Generac Power Systems 43734, 43733 Spark Plugs, Battery Maintenance, ‹ 4.5.1 Battery Replacement

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Section 4 — Maintenance

Guardian Liquid-cooled 40 kW Generator

Figure 4.3 – Engine Air Cleaner

Air Cleaner

See the “Service Schedule,” Section 4.12, for recom- mended air cleaner maintenance.

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 per- sonnel, 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.

16 Generac® Power Systems, Inc.

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Contents 0046262, 0046263 Introduction Authorized Dealer LocationIntroduction Inside Front Cover General Hazards Electrical Hazards Generator Prepackaged Transfer SwitchUNPACKING/INSPECTION Generator AC Connection SystemsSpecifications Main Circuit BreakerEngine Protective Devices Fuel Requirements Recommendations ‹ 1.8.2 Generator and Load Compatibility‹ 1.9.1 Conversion to LP GAS Vapor Emissions Control System Coolant‹ 1.12.1 AIR Fuel Ratio Controller Nfpa Standards Standby Generator InstallationBasic Standby Electric System Other Published StandardsMethod Transfer Switch Start Signal Connections‹ 2.6.1 PRE-PACKAGED Type Switch Grounding the GeneratorBattery Installation Preparation Before START-UP‹ 2.7.1 Vented Batteries ‹ 2.8.3 Fuel System ‹ 2.8.2 Transfer Switch‹ 2.8.1 Prior to Initial START-UP ‹ 2.8.4 Generator SET LubricationUsing the AUTO/OFF/MANUAL Switch Sequence of Automatic Operation Engine Heater‹ 3.2.3 Manual Position Weekly Exercise Cycle Checking the Engine OIL LevelChanging the Engine OIL and Filter Changing the Engine AIR Cleaner‹ 4.2.2 OIL and Filter Change Procedure ‹ 4.2.1 Engine OIL RecommendationsBattery Maintenance ‹ 4.5.1 Battery ReplacementSpark Plugs Overload Protection for Miscellaneous MaintenanceCooling System DC FuseOUT of Service Procedure ‹ 4.11.1 Removal from Service‹ 4.11.2 Return to Service Service Schedule SYSTEM/COMPONENT Procedure FrequencyTroubleshooting Guide Problem Cause CorrectionElectrical Data TS1 Generator D4992-A Guardian Liquid- Panel 4.3L Drawing No Section Wiring Diagram Control Panel Model No KW Generators No D6975 EC1 ACT Drain Pan Oil QTY Description Base Frame Assembly M6 Hinge Panel Face Panel BTM & Back Control Exploded Views and Parts Lists Cover Plate AVR ALT Leads Sensing Wire QTY To Engine Flywheel Washer Lock M12 Exploded Views and Parts Lists Engine 4.3L GM Exploded Views and Parts Lists MOUNT, Engine R & L KIT Radiator Copper Brass DIA. Clamp Assembly 2 Compartment To Engine Front NUT Wing 1/4-20 Nylk To Stepper Motor Support Solenoid NAT GAS Attach to REGULATOR, N/G R600S Exploded Views and Parts Lists Muffler Catalyst 4.3L Assembly Motor Stepper To Thermostat Housing Guardian Liquid-cooled 40 kW Generators Guardian Liquid-cooled 40 kW Generators Your Warranty Rights and Obligations MANUFACTURER’S Emission Control System Warranty CoveragePURCHASER’S/OWNER’S Warranty Responsibilities Emission Control System Warranty Emission Related Parts Include the FollowingWarranty Schedule This Warranty Shall not Apply to the Following