Maintenance

Section 4 Maintenance
Maintenance the first three months or first 50 hours of operation
after installation and startup of the unit.
Regular maintenance will improve performance and
extend engine/equipment life. Generac Power Systems, The various service maintenance intervals are
Inc. recommends that all maintenance work be per- designated by interval numbers:
formed by an Independent Authorized Service Dealer 1. A frequent, periodic inspection of the generator set
(IASD). Regular maintenance, replacement, or repair of to ensure it is ready to operate when required and
the emissions control devices and systems may be per- to identify any potential problem areas. Performed
formed by any repair shop or person of the owner’s monthly, or every 24 hours (interrupted) of
choosing. To obtain emissions control warranty service operation of the unit.
free of charge, the work must be performed by an IASD.
2. An operational service inspection of the generator
See the emissions warranty.
set to ensure it is ready to operate and carry the
Periodic inspection, service, and maintenance of this unit load when required, and to identify any potential
is critical in ensuring its reliable operation. The following problem areas. Performed semi-annually (6
is the manufacturer’s recommended maintenance months) or every 125 hours of operation of the unit.
schedule. The established intervals are the maximum
3. A mid-level service inspection of the generator set
required when the unit is used in typical standby service
to ensure it is ready to operate and carry the load
applications (approximately 250 hours per year). The
when required, and to identify any potential
maintenance items will need to be performed more
problem areas. Performed annually or every 250
frequently if the unit is used in severe applications (such
hours of operation of the unit.
as long duration outages, very high or very low ambient
conditions, or extremely dirty or dusty environments). 4. A comprehensive service inspection of the
Use calendar time or hours of operation, whichever generator set to ensure it is properly serviced and
occurs first, from the previous maintenance interval to ready to operate and carry the load when required,
determine the next required maintenance interval. Note and to identify any potential problem areas.
that some checks are based only on hours of operation. Performed biannually (every 24 months or 500
hours).
There may be times when the generator must operate
continuously for long periods of time (for example, NOTE: Maintenance levels 2, 3, and 4 require the use of
extended utility outages). During such extended the applicable engine service manual and must be
operational periods some items will require more performed by a qualified service technician.
frequent checking (based on hours). Use the “Extended
Run-Time Maintenance Checks” recommendation for
such periods of operation.
Maintenance Schedule
Be sure to follow all applicable safety and caution The following pages contain the maintenance schedule
statements found in the unit operating manual or engine describing the checks/tasks which need to be
service/maintenance manual before performing any accomplished at each designated maintenance interval.
maintenance checks or service. Some maintenance level tasks are combined. For
example, if the six month tasks are due, both the monthly
and the six month task should be completed at the same
Service Maintenance Intervals time. Similarly, when the annual tasks are due, the
Extended Run-Time Maintenance Checks: Daily monthly and semi-annual tasks should also be
checks which must be performed when the unit is completed. There is space on the sheets for recording
operated continuously for extended periods of time. the date and signature of the person completing the task,
These checks and routine monthly checks can be as well as recording the engine hours and other pertinent
performed by an Authorized Operator. information. At the bottom of each sheet, space is also
provided to record any fluids added, parts replaced or
NOTE: For units equipped with a gearbox, the gearbox corrective action taken. All of this recorded information
oil should be checked monthly or every 100 hours of provides a detailed maintenance history of the unit. This
operation. maintenance history may be required for warranty
1A. A one-time post installation, initial operation, validation purposes, and is a good idea to maintain
service inspection of the generator set to ensure it throughout the lifetime of the unit.
is ready to operate, transfer to, and carry the load It is recommended by the manufacturer that service
when required, and to identify any potential procedures beyond the normal monthly checks be
problem areas. Performed ONLY ONCE following performed by an IASD.

