EcoGen 6kW Generator
Owner's Manual
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Model 005818-0
Introduction .............................................. 1
Read This Manual Thoroughly ................................................1
Safety Rules ............................................. 1
Contents ...............................................................................1
Operation and Maintenance....................................................1
How to Obtain Service ...........................................................1
Standards Index .....................................................................3
General Information ................................. 4
1.1 Unpacking/Inspection .....................................................4
1.2 Protection Systems ........................................................4
1.3 Emission Information......................................................4
1.4 The Generator ................................................................5
1.5 Specifications ................................................................5
1.6 Ready to Run .................................................................5
1.7 Fuel Requirements and Recommendations ......................6
1.8 Fuel Consumption ..........................................................6
1.9 Location .........................................................................6
1.10 Battery Requirements .....................................................9
1.11 Battery Installation ..........................................................9
1.12 The Battery ....................................................................9
1.13 Battery Charger ............................................................10
Post Installation Start-up and
Adjustments ........................................... 10
2.1 Activate the Generator ..................................................10
2.2 Before Initial Startup .....................................................10
2.3 Electrical Checks ..........................................................10
2.4 Generator Tests Under Load ..........................................12
2.5 Checking Automatic Operation ......................................12
Operation ................................................ 12
3.1 Control Panel Interface .................................................12
3.2 Automatic Operation .....................................................13
3.3 Sequence of Automatic Operation .................................13
3.4 Side Compartment .......................................................14
3.5 Protection Systems ......................................................14
Maintenance ........................................... 16
4.1 Fuse .............................................................................16
4.2 Checking the Engine Oil Level .......................................16
4.3 Changing the Engine Oil ................................................16
4.4 Changing the Engine Air Cleaner ...................................17
4.5 Spark Plugs ..................................................................17
4.6 Battery Maintenance .....................................................18
4.7 Adjusting GT-530 Valve Clearance .................................18
4.8 Cooling System ............................................................19
4.9 Attention After Submersion ...........................................19
4.10 Corrosion Protection.....................................................19
4.11 Out of Service Procedure ..............................................19
4.12 Service Schedule .........................................................21
Troubleshooting ..................................... 22
5.1 Troubleshooting Guide ..................................................22
Appendix................................................. 23
6.1 Menu System Navigation ..............................................23
Installation Diagrams ............................ 25
Oil Make-up System ............................... 29
Notes ....................................................... 30
Warranty ................................................. 32
Table of Contents
1
INTRODUCTION
Thank you for purchasing this compact, high performance, air-cooled,
engine-driven generator. It is designed to supply electrical power to
operate an inverter/battery charger as a component in an off-grid power
solution.
This unit is factory installed in an all-weather, metal enclosure and is
intended exclusively for outdoor installation. This generator will operate
using vapor withdrawn liquid propane (LP).
NOTE:
This generator is suitable for supplying typical residential loads such
as Induction Motors (sump pumps, refrigerators, air conditioners,
furnaces, etc.), Electronic Components (computer, monitor, TV, etc.),
Lighting Loads and Microwaves.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Dealer
for starting, operating and servicing procedures.
SAFETY RULES
Throughout this publication, and on tags and decals affixed to the genera-
tor, DANGER, WARNING, CAUTION and NOTE blocks are used to alert
personnel to special instructions about a particular operation that may be
hazardous if performed incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
n
This symbol points out important safety information that,
if not followed, could endanger personal safety and/or
property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock hazard.
The operator is responsible for proper and safe use of the equipment. The
manufacturer strongly recommends that the operator read this Owner's
Manual and thoroughly understand all instructions before using this
equipment. The manufacturer also strongly recommends instructing other
users to properly start and operate the unit. This prepares them if they
need to operate the equipment in an emergency.
CONTENTS
This manual contains important instructions that should be followed dur-
ing installation and maintenance of the generator and batteries for the 6kW
LP, V-twin GT-530 Engine.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to make sure
that all maintenance for safe operation is performed promptly, and to have
the equipment checked periodically by a Dealer. Normal maintenance ser-
vice and replacement of parts are the responsibility of the owner/operator
and, as such, are not considered defects in materials or workmanship
within the terms of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures a minimum number
of problems and keep operating expenses at a minimum. See a Dealer for
service aids and accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, contact a Dealer for
assistance. Service technicians are factory-trained and are capable of
handling all service needs.
When contacting a Dealer about parts and service, always supply the
complete model number and serial number of the unit as given on its data
decal, which is located on the generator. See section "The Generator" for
decal location.
Model No. _________________ Serial No. ______________
Data Label Sample
Safety Rules
2
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Manual&3:$&C9"'&"'(& #:9"A&-'(&;(:(43"84&23:&8=(43"(&)35(6%<&(559D
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@39:"39:($A&E3:%&3229$(:")&34(&23#)($&7%&53969:;&"8&58668C&)9@=6(&
3:$&5#:$3@(:"36&4#6()&84&=4(23#"98:)A
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"'3"&@9;'"&9:>86>(&3&'3F34$A&-'(&C34:9:;)&9:&"'9)&@3:#36<&3:$&8:&
"3;)&3:$&$(236)&3559G($&"8&"'(&#:9"&34(<&"'(4(584(<&:8"&366D9:26#)9>(A&H5&
#)9:;&3&=482($#4(<&C84I&@("'8$&84&8=(43"9:;&"(2':9?#(&"'(&@3:#D
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8"'(4)A&*6)8&@3I(&)#4(&"'(&=482($#4(<&C84I&@("'8$&84&8=(43"9:;&
"(2':9?#(&#"969F($&$8()&:8"&4(:$(4&"'(&;(:(43"84&#:)35(A
n
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance or being careless can
cause possible injury or death. Permit only
responsible and capable persons to install,
operate and maintain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
n
Parts of the generator are rotating and/or
hot during operation. Exercise care near run-
ning generators.
n
Installation must always comply with appli-
cable codes, standards, laws and regula-
tions.
n
A running generator gives off carbon mon-
oxide, and odorless, colorless poison gas.
Breathing in carbon monoxide can cause
headaches, fatigue, diziness, nausea, vomit-
ting, confusion, fainting, siezures or death.
