Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 owner manual

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4.10 SCHEDULED MAINTENANCE

Section 4 — Maintenance

Guardian Liquid-cooled 25 kW Generator

4.10 SCHEDULED 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 the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to deter- mine 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 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 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 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 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.

3An 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 Generac Service Dealer.

4A 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 Generac Service Dealer.

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Contents This manual should remain with the unit SHOULD ATTEMPT INSTALLATIONOwner’s Manual Liquid-cooled,Prepackaged Standby GeneratorsINTRODUCTION AUTHORIZED SERVICE DEALER LOCATION‹OPERATION AND MAINTENANCE ‹HOW TO OBTAIN SERVICEINTRODUCTION Table of ContentsParts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator ‹STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.4GENERATOR AC CONNECTION SYSTEMS 1.2TRANSFER SWITCH1.1GENERATOR 1.3AUTOMATIC SYSTEM OPERATIONFigure 1.4 - Low Oil Pressure Switch ‹1.7.1 LOW OIL PRESSURE SWITCH‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹1.7.3 LOW COOLANT LEVEL SWITCH1.8UNPACKING 1.10 SPECIFICATIONS‹1.7.6 LOW BATTERY ‹1.8.1 UNPACKING PRECAUTIONS‹ 1.10.2 GENERATOR 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 — Reconfigure the Fuel System 1.11 FUEL CONSUMPTION1.14 COOLANT RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1STANDBY GENERATOR INSTALLATION 1.13 ENGINE OIL RECOMMENDATIONS‹2.1.2 OTHER PUBLISHED STANDARDS 2.3GENERATOR MOUNTING AND SUPPORT2.4BASIC STANDBY ELECTRIC SYSTEM 2.2GENERATOR LOCATION2.7GROUNDING THE GENERATOR 2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.6TOTAL CIRCUIT ISOLATION METHODStandby generators installed with automatic 2.10BATTERY INSTALLATIONPos2 OFF — Standard Prepackaged ATS Application ‹2.10.1 VENTED BATTERIES‹2.11.1 PRIOR TO INITIAL START-UP 3.1ENGINEERED GTS TRANSFER SWITCH‹2.11.2 TRANSFER SWITCH 2.11 PREPARATION BEFORE START-UP3.2CONTROL CONSOLE COMPONENTS ‹3.2.2 FAULT INDICATOR LEDS‹3.2.1 AUTO/OFF/MANUAL SWITCH ‹3.2.5 SET EXERCISE TIME SWITCH‹3.2.6 SYSTEM READY LED 3.4ENGINE GOVERNOR ADJUSTMENTS3.3MANUAL TRANSFER AND START-UP 3.7WEEKLY EXERCISE CYCLE Figure 3.2 — Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.6AUTOMATIC OPERATIONC. ONCE ANNUALLY 3.8CONTROL BOARD DIP SWITCH SETTINGSA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHSFigure 4.1 — Intake Manifold Installation 4.2EXHAUST MANIFOLD PROCEDURE4.3INTAKE MANIFOLD PROCEDURE 4.4CYLINDER HEAD PROCEDURE4.7CHECKING FLUID LEVELS 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.6OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM‹4.8.9 INSPECT ENGINE GOVERNOR ‹4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 – Setting the Spark Plug Gap ‹4.8.8 CHECK FAN BELT‹4.9.3 BATTERY MAINTENANCE 4.9MISCELLANEOUS MAINTENANCE‹4.9.1 CLEANING THE GENERATOR ‹4.9.2 BATTERYService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCETasks MaintenanceLevel Maintenance CORRECTION TROUBLESHOOTING POINTSPROBLEM CAUSESection 6 — Notes Section 7 - Electrical Data 26 Generac Power Systems, IncSection 7 - Electrical Data 28 Generac Power Systems, Inc Section 7 - Electrical Data 30 Generac Power Systems, Inc Section 7 - Electrical Data 32 Generac Power Systems, Inc Section 7 - Electrical Data MOUNT DESCRIPTION ITEMPART NO 31 7 11 Enclosure — Drawing No. 0E9720-D 54 36 30 0C2267 40 Generac Power Systems, Inc 0C2267 Engine — Drawing No. 0E9918-E 42 Generac Power Systems, Inc0E9909 0E1028A I/N 0E8456 LOCKTIGHT 0F1659A Muffler — Drawing No. 0F2930-B Stepper Motor — Drawing No. 0E9979-C Radiator — Drawing No. 0E9965-D Installation Diagram — Drawing No. 0F1020-A Section 9 — Installation DiagramCALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES 1-800-333-1322EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYP.O. BOX 297 • WHITEWATER, WI WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC