Maintenance
Owner’s Manual for Stationary Industrial Generators 25
4.6 — Maintenance Level 3 - Annual
These maintenance tasks must be performed by a trained/qualified service technician. Perform these tasks every 12
months or every 250 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly and Semi-
Annual maintenance tasks. Comply with all safety notices contained in the Owner’s Manual. Some of the tasks will
require the use of the applicable engine service manual.
Qualified Service Technician Maintenance Tasks
Requires approximately 6.0 hours per unit.
Task Completed
Date/Initials
1.
Disable the unit from operating per the procedure found in the owner’s manual. Some of the
following tasks will require the use of the applicable engine service manual.
2. Change the engine oil.
3. Change the engine oil filter(s).
4. Inspect the air filter. Replace as necessary.
5. Gaseous Units Only: Inspect, clean, and gap the spark plugs. Replace as necessary.
6. Gaseous Units Only: Inspect ignition wires for damage, deterioration and tightness. Replace
as necessary.
7. Diesel Units Only: Test the fuel quality. If required, strip any water/sediment from the tank.
Filter or polish the fuel and add any additional additives required to maintain fuel quality.
8. Diesel Units Only: Change the primary and secondary fuel filters (if equipped). Clean any
water separator or mechanical strainer (if equipped). Prime and bleed the fuel system per the
engine service manual procedures.
9. Check the engine accessory drive belts and fan coupling device (if equipped) for correct
tension, wear or abrasion, deterioration, or damage. Correct as necessary.
10. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and fil-
ters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.
11. Visually inspect the radiator and charge air core (if equipped) for any build up of dirt, debris,
or oil contamination (external). Clean, correct as necessary.
12. Check the coolant thermal protection level. Correct as necessary.
13. Check all wiring connections in the high voltage and low voltage connection panels. Check
for loose connections, corrosion, arcing or damage. Check torque on all main load lugs at
generator connections (MLCB) and transfer switch connections (refer to applicable transfer
switch manual). Correct as necessary.
14. Return unit to operational condition and test. Place unit in automatic and open the service dis-
connect to force the unit to start and transfer to the load. Exercise unit against the load for 1
hour (60 minutes). Visually inspect for leaks, loose connections or components, and any abnor-
mal operating conditions. Record unit voltage, frequency and kW while running. Restore utility
power and monitor transfer to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:
15. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.
16. Return the unit to operational condition and place back in automatic operation.
Date inspection Completed: Unit hour Meter Reading:
Technician/Authorized Operator signature signifying inspection complete:
Record any oil or coolant added and notes about any discrepancies found and corrective action taken.
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