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Westerbeke Manuals
Portable Generator
4.2 MCGA
Operator's manual
Westerbeke 4.2 MCGA Operator's Manual
Marine gasoline generators
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Operators Manual
Table of Contents
Important Safety Information
2 Introduction
Documentation
Quick Start Operators Guide
Figure 1: Parts Diagram
Parts Diagram
Figure 2: Customer Identification Card
Figure 3: Product Serial Number, Model Number, and Other Specifications
Warranty Procedures
Checklist: Protecting Your Investment
Conventions Used in this Manual
Gasoline Engines
Manuals and Software
Amperage Drain
Figure 4: Spare Parts Kit
Ordering Parts
Spare Parts, Kits, and Accessories
Figure 5: Suggested Spare Parts
Figure 6: Siphon-Break (Anti-Siphon Valve) with Stainless Steel Loop
Exhaust System Requirements
How to Install a Remote Oil Filter
3 Installation
Codes and Regulations
Carbon Monoxide Detector
Siphon-Break Requirements
Figure 7: Remote Oil Filter (Detailed View)
Figure 8: Remote Oil Filter (after Installation)
4 Startup and Basic Operation
Engine Coolant
Engine Oil
Fuel Source
Fuel Supply Components
Coolant Recovery Tank
Figure 9: Engine Coolant Recovery Tank
How to Bleed the Fuel System
Figure 10: Fuel System
Figure 14: Coolant Temperature Sensor
Figure 13: Exhaust Temperature Switch
Figure 15: Control Panel DC Circuit Breaker
Break-In Procedure for Daily Operation
Checklist: Initial Startup
Checklist: Daily Startup
How to Start and Stop the Generator
Figure 11: Control Panel DC Circuit Breaker and Start/Stop Switch
Figure 12: Remote Start/Stop Panels
Safety Shutdown Switches and Leds
Figure 16: Engine Oil and Coolant System Components
5 Maintenance
Maintenance Schedule
Figure 17: Fuel System Components
Maintenance: Fuel System
Figure 18: Harness Lift Pump DC Auxiliary Power Adapter (Part Number 056264)
Figure 19: Cooling System Heat Exchanger (Left) and Thermostat (Right)
Maintenance: Engine
Maintenance: Cooling System
Figure 20: Engine Oil Drain Hose (Left) and Oil Filter Assembly (Right)
Figure 21: Engine Oil Sump
Figure 24: Engine Oil Filter, Oil Pressure Sender, and Oil Pressure Switch
Figure 23: Air Screen/Flame Arrestor
Figure 25: Battery Charger and 30A Fuse
Figure 26: Catalyst Installation
Maintenance: Connections, Motors, and Circuit Breakers
Figure 27: BC Generator AC Terminal Connections
Figure 28: Generator Windings Schematic Diagram
Figure 29: Shore Power Transfer Switch
Figure 30: Shore Power Transfer Switch Configurations
Figure 31: Typical Diagnostic Software Kit (Control Box, Cable, and Other Components)
Engine Troubleshooting
6 Diagnostics and Troubleshooting
Diagnostics Software for Microsoft Windows
Figure 32: Wiring Diagram for Start/Stop Panel with Fault Display
Figure 33: Wiring Diagram for Start/Stop Panel Rocker Switch Only
7 Wiring Diagrams
Remote Start/Stop Panels
8 Lay-Up and Recommissioning
Lay-Up Prep: Lubrication System
Lay-Up Prep: Intake Manifold
Lay-Up Prep: Cylinder Lubrication
Lay-Up Prep: Fuel System
Lay-Up Prep: Starter Motor
Lay-Up Prep: Raw Water Cooling Circuit
Lay-Up Prep: Batteries
Lay-Up Prep: Spare Parts
How to Recommission after a Lay-Up
9 Generator Specifications
Specifications: Engine
Specifications: Fuel System
Specifications: Electrical System
Specifications: Air Requirements
Specifications: Cooling System
Specifications: Lubrication System
Specifications: AC Generator (Single Phase)
Specifications: Ignition System
Specifications: Engine Component Tightening Torque
Figure 22: Spark Plug
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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
REVISION
AUGUST 2018
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Table of Contents
Troubleshooting
Diagnostics and Troubleshooting
42
Engine Troubleshooting
43
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Summarization of Contents
Important Safety Information
Operational Hazard Warnings
Covers risks like electric shock, accidental starts, burns, fire, explosions, and injury from moving parts.
Battery and Exhaust Gas Safety
Guidelines for safe battery handling and awareness of carbon monoxide hazards.
Noise Hazard and Standards Compliance
Information on noise hazards, safety standards, and generator CO emissions.
Introduction to Westerbeke Generators
Quick Start and Documentation
Guidance for rapid setup, operation, and available documentation resources.
Parts Diagram and Warranty Procedures
Visual guide to generator parts and instructions for warranty registration.
Manual Conventions and Engine Details
Explanation of manual notations, engine features, and operational considerations.
Extended Operation and Spare Parts
Information on amperage drain during non-use and recommended spare parts.
Generator Installation Procedures
Codes, Regulations, and CO Detectors
Compliance with marine standards and recommendations for carbon monoxide detectors.
Siphon-Break and Exhaust System Requirements
Guidelines for preventing water ingress and exhaust system setup.
Remote Oil Filter Installation
Step-by-step instructions for installing an optional remote engine oil filter.
Startup and Basic Operation
Fuel Source and Supply Management
Guidelines for selecting and supplying clean, appropriate gasoline for the generator.
Engine Oil and Coolant Management
Recommendations for engine oil type, capacity, and coolant mixture.
Fuel System Bleeding and Generator Control
Procedure for bleeding the fuel system and operating the start/stop controls.
Shutdowns, Sensors, and Break-in Procedure
Information on safety shutdowns, sensor functions, and the engine break-in procedure.
Generator Maintenance Schedule
Daily Checks Before Startup
Essential checks to perform before starting the generator each day.
Maintenance Intervals and Tasks
Schedule of maintenance tasks based on operating hours or time intervals.
Fuel System Maintenance Procedures
Procedures for servicing the fuel pump, filters, and water separator.
Cooling System Maintenance Procedures
Steps for draining, refilling, and maintaining the engine's cooling system.
Diagnostics and Troubleshooting Guide
Diagnostic Software for Windows
Information on using EC11 software for engine monitoring and diagnostics.
Engine Troubleshooting Chart
Common engine problems, their possible causes, and troubleshooting steps.
Wiring Diagrams and Connections
Remote Start/Stop Panel Wiring
Diagrams for connecting remote start/stop panels with and without fault display.
Lay-Up and Recommissioning Procedures
Lay-Up Preparation Steps
Procedures for preparing the engine for off-season storage, covering lubrication, batteries, fuel, etc.
Raw Water Cooling and Intake Prep
Steps for preparing the raw water cooling circuit and intake manifold for lay-up.
Recommissioning After Seasonal Storage
Steps to follow to prepare the engine for operation after a lay-up period.
Generator Specifications
Engine Specifications
Detailed technical data for the generator's engine, including type, bore, stroke, and HP.
Fuel System and Electrical System Specs
Specifications for the fuel system type, source, and the generator's electrical components.
Air Requirements and Cooling System Specs
Information on air flow needs, cooling system details, and operating temperatures.
Lubrication, Ignition, and Generator Specs
Details on lubrication system, ignition system, AC generator ratings, and component torque.
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