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GE EER2001 Convection Oven User Manual

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1. 18 4 3 Intake Manifold Procedure 18 4 4 Cylinder Head Procedure 18 Ao COOL SWEN cro seperate ali ese a tae onon ko pleyin 18 4 6 Overload Protection for Engine DC Eleciical E ME 19 At Checking Fluid Levels E 19 4 8 Maintenance Owner Operator EH CR IL TL u ete cre er eer nt Sm ss 19 4 9 Miscellaneous Maintenance 21 4 10 Scheduled Maintenance 22 Section 5 TROUBLESHOOTING 25 Section 6 ELECTRICAL DATA 26 Section 7 EXPLODED VIEWS AND PARTS LISTS uuu ss seg 34 Section 8 INSTALLATION DIAGRAM 51 Section 9 WARRANTY 52 SAFETY RULES Important Safety Instructions Liquid cooled 25 kW Generators A SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safetu should be stressed to all operators potential operators and service and repair technicians for this equipment SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNI
2. D 86 CRANK SHIELD L21 O CHIL 3 Loe COL G te3ldesp ay f 0 Sh G 27 Section 6 Electrical Data Liquid cooled 25 kW Generators ELECTRICAL U DATA EF Electrical Schematic 2 5L Engine 15kW amp 20kW units Drawing No 0F2184 B F2 13A CONTROL PANEL LEGEND CES AVR AUTOMATIC VOLTAGE REGULATOR B C BATTERY CHARGER 1 gt A BRI BRIDGE RECTIFIER 13 CB2 CIRCUIT BREAKER EXCITATION FI FUSE BAT POWER 154 ATO TYPE PCB J F2 FUSE B C 5A ATU TYPE NOT USD 1 i J2 CONNECTOR 2 ON PCD NOT USED 2 ID CONNECTOR 3 ON PCB BAK 3 wi RI RESISTOR 5 CHM 25 WATT P 4 W2 TR RLI RELAY 1 START RELAY IEW 7S Een W RL2 RELAY 2 ENGINE RUN CREEN W4 6 W4 SWI AUTO OFF MANUAL SWITCH DCB Wo NE SW2 SET EXERCISER SWITCH NOT USED t 1 1SA TBI TERMINAL BLOCK 1 START RELAY L 2 56A 15 TRANSFORMER 1 56 VA 240 16 VAC FUELCRUN RELAY 3 14 A SWZ SW 2 WIRE START 4 183 MOMENT OPEN 5 15E 2 WIRE START 6 178 NAN AUTO INPUT 7 15A 16VAC SENSECD 8 224 ALARM RELAY 9 XFER RELAY 10 23 MAN INPUT 1 1 239 16VAC SENSED 1 2 225 NOT USED 1 3 m 1 4 0 fi Yo 14 DOOR 0 OJ 194 TB1 A3 TRANSFER COIL RELAY 83 Tpi A2 REMOTE START CCID 17 8 4 TB1 A1 REMOTE START 14A i 14 i ay Lait X i54 5 NI TBI A6 UTILITY FROM T SW Ne TBI AS
3. 29 USING A GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with a GTS type engineered auto matic transfer switch In this application the GTS transfer switch is responsible for utility sensing weekly exercising and load transferring Position two of the eight position DIP switch is used to turn over this control to the GTS In order for the battery charger to work it is neces sary to provide a fused 240 VAC utility source to the N1 and N2 terminals in the control panel Pos2 ON GTS Application The control board will NOT monitor utility The control board will NOT perform a weekly exer cise The five red LEDs will flash one at a time in this mode e The control board will NOT activate the transfer output The control board WILL monitor all engine condi tions and shut down on all the faults listed in this document Pos2 OFF ATS Application e The control board will perform all of the automatic features listed in this document e The two wire start connections wires 178 183 should NOT be connected NOTE If the generator is installed in conjunction with an engineered GTS type engineered transfer switch refer to the applicable transfer switch manual for exact operating parameters and timing sequenc es 2 10 BATTERY INSTALLATION A DIT A Standby generators installed with automatic transfer switches will crank and start automati
4. zl O O1 WP oo O O MN Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact an Authorized Service Dealer Auto reset Wait 5 min and attempt restart 25 ELECTRICAL DATA Section 6 Electrical Data Liquid cooled 25 kW Generators Wiring Diagram 2 5L Engine 15kW amp 20kW units Drawing No 0F2183 B CUNTRUL PANEL LEGEND a AVR AUTOMATIC VOLTAGE REGULATOR ee B C BATTERY CHARGER GE 13 BRI BRIDGE RECTIFIER 15 CB2 CIRCUIT BREAKER EXCITATION Fi FUSE BAT POWER 15A ATO TYPE F2 FUSE B C 5A ATO TYPE met L enn J2 CONNECTOR 2 ON PCB mite J3 CONNECTOR 3 UN PCB MA e Wi KE Ri RESISTOR 5 DN 25 WATT ae L 4 W2 pa RLI RELAY 1 START RELAY mea 5 W3 A RL2 RELAY 2 ENGINE RUN Hh Ee SWL AUTO OFF MANUAL SWITCH SW2 SET EXERCISER SWITCH PCB J2 TBI TERMINAL BLOCK 1 ak i x SS TRI TRANSFORMER 1 56 VA 240 16 VAC FUELCRUN RELAY 3 TA en SIZE 2 VIRE STR 4 183 NOTE ALL WIRES ARE MM MEN PA 5 FE I
5. 5 Install brass hose fitting into Port 2 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressure and type for configuration not to exceed 14 inch es water column 10 Move DIP switch position 4 on the control board to the off position LP vapor see Figure 3 2 and Section 3 8 11 Reverse the procedure to convert back to natural gas Figure 1 8 Reconfigure the Fuel System FUEL HOSE FUEL HOSE BRASS HOSE BRASS HOSE a PLUG FITTING FITTING OUT OUT PORT 1 PORT 2 FUEL INLET NG FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made A Dita A Serious injury or damage may occur if not con figured properly Please consult an Authorized Service Dealer with any questions 1 13 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SF Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Below 32 F 0 C SAE 10W or 15W 40 INSTALLATION Hh Section 2 Installa
6. GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Revision 2 05 Part No OF5097 Revision D 07 19 0585 Printed in U S A
7. QUIE T SOURCE Owner s Manual Liquid cooled Prepackaged Standby Generators Model Number 005031 2 25kW This manual should remain with the unit caution A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION Thank you for purchasing this model of the QuietSource standby generator series Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to spe cial instructions about a particular service or opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A pan A After this heading read instructions that if not strictly complied with will result in serious person al injury including death or property damage warninc Ak After this heading read instructions that if not strictly complied with may result in personal inju
8. cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and pos sible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct the generator main line circuit breaker is switched to OFF the AUTO OFF MANUAL switch on the control con sole is switched to OFF the 15A and 5A fuses have been removed from the control console utility fed supply to battery charger terminals N1 and N2 is removed and the system is ready to be placed into operation Ensure that the 5A and 15A fuses in the control panel are removed when connecting or disconnecting battery cables 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 shat ter 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 A Battery electrolyte fluid is an extremely corro sive 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 th
9. 13 Verify that all the voltage regulators LED s are ON 14 Turn OFF the generator 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS Check battery condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator 3 Flush cooling system a a s 17 MAINTENANCE S Section 4 Maintenance Liquid cooled 25 kW Generators FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 operat ing hours or six months whichever comes first 2 Retorque cylinder head see torque specs 3 Retorque intake and exhaust manifold see torque specs EVERY 500 OPERATING HOURS 1 Service air cleaner 2 Check starter 3 Check engine DC alternator EVERY 800 OPERATING HOURS 1 Retorque cylinder head see torque specs 2 Retorque intake and exhaust manifold see torque specs 3 Check engine compression 4 Check valve clearance 2 EXHAUST MANIFOLD PROCEDURE If necessary clean gasket surfaces on exhaust manifold and cylinder head 2 Install exhaust manifold and exhaust manifold gasket 3 Install fasteners NO
10. 2 0F0789 1 BACK amp BOTTOM CONTROL PANEL 3 0F0791 1 PANEL FRONT 2 5L CONTROL PNL 4 0E9704 1 ASSY PCB HSB CONTROLLER 2 5L 5 067680 1 ASSY VOLTAGE REGULATOR 60HZ 6 0E6875A 2 RELAY 12VDC C FORM W DIODE 7 0C3910 1 XFMR 240 16V 1VA amp 56VA 8 054450 1 CIRCT BRK 5 5 X 1 ETA 46 500 P 9 0D5070A 1 ASSY PCB 2A 12V UL BATT CHRGR 10 057073 1 JUNCTION BLOCK 3 8 16 11 040213 2 PCB SUPPORT SNAP IN 1 4 12 0C2265 16 SCREW PHTT M4 0 7 X 12 ZYC 13 029673 1 DIO BRIDGE 25A 600V 14 0F0793 1 BRACKET CB SIEMENS BQ 15 0E7890 1 BRKT CB MTG BACK 16 0A2077 1 CB 0125A 2P 240V S BQ2 LL 17 0F1264 1 ADPTR LH SIDE WICKMAN 178 6192 18 0F1263 1 ADPTR RH SIDE WICKMAN 178 6191 19 0F1262 2 HOLDER FUSE WICKMANN 178 6150 20 0E7403A 1 FUSE ATO TYPE 5 AMP TAN 21 0E7403C 1 FUSE ATO TYPE 15 AMP BLUE 22 0E2514 1 FITTING CONDUIT STR 1 1 2 23 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 24 023897 4 WASHER FLAT 10 ZINC 25 022152 2 WASHER LOCK 10 26 051716 2 NUT HEX M5 0 8 G8 YEL CHR 27 082573 1 SWITCH ROC DPST 125V SPD 28 0E4494 1 SWITCH ROC DPDT ON OFF ON 29 004167 REF BLOCK TERM 20A 14 X 6 X 1100V 30 0C2699 4 SCREW PHTT 6 32 X 3 8 ZYC 31 0C2212 1 SCREW PHTT M4 0 7 X 16 ZYC 32 047411 4 SCREW HHC M6 1 0 X 16 G8 8 33 022097 4 WASHER LOCK M6 1 4 34 022473 4 WASHER FLAT 1 4 M6 ZINC 35 0E7358 4 SCREW PPPH HI LO 4 24 X 3 8 37 0F0798 1 HARNESS CTRL PNL 2 5L FORD AL NOT SHOWN 38 0E6881 REF SOCKET RELAY 39 001127 1 DECAL AVR COVER 40 0C1229 1 DECAL WARNING ELECTRICAL SHOCK 41 0