Generator Installation and Operating Manual 19

Maintenance

Notes and Maintenance Item Explanations

Maintenance Item Description

Change oil and filter shortly after start up or commissioning of the unit. The recommendation
is that this be done after the first 50 hours of operation or after the first three months of
Oil and Oil Filter service. Perform oil and filter changes every 250 hours (or yearly) thereafter. If an oil analysis
program is used (annually), the acceptable oil change interval can be extended to 500 hours
or every two years, based on the results of the analysis.

Change gearbox oil every two years or 600 hours of operation. Check gearbox oil level
Gearbox Oil (If Equipped)
monthly or every 100 hours of operation.

Check coolant annually for proper thermal protection levels. Drain, flush, and refill the cooling
Coolant Quality
system with fresh coolant every two years regardless of operating hours.

Change coolant, fuel (gaseous supply hoses from regulator to mixer), oil, charge air cooling,
Flexible Hoses
and block heater hoses, flexible joints, etc.) every two years regardless of operating hours.

Replace accessory drive belts every two years regardless of operating hours. If necessary,
Accessory drive belts
check and replace automatic tensioner (if used).
Magnetic Pickup(s) mounted on Remove, clean, inspect, and reset magnetic pickups to the correct operational output voltage
flywheel housing every two years.

Crank and/or Cam Pickup for

Visually inspect (outside) for cleanliness and tightness.
ignition system

NOTE: Certain applications may require more frequent maintenance checks and more frequent operation under load.
NOTE: This schedule does not reflect all of the possible requirements of an individual engine manufacturer service
schedule, particularly if the unit is used in other than a standby power application.
NOTE: For more information about service schedules and support for your application, please contact your local IASD.

Disabling a Generator for 1. Set the control panel AUTO/OFF/MANUAL switch

to the OFF position.
Maintenance
2. Remove the control panel fuse (see wiring
There are two conditions when maintenance checks diagram).
may have to be performed on the unit: 3. Turn OFF power to the battery charger (remove
1. When the unit is in standby mode (automatic) and battery charger ATC style fuse or open the battery
NOT running. To disable the unit from starting in charger circuit breaker located in the load control
this condition, in order to perform maintenance panel).
checks or service, follow the steps in To Disable 4. Disconnect the negative battery cable.
the Generator From Starting.
NOTE: The battery charger must be turned OFF
2. When the unit is running and providing power to
BEFORE disconnecting the battery cable to prevent an
the load. To shut down the unit safely, without over-current condition from burning out sensitive control
damaging loads or the generator, follow the steps panel components and circuits.
for shutting down a unit while in operation. See
Shutdown and Restart an Operating Generator. NOTE: Following any maintenance, reverse these steps
Before shutting down an operating unit for so the unit is returned to standby setup for normal
maintenance, always warn personnel that power operation.
will be shut down temporarily, so equipment that
might be damaged can be properly turned OFF or
Shutdown and Restart an Operating Generator
placed in standby.
If the unit is operating and required checks must be
performed:
To Disable the Generator From Starting
1. Verify power to the load can be interrupted (warn
To prevent injury, BEFORE performing any maintenance, any equipment users that there will be a temporary
disable the generator set from starting and/or connecting power disruption). There may be other procedures
to the load:

20 Generator Installation and Operating Manual

 Maintenance

that must be done before shutting a unit down, Check Engine Oil Level
depending on application. An Authorized Operator should check the levels of
2. Open the utility MLCB. engine oil and engine coolant monthly (or every 24 hours
3. Open the generator MLCB. of operation). The oil level should be maintained between
the FULL and ADD marks on the engine dipstick.
4. Allow the unit to cool down (running at no-load) for Recommended fluids are listed in Engine Oil
approximately five minutes to prevent damage to Recommendations.
critical engine components.
To check the engine oil:
5. Set the control panel AUTO/OFF/MANUAL switch
1. Locate the engine oil dipstick.
to the OFF position. There may be safety tag-outs
or lockouts required at this point, depending on 2. The most accurate oil level readings are measured
application. when the engine is cold. If the engine was running,
6. Perform the necessary maintenance checks or wait at least ten minutes before proceeding.
tasks (based on the hourly requirements). 3. Remove the dipstick and wipe it dry with a clean,