GENERAL HAZARDS
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8=(43"84& 36)8& @#)"& 28@=6%& C9"'& 366& )#2'& 28$()<& )"3:$34$)& 3:$&
4(;#63"98:)A
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@9;'"&4(:$(4&"'(&)%)"(@&#:)35(&84&9:&:8:28@=693:2(&C9"'&3==69D
2376(&28$()&3:$&)"3:$34$)A
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32284$9:;&"8&@3:#532"#4(4N)&9:)"4#2"98:)O4(28@@(:$3"98:)A
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249"9236&"8&2844(2"&;(:(43"84&8=(43"98:A&K8& :8"& 36"(4& "'(&9:)"36D
63"98:&84&=(4@9"&(>(:&=34"936&7682I3;(&85&>(:"963"98:&=48>9)98:)<&
3)&"'9)&23:&)(498#)6%&355(2"&)35(&8=(43"98:&85&"'(&;(:(43"84A&The
generator MUST be installed and operated outdoors only.
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53"9;#($A
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6(3I3;(<&896&6(3I3;(<&("2A
EXHAUST HAZARDS
R(:(43"84& (:;9:(& (G'3#)"& 28:"39:)& K,*K1.& 23478:& @8:8GDJ&
9$(<& 3:& 8$846())<& 286846())& =89)8:8#)& ;3)A& B4(3"'9:;& 23478:&
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ELECTRICAL HAZARDS
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8=(43"98:A& *>89$& 28:"32"& C9"'& 734(& C94()<& "(4@9:36)<& 28::(2D
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3:&8=(43"9:;&#:9"<&)"3:$&8:&3:&9:)#63"($<&$4%&)#4532(&"8&4($#2(&
)'82I&'3F34$A
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9:;& 9:& C3"(4<& C'96(& 734(588"<& 84& C'96(& '3:$)& 84& 5(("& 34(& C("A&
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FIRE HAZARDS
P).$6(.#$5&6#':B$'"#$=#*#.&').$745'$>#$(*5'&++#0$&*0$7&(*'&(*#0$9$
<.)<#.+:?$ Installation must always comply with applicable
codes, standards, laws and regulations.$A0"#.#$5'.(-'+:$
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=#*#.&').$ (5$ (*5'&++#0$ (*$ &--).0&*-#$ E('"$ '"#$ 7&*46&-'4.#.L5$
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5'&*0&.05B$+&E5$&*0$.#=4+&'()*5?
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EXPLOSION HAZARDS
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6).$+#&D5?$%)$+#&D&=#$(5$<#.7(''#0?
STANDARDS INDEX
T*$ '"#$ &>5#*-#$ )6$ <#.'(*#*'$ 5'&*0&.05B$ -)0#5B$ .#=4+&'()*5$ &*0$
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CALIFORNIA PROPOSITION 65 WARNING
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CALIFORNIA PROPOSITION 65 WARNING
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Safety Rules
n
Only qualified electricians or contractors
should attempt such installations, which must
comply strictly with applicable codes, stan-
dards and regulations.
1.1 UNPACKING/INSPECTION
!"#$%&'()*+,-(./&+*%$"'001&-(2)$+#$&+4(#$(#2&"4%&5*6*.$7
83-2&2#*(591&.$($%*#4%&2$#&-2&%$*51&"4%&-(2#*00*#-4(&:-#3&*&"*+#4%1&;&
2'))0-$5&*(5&)%$<64'(#$5&9*2$&)*5&*(5&3*2&*&:$*#3$%&)%4#$+<
#-=$&$(+042'%$*#&-2&-(#$(5$5&"4%&outdoor installation only.
If this generator is used to power electrical load
circuits normally powered by a utility power
source, it is required by code to install a trans-
fer switch. The transfer switch must effectively
isolate the electrical system from the utility
distribution system when the generator is oper-
ating (NEC 700, 701 & 702). Failure to isolate an
electrical system by such means will result in
damage to the generator and also may result in
injury or death to utility power workers due to
backfeed of electrical energy.
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5*6*.$7
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'(04+,$5&9$"4%$&*##$6)#-(.&0-"#$&%44"7
1.2 PROTECTION SYSTEMS
F(0-,$& *(& *'#4649-0$& $(.-($/& #3$& .$($%*#4%& 6*1& 3*=$& %'(&"4%&
04(.&)$%-452& 4"& #-6$&:-#3&(4&4)$%*#4%& )%$2$(#& #4&64(-#4%&$(.-($&
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1.3 EMISSION INFORMATION
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"4004:-(.I
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4
General Information
5
1.4 THE GENERATOR
Figure 1.1 * 6kW, V-twin, GT-530 Engine
(door removed)
Air Filter External Oil Fill/Dipstick
Control
Panel
Data
Label
Circuit
Breaker
Fuel Inlet
(back)
Fuel
Regulator
Composite
Base
Battery
Compartment
Oil FilterExhaust
Enclosure
Engine Oil
Dipstick
Engine
Oil Fill
Figure 1.2 * Data Label Sample
1.5 SPECIFICATIONS
1.5.1 GENERATOR
Fuel Type ....................................................................................... LP vapor only
Rated Voltage .........................................................................................120 VAC
Rated Maximum Load Current (Amps) at 120 Volts (LP)* .............................50.0
Main Circuit Breaker ................................................................................ 50 Amp
Phase ................................................................................................................1
Number of Rotor Poles .......................................................................................2
Rated AC Frequency ....................................................................................60 Hz
Battery Requirement ........................ Group 26R, 12 Volts and 525 CCA Minimum
Weight (unit only in lbs.) ................................................................................387
Enclosure ..................................................................................................... Steel
Normal Operating Range: This unit is tested in accordance to UL 2200 standards
with an operating temperature of 20 °F (-29 °C) to 122 °F. (50 °C). For areas
where temperatures fall below 32 °F (0 °C), a cold weather kit is highly recom-
mended. When operated above 104º F (40º C) there may be a decrease in engine
power. (Please reference the engine specifications section).
These generators are rated in accordance with UL2200, Safety Standard for
Stationary Engine Generator Assemblies; and CSA-C22.2 No. 100-04 Standard
for Motors and Generators.
1.5.2 ENGINE
Type of Engine ......................................................................................... GT-530
Number of Cylinders ..........................................................................................2
Rated Horsepower @ 3,600 rpm* ...................................................................18
Displacement .............................................................................................530cc
Cylinder Block .........................................................Aluminum w/Cast Iron Sleeve
Valve Arrangement ..................................................................... Overhead Valves
Ignition System ................................................................. Solid-state w/Magneto
Recommended Spark Plug ..................................................................... BPR6HS
Spark Plug Gap ................................................................. 0.76 mm (0.030 inch)
Compression Ratio.......................................................................................9.5:1
Starter .....................................................................................................12 VDC
Oil Capacity Including Filter ..........................................................Approx. 1.7 Qts
Recommended Oil Filter ............................................................. Part # 070185F
Recommended Air Filter ............................................................... Part # 0E9371
Operating RPM............................................................................................2,600
* Engine power is subject to and limited by such factors as fuel Btu content, ambi-
ent temperature and altitude. Engine power decreases about 3.5 percent for each
1,000 feet above sea level; and also will decrease about 1 percent for each 6 C
(10 F) above 16 C (60 F) ambient temperature.