11. This prevents overloading the generator by keeping electrical loads below the wattage amperage capac ity of the generator If the generator is powering only critical loads within its wattage amperage capac ity during utility power outages consider using the emergency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel The generator only supplies electrical circuits con nected to the emergency distribution panel during utility power outages Load circuits powered by that panel must be within the wattage amperage capacity of the generator set The transfer switch must meet the following requirements It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit It must be installed between the building s main distribution panel and the emergency distribution panel 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electri cal loads in the circuit is to be installed the Total Circuit Isolation Method may be used The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service The transfer switch is installed between the util ity service entrance and the building distribution panel 2 7 GROUNDING THE GENERATOR The National Electrical Code req
12. UTILITY FROM T SW 6A C3 TBI A4 TRANSFER COIL RELAY 86 TA x 15JA CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMLY GENERATOR CBI MAINLINE CIRCUIT BREAKER C40V DUTPUT TU TRANSFER SWITCH TBL INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK as Section 6 Electrical Data Liquid cooled 25 kW Generators i i ELECTRICAL Electrical Schematic 2 5L Engine 15kW amp 20kW units Drawing No 0F2184 B lt DATA ii ENGINE WIRING LEGEND PCB Ji ALT D C CHARGE ALTERNATOR EG H2 L 1 BAT 12VDC BATTERY M 9 2 15A CC STARTER CONTACTIR IEG GW 3 0 CP COIL PACK COOLANT SENSORS 4 85 CS CRANK SENSOR mie FS FUEL SOLENOID te HCT HIGH COOLANT TEMP SWITCH DISTRIBUTOR 12V 7 JI CONNECTOR 1 ON PCD NOT USED jen LOS LOW DIL PRESSURE SWITCH CRANK SENSOR IN L 9 O m ou STARTER MOTOR CRANK SENSE RET 10 79 l A STM STEPPER MOTOR WLS COOLANT LEVEL SWITCH NOT USED 1 1 DEG FIK 71 2 RI 13 15A DIL 9 14 15R COIL A GE Ka DISTRIBUTOR RET 1 6 DISTR INPUT 1 7 DEG PW 1 8 DEG ENABLE 1 9 LOW DIL PRESS 20 86 CRAM SHIELD Lei o 4 ee CUIL B 23 25B LOS 86 e pe 0 I HCT Sa Jan WLS 85 25 ANS 0 I Section 6 Electrical Data Liquid cooled 25 kW Generators ELECTRICAL a a I l DATA gt Wiring Diagram 2 5L Engine 25kW unit Drawing No 0F1286 B CUNTRUL PANEL LEGEND
13. partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions 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 See the installation diagram Liquid cooled 25 kW Generators warninc amp The exhaust system parts from this product get 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 4 6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 7 CHECKING FLUID LEVELS 4 7 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 3 at least every 20 hours of operation or prior to use e Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oi
14. 4 9 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That dealer will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 9 2 BATTERY All lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery e DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte
15. 8 3 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 12 minutes See Weekly Exercise Cycle 4 8 4 INSPECT COOLING SYSTEM Inspect engine cooling system See Maintenance Schedule Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 8 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels 4 8 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks 19 MAINTENANCE S Section 4 Maintenance Liquid cooled 25 kW Generators 4 8 7 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage 4 8 8 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required 4 8 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DX A A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excess
16. AVR AUTUMATIC VOLTAGE REGULATOR B C BATTERY CHARGER BRI BRIDGE RECTIFIER Be CIRCUIT BREAKER EXCITATION Fl FUSE BAT POWER C13A ATO TYPED Fe FUSE B C JA ATO TYPED Je CONNECTOR e UN PCB J3 CONNECTOR 3 ON PCB RLI RELAY 1 START RELAY Kle RELAY 2 ENGINE RUN SWI AUTO UFF MANUAL SWITCH SWe SET EXERCISER SWITCH TBI TERMINAL BLICK 1 TRI TRANSFORMER 1 56 VA 240 16 VAC ss 13 FI 13 Ee PUE Jo NOT USED Li l NOT USED 2 BLACK WI 3 wi ID 4 We WHITE 5 W3 GREEN M4 6 W4 PCB JZ NOT USED 1 START RELAY L 56A FUELCRUN RELAY 3 14A 2 VIRE SIRI 4 183 MENI PEN SES 15E gt VIRE START G 178 MAN AUTO INPUT 7 D 154A a SENSE 8 224 ALARM RELAY 9 YFER RELAY 1 O 23 WW INPUT 1 1 239 I6VAC SENSE 1 2 225 NOT USED 1 3 NB 1 416 o NOTE ALL WIRES ARE e 18 AWG UL LISTED UNLESS OTHERWISE NOTED AS SHOWN LILLE O DOOR OGROUNDING WIRE Mi I s moO CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMLY GENERATOR LH MAINLINE CIRCUIT BREAKER 40V OUTPUT TO TRANSFER SWITCH TBI INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK o 30 Section 6 Electrical Data Liquid cooled 25 kW Generators SS a i s ELECTRICAL Wiring Diagram 2 5L Engine 25kW unit Drawing No 0F1286 B SE DATA lt ENGINE WIRING LEGEND PCB J ALT D C C
17. a 9 2 3 Generator Mounting and Support 9 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 6 Grounding the Generator a a a patap po daaa s 10 2 88 Generator AC Neutral Connections 10 2 9 Using a GTS Transfer Switch 10 2 10 Battery Installation ssccssccoscsscescsanasecscesmvarsenessaumeece 11 2 11 Preparation Before Start Up 12 TABLE OF CONTENTS Table of Contents Liquid cooled 25 kW Generators Section 3 OPERATION 12 Ol GTS Transler SWI CON u uyak a po n ao makab ii 12 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 15 3 4 Engine Governor Gain Adjustments 15 3 5 Manual Retransfer and Shutdown 15 ob AULOMIANC OPETALION u u at gwo ba ka kk pak e l 16 3 7 Weekly Exercise Cycle 16 3 8 Control Board DIP Switch Settings 16 3 9 Voltage Regulator Adjustmentl 17 Section 4 MAINTENANCE 17 4 1 Maintenance Performed by Authorized Service PACING Luis palan e tata aka a anpasan eee 17 4 2 Exhaust Manifold Procedure
18. and laws the published information listed below may be used as installation guide for this equipment NOTE It is essential to use the latest version of any stan dard to ensure correct and current information 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 GENERAL a Liquid cooled 25 kW Generators INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven generator set The generator is designed to supply electrical power that operates criti
19. com INTRODUCTION IFC Read this Manual Thoroughly IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Service Dealer Location IFC SAFETY RULES 2 Standards Kal 3 Section 1 GENERAL INFORMATION 4 Tel GENET OT xs edesont ason asiste stay ii n biya ba aus 4 1 2 ek E 4 13 ATS Mode Automatic Operation 4 14 Generator AC Connection Systems 4 1 Main Circuit Breaker u u u au n See 4 16 Generator Fuel System 5 kit Engine Protective Devices uu bo aaa a asi 5 Lo TD bi iii vot aie aa aa ete a mre ason kan pe io ko ia Z 6 LO HillinG the Ge eriergqto egene 6 1 10 Specifications aie sekte ie ban dik bolet ai atak ie gene awanapaq 6 Tl e un a k l pk en 7 1 12 Reconfiguring the Fuel System for LP Vapor 7 1 13 Engine Oil Recommendations 7 1 14 Coolant Recommendatlions 8 1 15 Before Installation u u ak kk ri t ta ik eli ey ks 8 Section 2 INSTALLATION 8 2 1 Standby Generator Installation 8 22 eheralor LOCANON w sedo ayiti ik ss fat aa
20. fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 4 9 3 BATTERY MAINTENANCE The battery should be inspected per Section 4 7 Scheduled Maintenance The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary MAINTENANCE 2 Section 4 Maintenance Liquid cooled 25 kW Generators 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 A pan A 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 explo
