I made a very disturbing discovery today as I was installing new insulation in my generator compartment. The PVC pipe which connects the air filter to the air intake manifold on the Isuzu diesel engine was not in place. For some undetermined amount of time I have been running my generator with absolutely no air filtration.
The PVC assembly was in two pieces wedged at the very back of the generator compartment. The PVC was painted black and could not be seen even when the generator was rolled forward for maintenance. I had removed the tray beneath the generator in order to replace the insulation, that is the only way I was able to see the problem.
On my Power Tech 10 KW generator with the Isuzu engine, the PVC air plenum comes off the back of the air filter housing and goes about a foot to the right to the intake manifold. If you reach over the top of the engine you can feel the PVC to make sure it is properly connected on both ends.
On my generator apparently one of the PVC joints in the middle of the pipe had never had cement applied to it. That joint separated and left the two pieces cantilevered on their end connections. The stress of being cantilevered and the vibration of the engine eventually caused to fall out of their end connections. At some point both ends had come in contact with the exhaust system and partially melted.
So, PLEASE check the air intake systems on your generator.
Richard
Mine melted also. Posted pictures here a few years ago. Can't find them here?
Mine also failed, Isuzu 8Kw, and was not visible. Discovered in annual maintenance check. I went to the hardware store and rebuilt mine. Like you, I have no idea how long it had been apart.
Mine has a section of Gates hose connecting the two ends. I thought it was factory but maybe this one also failed sometime in the past.
jor