Emissions Compliance Period referred to on the nameplate
indicates the number ofoperating hours for which the engine
has been shown to meet Federal Emissions requirements.
Q~tagory C= 250 hrs, B=500 hrs, A=1000 hrs.
You should carefully review operator (Qwner Installation
and pther manuals and information you receive with your
genset. Tf you are unsure that the installation, use,
maintenance or service of your genset is authorized, you
should seek assistance from an approved WESlERBEKE
dealer.
California genset users may use the table below as an aid in
locating information re\iited to the California Air Resources
Board requirements for emissions control.
EMISSIO~S CONTROL INFORMATION TABLE
The California emissions control warranty statement is located in the same
Emissions Warranty Information
packet, if information as this manual when the genset is shipped from the
factory.
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 OU Requirements See ENGINE
OIL RECOMMENDATIONS.
EngineAdjustments
ECU.
Engine Emission ControlSystem The engine emission control system consists ofengine design
and precision
manufacture.
Catalyst See MAINTENANCE SCHEDULE.
Oxygen Sensor See MAINTENANCE
SCHEDULE.
Back Pressure See MAINTENANCE
SCHEDULE.
EXHAUST SYSTEM MAINTENANCE
DESCRIPTION
The catalyst is critical to minimizing exhaust emissions like
CO. Any water inf!:Usion into the engine's exhaust system will
likely quickly compromise the proper operation of the catalyst
NOTE: For information on installing Exhaust Systems,
referto WESTERBEKE'S INSTALLATION MANUAL
available atwww.westerbeke.com.
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 ofthe output
surface of the catalyst Any visual irregularity ofthe 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 irreguJ.arlty, the catalyst and sealing
gasket must be replaced. The water injected exhaust elbow
casting must be inspected al4o for corrosion and replaced as
needed. Upon careful reassembly of the catalyst, new sealipg
gasket, and exhaust elbow, checkfor the presence of CO '
wl:iile the engine is running. This must be performed with a
CO analyzer.
Referalso to TESTING THE BACK PRESU~ in this
manual.
POSITfON THE CLAMP OVER
THE TWO FLANGES (AND GASKET}
ANOTIGH1EN
SECURELY
INSTALLING A NEW
CATALYST
Engines & Generators
vii

TABLE OF CONTENTS
Parts Identification ............................................. 2 Battery Charging Circuit ................................... 19
Introduction ......................................................... 3
Engine Troubleshooting ..................................... 20
Fuel, Engine Oil and Engine Coolant .................. 5
PC Monitoring ................................................... 22
Preparations for Initial Start-Up ......................... 6
Control Box Components ................................... 22
Bleeding the Fuel System ................................ 6A
Generator Information ....................................... 23
Control Panel - Starting/Stopping Procedure ..... 7 AC Terminal Connections ...........................24
Remote-Stop/Start Procedure ............................. 8 Windings Schematic....................................24
Break-In Procedure (Daily Operation) ...................9
Shore Power Transfer Switch ............................ 25
Safety Shutdown Sensors/Switches .................. 10
Engine/Generator Wiring Diagrams (#55536) .... 26
Maintenance Schedule ...................................... 11
Ignition System Components ...................... 26
Fuel System ....................................................... 13
Control Box Components............................ 27
Gasoline/Water Separator/Filter.................. 13 Fuel System Components.......................:.... 28
Fuel Pump.................................................... 13
Battery Charging Circuit ............................. 28
Fuel Filter .................................................... 13
Exhaust System Components ...................... 29
Cooling System .................................................. 14 Throttle Body Components ......................... 29
Changing Coolant........................................ 14
ECU Components....................................... .30
Thermostat................................................... 15
Remote Panel Wiring Diagram ......................... .31
Zinc Anode .................................................. 15
DC Auxiliary Power Adapter .............................. 31
Heat Exchanger ...........................................16
MCG Generator Specifications .......................... 32
Raw Water Intake Strainer..........................16
Lay-up and Recommissioning .............. :: ........... 33
Raw Water Pump.........................................16
Remote Oil Filter ............................................... 34
Changing the Impeller................................. 16
Tightening Torque Specifications ................... .35
Engine Lubricating Oil.. ..................................... 17
Suggested Spare Parts ...................................... 36
Changing the Oil ........................................ 17
Replacing the Filter .................................... 17
Engine Adjustments ........................................... l8
Spark Plugs.................................................. 18
Air Screen...........:........................................ l8
Oil Pressure ................................................. 18
Engines & Generators
1

