Generac Power Systems Automobile Parts 0G2832 User Manual

Manual Part No. 0G2832

MITSUBISHI

GAS

ENGINE

2.4

SERVICE

MANUAL

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2.4 Liter Gas engine Table of Contents

service recommendations ................................................................................................................ a_2

mitsubishi contents ........................................................................................................................................

This engine has been engineered for use in

Generac Power Systems products. The contents of

this manual have been reprinted from the original

manufacturer’s service and repair manual.

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2.4 Liter Gas engine Service recommendations

◆

EnginE Oil REcOmmEndatiOns

do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result.

The unit has been filled with “break in” engine oil

at the factory. Use a high-quality detergent oil clas-

sified “For Service CC, SD, SE or SF.” Detergent oils

keep the engine cleaner and reduce carbon deposits.

Use oil having the following SAE viscosity rating,

based on the ambient temperature range anticipated

before the next oil change:

dangER

ethylene glycol base antifreeze is poisonous.

do not use your mouth to siphon coolant from

the radiator, recovery bottle or any container.

wash your hands thoroughly after handling.

Never store used antifreeze in an open con-

tainer because animals are attracted to the

smell and taste of antifreeze even though it is

poisonous to them.

temperature

oil Grade (recommended)

sae 30W

above 75º F (24º c)

40º to 75º F (4.4º to 24º c)

10º to 40º F (-12º to 4.4º c)

below 10º F (-12º c)

sae 20W or 15W-40

sae 10W or 15W-40

sae 5W-30 (synthetic) or 5W-20

Crankcase Oil Capacity.......1.1ꢀ5 U.S. Gallons (w/filter)

cOOlant

do not use any chromate base rust inhibitor

with ethylene glycol base antifreeze, or chro-

mium hydroxide (“green slime”) will form and

cause overheating. engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base antifreeze. Using any high

silicate antifreeze boosters or additives also

will cause overheating. we also recommend

that you do NoT use any soluble oil inhibitor

for this equipment.

◆

Use a mixture of half low silicate, ethylene glycol base

antifreeze and half soft water. Use only soft water and

only low silicate antifreeze. If desired, you may add a

high quality rust inhibitor to the recommended cool-

ant mixture. When adding coolant, always add the

recommended 50-50 mixture.

Coolant Capacity..................................1.80 U.S. gallons

ꢀ

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2.4 Liter Gas engine Service recommendations

8 kW - 35 kW small standby gEnERatOR sEts

Following is a recommended maintenance schedule for Generac small standby and residential generator sets

from 8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. The established

intervals in the schedule are the maximum recommended when the unit is used in an average service applica-

tion. They will need to be decreased (performed more frequently) if the unit is used in a severe application.

Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to

determine the next required maintenance interval.

service maintenance interval information:

The various service maintenance intervals are designated by interval numbers as follows:

1 An early inspection of the generator set to insure it is ready to operate when required and to identify any

potential problem areas.

Performed monthly or following each 10 hours of operation of the unit and requires approximately .5

man-hours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent

the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

•

Disable the generator set from starting and/or connecting to the load by setting the control panel

Auto-Off-Manual switch to the “OFF” position.

Remove the control panel fuse.

Turn off the battery charger.

Remove the negative battery cable.

•

The battery charger must be turned off Before removing the battery cable to prevent an over current

condition from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal

operation when required.

2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase

of the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

3 An operational inspection of the generator set to insure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit and requires approximately

1.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0

man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

ꢁ

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Liter Gas engine Service recommendations

Maintenance Tasks

Level 1

Level 2

Level 3

Level 4

Task

Recommended

to be done

monthly/ 10 hrs.

Required to be

done 3 months/

Break-in /30 hrs.

Required to

be done Semi-

Annually/50 hrs.

Required to be

done Annually/

100 hrs.

Comp.

(Date-

Initials)

Comp.

(Date-

Initials)

Comp.

(Date-

Initials)

Comp.

(Date-

Initials)

1.Disable the unit from

operating per the first

page warning.

2.Check the engine oil

level. Adjust as neces-

sary.

3.Check the engine cool-

ant level. Adjust as nec-

essary.

4.Check the engine cool-

ant thermal protection

level. Correct as neces-

sary.

5.Check the natural gas

delivery system on gas

engine driven units.

Tighten connections as

necessary.

6.Check the diesel fuel

supply level for diesel

engine driven units. Fill

as necessary.

7.Drain water and sedi-

ment from the diesel fuel

tank on diesel engine

driven units.

8.Drain water from the

fuel line water separa-

tor on diesel engine

driven units if the unit is

equipped with one.

9.Check the air inlets and

outlets for debris. Clean

as necessary.

10.Check the battery

electrolyte level if

accessible. Adjust as

necessary.

11.Check the battery

posts, cables, and

charger for loose con-

nections, corrosion,

and proper operation.

Correct as necessary.

12.Check the unit wiring

for loose connections,

corrosion, and dam-

age. Correct as neces-

sary.

13.Check the engine

accessory drive belts

for wear, weather

cracking, and damage.

Replace as necessary.

ꢀ

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2.4 Liter Gas engine Service recommendations

Maintenance Tasks

Level 1

Level 2

Level 3

Level 4

Task

Recommended

to be done

monthly/ 10 hrs.

Required to be

done 3 months/

Break-in /30 hrs.

Required to

be done Semi-

Annually/50 hrs.

Required to be

done Annually/

100 hrs.

Comp.

(Date-

Initials)

Comp.

(Date-

Initials)

Comp.

(Date-

Initials)

Comp.

(Date-

Initials)

14.Visually inspect the

unit looking for leaks,

wear or damage, loose

connections or compo-

nents, and corrosion.

Correct as necessary.

15.Test the engine and

transfer switch safety

devices. Correct and/or

adjust as necessary.

16.Initiate an automatic

start and transfer of the

unit to site load and

exercise it for at least 1

hour looking for leaks,

loose connections

or components, and

abnormal operating

conditions. Correct as

necessary.

17.Start and exercise the

unit at full rated load

(use a load bank if the

site load is not enough)

for at least 2 hours

looking for leaks, loose

connections or com-

ponents, and abnormal

operating conditions.

Correct as necessary.

18.Change the engine oil.

19.Replace the engine oil

filter(s).

20.Replace the engine air

filter(s).

21.Replace the engine

fuel filter(s) on diesel

engine driven units

and re-prime the fuel

system.

22.Check the engine

spark plugs on gas

engine driven units.

Clean and re-gap orre-

place as necessary.

23.Perform a 5 minute no-

load operational run of

the unit looking for any

post service problems.

24.Return the unit to

standby setup for oper-

ation when required.

ꢁ

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Notes

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P.O. BOX 310 EAGLE, WI 53119

Part No. 0G2832

Revision * (07/14/06)

Printed in U.S.A.

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