Westerbeke 7.5 MCGA - 100 Hour;Yearly Maintenance; 250 Hour;Yearly Maintenance; 500 Hour;Yearly Maintenance; 500 Hour;Two Year Maintenance

5 Maintenance Operator Manual for Gasoline Generators
page 22
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. You can prevent this 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 operational for an extended
time.
5.1.5 Every 250 Operating Hours or Yearly
 Exhaust Elbow/Exhaust System: Check the structural 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.
WARNING: An exhaust leak will cause exposure to carbon monoxide!
 Fuel Filter and O-Rings: Remove and replace fuel filter and all sealing O-rings.
 Inlet Fuel Filter: Remove and replace inlet fuel filter.
 Generator: Check that AC connections are clean and secure. Ensure wires have no chafing.
 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 O-
rings if needed.
5.1.6 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 2,000 operating hours.
5.1.7 Every 500 Operating Hours or Every Two Years
 Ignition System: Inspect for deterioration.
 Coolant System: Drain, flush, and refill the cooling system with the 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 using WD40 or equivalent.
5.1.8 Every 1,000 Hours or Every Five Years
 Engine Timing Belt: Remove and replace the timing belt.
CAUTION: 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: Remove and replace.
5.1.9 Every 2,000 Operating Hours
 Oxygen Sensor: Remove and replace the exhaust oxygen sensor.
 Catalyst: Remove and replace the exhaust catalyst and gasket.