Installation manual

MAINTENANCE SCHEDULE
SCHEDULED MAINTENANCE
EVERY 250 OPERATING HOURS OR YEARLY (cant.)
'Exhaust CO Level
·Exhaust Elbow
Exhaust System
·Exhaust System Back Pressure
Fuel Filter and O-Rings
Fuel Filter Inlet
Generator
Hoses
Spark Plugs
Vibration Isolators/Engine Mounts
Zinc Anode
I EVERY 500 OPERATING HOURS OR YEARLY
Raw Water Pump
EVERY 500 OPERATING HOURS OR EVERY TWO YEARS
Coolant System
Engine Compression, Head Bolt Torgue and
Valve Clearances
Starter Motor
Diverter Valve
I EVERY 1000 OPERATING HOURS OR EVERY FOUR YEARS
'Engine Timing Belt
Heat Exchanger
I EVERY 2000 OPERATING HOURS
·Oxygen Sensor
·Catalyst
*WESTERBEKE recommends this service
be performed by an authorized mechanic.
EXPLANATION OF SCHEDULED MAINTENANCE
Sample exhaust with CO analyzer.
Test exhaust elbow for structural integrity. Replace if elbow is corroded or deteriorated.
Always use a new gasket. NOTE: A leaking exhaust elbow or gasket can cause carbon
monoxide exposure!
Carefully inspect for leaks. Check anti-siphon valve operation. Check the exhaust elbow
for carbon and/or corrosion build -up on inside passages. Clean and replace as necessary.
Perform back pressure test to ensure system has not developed restrictions that will
increase pressure above 1.5 psi or 41 inches of water column at full operating amperage
load. Correct as needed.
Remove antr replace fuel filter and all sealing O-rings.
Remove and replace inlet fuel filter.
Check that AC connections are clean and secure. Ensure wires have no chafing.
See GENERATOR INFORMATION.
Engine hoses should be firm and tight. Replace if hoses become spongy, brittle or
delaminated. Check and tighten all hose clamps.
Replace spark plugs.
Check vibration isolators, brackets and mounting hardware.
Remove and replace zinc anode. Open heat exchanger end cap(s) and clean out debris.
Replace gasket and O-rings if needed.
Remove the dual pumps. Follow the instructions in this manual and disassemble both pumps.
Inspect and replace any worn parts. Lubricate, reassemble and install. With engine running,
check for leaks and for proper pumping action.
Drain, flush and re-fill the cooling system with appropriate antifreeze mix. Replace
the thermostat and coolant pressure cap.
Incorrect valve clearance will result in poor engine performance. Check the head
bolt torque and adjust the valve clearances. Check that the compression pressure is
within published specifications.
Check solenoid and motor for corrosion. Remove and lubricate. Clean and lubricate the starter
motor pinion drive.
Replace.
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.
Remove the heat exchanger for professional cleaning and pressure testing.
Remove and replace exhaust oxygen sensor. Inspect every 1,000 hours.
Remove and replace exhaust catalyst.
NOTE: The operation of the unit's "SAFE CO" system must
be monitored at least once an operating season. This
is to
ensure that the system is operating properly. Free system
diagnostic software is available
for use with a laptop by
contacting your area Westerbeke Distributor.
Em:zines & Generators
13