7. When all checks have been completed and any lint free cloth.
discrepancies corrected, set the control panel 4. Slowly insert the clean dipstick into the tube.
AUTO/OFF/MANUAL switch to the AUTO position. Visually confirm that the dipstick is fully seated in
8. When the generator is running, and all engine/ the dipstick tube. A visual inspection is required
generator parameters (voltage, frequency, coolant because some dipsticks will require more effort
temp, oil pressure, etc.) have been verified as than others to fully seat.
correct, close the generator MLCB. The unit will 5. After ten seconds remove the dipstick.
accept and carry the load. 6. Look at the oil level on both sides of the dipstick.
9. Make a last visual inspection of the generator set The lower of the two readings will be the correct oil
to make sure it is operating properly. level measurement.
10. Close the utility MLCB. 7. Add oil (if necessary) to adjust the level. After
adding or changing the oil, the engine should run
for one minute before checking the oil level.
Maintenance Tasks Remember to wait ten minutes to allow the engine
to cool and oil to fully drain into the oil pan.
Visually Inspect Unit
Typical causes of inaccurate oil level readings:
Perform a visual inspection of the unit periodically. If • Reading the high level of the dipstick.
problems are found contact your local IASD. Look for the
following: • Reading the dipstick before the oil fully drains into
the oil pan.
• Any debris, trash, grass or weed growth, which
would obstruct the flow of cooling air into and out of • Inserting and removing the dipstick too quickly.
the unit ventilation louvers. • The dipstick is not fully seated in the dipstick tube.
• Visually inspect hoses and hose connections for
signs of leakage. This includes all coolant hoses,
fuel hoses, exhaust system connections, intake
system connections, etc. Also look at the engine
block and gearbox (if equipped) for signs of fluid
leakage.
• Visually inspect the engine accessory drive belts
for evidence of obvious wear, fraying or
deterioration, and obvious looseness. A
“squealing” sound heard during starting and
running could indicate a loose belt.

Check Engine Fluids

The following checks can be performed by a trained
Authorized Operator. Observe all safety precautions
outlined in Introduction and Safety.

Generator Installation and Operating Manual 21

Maintenance

Check Coolant Level NOTE: Do NOT overfill the gearbox. If too much fluid is
added let the excess drain from the level check plug hole
DANGER and collect it in a suitable container or with rags.
Risk of poisoning. Do not use mouth to siphon
coolant. Doing so will result in death or serious
injury. A
(000149)
B
WARNING
C
Risk of burns. Do not open coolant system
until engine has completely cooled. Doing so
could result in serious injury.
(000154) 001063

CAUTION Figure 4-1. Gearbox Oil Servicing Points

Risk of overheating. Do not use any chromate base

rust inhibitor with propylene glycol base antifreeze, A Oil Filler/Vent Cap
boosters, or additives. Doing so will cause overheating
B Oil Level Check Plug
and possible equipment damage. (000165a)
C Oil Drain Plug
Visually check the coolant expansion tank and verify the
coolant level is between the “Cold” and “Hot” level To change the gearbox oil:
markings. To add coolant to the system add it to the
1. Disable the generator from starting.
expansion tank when the engine is cool (not at operating
temperature, not running). Add only a 50/50 mixture of 2. Remove the oil drain plug and drain the oil into an
the correct antifreeze and distilled or deionized water to appropriate container. Properly dispose of or
the coolant system. recycle the oil.
3. Reinstall the oil drain plug.
Check/Change Gearbox Oil (If Equipped)
4. To add oil to the gearbox, remove the oil level
Check monthly, or every 100 hours of operation. check plug and oil filler/vent cap.
Biannually (or every 600 hours), an authorized service 5. Add the recommended oil/stabilizer mix until it just
technician should completely drain and refill the gearbox. starts to flow from the oil level check plug opening.
Gear oil used is 80W-90. Lucas Heavy Duty Oil Stabilizer 6. Install and tighten the oil filler/vent cap and oil level
should be added as follows by Fluid volume: check plug.
• 390 Gearbox - Approximately 32 oz. total. 26 oz.
gear oil and 6 oz. Lucas Heavy Duty Oil Stabilizer. Return the generator to operating condition. Start the unit
and check for leaks.
• 520 Gearbox - Approximately 55 oz. total. 44 oz.
gear oil and 11 oz. Lucas Heavy Duty Oil Stabilizer.