SIPHON BREAK --fP
CONNECTION
FRONT I
PARTS IDENTIFICATION
LEFT
SIDE
WIRING HARNESS TO ECU CONNECTIONS
CHARGER FUSE
. AC·CIRCUIT BREAKER
yttROmE BODY
ANODE.
AIR BLEED
THERMOSTAT
CONTROL BOX
HEAT
ELECTRIC FUEL UFT PUMP,
FUEL
MODULE
2
FUEl: FILTER
FILL CAP
DIPSTICK
SUMP DRAIN HOSE
CONNECTION
GROUND
RIGHT SIDE

INTRODUCTION
This WESTERBEKE Generator is a product of
WESTERBEKE's long years ofexperience and advanced
technology. We take great pride in the superior durability and
dependable performance ofour 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. Aservice
Manual is available and can be ordered from your local
WESTERBEKFJUNIVERSAL dealer.
WARRANTY PROCEDURES
Your WESTERBEKE Wap-anty 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
customer 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 ldentlfic~tion Card
L...,.,.IWI!STI!IlBEKE.
I Engines & Generators
~Identtfication
WES'l'ERBBKB OWNER
MAIN~
HOME'i'bWN, USA
Model' Ser.#
Expires
NOTES, CAUTIONS AND. WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting. Criti~l)].
information will be highlighted by NOTES, CAliTIONS,
and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which if not strictly
observed, can result In the damage or destruction of your
engine.
A WARNING: Procedures, which If not properly
followed, can result In personal injury or loss oflife.
MANUALS/SOFTWARE
Westerbeke frequently updates manuais and-software. Please
insure that you will have the latest information by consulting
your WESTERBEKE representative or visit our website at
www.westerbeke.com
Fill in the information for your own reference.
NOTE: Technical information is provided in our Manuals for
your reference andconvenience. Westerbeke
recommends
that your engi11e, generator orclimate control system is
serviced and/or installed only by a qualified Westerbeke
distributor or dealer.
The 6.5/5.0 MCG Service Manual (#055743) is available as
· a pdf download at www.westerbeke.com. This Service
Manual can also be purchased in hard copy from your
Westerbeke Dealer.
Engines & Generators
3

INTRODUCTION
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted in aWESTERBEKE generator capable of
many hours ofdependable 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:
• Proper installation.
• An efficient well-designed exhaust system that includes
an anti-siphon break to prevent water from entering the
engine.
• Changing the engine oil and oilfilters as outlined in the
Maintenance
Schedule.
• Proper maintenance of aU engine andgenerator
components according
to the Maintenance Schedule in
this manual.
• Use clean, filtered unleadedfue~ maximum 10%
ethenol.
• Winterize your engine according to the lAY-UPAND
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 ofa 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.
4
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, 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 willfit 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 ofcarbon 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!
AMPERAGE DRAIN
There is a very small amount of amperage being drawn from
the unit's starting battery by the electronics on the unit when
the generator
is not in use. To prevent this and draw down of
the starting battery charge. Turn OFF either the panel DC
breaker or the starting battery switch when the unit will not
be operated for a period
of time.

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
:"muse llltlreseiJJIJI/elsamlma,a
Care Of The Fuel Supply 0
Use only clean properly filtered fuel! The fit and tolerance of
some components in the unit's fuel system are very critical;
dirtparticles 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 mixture 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 tempemtures 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 tempemtures
of -40"F.
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each genemtor.
The purpose of this recovery tank is to allow for engine
coolant expansion and contraction during engine opemtion,
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 engines exhaust
manifold.
Engines &Generators
5

PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
Before starting your generator for the first time or after a pro-
longed layoff, check the following items:
• Check the engine oil level: add oil to maintain the level at
the full mark on the dipstick.
• Check the fuel supply and examine the fuel filter/separator
bowls for contaminants.
• Check the DC electrical system. Inspect wire connections
and battery cable connections.
NOTE: The starting battery must be totally dedicated to the
generator and maintained by the generator's DC charging
alternator and
no other source.
• Check the coolant level in both the plastic recovery tank
and at the manifold.
NOTE: During the initialfilling of the cooling system, the
air bleedpetcock on the manifold should be opened to
purge airfrom the engine block. Once cooled, free of air
bubbles, flows from the petcock -close the petcock.
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
MANIFOLD
PRESSURE
CAP
THERMOSTAT
HOUSING .
MAX. FULL
COOLANT
RECOVERY TANK
...-t-~n:"'l'--- COOLANT
FILL
RAW WATER DRAIN
HEAT EXCHANGER
• Visually examine the unit. Look for loose or missing
parts, disconnected wires, unattached hoses, and check
threaded connections. Search for any gasoline leaks.
• Check AC wiring for correct connections as specified in
the wiring diagrams.
• Inspect exhaust system connections.
• Be sure no other generator or utility power is connected to
the load lines.
• Confirm that systems with a neutral line are·
properly grounded (or ungrounded) as the system requires,
and that generator neutral is properly connected to the
load neutral. In single phase systems an fucomplete or
open neutral can supply the wrong line-to-neutral
voltage
on unbalanced loads.
• Make certain the raw water thru-hull is open.
A CAUTION: When starting the generator, it is
recommended 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.
. ROCKER COVER
FRESH WATER
DRAIN
Engln~s_& Genera~ors
6

