Generac Power Systems 004992-0, 004992-1, 004992-1, 004992-0 owner manual Scheduled Maintenance

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Section 4 — Maintenance

Guardian 40kW Liquid-cooled Generators

4.7SCHEDULED MAINTENANCE

Following is a recommended maintenance schedule for Generac 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 application. Use calendar 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:

1An early inspection of the generator set to ensure it is ready to operate when required and to identify any poten- tial problem areas.

Performed monthly, this inspectin 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 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 condi- tion 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.

2A break-in service inspection of the generator set to ensure 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 service dealer.

3An operational inspection of the generator set to ensure 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 service dealer.

4A mid-level inspection of the generator set to ensure 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 service dealer.

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Contents Liquid-cooled, Prepackaged Standby Generators Introduction ‹ Operation and Maintenance‹ HOW to Obtain Service ‹ Read this Manual ThoroughlyTable of Contents General Hazards Electrical Hazards Automatic System Operation Transfer SwitchGenerator Generator AC Connection Systems‹ 1.7.3 LOW Coolant Level Switch ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.2 High Coolant Temperature Switch Generator Fuel SystemUnpacking Lifting the Generator‹ 1.10.1 Generator Specifications SpecificationsReconfiguring the Fuel System ‹ 1.10.2 Engine SpecificationsEngine OIL Recommendations Torque SpecificationsBefore Installation Coolant RecommendationsBasic Standby Electric System Generator LocationGenerator Mounting Support ‹ 2.1.1 Nfpa StandardsTotal Circuit Isolation Method Emergency Circuit Isolation MethodGenerator AC Neutral Connections ‹ 2.9.1 PRE-PACKAGED ATS Transfer Switch Signal ConnectionsBattery Installation ‹ 2.9.2 GTS-TYPE ATSPreparation Before START-UP ‹ 3.2.2 Fault Indicator Leds Using AN Engineered GTS Transfer Switch‹ 3.2.1 AUTO/OFF/MANUAL Switch Control Console ComponentsManual Transfer START-UP Engine Governor Adjustments‹ 3.2.5 SET Exercise Time Switch ‹ 3.2.6 System Ready LEDAutomatic Operation Weekly Exercise CycleChecking Fluid Levels Overload Protection for Engine DC Electrical SystemCooling System ‹ 4.5.9 Inspect Engine Governor ‹ 4.5.2 Check Battery‹ 4.5.8 Check FAN Belt ‹ 4.5.1 Check Engine OIL Level‹ 4.5.11 Changing the Engine AIR Cleaner Miscellaneous Maintenance‹ 4.6.1 Cleaning the Generator ‹ 4.5.13 Coolant Change‹ 4.6.3 Battery Maintenance ‹ 4.6.4 Battery ReplacementScheduled Maintenance Service Maintenance Interval InformationLevel Maintenance Level Troubleshooting Points Problem Cause CorrectionElectrical Data Electrical Data Electrical Data Electrical Data Carrier Rear Bearing Boot Battery Cable Assy WireHold Down Battery Battery Post Covwer BlackSee Latch Detail Intake Duct HSB Assy GRD Wire 99HSBAssembly BASE-DOOR Ground Wire Duct Discharge RH FrontGenerac Power Systems, Inc Cover Front Panel HSB Assy 2A 12V UL BatteryControl BOX HSB Cover TOP Panel HSBGenerac Power Systems, Inc Flexplate 3.9L HSB COVER, Flywheel AccessASSEMBLY, Resistor MACHINING, 3.9L EnginePump VENTURI,3.9L Cryslr HSB 22FAN Tank Coolant RecoveryRadiator Copper Brass Radiator Support L/H SideTo Engine Plate AIR Cleaner TOP Base AIR Cleaner PlateHold Down AIR Cleaner Flange Fuel InletLeads STR-390--40AD HSB 433MM LONG3.9L Chrysler Rotor 390 30KW 1P Direct HSBRotor 390 40KW 1P Direct HSB Rear Bearing Carrier 390/DRCTWYE, Pipe 3.9L Chrysler NUT TOP Lock FL M12-1.75OUT Exhaust Flange 2 PipeInstallation Diagram Guardian 40kW Liquid-cooled Generators Guardian 40kW Liquid-cooled Generators This Warranty Shall not Apply to the Following