Ford — Procedure (Steps: 3)

For these Ford models: 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR, Rev. C 02/10, V-type.

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Procedure

1. Inspect the battery posts and cables for tightness and corro- sion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries and, if nec- essary, 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 battery hydrometer. DANGER  Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charg- ing. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smok- ing, open flame, sparks or any spark producing tools or equipment near the battery.  Battery electrolyte fluid is an extremely caus- tic 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 the fluid is spilled, flush the affected area immediately with clear water.  Do not use any jumper cables or booster battery to crank and start the generator engine. If the battery has completely discharged, remove it from the generator for recharging.  Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.  Be sure the 120VAC power supply to the battery is turned OFF, or sparking may occur at the bat- tery posts as the cables are attached and cause an explosion. BATTERY REPLACEMENT ‹ When replacing batteries, use the same number and the type of battery that was supplied with the unit, and is listed in the parts list in the back of this manual. NOTE: The BCI number should be located directly on the battery. Stationary Emergency Generator Maintenance 10-4 Maint004 Rev. F 06/09 SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. 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: 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas. 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 15 amp 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 condition 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 opera- tion when required. 2 A wear-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 or the first 30 hours of operation after purchase of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer. 3 An 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 or following each 50 hours of operation of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer. 4 A 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 or following each 100 hours of operation of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer. 5 A comprehensive inspection of the generator set to insure it is properly serviced and ready to operate and carry the load when required, and to identify any potential problem areas. Performed annually or following each 250 hours of operation of the unit. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by a Service Dealer. 11-1 Stationary Emergency Generator Service Sched

Source: manual:167304C.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.