Service manual

Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ...................................................................................... 1
1.1 Save These Instructions ........................................................................................................ 1
1.2 General Precautions .............................................................................................................. 1
1.3 Generator Voltage is Deadly .................................................................................................. 2
1.4 Engine Exhaust is Deadly ...................................................................................................... 2
1.5 Fuel is Flammable and Explosive .......................................................................................... 2
1.6 Batteries Can Explode ............................................................................................................ 2
1.7 Moving Parts Can Cause Severe Personal Injury or Death .................................................. 3
1.8 The Hazards of Carbon Monoxide.......................................................................................... 3
1.8.1 What Is Carbon Monoxide Poisoning? ........................................................................ 3
1.8.2 What Are the Special Risks of CO Near the Home? ................................................... 3
1.8.3 Only You Can Protect Yourself From CO Poisoning! .................................................. 4
2. INTRODUCTION............................................................................................................................ 5
2.1 About this Manual ................................................................................................................... 5
2.2 About the Generator Set......................................................................................................... 5
2.2.1 Model Specifications .................................................................................................... 6
2.3 Generator Set Nameplate ...................................................................................................... 8
3. MAINTENANCE .......................................................................................................................... 11
3.1 Periodic Maintenance Schedule .......................................................................................... 11
3.2 Cleaning the Housing Top ................................................................................................... 12
3.3 Exercising the Generator Set ............................................................................................... 12
3.4 Complete System Test ........................................................................................................ 12
3.5 Engine Oil Maintenance........................................................................................................ 13
3.5.1 Recommended Engine Oil ........................................................................................ 13
3.5.2 Checking Engine Oil Level ........................................................................................ 13
3.5.3 Add or Drain Oil ......................................................................................................... 13
3.5.4 Changing Engine Oil and Oil Filter ........................................................................... 14
3.6 Replacing the Air Filter Element .......................................................................................... 15
3.7 Battery Maintenance ............................................................................................................ 16
3.8 Spark Plugs .......................................................................................................................... 16
3.9 Accessory Heater Kits ......................................................................................................... 17
3.10 Maintenance Record .......................................................................................................... 17
4. SERVICE .................................................................................................................................... 19
4.1 Placing the Generator Set Back in Service ......................................................................... 19
4.2 Transfer Switch ..................................................................................................................... 19
4.3 Engine .................................................................................................................................. 20
4.4 Engine - Generator Assembly .............................................................................................. 20
4.4.1 Engine - Alternator Removal ..................................................................................... 20
4.4.2 Engine-Alternator Installation .................................................................................... 21
4.5 Fuel System Components Testing........................................................................................ 23
A030A239 (Issue 10) i