To check gearbox oil level:

1. Disable the generator from starting.
2. Remove the oil level check plug. See Figure 4-1.
3. The oil level should be at the bottom edge of the oil
level check plug hole.
4. To add oil, remove the oil filler/vent cap, and fill
through the vent line.
5. Replace the vent cap and oil level check plug and
tighten.

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 Maintenance

Battery Inspection An Authorized Operator should inspect the engine bat-

tery system monthly. At this time, the battery fluid level
DANGER should be checked and distilled water added if needed.
Electrocution. Do not wear jewelry while Battery cables and connections also should be inspected
working on this equipment. Doing so will for cleanliness and corrosion.
result in death or serious injury. Once every six months, an Authorized Service
(000188) Technician should inspect the battery system. At this time
the battery condition and state of charge should be
checked using a battery hydrometer. The battery should
WARNING be recharged or replaced as required.
Sudden start-up. Always set the safety disconnect
switch to MANUAL before working on equipment. NOTE: A negative ground system is used. Battery
Failure to do so could result in death or serious injury. connections are shown on the wiring diagrams. Verify the
(000194) battery is correctly connected and terminals are tight.
Observe battery polarity when connecting the battery to
the generator set.
WARNING
Explosion. Batteries emit explosive gases while
Battery Installation and Replacement
charging. Keep fire and spark away. Wear protective
gear when working with batteries. Failure to do so When required, the battery must be replaced with one of
could result in death or serious injury. equivalent size, voltage, and CCA (cold crank amp
(000137a) capacity). Consult the Unit Specification Sheet or contact
the local IASD for proper battery sizing.
WARNING A new battery must be filled with the proper electrolyte
Explosion. Batteries emit explosive gases. and be fully charged before installing.
Always disconnect negative battery cable
first to avoid spark. Failure to do so could Preliminary Instructions
result in death or serious injury. (000238) 1. Set the AUTO/OFF/MANUAL switch on the
generator control panel to OFF.
2. Turn off utility power supply to the battery charger
WARNING
circuit.
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause 3. Remove the 10A fuse from the generator control
burns and blindness. If electrolyte contacts skin or eyes, panel.
flush with water and seek immediate medical attention.
4. Remove the ATC style fuse from the battery
(000162)
charger.

WARNING Battery cables are connected to the generator connection

points at the factory. Connect the cables to the battery
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can posts as shown in Figure 4-2 and Figure 4-3.
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate 12 VDC System
medical attention. (000163a) 1. Connect the red battery cable from the starter
contactor to the positive (POS or +) battery post.

WARNING
Vision Loss. Eye protection is required to avoid
spray from spark plug hole when cranking engine.
Failure to do so could result in vision loss.
(000181)

WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
(000228)

Generator Installation and Operating Manual 23

Maintenance

2. Connect the black battery cable to the frame 2. Install the 10A fuse in the generator control panel.
ground to the negative (NEG or -) battery post. 3. Turn on the utility power supply to the battery
charger circuit.
E 4. If the unit was previously operational, turn the
AUTO/OFF/MANUAL switch on the generator
A F control panel to AUTO.

