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  
Task  
Task  
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  
Task  
Task  
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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