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INSTALLATION INSTRUCTIONS FORTIMING BELT REPLACEMENT
Standby Generator System - 25kW - 30kW
80016534 Rev -
Briggs & Stratton Power Products Group, LLCP.O. Box 702Milwaukee, WI 53201-0702
Copyright © 2015. All rights reserved. No part of this material may be reproduced or transmitted in any form without the express written permission of Briggs & Stratton Power Products Group, LLC.
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FORWARD
This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for standby generators. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices. Persons untrained or unfamiliar with these procedures or products should not attempt to perform such work.
Proper maintenance and repair is important to safe, reliable operation of all standby generators. The troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for the generators described herein. Alternative methods or procedures may pose risk to personal safety and the safety and/or reliability of the standby generator and are not endorsed or recommended by Briggs & Stratton.
All information, illustrations, and specifications contained in this manual were based on the data available at the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product or the product manuals at any time without prior notice.
Visit www.ThePowerPortal.com for the most up-to-date information and latest manual revision.
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Table of Contents
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . 4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Important Safety InstructionsSAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
Safety Symbols and Meanings
Fire
Toxic Fumes
Explosive Pressure
Rotating Fan Blade
Lift Hazard Read Manual
Exploding BatteryRotating Belt/Pulley
Chemical BurnAuto Start
Hot SurfaceRotating Parts
Electrical ShockExplosion
The safety alert symbol indicates a potential personal injury hazard. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to designate a degree or level of hazard seriousness. A safety symbol may be used to represent the type of hazard. The signal word NOTICE is used to address practices not related to personal injury.
DANGER indicates a hazard which, if not avoided, will result in death or serious injury.
WARNING indicates a hazard which, if not avoided, could result in death or serious injury.
CAUTION indicates a hazard which, if not avoided, could result in minor or moderate injury.NOTICE addresses practices not related to personal injury.The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the generator system unsafe.
Save These Instructions WARNING Running engine gives off carbon
monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide could result in death, serious injury, headache, fatigue, dizziness, vomiting, confusion, seizures, nausea or fainting.
• Operate this product ONLY outdoors in an area that will not accumulate deadly exhaust gas.
• Keep exhaust gas away from any windows, doors, ventilation intakes, soffit vents, crawl spaces, open garage doors or other openings that can allow exhaust gas to enter inside or be drawn into a potentially occupied building or structure.
• Carbon monoxide detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/recommendations. Smoke alarms cannot detect carbon monoxide gas.
WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
WARNING Certain components in this product and related accessories contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.
WARNING Storage batteries give off explosive hydrogen gas during recharging. Slightest spark will ignite hydrogen and cause explosion, resulting in death or serious injury.
Battery electrolyte fluid contains acid and is extremely caustic.Contact with battery contents could cause severe chemical burns.• DO NOT dispose of battery in a fire. Recycle battery.• DO NOT allow any open flame, spark, heat, or lit
cigarette during and for several minutes after charging a battery.
• DO NOT open or mutilate the battery.• Wear protective goggles, rubber apron, rubber boots
and rubber gloves.• Remove watches, rings, or other metal objects.• Use tools having insulated handles.
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WARNING Generator produces hazardous voltage. Failure to properly ground generator could result in electrocution. Failure to isolate generator from utility power could result in death or serious injury to electric utility workers due to back feed of electrical energy.
• DO NOT touch bare wires or bare receptacles.• DO NOT use generator with electrical cords which
are worn, frayed, bare or otherwise damaged.• DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands or feet are wet.
• If you must work around a unit while it is operating, stand on an insulated dry surface to reduce the risk of a shock hazard.
• DO NOT allow unqualified persons or children to operate or service generator.
• In case of an accident caused by electrical shock, immediately shut down the source of electrical power and contact the local authorities. Avoid direct contact with the victim .
• Despite the safe design of the generator, operating this equipment imprudently, neglecting its maintenance or being careless could cause possible injury or death.
• Remain alert at all times while working on this equipment. Never work on the equipment when you are physically or mentally fatigued.