B
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
(000228)
Always recycle batteries in accordance with local laws
001061
and regulations. Contact your local solid waste collection
Figure 4-2. 12 VDC System site or recycling facility to obtain information on local
C E
recycling processes. For more information on battery
A recycling, visit the Battery Council International website
at: http://batterycouncil.org
D F

B
CAUTION
Equipment damage. Do not make battery
connections in reverse. Doing so will result
in equipment damage.
(000167a)

001062
Other Maintenance Checks
Figure 4-3. 24 VDC System The following inspections should be performed by an
IASD, or an Authorized Operator. These maintenance
items require a high level of experience and skill to
A Black Lead to Frame
evaluate and correct.
B Black (-)
• Inspect engine accessory drive belts
C Red or Black Jumper • Inspect hoses and connections
D Wire 13 (if used) • Inspect fuel supply system
E Red Lead from Starter Contactor • Inspect exhaust system

F Red (+)
Maintenance and Repair Parts
24 VDC System All non-emissions related service maintenance or repairs
should be completed by an authorized service technician
1. Connect the red battery cable from the starter
to maintain the warranty status of a unit. Emissions
contactor to the positive (POS or +) post of battery related maintenance and repairs may be performed by a
A. person or repair shop of the owner’s choosing.
2. Connect the black battery cable to the frame
ground to the negative (NEG or -) post of battery B.
NOTE: On 24V gaseous units, center tap wire number
13 between the batteries as shown in Figure 4-3.
3. Connect either a black or red jumper cable from
the negative (NEG or -) post of battery A to the
positive (POS or +) post of battery B.

Final Instructions
1. Install the ATC style fuse in the battery charger.

24 Generator Installation and Operating Manual

 Maintenance

Extended Run-Time Maintenance Checks

These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices
contained in the owner’s manual.

IASD/Authorized Operator Maintenance Tasks. Task Completed

Perform steps 1 through 8 and 11 every 24 continuous operating hours. Date/Initials

1. Before shutting the unit down, perform a thorough visual inspection for leaks, loose
components or connections, excessive apparent wear or damage. Any discrepancies noted
should be further inspected and corrected while the unit is shut down.

2. Shut the unit down per the procedure in the owner’s manual.
3. Check the engine oil level. The level should be between the low and full markings on the
dipstick. Adjust as necessary.

4. Check the engine coolant level. Make sure the level in the coolant catch tank is between the
cold and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate
coolant.
5. Visually inspect the engine accessory drive belts and fan coupling device (if equipped) for
correct tension and any signs of abrasion, wear, deterioration or damage. Correct as
necessary.

6. Visually inspect all hoses and connections (exhaust, intake, coolant, block heater, fuel lines and
filters, oil filters, etc) for leaks, tightness, signs of deterioration, wear, or damage. Correct as
necessary.

7. Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as
necessary.

8. Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.

9. Gearbox Equipped Only: Check the gearbox oil level every 100 operating hours. Adjust as
necessary.

10. Weekly When Operating: Check the battery electrolyte level (if accessible). Adjust as
necessary (add only distilled or deionized water to replenish battery cells).

11. Return the unit to operational condition and restart. Check unit voltage and frequency. Visually
inspect the unit for leaks, loose connections or components. Place the unit back in service.

Date inspection Completed: Unit Hour-Meter Reading:

IASD/Authorized Operator signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 25

Maintenance

Maintenance Level 1A
One Time at 50 Hours / 3 Months. These maintenance tasks must be performed by an IASD. Comply with all safety
notices contained in the owner’s manual. Some of these tasks require the use of the applicable engine service manual.

IASD Tasks. Task Completed

Perform these tasks in addition to the regularly scheduled Monthly maintenance tasks Date/Initials

1. Disable the unit from operating per the procedure found in the owner’s manual.

2. Check engine valve clearance (valve lash) as specified in the engine service manual.
NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service
manual.
3. Change the engine oil.

4. Change the oil filter(s).

5. Check the engine accessory drive belts and fan coupling device (if equipped) for correct
tension, wear or abrasion, deterioration, or damage. Correct as necessary.
6. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and
filters, oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

7. Check wiring connections (at MLCB, customer connections, control terminal strips, battery,
etc) for loose connections, corrosion or damage. Correct as necessary.

