9-1
9. Engine
TESTING COMPRESSION / LEAKDOWN
Test engine compression and / or leakdown to con-
firm whether the engine is worn. Compression
should fall between 153 and 188 psi and not vary
between cylinders by more than 10 percent.
TESTING CRANKCASE VACUUM
Test crankcase vacuum to confirm whether the en-
gine is worn or the breather valve is malfunctioning.
Vacuum should be 7 to 10 inches of water column as
measured through a tap in the oil fill cap.
REMOVING AND INSTALLING
GENERATOR / ENGINE ASSEMBLY
Figure 9-1 illustrates how the engine is mounted on
the generator/engine base. The flywheel, exhaust
manifold and mounting bolts are accessible for re-
moval on the bottom side of the base.
Removal
Remove the generator/engine assembly from the
genset, and then the engine, drive belt, exhaust
manifold or ignition coils (magnetos) from the gen-
erator/engine assembly.
1. Drain the engine oil because the genset will be
turned on its side to remove components.
2. Remove the two-piece control enclosure (Sec-
tion 5. Control) and disconnect the AC output
leads from their terminals on the circuit break-
ers and base.
3. Disconnect the grounding strap at the genera-
tor/engine base.
4. Disconnect fuel pump or fuel solenoid leads.
5. Disconnect the fuel lines at the engine (at the
fuel filter outlet [supply] and pressure regulator
[return] on EFI models, or at the carburetor or
LPG regulator on other models).
6. For Models HGJAA, HGJAB, HGJAD and
HGJAE disconnect the engine exhaust outlet at
the muffler flange and remove the heat shield
between the muffler and engine. For Models
HGJAC and HGJAF, remove the muffler.
7. If the engine is to be separated from the base,
disconnect all wiring from the engine:
A. Spark plug cables (two)
B. Ignition kill (two)
C. Starter motor and solenoid
D. Low oil pressure cutoff switch
E. On EFI models, the governor actuator, fuel
injector and MAP and MAT sensors, and
on models with carburetors, the choke
heater and fuel cutoff.
8. If the engine is to be separated from the base,
remove the generator/engine bracket and loos-
en or remove the cylinder shroud screws.
CAUTION
1) To prevent possible damage,
do not rest the generator/engine assembly
on its fan shroud. 2) Place blocks under the
assembly when it is rested upside-down so
that the weight will not bear on the choke
pulloff diaphragm (gasoline carburetors).
9. Remove the two fail-safe bolts. With assis-
tance, lift the generator/engine assembly off its
four mounting springs and rest it upside-down.
(Four 3/8–16 holes, one in each corner, are pro-
vided for lifting and support.)
Installation
Installation is the reverse of removal. Torque the fail-
safe bolts to 38 lb-ft (51 N-m). Check that the as-
sembly floats freely on its springs and does not
make contact with the drip pan.
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