21. of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary Shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Dealer 5 When the engine is inspected by a Generac Authorized Warranty Service Dealer the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original eng
22. source side and start the engine manually refer to the Owner s Manual of the particular transfer switch 3 4 ENGINE GOVERNOR GAIN ADJUSTMENTS Engine speed governing is also controlled by the engine control board The engine governor has been set by the factory during final testing of the generator and should not be adjusted If however adjustments are necessary the following procedure should be followed Figure 3 2 and Section 3 8 1 Move DIP switch 8 to the TEST mode OFF posi tion 2 Set all three potentiometers pots fully counter clockwise 3 Under no load condition increase the GAIN pot as much as possible without causing instability 4 Apply 1 4 1 2 3 4 and full load to the unit Decrease the GAIN pot if there is instability at any load point 5 Under full load condition increase the stability pot until the unit returns to 60 Hertz or 50 Hertz in 50 Hertz applications 6 Reduce load to 3 4 1 2 1 4 and no load Decrease the stability pot if there is instability at any load point 7 Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot If it is set too high it may introduce oscillations at some load It can be set to zero full CCW if a small amount causes oscillations at some load 8 Leave DIP switch 8 in TEST mode Section 3 Operation OPERATION Liquid cooled 25 kW Generators gt Figure 3 2 Engine Governor Adju
23. 25 X 25 G8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M10 SCREW SHC M10 1 5 X 35 G12 9 ENGINE FOOT 2 5L FORD DIPSTICK 2 5L FORD BRACKET DIPSTICK TUBE FAN 16 COOLING HARNESS 2 5L FORD ENGINE NOT SHOWN HARNESS 2 5L FORD BOSCH GOV NOT SHOWN SCREW HHC M10 1 0 X 25 G10 9 FLEXPLATE 2 5L FORD ADAPT CASTING MACH 2 5L FORD SCREW SHC M10 1 5 X 30 G12 9 SCREW SHC M10 1 50 X 40 G12 9 SPACER FLEXPLATE HSB GASKET 2 5L FORD EXHAUST MAN MANIFOLD EXHAUST MACHINED ITEM PART NO 35 0E9930 36 049821 37 0E9747 38 043116 39 022473 40 045772 41 064416 42 0F0252 43 0E9868 44 0F0035 45 026082 46 0E9928 47 0F0383 48 057823 49 0E9737 50 0F0393 51 045757 52 069860C 53 048031J 54 055596 55 077456 50 052677 57 049813 58 0E9738A 59 0F1132 60 0F1133 61 059355 62 076749 63 029032 64 0F1433 65 070007 66 070005 67 080826 68 045771 69 048031C NOTE TORQUE TO 44 FT LBS Liquid cooled 25 kW Generators Engine Drawing No 0E9918 F TY R a a a ORD N OED OW EA a TI 5 n oo 3 3 3 1 2 PARTS qea Yo DESCRIPTION HEAT SHIELD EXHAUST MANIFOLD SCREW SHC M8 1 25 X 30 G12 9 STARTER 12 VOLT SCREW HHC M6 1 0 X 12 G8 8 WASHER FLAT 1 4 M6 ZINC NUT HEX M10 1 5 G8 YEL CHR SCREW HHC M10 1 5 X 45 G8 8 SPRING BUSHING ALTERNATOR D C BRKT D C ALTERNATOR MACHINED SCREW HHC 3 8 16 X 2 1 4 G5 TENSIONER D C ALTERNATOR HOSE 2 5L FOR
24. 3 16 035461 17 069860C 18 0A7275 19 031669 20 065852 21 0A2111 24 0C2454 25 022287 26 077992 27 050275 TO THERMOSTAT TO BASE OF WATER INLET TUBE ON BLOCK TY 4 O a a REF DESCRIPTION HOSE 2 5L FORD LOWER RADIATOR BARBED STR 1 4 NPT X 3 8 HOSE OIL DRAIN ASSY 21 FOAM 1 5 X 1 ADHESIVE BACKING 21 5 LG BOLT CARR 1 4 20 X 1 3 4 JS500 SPRING CLIP HOLDER 37 62 SCREW SWAGE 10 32 X 5 16 Z YC SCREW TH FRM M6 1 X 16 N WA ZIJS SCREW HHC 1 4 20 X 3 4 G5 NUT HEX LOCK M6 1 0 SS NY INS DECAL WARNING FAN INSTALLATION Liquid cooled 25 kW Generators Section 8 Installation Diagram Installation Diagram Drawing No 0F1022 A U2ADN2 NW SSS399V MAIA ACIS INIJdLOD43 3SV8 L 9S S dort HI IA TV1IVaSAD oC ONIGNAOND INTa dlOO4 3Sva 86 82 LAN v NOILIJNNDD 13 13 JOdYVA d 1 X0 D N 8Z WE S EBB EIKKER L ZT 901 LAINI 13043 0t T 89 CE LHDIJH TIGAaJAD QLZ ZE 8S6 g JLON 33S AJILIVE IAA dl JIVI IINV IUaINDU JOINVAYVITDJ JYJODA AVJHAJIJAD 88 59 SE EZIT HLONJ7 T1VJJAD v v ASIA LIEZLI 8 9 8I 31DN Sas TAJLON 34S S3 H ONILNANONW d 1 dAl 92 Ib 8101 ST 8 L0 SATOH DONILNNON dAl 9 02 veS SJHINI J WY ISLINA Loi S r261 SE 61Ib LINN vliva LHDIJM 130100 3313308 00 621I Z LINLAD 1SNYHXIA 91d 1331S 8 E NIVAM TIO TANVd UN LANPZ E AOdVA d TM SY5 WAN
25. 47 1 COVER AIR CLEANER 14 048031C 2 CLAMP HOSE BAND 1 4 19 0D1509 1 DECAL INLET PRESSURE 16 0E0591 1 ADAPTER CARB TO AIR CLNR 17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 1 4 20 NYLK 19 0E1028A 1 CARBURETOR ASSY 2 5L FORD 20 059401 1 CARBURETOR GASKET 21 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 22 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 002454 3 SCREW TH FRM M6 1 X 16 N WA ZUS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 OE0590A 1 VENTURI 20MM 33 005133 1 0 RING 29 82 X 2 62 34 0E0665 1 SCREW THROTTLE PIN STOP 35 0E1108 1 THROTTLE ARM REWORK 36 033138 1 SCREW HHM 10 32 X 5 8 37 022152 1 WASHER LOCK 10 38 0E0645 1 LEVER THROTTLE STOP 39 034339 1 BARBED EL 90 3 8 NPT X 5 8 40 059194 1 HOSE 5 8 ID LPG 8 NG 24 LG 41 057823 2 CLAMP HOSE 10 56 1 06 42 0F0382 1 HOSE 3 8 90 DEG 2 5L PVC INCLUDED IN ITEM 19 CARBURETOR ASSY 45 Q A Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators KO Alternator Drawing No 0F5092 B LOCKTIGHT KS N TO 7 ki ke y Oo C E N Z Q O I 46 Section 7 Exploded Views and Parts Lists G es Liquid cooled 25 kW Generators Alternator Drawing No 0F5092 B KO ITEM PART NO TY DE
26. 7248 1 BALL BEARING 45 MM 31 070892 1 SLIP RING MACHINED 47 PARTS ITEM PART NO QTY DESCRIPTION OO JO Om A WD LISTS 2 0F2912 0F2869 0F2823 036434 036449 022129 022259 0E0170A 044149 0E8816 0F2925 0F2926 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Muffler Drawing No 0F2930 C po a BR N N a a PIPE MUFFLER OUT PIPE EXHAUST 2 5L FORD MUFFLER 2 5L FORD BOLT U 5 16 18 X 2 09 SADDLE 2 INCH WASHER LOCK M8 5 16 NUT HEX 5 16 18 STEEL EXHAUST BLANKET 800MM GASKET EXHAUST RING EXHAUST FLANGE 2 PIPE STRAP MUFFLER BRACKET MUFFLER 042568 022097 022473 049813 039253 045771 0A4010 022145 022131 085917 0D2611 052858 N b i P OI PPN OO SCREW HHC M6 1 0 X 20 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC NUT HEX M6 X 1 0 G8 YEL CHR SCREW HHC M8 1 25 X 20 G8 8 NUT HEX M8 1 25 G8 YEL CHR SCREW HHC M8 1 25 X 60 G8 8 FT WASHER FLAT 5 16 M8 ZINC WASHER FLAT 3 8 M10 ZINC WASHER LOCK 3 8 SS SCREW HHC 3 8 16 X 1 3 4 SS NUT TOP LOCK FL M8 1 25 Section 7 Exploded Views and Parts Lists G An Liquid cooled 25 kW Generators Stepper Motor Drawing No 0E9979 C KO ITEM 13 NEOPRENE COATING SECURE WIRE HARNESS Ba WITH TIE WRAP AG SHOWN INTAKE MANIFOLD REF CARBURETOR ARM REF 1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 0F0454 REF HAR
27. 8 0F0782 1 DUCT DISCHARGE MID AL 2 5L 39 026850 4 WASHER SHAKEPROOF EXT 1 4 STL 40 0912970064 2 ASSY WIRE 14AWG 7 5 0 GRN YEL 41 0912970063 2 ASSY WIRE 14AWG 7 5 0 GRN YEL 42 049813 10 NUT HEX M6 X 1 0 G8 YEL CHR 43 0F0784 1 CORNER POST REAR LH SIDE AL 44 0F0785 1 CORNER POST REAR RH SIDE AL 45 0E8665 1 BRACKET STIFFENER LH FRONT 46 0E8837 1 DOOR BATTERY COMPARTMENT 47 0A3359 1 SCREW BHSC M6 1 0 X 16 SS 48 0E8404 1 BRACKET STIFFENER RH FRONT ALL ITEMS NOTATED WITH Al ARE COMPONENTS OF 0F2179 37 Q A Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators KO Control Panel 15kW and 20kW Drawing No 0F2267 D 38 Section 7 Exploded Views and Parts Lists G es Liquid cooled 25 kW Generators Control Panel 15kW and 20kW Drawing No 0F2267 D KO ITEM PART NO TY DESCRIPTION 1 0F0790 1 TOP CONTROL PANEL 2 0F0789 1 BACK amp BOTTOM CONTROL PANEL 3 0F0791 1 PANEL FRONT 2 5L CONTROL PNL 4 0E9704 1 ASSY PCB HSB CONTROLLER 2 5L 5 067680 1 ASSY VOLTAGE REGULATOR 60HZ 6 0E6875A 2 RELAY 12VDC C FORM W DIODE 7 0C3910 1 XFMR 240 16V 1VA amp 56VA 8 048468 1 CIRCT BRK 8 X 1 ETA 46 500 P 9 0D5070A 1 ASSY PCB 2A 12V UL BATT CHRGR 10 057073 1 JUNCTION BLOCK 3 8 16 11 040213 2 PCB SUPPORT SNAP IN 1 4 12 0C2265 18 SCREW PHTT M4 0 7 X 12 ZYC 13 029673 1 DIO BRIDGE 25A 600V 14 0F0793 1 BRACKET CB SIEMENS BQ 15 0E7890 1 BRKT CB MTG BACK 16 0D5541 1 CB 0070A 2P 240V S BQ2 LL 0D5544 1 CB 0100
28. A 2P 240V S BQ2 LL 17 OF 1264 1 ADPTR LH SIDE WICKMAN 178 6192 18 0F1263 1 ADPTR RH SIDE WICKMAN 178 6191 19 0F1262 2 HOLDER FUSE WICKMANN 178 6150 20 0E7403A 1 FUSE ATO TYPE 5 AMP TAN 21 0E7403C 1 FUSE ATO TYPE 15 AMP BLUE 22 0E2514 1 FITTING CONDUIT STR 1 1 2 23 020911 2 SCREW PPHM M5 0 8 X 30 ZINC 24 023897 4 WASHER FLAT 10 ZINC 25 022152 2 WASHER LOCK 10 26 051716 2 NUT HEX M5 0 8 G8 YEL CHR 27 082573 1 SWITCH ROC DPST 125V SPD 28 0E4494 1 SWITCH ROC DPDT ON OFF ON 29 004167 REF BLOCK TERM 20A 14 X 6 X 1100V 30 0C2699 4 SCREW PHTT 6 32 X 3 8 ZYC J1 002212 1 SCREW PHTT M4 0 7 X 16 ZYC 32 047411 4 SCREW HHC M6 1 0 X 16 G8 8 33 022097 4 WASHER LOCK M6 1 4 34 022473 4 WASHER FLAT 1 4 M6 ZINC 35 0E7358 4 SCREW PPPH HI LO 4 24 X 3 8 36 064733 2 RES MTG BRACKET 37 0F0798A 1 HARNESS C PNL 2 5L QS 15 amp 20KW NOT SHOWN 38 0E6881 REF SOCKET RELAY 39 048352 1 RES 5R 5 25W 40 0C1127 1 DECAL AVR COVER 41 0C1229 1 DECAL WARNING ELECTRICAL SHOCK 42 0F2632 1 DECAL TERMINAL BLOCK 43 0F2629 1 DECAL CONTROL HSB 44 0E7193 1 DECAL WARNINGS HSB 45 0F6146 1 HANG TAG 2 WIRE START NOT SHOWN 15KW 20KW 39 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Control Panel 25kW Drawing No 0E7615 C 40 Section 7 Exploded Views and Parts Lists G es Liquid cooled 25 kW Generators Control Panel 25kW Drawing No 0E7615 C KO ITEM PART NO TY DESCRIPTION 1 0F0790 1 TOP CONTROL PANEL