• Before performing any maintenance on the generator, disconnect the battery cable indicated by a NEGATIVE, NEG or (-) first. When finished, reconnect that cable last.
• After your system is installed, the generator may crank and start without warning any time there is a power failure. To prevent possible injury, always set the generator’s system switch to OFF, remove the service disconnect from the disconnect box AND remove the 15 Amp fuse BEFORE working on the equipment.
WARNING Hazardous Voltage - Contact with power lines could cause electric shock or burns, resulting in death or serious injury. Lifting Hazard / Heavy Object - Could result in serious injury.
• If lifting or hoisting equipment is used, DO NOT contact any power lines.
• DO NOT lift or move generator without assistance.• DO NOT lift unit by roof as damage to generator
will occur.
WARNING Propane and Natural Gas are extremely flammable and explosive, which could cause burns, fire or explosion resulting in death or serious injury.
• Install the fuel supply system according to NFPA 37 and other applicable fuel-gas codes.
• Before placing the generator into service, the fuel system lines must be properly purged and leak tested.
• After the generator is installed, you should inspect the fuel system periodically.
• NO leakage is permitted.• DO NOT operate engine if smell of fuel is present or
other explosive conditions exist.• DO NOT smoke around the generator. Wipe up any
oil spills immediately. Ensure that no combustible materials are left in the generator compartment. Keep the area near the generator clean and free of debris.
WARNING Exhaust heat/gases could ignite combustibles or structures resulting in death or serious injury. Contact with muffler area could cause burns resulting in serious injury.
• DO NOT touch hot parts and AVOID hot exhaust gases.
• Allow equipment to cool before touching.• Exhaust outlet side of weatherproof enclosure must
have at least 5 ft. (1.5m) minimum clearance from any structure, shrubs, trees or any kind of vegetation.
• Standby generator weatherproof enclosure must be at least 5 ft. (1.5m) from windows, doors, any wall opening, shrubs or vegetation over 12 inches (30.5 cm) in height.
• Standby generator weatherproof enclosure must have a minimum of 5 ft. (1.5 m) overhead clearance from any structure, overhang, or trees.
• DO NOT place weatherproof enclosure under a deck or other type of structure that may confine airflow.
• Use only flexible fuel line provided. Connect provided fuel line to generator. DO NOT use with or substitute any other flexible fuel line.
• Smoke detector(s) MUST be installed and maintained indoors according to the manufacturer’s instructions/recommendations. Carbon monoxide alarms cannot detect smoke.
• Keep at least minimum distances shown in General Location Guidelines to insure for proper generator cooling and maintenance clearances.
• Replacement parts must be the same and installed in the same position as the original parts.
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NOTICE Improper treatment of generator could damage it and shorten its life.• Use generator only for intended uses.• If you have questions about intended use, contact your
authorized dealer.• Operate generator only on level surfaces.• Adequate, unobstructed flow of cooling and ventilating
air is critical to correct generator operation.• The access panels/door must be installed whenever the
unit is running.• DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.• Remain alert at all times while working on this
equipment. Never work on the equipment when you are physically or mentally fatigued.
• DO NOT start engine with air cleaner or air cleaner cover removed.
• DO NOT insert any objects through cooling slots.• DO NOT use the generator or any of its parts as a step.
Stepping on the unit could cause stress and break parts. This may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
• If connected devices overheat, turn them off and disconnect them from generator.
• Shut off generator if: -electrical output is lost; -equipment sparks, smokes, or emits flames; -unit vibrates excessively. -unit makes unusual noises.
WARNING Moving parts could crush and cut. Starter and other rotating parts could entangle hands, hair, clothing, or accessories resulting in serious injury.
• NEVER operate generator without protective housings, covers, or guards in place.
• DO NOT wear loose clothing, jewelry or anything that could be caught in the starter or other rotating parts.
• Tie up long hair and remove jewelry.• Before servicing, remove 15 Amp fuse from control
panel and disconnect Negative (NEG or -) battery cable.
