Generac Power Systems 004988-4 owner manual Maintenance Level

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Section 4 — Maintenance

Liquid-cooled 30 kW Generators

Maintenance

Level 1

 

Level 2

 

Level 3

 

Level 4

 

Tasks

Recom-

Task

Required

Task

Required

Task

 

Task

 

mended

Comp.

to be done

Comp.

to be done

Comp.

Required

Comp.

 

to be done

(Date-

3 months/

(Date-

Semi-

(Date-

to be done

(Date-

 

monthly/

Initials)

Break-in

Initials)

annually/

Initials)

Annually/

Initials)

 

10 hrs.

 

30 hrs.

 

50 hrs.

 

100 hrs.

 

13.Initiate an automatic start and transfer of the unit to

site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

14.Start and exercise the unit at full rated load (use a

load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary.

15. Change the engine oil.

16.Replace the engine oil filter(s).

17.Replace the engine air filter(s).

18.Replace the engine fuel filter(s) on diesel engine

driven units and re-prime the fuel system.

19.Check the engine spark plugs on gas engine driven

units. Clean and re-gap or replace as necessary.

20.Perform a 5 minute no-load operational run of the unit

looking for any post service problems.

21. Return the unit to standby setup for operation when required.

22

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Contents Liquid-cooled, Prepackaged Standby Generators Authorized Service Dealer Location ‹ Operation and Maintenance‹ HOW to Obtain Service IntroductionTable of Contents  Warning   Electrical Hazards  Transfer Switch GeneratorAutomatic System Operation Generator AC Connection Systems‹ 1.7.2 High Coolant Temperature Switch ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.3 LOW Coolant Level Switch LOW OIL Presure Switch LOW Coolant Level SwitchUnpacking Lifting the GeneratorSpecifications Reconfiguring the Fuel System‹ 1.10.1 Generator Specifications ‹ 1.10.2 Engine SpecificationsTorque Specifications Standby Generator InstallationBefore Installation Engine OIL RecommendationsGenerator Mounting Support Basic Standby Electric System‹ 2.1.2 Other Published Standards Transfer Switch Signal Connections Emergency Circuit Isolation MethodTotal Circuit Isolation Method Grounding the GeneratorBattery Installation Preparation Before START-UP‹ 2.9.2 GTS-TYPE ATS Using AN Engineered GTS Transfer Switch ‹ 3.2.1 AUTO/OFF/MANUAL Switch ‹ 3.2.2 Fault Indicator LED‹ 3.2.5 SET Exercise Time Switch Control Console ComponentsAdjustments Manual Transfer START-UP Engine GovernorRetransfer and Shutdown Automatic OperationWeekly Exercise Cycle Cooling SystemOverload Protection for Engine DC Electrical System Checking Fluid Levels‹ 4.5.11 Changing the Engine AIR Cleaner ‹ 4.5.8 Check FAN Belt‹ 4.5.9 Inspect Engine Governor ‹ 4.5.10 Changing Engine OILMiscellaneous Maintenance ‹ 4.6.3 Battery Maintenance‹ 4.6.1 Cleaning the Generator ‹ 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 Transfer Switch AUTO/OFF/MANUAL SwitchSET Exerciser Switch Size AWGOtherwise Noted AS Shown BATIgnition Coil On PCBSWITCH, AUTO/OFF/MANUAL SWITCH, SET ExerciserDPE 12V Battery RED ALTDEG Starter Motor GOVEngine Foot Boot Battery Cable Battery Post Cover BaclkBattery Post Cover RED + Hold Down BatteryTo a To B Plcs Assy Wire 14AWG 7.5 #0 GRN/YEL Intake Duct HSBDuct Discharge RH Front Duct Discharge LH FrontPage Assy 2A 12V UL Battery Control BOX HSBDecal AVR Cover Cover Front Panel HSBCooled 30 kW Drawing No Exploded Wire SET 3.0L Ford not Not SHOWN-USED to Hold OIL Drain AssemblyCoil Ignition 3.0L Ford Bracket DC ALT 3.0L FordFrame Tank Coolant Recovery Radiator R-IN,L-OUTVenturi 3.0L Ford HSB Side Support Radiator HSBTo B Weldment Mounting Base Flange Fuel InletAssy Regulator 3.0L NG or LPV Washer Flat 5/16 ZincLocktight Rotor 390 15KW 1P Direct HSB 2.5L Ford Rotor 390 20KW 1P Direct HSB 2.5L FordRotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 39030AD1 HSB TecumExhaust Flange 2 Pipe Pipe Muffler OUTWasher Lock 3/8 SS Gasket Exhaust RingPlate AIR Cleaner Adapter Element AIR CleanerCover AIR Cleaner Adapter Carburetor W/PVC ConnWarranty Schedule