29. AT M12 15 052891 4 SCREW HHC M12 1 75 X 80 G8 8 16 0536210261 1 ASSY WIRE 0 12 00 17 074906 1 SCREW HHTT M6 1 0 X 20 BP 18 077483 REF BATT 12VDC 75 AH 26 NOT SHOWN 19 0F0796 3 BRACKET CONTROL PANEL SUPPORT 20 025507 3 WASHER SHAKEPROOF EXT 7 16 STL 21 060619 1 SCREW SHC M10 1 50 X 40 G12 9 22 046526 1 WASHER LOCK M10 23 022131 1 WASHER FLAT 3 8 M10 ZINC 24 021991 1 EARTH STRAP 25 038805G 1 CABLE BATT BLK 1 X 41 50 26 050331 REF BATTERY POST COVER BLACK 27 050331A REF BATTERY POST COVER RED 28 038804J 1 CABLE BATT RED 1 X 40 50 29 045771 REF NUT HEX M8 1 25 G8 YEL CHR 30 022129 REF WASHER LOCK M8 5 16 31 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 32 075763 1 BOOT BATTERY CABLE 33 0E9748A 1 ASSY MTG BASE 2 5L AL ENCL 34 0F0795 3 SUPPORT CONTROL PANEL 2 5L 35 002454 33 SCREW THF M6 1 X 16 N WA ZS 36 065852 1 SPRING CLIP HOLDER 37 62 37 045764 1 SCREW HHTT M4 0 7 X 8 BP 35 cooled 25 kW Generators Section 7 Exploded Views and Parts Lists Enclosure Drawing No 0F1645 H Liquid PARTS N X se Ep SCH op l lt lt Hl yY WWLAG t HOLW1 3S Nap lt k r SO1d 2 8 OL gt 6 e NMOHS SV 4d 193S NOLLVTIASNI JYINDIUY 1VH1 TANVd JOOU dO WOldAL 3GIS YY4 NO SI WYO4 S3lVIS A FOIS YVAN NO SI NVOd S31V1S e TIVLJA HIV 36 Section 7 Exploded Views and Parts Lists G es Liquid cooled 25 kW Generators Enclosure Drawing No 0F1645 H KO ITEM PART NO T
30. B Set the GAIN pot to its centered mid position C Set the STABILITY pot to its centered mid position D DO NOT adjust the UNDERFREQUENCY ADJUST pot 4 Start the engine Let it stabilize and warm up at no load MAINTENANCE 2 9 Section 4 Maintenance 5 Verify that the three voltage regulator s LED s are ON 6 Check the reading on the AC frequency meter 7 Turn the voltage regulator s VOLTAGE ADJUST pot to obtain a line to line voltage of A 240 VAC if the generator has been configured for 60 Hertz operation B 200 VAC if the generator has been configured for 50 Hertz operation 8 Ifthe RED REGULATOR LED is flashing adjust the STABILITY pot in either direction until the flashing stops 9 Apply an electrical load and check the engine speed recovery A Adjust the UNDERFREQUENCY ADJUST pot CCW to reduce load during engine recovery B For flat regulation no voltage decrease as fre quency drops set the UNDERFREQUENCY ADJUST pot fully CW C To obtain a constant voltage regulation as fre quency decreases set the UNDERFREQUENCY ADJUST pot fully CCW 10 With the electrical load still applied check the REGULATOR LED for flashing If the LED is flashing adjust the STABILITY pot until the flash ing stops 11 If better response is needed adjust the GAIN pot clockwise CW as needed Then if needed cor rect for stability by adjusting the STABILITY pot 12 Turn OFF the electrical loads
31. D TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE PART l SEE OWNER S MANUAL FOR COMPLETE LED DETAILS ATTENTION POUR L ALIMENTATION DE RESERVE CONNECTER LA SORTIE DE L GENER UGONE CANADIEN DE L ECTRICITE PREMIERE PARTIE I oF A WARNING A MMM CAN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE TO ger PEREDA LAY REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATTER CERLE PAIDA TO SERVICING WARNING A 1 THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR OUTDOOR INSTALLATION ONLY USE OF SYNTHETIC OIL IS RECOMMENDED OF 2629 3 2 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 6 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an operat ing engine With OFF selected operation will not be possible A DI A A With switch set to AUTO engine can crank and start suddenly without warning Such automatic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on control console 3 2 2 FAULT INDICATOR LEDS SEE CHART ON PAG
32. D COOLANT BY PASS CLAMP HOSE 10 56 1 06 LOWER HOSE ADAPTER 2 5L FORD O RING 1 3 16 X 1 7 16 X 1 8 SCREW HHC M6 1 0 X 25 G8 8 HOSE OIL DRAIN ASSY 21 HOSE CLAMP BAND 5 8 BARBED STR 3 8NPT X 3 8 ADAPTER M12 1 75 3 8NPT WASHER NYLON 50 X 87 X 06 NUT HEX M6 X 1 0 G8 YEL CHR DIPSTICK TUBE 2 5L FORD COVER R H SIDE ENGINE ADAPTOR COVER L H SIDE ENGINE ADAPTOR SCREW SHC M10 1 50 X 50 G12 9 TANK COOLANT RECOVERY HOSE 9 32 ID 39 LG BRACKET 2 5L FORD WATER BOTTLE WASHER FLAT M6 SS WASHER LOCK M6 SS SCREW HHC M6 1 0 X 12 SS NUT HEX M8 1 25 G8 YEL CHR CLAMP HOSE BAND 1 4 43 Section 7 Exploded Views and Parts Lists LISTS PARTS d Fuel System Drawing No 0E9980 D Liquid cooled 25 kW Generators 2 6L N I V820130 ASSY YOLFIYNGYVYI NOISHSANOO YgOdVA d ANIDNA OL d3AO9 FA TWA OL 44 Section 7 Exploded Views and Parts Lists G es Liquid cooled 25 kW Generators Fuel System Drawing No 0E9980 D KO ITEM PART NO TY DESCRIPTION 1 0E8456 1 BRACKET FUEL REGULATOR 2 075580 1 FLANGE FUEL INLET 3 0E9967 1 ASSY FUEL REG 2 5L FRD N G L P 4 039253 4 SCREW HHC M8 1 25 X 20 G8 8 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 6 WASHER LOCK M8 5 16 7 045771 2 NUT HEX M8 1 25 G8 YEL CHR 8 OF1570 1 BODY CARBURETOR ASSEMBLY 9 0A6344 1 BARBED EL 90 1 8 NPT X 3 8 10 0F3994 REF PCV VALVE 2 5L FORD 11 0E1056 1 FUEL HOSE ASSM NAT GAS L P V 12 0F0397 1 HOSE CRANKCASE BREATHER 13 0A55
33. E 14 These red LEDs turn ON when one or more of the following engine faults occurs and the engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed Engine Speed Signal Fault High Coolant Temperature Low Coolant Level See Section 1 7 for further explanation of engine pro tection functions 13 OPERATION OD Condition Section 3 Operation Liquid cooled 25 kW Generators Generator Switch is in the OFF Mode system Ready for Automa Generator Switch is in the MANUAL Mode Weekly Exerciser Flashing Flashing IS not se Battery Voltage 12V or gt 1 minute Battery Vol AUC lt 6V Unit Shutdown due o Low Oil Pressure Unit Shutdown due to Ready Green Bat Rec Qil Red High Temp Red oe Flashing Flashing Q QM Qlan VE Unit Shutdown due o Engine Overspeeo Unit Failed to Start during it s Crank Cycle Utility Voltage is lt 45 of Nomina Engine Speed Signal Eaul Control Board is OFF in GIS Mode The five RED LED s will turn on one at a time ew TAT X indicates that the LED can be ON or OFF depending on the operating conditions 3 2 3 15 AMP FUSE This fuse protects the control console s DC control circuit against electrical overload and is located inside the control panel If the fuse has melted open because of an overload engine cranking and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacem
34. ET EXERCISER SWITCH TR TERMINAL BLOCK 1 wem El Y ISA TRANSFORMER 1 56 VA 240 16 VAC START RELAY r 556 A FUELCRUN RELAY 3 14A 2 WIRE START 4 183 MOMENT OPEN 5 15E 2 WIRE STRID 6 178 NAN AUTO INPUT 7 154 16VAC SENSED 8 224 ALARM RELAY 9 XFER RELAY 10 23 WW INPUT 7 1 1 239 16VAC SENSED 1 2225 NOT USED 1 3 WIR 1 40 DOOR o0 TB1 A6 UTILITY FROM T SW NI 14A 14 ST 15 X 154 5 N TBI AS UTILITY FROM T SW 6A 23 TB1 A4 TRANSFER COIL RELAY 194 TBI A3 TRANSFER COIL RELAY NB ce 183 E mae REMOTE START COD Lys 178 F IBI Al REMOTE START e e z Hm CUSTOMER CONNECTION 8 ALTERNATOR LEGEND BA BRUSH ASSEMLY GENERATOR CB1 MAINLINE CIRCUIT BREAKER 13 C40V OUTPUT TO TRANSFER SWITCH TB1 INTERCONNECT TERMINAL BLOCK NB NEUTRAL BLOCK LDA 32 Section 6 Electrical Data Liquid cooled 25 kW Generators i ELECTRICAL Electrical Schematic 2 5L 25kW unit Drawing No 0F1287 B lt DATA ENGINE WIRING LEGEND PCB J ALT D C CHARGE ALTERNATOR MG Hav 1 BAT 12VDC BATTERY RL 4 2 15A CC STARTER CONTACTOR EGD E3 0 cP COIL PACK COOLANT SENSIRS 4 85 S CRANK SENSOR mme rS FUEL SOLENOID DEGA 6 HCT HIGH COOLANT TEMP SWITCH DISTRIBUTIR 13V 7 JI CONNECTOR 1 ON PCD NOT USED 3 LOS LOW DIL PRESSURE SWITCH CRANK SENSOR IN 9