8. Return the unit to operational condition and test. Place the unit in automatic and open the
service disconnect to force the unit to start and transfer to the load. Exercise the unit against
the load for 15 minutes, visually inspecting for leaks, loose connections or components, and
any abnormal operating conditions. Record the unit voltage, frequency, kW and kVA while
running. Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct
any discrepancies.
Voltage: Frequency: kW: kVA:

9. If the control has alarm and/or event or run logs, record the alarm and event logs to a history
file for the unit.

10. Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

26 Generator Installation and Operating Manual

 Maintenance

Maintenance Level 1 - Monthly or Every 24 Hours

These maintenance tasks can be performed by an IASD or an Authorized Operator. Comply with all safety notices
contained in the owner’s manual.

IASD/Authorized Operator Maintenance Tasks Task Completed

Date/Initials

1. Disable the unit from operating per the instructions in the owner’s manual.

2. Check the engine oil level. The level should be between the low and full markings on the
dipstick. Adjust as necessary.

3. Gearbox Equipped Only: Check the gearbox oil level. Adjust as necessary.
4. Check the engine coolant level. Verify the level in the coolant catch tank is between the cold
and hot level markings. Adjust as necessary. Use only a 50/50 mixture of appropriate
coolant.

5. Check the battery electrolyte level (if accessible). Adjust as necessary (add only distilled or
deionized water to replenish battery cells).
6. Check the battery terminal posts, connections, cables and charger connections, and battery
hold-downs for signs of corrosion, looseness, etc. Remove, clean and tighten connections as
necessary.

7. Check operation and condition of the battery charger. Check operation and condition of
optional block heater, oil sump heater, and battery warmer (if equipped). Correct discrepancies
as necessary.

8. Check the air inlets and outlets (enclosure or building vents) for debris or blockage. Correct as
necessary.

9. Visually inspect the fuel supply system for signs of leaks or damage. Correct as necessary.

10. Perform a 5 minute, no-load operational test of the unit. Check unit voltage and frequency.
Visually inspect the unit for leaks, wear, damage, loose connections or components, and
corrosion. Correct as necessary.
Voltage: Frequency:

11. If the control has alarm and/or event or run logs, record the alarm and event logs to a history
file for the unit.
12. Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading:

IASD/Authorized Operator signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 27

Maintenance

Maintenance Level 2 - Semi-Annual or Every 125 Hours

These maintenance tasks must be performed by an IASD. Perform these tasks every six months or every 125 hours of
operation. Perform these tasks in addition to the regularly scheduled Monthly 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.

IASD Tasks Task Completed

Date/Initials

1. Disable the unit from operating per the procedure found in the owner’s manual.

2. Check the engine accessory drive belts and fan coupling device (if equipped) for correct
tension, wear, abrasion, deterioration, or damage. Correct as necessary.

3. Check all hoses, piping, and connections (intake, exhaust, coolant, block heater, fuel and filters,
oil lines and filters) for tightness, leaks, deterioration or damage. Correct as necessary.

4. Load test the battery or test electrolyte levels (specific gravity) with a hydrometer.

5. Return the unit to operational condition and test. Place the unit in automatic and open the
service disconnect to force the unit to start and transfer to the load. Exercise the unit against
the load for 15 minutes, visually inspecting for leaks, loose connections or components, and
any abnormal operating conditions. Record the unit voltage and frequency while running.
Restore utility power and monitor transfer to utility, cool-down and shutdown. Correct any
discrepancies.
Voltage: Frequency: kW: kVA:

6. If the control has alarm and/or event or run logs, record the alarm and event logs to a history file
for the unit.

7. Return the unit to operational condition.

Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

28 Generator Installation and Operating Manual

 Maintenance

Maintenance Level 3 - Annual or Every 250 Hours

These maintenance tasks must be performed by an IASD. 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.

