Manual Part No.

0G2832

2.4 G2 GAS
ENGINE

SERVICE
MANUAL
FOREWORD
This manual has been published by the generator manufacturer to aid our dealers’ mechanics
and company service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these prod-
ucts, or like or similar products. It is also assumed that they have been trained in the recom-
mended servicing procedures for these products, which includes the use of mechanics hand
tools and any special tools that might be required.
Proper service and repair is important to the safe, economical and reliable operation of the
products described herein. The troubleshooting, testing, service and repair procedures recom-
mended by the manufacturer and described in this manual are effective methods of performing
such operations. Some of these operations or procedures may require the use of specialized
equipment. Such equipment should be used when and as recommended.
We could not possibly know of and advise the service trade of all conceivable procedures or
methods by which service might be performed, or of any possible hazards and/or results of
each procedure or method. Therefore, anyone who uses a procedure or method not recom-
mended by the manufacturer must first satisfy himself that neither his safety, nor the product’s
safety, will be endangered by the service or operating procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. However, the manufacturer
reserves the right to change, alter or otherwise improve the product at any time without prior
notice. Some components or assemblies of the product described in this manual may not be
considered repairable. Disassembly, repair and reassembly of such components may not be
included in this manual.
The engines described herein may be used to power a wide variety of products. Service and
repair instructions relating to any such products are not covered in this manual. For information
pertaining to use of these engines with other products, refer to any owner’s or service manuals
pertaining to said products.
 2.4 Liter Gas Engine Table of Contents

SERVICE RECOMMENDATIONS .............................................................................................................................................. 2

OEM CONTENTS ............................................................................................................................................................................

This engine has been engineered for use by the manufacturer as the prime mover in a
gaseous engine-driven standby generator set application. The contents of this manual
have been reprinted from the original manufacturer’s service and repair manual. Due
to differences in application there may be components or assemblies and procedures
which do not match the information or views in this manual. Some common changes
may include; intake manifold and fuel system components, ignition system compo-
nents, accessory drive components, cooling fan, etc. Always consult the applicable
generator parts manual for specific component parts and manufacturer part numbers
which may have been substituted on the engine for this application.
2.4 Liter Gas Engine Service Recommendations

ENGINE OIL RECOMMENDATIONS COOLANT

The unit has been filled with 5W-20 engine oil at the factory. Use Use a mixture of half low silicate ethylene glycol base anti-freeze
a high-quality detergent oil classified “For Service SJ, SL, SH, SM, and deionized or distilled water. Cooling system capacity is listed
or GF-5.” Detergent oils keep the engine cleaner and reduce carbon in the specifications. Use only deionized or distilled water and only
deposits. low silicate anti-freeze. If desired, add a high quality rust inhibitor
to the recommended coolant mixture. When adding coolant, always
Crankcase Oil Capacity ......See applicable unit specification sheet add the recommended 50-50 mixture.
Cooling System:
Type.................................................Pressurized, Closed recovery
Any attempt to crank or start the engine
 before it has been properly serviced with the
recommended oil may result in an engine
Coolant Capacity ................ See applicable unit specification sheet.
System capacity will vary depending on
failure. type/size radiator used in the application.
NOTE:
For temperatures below 32° F, it is strongly recommended to Do not use any chromate base rust inhibitor
use an appropriate Cold Weather Start Kit (consult the unit
manufacturer). The recommended oil grade for temperatures  with ethylene glycol base anti-freeze or chro-
mium hydroxide will form (“green slime”)
below 32° F is 5W-30 synthetic oil. and cause overheating. Engines that have
been operated with a chromate base rust
inhibitor must be chemically cleaned before
adding ethylene glycol base anti-freeze.
Using any high silicate anti-freeze boost-
ers or additives will also cause overheating.
The manufacturer also recommends that any
soluble oil inhibitor NOT be used for this
equipment.

Do not remove the radiator pressure cap

 while the engine is hot or serious burns from
boiling liquid or steam could result.

Ethylene glycol base antifreeze is poisonous.

 Do not use mouth to siphon coolant from the
radiator, recovery bottle or any container.
Wash hands thoroughly after handling. Never
store used antifreeze in an open container
because animals are attracted to the smell
and taste of antifreeze even though it is poi-
sonous to them.

