Generac 2.4L Engine

Tools: Belt deflection gauge

1. Inspect belt for cracks, fraying, excessive wear or other damage.
2. Verify belt is free of grease and oil; replace if contaminated.
3. Using a suitable gauge, apply 22 Ibs (10 kgf) force midway between water pump and alternator pulleys.
4. Loosen DC alternator tension bracket screw.
5. Rotate alternator outward to reduce belt deflection.
6. Rotate inward to increase belt deflection.
7. Tighten DC alternator tension bracket screw to 17-22 ft-lbs (23-30 Nm).
8. Recheck belt deflection and repeat steps as necessary.

⚠ Fuel conversion software is password protected

⚠ Failure to convert both hardware and software violates EPA regulations

Tools: Flat blade screwdriver, Pipe sealant

1. Turn off the main gas supply.
2. Remove battery negative cable (black) from battery negative (-) terminal.
3. Remove carburetor fuel hose from outlet port.
4. Remove screw at front of power wire connector and pull connector from fuel solenoid.
5. Expand spring clamp on fuel enrichment hose and remove from hose barb.
6. Remove black pipe assembly from outlet port; remove fuel solenoid assembly if clearance is insufficient.
7. Rotate NG fuel jet counterclockwise to remove from outlet port.
8. Rotate LP fuel jet counterclockwise to remove from jet keeper port.

⚠ Auxiliary shutdown switches are not a primary means to shut down generator under normal conditions

1. Verify auxiliary shutdown switches are ON (I).
2. Press MANUAL key on control panel keypad to start engine.
3. With engine running, set one auxiliary shutdown switch to OFF (O); engine should shut down immediately.
4. If engine stops, set switch to ON (I), clear alarm, and restart to verify normal operation.
5. Verify operation of second auxiliary switch.
6. If engine does not stop, contact an IASD.

⚠ Always connect positive battery cable first to avoid spark

1. Loosen the two screws with nylon washers to release hold-down clamp from battery tray.
2. Install battery onto tray.
3. Install the two screws with nylon washers to secure hold-down clamp to battery tray.
4. Install positive battery cable (red) to positive (+) battery terminal.
5. Install negative battery cable (black) to negative (-) battery terminal.

⚠ Disconnect battery ground terminal before working on battery or battery wires

⚠ Always connect positive battery cable first

1. Remove negative battery cable (black) from negative (-) battery terminal.
2. Remove positive battery cable (red) from positive (+) battery terminal.
3. Install rubber protective cover over positive (+) battery terminal.
4. Loosen two screws with nylon washers to release battery hold-down clamp from battery tray.
5. Grasp battery strap and lift battery from battery tray.
6. Remove rubber protective cover from positive (+) battery terminal.
7. Set new battery onto battery tray and secure hold-down clamp.
8. Install positive cable then negative cable.

1. If engine was running, allow at least 10 minutes for oil to drain into oil pan.
2. Remove dipstick and wipe dry with a clean, lint free cloth.
3. Slowly insert dipstick into dipstick tube and verify fully seated.
4. Allow at least 10 seconds to elapse then slowly remove dipstick.
5. Verify oil level is at or near FULL mark; add oil as necessary.
6. Remove oil fill cap and slowly add oil; do not fill above FULL mark.
7. Install dipstick and oil fill cap.
8. Check oil drain hose for leaks, nicks, cuts, tears or deterioration.

⚠ Do not disconnect spark plug wires with engine running

Tools: Spark plug socket wrench, Wire feeler gauge, Wire brush

1. Remove battery negative cable (black) from battery negative (-) terminal.
2. Remove spark plug cables from spark plug terminals.
3. Thoroughly clean area around spark plugs.
4. Remove spark plugs from cylinder head using spark plug socket wrench.
5. Check condition of threads in cylinder head and on spark plugs.
6. Clean spark plugs using a wire brush and commercial solvent.
7. Check spark plug gap using a wire feeler gauge and adjust gap.
8. Finger tighten spark plugs into cylinder head then tighten to torque.

⚠ Allow engine to cool before draining coolant

Tools: Funnel, Wrench

1. Disconnect and empty coolant overflow reservoir, then reinstall.
2. Rotate and remove plastic cover at top of enclosure.
3. Slowly unscrew radiator cap.
4. Locate drain cock at bottom left side of radiator.
5. Rotate hex fitting to open drain cock.
6. Drain coolant into a suitable container.
7. Rotate hex fitting to close radiator drain cock.
8. Fill radiator with recommended coolant until full.

⚠ If unit has been running, wait five minutes for engine to cool

1. Open viewing window.
2. Move Main Circuit Breaker switch down to OFF (Open) position.
3. Verify both auxiliary shutdown switches are OFF (O).
4. Press OFF on control panel.
5. Remove T1 fuse from transfer switch.
6. Pull up rubber flap covering fuse holder and remove 7.5 amp fuse.
7. Disconnect NEGATIVE battery cable.
8. Place a DO NOT OPERATE tag on control panel and transfer switch.

1. Remove wing nut, lock washer, and flat washer from threaded rod to release air cleaner cover.
2. Remove air filter element and discard.
3. Thoroughly clean air cleaner cover of any dust, dirt, or debris.
4. Place new air filter element against adapter flange.
5. Install air cleaner cover over threaded rod.
6. Install flat washer, lock washer and wing nut; tighten wing nut until snug.

⚠ Allow engine to cool before draining oil

⚠ Avoid prolonged contact with used motor oil

Tools: Wrenches

1. Remove oil drain hose from holding clamp.
2. Use one wrench to hold hex on hose fitting, second wrench to remove drain plug.
3. Drain oil into a suitable container.
4. Install drain plug onto end of oil drain hose and install hose into holding clamp.
5. Rotate oil filter counterclockwise to remove from oil filter adapter.
6. Apply light coat of clean engine oil to gasket of new oil filter.
7. Install oil filter by hand until gasket contacts adapter; tighten 3/4 to one full turn.
8. Remove fill cap and fill engine with recommended quantity and type of oil.

1. Pull up rubber flap covering fuse holder and install 7.5 amp fuse.
2. Install T1 fuse in transfer switch.
3. Verify both auxiliary shutdown switches are ON (I).
4. Press AUTO on control panel; green LED confirms AUTO mode.
5. Move Main Circuit Breaker switch up to ON (Closed) position.
6. Close viewing window.
7. Remove DO NOT OPERATE tag from control panel and transfer switch.
8. Reset time and date.