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Summary of Contents for Westerbeke 7.5 MCGA
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Page 1: Operators Manual
M U LT I - P O RT S I N G L E – P H A S E MARINE GASOLINE GENERATORS OPERATORS MANUAL 7.5 MCGA or 5.0 MCGA 60 Hz 6.2 MCGA or 4.2 MCGA 50 Hz PART NUMBER 056556... - Page 2 In no event shall Westerbeke, publishers, authors, or editors of this guide be liable for any loss of profit or any other commercial damage caused or alleged to have b een caused directly or indirectly by this document.
- Page 3 MTBE is no longer a primary concern since it is no longer available.) sludge, or gums entering or forming in the engine or fuel system is not covered by the Westerbeke Corporation limited warranty. Ethanol is a solvent and tends to clean any dirt or contaminants on contact.
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Page 4: Table Of Contents
Operators Manual for Gasoline Generators 1 Important Safety Information C O N T E N T S 1 Important Safety Information 2 Introduction Quick Start Operators Guide ........................4 Documentation ............................4 Parts Diagram ............................5 Warranty Procedures ..........................6 Conventions Used in this Manual ...................... - Page 5 Operators Manual for Gasoline Generators 1 Important Safety Information 8 Lay-Up and Recommissioning Lay-Up Prep: Lubrication System ......................39 Lay-Up Prep: Intake Manifold ......................... 39 Lay-Up Prep: Cylinder Lubrication ......................39 Lay-Up Prep: Fuel System........................39 Lay-Up Prep: Starter Motor ........................39 Lay-Up Prep: Raw Water Cooling Circuit ....................
- Page 6 Operators Manual for Gasoline Generators L I S T O F F I G U R E S Figure 1: Parts Diagram ............................5 Figure 2: Customer Identification Card ......................... 6 Figure 3: Product Serial Number, Model Number, and Other Specifications ............6 Figure 4: Spare Parts Kit............................
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Page 7: Important Safety Information
Operator Manual for Gasoline Generators All fuel vapors are highly explosive. Use extreme care when handling and storing fuels. Store fuel in a well-ventilated area away from spark- Important Safety Information producing equipment and out of the reach of children. ... - Page 8 CO poisoning is one of the major safety risks associated with of exhaust gas with an appropriate CO analyzer. boating. It is a threat that must not be underestimated. Westerbeke Low- There are two locations where exhaust gas can be sampled: CO generators are designed to dramatically reduce normal levels of CO in the engine exhaust.
- Page 9 Scientific, GFG, TPI, Teledyne, and others. Engine Emission The engine emission control system Westerbeke recommends analyzers with a probe connected to the Control System consists of engine design and precision analyzer by a length of transparent tubing. They are slightly more manufacturing.
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Page 10: Introduction
Operator Manual for Gasoline Generators 2 Introduction This Westerbeke generator is a product of our many years of experience and advanced technology. We take great pride in the superior durability and dependable performance of our engines and generators. Thank you for selecting Westerbeke. -
Page 11: Parts Diagram
Operator Manual for Gasoline Generators 2 Introduction 2.3 Parts Diagram Figure 1: Parts Diagram page... -
Page 12: Warranty Procedures
Operator Manual for Gasoline Generators 2.4 Warranty Procedures Your Westerbeke Warranty Statement is included in the product documentation package. Complete and return the included warranty registration card or register your product online at www.westerbeke.com. You should receive your customer warranty identification card in the mail within 30 days of registering. If you do not, contact the factory and have your product model number, serial number, and in-service date available. -
Page 13: Conventions Used In This Manual
Westerbeke frequently updates our manuals and software. For the latest information, consult your Westerbeke representative or visit www.westerbeke.com. The 5.0 or 7.5 MCGA Service Manual is available as a PDF download from www.westerbeke.com. This Service Manual can also be purchased in hard copy from your Westerbeke dealer. -
Page 14: Amperage Drain
Include a complete part description and part number for each part needed (see the separately furnished Parts Catalog). Insist upon Westerbeke genuine parts because will fit or generic parts are frequently not made to the same specifications as original equipment. -