35. F2632 1 DECAL TERMINAL BLOCK 42 0F2629 1 DECAL CONTROL HSB 43 0E7193 1 DECAL WARNINGS HSB 44 0F6146 1 HANG TAG 2 WIRE START NOT SHOWN 41 42 PARTS qp is OG Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Engine Drawing No 0E9918 F MOTOR UNITS STEPPER ONLY ee RADIATOR FOR HARNESS GROUND ITEM PART NO 1 0E9909 2 0E9739 3 049814 4 0F0001 5 0D3488B 6 0A8584 i 0E0561 8 0A6751 9 035579 10 026925 11 0E9611 0E9611A 12 0E9681 13 039253 14 097962 15 022145 16 022097 17 022129 18 043107 19 022131 20 046526 21 052625 22 0E9708 23 0E9738 24 0E9929 25 0F0230 26 0E9834 0E9834A 27 OD5417 28 0E5048B 29 0E9655 30 057192 31 060619 32 0E8940 33 0E9680 34 0E9609 TY REF E 1 8 1 1 1 1 ch sch sesch a a DA a a CH Section 7 Exploded Views and Parts Lists DESCRIPTION ENGINE 2 5L FORD PULLEY 2 5L FORD WATER PUMP SCREW HHC M10 1 5 X 25 G8 8 CLUTCH COOLING FAN 2 5L FORD SERPENTINE BELT 40 85 LENGTH SWITCH OIL PRESSURE 10PSI 2POL ASSY WATER LEVEL SENSOR C E PL SW TMP 245DEG 3 8NPT BUSHING REDUCER 1 4 TO 1 8 PLUG STD PIPE 3 8 STEEL SQ HD MANIFOLD INTAKE MACHINED STEPPER MOTOR MANIFOLD INTAKE MACH BOSCH32 BOSCH GOV NOT SHOWN GASKET 2 5L FORD INTAKE MAN SCREW HHC M8 1 25 X 20 G8 8 SCREW SHC M6 1 0 X 25 G12 9 ZP WASHER FLAT 5 16 M8 ZINC WASHER LOCK M6 1 4 WASHER LOCK M8 5 16 SCREW HHC M8 1
36. FI i 1 3 4 2 Number of Main Bearings see a GOM PIE SSION Pallu uuu aS SS aa n no a de 9 37 to 1 No of Teeth on CranK ap oua kaka 36 1 Ignition Timing Waste Spark System at 1800 EGRET uuu ion panne ee ine danl 36 degrees BTDC Ignition Timing Waste Spark System at 1800 rom LP vapor 28 degrees BTDC opak PIU aD koubyestyays etan ao sea a eka ee p a oka komin 0 044 inch Recommended Spark Plugs Oste A seat sa a ale sa enp dete state ees AWSF 52 C SIT 30 50 psi Crankcase Oil Capacily 4 5 U S quarts 4 26 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery CODI E Pusher Type Cooling System Capacily 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and deionized water warning 4 Home standby control board assembly part num ber 0E9704 must be used on 1800 rpm genera tors 1 10 2 GENERATOR Single phase Mode 050 Rated Max Cont 25 POWE EDU 2DCCCLOL INOLO itation Svstem me of Stato 4 Wi Rotor Stator Insulation Class F H Rated power of generator is subject to and limited by such factors as ambient temperature altitude engine condition and other factors Engine power will decrease about 3 5 for each 1000 feet above sea level and will dec
37. HARGE ALTERNATOR DEG 12V fren BAT 12VDC BATTERY gt 4 2 18 ISA CC STARTER CONTACTOR DEG CND 3 CP COIL PACK LA CRANK SENSUR FS FUEL SOLENDID GNDI GROUND GNDe GROUND HOT HIGH COOLANT TEMP SWITCH JI CONNECTOR 1 CON PCB LUS LOW DIL PRESSURE SWITCH COULANT SENSURS 4 895 DEG W 3 DEG 3V g DISTRIBUTOR t l F 7 NOT USED T 5 CRANK SENSIR IN 9 D a CRANK SENSE RET L10 79 L H NOT USED 1 1 AN STARTER MOTOR DEG FDBK F12 SIM STEPPER MOTOR al 1318 isa WLS COOLANT LEVEL SWITCH mm 9 141815R ML A 151 25A DISTRIBUTOR RET 1 6 DISTR INPUT a DEG PW 1 8 DEG ENABLE 19 LOW DIL PRESS 20 86 CRANK SHIELD L21 O D Ee COIL 3 2318 en GROUND En BES Eu 31 Section 6 Electrical Data Liquid cooled 25 kW Generators ELECTRICAL a A DATA Electrical Schematic 2 5L 25kW unit Drawing No 0F1287 B Z CONTROL PANEL LEGEND 13 F CCIA AVR AUTOMATIC VOLTAGE REGULATOR co4 B C BATTERY CHARGER BRI BRIDGE RECTIFIER CB2 CIRCUIT BREAKER EXCITATION F1 FUSE BAT POWER 154 ATO TYPE PCB J3 F FUSE B C SA ATO TYPE NOT USED 1 J2 CONNECTOR 2 ON PCB NOT USED 2 J3 CONNECTOR 3 ON PCB BLACK W 3 WI RLI RELAY 1 START RELAY HILD 4 W2 TR1 RL RELAY 2 ENGINE RUN MITE B 5 W3 MI SW AUTO OFF MANUAL SWITCH REE 6 W4 s Ze SW2 S
38. LYN LINNI SNOIIJJNNOUJ JJIASJS 3NIDN3 vIJV an anis 0E E 68 EB S3 H ONILNMON dAL Seve 919 8 d S 09 JIIVIBE LINJBID INITNIYW ABILIVE 92 A9 HVS JLYCOWWOIOY TIIM AVAL 26 9 X 0 8J 9ZI X SOZ SNDISN3WI LEZE 28 JTISNI AYAL ABILIVE WALSAS GNNOND SAILVOIN LIDA 21 2 T NYd ID31ND3 NI 3GIAD3d LAYLS 31DN32 ONY ee as WASA UN H3LIMS XJJSNY JL SAVIT Oe IV X04 SINIDd NOILJ3NNDD lt I oe DOU ME e SILON Cents 51 Section 9 Warranty WARRANTY Liquid cooled 25 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifica tion or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emis
39. N GOV 2 5L FORD 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW PFHST 2 X 5 8 6 043146 3 SCREW HHC M6 1 0 X 10 G8 8 7 022097 5 WASHER LOCK M6 1 4 8 0E7358 REF SCREW PPPH HI LO 4 24 X 3 8 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD l 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A TIE WRAP 7 4 X 19 BLK UL 1 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH 49 PARTS Fin ITEM PART NO 1 CON Mm OF OMN 11 12 14 50 LISTS 0E9769 0F0779 0E9769A 0E9837 0F0123 0F0118 099502 002454 052250 022097 022473 022127 046627 060035 0F0127 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Radiator Drawing No 0E9965 F TY REF REF REF SS gt S PO H PA CO m gt DESCRIPTION SUPPORT RADIATOR 2 5L FORD SUPPORT RADIATOR 2 5L AL SUPPORT RADIATOR 2 5L FORD ALM RADIATOR 2 5L FORD VENTURI 16 FAN 2 5L FORD GUARD FAN 2 5L FORD CLAMP HOSE 24 B1 06 2 00 SCREW THF M6 1 X 16 N WA Z JS TAPE FOAM 1 X 1 21 LG WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC NUT HEX 1 4 20 STEEL CAP RADIATOR SPACER 41 X 75 X 87 ST ZNC HOSE UPPER RADIATOR 174MM TAL 5 ZE ADAPTER o Is 8 10 5 ITEM PART NO 15 0E983
40. NDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 e A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYSTEMS available from the American National Standard Institute 1430 Broadway New York N Y 10018 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet open ings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drifting consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A required mini mum allowance of space to any solid structure is three feet Five feet allowance of space is recom mended Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE INSTALLATION Hh Section 2 Installation Liquid cool
41. NG This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is prop erly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible cir cumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique chosen does not render the generator unsafe A pan A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to install operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator A Parts of the generator are rotating and or hot dur ing oper
42. O m SM STARTER MOTOR CRANK SENSE RET 10 79 ll STM STEPPER MOTOR NOT USED 11 WLS COOLANT LEVEL SWITCH EG FIK plen i te SA CHIL ai 14 15R COIL A2 I EEN DISTRIBUTOR RET 1 6 DISTR INPUT 172 DEG PIM 1 8 DEG ENABLE 1 9 LOW DIL PRESS 20 86 CRANK SHIELD Lann L BIEL EE g CHIL 3 23 25B LOS 86 pe 0 li HCT 85 mi Man WLS 85 25 W 0 i 383 Section 7 Exploded Views and Parts Lists Liquid cooled 25 kW Generators Mounting Base Drawing No 0F0104 B PARTS Kao is OG TO REAR COMPARTMENT DUCT REAR BEARING CARRIER 24 20 34 2 0 oy 35 TO ENGINE BLOCK TO STARTER TO STARTER CONTACTOR SM Pa w 31 4 HARNESS k OL go WIRE 0 TO ON ENGINE a MOUNT 16 gt 17 Section 7 Exploded Views and Parts Lists G es Liquid cooled 25 kW Generators Mounting Base Drawing No 0F0104 B KO ITEM PART NO TY DESCRIPTION 1 OF1705 1 SUPPORT BATTERY TRAY 2 0E8834 1 HOLD DOWN BATTERY 3 0E9911 1 ASSEMBLY BATTERY TRAY 4 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 5 022097 4 WASHER LOCK M6 1 4 6 026850 2 WASHER SHAKEPROOF EXT 1 4 STL D 055414 1 LUG SLDLSS 2 8 X 17 64 CU 8 022473 4 WASHER FLAT 1 4 M6 ZINC 9 047411 4 SCREW HHC M6 1 0 X 16 G8 8 10 052860 4 NUT FLANGED HEX M12 1 75 11 052251 4 DAMPENER VIBRATION 40 BLUE 12 052257 4 SPACER 49 X 62 X 1 87 PWDR ZNC 13 052252 4 DAMPENER VIBRATION 14 052259 4 WASHER FL
43. SCRIPTION 1 OF1659A ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD 1 0F1657A 1 ROTOR 390 20KW 1P DIRECT HSB 2 5L FORD 0F1655A 1 ROTOR 390 25KW 1P DIRECT HSB 2 5L FORD 0F5073A 1 ROTOR 390__30AD1 HSB TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT HSB 2 0F1660A 1 STR 390 15AD HSB 382MM LONG 2 5L FORD 0F1658A 1 STR 390 20AD HSB 382MM LONG 2 5L FORD 0F1656A 1 STR 390 25AD HSB 382MM LONG 2 5L FORD 0F5074A 1 STR 390__30AD1 HSB TECUM 0E7412A 1 STR 390 40AD HSB 433MM LONG 3 0E5706 1 REAR BEARING CARRIER 390 DRCT 4 0E5048 REF FLEXPLATE 3 0L FORD 0E5048B REF FLEXPLATE 2 5L FORD 0E5048A REF FLEXPLATE HSB 3 9L CHRYSLER 5 0E6668 1 FLYWHEEL ASSY 3 0L HSB LG GEAR 6 0E6076 1 REVCOR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD 04576100BF 4 STUD M14 2 0 X 540 G5 ZINC 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 1 WASHER SHAKEPROOF INT 8 14 092980 4 SCREW PPHM M4 0 7 X 25 15 057192 4 SCREW SHC M10 1 5 X 30 G12 9 16 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 19 022264 4 WASHER LOCK 8 M4 20 038150 4 WASHER FLAT 8 ZINC 21 077043F 1 CONDUIT FLEX 1 1 4 30 LG 3 0L FORD amp 3 9L CHRYSLER 077043F 1 CONDUIT FLEX 1 1 4 18 LG 2 5L FORD ROTOR REPLACEMENT PARTS 30 04
