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 • Throbbing in Temples
•Nausea • Muscular Twitching
•Headache • Vomiting
• Weakness and Sleepiness •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 (E1 0) is not allowed
and may void warranty.

Engines & 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
personne~ and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Oo 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 off electrical 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. Arunning 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 bum.
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 of the 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 NaT 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!
11 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.
BATTERY 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 1gruted by elec~cal
arcing or by lit tobacco products. Shut o~ all ele~tncal
equipment in the vicinity to prevent electrical arcmg
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal of the starter solenoi~.
Do not test the battery condition by shorting the termmals
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.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remo~e
wristwatch, rings, and any other jewelry before handlmg
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
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 whic? 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.
Engines & Generators
ii
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 running the generator set or engine.
11 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 flu-like 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 of exhaust. 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 of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness Throbbing in temples
Headache 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.
 SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that INSTALliNG ENGINES AND GENERATORS
could be caught in moving parts. Read the following ABYC, NFPA and USCG publications
• Make sure all attaching hardware is properly tightened. for safety codes and standards. Follow their recommenda-
Keep protective shields and guards in their respective tions when installing your engine.
places at all times. ABYC (American Boat and Yacht Council)
• Do not check fluid levels or the drive belt's tension while "Standards and Technical Information Reports for Small
the engine is operating. Craft"
• Do not allow any swimming or activity around or near Order from:
the exhaust discharge opening for the generator while the ABYC
generator is operating. Carbon Monoxide poisoning or 613 Third Street, Suite 10
death can occur. Annapolis, MD 21403
www.abycinc.org
HAZARDOUS NOISE NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
A WARNING: High noise levels can cause hearing Order from:
loss!
NFPA
• Never operate an engine without its muffler installed. 11 Tracy Drive
Avon Industrial Park
• Do not run the engine with the air intake (silencer) or Avon, MA 02322
flame arrester removed.
USCG (United States Co~t Ouard)
• Do not run engines for long periods with their enclosures "USCG 33CFR183"
open (when installed).
Order from:
A WARNING: Do not work on machinery when you are U.S. Government Printing Office
Washington, D.C. 20404
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 inc~uding 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
E·l lAC and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).

Engines & Generators

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

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
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper .; . AVAILABLE 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
wim sTAINLEss
·r sJPHoN~BREAK
LOOP'
EXHAUST SYSTEM
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 Iieed 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.

Adetailed Marine Installation Manual covering gasoline and diesel,

engines and generators, is supplied with each unit. Apdf is available
to download from our website at www.westerbeke.com.

Engines & Generators

iv
 CARBON MONOXIDE "CO"n.OW·CO GENERATORS
IMPORTANT INFORMATION
DESCRIPTION In a closed space, such as the engine compartment, the boat,
Carbon monoxide "CO" is a component of engine exhaust. It or underneath a stern swim platform, concentrations will
is a colorless, tasteless, odorless, lighter than air poisonous potentially rise to the undiluted level emanating from the
gas that can kill you without any warning. CO poisoning is exhaust system due to a lack of fresh air to dilute the exhaust
one of the major safety risks associated with boating. It is a gas. Therefore, one should never rely on dilution of the
threat that must not be underestimated. exhaust to provide a margin of safety.
Westerbeke Low-CO generators achieve reduction of CO
Westerbeke Low-CO generators are designed to dramatically by precise control control of the engine's air/fuel ration
reduce normal levels of CO in the engine exhaust. coupled with after treatment in a special catalyst. CO
Several standards for CO have been published, expressed in emissions are not the same for every model because each
parts per million "ppm" and hours of exposure: engine is different. Also, certain fuel system components are
commonized across several engine models being adequate
Regulator CO ppm Exposure Hours for some and extra-adequate for others, thus producing
different CO levels for different models.
EPA 9 8
The fuel system which accomplishes the required precise
ACGill 25 8
air/fuel ratio control is comprised of many different
EPA 35 1 components: purchased sub-assemblies, machined castings,
NIOSH 35 8 sensors, electronics and others. Because of the extreme level
OSHA 50 8 of CO reduction, any variability in the functioning of any
these components can and will cause variability of the CO
ACGill 125 0.5 output.
NIOSH 200 0.0
CO concentration also varies with load. Usually, but not
NIOSH 1200 0.0 always, the worst case CO concentration occurs at maximum
(IDLH) load.
1200 ppm is the so-called IDLH concentration •
IMMEDIATELY DANGEROUS TO LIFE AND HEALTH. INSPECTION
A city in California characterizes the effect of CO The catalyst is critical to optimizing CO levels. Any water
concentration this way: intrusion into the exhaust system will likely quickly
compromise the proper operation of the catalyst.
Parts per Million Responses Westerbeke's exhaust system installation instructions must be
25 Permissible exposure level, no adhered to.
apparent toxic symptoms. NOTE: Water intrusion is not a product defect and is not cov-
100 No poisoning for long period. ered under warranty, neither Westerbeke s normal
Allowable for several hours. product warranty nor the emissions specific warranty
mandated by various regulating authorities such as EPA
200 Should not be exposed above
and CARE.
this level for any period of
time. A possible mild frontal Maintenance of any components affecting the flow of air or
headache in two to three hours. the flow of fuel to the engine is critically important, such as
fuel filters and air filters (if any).
Even though the generator normally produces very low levels Inspection of the catalyst at the prescribed intervals is
of CO, an exhaust leak of untreated exhaust would be critically important. The exhaust elbow is removed by
extremely dangerous. For this reason it is extremely impor- loosening the metal clamp to provide a view of the output
tant to install a CO detector near the generator and to be sure surface of the catalyst. Any visual irregularity of the normal
it is always turned on and functioning properly. If this detec- flush, honeycomb appearance is most likely a result of water
tor sounds, do not turn it off, assuming it is a false signal. intrusion. The cause of the irregularity must be identified and
You can not taste, smell, or otherwise detect CO. Leave the addressed. If there is irregularity, the catalyst and gasket must
detector on, turn off all engines and generators, evacuate the be replaced. Upon careful reassembly of the catalyst, exhaust
boat leaving ports and hatches open, and seek professional elbow gasket, and exhaust elbow, check for the presence of
help. CO while the engine is running. This must be performed with
a CO analyzer.
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
 CARBON MONOXIDE. "CO"/lOW·CO GENERATORS
IMPORTANT INFORMATION
Catalyst perfonnance will degrade over time. As the Wnenever taking the time to verify proper CO concentration
generator accumulates operating hours, CO concentrations from the exhaust with a CO analyzer, always take the
will increase. The catalyst must be replaced every 2,000 opportunity to use the analyzer to "sniff' around the engine
hours of engine operation. looking for CO from exhaust leaks. Pay close attention to the
connection ofthe cylinder head to the exhaust manifold, the
Verification of satisfactory CO levels must be doue exhaust manifold to.the water injected exhaust elbow, and all
seasonally or each 1,000 hours (which ever occurs first). subsequent downstream exhaust components and hoses.
Verification involves actual sampling of exhaust gas with an Remember, exhaust gas that has not yet passed through the
appropriate CO analyzer. · catalyst is raw, untreated exhaust and is very high in CO
content.
There are two locations where exhaust gas can be sampled.
Dry, but hot, exhaust can be sampled at the plugged tapped Analyzers usually require periodic calibration. Follow the
hole in the exhaust elbow intended for back pressure instructions that come with the analyzer very carefully
measurements. Measurements at this location may not be regarding calibration.
practical in all instances due to the high exhaust temperature,
temperature limits of the analyzer, safety concerns over The following are manufacturers that offer CO analyzers:
temperatures involved or the possibility of high levels of CO. Extech, TIF; Testa, TSI, Bacharach, Fluke, Monoxor, Pyrite,
The other location is the boat's exhaust outlet, which Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI,
contains entrained cooling water (except dry stack exhaust Teledyne and others. Westerbeke recommends analyzers with
systems). Only analyzers with probes should be used at this a probe connected to the analyzer by a length of transparent
location and it is critical that the probe not ingest water. tubing. They are slightly more expensive than those with the ·
Probe-type analyzers have an air pump drawing a gas sample sensor built into one end of the analyzer, but they allow you
through the probe. As a result, they tend to ingest water when to sample the exhaust corning out of the boat's exhaust outlet.
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 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.