Page 15: Figure 5: Suggested Spare Parts
Operator Manual for Gasoline Generators 2 Introduction For your convenience, we offer two spare part kits, each packaged in a water-tight storage case: Kit A includes the basic set of the most essential recommended spare parts. ■ Kit B includes everything in Kit A, plus additional spare parts for more extensive off-shore cruising. ■... -
Page 16: Installation
If you have any doubt about the position of the water-injected exhaust elbow relative to the vessel waterline under the various operating conditions for your vessel, install a siphon-break, available from Westerbeke or your local authorized Westerbeke dealer. -
Page 17: Exhaust System Requirements
When installing this kit, apply a thin coat of clean oil to the O-ring and the filter gasket where the filter contacts the base. Tighten firmly by hand. Thread on the optional Westerbeke remote oil filter kit. Always install this kit with the oil filter facing down. Hand-tighten an additional three-quarters (¾) turn after the O-ring contacts the base. -
Page 18: Figure 8: Remote Oil Filter (After Installation)
If there is no oil pressure reading, shut down immediately and check the hose connections. Figure 8: Remote Oil Filter (After Installation) NOTE: Westerbeke is not responsible for engine failure due to the improper installation of the remote oil filter. page... -
Page 19: Startup And Basic Operation
5.1: Maintenance Schedule. Westerbeke does not approve or disapprove the use of synthetic oils. If synthetic oils are used, engine break-in must be performed using conventional oil. The required oil change intervals are listed in this manual and cannot be extended, even if synthetic oils are used. -
Page 20: Coolant Recovery Tank
4 Startup and Basic Operation Operator Manual for Gasoline Generators 4.5 Coolant Recovery Tank A coolant recovery tank kit is supplied with each generator to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and without introducing air into the cooling system. -
Page 21: How To Start And Stop The Generator
Operator Manual for Gasoline Generators 4 Startup and Basic Operation Figure 10: Fuel System 4.7 How to Start and Stop the Generator 4.7.1 How to Start and Stop the Generator (Control Panel) The start/stop rocker switch is the only functional component on the generator control panel (and optional remote control panel) used to start and stop the generator. -
Page 22: Figure 11: Control Panel Dc Circuit Breaker And Start/Stop Switch
4 Startup and Basic Operation Operator Manual for Gasoline Generators Figure 11: Control Panel DC Circuit Breaker and Start/Stop Switch 4.7.2 How to Start and Stop the Generator (Remote Control Panel) You can also perform the same steps using an optional remote control panel. Two remote start/stop panels are available that allow for the engine/generator to be controlled from any location on the boat. -
Page 23: Safety Shutdown Switches And Leds
Operator Manual for Gasoline Generators 4 Startup and Basic Operation 4.7.4 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 power to the ECU. -
Page 24: Figure 13: Exhaust Temperature Switch
4 Startup and Basic Operation Operator Manual for Gasoline Generators This is a normally open contact switch. It functions with the time relay circuit to ensure DC voltage to the fuel pump circuit is terminated when the unit shuts down. An oil pressure sender (to the left of the oil filter) sends DC voltage to the ECU that it interprets as oil pressure. -
Page 25: Break-In Procedure For Daily Operation
Operator Manual for Gasoline Generators 4 Startup and Basic Operation 4.8.6 Fuse Protection Six 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 blade fuse by the starter motor for the battery charge circuit. -
Page 26: Checklist: Daily Startup
4 Startup and Basic Operation Operator Manual for Gasoline Generators 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. -
Page 27: Maintenance
Operator Manual for Gasoline Generators 5 Maintenance 5 Maintenance 5.1 Maintenance Schedule The maintenance intervals specify operating hours or a time interval, whichever comes first. For example, if maintenance is due every 250 hours or six months, and you have logged 300 hours in only two months, do not delay maintenance another four months. - Page 28 5 Maintenance Operator Manual for Gasoline Generators 5.1.4 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. TIP: A very small amount of battery drain results from the amperage being drawn from the starting battery by the electronics on the unit when the generator is not in use.
