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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 N-m (5-7 lb-ft).
• Final pass = 26-38 N-m (19-28 lb-ft).
4.4 CYLINDER 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 N-m (52 lb-ft) in
sequence. Retighten to 70 N-m (52 lb-ft) in
sequence. Then turn all head bolts an additional
90 - 100 degrees in sequence.
Figure 4.2 — Cylinder Head Installation
4.5 COOLING 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.)
The exhaust system parts from this product get
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
4.6 OVERLOAD PROTECTION FOR
ENGINE DC ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled
by a solid state Engine Controller circuit board.
Battery voltage is delivered to that circuit board via a
15 amp fuse. These overcurrent protection devices
will open if the circuit is overloaded.
If a circuit breaker opens or a fuse element
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
fuse.
4.7 CHECKING FLUID LEVELS
4.7.1 CHECK ENGINE OIL
Check engine crankcase oil level (Figure 4.3) at least
every 20 hours of operation, or prior to use.
• Remove oil dipstick and wipe dry with a clean,
lint-free cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove
oil fill cap. Add the recommended oil to bring oil
level up to the FULL mark. DO NOT FILL ABOVE
THE “FULL” MARK. See “Engine Oil Recommen-
dations” for recommended oils.
Figure 4.3 - Oil Dipstick and Oil Fill Cap
Oil Dipstic
k
Oil
Filter
Oil Fill Cap
Engine
Air Cleaner
!
Section 4 — Maintenance
Liquid-cooled 15, 20 and 25 kW Generators