Engines & Generators

vi
 EMISSIONS
This genset meets the requirements of California'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 of the engine label is prohibited.
Federal Emissions Compliance Period: The Federal
Emissions Compliance Period referred to on the nameplate
indicates the number of operating hours for which the engine
has been shown to meet Federal Emissions requirements.
Ghtagory 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 WESTERBEKE
dealer.
California genset users may use the table below as an aid in
locating information re\)lted to the California Air Resources
Board requirements for emissions control.

EMISSIO~ 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 MAJNI'ENANCE SCHEDULE.
Engine Ignition Timing See MAINI'ENANCE SCHEDULE.
Engine Lubricating OH Requirements See ENGINE OIL RECOMMENDATIONS.
Engine Adjustments ECU. .
Engine Emission Control System The engine emission control system consists of engine design and precision
manufacture.
Catalyst See MAJNI'ENANCE SCHEDULE.
Oxygen Sensor See MAINTENANCE SCHEDULE.
Back Pressure See MAJNI'ENANCE SCHEDULE.

EXHAUST SYSTEM MAINTENANCE

DESCRIPTION NOTE: For information on installing Exhaust Systems,
The catalyst is critical to minimizing exhaust emissions like refer to WESTERBEKE'S JNSI'All.ATION MANUAL
CO. Any water intrusion into the engine's exhaust system will available at wwmwesterbeke.com.
likely quickly conipromise the proper operation of the catalyst. Refer also to TESTING THE BACK PRESURE in this
manual.
Inspection of the catalyst at the prescribed intervals is
POSITION THE CLAMP OVER INSTALLING A NEW
critically important. The exhaust elbow is removed by THE TWO FLANGES (AND GASKET}
loosening the metal clamp to provide a view of the output AND TIGHTEN · CATALYST
surface of the catalyst Any visual irregularity of the normal SECURELY ADJUSTABLE
flush, honeycomb appe~ce is most likely a result of water CLAMP
intrusion. The cause of the irregularity must be identified and
addressed. If there is irregruarity, the catalyst and sealing
gasket must be replaced. The water injected exhaust elbow
casting must be inspected al$0 for corrosion and replaced as
needed. Upon careful reassembly of the catalyst, new sealipg
gasket, and exhaust elbow, check for the presence of CO ·
while the engine is running. This must be performed with a
CO analyzer.

Engines & Generators

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

SIPHON BREAK
CONNECTION

. AC·CIRCUIT BREAKER

TEST PORT
EXHAUST BACK PRE:SUF!E-

FRONT '

EXHAUST HOSE CONNECTION. LEFT

SIDE
ANODE T!iROnLE BODY
AIR BLEED

OILRLLCAP
THERMOSTAT

DIPSTICK

CONTROL BOX

HEAT

SUMP DRAIN HOSE

AIR SCREEN CONNECTION

GROUND
. FIJEtFILTER
ELECTRIC FUEL UFT PUMP ,
MODULE RIGHT SIDE

2
 INTRODUCTION
This WESTERBEKE Generator is a product of MANUALS/SORWARE
WESTERBEKE's long years of experience and advanced Westerbeke frequently updates manuais anlsoftware. Please
technology. We take great pride in the superior durability and insure that you will have the latest information by consulting
dependable performance of our engines and generators. your WESTERBEKE representative or visit our website at
Thank you for selecting WESTERBEKE. www. westerbeke.com
In order to get the full use and benefit from your generator, it
is important that you operate and maintain it correctly. This SERIAL NUMBER LOCATION%'\
manual is designed to help you do this. Please read this .o <"-i~·"",_~~-The engine serial
Fill in the information · V'J ~-- 1---.J:." f!Umber is s~amped
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
below for reference. ~/
. Jl'ftA
~.,~'"
I. #~.....
\1:;.-
l'
I
\ mto the engzne block.

is an Installation Manual and Parts Information. A service

Manual is available and can be ordered from your local
WESTERBEKEIUNNERSAL dealer.
r,,
I'&?
I !I
WARRANTY PROCEDURES The engine model
Your WESTERBEKE Wa,rranty Statement is included in the. number and serial
product documentation package. There is a warranty , number are printed
registeration card you can fill out and mail to Westerbeke on a decal on the
engine manifold.
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 lllail 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
·,.....,.,WESTEIIBEICE
I Engines & Generators
CU~~Iden6ficanon
WES'I'BRBEKE OWNER
MAIN~
HOMEIUWN, USA
Model' Ser. # FiU in the information for your own reference.
Expires
NOTE: Technical information is provided in our Manuals for
your reference and convenience. Westerbeke recommends
NOTES, CAUTIONS AND. WARNINGS that your engir~e, generator or climate control system is
As this manual takes you through the operating procedures, setviced and/or installed only by a qualified Westerbeke
maintenance schedules, and troubleshooting. CritiJ::al distributor or dealer.
information will be highlighted by NOTES, CAuTIONS,
and WARNINGS. An explanation follows: The 6.5/5.0 MCG Service Manual (#055743) is available as
NOTE: An operating procedure essential to note. · a pdf download at www. westerbeke.com. This Service
Manual can also be purchased in hard copy from your
Westerbeke Dealer.
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 of life.

Engines & Generators

3
 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:
• 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 oil filters as outlined in the
Maintenance Schedule.
• Proper maintenance of all engine and generator
components according to the Maintenance Schedule in
this manual.
• 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.
Engines & Generators
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 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!
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
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.

=for
higher. Ethanol gasoline must not exceed E10 (10"/o}.

IJSBinlllese mmtels am/ ra

Gasoline with higher percentages of Ethanol are not 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

Care Of The Fuel Supply 0

Use only clean properly filtered fuel! The fit and tolerance of
quality antifreeze that contains Supplemental Cooling
Additives (SCAs') that keep the antifreeze chemically
balanced, crucial to long term protection.
some components in the unit's fuel system are very critical; The distilled water and antifreeze should ben pre-mixed
dirt particles which might pass through the filter can damage before being poured into the cooling circuit.
these finely finished parts. It is important to buy clean fuel, NOTE: Use the new environmentally-friendly, long lasting,
and keep it clean. The best fuel can be rendered antifreeze that is now available.
unsatisfactory by careless handling or improper storage
facilities. To assure that the fuel going into the tank for your A proper 50/50 mixture as recommended will protect the
engine's daily use is clean and pure, the following practice is engine coolant to temperatures of -40"F.
advisable:
COOLANT RECOVERY TANK
Purchase a well-known brand of fuel.
A coolant recovery tank kit is supplied with each generator.
Install and regularly service a good, Coast Guard approved The purpose of this recovery tank is to allow for engine
metal bowl type filter/water separator between the fuel tank coolant expansion and contraction during engine operation,
and the engine. without the loss of coolant and without introducing air into
the cooling system.
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.