1.6 READY TO RUN
The "Ready to Run" on the display is ready when all of the following
conditions are true:
1. The AUTO/OFF/MANUAL switch is set to the AUTO position.
2. The utility voltage being supplied to the unit is being sensed
by the PCB. If the utility sense voltage is not connected to the
unit or if it is below approximately 150-160 volts AC, then
the system will display the message "No Utility Present". This
indicates that if the AUTO/OFF/MANUAL switch is placed in
the Auto position, the generator will start.
3. No alarms are present, for example, low oil pressure, high
temperature, etc.
General Information
!"#$ $%&'($)'*&+)','-./$0-1$
)'23,,'-10.+3-/
This unit uses a LP vapor withdrawal system only. This type of
system uses the vapors formed above the liquid fuel in the storage
tank.
Recommended fuels should have a Btu content of at least 2,520
Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu
content of the fuel.
Required fuel pressure for liquid propane, 10 inches to 12 inches
of water column (0.36 to 0.43 psi). The primary regulator for the
propane supply is NOT INCLUDED with the generator.
NOTE:
All pipe sizing, construction and layout must comply NFPA 58
for liquid propane applications. Once the generator is installed,
verify that the fuel pressure NEVER drops below 10 inches
water column.
Prior to installation of the generator, the installer should consult
local fuel suppliers or the fire marshal to check codes and regula-
tions for proper installation. Local codes will mandate correct rout-
ing of gaseous fuel line piping around gardens, shrubs and other
landscaping to prevent any damage.
Special considerations should be given when installing the unit
where local conditions include flooding, tornados, hurricanes,
earthquakes and unstable ground for the flexibility and strength of
piping and their connections.
Use an approved pipe sealant or joint compound on all threaded
fitting.
All installed gaseous fuel piping must be purged and leak tested
prior to initial start-up in accordance with local codes, standards
and regulations.
!"4$ %&'($23-/&,5.+3-
Unit
LP Vapor
1/2 Load Full Load
6 kW 0.82/30 1.47/54
** LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
Verify that gas pipe and regulator is capable of providing enough
fuel flow to include household appliances.
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7D978"
NOTE:
A minimum of one approved manual shut-off valve must be
installed in the gaseous fuel supply line. The valve must be eas-
ily accessible. Local codes determine the proper location.
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n
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P@L?$7CC=@>7R=9$>:B98$7EB$8L7EB7DB8"
1.9.1 GENERATOR
Install the generator set, in its protective enclosure, outdoors,
where adequate cooling and ventilating air is always available
(Figure 1.3). Consider these factors:
The installation of the generator Y must comply strictly with
NFPA 37, NFPA 58, and NFPA 70 standards.
Install the unit where air inlet and outlet openings will not Y
become obstructed by leaves, grass, snow, etc.. If prevailing
winds will cause blowing or drifting, consider using a wind-
break to protect the unit.
Install the generator on high ground where water levels will not Y
rise and endanger it.
Allow sufficient room on all sides of the generator for mainte-Y
nance and servicing. This unit must be installed in accordance
with current applicable NFPA 37 and NFPA 70 standards; as
well as any other federal, state and local codes for minimum
distances from other structures. DO NOT install under wooden
decks or structures unless there is at least four (4) feet of clear-
ance above the generator, three (3) feet of clearance on sides
and front, and 18 inches of clearance at back of unit.
Install the unit where rain gutter down spouts, roof run-off, Y
landscape irrigation, water sprinklers or sump pump discharge
does not flood the unit or spray the enclosure, including any air
inlet or outlet openings.
6
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7
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Figure 1.3 + Generator Clearances
1.9.2 NEW INSTALLATION GUIDELINES FOR
STATIONARY AIR-COOLED GENERATORS
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)3'02'"0"[/0:1*#$+1&)':%$)-+%&#'%"3'$()'-)#*&$#'%"3'/0"/&*#+0"#'
2-0:'$()'+"3)7)"3)"$'$)#$+"6'&%1'+"3+/%$)3'$(%$'%";'2+-)',+$(+"'$()'
6)")-%$0-' )"/&0#*-)' ,0*&3' "0$' 70#)' %";' +6"+$+0"' -+#O' $0' ")%-1;'
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-)#70"#)8
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$()' 6*+3)&+")#' 20-' +"#$%&&%$+0"' 02' $()' 6)")-%$0-#' &+#$)3' %10.)' %-)'
/(%"6)3'$0'T_'+"/()#'LZUY::N'2-0:'$()'1%/O'#+3)'02'$()'6)")-%[
$0-'$0'%'#$%$+0"%-;',%&&'0-'1*+&3+"68'V0-'%3)P*%$)':%+"$)"%"/)'%"3'
%+-2&0,'/&)%-%"/)4'$()'%-)%'%10.)'$()'6)")-%$0-'#(0*&3'1)'%$'&)%#$'
Z'2))$',+$('%':+"+:*:'02'X'2))$'%$'$()'2-0"$'%"3')"3#'02'$()')"/&0[
#*-)8'@(+#',0*&3'+"/&*3)'$-))#4'#(-*1#'%"3'.)6)$%$+0"'$(%$'/0*&3'
01#$-*/$'%+-2&0,8'D))'$()'3+%6-%:'0"'$()'-).)-#)'02'$(+#'7%6)'%"3'
$()'+"#$%&&%$+0"'3-%,+"6',+$(+"'$()'0,")-`#':%"*%&'20-'3)$%+
I)")-%$0-' )Q(%*#$' /0"$%+"#' G=BGCH' /%-10"' :0"0Q+3)'6%#8' @(+#'
3%"6)-0*#'6%#'/%"'/%*#)'*"/0"#/+0*#")##'0-'3)%$(8'G0'"0$'7&%/)'
$()'*"+$'")%-',+"30,#4'300-#4'2-)#('%+-'+"$%O)#'L2*-"%/)#4')$/8N'0-'
%";'07)"+"6#'+"'$()'1*+&3+"6'0-'#$-*/$*-)4'+"/&*3+"6',+"30,#'%"3'
300-#'02'%"'%$$%/()3'6%-%6)8
If the AUTO/OFF/MANUAL switch is not set to
its OFF position, the generator can crank and
start as soon as the battery cables are con-
nected. If the battery charger power supply
is not turned off, sparking can occur at the
battery posts and cause an explosion.
