Generac Power Systems 004988-4 Scheduled Maintenance, Service Maintenance Interval Information

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Section 4 — Maintenance

Liquid-cooled 30 kW Generators

4.7SCHEDULED MAINTENANCE

The following is a recommended maintenance schedule for 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 applica- tion. 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 ensure it is ready to operate when required and to identify any poten- tial 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 15A and 4A fuses.

Turn off the battery charger.

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 ensure 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 Service Dealer.

3An operational inspection of the generator set to ensure 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 Service Dealer.

4A mid-level inspection of the generator set to ensure 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 Service Dealer.

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Contents Liquid-cooled, Prepackaged Standby Generators ‹ HOW to Obtain Service Authorized Service Dealer Location‹ Operation and Maintenance IntroductionTable of Contents  Warning   Electrical Hazards  Automatic System Operation Transfer SwitchGenerator Generator AC Connection Systems‹ 1.7.3 LOW Coolant Level Switch ‹ 1.7.2 High Coolant Temperature Switch‹ 1.7.1 LOW OIL Pressure Switch LOW OIL Presure Switch LOW Coolant Level SwitchUnpacking Lifting the Generator‹ 1.10.1 Generator Specifications SpecificationsReconfiguring the Fuel System ‹ 1.10.2 Engine SpecificationsBefore Installation Torque SpecificationsStandby Generator Installation Engine OIL RecommendationsBasic Standby Electric System Generator Mounting Support‹ 2.1.2 Other Published Standards Total Circuit Isolation Method Transfer Switch Signal ConnectionsEmergency Circuit Isolation Method Grounding the GeneratorPreparation Before START-UP Battery Installation‹ 2.9.2 GTS-TYPE ATS Using AN Engineered GTS Transfer Switch ‹ 3.2.5 SET Exercise Time Switch ‹ 3.2.1 AUTO/OFF/MANUAL Switch‹ 3.2.2 Fault Indicator LED Control Console ComponentsRetransfer and Shutdown AdjustmentsManual Transfer START-UP Engine Governor Automatic OperationWeekly Exercise Cycle Cooling SystemOverload Protection for Engine DC Electrical System Checking Fluid Levels‹ 4.5.9 Inspect Engine Governor ‹ 4.5.11 Changing the Engine AIR Cleaner‹ 4.5.8 Check FAN Belt ‹ 4.5.10 Changing Engine OIL‹ 4.6.1 Cleaning the Generator Miscellaneous Maintenance‹ 4.6.3 Battery Maintenance ‹ 4.5.13 Coolant Change‹ 4.6.4 Battery Replacement ‹ Periodic Replacement PartsScheduled Maintenance Service Maintenance Interval InformationLevel Maintenance Level Troubleshooting Points Problem Cause CorrectionLiquid-cooled 30 kW Generators Installation Diagram SET Exerciser Switch Transfer SwitchAUTO/OFF/MANUAL Switch Size AWGIgnition Coil Otherwise Noted AS ShownBAT On PCBSWITCH, SET Exerciser SWITCH, AUTO/OFF/MANUALDPE DEG 12V Battery REDALT Starter Motor GOVEngine Foot Battery Post Cover RED + Boot Battery CableBattery Post Cover Baclk Hold Down BatteryTo a To B Plcs Duct Discharge RH Front Assy Wire 14AWG 7.5 #0 GRN/YELIntake Duct HSB Duct Discharge LH FrontPage Decal AVR Cover Assy 2A 12V UL BatteryControl BOX HSB Cover Front Panel HSBCooled 30 kW Drawing No Exploded Coil Ignition 3.0L Ford Wire SET 3.0L Ford notNot SHOWN-USED to Hold OIL Drain Assembly Bracket DC ALT 3.0L FordFrame Venturi 3.0L Ford HSB Tank Coolant RecoveryRadiator R-IN,L-OUT Side Support Radiator HSBTo B Assy Regulator 3.0L NG or LPV Weldment Mounting BaseFlange Fuel Inlet Washer Flat 5/16 ZincLocktight Rotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 390 15KW 1P Direct HSB 2.5L FordRotor 390 20KW 1P Direct HSB 2.5L Ford Rotor 39030AD1 HSB TecumWasher Lock 3/8 SS Exhaust Flange 2 PipePipe Muffler OUT Gasket Exhaust RingCover AIR Cleaner Plate AIR Cleaner AdapterElement AIR Cleaner Adapter Carburetor W/PVC ConnWarranty Schedule