NOTE: This tank, with its short run ofplastic hose, is best
located at or above the level of the engines exhaust
manifold.

Engines & Generators

5
 PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
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 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.
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
• 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 incomplete 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.

MANIFOLD
PRESSURE
CAP

THERMOSTAT
HOUSING

. ROCKER COVER

ZINC RAW WATER DRAIN

ANODE

HEAT EXCHANGER

Engines & Genera(ors

FRESH WATER
DRAIN
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 pressure gauge
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 purpp. 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 module and
. connect it to the Schrader valve on the fuel rail.
5. Re-connect the fuel module to the engine harness.
6. Open the bleed valve on d1e 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 flames! Clean up spilled fuel
and properly discard of cloths and towels.·

J~~ --~~
~ERV~VE
~~·- .?"' ~:~~~ l
- ~ • ~--ATTACH TO THE
. _. ~ SCHRADER VALVE
·FUEL RAIL
VALVE
"SNAP·ON·TOOL" PROVIDES AN
EXCEU.ENT PRESSURE GAUGE KIT
FOR PRESSURE TESTING AND
BLEEDING SCHRADER TEST PORTS I .~-~~,,
(t __ . . -- I

..y~
~--- --· -t-
TO FUEL i ' I
I
RAIL il FROM HIGH
PRESSURE
PUMP MODULE

t!
i'·
I
j
.-*'_.

FUEL FILTER

Engines & Generators

6a
 CONTROL PANEL • START/STOP PROCEDURE
TO START: (DC CIRCUIT BREAKER ON)
Simply press the rocker switch to the ~~ position ~d r~lease
(the switch will revert to its center posttion) the engme wtll
START electronically. A GREEN LED on the switch will
indicate the engine is running. .
NOTE: There is afew 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
shutdown.
CONTROL PANEL • OPERATING INSTRUCTIONS
DC CIRCUIT BREAKER
TURN OFF WHEN
PERFORMING.
.MAINTENANCE TO
PREVENT ACCIDENTAL
STARTING
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.
Engines & Generators
7
DC CIRCUIT BREAKER
GREEN LED
THIS LED ILLUMINATE$ FAINTLY
WHEN THE ENGINE IS NOT
RUNNING (DC CIRCUIT
BREAKER ON).
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, correct 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,
EXTERNALALARM, 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 deterinine the fault (the fire suppression circuit must
be closed when the circuit is nmning).
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) ftomhigh amperage or short circuit.
BLEEDING THE FUEL SYSTEM
NOTE: Bleeding of air from the fuel system is required at
the initial commissioning of the generator. Refer to the
previous page.
 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 PART NO
from either the remote or the main panel. 4"
(101.6
REMOTE START/STOP PANEL (with LED Fault Display) mm)

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.
The start/stop rocker switch functions the same as the
start/stop rocker switch on the generator's control panel ~---- 4" (101.6mm) -.. - - - - - - ' l ·)loilloll
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. 3.19 (81.03mm)
PART N0.055345
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.

Engines & Generators

8
 BREAK-IN PROCEDURE/THE DAILY OPERATION
BREAK..IN PROCEDURE
Mter 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.
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.

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.
• 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.

A CAUTION: Do not operate the generator for long

periods of time without a load being placed on the
generator.

Engines & 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 dowri the· generator's engine. When
an automatic shutdown occurs, one of the control panel fault
· LED lights will illuminate indicatipg 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 (Hall Effect)
A speed sensor is mounted on a bracket adjacent to the
front crank shaft pulley. It monitors pulley rotation and
sends a voltage signal to the ECU that interprets it as
crankshaft speed. If a speed threshold is reached, either
overspeed or underspeed. The ECU will shut the unit
down. If both speed LEOs are illuminated, it indicates
an overspeed. If both are flashing it is an 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 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.
Engines & Generators
10
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 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.
-~-.)
.
. ·.... ·
_:..
.
·.
.
'
.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.
FUSE PROTEC'DON
Four DC circuit protectors are found in the engines electrical
circuit. A 15 amp DC breaker and an 8 amp buss fuse on the
control panel. A 30 amp buss fuse in the control panel and a
30 amp spade fuse by the starter motor for the battery charge
circuit.
 MAINTENANCE SCHEDULE
A 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 tum off the battery switch.
SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED MAINTENANCE

IDAILY CHECK BEFORE START-UP

Coolant Level Check at recovery tank, if empty, check at manifold. Add coolant if needed.
Engine Oil 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.

IINITIAL 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 once 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 Filler and "0" Rings Initial change, then every 250 hours or once a year.

I 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
our own ins ection 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.

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.

Engines & 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

I EVERY 250 OPERATING HOURS OR YEARLY

*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 Filler and 0-Rings Remove and replace fuel filter and all sealing 0-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 0-rings if needed.

I EVERY 500 OPERATING HOURS OR YEARLY

*Raw 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.

IEVERY 500 OPERATING HOURS OR EVERY TWO YEARS

*Ignition System Inspect for deterioration. Test resistance.
. ·· *Coolant System Drain, flush and re-fill the cooling system with 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 PN#054SOO Remove and replace.

I EVERY 2000 OPERATING HOURS

*Oxygen Sensor Remove and replace exhaust oxygen sensor.

,.·.
*Catalyst Remove and replace exhaust catalyst.

A 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 co"ect tools for each job. When servicing/replacing DC components, turn off
the DC circuit breaker on the control panel.

*WESTERBEKE recommends this s~rvice be performed by a knowledgeable mechanic.

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.
 FUEL SYSTEM
--·
FUEL SYSTEM COMPONENTS
Incoming fuel (from the owner installed Gasoline Water
Separator/Filter) is pumped thru the Inlet 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
PUMP MODULE
I
I
I
I

t
!
I
I

I
)
Ac'~

FUEL FILTER
FUEL
f.ILTER

FUEL DRAIN INCOMING FUEL

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
FUEL WATER
SEPARATOR
PN.049602
FUEL PUMP
Periodically check the fuel connections to and out of tJ1e
pump and make sure that no leakage is present and that the
fittings are tight and secure. The engine mounted fuel pump
is maintenance free.
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 "0" 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 is
serviced and once a season to ensure any air that may have
accumulated in the system is removed. Bleeding instructions
are found in the model's SERVICE MANUAL.

13
 COOLING SYSTEM
FRESH WATER COOLING CIRCUIT
An antifreeze mixture is pumped through the engine by a belt
diiven circulating pump, absorbing heat from the engine. The
coolant then passes through the them1ostat, 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 is
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.
A CAUTION: Proper cooling system maintenance is
critical; a substantial number of engine fai/ur#Js 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 contanrinated, it can lead to overheating problems.
Drain the.(.mgine 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.
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 biim 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.

A CAUTION: The engine must be allowed to cool ·

down before attempting these procedures. Not only is
the surface of the engine hot but coolant temperatures
can be at 19ff F.

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.