General Information
8
General Information
Figure 1.4 + Installation Guidelines
18 inches
Minimum Distance
36 inches
36 inches
36 inches
60 inches 60 inches
Existing Wall
No windows or openings in the wall permitted
within 5 feet from any point of the generator.
Top o f G ene ra tor
60” Minimum
60” Recommended
Minimum From Ends
18 inches
Minimum
Generator
Clearance from windows,
doors, any openings in the
wall, shrubs or vegetation
over 12” in height
Clearance from the ends and front of the
generator should be 36 inches. This
would include shrubs, trees and any
kind of vegetation. Clearance at the top
should be a minimum of 48 inches from
any structure, overhang or projections
from the wall. The generator should not
be placed under a deck or other
structure that is closed in and would limit
or contain air flow.
These guidelines are based upon fire
testing of the generator enclosure and
the manufacturer’s requirement for air
flow for proper operation. Local codes
may be different and more restrictive
than what is described here.
This drawing supersedes installation instructions in all Carrier air-cooled installation and owner’s manuals dated
previous to May 26, 2007.
This drawing supersedes installation instructions in all air-cooled installation and owner's manuals dated previous to May 26, 2007.
9
!"!#$ %&''()*$)(+,-)(.(/'0
See the Specifications section for correct battery size and rating.
!"!!$ %&''()*$-/0'&11&'-2/
Fill the battery with the proper electrolyte fluid if necessary and
have the battery fully charged before installing it.
Before installing and connecting the battery, complete the follow-
ing steps:
1. Set the generator's AUTO/OFF/MANUAL switch to OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 7.5A fuse from the generator control panel.
Battery cables were factory connected at the generator (Figure
1.5). Connect cables to battery posts as follows:
4. Connect the red battery cable (from starter contactor) to the
battery post indicated by a positive, POS or (+).
5. Connect the black battery cable (from frame ground) to the
battery post indicated by a negative, NEG or (W).
6. Install battery post covers supplied with the generator.
Figure 1.5 + Battery Cable Connections
NOTE:
Dielectric grease should be used on battery posts to aid in the
prevention of corrosion.
NOTE:
Damage will result if battery connections are made in reverse.
NOTE:
In areas where temperatures regularly fall below 32° F (0° C) it
is recommended that a pad type battery heater be installed to
aid in cold climate starting.
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10
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!""),-")!2"&%+%&/,%*'1)1"&,%*')+*#),-")&*##"&,)1%=")/'4)#/,%'()9-"')
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@4@A! "6BBCDE!FG6DHCD
NOTE:
The battery charger is integrated into the control module
in all models and requires input to the generator between
90-265VAC.
E,)*2"#/,"1)/1)/)F!3/#,)G-/#("#F)9-%&-)"'15#"1)*5,25,)%1)&*',%'56
/770)*2,%3%="4),*)2#*3*,")3/H%353)./,,"#0)7%+")/'4)&-/#(%'()7"$"71)
/#")/,)1/+")&*'4%,%*'1;)I-")51"#)&/')3*'%,*#).*,-)./,,"#0)$*7,/(")
/'4)&5##"',)&-/#(")%').*,-)FB**1,F)/'4)FJ7*/,F)3*4"1)*'),-")KGL)
4%127/0)*'),-")&*',#*77"#;
NOTE:
There is a warning on the LCD display when the battery needs
service.
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*+)/)2*9"#)*5,/(";
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I4I! "CNMDC!JLJBJ6O!PB6DB:QR
NOTE:
These units have been run and tested at the factory prior to
being shipped and do not require any type of break-in.
NOTE:
This unit comes filled with oil from the factory. Check the oil
level and add the appropriate amount if necessary.
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11
ACTIVATION CHART
CHOOSE LANGUAGE TROUBLESHOOTING
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ENTER ACTIVATION CODE (Passcode) TROUBLESHOOTING
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PSPRL:
;SELECT HOUR (0-23)@
;- +@6
Escape Enter
Serial 123456789
Passcode XXXXX +/-
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To Activate go to
www.activategen.com
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Language
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Post Installation Start-up and Adjustments
12
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NOTE:
It is important not to proceed until certain that generator AC
voltage and frequency are correct and within the stated limits.
=7>! !0?@?ABCDA!C?ECE!F@G?A!
HDBG
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3.1.1 USING THE AUTO/OFF/MANUAL SWITCH
(FIGURE 3.1)
n
Q)*+!*+&!6()*%+!6&*!*$!BFCDR!*+&!&.5).&!S,:!
%#,.<!,.'!6*,#*!,*!,.:!*)S&!()*+$-*!(,#.).57!
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1$(&#!6$-#%&!2$3*,5&!'#$$16!9&3$(!,!1#&6&*!
3&2&3!$#!'-#).5!*+&!.$#S,3!&T&#%)6&!%:%3&7!C$!
1#&2&.*!1$66)93&!).U-#:!*+,*!S)5+*!9&!%,-6&'!
9:!6-%+!6-''&.!6*,#*6R!,3(,:6!6&*!*+&!6()*%+!
*$!DPP!,.'!#&S$2&!*+&!;-6&6!9&;$#&!($#<4
).5!$.!$#!,#$-.'!*+&!5&.&#,*$#!$#!*#,.6;&#!
6()*%+7!C+&.R!13,%&!,!VGD!@DC!D"?ABC?W!
*,5!$.!*+&!5&.&#,*$#!1,.&3!,.'!$.!*+&!*#,.64
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4+*,(#373*&4#0-&)+*,0'"
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.'1&33#*%&)&#,3#+#.*,1,*7#>+,1.)&"
D1&#,*)$.
13
Operation
Figure 3.1 + Generator Control Panel
Escape
MAIN FUSE
AUTO OFF MANUAL
7.5 AMP
Enter
!"#$% &'()*% "#+,(% -"% #&% *.,% /,$,(0*#(1% *.,% 2')"304% '$*,(&05,% +'33%
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*#%),*%*.,%9'$'9-9%),**'$/)%*#%#",(0*,7%8.,),%),**'$/)%0(,%:-((,$*%
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,?,(5'),%*'9,%')%,$*,(,2%@A'/-(,%B7CD7
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5-((,$*%8'9,%0$2%;0*,7
NOTE:
The current date/time will need to be reset every time the 12
volt battery is disconnected and then reconnected, and/or when
the fuse is removed.
