Generac 004912-0, 004912-1, 004913-0, 004913-1 owner manual Scheduled Maintenance

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Section 4 — Maintenance

Centurion Liquid-cooled 15 kW and 25 kW Generators

4.9SCHEDULED MAINTENANCE

The following is a recommended maintenance schedule for Centurion small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas.

Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 man- hours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

Disable the generator set from starting and/or connecting to the load by setting the control panel AUTO-OFF-MANUAL switch to the “OFF” position.

Remove the control panel fuse.

Turn off utility supply to engine water heater.

Turn off the battery charger by turning off utility supply to the transfer switch.

Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required.

2A break-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer.

3An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer.

4A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer.

20 Generac® Power Systems, Inc.

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Contents Centurion ‹ HOW to Obtain Service Authorized Service Dealer Location‹ Operation and Maintenance IntroductionInside Front Cover General Hazards Electrical Hazards Automatic System Operation Transfer SwitchGenerator Generator AC Connection SystemsMain Circuit Breaker ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.2 High Coolant Temperature Switch Generator Fuel SystemUnpacking Lifting the GeneratorFuel Consumption SpecificationsReconfiguring the Fuel System ‹ 1.10.1 GeneratorGenerator Installation Torque SpecificationsBefore Installation Engine OIL RecommendationsBasic Standby Electric System Generator LocationGenerator Mounting Support ‹ 2.1.1 Nfpa StandardsEmergency Circuit Isolation Method Total Circuit Isolation MethodGrounding the Generator Generator AC Neutral Connections Transfer Switch Start Signal ConnectionsBattery Installation ‹ 2.10.1 Vented BatteriesPreparation Before START-UP ‹ 3.2.3 Fault Indicator Lamp Using a Standard GTS Transfer Switch‹ 3.2.2 AUTO/OFF/MANUAL Switch Control Console ComponentsWeekly Exercise Cycle ‹ 3.2.6 SET Exercise Time SwitchManual Transfer START-UP Automatic Operation Engine Block HeaterOverload Protection for Engine DC Electrical System Cooling SystemChecking Fluid Levels ‹ 4.5.4 Inspect Cooling System ‹ 4.4.2 Battery Fluid‹ 4.5.2 Check Battery ‹ 4.5.5 Perform Visual Inspection‹ 4.6.1 Cleaning the Generator Miscellaneous Maintenance‹ 4.5.10 Changing the Engine AIR Cleaner ‹ 4.5.11 Spark Plugs‹ 4.6.4 Battery Replacement ‹ 4.6.2 Battery‹ 4.6.3 Battery Maintenance ‹ 4.6.5 Rodent Protection‹ 4.7.2 Return to Service OUT of Service Procedure‹ 4.7.1 Removal from Service Fuel Pipe SizingScheduled Maintenance Service Maintenance Interval InformationLevel Maintenance Level Troubleshooting Points Problem Cause CorrectionCenturion Liquid-cooled 15 kW and 25 kW Generators Installation Diagram Section DC-VR Customer Connection 120/240V 1-PHASE To Control Panel Terminal Strip Cover Connector Housing Housing Governor ConnectorConnector Interface Assembly ASM Motor StepperDampener Vibration BASE,MOUNTING 1.5L STNRD&ACSTCWasher Shakeproof EXT 5/16 STL Washer Flat 5/16 ZincWeld Stud Under Roof Assembly Cover Access Assembly BASE-DOOR Ground WireGRD Wire Assy 99HSB Roof ACSTC&STND Cmprtmnt 1.5LPanel for Access Cover Cable Washer Self Locking Dome Roof Acstc & Stnd Cmprtmnt 1.5LDoor Weldment 1.5 EPS Baffle Cntrl PNL 1.5L AcousticTo a Hourmeter Wire AssemblySilksc Holder FuseHardware Ground Wire Starter Switch OIL PressureARM Adjust Alternator ENGINE-1.5L16 7 Venturi 1.5L Modine Tank Coolant RecoveryRadiator 1.5L Guard FAN 1.5L ModineVapor Weldment Mounting Base Cover AIR CleanerGasket AIR Cleaner Adapter Flange Fuel InletTo Engine Crankshaft Assy Rotor 15KW Housing BlowerAssy Rotor 10KW Assy Rotor 20KWBRACKET, Battery Hold Down ASSY,WIRE#16 REDBOOT, Battery Cable Battery Post Cover RED+Saddle 2 Inch Manifold Exhaust 1.5LNipple TOE 1.5NPTX5.5 BLK Iron PIPE,EXHAUST 1.5L STNDRD&ACSTCMANUFACTURER’S Emission Control System Warranty Coverage Your Warranty Rights and ObligationsPURCHASER’S/OWNER’S Warranty Responsibilities Emission Control System Warranty Emission Related Parts Include the FollowingWarranty Schedule