COOLANT
DRAIN
COOLANT DRAIN PLUG
LOCATED JUST BELOW
THE INTAKE MANIFOLD

14
 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
hannful deposits found in raw water.
~TO SIPHON BREAK
AND EXHAUST
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 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
CLEAN OUT DE~R/S checked, cleaned, or replaced easily. Carry a spare thermostat
·~•11'1\"-'~'u and gasket.
If you suspect a faulty thermostat, place it in a pan of water ·
and bring to a boil: A working thermostate should open about 112".

TO COOLANT
RECOVERY TANK
MAN I
PRESSURE CAP l..,.
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 peifonned more often.

ZINC ANODE
GASKET
A zinc anode (or pencil) is located in the raw water cooling APPLY SEALANT
circuit within the heat exchanger. The purpose of the zinc GASKETS WHEN
anode is to sacrifice itself to electrolysis action taking place · /NSTALUNG
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
THERMOSTAT
should be <;arried on board.

ZINC····~ I NEW
l 1
REPLACE CLEAN & REUSE
I"!!"_~~WEBTERBEKE
Engines & Generators

15
 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
NOTE: Always install the strainer at or below the waterline so up in the strainer, slowing the flow of raw water through the
the strainer will always be self-priming. cooling system.
A 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 the following maintenance after every 100 hours of INCOMING
operation: RAW WATER
1. Close the raw water seacock.
2. Remove and clean the strainer filter.
3. Clean the glass.
4. Replace the washer if necessary. INSPECT AND
5. Reassemble and install the strainer. CLEAN EVERY
tOO HOURS
6. Open the seacock.
7. Run the engine and check for leaks. +
NOTE: The external thru-hull opening slwuld be of the flush
type with a clear opening. No perforated or slot type external
NOTE: Also follow the above procedure after having run hard
opening. Let all the filtering be accomplished on the inside of
aground.
the hull where there is easy access to t~e st~ainer.

RAW WATER PUMP Changing the Raw Water Pump Impeller

The raw water pump is a self-priming, rotary pump with a
non-ferrous housing and a Neoprene impeller. The impeller
has flexible blades which wipe against a curved cam plate
within the impeller housing, producing the pumping action.
Never allow the pump to run dry. There should always be
a spare impeller and impeller cover gasket aboard (an
impeller kit). Raw water pump impeller failures occur when
raw water is not present during engine operation. 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
tom impeller blades. See MAINTENANCE SCHEDULE.
NOTE: Should a failure occur with the pumps internal parts
(seals and bearings), it may be more cost efficient to
purchase a new pump and rebuild the original pump as
a spare.
NOTE: Never allow the. pump to run dry. Even a short period
of d1y n.mning may destroy the impeller.
Close the raw water intake valve. Remove the pump cover
and, using an impeller puller, screw drivers, or pliers,
carefully pry the impeller out of the pump. Install the new
impeller and gasket. Move the blades to conform to the
curved cam plate apd push the impeller into the pumps hous-
ing. When assembling, apply a thin coating of lubricant to
the impeller and gasket. Open the raw water intake valve.
NOTE: Should a failure occur with the pumps intemal parts
(seals and bearings), it may be more cost efficient to
purchase a new pump and rebuild the original pump as
a spare.
NOTE: If any of the vanes have broken off the impeller they
must be found to prevent blockage in the cooling circuit.
They often can be found in the heat exchanger.

IMPELLER RAW WATER THE SCREW MUST

INSPECTION: CHECK AT THE BASE Of PUMP LINE UP WITH THE
EACH BLADE BY BENDING VIGOROUSLY. PN 042026 SLOT IN THE SHAFT
REPLACE THE IMPELLER IF THERE
ARE ANY CRACKS.
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).

WHEN ASSEMBliNG: APPLY A THIN COAT OF

GLYCERIN TO THE INSIDE OF THE COVER, THE
COVER 0-R/NG, AND THE IMPELLER ~ WESTERBEKE
Engines & Generators
·16
 ENGINE LUBRICATING OIL
APPLY A THIN COAT OF CLEAN OIL TO THE
ENGINE OIL FILTER GASKET WHEN INSTALLING. AFTER THE
Use a good brand of engine oil with an API and SAE FILTER CONTACTS THE BASE TIGHTEN FIRMLY BY HAND
designations as listed in the SPECIFICATION Section of
this manuaL OIL FILTER ASSEMBLY
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 OIL PRESSURE
intervals must be as listed in the MAINTENANCE SENDER
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.
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
CHANGING THE ENGINE OIL to drain the oil into a container before removing it. This helps
The engine oil should be warm. Remove the oil drain hose to lessen spillage. An automotive filter wrench should be
from its attachment bracket and lower it into a container and helpful in removing the old oil filter. Place some paper towels
allow the oil to drain, or attach a pump to the end of the drain and a plastic bag around the filter when unscrewing it to catch
hose and pump the old oil out. Make sure the oil drain hose any oil that's in the filter. Inspect the old oil filter as it is
is properly secured in its holder after all of the old oil has removed to make sure that the rubber sealing gasket comes
been drained. off with the old oil filter. If this rubber sealing gasket remains
sealed against the oil filter adapter, gently remove it. When
Always observe the old oil as it is removed. A yellow/gray
installing the new oil filter element, wipe the filter gasket's
emulsion indicates the presence of water in the oil. Although
sealing surface on the oil filter adapter free of oil and apply a
this condition is rare, it does require prompt attention to
thin coat of clean engine oil to the rubber sealing gasket on
prevent serious damage. Call a competent mechanic if water
the oil filter. Screw the filter onto the threaded oil filter stub,
is present in the oil. Raw water present in the oil can
and tighten the filter firmly by hand.
be the result of a fault in the exhaust system attached to the
engine and/or a siphoning through the raw water cooling NOTE: Use genuine WESTERBEKE oil filters. Generic filters
circuit into the exhaust, filling into the engine. are not recommended.

~ REMOV£ USING AN SMM (11116") SOCKET REFILLING THE OIL SUMP

"&/ff;. TO DRAIN THE OIL OR PUMP .THE WARMED
. OIL UP THRU THE HOSf.
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.

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.

Engines & Generators

17
 ENGINE ADJUSTMENTS
SPARK PLUGS AIR SCREEN/FLAME ARRESTER
The spark plugs should be cleaned and re-gapped after the 1ne air screen/ flame arrester should be clearred 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.

A WARNING: Do not remove the spark plugs while

the engine is hot. Allow the engine to cool before
INSPECT THE SEALING EDGES,
removing them. IF WORN..... /NSTALLANEW
AIR SCREEN.
SPARK PLUG GAP: 0.028-0.031 in (0.7-0.08 mm)
SPARK PLUG TORQUE: 11-151b-H (1.5-2.31 kg-m)

NOTE: Loctite Anti-Seize applied to the threaded portion of

the spark plugs will retard corrosion, making future removal
of the spark plugs easier.

GAP

INSPECT FOR
WEAR & CARBON
INSPECT FOR
DAMAGE 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: It 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 mnning.
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
for leaks. Inspect the wire connections at the oil gallery
(pressure sender).

A WARNING: If the oil pressure light illuminates

but the engine does not shut down, this is a low oil
pressure warning.

