Generac Power Systems 004626-5, 004373-6 Spark Plugs, Battery Maintenance, Cooling System

Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

4.4SPARK PLUGS

Reset the spark plug gap or replace the spark plugs as necessary. See Section 4.12.

1.Clean the area around the base of the spark plugs to keep dirt and debris out of the engine. Clean the plugs by scraping using a wire brush. Do not “blast” the spark plugs to clean.

2.Remove the spark plugs and check the condition. Replace the spark plugs if worn or if reuse is ques- tionable. See the “Service Schedule,” Section 4.12, for recommended inspection.

3.Check the spark plug gap using a feeler gauge. Adjust the gap to 0.045 inch (1.1 mm) by carefully bending the ground electrode (Figure 4.4).

Figure 4.4 – Setting the Spark Plug Gap

0.045 inch (1.1 mm)

4.5BATTERY MAINTENANCE

The battery should be inspected per the “Service Schedule,” Section 4.12. The following procedure should be followed for inspection:

1.Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

2.Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES.

3.Have the state of charge and condition checked. This should be done with an automotive-type bat- tery hydrometer or load test.

DANGER

Standby generators installed with automatic transfer switches will crank and start automatical- ly when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until the NORMAL source voltage at the transfer switch is correct and the system is ready to be placed into operation.

Storage batteries give off explosive hydrogen gas. ! This gas can form an explosive mixture around

the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the bat- tery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caustic ! 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 fluid is spilled, flush the affected area immediately with clear water.

Do not dispose of the battery in a fire. The bat- tery is capable of exploding.

Do not open or mutilate the battery. Released ! electrolyte can be toxic and harmful to the skin

and eyes.

The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles.

‹4.5.1 BATTERY REPLACEMENT

Generac uses a Group 27F vented type battery that has 600 CCA @ 0º F. Generac’s part number is 058665.

NOTE:

The BCI number should be located directly on the battery.

4.6COOLING SYSTEM

Air intake and outlet openings in the generator compart- ment must be open and unobstructed for continued prop- er operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.

The exhaust system of this product gets extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

16 Generac® Power Systems, Inc.