IASD Tasks 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
filters, 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
disconnect 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
abnormal 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:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

Generator Installation and Operating Manual 29

Maintenance

Maintenance Level 4 - Bi-Annual or Every 500 Hours

These maintenance tasks must be performed by an IASD. 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.

IASD Tasks 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. Check engine valve clearance (valve lash) as specified in the engine service manual.
NOTE: This is NOT required for engines with hydraulic lifters. Check the engine service manual.

3. Gearbox Equipped Only: Change the gearbox oil. Can be extended to 600 hours.

4. Replace the engine air filter(s).

5. Gaseous Units Only: Replace the spark plugs. Gap per the engine specifications.
6. Replace the engine accessory drive belts. Inspect and lubricate (if required) the belt tensioning
device (if equipped) and replace if necessary.

7. Drain and flush the cooling system. Refill with fresh coolant of appropriate type (50/50 mixture).

8. 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.

9. Replace fuel filter. Verify the fuel system is bled and primed before running unit (diesel only).

10. Remove, clean, inspect, reinstall and reset to correct voltage level the flywheel magnetic
pickup(s) (if equipped).

11. Return the unit to operational condition and test. Place the unit in automatic and open the
service 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:

12. If control has alarm and/or event or run logs, record the alarm and event logs to a history file.

13. Return the unit to operational condition and place back in automatic operation.

Date inspection Completed: Unit hour Meter Reading:

IASD signature signifying inspection complete:

Record any oil or coolant added and notes about any discrepancies found and corrective action taken.

30 Generator Installation and Operating Manual

 Warranty Information

Section 5 Warranty Information

For Stationary Emergency Spark-Ignited Generators

United States Environmental Protection Agency Warranty Statement

(Stationary Emergency Spark-Ignited Generators)
Warranty Rights, Obligations and Coverage
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or
component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis,
replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility. Your emission control system may
include parts such as the fuel metering, ignition, and exhaust systems and other related emission related components listed below. Generac
will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse, neglect,
unapproved modification, or improper maintenance of your engine. For engines less than 130 HP the warranty period is two years from the
date of sale to the ultimate purchaser. For engines greater than or equal to 130 HP the warranty period is three years or 2500 hours of
operation, whichever comes first, from the date of the engine being placed into service. For high-cost warranted components, the Emission
Control System warranty is valid for 5 years or 3500 hours of operation, whichever comes first.

Purchaser's/Owner's Warranty Responsibilities

As the engine purchaser/owner you are responsible for the following: 1) The engine must be installed and configured in accordance to
Generac's installation specifications. 2) The completion of all maintenance requirements listed in your Owner's Manual. 3) Any engine setting
adjustment must be done in accordance and consistent with the instructions in the Owner's Manual. 4) Any emission control system or
component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize
emissions at all times.
Generac may deny any and/or all Emission Control System Warranty coverage or responsibility of the engine, or an emission control system
or component on your engine thereof, if it has failed due to abuse, neglect, unapproved modification or improper maintenance, or the use of
counterfeit and/or “gray market” parts not made, supplied or approved by Generac. Warranty service can be arranged by contacting either
your selling dealer or a Generac Authorized Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or
repair facilities. The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being
transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System
Warranty related information, Generac Power Systems, Inc., PO. Box 8, Waukesha, WI 53187, or call 1-800-333-1322, email
[email protected], or visit www.generac.com.

Important Note
This warranty statement explains your rights and obligations under the Emission Control System Warranty, which is provided to you by
Generac pursuant to federal law. Note that this warranty shall not apply to any incidental, consequential, or indirect damages caused by
defects in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other
warranties, expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular
purpose. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Emission Related Parts Include the Following (if so equipped)