44. SE 18 AWG UL LISTED UNLESS 2 VIRE SIRI 6 178 MAN AUTO wan 7 L 15A or SENSE 8 224 ALARM RELAY 9 pg RELAY 10 23 NAN INPUT 1 1 239 L6VAC SENSED 1 2 225 NOT USED 1 S ND B 1 AT DOOR QGROUNDING WIRE e O 26 ALL Mi ii e LU HU BA BRUSH ASSEMLY GENERATOR CBI MAINLINE CIRCUIT BREAKER NB NEUTRAL BLOCK OTHERWISE NOTED AS SHOWN CUSTOMER CONNECTION amp ALTERNATOR LEGEND 40V OUTPUT TO TRANSFER SWITCH TBL INTERCONNECT TERMINAL BLOCK Section 6 Electrical Data Liquid cooled 25 kW Generators T ELECTRICAL Wiring Diagram 2 5L Engine 15kW 8 20kW units Drawing No 0F2183 B Wa DATA W s ENGINE WIRING LEGEND We JI ALT D C CHARGE ALTERNATOR DEG HAV 1 BAT 12VDC BATTERY M L 2 Misa C STARTER CONTACTOR DEG DI 3 CP COIL PACK S CRANK SENSUR S FUEL SULENUID GNDI GROUND 1 GNDe GROUND 2 HCT HIGH COOLANT TEMP SWITCH JI CONNECTOR 1 UN PCB LOS LOW DIL PRESSURE SWITCH AN STARTER MOTOR STM STEPPER MOTOR WLS COOLANT LEVEL SWITCH COOLANT SENSIKS 4 83 DEGOV 5 DEG ON a DISTRIBUTOR IV 7 NOT USED T o CRANK SENSOR IN 9 U CRANK SENSE RET 10 79 NOT USED ti 1 DEG FIBK 1 2 1318 15A NO Ni RI coi w 1 448 15R on a 1 518 a5a4 1 DISTRIBUTOR RET 1 6 DISTR INPUT ti DEG PW 1 B DEG ENABLE 19 LOW DIL PRESS
45. TE Exhaust manifold fasteners must be tightened in two stages 4 Tighten fasteners to 20 30 N m 15 22 lb ft dur ing the first stage 5 Retighten fasteners to 60 80 N m 44 59 Ib ft during the second stage 4 3 INTAKE MANIFOLD PROCEDURE l Clean and inspect the mounting surfaces of the intake manifold and the cylinder head Both sur faces must be clean and flat Figure 4 1 2 Clean and lightly oil the manifold bolt stud threads Figure 4 1 Intake Manifold Installation FASTENER TORQUE SEQUENCE FPP00283 18 3 Install a new lower intake manifold gasket 4 Position the lower intake manifold to the cylinder head 5 Install retaining bolts studs finger tight 6 Tighten all bolts studs to specifications in the tightening sequence shown First pass 7 10 N m 5 7 lb ft e Final pass 26 38 N m 19 28 lb ft 4 4 CYLINDER HEAD PROCEDURE 1 Position head gasket on the block Figure 4 2 2 Position cylinder head to cylinder block 3 Install 10 cylinder head bolts in numerical sequence Tighten to 70 N m 52 lb ft in sequence Retighten to 70 N m 52 lb ft in sequence Then turn all head bolts an additional 90 100 degrees in sequence Figure 4 2 Cylinder Head Installation CYLINDER HEAD GASKET CYLINDER P L s Adh AS u U i i LA SA Yon H e lt Za a i s SOU Ti E m Le d LS FPP00024 4 5 COOLING SYSTEM Air intake and outlet openings in the generator com
46. Y DESCRIPTION 1 0F0783 1 DUCT INTAKE MID AL 2 5L 2 0F0781 1 DUCT DISCHARGE RH AL 2 5L 3 0F0780 1 DUCT DISCHARGE LH AL 2 5L 4 002454 34 SCREW TH FRM M6 1 X 16 N WA Z JS 5 0F0779 1 SUPPORT RADIATOR 2 5L AL 6 0E0072AB 1 Al INSULATION SIDE REAR CORNER POST RH 7 0E0072AC 1 Al INSULATION INTAKE DUCT TOP PANEL 8 0E0072AD 1 Al INSULATION LH SIDE REAR CORNER POST PANEL BOTTOM 9 0E5912 2 DOOR SIDE HSB AL 10 0F0787 1 SUPPORT RH SIDE AL 2 5L 11 089961 2 FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG 12 0A2115 4 WASHER NYLON 257 13 0E0072AE 1 AI NSULATION LH SIDE REAR CORNER POST PANEL TOP 14 0F0165A 1 HINGE TYPE B W STUDS SOCKET 15 0F0165 1 HINGE TYPE B W STUDS PIN 17 022097 13 WASHER LOCK M6 1 4 18 022473 13 WASHER FLAT 1 4 M6 ZINC 19 0E7570 2 GAS SPRING 20 0E7571 4 BALL STUD GAS SPRING MOUNT 21 070015 4 NUT HEX 5 16 18 LOCK 22 0E7662 4 SCREW WING M6 1 00 X 25 23 OFO164A 1 HINGE TYPE A W STUDS SOCKET 24 0F0164 1 HINGE TYPE A W STUDS PIN 25 0D2023 3 GASKET CLIP ON SELF GRIPPING 84 LG 26 078115 8 WASHER SELF LOCKING DOME 27 0F2179 1 KIT SAE FOAM 2 5L QUIET SOURCE 28 0F0788 1 ROOF 2 5L FORD AL 29 0E7829B 2 Al DOOR PANEL 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0F0786 1 SUPPORT LH SIDE AL 2 5L 33 0E0072Q 2 Al INSULATION RAD SUPPORT PANEL 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E0072Y 1 Al INSULATION SIDE BRACE PANEL RH 36 OEOO72AF 1 Al INSULATION SIDE BRACE PANEL LH 37 0E0072AA 1 Al INSULATION ROOF PANEL 3
47. ZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department Important Safety Instructions SAFETY RULES Liquid cooled 25 kW Generators EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materi als are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris These generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the units fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly STANDARDS INDEX In the absence of pertinent standards codes regulations
48. alled with a GTS engineered type automatic transfer switch Set DIP switch on engine control PCB to GTS type see Section 3 8 When using a GTS type transfer switch it controls automatic operation and automatic transfer as fol lows Solid state circuits in the transfer switch monitor utility power source voltage When utility source voltage drops below a pre set level transfer switch action signals the genera tor to start The engine then cranks and starts as controlled by the pre packaged generator s Control Module circuit board After the engine starts and when the generator AC output voltage and frequency have reached a pre set value transfer switch circuits signal the transfer switch main contacts to actuate to the Standby power source side Generator AC output then powers load circuits When the utility power source voltage is restored above a pre set level transfer switch circuits signal the switch main contacts to move back to their util ity power source side Following re transfer back to the utility power source side transfer switch circuit board action signals the generator to stop Engine then shuts down GTS Mode Operation When in GTS mode the control board willrespond as follows based on the generator AUTO OFF MANUAL switch position OFF The generator will not start and run in this position MANUAL The control board will start and run the generator whenever the switc
49. andards and regula tions pertaining to the installation caution A After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regulations NOTE For more information about the installation of a standby system contact an Authorized Service Dealer 2 1 1 NFPA STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 e NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES e NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION e NFPA No 68 GUIDE FOR EXPLOSION VENTING e NFPA No 70 NATIONAL ELECTRICAL CODE e NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE e NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following informa tion pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTENANCE OF FARM STA
50. ansferable coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING e Quietsource generators that utilize non Generac replacement parts e Quietsource generators utilizing non Generac automatic transfer switches e Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems e Any Quietsource generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as co
51. ate unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only fac tory approved parts Before performing any maintenance on the generator dis connect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc AA ELECTRICAL HAZARDS A All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous volt ages to the transfer switch as well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as
52. ation Exercise care near running genera tors N GENERAL HAZARDS A e For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regu lations 2 A Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strict ly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and ser viced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequ
53. blown 2 Loose or corroded or defective battery cables 3 Defective starter contactor 4 Delective starter motor 5 Dead or Defective Battery 6 5 amp fuse blown Engine cranks but won t start 1 Out of fuel 2 Fuel solenoid FS is defective 3 Open Wire 14A from Engine Control circuit board 4 Spark plugs defective Engine starts hard runs rough 1 Flame arrestor air cleaner plugged or damaged 2 Plugged fuel line 3 Defective spark plugs Engine starts then shuts down 1 Engine oil level is low 2 Engine is overheated 3 Defective Low Oil Pressure Switch 4 Defective Coolant Temperature Switch 5 Defective Control Module circuit board 6 Coolant Level is Low d Defective Low Coolant Level Switch AUTO OFF MANUAL Switch at OFF 1 Defective AUTO OFF MANUAL switch engine continues to run 2 Open disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board 3 Defective Control Module circuit board No AC output from generator 1 Main line circuit breaker open 2 Circuit breakers amp fuses open 9 Transfer switch set to NORMAL position 4 Generator internal failure 5 Thermal circuit breaker open TROUBLESHOOTING CORRECTION i 2 oO O1 Co Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel 2 Replace solenoid
