Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change frequencies. Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows: • • • • Before working on the Stationary Emergency Generator, ensure the following: The AUTO/OFF/MANUAL switch is in the OFF position. The control panel fuse has been removed from the control box. The 120VAC supply to the battery charger is switched OFF. The negative battery cable has been removed. 1. 2. 3. CHECK ENGINE OIL 4. Check engine crankcase oil level (Figure 10.1) according to the Service Schedule and SIB10-10-L24G. • • • • 5. Remove oil dipstick and wipe dry with a clean, lint-free cloth. Install oil dipstick, then remove again. Oil should be between FULL and ADD marks. If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE “FULL” MARK. See “Engine Oil Recommendations” for recommended oils. 6. refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE nAfter ENGINE WITH OIL BELOW THE DIPSTICK Figure 10.1 - Oil Dipstick and Oil Fill Cap Oil Fill Remove the drain hose from its retaining clip or cut the zip-tie securing the oil drain hose. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container. When all oil has drained, install and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip-tie, or place the hose in its retaining clip. Turn OIL FILTER (Figure 10.1) counterclockwise and remove. Properly dispose of old filter. Apply light coating of new engine oil to seal of new oil filter. Install FILTER and tighten by hand only. DO NOT OVER TIGHTEN. Remove OIL FILL CAP and add recommended oil. Crankcase oil capacity is listed in the "Specifications" section. 7. 8. Oil Dipstick 9. “ADD” MARK. Start engine and check for oil leaks. Shut OFF engine and wait 10 minutes for the oil to settle down into the oil pan. Recheck oil level on dipstick. DO NOT fill above the dipstick "FULL" mark. Dispose of used oil at a proper collection center. COOLING INTAKE/OUTLET Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down. (See the installation diagram.) Oil Filter get extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. The exhaust system parts from this product CHANGING ENGINE OIL must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system. oil may cause burns. Allow engine to cool before draining oil. Avoid prolonged nHot or repeated skin exposure with used oil. INSPECT COOLING SYSTEM • Inspect engine cooling system. See the Service Schedule. • Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found. • Check hose clamps for tightness. 10-1 Maint029 Rev. A 10/10 Thoroughly wash exposed areas with soap. Maintenance ENGINE COOLANT CHECK FAN BELT Check coolant level in coolant recovery bottle. See the Specifications and Service Schedule sections. • Inspect fan belts every year. Replace any damaged, deteriorated, worn or otherwise defective belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required. • Check fan belt alignment (see Figure 10.2). • Add recommended coolant mixture as necessary. • Periodically remove radiator pressure cap (only when engine has cooled down) to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact a Service Facility. Inspect cooling system and coolant recovery system for leaks. Figure 10.2 – Fan Belt COOLANT CHANGE Every year, have a service facility drain, flush and refill the cooling system. See the Specifications and Service Schedule for cooling system recommendations. OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via the control panel fuse. This overcurrent protection device will open if the circuit is overloaded. a circuit breaker opens or a fuse element find the cause of the overload before nIfmelts, resetting the circuit breaker or replacing the INSPECT ENGINE GOVERNOR Visually inspect electronic governor. fuse. EXERCISE SYSTEM not attempt to adjust the governor. Only qualified service facilities should adjust nDo the governor. Excessively high operating Starts the Stationary Emergency Generator engine once every seven days and lets it run for 12 minutes. speeds are dangerous and increase the risk of personal injury. Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life. Correct rated frequency and voltage are supplied only at the proper governed speed. Some connected electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified service technicians should adjust the governed speed. PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine-generator monthly. Look for obvious damage, loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks. INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security, damage. CHANGING THE ENGINE AIR FILTER To replace the engine air filter, remove the air filter cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 10.3). See the Service Schedule for air filter maintenance. 10-2 Maint029 Rev. A 10/10 Maintenance Figure 10.3 – Engine Air Filter electrolyte fluid is an extremely corrosive sulfuric acid solution that can cause nBattery severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water. Air Filter not use any jumper cables or booster battery to crank and start the generator nDo engine. If the battery has completely dis- charged, remove it from the generator for recharging. sure the AUTO/OFF/MANUAL switch is set to the OFF position, before connecting nBe the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected. tery is turned OFF, or sparking may occur at Be sure the 120VAC power supply to the bat- SPARK PLUGS the battery posts as the cables are attached and cause an explosion. Reset the spark plug gap or replace the spark plugs as necessary. 2. 3. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean. Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule” section for recommended inspection. Check the spark plug gap using a wire feeler gauge. See the Specifications section for the required spark plug gap. BATTERY REPLACEMENT NOTE: Unit DOES NOT include battery. When supplying or replacing the battery, the recommended number and type of battery is listed in the Specifications Section. NOTE: The BCI number should be located directly on the battery. BATTERY MAINTENANCE BATTERY FLUID The battery should be inspected per the Service Schedule section. The following procedure should be followed for inspection: 1. 2. 3. Check battery electrolyte fluid based on the Service Schedule. Fluid should cover separators in all battery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN BATTERY. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer. CLEANING THE STATIONARY EMERGENCY GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water. gas. This gas can form an explosive mixture Storage batteries give off explosive hydrogen around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery. Once each year have the generator cleaned and inspected by a Service Dealer. That dealer will use dry, low pressure air to clean internal windings. Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying. 10-3 Maint029 Rev. A 10/10 1.