Display Interface Menus
8.,%H:;%2')"304%')%#(/0$'>,2%0)%2,*0'3,2%6,3#+I
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+'33% 6,% 0-*#90*'50334% "#)*,2% #$% *.')% "0/,% 0)% +,33% 0)% &30).'$/%
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P4)*,9)%),5*'#$%S%:3,0(%G30(97
8.,%2')"304%605N3'/.*%')%$#(90334%#&&7%E&%*.,%-),(%"(,)),)%0$4%N,41%M%
*.,%605N3'/.*%+'33%5#9,%#$%0-*#90*'50334%0$2%(,90'$%#$%&#(%BO%
),5#$2)%0&*,(%*.,%30)*%N,4%+0)%"(,)),27
8.,%JT0'$%T,$-L%"0/,%+'33%033#+%*.,%-),(%*#%$0='/0*,%*#%033%#*.,(%M%
"0/,)% #(% )-6S9,$-)% 64% -)'$/% *.,% H,&*<U'/.*% 0$2% V$*,(% N,4)7%
8.')%"0/,%50$%6,%055,)),2%0*%0$4%*'9,%+'*.%),=,(03%"(,)),)%#&%
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4#-%605N%*#%*.,%"(,='#-)%9,$-%-$*'3%*.,%90'$%9,$-%')%(,05.,27%
8.')% "0/,% 2')"304)% *.,% !#+'$/% #"*'#$)I% KEP8WUXY% P8G8!PY%
V;E8Y%GZ;%;V[!\7%@P,,%*.,%G"",$2'?%S%]T,$-%P4)*,9]7D
3.2 AUTOMATIC OPERATION
8#%),3,5*%0-*#90*'5%#",(0*'#$1%2#%*.,%!#+'$/I
C7% T0N,%)-(,%*.,%(,9#*,%FS+'(,%5#$*05*)%0(,%),*%*#%*.,'(%WRVZ%
"#)'*'#$7
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V3,5*('503%;0*0%),5*'#$D7
B7% P,*%*.,%/,$,(0*#(^)%G!8W<WAA<TGZ!GH%)+'*5.%*#%G!8W7
_7% P,*%*.,%/,$,(0*#(^)%90'$%5'(5-'*%6(,0N,(%*#%'*)%WZ%@#(%:HWPV;D%
"#)'*'#$7
Q'*.%*.,%"(,5,2'$/%)*,")%5#9"3,*,1%*.,%/,$,(0*#(%+'33%)*0(*%0-*#S
90*'50334% +.,$% (,9#*,% FS+'(,% )*0(*% 5#$*05*)% 0(,% :HWPV;% @WZD7%
G&*,(% *.,% -$'*% )*0(*)1% 3#02)% 0(,% *(0$)&,((,2% *#% *.,% /,$,(0*#(% 0$2%
5.0(/,)% *.,% 60**,(4% "05N% 64% *.,% '$=,(*,(% )4)*,97% U,&,(% *#% *.,%
P,`-,$5,%#&%G-*#90*'5%W",(0*'#$%),5*'#$7
3.3 SEQUENCE OF AUTOMATIC
OPERATION
3.3.1 REMOTE START ON
E$'*'03%:#$2'*'#$)I%\,$,(0*#(%'$%G-*#1%(,024%*#%(-$7%Q.,$%(,9#*,%M%
)*0(*% 5#$*05*)% 0(,% :HWPV;% @WZD1% *.,% ,$/'$,% +'33% 5(0$N% 0$2%
)*0(*7
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2#+$%0&*,(%#$,%@CD%9'$-*,%5##3S2#+$%*'9,7
3.3.2 CRANKING
8.,%)4)*,9%+'33%5#$*(#3%*.,%5453'5%5(0$N'$/%0)%!#+)I%%Ca%),5#$2%
5(0$N1%),=,$%@bD%),5#$2%(,)*1%Ca%),5#$2%5(0$N1%),=,$%@bD%),5#$2%
(,)*%!#+,2% 64% *.(,,%@BD% 022'*'#$03% 5453,)%#&% ),=,$% @bD%),5#$2%
5(0$N)%!#+,2%64%),=,$%@bD%),5#$2%(,)*)7
Choke Operation
C7% 8.,% cBO55% ,$/'$,)% .0=,% 0$% ,3,5*('5% 5.#N,% #$% *.,% )*,"",(%
9#*#(%6(05N,*%*.0*%')%0-*#90*'50334%5#$*(#33,2%64%*.,%,3,5*(#$'5%
5#$*(#3%6#0(27
Failure to Start
8.')%')%2,&'$,2%0)%0$4%#&%*.,%!#+'$/%#55-((,$5,)%2-('$/%5(0$NS
'$/I
C7% Z#*%(,05.'$/%)*0(*,(%2(#"#-*%+'*.'$%*.,%)",5'&',2%5(0$N%5453,7%
P*0(*,(%2(#"#-*%')%2,&'$,2%0)%&#-(%@_D%5453,)%0*%C1OOO%URT7
F7% U,05.'$/%)*0(*,(%2(#"#-*1% 6-*% *.,$% $#*% (,05.'$/% FFOO% URT%
+'*.'$%Cc%),5#$2)7%E$%*.')%50),%*.,%5#$*(#3%6#0(2%+'33%/#%'$*#%
0%(,)*%5453,%&#(%),=,$%@bD%),5#$2)1%*.,$%5#$*'$-,%*.,%(,)*%#&%
*.,%5(0$N%5453,7
;-('$/%0%(,)*%5453,%*.,%)*0(*%0$2%&-,3%#-*"-*)%0(,%2,S,$,(/'>,2%0$2%
*.,%90/$,*#%#-*"-*%')%).#(*,2%*#%/(#-$27
14
!"#$%&$'(!)$*&+&)$,
The following notes apply during cranking cycle.
1. Starter motor will not engage within five (5) seconds of the
engine shutting down.
2. The fuel output will not be energized with the starter.
3. The starter and magneto outputs will be energized together.
4. Once the starter is energized the control board will begin look-
ing for engine rotation. If it does not see an RPM signal within
three (3) seconds it will shut down and latch out on RPM
sensor loss.
5. Once the control board sees an RPM signal it will energize the
fuel solenoid, drive the throttle open and continue the crank
sequence.