18
 .BATTERY CHARGING CIRCUIT
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: The battery charging circuit is totally separate from
the AC output of the generator. The generator output affects
the circuits output, but not the reverse.
A 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
wiring harness behind the fuel filter.
NOTE: When the generator is first started, the charger will
produce a low charging rate. This charging rate will rise as
the generator is operated.
Engines & Generators
19
BATTERY.
The minimum recommended capacity of the battery used in .
the en'gine's 12 volt DC control circuit is 800-1000 CCA. This
MUST be a dedicated battecy.
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.
• Check the electrolyte level and specific gravity with a
hydrometer. ·
• 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).
• ·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 tum off the DC battery switch to the generator).
A 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.
 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.

Problem Possible cause

Engine does not crank. 1.DG panel breaker OFF.
2.DC battery OFF.
3.K2 relay faulty.
4.Starter solenoid faulty.
5.DG battery low/dead.
6.Water filled cylinder.
7.DC panel 8 amp buss fuse is faulty.
Engine cranks, does not start 1.Fuel starvation.
·•
(engine will crank 8 seconds) 2.Air in fuel system.
(3 crank cycles before underspeed fault occurs) 3.Fouled spark plugs.
4Jaulty ignition coil.
Engine starts, runs and the shuts down. 1.Fuel starvation.
2.Air in fuel system.
3.Faulty shutdown switch/sensor.
4.Faulty fuel pump.

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 screen.
3.Hign 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.Goolant 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. 1.0illevel low.
2.Faulty oil pressure sendor.
3.0il viscosity incorrect.

20
 ENGINE TROUBLESHOOTING
Problem Possible Cause
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 charger 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.
2.1ncorrect ignition timing.
3.Fuel supply issue.
4.High engine compartment temperature.
Black exhaust smoke. 1.Dirty air screen.
2.Faulty injector.
Blue exhaust smoke. t.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.Faulty speed sensor.
2.1ntake manifold vacuum leak.
Pair of Speed LED's are illuminated-flashing. 1.AC generator overload.
2.Fuet starvation.
External alarm LED is illuminated. t.Loose connection.
2.Faulty fire suppression shutdown devise.

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.

21
 SOFTWARE DIAGNOSTICS
PC INTERFACE SOFTWARE
Diagnostic Software Kit #05541 0 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).
CABLE AND DIAGNOSTIC SOFTWARE KIT
PART 1055410 (USB to ECU) SEE BELOW.
Your areas distributor can be found on our website:
www.westerbeke.com
The Diagnostic Software (EC 11) is designed to aide the
technician in monitoring the engine's operation and the
ECU (Electronic Control Unit) functions.
Once downloaded, this software provides IDLE Mode
diagnostics, FAILURE Record and Run Time Data Logging
to EXCEL.
The Diagnostic Software will run on Windows 98, XP,
Vista and Windows 7. These MUST have a minimum of 128
megi\bytes of RAM (Random Access Memory). The
communications cable plugs into a USB port. When using
serial to USB adapters, the communication port that the
adapter is using MUST be known in order to configure the
Diagnostic Software.
The Westerbeke communication cable is unique to this
Diagnostic Software and MUST be used or otherwise
damage to the ECU will occur if any communications cable
is substituted. The Diagnostic Software is designed with
multiple screens, tabs and pull down menues to aid the user
in the diagnostic process.
The Diagnostic Software is for monitoring the operation of ·
the engine/generator and is also used to change the ECU
target frequency between 50Hz and 60Hz.
Refer to WESTERBEKE'S MCG Service Manual for the
Software Diagnostic Monitoring and Troubleshooting Data.

CONTROL BOX INTERNAL COMPONENTS

TYPICAL ASSEMBLY
THE COMMUNICATIONS CABLE IS AVAILABLE
FOR· DIAGNOSTIC MONITORING OF THE ENGINES
OPERATION USING PC SOFTWARE. ~.

FOR WIRING CONNECTIONS

TO THESE COMPONENTS
REFER TO THE WIRING
DIAGRAMS IN THIS MANUAL

Engines & Generators

22
 GENERATOR INFORMATION
USE OF ELECTRIC MOTORS LOAD TEST
The power required to start an electric motor is considerably Run the generator first with no load applied, then at half the
more than is required to keep it running after it is started. generator's capacity, and finally loaded to its full capacity
Some motors require much more current to start them than as indicted on the generator's data plate. The output voltage
others. Split-phase (AC) motors require more current to start, should be checked periodically to ensure proper operation
under similar circumstances, than other types. They are of the generating plant and the appliances it supplies. To
commonly used on easy-starting loads, such as washing monitor voltagr and load, check it with a portable meter and
machines, or where loads are applied after the motor is amp probe.
started, such as small power tools. Because they require 5
to 7 times as much current to start as to run, their use Generator Maintenance
hould be avoided, whenever possible, if the electric motor is Maintaining reasonable cleanliness is important. Connections
to be driven by a small generator. Capacitor and repulsion- of terminal boards and rectifiers may become corroded, and
induction motors require from 2 to 4 times as much current insulation surfaces may start conducting if salts, dust, engine
to start as to run. The current required to start any motor exhaust, carbon, etc. are allowed to build up. Clogged
varies with the load connected to it. An electric motor ventilation openings may cause excessive heating and
connected to an air compressor, for example, will require reduced life of windings.
more current than a motor to which no load is connected. In addition to periodic cleaning, the generator should be
In general, the current required to start 115-Volt motors connected inspected for tightness of all connections, evidence of
to medium starting loads will be approximately as follows: overheated terminals and loose or damaged wires.
MOTOR SIZE AMPS FOR AMPS FOR
(HP) RUNNING STARTING
r---------------(AMPERE~)____ (AM~~R_lli__ __
1/6 3.2 6.4 to 22.4 *
1/4 4.6 9.2 to 32.2*
r------------
1/3 5.2 10.4 to 72.8 *
1/2 7.2 14.4 to 29.2*
r-------------------------------------
3/4 10.2 20.4 to 40.8 *
1 13 26 to 52

*NOTE: In 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, tum 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.

23
 BC GENERATOR SINGLE PHASE
DESCRIPTION AC TERMINAL CONNECTIONS
The BC generator is a brushless, self-excited generator which
requires only the driving force of the engine to produce an 1 4 2 5
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
CIRCUJr
larger current in the exciter windings. This mutual build up BREAKER
of current in the four rotating poles and in the exciter
ISOLATED
windings quickly reaches the saturation point of the POST
capacitor(s) and a regulated energy field is then maintained (NEUTRAL) 120V/60Hz
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
l1 - N
equipment. The generator is a single-phase, reconnectable 1 6
120 volt AC two-wire at 60 hertz or 115 volt AC two-wire or 4 3
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, cunent
and frequency rating of the generator. An AC wiring decal is CIRCUIT
BREAKER
affixed to the inside of the louvered cover at the generator
ISOLATED
end. A diagram of the various AC voltage connections is
POST
provided on the decal. An Integral Controller (IC) is mounted
inside the generator and supplies a continuous DC charge to
230V/50Hz
the generators starting battery when the generator is running.
N L1
Circuit Breaker ( AC )
A circuit breaker is installed on all single phase NOTE: Correctly position the case ground wire (white/green)
WESTERBEKE generators. This circuit breaker will auto- onto the neutral/ground terminal.
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.

BATTERY CHARGING CIRCUIT
AMP FUSE
Located In the wiring
harness, refer to the
wiring diagram in
this manual.

