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SERVICE SCHEDULE

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 calendar time or accumulated run time, 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:

1

   An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-

tial problem areas.

   

Performed monthly this 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 5 amp and 15 amp control panel fuses.
  •  Turn off the battery charger (turn OFF utility supply to ATS).
  •  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.

2

   A 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 30 run time 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.

3

   An 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 this 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.

4

   A 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 this 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.

11-1

Standby Generator Sets

Service Schedule

SrvSchd002  Re

v. B  12/05

Содержание 005212-0

Страница 1: ...AL This manual should remain with the unit A new standard of reliability Serial Number QT 2 5L 25kW Model 005212 0 CAUTION ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION Cover0...

Страница 2: ...Start up Checklist 8 2 Preparation for Start up 8 2 Start up Inspection 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfe...

Страница 3: ...ator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance w...

Страница 4: ...will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will...

Страница 5: ...ard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owne...

Страница 6: ...is manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this...

Страница 7: ...y result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for...

Страница 8: ...g cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL swit...

Страница 9: ...sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optim...

Страница 10: ...nic Frequency Regulation Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Spin on Cartridge Crankcase Oil Capacity 4 U S qts COOLING SYSTEM...

Страница 11: ...ch inside the control panel must be in the LP or NG position when switching to differ ent fuels Figure 6 2 Reconfigure the Fuel System NG FUEL SYSTEM LP FUEL SYSTEM Port 1 Port 2 FUEL HOSE BRASS HOSE...

Страница 12: ...reaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE...

Страница 13: ...il level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equippe...

Страница 14: ...n The engine should now crank and start Check voltage at the generator terminals For 3 phase units check phase rotation at the transfer switch terminals The generator phase rotation must match the uti...

Страница 15: ...ansfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the gener...

Страница 16: ...valve clearance EXHAUST MANIFOLD PROCEDURE 1 If necessary clean gasket surfaces on exhaust manifold and cylinder head 2 Install exhaust manifold and exhaust manifold gasket 3 Install fasteners NOTE Ex...

Страница 17: ...gure 10 3 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD m...

Страница 18: ...eeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some c...

Страница 19: ...ry If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge...

Страница 20: ...e connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the 120VAC power supply to the battery is t...

Страница 21: ...ent 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...

Страница 22: ...gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Chec...

Страница 23: ...d 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 a...

Страница 24: ...ded in SPECIFICATIONS Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Swi...

Страница 25: ...Standby Generator Sets Notes...

Страница 26: ......

Страница 27: ...7329 1 LUG SLDLSS 350 6 X 13 32 AL CU 22 057073 1 JUNCTION BLOCK 3 8 16 23 023484J 1 BUSHING SNAP SB 2000 26 24 0E3257 15 SCREW HWHTF M6 1 0 X 16 25 0E7890 REF BRKT CB MTG BACK 2P 0E6002 REF MTG TRACK...

Страница 28: ......

Страница 29: ...9 070892 1 SLIP RING MACHINED 10 047248 1 BALL BEARING 45 MM 11 023454 1 KEY WOODRUFF E 12 077043E 1 CONDUIT FLEX 1 0 ID 20 LG 13 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 14 052646 4 WASHER FLAT M14 1...

Страница 30: ......

Страница 31: ...R FLAT 1 4 M6 ZINC 15 022097 12 WASHER LOCK M6 1 4 16 0C8566 8 SCREW HHFC M6 1 0 X 20 G8 8 17 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 18 0C2454 24 SCREW THF M6 1 X 16 N WA Z JS 19 040976 8 SCREW SHC M8 1...

Страница 32: ......

Страница 33: ...1 75 8 052251 4 DAMPENER VIBRATION 40 BLUE 9 052257 4 SPACER 49 X 62 X 1 87 PWDR ZNC 10 052252 4 DAMPENER VIBRATION 11 052259 4 WASHER FLAT M12 12 052891 4 SCREW HHC M12 1 75 X 80 G8 8 13 0536210261 1...

Страница 34: ......

Страница 35: ...POST COVER RED 8 050331 REF BATT POST COVER BLK 9 038805J 1 CABLE BATTERY BLK 1 X 30 00 10 038804U 1 CABLE BATTERY RED 1 X 28 00 11 045771 REF NUT HEX M8 1 25 G8 YEL CHR 12 022129 REF WASHER LOCK M8...

Страница 36: ......

Страница 37: ...ORD EXHAUST MAN 34 0E9609 1 MANIFOLD EXHAUST MACHINED 35 0E9930 1 HEAT SHIELD EXHAUST MANIFOLD 36 049821 3 SCREW SHC M8 1 25 X 30 G12 9 37 0E9747 1 STARTER 12 VOLT 38 047411 4 SCREW HHC M6 1 0 X 16 G8...

Страница 38: ......

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Страница 40: ......

Страница 41: ...IR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0E0590A 1 VENTURI 20MM 33 0C5133 1 0 RING 29 82 X 2 62 34 0E0665 1 SCREW THROTTLE PIN STOP 35 0E1108A 1 THROTTLE ARM REWORK 2 5L FORD 36...

Страница 42: ......

Страница 43: ...W THF M6 1 X 16 N WA Z JS 19 078115 20 WASHER SELF LOCKING DOME 20 0F3890B 2 RETAINER INSULATION 820 21 0F3890 4 RETAINER INSULATION 450 22 0F7365 2 INSULATION SIDE DOOR C1 23 0F7365B 1 INSULATION REA...

Страница 44: ......

Страница 45: ...36449 2 SADDLE 2 INCH 10 022129 6 WASHER LOCK M8 5 16 11 022259 4 NUT HEX 5 16 18 STEEL 12 038750 3 SCREW HHC M6 1 0 X 30 G8 8 13 044149 1 GASKET EXHAUST RING 14 0E0170A 1 EXHAUST BLANKET 988MM 15 0E8...

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Страница 50: ......

Страница 51: ......

Страница 52: ...aminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 4 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Syst...

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