2
 2.4 Liter Gas Engine Service Recommendations

RECOMMENDED MAINTENANCE FOR LIQUID-COOLED SPARK-IGNITED GASEOUS ENGINE DRIVEN STANDBY GENERATOR
SETS
Periodic inspection, service and maintenance of this unit is critical to ensuring its reliable operation. The following is a recommended
maintenance schedule for liquid-cooled spark-ignited gaseous engine driven standby generator sets from 20 to 300kW in size. The estab-
lished intervals in the schedule are the maximum required when the unit is used in typical standby service application (approximately
200 hours per year). The maintenance items will need to be performed more frequently if the unit is used in a severe standby application
(such as long duration outages, very high or very low ambient conditions, or extremely dirty, dusty or humid environments). Use the unit
hour meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next required maintenance
interval. Note that some checks are based on hours of operation.
Because this unit is intended for standby operation, there may be times when it operates continuously for long periods of time (for
example, extended utility outages). During such operational periods some items will require more frequent checking (based on hours).
There is an extended run service interval recommendation for such periods of operation.
Be sure to follow all applicable safety and caution statements found in the specific unit operating manual or maintenance manual before
performing any maintenance checks or service.

There are two conditions when checks may have to be performed on the unit: first is when the
 unit is in standby mode (automatic) and NOT running. To disable the unit from starting in this
condition, to perform maintenance checks or service, follow the steps below. The second condi-
tion is when the unit is running and providing power to the load. To shut down the unit safely,
without damaging loads or the generator, follow the steps for shutting down a unit while in opera-
tion. Before shutting down an operating unit for maintenance, always make sure that personnel
are warned that the power will be shut down temporarily, so that equipment that might be dam-
aged can be properly turned off or placed in standby.

TO DISABLE THE GENERATOR FROM STARTING

To prevent injury, BEFORE performing any maintenance, disable the generator set from starting and/or connecting to the load by doing
the following:
1. Set the control panel “Auto-Off-Manual” switch to the “Off" position.
2. Remove the control panel fuse.
3. Turn off power to the battery charger.
4. Remove the negative battery cable.
NOTE:
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 any maintenance, reverse these steps to insure the unit is returned to
standby setup for normal operation (automatic).

3
2.4 Liter Gas Engine Service Recommendations

TO SHUT DOWN AND RESTART AN OPERATING GENERATOR

If the unit is operating (for an extended run period) and required checks must be performed, do the following:
1. Ensure that power to the load can be interrupted (warn any equipment users that there will be a temporary power disruption).
NOTE:
There may be other procedures required by the application/installation, before the generator can be shut down. Always check first.
2. Open the generator Main Line Circuit Breaker (MLCB).
3. Let the unit cool down (running at no-load) for approximately 5 minutes to prevent damage to critical engine components.
4. Set the control panel “Auto-Off-Manual” switch to the “Off” position. There may be safety tag-outs or lockout required at this point
depending on application. Always check.
5. Perform the necessary maintenance checks or tasks (based on the hourly requirements).
6. When all checks have been completed and any discrepancies corrected, set the control panel “Auto-Off-Manual” switch to the “Auto”
position.
7. When the generator is running, and all engine/generator parameters (i.e. voltage, frequency, coolant temp, oil pressure…) have been
verified as correct, close the Generator Main Line Circuit Breaker (MLCB). The unit will accept and carry the load.
8. Make a last visual inspection of the generator set to make sure it is operating properly.

SERVICE MAINTENANCE INTERVAL INFORMATION

The various service maintenance intervals are designated by interval numbers as follows:
Extended Run Time Maintenance Checks. Daily checks which must be performed when the unit is operated continuously for extended
periods of time.
1. A frequent, periodic 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 24 hours of operation of the unit and requires approximately .5 man-hours per unit to
complete. Note: the gearbox oil (if equipped) should be checked monthly or every 100 hours of operation.
1A. A one-time post installation, initial operation, service inspection of the generator set to insure it is ready to operate, transfer to,
and carry the load when required, and to identify any potential problem areas. Performed ONLY ONCE following the first three
months or the first 50 hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to com-
plete.
2. An operational 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 semi-annually (6 months) or following each 100 hours of operation of the unit and requires
approximately 2.0 man-hours per unit to complete.
3. A mid-level 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 annually or following each 200 hours of operation of the unit and requires approximately 6.0
man-hours per unit to complete.
4. A comprehensive service inspection of the generator set to insure it is properly serviced and ready to operate and carry the load
when required, and to identify any potential problem areas. Performed biannually and requires approximately 8.0 man-hours per unit
to complete.