54. cal electrical loads during utility power failure The unit has been facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the operation of 120 and or 240VAC single phase loads This model is available and rated as follows Model 005031 2 Provides 25 000 watts 25 kW of single phase power warninc amp A If this generator is used to power electrical load Circuits normally powered by a utility power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system is intended to be used with a matched automatic transfer switch It may be sup plied in either a NEMA 1 enclosure or a NEMA 3R enclosure The NEMA 1 enclosure is intended for indoor use only The NEMA 3R enclosure is weather proof and can be used indoors or outdoors Follow these rules Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if necessary This can be done by placing washers between the swi
55. ccording to code No fuel leakage is permitted 12 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inches 10 to 16 mm 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 GTS TRANSFER SWITCH When required the pre packaged standby genera tor can be inst
56. cessary to group the critical essential loads together and wire them into a separate emergency distribution panel This generator can be installed in conjunction with a GTS type transfer switch if necessary see Section 2 9 The standard prepackaged transfer switch ATS mode does not have sensing or controlling circuit boards Instead the generator control console hous es a Printed Circuit Board Assembly which con trols all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION A DX A ZAN Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy If an open bottom is used the engine generator must be installed over non combustible materi als and should be located such that combustible materials are not capable of accumulating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes st
57. ch settings are not set correctly the generator may not start or operate correctly WARNING amp ZAN 240 VAC can be present within the control panel If it is necessary to select an alternate switch posi tion move the AUTO OFF MANUAL switch to the OFF position Remove the 15 amp fuse in the genera tor control panel Move the DIP switch position that needs to be changed to its new position Wait five seconds then re install the 15 amp fuse The ON position is marked on the switch and is shown in Figure 3 2 Switch Position 1 Selects the generator alternator output frequency and is factory pre set for 60 Hz Switch Position 2 Selects the type of transfer switch and is factory pre set for an automatic trans fer switch ATS Switch Position 3 Selects the type of governor control used and is factory pre set for stepper motor operation Switch Position 4 Selects the type of fuel being used and is factory pre set for natural gas NG Switch Position 5 Selects the engine displacement and is factory pre set for a 2 5 liter 2 5L engine Switch Position 6 Selects the number of engine cylinders and is factory pre set for four cylinders Switch Position 7 Selects the direction of rotation of the governor stepper motor and is factory pre set for CCW rotation rotation is observed looking at the stepper shaft as it moves from closed throttle to open throttle Liquid cooled 25 kW Generat
58. cts close which causes the engine to shut down automatically Figure 1 5 Figure 1 5 High Coolant Temperature Switch 1 7 3 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shutdown To prevent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automati cally shuts down Figure 1 6 Liquid cooled 25 kW Generators 1 7 4 OVERSPEED SHUTDOWN Should AC frequency exceed about 72 Hz cir cuit board action will automatically shutdown the engine 1 7 5 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking pro cess when attempting to start the engine The first crank cycle is a 15 second crank followed by a seven second rest This is followed by five more crank cycles each with a seven second crank followed by a seven second rest If the engine fails to start after all six attempts the start attempt is stopped and the overcrank LED turns on 1 7 6 LOW BATTERY The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 12 VDC for one minute Low battery voltage is a non latching alarm which will automatically clear if the battery voltage rises above 12 VDC If battery voltage goes below 6 VDC during cranking the
59. e gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 Figure 1 3 Engine Protective Devices HIGH COOLANT TEMPERATURE LOW OIL LOW COOLANT LEVEL SWITCH SWITCH PRESSURE S N f et l A Q AN Z N AW Ay ACW S m Z ee Section 1 General Information Liquid cooled 25 kW Generators 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 7 2 HIGH COOLANT TEMPERATURE SWITCH Normally open N O thermostatic switch has sens ing tip which is immersed in captive coolant Should coolant temperature exceed about 230 F 110 C the switch conta
60. e affected area immediately with clear water INSTALLATION DI Section 2 Installation Liquid cooled 25 kW Generators warnings amp AA 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 ZAN 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 2 10 1 VENTED BATTERIES caution A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures are to be observed e Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes flush thor oughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbon ate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas Th
61. e following pro cedure are to be followed e DO NOT SMOKE when near batteries e DO NOT cause flame or spark in battery area and e Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries The recommended battery is Group 26 12VDC 550 CCA 75 AH minimum All batteries must be at 100 percent state of charge before they are installed on the generator 11 OPERATION Section 3 Operation J gt Liquid cooled 25 kW Generators When using maintenance free batteries it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the inter vals specified in Section 4 Maintenance A nega tive ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed ser viced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Sa
62. ed 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 Service Dealer 22 Section 4 Maintenance Liquid cooled 25 kW Generators MAINTENANCE S Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Required Required Task mended to be done to be done Required Comp to pe e wa SS e Pe done Date 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 a necessary thermal protection evel orrect as nece 5 Check the natural me delivery system on gas engine driven units Tighten connections as LIC CC e 6 Check the air inlets and outlets for debris Clean as nece 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 orrect 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 corr
63. ed 25 kW Generators 2 5 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY GENERATOR output are connected to an approved transfer switch The trans fer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY aa POWER SUPPLY 8 SWITCH TO LOAD CIRCUITS STANDBY GENERATOR _ OUTPUT S MAIN LINE CIRCUIT BREAKER NOTE The manufacturer recommends the use of a Generac Power Systems transfer switch in con junction with this generator INSTALLATION DI Section 2 Installation Liquid cooled 25 kW Generators 2 5 EMERGENCY CIRCUIT ISOLATION METHOD
64. ent fuse type ATO 3 2 4 5 AMP FUSE This fuse protects the battery charger against electri cal overload and is located inside the control panel If the fuse needs to be replaced use only an identical 5 amp replacement fuse type ATO NOTE This fuse will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset 14 3 2 5 SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically See Weekly Exercise Cycle see Figure 3 3 and Section 3 7 3 2 6 SYSTEM READY LED The System Ready LED green has two main pur poses First the LED will be ON when the AUTO OFF MANUAL switch is in the AUTO position utility is present and there are no system alarms This ON state indicates the system is fully ready for automatic operation The system ready LED will be OFF when the switch is in the MANUAL or OFF positions The system ready LED is also used to indicate the presence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes The LED will flash at the rate of 1 2 second on 1 2 second off if the utility sensing level is below the transfer back threshold This secondary function is only available with DIP switch two in the OFF position ATS automatic transfer switch application 3 5 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMERGENCY power