STATOR WINDING

GENERATOR WINDINGS
-----()4 -sCHEMATIC
STATOR WINDING
-----()5
"------ea

~fir!
'~JT lt~r
EXCITER WINDING

CAPACITOR 'CAPACITOR

24
 SHORE POWER TRANSFER SWITCH

SINGLE LINE 120 VOLT SYSTEM

Generator

~
Notice the repositioning of the white wire ground load on the
terminal block to the generator case.

(®
/ -----®\
.~~'
GENERATOR
~ I.
~
:r:
~ m·
§' I (ID
\ ...... __ @I
..,.. I N L1
(il;'-
~i
z
CC;
m,• ~~
z:

SHIP'S
LOAD

/,.....-,,
'---(N-EU-T-RA-l-1)1'-{5 ~1
.----_c._'<-{7 @I
' ..... _,... /

- SHIP'S
- GROUND
If the installer connects shore power to the vessel's AC -:- SHORE
GROUND
circuit, this must be done by means of the Shore Power ~
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. Switching Shore Power to Generator Power

Generator NOTE: This diagram shows connections for a A CAUTION: Heavr motor leads should be shut off
before switching shore power to generator power or
~ two wire, 120V system from the generator with
a three wire -120V boat system. vice-versa because voltage surges induced by switching
120 VOLT/60HZ THREE with heavy AC loads 011 the vessel being operated may
cause damage to the exciter circuit components in the
WIRE CONFIGURATION
generator.

-
z
..
"!
:s
41
a:
~ A CAUTION: Damage to tl1e generator can result If
utility shore power and generator output are connected
z
at tile same time. This type of generatur damage Is not
-
l(
..J
Ill
covered under the warranty; it is the installer's
responsibility to make sure all AC connections are
L2
/---..., L1
correct.
'---+-+----\f<,~OO
1
: ~=~~~.!...-.N SHIPS LOAD
'! __ / (no 240V equipment)
:i Ground It•
:I (GRN.
Notice the repositioning of the wlnte wire ground load on the
~ terminal block to the generator case.

Shore Power

Engines & Generators

25
 OPT IOMAl
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lRI.ft/IGNTIONl >
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0

~ (CU.J2·1 GRY·I6GA ==
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c.n
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WB02·3 REDIYI0·16GA 0 w
ECU.J2·19 GRN-18GA~ O'l

IGNITION SYSTEM COMPONENTS

 RED-t8GA
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: o~
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(DC.P1l

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-- 12 ' ECU.Jl-31 WHTIBLK/BLU-20GA
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r- --< LEO OUT - COOLANT TEMP r-'

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£CU.J2·30 WHTIBLK/ORG-20GA
0 "" LEO OUT - EXH TEMP FAIL r-
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2 WHT/6LK/ORG-20JA ECU.JZ-29 WHT/6LKIGRY-20GA
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:::=:::: • ECU.J2-28 WHTIBLK/YEL-20GA
r-
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~
WHT/BLK/GRY-20GA START SWITCH OUTPUT
Ill !-
-f ECU.JI-1 PNK·IBGA
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> LEO OUT • RUN INDICATOR ::::_:::::
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J->J ID
ECU.J2·21 WHT/BLK/RED-18GA
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cl ECU, REM SWITCH & RELAY COIL POWER
WHT IBLK/YEL -20GA
s Kl-86 GRY·I6GA

<<
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RELAY lOAD POWER SUPPLY
BATTERY > INPUT
---
..::::~:::
Kl-30 REO/WHT-14GA

::::::,
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RUN RELAY INPUT
K2 ·81 RED IV 10- 18GA

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7

•
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-:~·OIL PRESSURE LED
--:--E- 1 COOLA NT TEMP lED

~ 6 EXHAU ST TEMP LED

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5 /ovERI UNDER SPEED LED
"' ' • ~·STOP INPUT !FROM SWITCH!
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==
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+12V SUPPLY CJl
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I BLK-18GA
PANEL EOX w
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R(D/WHT- toGA
I !P8.STUD EXT>

\~ ~··r
6ATLGND tSTRI BLK-18GA

,c:S d:,2
I OH ONI
. ----..__;
4= =3
"'"'"' CIRCUIT
BREAKER
I15Al HOUR METER
FIRE ALARM

-ci=
REMOVE JUMPER fOR
FIRE SUPPRESSION
SYSTEM CONNECTION
ECU.JI-2 WHTIGRY·I8GA
DC CONTROL PANEL BOX COMPONENTS
OP.SENOER-S(NS.GNO WHT/6LK·IaGA
(SEE NOTE ll 0

NOTES:
I. FIRE SUPPRESSION SYSTEM CONNECTION IS NOT A POWER SOURCE. THIS
CIRCUIT MUST BE CLOSED TO RUN. AN OPEN CIRCUIT WILL STOP THE
GENSET.
 ~--JU__N~C~~~~-----------------------------------------=~~~~
WHT/SLKIGRN-16GA ECU-J2-II

K2-C87l RED/VI0-16GA
WHT/6LK/8RN-16GA ECU.J2·23

WHTISLK/BLU·I&GA ECU.J2-22
FUEL INJECTOR •3 FUEL INJECTOR •2 FUEL INJECTOR •1
{INJ.3) f1NJ.2l INJJ

OIL
PRESSURE
VIO/WHT·I&GA
SWITCH
r-- (OP .SWITCH)

VI 0/WHT- I GGA

BATUMD
BLK-16GA
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CJ1
FUEL SYSTEM COMPONENTS CJ1
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BLK/WHT-IZGA I f
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AC GENERATOR

WHT/RED-12GA
0
LEAD WIRE fROM 30A FUSE LEAD WIRE FROM
FUSE HOLDER FUSE HOLDER
REO/WHT-12GA BATTdSTRl

There is a small DC amperage drain from the starting

BATTERY CHARGER BATTERY CHARGING CIRCUIT 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).
 WHTIBLK·18GA r IRLALARM·GNO
WHT/BLK·ZOGA MAP·!
WHT/8LK·20GA AIR.TEMP·Z
WHT/6l~-20GA ECT-2

:~i:m: :~~ E~~u:~~~ii ~SEN$_GN[)

WIITIGRN·20GA£CU.JI·I.!~~ COClUNT
ENOl'£ WHTIBLK • 20GA
WHl/8LK·20GA"
CAM· 3
CRANK·3

WH1/6V·ZOGA OP.SENDER·SENS.GNDt~ TBI" SENSOR WHTIBRN·ZOGA €CU.J1·6 --c:l

tEC1l OL PRESSlR:
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IS1EPPERI WHT/BLK-20GA OP.SENDER·SENS.GND~€ •1 1

WHT/ORG·ZOGA
• ..AJiiC f • £CU J 1 • 9 REO IV 10· IBGA
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WHT 16LK·ZDGA
WHT/VI0-18GA ECU Jl·l~ , ~,,lij@lPu,,w

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WHT /8LK·20GA OP.S[NDER·S£NS.GNI> ~..,;::::<E:::-__.,3 1-r---'r
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~(II INTAkE AIR
TBotP SENSOR
O'fl~C
~ .... WHT IBLK·ZOGA fAR.TEMPI
ENGINE BLOCK COMPONENTS
~
c.n
COMPONENTS LOCATED ON THE INTAKE THROTTLE BODY c.n
CJ1
(J.)
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GRNIYEL·ZOGA ECU Jl-14~