WARNING Hot pressurized coolant could cause serious injury.
• DO NOT open radiator cap when hot.• Before servicing, allow coolant to cool.
CAUTION Installing the 15A fuse could cause the engine to start at any time without warning resulting in minor or moderate injury.
• Observe that the 15 Amp fuse has been removed from the control panel for shipping.
• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.
CAUTION Excessively high operating speeds could result in minor injury and/or equipment damage. Excessively low speeds impose a heavy load on generator.
• DO NOT tamper with governed speed. Generator supplies correct rated frequency and voltage when running at governed speed.
• DO NOT modify generator in any way.
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ProcedureThis manual covers the replacement of the timing belt on the 1.6L engine.Tools Needed:• Metric socket set• Metric wrench set• Metric hex wrench or socket set• Pry bar• Blue Loctite 242• Grey or Black RTV Silicone• Ft-lb torque wrench• Needle nose pliers• Gasket scraper or razor blade 1. Remove the 15A fuse (a, Figure 1) from the control
panel.
a
Figure 1 2. Disconnect the negative battery cable (a, Figure 2) from
the battery.
a
Figure 2
3. Remove the spark plugs and wires as follows: a. Pull the spark plug wires (b, Figure 3) from the valve
cover, noting their position.
b
b
Figure 3 b. Use a 5/8” spark plug socket wrench to remove the
spark plugs.
Figure 44. Remove the accessory drive belt as follows:
a. Use a 13mm socket wrench to loosen the top and bottom mounting bolts (a, Figure 5) on the engine alternator.
a
Figure 5
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b. Use a 13mm socket wrench to loosen the belt tension adjustment screw (b, Figure 6) on the engine alternator.
b
Figure 6 c. Slide the accessory drive belt off the pulleys as shown
in Figure 7.
Figure 75. Remove the engine cooling fan as follows:
a. Use a 6mm socket wrench to remove the four socket head screws from the fan. Gently rest the fan inside the radiator shroud.
Figure 8
b. Use a 10mm socket wrench to remove the four bolts (a, Figure 9) on the engine flywheel guard (b) on the alternator adapter casting.
a b
Figure 9 c. Use a pry bar between the teeth on the engine flywheel
and the alternator adapter casting to prevent engine rotation.
Figure 10 d. Use a 6mm hex wrench to remove the two socket
head screws (c, Figure 11) from the engine cooling fan spacer on the crankshaft pulley.
c
Figure 11
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e. Slide the fan spacer (d, Figure 12) out from the crankshaft accessory drive pulley.
d
Figure 126. Move the engine alternator wire harness (a, Figure 13)
to the side of the valve cover. Remove the oil fill cap (b) and disconnect the PCV hose (c) and breather hose (d).
ba c d
Figure 137. Remove valve cover as follows:
a. Use a 10mm socket wrench to remove the four nuts (a, Figure 14) securing the valve cover to the cylinder head.
a
Figure 14
b. Remove the valve cover by prying gently as shown in Figure 15.
Figure 158. Align crankshaft pulley and camshaft sprocket spoke as
follows: a. Figure 16. Use a 17mm socket wrench on the
crankshaft accessory drive pulley bolt to turn the engine clockwise. Set the No.1 cylinder (the cylinder closest to the timing belt) to top dead center (TDC) on the compression stroke. On the compression stroke, all valves on the No. 1 cylinder will be closed.
Figure 16 b. Figure 17. The hole on the camshaft sprocket spoke
must align vertically with the notch on top of the camshaft bearing cap.
Figure 17
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c. Use an 8mm socket wrench to remove the screw (a, Figure 20) securing the right side of middle timing belt cover (d). Remove the middle timing belt cover.
d. Use an 8mm socket wrench to remove the long screw (c) securing the left side of middle and lower timing belt cover (e). Remove the middle timing belt cover.
e. Use an 8mm socket wrench to remove the screws (a) securing the lower timing belt cover. Remove the lower timing belt cover.
a
c
b
a
d
ec
a
Figure 20f. Check and adjust (if necessary) the valve clearances
(f, Figure 21). Reference the appropriate procedure for this maintenance item.
f
Figure 21
9. Remove crankshaft accessory drive pulley as follows: a. Figure 18. Use a pry bar between the teeth on the
engine flywheel and the alternator adapter casting to prevent engine rotation.
