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.