DIY: Converting Your Generator to Run on Propane (LP Gas) – A Step-by-Step Guide

Power outages are a major inconvenience, and having a reliable generator can be a lifesaver. However, gasoline-powered generators have their drawbacks: fuel storage issues, gasoline degradation over time, and potential carburetor problems due to stale fuel. Converting your generator to run on propane (LP gas) offers numerous advantages, including cleaner burning, longer shelf life for fuel, and often, lower overall running costs. This comprehensive guide will walk you through the process of installing an LP gas conversion kit on your generator, providing detailed steps, safety precautions, and essential tips to ensure a successful conversion.

Why Convert Your Generator to Propane?

Before we dive into the installation process, let’s highlight the key benefits of converting your generator to propane:

• Fuel Stability: Propane has a virtually indefinite shelf life, unlike gasoline, which can degrade in as little as 3-6 months. This eliminates the need for fuel stabilizers and the worry of stale fuel clogging your carburetor.
• Cleaner Burning: Propane burns cleaner than gasoline, producing fewer emissions. This is better for the environment and reduces the risk of carbon monoxide poisoning.
• Cost-Effectiveness: In many regions, propane is cheaper than gasoline, especially when considering the cost of fuel stabilizers and carburetor cleaning.
• Ease of Storage: Propane tanks are relatively easy to store and transport, and they don’t pose the same spillage risks as gasoline.
• Reduced Maintenance: Propane’s clean-burning properties can lead to less maintenance on your generator’s engine, extending its lifespan.

Is This Conversion Right for You?

While converting to propane offers many benefits, it’s essential to consider whether it’s the right choice for you. Here are a few factors to consider:

• Generator Compatibility: Not all generators are suitable for conversion. Check the compatibility of the conversion kit with your specific generator model. Most kits are designed for common gasoline-powered generators.
• Mechanical Skills: This conversion involves basic mechanical skills and knowledge. If you’re not comfortable working with engines, it’s best to consult a qualified mechanic.
• Safety Precautions: Working with fuel and engines can be dangerous. It’s crucial to follow all safety precautions and use common sense throughout the process.
• Cost of Conversion: Consider the cost of the conversion kit, propane tank, regulator, and any additional fittings or tools you may need. Weigh this cost against the long-term savings and benefits of propane.
• Local Regulations: Check your local regulations regarding propane tank storage and generator usage. Some areas may have restrictions or require permits.

Tools and Materials You’ll Need

Before you begin the conversion, gather all the necessary tools and materials. This will make the process smoother and more efficient.

• LP Gas Conversion Kit: Choose a kit specifically designed for your generator model. These kits typically include a regulator, fuel lines, carburetor adapter, and mounting hardware.
• Propane Tank: Select a propane tank of appropriate size for your needs. A 20-pound tank is a common choice for portable generators.
• Propane Regulator: Ensure your propane tank has a regulator that’s compatible with the conversion kit. Some kits include a regulator, while others require you to purchase one separately.
• Wrench Set: You’ll need a set of wrenches in various sizes to disconnect and reconnect fuel lines and fittings.
• Screwdriver Set: A Phillips head and flathead screwdriver set will be necessary for removing and installing various components.
• Pliers: Pliers will be helpful for gripping and manipulating fuel lines and fittings.
• Socket Set: A socket set can be useful for removing and installing bolts and nuts.
• Hose Cutter or Utility Knife: Use a hose cutter or utility knife to cut fuel lines to the correct length.
• Thread Sealant Tape (Teflon Tape): Apply thread sealant tape to threaded fittings to prevent leaks.
• Safety Glasses: Always wear safety glasses to protect your eyes from debris.
• Gloves: Wear gloves to protect your hands from fuel and sharp edges.
• Fire Extinguisher: Keep a fire extinguisher nearby in case of emergencies.
• Leak Detector Spray or Soapy Water: Use leak detector spray or soapy water to check for leaks after the conversion.
• Shop Rags: Have shop rags on hand to clean up any spills.
• Manual: Keep the generator and conversion kit manuals handy.