Figure 18 b. Figure 19. Use a 17mm socket wrench to remove
the crankshaft accessory drive pulley bolt and the accessory drive pulley. If necessary, return the No. 1 cylinder to TDC on the compression stroke by repeating Step 8.
Figure 1910. Remove timing belt covers as follows:
a. Use an 8mm socket wrench to remove the screws (a, Figure 20) securing the top of upper timing belt cover (b).
b. Use an 8mm socket wrench to remove the long screws (c) securing the top and middle timing belt cover (d). Remove the top timing belt cover and the wire form wire harness retainer.
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b. Install the tensioner mounting bolt (c, Figure 25) and move the tensioner to the left as far as possible.
c. Tighten the bolt to keep it in place.
c
Figure 2513. Install the new timing belt as follows:
a. Align the hole on the camshaft sprocket spoke (a, Figure 26) vertically with the notch on top of the camshaft bearing cap (b).
a b
Figure 26
b. Align the timing mark (c, Figure 27) on the crankshaft sprocket with the mark on the oil pump cover (d).
c
d
Figure 27
11. Remove timing belt tensioner, spring and timing belt as follows:
a. Figure 22. Use a 13mm socket to remove the timing belt tensioner assembly and spring.
Figure 22
b. Slide the timing belt (a, Figure 23) off the camshaft and crankshaft sprockets.
a
Figure 2312. Install the new timing belt tensioner assembly and spring
as follows: a. Hook one end of the spring onto the tensioner (a,
Figure 24) and hook the opposite end of the spring onto the post (b) on the engine block.
a
b
Figure 24
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c. Slide the new timing belt (e, Figure 28) into place on the camshaft (f) and crankshaft sprockets (g).
f
e
g
Figure 2814. Use a 13mm socket to loosen the belt tensioner
assembly bolt (a, Figure 29) to allow the tensioner assembly to apply pressure on the timing belt.
a
Figure 2915. Tighten the belt tensioner assembly bolt as follows:
a. Slowly rotate the crankshaft (a, Figure 30) clockwise two complete revolutions and check that the belt is riding on the sprockets properly and the timing marks are correct.
a
Figure 30
b. The hole in the camshaft sprocket (b, Figure 31) should be aligned with the notch on the camshaft bearing cap (c).
b c
Figure 31
c. The timing mark on the crankshaft sprocket (d, Figure 32) should be aligned with the mark on the oil pump cover (e).
d
e
Figure 32 d. Use a 13mm socket wrench to tighten the belt tensioner
assembly bolt (f, Figure 33) to 35 ft-lbs.
f
Figure 33
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16. Re-install the timing belt covers as follows: a. Use the short screws (a, Figure 34) to secure the
bottom of the lower timing belt cover (e). b. Use a long screw (c) to secure the top of the lower
timing belt cover and bottom of the middle timing belt cover (d)
Note: The middle cover overlaps the lower cover. c. Use a short screw (a) to secure the right side of middle
timing belt cover (d). d. Use the long screws (c) to secure the top of the middle
timing belt cover (d) and the bottom of the upper timing belt cover (e).
Note: The upper cover overlaps the middle cover. e. Fasten the wire form wire harness retainer (f, Figure 35)
on the overlap of the bottom right top cover and the top right middle cover.
f. Use short screws (a, Figure 34) to secure the top of upper timing belt cover (b).
g. Use an 8mm socket wrench to tighten all screws (a) and (c) to 10 ft-lbs.
a
cb
a
d
ec
a
Figure 34
h. Secure the wire harness (g, Figure 35) by bending the wire form retainer over the harness.
f
g
Figure 35
17. Re-install crankshaft pulley as follows: a. Figure 36. Use a pry bar between the teeth on the
engine flywheel and the alternator adapter casting to prevent engine rotation.