6. Starter motor will disengage when speed reaches starter
dropout.
7. If the generator does not reach 2200 RPM within 15 seconds,
re-crank cycle will occur.
8. If engine stops turning between starter dropout and 2200
RPM, the board will go into a rest cycle for seven (7) seconds
then re-crank (if additional crank cycles exist).
9. Once started, the generator will wait for a hold-off period
before starting to monitor oil pressure and oil temperature
(refer to the Alarm Messages section for hold-off times).
10. During Manual start cranking, if the Mode switch is moved
from the Manual position, the cranking stops immediately.
11. During Auto mode cranking, if the remote start contacts OPEN
(OFF), the cranking cycle does NOT abort but continues until
complete. Once the engine starts, it will run for one (1) min-
ute, then shut down.
-.-./( 012341(54604(377
Initial Condition: Generator supplying power to customer load.
Once the contacts open, the controller will run the engine through
a one (1) minute cool down period and then shut down.
3.4 SIDE COMPARTMENT
(FIGURES 3.2 & 3.3)
Local codes may require this compartment to be locked. A hasp is
provided so the owner can secure the compartment with their own
padlock. Check local codes in the area.
-./.8( 269:(!90!;94(<016=10
This is a 1-pole breaker rated according to the Specifications sec-
tion.
7&'>"?(-.@(A(5&*?(!)BC#"+B?$+
7&'>"?(-.-(A(3C?$(5&*?(!)BC#"+B?$+
3.5 PROTECTION SYSTEMS
-.D.8( 6E6025
Highest Priority (Latching) Displayed on the control panel. They
must be cleared before the alarm message goes away. The alarm
log records each occurrence (see Appendix - "Menu System").
E)F(3&G(H"?,,>"?(I5J>+*)F$(6G#"BK
A five (5) second delay on start-up and seven (7) second delay
once the engine is running.
This switch (Figure 3.4) has normally closed contacts that are
held open by engine oil pressure during operation. Should the oil
pressure drop below the five (5) PSI range, switch contacts close
and the engine shuts down. The unit should not be restarted until
oil level is verified.
Operation
15
High Engine Temperature (Shutdown Alarm 7 Auto Reset)
A 10 second delay on start-up and one (1) second delay before
shutdown. Auto reset when the condition clears and restart the
engine if a valid start signal is still present.
This switch>s contacts (Figure 3.4) close if the temperature should
exceed approximately 140° C (284° F), initiating an engine shut-
down. Once the oil temperature drops to a safe level the switch>s
contacts open again.
Over Crank (Shutdown Alarm)
This occurs if the engine has not started within the specified crank
cycle. (See "Cranking" section.)
Figure 3. 4 7 Low Oil Pressure and
High Temperature Switches
High Temp Switch
Low Oil Switch
Oil Filter
Over Speed (Shutdown Alarm)
3000 RPM for three (3) seconds or 3300 RPM immediately. This
feature protects the generator from damage by shutting it down
if it happens to run faster than the preset limit. This protection
also prevents the generator from supplying an output that could
potentially damage appliances connected to the generator circuit.
Contact the nearest Dealer if this failure occurs.
RPM Sense Loss (Shutdown Alarm)
During cranking, if the Control Board does not see a valid RPM
signal within three (3) seconds, it will shut down and lock out on
RPM sense loss. While engine is running, if RPM signal is lost for
one (1) second the Control Board will shut the engine down, wait
15 seconds, then re-crank the engine. If no RPM signal is detected
within the first three (3) seconds of cranking, the Control Board
will shut the engine down and latch out on RPM sensor loss. If the
RPM signal is detected, the engine will start and run normally. If
the RPM signal is subsequently lost again, the Control Board will
try one more re-crank attempt before latching out and displaying
the RPM sensor failure message.
Under-frequency (Shutdown Alarm)
After starting, if the generator stays under frequency for more than
30 seconds it will shut down. The under-frequency setting is 55
Hz.
Internal Fault (Shutdown Alarm)
This alarm cannot be cleared, call service dealer.
Undervoltage (Shutdown Alarm)
If the generator voltage falls below 85% of nominal for more than
15 seconds, it shuts down.
Overvoltage (Shutdown Alarm)
If the generator voltage rises above 110% of rating for greater than
three (3) seconds, an alarm will be issued and the unit will shut
down.
If the generator voltage rises above 130% of rating for greater than
0.5 seconds, an alarm will be issued and the unit will shut down.
Clear Alarm
Clear the alarm by setting the AUTO/OFF/MANUAL switch to the
OFF position. Press the ENTER key to unlatch any active fault and
clear the corresponding alarm message.
3.5.2 WARNINGS
Second Priority (Non-latching) Displayed on the control panel
and the external yellow LED (V-twins only). Warnings automati-
cally clear when the monitored condition goes away. Warnings are
recorded in the alarm log. Warnings cannot cause shutdowns.
Low Battery
The Control Board monitors battery voltage and displays a warn-
ing if the battery voltage falls below 11.9 volts for one (1) minute.
Warning is automatically cleared if the battery voltage rises above
12.4 volts. Battery voltage is not monitored during the crank
cycle.
3.5.3 MAINTENANCE ALERTS
Third priority
Maintenance Message
When a maintenance period expires, a warning message will
be displayed. The alert can be reset by pressing the Enter key,
which will cause the user to be prompted to confirm the action.
Resetting will clear the alert and reset the maintenance counters
for all conditions annunciated. The history log will record the alert.
The maintenance counter will not accumulate without battery
power. Once battery power is restored, the set time prompt will be
displayed. The maintenance counters will be adjusted to the new
time and date.
NOTE:
Since most maintenance alerts will occur at the same time
(most have 500 hour or two (2) year intervals), only one will
appear on the display at any one time. Once the first alert is
cleared, the next active alert will be displayed.