MAINTENANCE SCHEDULE
The following sheets identify the maintenance tasks recommended to be accomplished for each interval. Typically maintenance level tasks
are combined; for example, if the 6 month tasks are due, both the monthly and the 6 month task sheets should be completed. There are
spaces for recording the date and signature of the person completing the task, as well as recording the engine hours. There is also space
at the bottom of each sheet to record any fluids added or corrective action taken. All of this information, when recorded, provides a detailed
maintenance history of the unit. This maintenance history may be required for warranty validation purposes, and is a good idea to maintain
throughout the lifetime of the unit.

4
 2.4 Liter Gas Engine Service Recommendations

Extended Run Time Task Completed

Maintenance Tasks
Maintenance Checks Date/Initials
1. Before shutting the unit down, perform a thorough visual inspection of the
unit for leaks, loose components or connections, excessive wear or dam-
age. Any discrepancies noted should be further inspected and corrected
while the unit is shut down.
2. Shut the unit down per the “To Shut Down and Restart an Operating
Generator” procedure.
3. Check the engine oil level. Adjust as necessary.
4. Check the engine coolant level. Adjust as necessary. Add only a 50/50
mixture of appropriate coolant.
Every 24 operating hours 5. Check the engine accessory drive belts and fan coupling device (if
equipped) for correct tension, wear, deterioration, or damage. Correct as
(Requires approximately
necessary.
0.5 man-hours per unit)
6. Check all hoses and connections (coolant, block heater, oil, fuel) for tight-
ness, leaks, deterioration, or damage. Correct as necessary.
7. Check the air inlets and outlets for debris or blockage. Clean as neces-
sary.
8. Check the NG or LP delivery system for leaks. Tighten/repair connections
as necessary.
Every 100 operating hours 9. Check the gearbox oil level (if equipped). Adjust as necessary.
10. Check the battery electrolyte level (if accessible). Adjust as necessary
Weekly when operating
(add only distilled or deionized water to replenish battery cells).
11. Restart the unit per the “To Shut Down and Restart an Operating
Generator” procedure. Check unit voltage and frequency. Visually inspect
the unit for leaks, loose connections or components. Place the unit back
in service.
Technician’s signature signify-
ing inspection completed.

Date inspection completed.

Unit Hour Meter Reading at

Completion of the Inspection
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

5
2.4 Liter Gas Engine Service Recommendations

Maint Maintenance Task Completed

Maintenance Tasks
Level Interval Date/Initials
1. Disable the unit from operating per the “Disable the Generator” procedure.
2. Check the engine oil level. Adjust as necessary.
3. Check the gearbox oil level (if equipped). Adjust as necessary.
4. Check the engine coolant level. Adjust as necessary. Add only a 50/50
mixture of appropriate coolant.
5. Check the battery electrolyte level (if accessible). Adjust as necessary
(add only distilled or deionized water to replenish battery cells).
6. Check the battery terminal posts, connections, cables and charger con-
Monthly nections for signs of corrosion. Remove, clean and tighten connections as
necessary.
7. Check operation and condition of battery charger, block heater, oil sump
1 (Requires heater, battery warmer (if equipped). Correct discrepancies as necessary.
approximately
0.5 man-hours 8. Check the air inlets and outlets for debris or blockage. Clean as
per unit) necessary.
9. Check the NG or LP delivery system for leaks and correct gas supply
pressure. Tighten/repair connections as necessary.
10. Perform a 5 minute, no-load operational test of the unit. Check unit volt-
age and frequency. Visually inspect the unit for leaks, wear, damage,
loose connections or components and corrosion. Correct as necessary.
11. If the control has alarm and/or event/run logs, record the alarm and
event logs to a history file for the unit.
12. Return the unit to operational condition and place back in Automatic
operation.
Technician’s signature signify-
ing inspection completed.

Date inspection completed.

Unit Hour Meter Reading at

Completion of the Inspection
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

6
 2.4 Liter Gas Engine Service Recommendations

Maint Maintenance Task Completed

Maintenance Tasks
Level Interval Date/Initials
1. Disable the unit from operating per the “Disable the Generator” procedure.
In addition to the Monthly scheduled maintenance tasks, perform the fol-
lowing:
2. Change the engine oil.
3. Change the engine oil filter(s).
At first 3 months of 4. Check engine valve clearance (valve lash) as specified in the engine
operation or after service manual. NOTE: this is not required for engines with hydraulic
the first 50 hours lifters.
of operation only. 5. Check the engine accessory drive belts and fan coupling device (if
equipped) for correct tension, wear, deterioration, or damage. Correct as
necessary.
Do these tasks
in addition to the 6. Check all hoses and connections (coolant, block heater, oil, fuel) for tight-
1A regularly scheduled ness, leaks, deterioration, or damage. Correct as necessary.
monthly mainte- 7. Check wiring connections (at MLCB, customer connections and control
nance tasks. panel) for loose connections, corrosion or damage. Correct as neces-
sary.

