Guardian Technologies 004988-4 ‹ 4.6.4 Battery Replacement, ‹ Periodic Replacement Parts

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Section 4 — Maintenance

Liquid-cooled 30 kW Generators

DANGER

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charg- ing. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shat- ter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smok- ing, open flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caus- tic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If the fluid is spilled, flush the affected area immediately with clear water.

Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.

Ensure that the 15A and 4A fuses are removed from the control console, the AUTO/OFF/ MANUAL switch is set to OFF, and the utility supply to the battery charger is removed before removing or connecting battery cables. If the switch is set to AUTO or MANUAL, the genera- tor can crank and start as soon as the battery cables are connected.

Be sure the UTILITY power supply to the battery charger is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

‹4.6.4 BATTERY REPLACEMENT

When replacing batteries, use the same number and the type of battery that follows:

 

BCI Group No.

CCA

 

 

26/26R

525 @ 0 deg. F

 

 

27

600 @ 0 deg. F

 

 

 

 

 

NOTE:

The BCI number should be located directly on the battery.

‹PERIODIC REPLACEMENT PARTS

Part Name

Part Number

Oil Filter

# 0E7180

Radiator Cap

# 046627

Air Cleaner

# 0C8127

Spark Plug

# 0E7079

 

 

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Contents Liquid-cooled, Prepackaged Standby Generators ‹ Operation and Maintenance Authorized Service Dealer Location‹ HOW to Obtain Service IntroductionTable of Contents  Warning   Electrical Hazards  Generator Transfer SwitchAutomatic System Operation Generator AC Connection Systems‹ 1.7.1 LOW OIL Pressure Switch ‹ 1.7.2 High Coolant Temperature Switch‹ 1.7.3 LOW Coolant Level Switch LOW OIL Presure Switch LOW Coolant Level SwitchLifting the Generator UnpackingReconfiguring the Fuel System Specifications‹ 1.10.1 Generator Specifications ‹ 1.10.2 Engine SpecificationsStandby Generator Installation Torque SpecificationsBefore Installation Engine OIL RecommendationsGenerator Mounting Support Basic Standby Electric System‹ 2.1.2 Other Published Standards Emergency Circuit Isolation Method Transfer Switch Signal ConnectionsTotal Circuit Isolation Method Grounding the GeneratorBattery Installation Preparation Before START-UP‹ 2.9.2 GTS-TYPE ATS Using AN Engineered GTS Transfer Switch ‹ 3.2.2 Fault Indicator LED ‹ 3.2.1 AUTO/OFF/MANUAL Switch‹ 3.2.5 SET Exercise Time Switch Control Console ComponentsManual Transfer START-UP Engine Governor AdjustmentsRetransfer and Shutdown Automatic OperationCooling System Weekly Exercise CycleChecking Fluid Levels Overload Protection for Engine DC Electrical System‹ 4.5.8 Check FAN Belt ‹ 4.5.11 Changing the Engine AIR Cleaner‹ 4.5.9 Inspect Engine Governor ‹ 4.5.10 Changing Engine OIL‹ 4.6.3 Battery Maintenance Miscellaneous Maintenance‹ 4.6.1 Cleaning the Generator ‹ 4.5.13 Coolant Change‹ Periodic Replacement Parts ‹ 4.6.4 Battery ReplacementService Maintenance Interval Information Scheduled MaintenanceLevel Maintenance Level Problem Cause Correction Troubleshooting PointsLiquid-cooled 30 kW Generators Installation Diagram AUTO/OFF/MANUAL Switch Transfer SwitchSET Exerciser Switch Size AWGBAT Otherwise Noted AS ShownIgnition Coil On PCBSWITCH, AUTO/OFF/MANUAL SWITCH, SET ExerciserDPE ALT 12V Battery REDDEG Starter Motor GOVEngine Foot Battery Post Cover Baclk Boot Battery CableBattery Post Cover RED + Hold Down BatteryTo a To B Plcs Intake Duct HSB Assy Wire 14AWG 7.5 #0 GRN/YELDuct Discharge RH Front Duct Discharge LH FrontPage Control BOX HSB Assy 2A 12V UL BatteryDecal AVR Cover Cover Front Panel HSBCooled 30 kW Drawing No Exploded Not SHOWN-USED to Hold OIL Drain Assembly Wire SET 3.0L Ford notCoil Ignition 3.0L Ford Bracket DC ALT 3.0L FordFrame Radiator R-IN,L-OUT Tank Coolant RecoveryVenturi 3.0L Ford HSB Side Support Radiator HSBTo B Flange Fuel Inlet Weldment Mounting BaseAssy Regulator 3.0L NG or LPV Washer Flat 5/16 ZincLocktight Rotor 390 20KW 1P Direct HSB 2.5L Ford Rotor 390 15KW 1P Direct HSB 2.5L FordRotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 39030AD1 HSB TecumPipe Muffler OUT Exhaust Flange 2 PipeWasher Lock 3/8 SS Gasket Exhaust RingElement AIR Cleaner Plate AIR Cleaner AdapterCover AIR Cleaner Adapter Carburetor W/PVC ConnWarranty Schedule

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