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Page 29: Maintenance: Fuel System
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. Westerbeke part number 049602 is shown in the diagram on this page. -
Page 30: Figure 18: Harness Lift Pump Dc Auxiliary Power Adapter (Part Number 056264)
5 Maintenance Operator Manual for Gasoline Generators 5.2.2 Fuel Pump Periodically check the fuel connections to and from the pump. Verify that no leakage is present and that the fittings are tight and secure. The high-pressure fuel pump in the fuel module requires no additional maintenance. -
Page 31: Maintenance: Cooling System
Operator Manual for Gasoline Generators 5 Maintenance 5.3 Maintenance: Cooling System CAUTION: Proper cooling system maintenance is critical. Often times engine failures can be traced back to cooling system corrosion. 5.3.1 Fresh Water Cooling Circuit An antifreeze mixture is pumped through the engine by a belt driven circulating pump. The coolant then passes through the thermostat, into the heat exchanger absorbing heat from the engine, then into the jacketed exhaust manifold into the suction side of the circulating pump and then through the engine block. -
Page 32: Figure 19: Cooling System Heat Exchanger (Left) And Thermostat (Right)
5 Maintenance Operator Manual for Gasoline Generators 5.3.3 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. - Page 33 Operator Manual for Gasoline Generators 5 Maintenance 5.3.5 Cooling System Thermostat The thermostat controls the coolant temperature as the coolant continuously flows through the closed fresh water 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).
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Page 34: Maintenance: Engine
Chapter 5.1: Maintenance Schedule. Westerbeke 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 5.1: Maintenance Schedule and cannot be extended if synthetic oils are used. -
Page 35: Figure 21: Engine Oil Sump
Screw the filter onto the threaded oil filter stub. Where the filter contacts the base, tighten firmly by hand. TIP: Use genuine Westerbeke oil filters. Generic filters are not recommended. 5.4.3 How to Refill the Engine Oil Add fresh oil through the valve cover. -
Page 36: Figure 23: Air Screen/Flame Arrestor
5 Maintenance Operator Manual for Gasoline Generators TIP: Loctite Anti-Seize applied to the threaded portion of the spark plugs will retard corrosion, making future removal of the spark plugs easier. WARNING: Do not remove the spark plugs while the engine is hot. Allow the engine to cool before removing them. 5.4.5 How to Clean the Air Screen/Flame Arrestor The air screen/flame arrestor should be cleaned after the first 50 hours of operation. -
Page 37: Figure 25: Battery Charger And 30A Fuse
Operator Manual for Gasoline Generators 5 Maintenance 5.4.7 Battery Charging Circuit The battery charger is an encapsulated, solid-state unit that supplies a DC charging voltage to the generator starting battery while the generator is operating. The battery charging circuit is separate from the AC output of the generator. -
Page 38: Maintenance: Connections, Motors, And Circuit Breakers
CO while the engine is running. This must be performed with a CO analyzer. WARNING : Never reuse an exhaust sealing gasket. Always replace with a new gasket. NOTE: For information on installing exhaust systems, see the Installation Manual available at www.westerbeke.com. Figure 26: Catalyst Installation 5.5 Maintenance: Connections, Motors, and Circuit Breakers... - Page 39 5.5.4 AC Circuit Breaker A circuit breaker is installed on all single-phase Westerbeke generators. This circuit breaker will automatically 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 being supplied into the boat.