Figure 36
b. Remove the crankshaft pulley bolt (a, Figure 37) and reinstall the crankshaft pulley (b).
ba
Figure 37 c. Figure 38. Ensure the keyway lines up between the
crankshaft and crankshaft accessory drive pulley and that the pulley is fully seated.
d. With the pry bar in place to prevent rotation, tighten the crankshaft accessory drive pulley bolt to 81 ft-lbs.
Figure 3818. Reinstall the valve cover as follows:
a. Figure 39. Clean the mating surface of the valve cover gasket on the cylinder head and remove any RTV.
Figure 39
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b. Clean the valve cover and gasket, and the cylinder head of any oil using appropriate solvent.
c. If the valve cover gasket is still pliable and in good condition, it may be reused. If not, remove the gasket and install a new gasket onto the valve cover.
d. If the half circle plug (a, Figure 40) in front of the intake camshaft was removed, apply grey or black RTV silicone to the sealing surface of the plug and reinstall into the cylinder head.
a
Figure 40 e. Figure 41. Apply grey or black RTV silicone along the
sharp corners of the cylinder head where the camshaft seal caps mate.
Figure 41
f. Reinstall the valve cover (a, Figure 42) and the stud seals and nuts. Use a 10mm socket wrench to torque the nuts to 7 ft-lbs.
a
Figure 42
19. Re-install hoses and oil fill cap.a. Reinstall the breather hose (a, Figure 43), the PCV
hose (b), and the oil fill cap (c).
a
b
c
Figure 43
b. Reposition the wire harness (d, Figure 44) in the valve cover pocket.
d
Figure 4420. To install the spark plugs and spark plug wires:
a. Figure 45. Verify spark plug gap is 0.028” – 0.031”. Adjust as necessary.
Figure 45
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b. Install the spark plugs (a, Figure 46) using a 5/8” spark plug socket. Tighten to 13 ft-lbs.
a
Figure 46
c. Reconnect the spark plug wires (b, Figure 47) .
b
Figure 4721. Reinstall the accessory drive belt as follows:
a. Fit the drive belt over crankshaft pulley and alternator pulley.
b. Figure 48. Use a 13mm socket to apply tension with the engine alternator adjustment screw to achieve ½” slack in the belt halfway between the crankshaft pulley and the engine alternator pulley.
a
Figure 48 c. Use a 13mm socket wrench to tighten the top alternator
mounting bolt (a, Figure 49) to 35 ft-lbs and the lower mounting bolt (b) to 18 ft-lbs.
a
b
Figure 49
22. Reinstall the cooling fan as follows: a. Figure 50. Use a pry bar between the teeth on the
engine flywheel and the alternator adapter casting to prevent engine rotation.
Figure 50
b. Reinstall the fan spacer (a, Figure 51).
a
Figure 51 c. Apply Loctite 242 to the threads on the two socket head
bolts (b, Figure 52). Use a 6mm hex wrench to install the two socket head bolts and tighten to 29 ft-lbs.
b
Figure 52
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d. Reinstall the cooling fan noting the direction of rotation (c, Figure 53).
c
Figure 53 e. Figure 54. Apply Loctite 242 to the threads on the four
socket head bolts. Use a 6mm hex wrench to install the four bolts and tighten to 29 ft-lbs.
Figure 54
f. Reinstall the engine flywheel guard (d, Figure 55) on the alternator adapter. Use a 10mm socket wrench to install the four bolts (e) and tighten to 7 ft-lbs.
e
d
Figure 55
23. Connect the negative battery cable (f, Figure 56) to the battery (g).
f
g
Figure 5623. Reinstall the 15A fuse (a, Figure 57) in the control panel.
a
Figure 5724. Start and run the engine for at least 5 minutes. Stop the
engine and check for coolant and/or oil leaks.25. Check oil and coolant levels. Fill as needed.25. Figure 58. Reset the control panel to automatic mode.
Figure 58