Operation
16
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2(3(2
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2#1.))#/9(06./-E$-##$0"#$K/76/#$L63$G#1.))#/9(06./-$-#106./&
H"#/$ 3.@$ A(00#2B$ 3#8#3-$ /#1#--60(0#$ 2,//6/7$ 0"#$ 7#/#2(0.2$ +.2$
#I0#/9#9$*#26.9-$.+$06)#E$0"#$.63$3#8#3$-".,39$A#$1"#1F#9$@##F3B&
!.$1"#1F$0"#$#/76/#$.63$3#8#3E$*2.1##9$(-$+.33.@-$:;67,2#-$M&=E$M&>$
(/9$M&<?N
=&$ C+$0"#$7#/#2(0.2$6-$2,//6/7E$+62-0$0,2/$L;;$(33$(--.16(0#9$3.(9-$
2,//6/7$6/$0"#$2#-69#/1#&$J#1./9E$0,2/$0"#$7#/#2(0.2O-$)(6/$
1621,60$A2#(F#2$0.$0"#$L;;$*.-606./&
>&$ P.8#$0"#$QR!LSL;;SPQTRQU$-@601"$0.$0"#$L;;$*.-606./&
<&$ G#).8#$0"#$96*-061F$(/9$@6*#$60$92B$@60"$($13#(/$13.0"&
M&$ 5.)*3#0#3B$6/-#20$0"#$96*-061FV$0"#/E$2#).8#$60$(7(6/&$!"#$.63$
3#8#3$-".,39$A#$(0$0"#$96*-061F$W;,33X$)(2F&$C+$/#1#--(2BE$(99$
.63$0.$0"#$W;,33X$)(2F$./3B&$4L$TL!$;CUU$QYLZK$![K$W;RUUX$
PQG\&
'&$ C/-0(33$0"#$96*-061F&
]&$ G#-#0$0"#$QR!LSL;;SPQTRQU$-@601"$0.$60-$.2676/(3$*.-606./&
%&$ C+$0"#$7#/#2(0.2$ @(-$ 2,//6/7E$ +62-0$0,2/$ 0"#$ 7#/#2(0.2O-$)(6/$
1621,60$ A2#(F#2$ A(1F$ 0.$ 0"#$ LT$ *.-606./&$ J#1./9E$ 0,2/$ LT$
/##9#9$3.(9-$6/$0"#$2#-69#/1#&
^$G#*#(0$-0#*-$<$0"2.,7"$'$+.2$0"#$.63$2#-#28.62&
n
.4546$78469:4$:;4$4<=><4$?>:;$:;4$7>@$@454@$
A4@7?$:;4$BCDDE$F96G$7<$:;4$D>8H:>IG"$J7><=$
:;>H$I7K@D$D9F9=4$:;4$4<=><4"
NOTE:
When checking the oil level in the reservoir, it is normal that the
oil is steadily consumed, especially for the first 500 hours. At
the first service interval, the oil level in the reservoir will likely
be near the bottom of the dipstick. It is important that the engine
oil level remains within the limits of the dipstick.
Figure 4.1 + Oil Dipstick and Fill
Oil Fill
Oil Dipstick
Oil Drain Hose
!"L$ *+C./-./$0+($(./-.($1-2
n
+7:$7>@$F9M$I9KH4$AK6<H"$C@@7?$4<=><4$:7$
I77@$A4N764$D69><><=$7>@"$C57>D$867@7<=4D$
76$64849:4D$HG><$4O87HK64$?>:;$KH4D$7>@"$
0;767K=;@M$?9H;$4O87H4D$9649H$?>:;$H798"
4.3.1 OIL CHANGE INTERVALS
J##$0"#$_J#2861#$J1"#9,3#_$-#106./&
4.3.2 ENGINE OIL RECOMMENDATIONS
Q33$.63$ -".,39$)##0$ )6/6),)$ Q)#261(/$`#02.3#,)$C/-060,0#$:Q`C?$
J#2861#$53(--$JaE$JU$.2$A#00#2&$R-#$/.$-*#16(3$(996068#-&$JB/0"#061$
'HD<b$6-$,-#9$,/9#2$(33$1./9606./-&
n
C<M$9::4F8:$:7$I69<G$76$H:96:$:;4$4<=><4$
A4N764$>:$;9H$A44<$867846@M$H465>I4D$?>:;$:;4$
64I7FF4<D4D$7>@$F9M$64HK@:$><$9<$4<=><4$
N9>@K64"
P9><:4<9<I4
17
4.3.3 OIL & OIL FILTER CHANGE PROCEDURE
To change the oil, proceed as follows:
1. Start the engine by moving the AUTO/OFF/MANUAL switch to
MANUAL and run until it is thoroughly warmed up. Then shut
OFF the engine by moving the switch to the OFF position.
2. Immediately after the engine shuts OFF, pull the oil drain hose
(Figure 4.1) free of its retaining clip. Remove the cap from the
hose and drain the oil into a suitable container.
3. After the oil has drained, replace the cap onto the end of the
oil drain hose. Retain the hose in the clip.
Change the engine oil filter as follows:
1. With the oil drained, remove the old oil filter by turning it
counterclockwise.
2. Apply a light coating of clean engine oil to the gasket of the
new filter. See the Specifications section for recommended
filter.
3. Screw the new filter on by hand until its gasket lightly contacts
the oil filter adapter. Then, tighten the filter an additional 3/4 to
one turn (Figure 3.4).
4. Refill with the proper recommended oil (see the Engine Oil
Recommendations section). See the Specifications section
for oil capacities.
5. Start the engine, run for one (1) minute, and check for leaks.
6. Shutdown and recheck oil level, add as needed. DO NOT
OVER FILL.
7. Reset the AUTO/OFF/MANUAL switch to the AUTO position.
8. Dispose of used oil at a proper collection center.
* Repeat steps 2 and 3 for the oil reservoir.
4.4 CHANGING THE ENGINE AIR
CLEANER
See "The Generator" section for the location of the air cleaner. Use
the following procedures (Figure 4.2):
1. Lift the roof and remove the door.
2. Turn the two screws 1/4 turn counterclockwise to loosen.
3. Remove the cover and air filter.
4. Wipe away dust or debris from inside of the air box and
around edges.
5. Install the new air cleaner into the air box.
6. Install the cover. Turn the two cover screws 1/4 turn clock-
wise to tighten.
See the Service Schedule section for air cleaner maintenance. See
the Specifications section for air filter replacement part number.
Figure 4.2 ; Engine Air Cleaner
4.5 SPARK PLUGS
Reset the spark plugs gap or replace the spark plugs as necessary.
See the Service Schedule section for maintenance requirements.
1. Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine.
2. Remove the spark plugs and check the condition. Replace
the spark plugs if worn or if reuse is questionable. See the
Service Schedule section for recommended inspection. Clean
by scraping or washing using a wire brush and commercial
solvent. Do not blast the spark plugs to clean.
3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.76 mm (0.030 inch) by carefully bending the ground
electrode (Figure 4.3).
