Section 4 — Maintenance
FIRST 100 OPERATING HOURS
1.Change engine oil and oil filter. After initial change, service engine oil and filter at 150 operat- ing hours or six months, whichever comes first.
2.Retorque cylinder head (see torque specs).
3.Retorque intake and exhaust manifold (see torque specs).
3.Install a new lower intake manifold gasket.
4.Position the lower intake manifold to the cylinder head.
5.Install retaining bolts/studs finger tight.
6.Tighten all bolts/studs to specifications in the tightening sequence shown:
•First pass = 7=10
•Final pass =
EVERY 500 OPERATING HOURS
1.Service air cleaner.
2.Check starter.
3.Check engine DC alternator.
EVERY 800 OPERATING HOURS
1.Retorque cylinder head (see torque specs).
2.Retorque intake and exhaust manifold (see torque specs).
3.Check engine compression.
4.Check valve clearance.
4.2EXHAUST MANIFOLD PROCEDURE
1.If necessary, clean gasket surfaces on exhaust manifold and cylinder head.
2.Install exhaust manifold and exhaust manifold gasket.
3.Install fasteners.
NOTE:
Exhaust manifold fasteners must be tightened in two stages.
4.Tighten fasteners to
5.Retighten fasteners to
4.3INTAKE MANIFOLD PROCEDURE
1.Clean and inspect the mounting surfaces of the intake manifold and the cylinder head. Both sur- faces must be clean and flat (Figure 4.1).
2.Clean and lightly oil the manifold bolt/stud threads.
Figure 4.1 — Intake Manifold Installation
18
4.4CYLINDER HEAD PROCEDURE
1.Position head gasket on the block (Figure 4.2).
2.Position cylinder head to cylinder block.
3.Install 10 cylinder head bolts in numerical sequence. Tighten to 70
Figure 4.2 — Cylinder Head Installation
4.5COOLING SYSTEM
Air intake and outlet openings in the generator com- partment must be open and unobstructed for contin- ued proper operation. This includes such obstruc- tions 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.)
