Manual Part No.

0G4556

2.4

LITER

HYUNDAI GAS ENGINE

SERVICE MANUAL

FOreWOrD
This manual has been published by GENERAC POWER SYSTEMS, INC. to aid our dealers mechanics, company service personnel and general consumers when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured and marketed by GENERAC POWER SYSTEMS, INC. It is also assumed that they have been trained in the recommended servicing procedures for these products, which includes the use of mechanics hand tools and any special tools that might be required. Proper service and repair is important to the safe, economical and reliable operation of the products described herein. The troubleshooting, testing, service and repair procedures recommended by GENERAC POWER SYSTEMS, INC. and described in this manual are effective methods of performing such operations. Some of these operations or procedures may require the use of specialized equipment. Such equipment should be used when and as recommended. We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not recommended by the manufacturer must first satisfy himself that neither his safety, nor the products safety, will be endangered by the service or operating procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. However, GENERAC POWER SYSTEMS, INC. reserves the right to change, alter or otherwise improve the product at any time without prior notice. Some components or assemblies of the product described in this manual may not be considered repairable. Disassembly, repair and reassembly of such components may not be included in this manual. The engines described herein may be used to power a wide variety of products. Service and repair instructions relating to any such products are not covered in this manual. For information pertaining to use of these engines with other products, refer to any owners or service manuals pertaining to said products.

2.4 Liter Gas Engine Table of Contents

SERVICE RECOMMENDATIONS . ............................................................................................................... A_2 HYUNDAI CONTENTS..............................................................................................................................................

This engine has been engineered for use in Generac Power Systems products. The contents of this manual have been reprinted from the original manufacturers service and repair manual.

2.4 Liter Gas Engine Service Recommendations 8 KW - 35 KW SMALL STANDBY GENERATOR SETs
Following is a recommended maintenance schedule for Generac small standby and residential generator sets from 8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. 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 application. 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: 1  An early inspection of the generator set to insure it is ready to operate when required and to identify any potential 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:  isable the generator set from starting and/or connecting to the load by setting the control panel D Auto-Off-Manual switch to the OFF position. Remove the control panel fuse. 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. 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 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 Generac 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 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 Generac 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 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 Generac Service Dealer.

2.4 Liter Gas Engine Service Recommendations

GENERAC POWER SYSTEMS, INC.

RECOMMENDED SCHEDULED MAINTENANCE PROGRAM
SERVICE WORK TO BE PERFORMED BY FACTORY-TRAINED PERSONNEL ONLY.

DEALER INFORMATION
NAME: ACCOUNT #: ADDRESS: PHONE: TECHNICIAN: SIGNATURE: NAME: ADDRESS: SITE: PHONE:

OWNER INFORMATION

SIGNATURE:

PURCHASE DATE: APPLICATION: Standby Power

START-UP DATE: Prime Power Rental/Trailerized

GENERATOR & TRANSFER SWITCH INFORMATION GENERATOR

MODEL NUMBER: SERIAL NUMBER:

TRANSFER SWITCH
MODEL NUMBER: SERIAL NUMBER:

HOUR METER READING at Completion of the Inspection:

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 fuse. Turn off the battery charger. Remove the negative battery cable.

WARNING!

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.

NOTE:

2.4 Liter Gas Engine Service Recommendations

Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level. Correct as necessary. 5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary. 6. Check the diesel fuel supply level for diesel engine driven units. Fill as necessary. 7. Drain water and sediment from the diesel fuel tank on diesel engine driven units. 8. Drain water from the fuel line water separator on diesel engine driven units if the unit is equipped with one. 9. Check the air inlets and outlets for debris. Clean as necessary. 10. Check the battery electrolyte level if accessible. Adjust as necessary. 11. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary. 12. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessary. 13. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary.
Task Comp. (DateInitials)

Level 2 Required to be done 3 months/ Break-in /30 hrs.

Task Comp. (DateInitials)

Level 3
Task

Level 4
Task Comp. (DateInitials)

Required to Required to be Comp. be done Semidone Annually/ (DateAnnually/50 hrs. Initials) 100 hrs.

2.4 Liter Gas Engine Service Recommendations

Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. 14. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary. 15. Test the engine and transfer switch safety devices. Correct and/ or adjust as necessary. 16. 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. 17. 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. 18. Change the engine oil. 19. Replace the engine oil filter(s). 20. Replace the engine air filter(s). 21. Replace the engine fuel filter(s) on diesel engine driven units and re-prime the fuel system. 22. Check the engine spark plugs on gas engine driven units. Clean and re-gap orreplace as necessary. 23. Perform a 5 minute noload operational run of the unit looking for any post service problems. 24. Return the unit to standby setup for operation when required.
Task Comp. (DateInitials)

Level 2 Required to be done 3 months/ Break-in /30 hrs.

Task Comp. (DateInitials)

Level 3
Task

Level 4
Task Comp. (DateInitials)

Required to Required to be Comp. be done Semidone Annually/ (DateAnnually/50 hrs. Initials) 100 hrs.

Notes

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P.O. BOX 310 EAGLE, WI 53119

Part No. 0G4556 Revision * (01/11/07) Printed in U.S.A.