==e
EXHAUST WHT/8LKIV10-ZOGA [CU Jl·l5
WHT IGRY·t&GA ECU.JI·IG
WHTIBLK·I8GA OP.S(NO[R.SENS.GMO
TEI\F
SWITCH
IEX.TEMPJ
0 REDIVI0-16GA 0-1~71 WIDE BAND
OXYGEN SENSOR
TAN·IGGA ECU JZ-10 E--"'1------r '---j1~J.JJ'- 1WB02J
BL K /WHT- 18GA ECU J I - 2 2 E--'f------'
WHTIBLKIORG·20GA ECU Jl-8 E--''t----J

EXHAUST SYSTEM COMPONENTS

 :WIRING DIAGRAM #55536

ECU_J2
,....12 ,....35
BLU·18GA STEPPER-I -v 23v STEPPER-2 BRN-18GA
0 INJECTOR_2 WHT/BLK/BRN- 16GA
WHT /BLK/GRN· 16GA I NJECTOR_I -o (). 0 STEPPER-4 WHT-18GA
..... INJECTOR.3 WHT /BlK/BLU· 16GA
TAN·ISGA WB02-4 ~
..... 0 STEPPER-3 YEL-18GA
~
DC.PI-6 WHT/8LK/RED-18G A
0 ,....
"" K2·85 WHT/RED-18GA
0 .......
ORG·IBGA RELAY K1-85 "" ,....
0
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oc_p 1- 12
DC .PI- I I
WHT/BLK/6LU·20GA
WHT/BLK/ORG-20GA
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0 DC.P I ·I 0 WHT/BLK/GRY·20GA
0
0 ""
~ DC.P 1·9 WHT/BLK/YEL·20GA
0
0 0
0
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BLK-16GA BATT.GND ..... 0 0
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GRY-16GA K3-86
'"', 130
24::;

ECU ,.-----..,.
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8 23
WHT/BLK/ORG-20GA WB02·6 ,.... ,....150
...... ,..... WB02·2 WHT/BLK/VI0·20G A
WHT/BLK/RED-ISGA MAP-3 ,.... WB02·5 BLK/WHT-ISGA
,... WB02· I GRN/YEL-20GA
WHT/BRN·20GA OP.SENDER-1 ,..., 0 OP.SENDER-SENS.GND WHT/BLK-ISGA
,.... ECT· I WHT/GRN-20GA
WHT/ORG-20GA MAP·4 ..., 0
0
0 ..... 0
,... ..., AIR. TEMP· I WHT/BLU-20GA
WHT/VIO·ISGA CAM-2 ~
,... 0
CRANK-2 WHT/YEL-20GA
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-
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WHT/GRY-IBGA FIRE.ALARM-2 ..., ,.. "' DC. PI- 8 WHT/BLK/GRN-ISGA

PNK-ISGA DC.PI-7 ... ~

$ :::-
JUNC- 2 RED/VIO-IBGA
EX.TEMP.I WHT/GRY-18GA
I
16

ECU CONNECTIONS

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 tum 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 auxilliarjr
component. Re-set the DC power breaker on the control
panel.

ADAPTER PN. 052274

REMOTE PANELS WIRING

.REMOTE
CONNECTOR
r--~
POWER
z LEDOUT ·RUN INDI<;ATOR
3 START SWITCH OUTPUT
4 STOP SWITCH OUTPUT WHT /BLK fGRN • t8GA
5 LED OUT · OVERSPEEO
6 LED OUT • EXH TEMP FA.IL
1' LED OUT • COOLANT TEMP
8 ltD OUT • LOW OIL PRESS
STOP/START PANEL
WITH FAULT DISPLAY
PN. 054928
PNK·I8GA
WHTIBLK/YEL-20GA
WHT/BLK/GRY·20GA EXTENSION HARNESS
WHT /BLK IORG • 20GA 15' PN. 054931
.WBT IBLK tBL U• 20GA 30' PN. 054932

REMOTE
CONNECTOR
r--i STOP/START PANEL
,_..:.::::... POWER REO·ISGA ROCKER SWITCH ONLY
:~~~ ...~~~R~U-N~IN_D_I_CA_T_O_R~--~~----------~W~H~T-/B~L~K~/-RE_D_·_I_S_GA--------------------~ PN.055345
tl .-
:r~:·~~3rt-S~T~A~RT~S~W~I~TC~H~·~O~U~TP~U~T~--------~
:r-:::__ STOP SWITCH OUTPUT

.
1

,r.::::-=-- s
,... -
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. PNK -·1 SGA
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., ... =--- 7

18-: ::> >;:.-- 8

L--1 WHT IBLK I GRN ··I 8GA

Engines & Generators

31
 MCG GENERATOR SPECIFICATIONS
ENGINE SPECIFICATIONS COOLING SYSTEM
Engine Type 3-cylinder, 4-cycle, , overhead camshaft General Fresh water-cooled block through raw
w/counterbalance shaft, water cooled water-cooled heat exchanger circuit
gasoline engine
Fresh Water Pump Centrifugal type, metal impeller, belt-driven.
Bore & Stroke 2.56 x 2.61 inches (65.0 x 66.3 rnm)
Raw Water Pump Positive displacement, rubber impeller,
Total Displacement 40.3 cubic inches (0.66 liters) belt-driven.
Bearings Four main bearings Raw Water Flow, 4.9 US gpm (18.51iters)@ 1800 rpm
(approx. measure before discharging into
Compression Chamber Semi-spherical exhaust elbow).
Compression Ratio 9.8:1 Cooling Water Capacity 3.5 qts (3.3 liters).
Hp@1800/1500 rpm 10.0 Operating Temperature 170° - 190° F (77° - 88° C)
Firing Order 1 - 3- 2
Aspiration Naturally aspirated
1rr' , ' , 'l-UBRICATION SYSTEM
General Forced lubrication by gear pump.
Direction of Rotation Counterclockwise viewed from the back end
25° continuous, all directions Oil Filter Full flow, paper element spin-on disposals.
Inclination
Oil Capacity 3.0 qts. (2.8 liters).
Dry weight Refer to the sales brochure
Operating Oil Pressure 30-45 psi (2.1 -3.1 kg/em'),
Governor Electronic
Oil Grade API Service Catagory SJ, SL, SM or SN
FUEL SYSTEM . SAE 40. ONLY (No Multi-Weight Oils).

