Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 Level, Tasks

Page 24
Maintenance

Section 4 — Maintenance

Guardian Liquid-cooled 25 kW Generator

Maintenance

Level 1

 

Level 2

 

Level 3

 

Level 4

 

Tasks

Recom-

Task

Required

Task

Required

Task

 

Task

 

mended

Comp.

to be done

Comp.

to be done

Comp.

Required

Comp.

 

to be done

(Date-

3 months/

(Date-

Semi-

(Date-

to be done

(Date-

 

monthly

Initials)

Break-in

Initials)

annually

Initials)

Annually

Initials)

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 air inlets and outlets for debris. Clean as necessary.

7. Check the battery electrolyte level if accessible. Adjust as necessary.

8.Check the battery posts, cables, and charger for

loose connections, corrosion, and proper operation. Correct as necessary.

9.Check the unit wiring for loose connections,

corrosion, and damage. Correct as necessary.

10.Check the engine accessory drive belts for

wear, weather cracking, and damage. Replace as necessary.

11.Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary.

12.Test the engine and

transfer switch safety devices. Correct and/or adjust as necessary.

22 Generac® Power Systems, Inc.

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Contents SHOULD ATTEMPT INSTALLATION Owner’s ManualLiquid-cooled,Prepackaged Standby Generators This manual should remain with the unitAUTHORIZED SERVICE DEALER LOCATION ‹OPERATION AND MAINTENANCE‹HOW TO OBTAIN SERVICE INTRODUCTIONTable of Contents INTRODUCTIONGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot ELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹STANDARDS INDEX1.2TRANSFER SWITCH 1.1GENERATOR1.3AUTOMATIC SYSTEM OPERATION 1.4GENERATOR AC CONNECTION SYSTEMS‹1.7.1 LOW OIL PRESSURE SWITCH ‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH‹1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch1.10 SPECIFICATIONS ‹1.7.6 LOW BATTERY‹1.8.1 UNPACKING PRECAUTIONS 1.8UNPACKING1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR Figure 1.8 — Reconfigure the Fuel System1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR1.15 BEFORE INSTALLATION 2.1STANDBY GENERATOR INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.3GENERATOR MOUNTING AND SUPPORT 2.4BASIC STANDBY ELECTRIC SYSTEM2.2GENERATOR LOCATION ‹2.1.2 OTHER PUBLISHED STANDARDS2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH 2.5EMERGENCY CIRCUIT ISOLATION METHOD2.6TOTAL CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATOR2.10BATTERY INSTALLATION Pos2 OFF — Standard Prepackaged ATS Application‹2.10.1 VENTED BATTERIES Standby generators installed with automatic3.1ENGINEERED GTS TRANSFER SWITCH ‹2.11.2 TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹2.11.1 PRIOR TO INITIAL START-UP‹3.2.2 FAULT INDICATOR LEDS ‹3.2.1 AUTO/OFF/MANUAL SWITCH‹3.2.5 SET EXERCISE TIME SWITCH 3.2CONTROL CONSOLE COMPONENTS3.4ENGINE GOVERNOR ADJUSTMENTS 3.3MANUAL TRANSFER AND START-UP‹3.2.6 SYSTEM READY LED Figure 3.2 — Engine Governor Adjustment Figure 3.3 - “Set Exercise Time” Switch3.6AUTOMATIC OPERATION 3.7WEEKLY EXERCISE CYCLE3.8CONTROL BOARD DIP SWITCH SETTINGS A. EVERY THREE MONTHSB. ONCE EVERY SIX MONTHS C. ONCE ANNUALLY4.2EXHAUST MANIFOLD PROCEDURE 4.3INTAKE MANIFOLD PROCEDURE4.4CYLINDER HEAD PROCEDURE Figure 4.1 — Intake Manifold Installation4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM 4.6OVERLOAD PROTECTION FORENGINE DC ELECTRICAL SYSTEM 4.7CHECKING FLUID LEVELS‹4.8.11 CHANGING THE ENGINE AIR CLEANER Figure 4.4 – Setting the Spark Plug Gap‹4.8.8 CHECK FAN BELT ‹4.8.9 INSPECT ENGINE GOVERNOR4.9MISCELLANEOUS MAINTENANCE ‹4.9.1 CLEANING THE GENERATOR‹4.9.2 BATTERY ‹4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationMaintenance LevelTasks Maintenance TROUBLESHOOTING POINTS PROBLEMCAUSE CORRECTIONSection 6 — Notes 26 Generac Power Systems, Inc Section 7 - Electrical DataGenerac Power Systems, Inc. 28 Generac Power Systems, Inc Generac Power Systems, Inc 30 Generac Power Systems, Inc Generac Power Systems, Inc. 32 Generac Power Systems, Inc Generac Power Systems, Inc. MOUNT ITEM PART NODESCRIPTION 31 7 11 Enclosure — Drawing No. 0E9720-D 54 36 30 0C2267 40 Generac Power Systems, Inc 0C2267 42 Generac Power Systems, Inc Engine — Drawing No. 0E9918-E0E9909 0E1028A I/N 0E8456 LOCKTIGHT 0F1659A Muffler — Drawing No. 0F2930-B Stepper Motor — Drawing No. 0E9979-C Radiator — Drawing No. 0E9965-D Section 9 — Installation Diagram Installation Diagram — Drawing No. 0F1020-AYOUR WARRANTY RIGHTS AND OBLIGATIONS PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES1-800-333-1322 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWINGGENERAC POWER SYSTEMS, INC P.O. BOX 297 • WHITEWATER, WI