Figure 4.3 ? Setting the Spark Plug Gap
Maintenance
18
4.6 BATTERY MAINTENANCE
!"#$%&''#()$*"+,-.$%#$/0*1#2'#.$1#($'"#$34#(5/2#$42"#.,-#3$*#26
'/+07$!"#$8+--+9/0:$1(+2#.,(#$*"+,-.$%#$8+--+9#.$8+($/0*1#2'/+0;
<7$ =0*1#2'$'"#$%&''#()$1+*'*$&0.$2&%-#*$8+($'/:"'0#**$&0.$2+((+6
*/+07$!/:"'#0$&0.$2-#&0$&*$0#2#**&()7
>7$ ?"#2@$'"#$%&''#()$8-,/.$-#5#-$+8$,0*#&-#.$%&''#(/#*$&0.A$/8$0#26
#**&()A$8/--$9/'"$B/*'/--#.$C&'#($D0-)7$B+$0+'$,*#$'&1$9&'#($/0$
%&''#(/#*7
E7$ F&5#$'"#$*'&'#$+8$2"&(:#$&0.$2+0./'/+0$2"#2@#.7$!"/*$*"+,-.$
%#$.+0#$9/'"$&0$&,'+G+'/5#6')1#$%&''#()$").(+G#'#(7$
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when work-
ing on batteries:
H Remove the 7.5A fuse from the generator con-
trol panel.
H Remove watches, rings or other metal objects.
H Use tools with insulated handles.
H Wear rubber gloves and boots.
H Do not lay tools or metal parts on top of the
battery.
H Disconnect charging source prior to connecting
or disconnecting battery terminals.
n
Do not open or mutilate the battery.
Released electrolyte has been known to
be harmful to the skin and eyes, and to be
toxic.
n
The electrolyte is a dilute sulfuric acid that
is harmful to the skin and eyes. It is electri-
cally conductive and corrosive. The follow-
ing procedures are to be observed:
H Wear full eye protection and protective clothing.
H Where electrolyte contacts the skin, wash it off
immediately with water.
H Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek
medical attention.
H Spilled electrolyte is to be washed down with
an acid neutralizing agent. A common practice
is to use a solution of 1 pound (500 grams)
bicarbonate of soda to 1 gallon (4 liters) of
water. The bicarbonate of soda solution is to
be added until the evidence of reaction (foam-
ing) has ceased. The resulting liquid is to be
flushed with water and the area dried.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
H DO NOT SMOKE when near the battery.
H DO NOT cause flame or spark in battery area.
H Discharge static electricity from body before
touching the battery by first touching a ground-
ed metal surface.
n
Be sure the AUTO/OFF/MANUAL switch is
set to the OFF position before connecting
the battery cables. If the switch is set to
AUTO or MANUAL, the generator can crank
and start as soon as the battery cables are
connected.
Be sure the utility power supply is turned off
and the 7.5A fuse is removed from the gener-
ator control panel, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
4.7 ADJUSTING GT-530 VALVE
CLEARANCE
After the first six (6) months of operation or 500 hours of
operation, check the valve clearance in the engine, adjust if
necessary.
Important:$ =8$ 8##-/0:$ ,02+G8+('&%-#$ &%+,'$ .+/0:$ '"/*$ 1(+2#.,(#$
+($'"#$1(+1#($'++-*$&(#$0+'$&5&/-&%-#A$1-#&*#$2+0'&2'$'"#$B#&-#($8+($
*#(5/2#$&**/*'&02#7$!"/*$/*$&$5#()$/G1+('&0'$*'#1$'+$#0*,(#$-+0:#*'$
-/8#$8+($'"#$#0:/0#7
To check valve clearance:
!"#$#0:/0#$*"+,-.$%#$2++-$%#8+(#$2"#2@/0:7$=8$5&-5#$2-#&(&02#$/*$H$
I7II>3$6$I7IIJ3$KI7IL$6$I7<GGMA$&.N,*'G#0'$/*$0+'$0##.#.7
O#G+5#$*1&(@$1-,:$9/(#*$&0.$1+*/'/+0$9/(#*$&9&)$8(+G$1-,:*7H$
O#G+5#$*1&(@$1-,:*7H$
P&@#$*,(#$'"#$1/*'+0$/*$&'$!+1$B#&.$?#0'#($K!B?M$+8$/'*$2+G6H$
1(#**/+0$*'(+@#$K%+'"$5&-5#*$2-+*#.M7$!+$:#'$'"#$1/*'+0$&'$!B?A$
(#G+5#$ '"#$ /0'&@#$ *2(##0$ &'$ '"#$ 8(+0'$ +8$ '"#$ #0:/0#$ '+$ :&/0$
&22#**$ '+$ '"#$ 8-)9"##-$ 0,'7$ Q*#$ &$ -&(:#$ *+2@#'$ &0.$ *+2@#'$
9(#02"$'+$(+'&'#$'"#$0,'$&0.$"#02#$'"#$#0:/0#$/0$&$2-+2@9/*#$
./(#2'/+07$ C"/-#$ 9&'2"/0:$ '"#$ 1/*'+0$ '"(+,:"$ '"#$ *1&(@$ 1-,:$
"+-#7$!"#$1/*'+0$ *"+,-.$ G+5#$,1$&0.$.+907$!"#$ 1/*'+0$ /*$&'$
!B?$9"#0$/'$/*$&'$/'*$"/:"#*'$1+/0'$+8$'(&5#-7
To adjust valve clearance (if necessary), (Figure 4.4):
P&@#$*,(#$'"#$#0:/0#$/*$&'$RIS$'+$TIS$U7H$
P&@#$*,(#$'"&'$'"#$*1&(@$1-,:$9/(#$/*$(#G+5#.$8(+G$'"#$*1&(@$H$
1-,:$&0.$+,'$+8$'"#$9&)7
O#G+5#$'"#$8+,($*2(#9*$&''&2"/0:$'"#$5&-5#$2+5#(7H$
V++*#0$'"#$(+2@#($N&G$0,'7$Q*#$&$<IGG$&--#0$9(#02"$'+$',(0$H$
'"#$1/5+'$%&--$*',.$9"/-#$2"#2@/0:$2-#&(&02#$%#'9##0$'"#$(+2@#($
&(G$&0.$'"#$5&-5#$*'#G$9/'"$&$8##-#($:&,:#7$?+((#2'$2-#&(&02#$
/*$I7II>6I7IIJ$/02"$KI7IL6I7<$GGM7
NOTE:
Hold the rocker arm jam nut in place as the pivot ball stud is
turned.
Maintenance
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