General Multi-port fuel injection

AC GENERATOR (Single Phase)
Fuel Unleaded gasoline with an octane rating of 89
Single Phase Brush less, four-pole capacitor, regulated.
or higher
1800 rpm/60Hz, 1500 rpm/50Hz
Fuel Consumption 5.0 MCG (,74 gph) Ratings:
(full load) approx. 4.2 MCD (,63 gph) 4.2KW 230 volts, 18.2 amps, 50Hz
single phase. 4 wire, 1.0 power factor
6.5 MCG (.76 gph)
5.2 MCG (.71 gph) 5.0KW 120 volts, 41 .6 amps, 60Hz
single phase, 4 wire, 1.0 power factor
Fuel Hose Size 1/4" LD. minimum- 3/8" LD. maximum
(supply and return) 5.2KW 230 volts, 22.6 amps, 50Hz
single phase, 4 wire, 1.0 power factor
Fuel Pump 12 volt electric (high/low pressure)
6.5KW 120 volts, 54 amps, 60Hz
Fuel Filter (on engine) Replaceable cartridge-canister type single phase, 4 wire, 1.0 power factor
Air Cleaner Metal screen type - cleanable
(flame arrester) IGNITION SYSTEM
General Battery ignition 12 volts negative ground.
ELECTRICAL SYSTEM Distributor with ignition module and ignitor.
Ignition coil and spark plugs.
Start Battery 12-Volt, (-) negative ground
Battery must be totally dedicated to the Distributor Solid state type with signal generator and
generator and maintained only by the DC ignitor.
charge controller system in the AC generator
Spark Plug Thread Gap 11mm x 1.25 pitch
Battery Capacity 800 - 1000 Cold Cranking Amps rated (CCA)
(minimum) Spark Plug Gap 0.028- 0.031 inches (0.7- 0.8mm)
Starter 120 Volt, reduction-solenoid mounted Ignition Timing 15°BTDC at1800RPM ± 1o
(Vacuum advance hose disconnected)
DC Charging Solid state controller, 12 Amp rated
Spark Plugs 14mm
DC Cold Cranking Amps 150 - 176 Amps
Ignition Coif 12 volt
AIR REQUIREMENTS Distributor Breakerless with ignitor and pick up
assembly
Generator Cooling 225 -2 50 CFM (6.3- 7.0 cmm)
Engine Combustion 21 CFM (0.6 cmm)
(all models)
Engine Cooling 100 CFM (2.8 cmm)
Note: Forced ventilation should be provided to maintain oenerators
compartment temperature below 122°F (50°C),

Engines & Generators

32
 LAY·UP & 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.
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: At 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 ~ 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"!(, IE10l is not allowed
and may void warranty.
33
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 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.
BAnERIES
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 batteries 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.
 LAY·UP & RECOMMISSIONING
Spare Parts
Lay-up time provides a good opportunity to inspect your 3. Reinstall the batteries that were removed during the
Westerbeke engine to see if external items such as drive l;>elts lay-up, and reconnect the battery cables, making sure the
or coolant hoses need replacement. Check your basic spares terminals are clean and that the connections are tight.
kit and order items not on hand, or replace those items used Check to make sure that the batteries are fully charged.
during the lay-up, such as filters and zinc anodes. Refer to the 4. Remove the spark plugs, wipe clean, re-gap, and install to
SPARE PARTS section of this manual. proper tightness [gasoline].
Recommissioning 5. ; Start the engine in accordance with procedures described
The recommissioning of your Westerbeke engine after a in the PREPARATIONS FOR STARTING section of this
seasonal lay-up generally follows the same procedures as manual.
those described in the PREPARATIONS FOR STARTING
section regarding preparation for starting and normai 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 ~mpeller
removed during lay-up (or a replacement, if required).
Install the raw water pump cover with a new cover gasket.

REMOTE OIL FILTER (0

II
APPLY A THIN COAT OF CLEAN OIL TO THE O·RING WHEN PN: 040078 FASTEN SECURELY TO A BULKHEAD
INSTALLING THIS KIT. THREAD THE KIT ON, THEN HAND (SCREWS ARE OWNER SUPPLIED)
TIGHTEN AN ADDITIONAL3/4 AFTER THE O·RING
CONTACTS THE BASE. . -

THE "OUT" CONNECTION HOSE

MUST ATTACH TO THE "IN"
CONNECTION AT THE
REMOTE OIL FILTER.
NOTE; The "l!J" and "QUit" m1ar/r!lngs"
on the kit (if the hoses are .
y . . . . . · - · ••••

for lnstaHation) so they can be

teconnected 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
in.Structions on removing the oil filter.
To install, simply remove the engine oil ftlter 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.
APPLY A THIN COAT OF CLEAN OIL TO THE
FILTER GASKET WHEN INSTALLING. AFTER THE
FILTER CONTACTS THE BASE.
tighten It nrmty by hand ..
A CAUTION: It is vital to install the oil lines
co«ectly. 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.

34
 TIGHTENING TORQUE SPECIFICATIONS

Timing Belt Nm H.lbs. Front Case, Counterbalance Shaft Nm ft. lbs.

~lyWheet bolt 135-145 98-105. Front case bolts 8-10 6-7
Timing belt cover bolts 10-12 7~9 Oil pump cover bolts 8-10 6-7
Camshaft sprocket bolts 80-100 58·72 Oil pan bolts 10·12 7-9
Oil pump sprocket nuts 50-57 36·41 Oil drain plug 35-45 25-33
Trming tensloner nuts 22c30 16-22 Oil screen bolts 15-22 11-16
Timing belt rear cover bolts 10-12 7-9 Oil pump drtven gear bolt 34-40 25-29
Rocker .Arms and Rocker Shaft Rear cover bolts 10-12 7-9
Rocker cover shaft 29-35 21-25 Piston and Connecting Rod
Camshaft tnrust plate bolt 10-12 7·9 Connecting rod cap nut .15 + go• turn 11 +go• turn
Rocker arm adjust nut 8-10 6-7 Crankshaft, Bearing·
Cylinder Head, Valve Oil seal case bolts 10-12 7-9
Cylinder head bolt (cold engine} 60-70 43-51 Bearing cap bolts 50-55 36-40
Spark plug, 15.2 11-15/b-ft Cylinder Block
~ocket cover 12-13 9-10 Taper plug 1/16 NPT. 8-12 6·9
Miscellaneous Taper plug 1/8 NPT 15-22 11-16
Coolant temperature sender 12-18 9-13 Water drain plug 35·45 25-33
Coolant temperature switch 12-18 9-13 Taper plug 1/4 NPT 35-45 25-33
Generator mounts 34-47 23-34 Oil pressure switch 12-18 9-13
Exhaust manifold 16-23 12·17 Oil pressure sender 12·18 9-13
Thenmostat housing 8-11 6-8 Wafer Pump
Front ' Crankshaft bolt 135-145 98-105 Water pump 8-10 6-7.

35
 SUGGESTED SPARE PARTS
.WESTERBEKE MARINE GASOLINE GENERATORS
. ~ . CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION
· PRESSIBIE CAP · .· ENGUIE ~~~ Ai!.

RAW
GASKET AND IMPELLERS

ZINC ANODES

HARDWARE KIT

30AFUSE

PARTS KITS
WES1ERBEKE also offers two Spare Parts Kits,
each packaged in a T4gged, rust free toolbox. · Kit 8
KIT A includes the basic spares.
Impeller Kit
KIT B is for more extensive off-shore cruising.
Water Pump Repair Kit
Kit A Thermostat Kit
Impeller Kit Zinc Anodes
Heat Exchanger Gasket Complete Gasket Kit
Oil Filter Heat Exchanger Gasket
Drive Belt Fuel Filter with Gasket
Zinc Anodes Oil Filter
Spark Plugs Drive Belt
Fuel Filters Spark Plugs
Fuel Filters

Engines & Generators

36 '
 ··~~~R•DrU'II!!!' GASOLINE
riWI/ii,.-;,. 1/ii,J ~1/ii, GENERATOR
~,.;-- WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK
.§J!J,f;J 150 JOHN HANCOCK ROAD • TAUNTON MA 02780..7319 • TEL. (508)823·7677
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1221-2/2016