(Requires 8. Return the unit to operational condition and test. Place the unit in auto-
approximately matic and open the service disconnect to force the unit to start and trans-
2.5 man-hours fer to the load. Exercise the unit against the load for 15 minutes, visually
per unit) inspecting for leaks, loose connections or components, and any abnormal
operating conditions. Record the unit voltage and frequency while run-
ning. Restore utility power and monitor transfer to utility, cool-down and
shutdown. Correct any discrepancies.
9. If the control has alarm and/or event/run logs, record the alarm and event
logs to a history file for the unit.
10. Return the unit to operational condition.
Technician’s signature signify-
ing inspection completed.

Date inspection completed.

Unit Hour Meter Reading at

Completion of the Inspection
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

7
2.4 Liter Gas Engine Service Recommendations

Maint Maintenance Task Completed

Maintenance Tasks
Level Interval Date/Initials
1. Disable the unit from operating per the “Disable the Generator” procedure.
In addition to the Monthly scheduled maintenance tasks, perform the
following:
Every 6 months 2. Check the engine accessory drive belts and fan coupling device (if
equipped) for correct tension, wear, deterioration, or damage. Correct as
necessary.
Do these tasks in 3. Check all hoses and connections (coolant, block heater, oil, fuel) for
addition to tightness, leaks, deterioration, or damage. Correct as necessary.
the regularly
scheduled monthly 4. Load test the battery or test electrolyte levels (specific gravity) with a
maintenance tasks. hydrometer. Correct condition or replace battery as needed.
2
5. Return the unit to operational condition and test. Place the unit in auto-
matic and open the service disconnect to force the unit to start and trans-
fer to the load. Exercise the unit against the load for at least 30 minutes,
(Requires and visually inspect for leaks, loose connections or components, and any
approximately abnormal operating conditions. Restore utility power and monitor transfer
2.0 man-hours to utility, cool-down and shutdown. Correct any discrepancies.
per unit) 6. If the control has alarm and/or event/run logs, record the alarm and event
logs to a history file for the unit.
7. Return the unit to operational condition and place back in Automatic
operation.
Technician’s signature signify-
ing inspection completed.

Date inspection completed.

Unit Hour Meter Reading at

Completion of the Inspection
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

8
 2.4 Liter Gas Engine Service Recommendations

Maint Maintenance Task Completed

Maintenance Tasks
Level Interval Date/Initials
1. Disable the unit from operating per the “Disable the Generator” procedure.
In addition to the Monthly scheduled maintenance tasks, perform the
following:
2. Change the engine oil.
3. Change the engine oil filter(s).
4. Inspect air filter. Replace as necessary.
5. Inspect, clean, gap spark plugs. Replace as necessary.
6. Inspect ignition wires for damage, deterioration, tightness. Replace as
necessary.
7. Remove, clean, inspect, re-install and adjust the flywheel magnetic pickup
(if equipped). Use the appropriate service bulletin or maintenance instruc-
Every 12 months tion for proper voltage setting and procedure.
(Yearly) 8. Check the engine accessory drive belts and fan coupling device (if
equipped) for correct tension, wear, deterioration, or damage. Correct as
necessary.
Do these tasks in
addition to 9. Check all hoses and connections (coolant, block heater, oil, fuel) for
the regularly tightness, leaks, deterioration, or damage. Correct as necessary.
3 scheduled monthly 10. Visually inspect the radiator core (externally) for any build-up of dirt,
maintenance tasks. debris, or oil contamination. Clean, correct as necessary.
11. Check the coolant thermal protection level. Correct as necessary.
(Requires 12. Load test the battery or test electrolyte levels (specific gravity) with a
approximately hydrometer.
6.0 man-hours 13. Check wiring connections (at MLCB, customer connections and control
per unit) panel) for loose connections, corrosion or damage. Check torque on
main load lugs at all generator connections (MLCB) and transfer switch
connections. Correct as necessary.
14. Return the unit to operational condition and test. Place the unit in
automatic and open the service disconnect to force the unit to start and
transfer to the load. Exercise the unit against the load for at least 1 hour,
and visually inspect for leaks, loose connections or components, and
any abnormal operating conditions. Restore utility power and monitor
transfer to utility, cool-down and shutdown. Correct any discrepancies.
15. If the control has alarm and/or event/run logs, record the alarm and
event logs to a history file for the unit.
16. Return the unit to operational condition and place back in Automatic
operation.
Technician’s signature signify-
ing inspection completed.
Date inspection completed.