Safety Precautions

Safety is paramount when working with fuel and engines. Follow these safety precautions to prevent accidents and injuries:

• Work in a Well-Ventilated Area: Perform the conversion outdoors or in a well-ventilated area to avoid inhaling fuel vapors.
• Disconnect the Spark Plug: Disconnect the spark plug wire to prevent accidental starting of the generator.
• Allow the Engine to Cool: Ensure the engine is completely cool before starting the conversion.
• Drain the Fuel Tank: Drain all gasoline from the fuel tank and carburetor before working on the fuel system. Dispose of the gasoline properly.
• Wear Safety Glasses and Gloves: Protect your eyes and hands from fuel and sharp edges.
• No Smoking or Open Flames: Do not smoke or have any open flames nearby while working on the fuel system.
• Keep a Fire Extinguisher Nearby: In case of a fuel leak or fire, have a fire extinguisher readily available.
• Double-Check Connections: After completing the conversion, double-check all fuel line connections to ensure they are tight and leak-free.
• Test for Leaks: Use leak detector spray or soapy water to test for leaks before starting the generator.

Step-by-Step Installation Guide

Now that you have the tools, materials, and safety precautions in place, let’s proceed with the installation process. This guide assumes you have a basic understanding of engine mechanics. If you’re unsure about any step, consult a qualified mechanic.

Step 1: Prepare the Generator

1. Turn off the Generator: Ensure the generator is turned off and the engine is completely cool.
2. Disconnect the Spark Plug: Disconnect the spark plug wire to prevent accidental starting.
3. Drain the Fuel Tank: Drain all gasoline from the fuel tank using a siphon or drain plug. Dispose of the gasoline properly.
4. Drain the Carburetor: Locate the carburetor drain screw and open it to drain any remaining gasoline from the carburetor.
5. Clean the Area: Clean the area around the carburetor and fuel lines to remove any dirt or debris.

Step 2: Remove the Air Filter Assembly

1. Locate the Air Filter Housing: The air filter housing is typically located on top of or beside the carburetor.
2. Remove the Air Filter Cover: Remove the screws or clips holding the air filter cover in place.
3. Remove the Air Filter: Take out the air filter and set it aside. You may need to replace it if it’s dirty.
4. Remove the Air Filter Housing: Remove the screws or bolts holding the air filter housing to the carburetor. Carefully remove the housing.

Step 3: Install the Carburetor Adapter

1. Identify the Carburetor Inlet: Locate the carburetor inlet where the air filter housing was attached.
2. Install the Adapter: Attach the carburetor adapter plate to the carburetor inlet using the provided bolts or screws. Ensure the adapter is securely fastened and aligned correctly. Some adapters require a gasket – ensure it’s properly placed.
3. Tighten the Bolts: Tighten the bolts or screws to the specified torque to prevent leaks. Refer to the conversion kit instructions for torque specifications.

Step 4: Install the LP Gas Regulator

1. Locate a Suitable Mounting Location: Find a suitable location to mount the LP gas regulator. It should be close to the carburetor adapter and away from heat sources.
2. Mount the Regulator: Attach the regulator to the chosen location using the provided mounting bracket and hardware.
3. Connect the Fuel Line from the Propane Tank: Connect a fuel line from the propane tank regulator to the LP gas regulator. Use thread sealant tape on the fittings to prevent leaks.
4. Connect the Fuel Line to the Carburetor Adapter: Connect a fuel line from the LP gas regulator to the carburetor adapter. Use thread sealant tape on the fittings to prevent leaks.

Step 5: Adjust the Regulator (If Applicable)

1. Locate the Adjustment Screw: Some LP gas regulators have an adjustment screw to fine-tune the fuel mixture.
2. Adjust the Screw: If your regulator has an adjustment screw, follow the instructions in the conversion kit to adjust it for optimal performance. Typically, you’ll start the generator and adjust the screw until the engine runs smoothly.

Step 6: Reinstall the Air Filter Assembly

1. Reattach the Air Filter Housing: Reattach the air filter housing to the carburetor adapter using the screws or bolts you removed earlier.
2. Install the Air Filter: Install the air filter into the housing.
3. Reattach the Air Filter Cover: Reattach the air filter cover and secure it with the screws or clips.