.BLEEDING THE FUEL SYSTEM
DESCRIPTION
1. Disconnect the fuel module from the engine wiring
harness.
2. Attach your fuel pressure gauge set (Snap On #MT337B,
OTC 7211) or equivalent to the Schrader valve on the fuel
module. Direct the bleed hose from the pressuregauge
into a proper container.
3. Open the bleed valve on the pressure gauge, Depress the
STOP switch and hold it depressed. This activates the low
pressure fuel
puQ1p. Observe the :(uel flow through the
bleed hose and when no air bubbles are seen, close the
bleed valve and observe the fuel pressure. Typically about
3-5 psi
4. Remove the pressue gauge from the fuel
mod1:1le and
. connect it to the Schrader valve
on the fuel rail.
5. Re-connect the fuel module to the engine harness.
VALVE
"SNAP-ON· TOOL • PROVIDES AN
EXCELLENT PRESSURE GAUGE KIT
· FOR PRESSURE TESTING AND
BLEEDING SCHRADER TEST PORTS .
COOLANT DRAIN
6. Open the bleed valve on the fuel pressure gauge. Depress
the STOP switch and hold it depressed. This activates
both the low pressure and high pressure fuel pumps.
Observe the fuel flow through the bleed hose and when
no
air bubbles are seen, close the bleed valve and observe the
fuel pressure.
The pressure should be in the 40 psi range.
7. Remove the pressure gauge set and replace the caps on
the two Schrader valves.
8. Insure that all harness connections are secure, operate the
generator and check that there are no fuel leaks.
NOTE: The fuel system will need to be bled any time the fuel
filters are serviced.
A WARNING: The fuel is under extreme pressure! .
No smoking and no open «ames! Clean up spilled fuel
and properly discard of cloths and towels.·
I
.-----.
, ___ __. I
---- I
..y---- -;.~FUEL J I
RAIL : i FROM HtGH
-/Ni'JON.TING FUEL
PRESSURE
PUMP MODULE
........ --
t
I
i.
i
)
Engines &Generators
6a

CONTROL PANEL • START/STOP PROCEDURE
TO START: (DC CIRCUIT BREAKER ON)
Simply press the rocker switch to the ~~ position ~d re!ease
(the switch will revert to its center posttion) the engme will
START electronically. AGREEN LED on the switch will
indicate the engine is running.
NOTE: There is afew second delay while the ECUself-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
shutdown.
DC CIRCUIT BREAKER
GREEN LED
THIS LED ILLUMINATES FAINTLY
WHEN THE ENGINE IS NOT
RUNNING (DC CIRCUIT
BREAKER ON).
CONTROL PANEL • OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
DC CIRCUIT BREAKER
TLIRN OFF WHEN
PERFORMING
. MAINTENANCE TO
PREVENT ACCIDENTAL
STARTING
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.Investigatethe cause of this no-start, correct it and
reset the ECU.
A CAUTION: Prolonged cranking can result in the
exhaust nlling 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, OILPRESSURE, ENGINE1EMPERATURE,
EXTERNALALARM, EXHAUST1EMPERATURE
and
SPEED (flashes).
Should the generator shut down from one ofthese
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 LIGHTindicates 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 deteimine 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 Kl, K2, K3
relays (closed circuit) ftom high amperage or short circuit.
BLEEDING THE FUEL SYSTEM
NOTE: Bleeding of airfrom the fuel system is required at
the initial commissioning of the generator. Refer to the
previous page.
Engines & Generators
7

REMOTE STOP/START PANELS
DESCRIPTION
1\vo 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. A three position start/stop rocker switch.
2. A green LED run indicator light
on the rocker switch.
3. A four position LED fault shutdown display.
PART NO
4"
(101.6
mm)
The start/stop rockerswitch functions the same as the
start/stop rockerswitch on the generator's control panel
as previously explained.
1+------4" (101.6mm) - .. -------'l~IOol-
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
fault 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.
PART N0.055345
Engines & Generators
8
:ug (81.03mm)

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.
A 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 is 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 long
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.
• 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.
• 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.
Engines &Generators
g