1) Fuel Metering System 3) Ignition System Including A) Spark Plug, B) Ignition Module,
1.1) Gasoline Carburetor Assembly and Internal Components C) Ignition Coil, D) Spark Plug Wires
A) Fuel Filter, B) Carburetor, C) Fuel Pump 4) Exhaust System
1.2) Carburetion Assembly and Its Components A) Catalyst Assembly*, B) Exhaust Manifold, C) Muffler,
A) Fuel Controller, B) Carburetor and Its Gaskets, D) Exhaust Pipe, E) Muffler Gasket
C) Mixer and Its Gaskets, D) Primary Gas Regulator, 5) Crankcase Breather Assembly Including
E) Liquid Vaporizer A) Breather Connection Tube, B) PCV Valve
1.3) Fuel Regulator 6) Oxygen Sensor
2) Air Induction System Including A) Intake Pipe/Manifold, 7) Diagnostic Emission-Control System
B) Air Cleaner

*High-Cost Warranted Component

Part No. 10000012792 Revision F (3/17)

Generator Installation and Operating Manual 31

Warranty Information

United States Environmental Protection Agency Compliance Requirements

(Stationary Emergency Spark-Ignited Generators)
Purchaser's/Owner's Record Keeping Responsibilities
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record
keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion
Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60. As the engine purchaser/owner who operates and maintains
their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in
this Owner's Manual, you are required to meet the following notification and record keeping requirements to demonstrate compliance: 1)
Maintain documentation that the engine is certified to meet emission standards. 2) Record keeping of maintenance conducted. 3) Record
keeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel
solely during emergency operations provided the engine is not certified to operate on propane. 4) Meet all compliance notifications submitted
to the purchaser/owner and maintain all supporting documentation. 5) Record keeping of hours of operation, including what classified the
operation as emergency and how many hours are spent for non-emergency operation. For emergency engines greater than or equal to 130
HP, record keeping of hours of operation begins January 1, 2011. For emergency engines less than 130 HP, record keeping of hours of
operation begins January 1, 2009; engines are equipped with non-resettable hour meters to facilitate record keeping.
Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping/reporting requirements.
Your permit to construct and/or operate the engine may be contingent upon compliance with those requirements. Check with your local Air
Quality Management or Air Pollution Control District for specific requirements.
Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing,
provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the
engine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of
emergency stationary ICE in emergency situations. The purchaser/owner may petition the Administrator for approval of additional hours to
be used for maintenance checks and readiness testing, but a petition is not required if the owner maintains records indicating that Federal,
State, or local standards require maintenance and testing of emergency ICE beyond 100 hours per year. Emergency stationary ICE may
operate up to 50 hours per year in non emergency situations, but those 50 hours are counted towards the 100 hours per year provided for
maintenance and testing.
The 50 hours per year for non-emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to
an electric grid or otherwise supply power as part of a financial arrangement with another entity. For purchaser/owner of emergency engines,
any operation other than emergency operation, maintenance and testing, and operation in non-emergency situations for 50 hours per year,
as permitted in this section is prohibited.
If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control systems in accordance
to the specifications and guidelines in this Owner’s Manual, EPA will not require engine performance testing. If not, your engine will be
considered non-certified and you must demonstrate compliance according to Subpart JJJJ - Standards of Performance for Stationary Spark
Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.

Emission-Related Installation Instructions

Your certified emergency stationary engine has pre-set emission control systems or components that require no adjustment. Inspection and
replacement of an emissions related component is required to be done so in accordance with the requirements cited in the United States
Environmental Protection Agency Warranty Statement or can be arranged by contacting either your selling dealer or a Generac Authorized
Warranty Service dealer, 1-800-333-1322 for the dealer nearest you. Failing to follow these instructions when installing a certified engine in a
piece of non-road equipment violates federal law 40 CFR 1068.105 (b), subject to fines or penalties as described in the Clean Air Act.

Part No. 10000012792 Revision F (3/17)

32 Generator Installation and Operating Manual

 Warranty Information

For Stationary Emergency Compression-Ignition Generators

To receive information about how to make an emissions-
related warranty claim and how to make arrangements
for authorized repairs, call 1-800-333-1322 or go to
www.generac.com.

Generator Installation and Operating Manual 33