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Page 40: Figure 27: Bc Generator Ac Terminal Connections
5 Maintenance Operator Manual for Gasoline Generators Figure 27: BC Generator AC Terminal Connections Figure 28: Generator Windings Schematic Diagram INTEGRAL CONTROLLER 30A FUSE 30A FUSE ROTOR WINDING 60 Hz CHARGER 50 Hz BATTERY CHARGING CIRCUIT STATOR WINDING STATOR WINDING ROTOR WINDING EXCITER WINDING EXCITER WINDING... -
Page 41: Figure 29: Shore Power Transfer Switch
If the installer connects shore power to the AC circuit on your vessel, this must be done by means of a shore power transfer switch. Ship-to-shore switches are available from Westerbeke or an authorized dealer. Figure 29: Shore Power Transfer Switch Set the transfer switch shown in the diagram to the OFF position. -
Page 42: Diagnostics And Troubleshooting
The communications cable plugs into a USB port. When using serial to USB adapters, the communication port that the adapter uses must be known to configure the diagnostic software. NOTE: The Westerbeke communications cable is unique to this diagnostic software and must be used. An incompatible cable may damage the ECU. -
Page 43: Engine Troubleshooting
Operator Manual for Gasoline Generators 6 Diagnostics and Troubleshooting 6.2 Engine Troubleshooting The following troubleshooting chart describes common engine problems and possible causes. NOTE: When servicing the engine/generator, the main circuit breaker (control panel) disconnects all AC power and can be switched off and reset manually. -
Page 44: Wiring Diagrams
7 Wiring Diagrams Operator Manual for Gasoline Generators 7 Wiring Diagrams The Wiring Diagram is available online and a printed copy is included in the standard equipment kit with your generator. 7.1 Remote Start/Stop Panels Figure 32: Wiring Diagram for Start/Stop Panel with Fault Display POWER RED-18GA START/STOP... -
Page 45: Lay-Up And Recommissioning
Operator Manual for Gasoline Generators 8 Lay-Up and Recommissioning 8 Lay-Up and Recommissioning 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 following procedures allow you to perform your own lay-up and recommissioning, or you may use them as a checklist if others do the procedures. -
Page 46: Lay-Up Prep: Raw Water Cooling Circuit
8.8 Lay-Up Prep: Spare Parts Lay-up time provides an opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement. Check your basic spares kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes. -
Page 47: Generator Specifications
Operator Manual for Gasoline Generators 9 Generator Specifications 9 Generator Specifications 9.1 Specifications: Engine Item Description Engine Type 3-cylinder, 4-cycle, overhead camshaft water cooled gasoline engine Bore & Stroke 2.69 x 2.75 inches (68.5 x 70.0 mm.) Total Displacement 48.5 cubic inches (0.796 liters) Bearings Four (4) main bearings Combustion Chamber... -
Page 48: Specifications: Cooling System
Battery ignition 12-volt negative ground, ignition coil and spark plugs. Ignition System TCI Ignition Spark Module Spark Plug Gap 0.028-0.031 inches (0.7-0.8 mm) Spark Plug Thread 11.0 mm x 1.25 pitch Ignition Timing Electronic Control Spark Plugs Westerbeke 056754 Ignition Coil 12 volts – coil on plug type page... -
Page 49: Specifications: Engine Component Tightening Torque
Operator Manual for Gasoline Generators 9 Generator Specifications 9.9 Specifications: Engine Component Tightening Torque Engine Component Ft. Lbs. Timing Belt Flywheel Bolt 86-88 63-65 Timing Belt Cover Bolts 10-12 Camshaft sprocket bolts 80-100 58-72 Oil pump sprocket nuts 50-57 36-41 Timing tensioner nuts 22-30 16-22... - Page 50 9 Generator Specifications Operator Manual for Gasoline Generators ©2018 Westerbeke, Inc. All Rights Reserved. Westerbeke Corporation Myles Standish Industrial Park 150 John Hancock Rd. Taunton, MA 02780-7319 USA Phone: (508) 823-7677 FAX: (508) 884-9688 www.westerbeke.com page...
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