Unit Hour Meter Reading at

Completion of the Inspection
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

9
2.4 Liter Gas Engine Service Recommendations

Maint Maintenance Task Completed

Maintenance Tasks
Level Interval Date/Initials
1. Disable the unit from operating per the “Disable the Generator” procedure.
In addition to the Monthly and Yearly scheduled maintenance tasks, per-
form the following:
2. Change the gearbox oil (if equipped) (or at 600 hours).
3. Replace the engine air filter.
Every 24 months 4. Replace the engine spark plugs; gap per the engine specifications.
(Bi-Annually) 5. Replace the engine accessory drive belts. Inspect the belt tensioner (if
equipped) and replace if necessary.
Do these tasks in 6. Drain and flush the cooling system. Refill with fresh coolant of appropriate
addition to type (50/50 mixture).
the regularly 7. Replace all coolant hoses, including the hoses to/from the block heater
scheduled Monthly and/or vaporizer (if equipped).
4 and Yearly
maintenance 8. Replace all flexible fuel hoses.
tasks. 9. Return the unit to operational condition and test. Place the unit in auto-
matic and open the service disconnect to force the unit to start and
transfer to the load. Use a load bank and bring the unit to full rated load
(Requires (100%kW, at rated kVA) if possible. Exercise the unit against the load for
approximately at least 2 hours, and visually inspect for leaks, loose connections or com-
8.0 man-hours ponents, and any abnormal operating conditions. Remove the load bank
per unit) load, restore utility power and monitor transfer to utility, cool-down and
shutdown. Correct any discrepancies.
10. If the control has alarm and/or event/run logs, record the alarm and
event logs to a history file for the unit.
11. Return the unit to operational condition and place back in Automatic
operation.
Technician’s signature signify-
ing inspection completed.

Date inspection completed.

Unit Hour Meter Reading at

Completion of the Inspection
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

10
 SPECIFICATIONS

TORQUE SPECIFICATIONS
Item Specification (ft-lbs)
Ignition system
Ignition coil 7.2
Crankshaft pulley bolts 18
Spark plugs 18
Water pump pulley bolts 6.5
Exhaust manifold
Water pump bolts 10
Thermostat housing bolts 17.5
Timing belt
Auto-tensioner bolts 17.5
Camshaft sprocket bolt 65
Counterbalance shaft sprocket bolt 33
Crankshaft bolt 87
Engine support bracket bolt 35
Idler pulley bolt 26
Oil pump sprocket nut 40
Tensioner "B" bolt 14
Tensioner arm bolt 16
Tensioner pulley bolt 35
Timing belt cover bolts (bolt, washer assembly) 8
Timing belt cover bolts (flange bolt and nut) 8
Inlet manifold and water pump
Engine hanger bolt 14
Pressure switch 7.2
Water temp gauge 21.5
Water outlet fitting bolts 14.5
Rocker arms and camshaft
Rocker arms and rocker arm shaft bolts 23
Rocker cover bolts 3
Thrust screw 14
 SPECIFICATIONS

Item Specification (ft-lbs)

Cylinder head and valves
Cylinder head bolts 120 → +90° → +90°
Oil pan and oil pump
Drain plug 32.5
Flange bolt 27
Front case bolts 17.5
Oil filter bracket bolts 14
Oil filter 14
Oil pan bolts 5
Oil pump cover bolts 13
Oil pump cover screws 7.2
Oil screen bolts 14
Plug 17.5
Relief plug 32.5
Piston and connecting rod
Connecting rod cap nuts 120 → +90° to 100°
Crankshaft and cylinder block
Bearing cap bolts 2.5 → +90° to 100°
Bell housing cover bolts 6.5
Oil seal case bolts 8
Rear plate bolts 8
Notes
Notes
Part No. 0G2832 Revision C (04/19/12) Printed in U.S.A.