Maintenance
26 Owner’s Manual for Stationary Industrial Generators
4.7 — Maintenance Level 4 - Bi-Annual
These maintenance tasks must be performed by a trained/qualified service technician. Perform these tasks every 24
months or every 500 hours of operation. Perform these tasks in addition to the regularly scheduled Monthly, Semi-
Annual and 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. Gearbox Equipped Only: Change the gearbox oil. Can be extended to 600 hours.
3. Replace the engine air filter(s).
4. Gaseous Units Only: Replace the spark plugs. Gap per the engine specifications.
5. Replace the engine accessory drive belts. Inspect and lubricate (if required) the belt tensioning
device (if equipped) and replace if necessary.
6. Drain and flush the cooling system. Refill with fresh coolant of appropriate type (50/50 mixture).
7. Replace all flexible hoses: Coolant hoses including the block heater hoses and vaporizer
hoses (if equipped); charge air system connection hoses/joints/couplings, and any flexible fuel
or oil lines.
8. Remove, clean, inspect, reinstall and reset to correct voltage level the flywheel magnetic
pickup(s) (if equipped).
9. Return the unit to operational condition and test. Place the unit in automatic and open the ser-
vice disconnect to force the unit to start and transfer to the load. Use an appropriate load bank
to supplement load to full rated load (100% kW at rated kVA) if possible. Exercise the unit
against the load for 2 hours (120 minutes). Visually inspect for leaks, loose connections or
components, and any abnormal operating conditions. Record the unit voltage, frequency, kW
and kVA while running. Remove the load bank load, restore utility power and monitor transfer
to utility, cool-down and shutdown. Correct any discrepancies.
Voltage: Frequency: kW: kVA:
10. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.
11. 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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