Step 7: Connect the Propane Tank

1. Connect the Propane Tank Regulator: Connect the propane tank regulator to the propane tank.
2. Open the Propane Tank Valve: Slowly open the propane tank valve.

Step 8: Check for Leaks

1. Apply Leak Detector Spray or Soapy Water: Apply leak detector spray or soapy water to all fuel line connections, including the propane tank regulator, LP gas regulator, and carburetor adapter.
2. Look for Bubbles: Watch for bubbles forming at the connections. Bubbles indicate a leak.
3. Tighten Connections: If you find a leak, tighten the connection and recheck for leaks.
4. Repeat as Needed: Repeat the leak checking process until all connections are leak-free.

Step 9: Reconnect the Spark Plug and Start the Generator

1. Reconnect the Spark Plug: Reconnect the spark plug wire to the spark plug.
2. Start the Generator: Start the generator according to the manufacturer’s instructions.
3. Observe Performance: Observe the generator’s performance. It may take a few seconds for the propane to reach the engine.
4. Adjust as Needed: If the engine runs roughly or stalls, adjust the LP gas regulator (if applicable) or consult the conversion kit instructions for troubleshooting.

Troubleshooting Common Issues

Even with careful installation, you may encounter some issues during the conversion process. Here are some common problems and their solutions:

• Generator Won’t Start:
  • Problem: The generator may not start due to a lack of fuel or improper fuel mixture.
  • Solution: Check the propane tank level, ensure the propane tank valve is open, and verify that the fuel lines are properly connected. Adjust the LP gas regulator (if applicable) to fine-tune the fuel mixture.
• Engine Runs Roughly:
  • Problem: The engine may run roughly due to an improper fuel mixture.
  • Solution: Adjust the LP gas regulator (if applicable) to fine-tune the fuel mixture. Refer to the conversion kit instructions for guidance.
• Engine Stalls:
  • Problem: The engine may stall due to a lean fuel mixture.
  • Solution: Adjust the LP gas regulator (if applicable) to richen the fuel mixture.
• Fuel Leaks:
  • Problem: Fuel leaks can occur at fuel line connections.
  • Solution: Tighten the connections and recheck for leaks. Use thread sealant tape on the fittings to prevent leaks. If the leak persists, replace the fuel line or fitting.
• Propane Tank Icing:
  • Problem: The propane tank may ice up during extended use, especially in cold weather.
  • Solution: Use a larger propane tank or a tank warmer to prevent icing.

Maintenance Tips for Propane-Converted Generators

To ensure the longevity and reliability of your propane-converted generator, follow these maintenance tips:

• Regularly Check Fuel Lines: Inspect fuel lines for cracks, leaks, or damage. Replace damaged fuel lines immediately.
• Clean the Air Filter: Clean the air filter regularly to ensure proper airflow to the engine. Replace the air filter as needed.
• Check the Spark Plug: Inspect the spark plug for wear or damage. Clean or replace the spark plug as needed.
• Change the Oil: Change the engine oil according to the manufacturer’s recommendations.
• Check the Carburetor Adapter: Inspect the carburetor adapter for leaks or damage. Tighten the bolts or screws as needed.
• Store the Generator Properly: When not in use, store the generator in a dry, well-ventilated area. Disconnect the propane tank and store it separately.
• Run the Generator Periodically: To keep the engine lubricated and prevent corrosion, run the generator for a short period every few months.

Conclusion

Converting your generator to run on propane is a worthwhile investment that offers numerous benefits, including fuel stability, cleaner burning, and potential cost savings. By following this step-by-step guide and taking the necessary safety precautions, you can successfully convert your generator and enjoy a more reliable and convenient power source during outages. Remember to consult the conversion kit instructions and your generator’s manual for specific details and recommendations. If you’re unsure about any step, don’t hesitate to seek assistance from a qualified mechanic. With proper installation and maintenance, your propane-converted generator will provide years of dependable service.