Isuzu C-240 Engine

1. Place MASTER SWITCH to PRIME & RUN
2. Push PRESS TO TEST on malfunction indicator panel
3. Ensure all indicator lights lit, then all go out
4. Press BATTLE SHORT press to test light
5. Press AC CIRCUIT INTERRUPTER press to test light

⚠ High voltage is produced when generator set is in operation; shut down before maintenance.

Tools: Multimeter

1. Remove VOLTAGE adjust potentiometer.
2. Set multimeter for ohms across two outer terminals.
3. Rotate potentiometer shaft counterclockwise as far as it will go.
4. Connect multimeter between center terminal and either outer terminal.
5. Rotate shaft clockwise at an even rate while observing multimeter.
6. Replace potentiometer if indication changes erratically or does not reach maximum ohms.

⚠ DO NOT operate generator set in enclosed areas unless exhaust is properly vented outside.

⚠ Hot exhaust gases can ignite flammable materials.

1. Provide ducts and vents to outside of building if cooling air supply is inadequate.
2. Make building air intake and outlet openings same size or larger than those on generator set.
3. Install gas-tight metal pipe from exhaust pipe to outside of building.
4. Make exhaust pipe extension short and straight with only one 90 degree bend if needed.
5. Shield exhaust pipe with fireproof material where it passes through a flammable wall.
6. Allow space on all sides for service and maintenance.

⚠ Never start generator set unless properly grounded

1. Insert ground cable through slot on terminal marked GND
2. Connect coupling to ground rod and screw in driving stud
3. Drive ground rod until coupling is just above surface
4. Remove driving stud and install another rod section
5. Install another coupling and driving stud, drive down
6. Repeat until ground rod driven eight feet or deeper
7. Connect clamp and ground cable to ground rod

⚠ Never connect or disconnect load cables while generator set is running

Tools: Terminal nut wrench

1. Shutdown generator set
2. Select required output terminals from Table 1
3. Open output load terminal door
4. Ensure jumper securely fastened between LO and ground
5. Loosen terminal nuts on selected terminals
6. Insert load cable ends through entrance box into studs
7. Tighten load terminal nuts
8. Secure wrench in bracket and close door

Tools: Generator Mechanical Tool Kit

1. Shut down generator set
2. Open air cleaner access door
3. Loosen retaining clamp and remove end cap
4. Remove wing nut and air cleaner element
5. Wipe housing interior with clean lint-free cloth
6. Install air cleaner element, wing nut, end cap
7. Hand tighten retaining clamp

⚠ Battery acid can cause burns; wear goggles and chemical gloves

Tools: Generator Mechanical Tool Kit

1. Shut down generator set
2. Open battery access door
3. Inspect case, corrosion, connections, battery caps
4. Remove battery caps
5. Add distilled water to each cell as required
6. Replace battery caps
7. Close battery access door

⚠ Reconnect cables in reverse order of removal.

⚠ Never start the generator set unless it is properly grounded.

1. Position serviced and fully charged batteries in generator set.
2. Apply general purpose grease to battery posts and cable terminal lugs.
3. Install hook bolts and battery hold-down with new lock washers, washers, and nuts.
4. Connect positive cable terminal lug.
5. Position interconnect battery cable connect terminals.
6. Connect negative battery cable terminal lug and close access door.

⚠ Disconnect the negative lead to the grounding stud first.

⚠ Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift.

1. Shut down generator set.
2. Open battery compartment access door.
3. Disconnect negative battery cable terminal lug.
4. Disconnect interconnect battery cable terminals and remove cable.
5. Disconnect positive battery cable terminal lug.
6. Remove nuts, washers, lock washers, hook bolts, and battery hold-down.
7. Remove batteries.

⚠ Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift.

⚠ Batteries give off a flammable gas; do not smoke or use open flame.

1. Refer to TM 9-6140-200-14 when servicing batteries.
2. Inspect batteries for damage.
3. Check battery cables for proper polarity connection, damage, and loose connections.

⚠ Battery acid can cause burns to unprotected skin.

⚠ Batteries give off a flammable gas.

Tools: Hydrometer

1. Shut down generator set.
2. Open battery access door and disconnect negative battery cable.
3. Remove battery vent caps.
4. Test specific gravity of electrolyte in each cell with a hydrometer.
5. Recharge or replace batteries as necessary.
6. Install vent caps, connect negative cable, close access door.

⚠ Cooling system operates at high temperature and pressure

Tools: Generator Mechanical Tool Kit

1. Shut down generator set
2. Open left side engine access door
3. Remove cap on coolant recovery bottle
4. Fill bottle to HOT line if hot or COLD line if cold
5. Install coolant recovery bottle cap
6. Close left side engine access door