65. ercise Time Switch SEE OWNER S MANUAL FOR COMPLETE LED DETAILS AUTO OFF OFF ON SET MANUAL EXERCISE TIME TOSET EXERCISERTME n 1 PLACE AUTO OFF MANUAL SWITCH TO AUTO POSITION 2 HOLD SET EXERCISE TIME SWITCH IN ON POSITION FOR THREE SECONDS AND RELEASE SEE OWNER S MANUAL FOR COMPLETE DETAILS THE EXERCISER IS NOW SET ALL FIVE RED LED S WILL FLASH FOR 10 SECONDS THEN THE UNIT WILL START RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN 0F2629 If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In this state the generator will still start and run in manual mode or automatically start and run if utility is lost while in Auto mode but it will not perform a weekly exercise cycle 16 If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been switched to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set 3 8 CONTROL BOARD DIP SWITCH SETTINGS Located on the control board is an eight position DIP switch see Figure 3 2 The eight different switches are used to configure the control board for the spe cific engine and governor being used and are pre set at the factory caution AA A If the DIP swit
66. f so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 53 Section 9 Warranty WARRANTY Liquid cooled 25 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR QUIETSOURCE PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Quietsource generator will be free from defects in material and workmanship for the items and period set forth below Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or an Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Quietsource prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent tr
67. fety Rules on pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equip ment 2 11 1 PRIOR TO INITIAL START UP caution amp Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems for additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and volume and b is properly purged and leak tested a
68. h is in the manual position AUTO The control board will monitor the two wire start circuit When a two wire start is issued the con trol board will immediately start and run the genera tor When the two wire start is removed the control board will immediately stop the generator NOTE If the generator is installed in conjunction with an engineered GTS type transfer switch refer to the applicable transfer switch manual for exact oper ating parameters and timing sequences For proper battery charger operation it will be nec essary to supply a fused 240VAC utility fed supply to terminals N1 and N2 in the control panel 3 2 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console Figure 3 1 are as follows Section 3 Operation OPERATION Liquid cooled 25 kW Generators J gt Figure 3 1 Generator Control Console OVER CRANK _ A CAUTION A OVER SPEED _ LOW COOL LEVEL x x HI COOL TEMP LOW OIL PRESS LOW BATTERY LED INDICATORS SYSTEM READY _ FLASHING GREEN LED NO UTILITY SENSE 5 FLASHING RED LED S EXERCISER NOT SET IN AUTO MODE ONLY SOLID GREEN LED SYSTEM READY UTILITY POWER ON RISK OF ELECTRICAL SHOCK DO NOT REMOVE COVER NO USER SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL CAUTION A FOR STAND BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATE
69. ine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator i
70. ion Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder
71. ively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incor rect frequency and or voltage Only qualified service technicians should adjust the governed speed 4 8 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 4 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters 20 caution amp AN After refilling the crankcase with oil always chec
72. k oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 4 8 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 1 See the Service Schedule for air cleaner mainte nance 4 8 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary Figure 4 4 See Section 6 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent 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 questionable See the Service Schedule Section 6 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 07 1 17 mm 0 042 0 046 inch by carefully bending the ground elec trode Figure 4 4 Figure 4 4 Setting the Spark Plug Gap SET PLUG GAP AT 1 07 1 17 mm 0 042 0 046 inch von Oe me 7 ki N 4 8 13 COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See Specifications for cooling system recommendations 49 MISCELLANEOUS MAINTENANCE
73. l fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils Figure 4 3 Oil Dipstick and Oil Fill Cap Engine Air Cleaner Oil Fill Cap Oil d 8 Iter Fi Z MAINTENANCE 2 Section 4 Maintenance 4 7 2 BATTERY FLUID Check battery electrolyte fluid based on the Maintenance Schedule Fluid should cover separa tors in all battery cells If fluid level is low add dis tilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY 4 7 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recov ery system for leaks 4 8 MAINTENANCE OWNER OPERATOR CAN PERFORM 4 8 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels 4 8 2 CHECK BATTERY e See Checking Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 4
74. llision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s e Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period e Expenses related to customer instruction or troubleshooting where no manufacturing defect is found e Rental equipment used while warranty repairs are being performed e Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc e Overnight freight costs for replacement part s e Overtime labor e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you
75. low battery voltage alarm is latched cranking is terminated and the low battery LED stays on 1 77 15A DC FUSE This fuse is located inside the control panel It pro tects the panel wiring and components from damag ing overload The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating 1 8 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton Section 1 General Information 1 8 2 INSPECTION Upon delivery carefully inspect the generator for any damage that may have occurred during shipment If loss or damage is noted at the time of delivery have the person s making delivery note all damage on the freight bill or affix their signature under the consign or s memo of loss or damage 1 9 LIFTING THE GENERATOR A warninc amp A When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 ENGINE UEL u uuu aus ss Ford NEIE 153 inches 2 5 liters Cylinder Arrangement 4 in line Valve Arrangemetnt Overhead Cam
76. luo i Motorcraft AWSE 52 pplied with engine 077483 Section 4 Maintenance MAINTENANCE Liquid cooled 25 kW Generators S 4 10 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for 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 applica tion Use the unit hour meter or calendar time whichever occurs first 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 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 cont
77. ors Switch Position 8 Selects whether the control is in the Normal Mode of operation or Test Mode In the Normal Mode of operation pre determined governor gains are used and the gain trimpots on the control board Gain Stability and Differential are not active and have no effect on the gains In Test Mode the gain trimpots are active and can be adjusted See Section 3 4 3 9 VOLTAGE REGULATOR ADJUSTMENT Four adjustment potentiometers are provided on the voltage regulator installed in the control panel Figure 3 4 These are a voltage adjust b gain c stability and d underfrequency adjust The voltage regulator potentiometers have been factory set and SHOULD NOT be adjusted If however adjustments are necessary contact the local Dealer to implement the following procedure WARNING High voltage is present inside the control panel during this procedure 1 Disconnect all electrical loads from the generator initial adjustments are done under no load con ditions Figure 3 4 Voltage Regulator O VOLTAGE ADJUST GAIN STABILITY gt UNDERFREQUENCY ADJUST di REGULATOR gt SENSING gt EXCITATION gt Oooo eebe 2 Connect an accurate AC voltmeter and AC fre quency meter to the generator s AC output leads 3 On the voltage regulator set the potentiometers as follows A Turn the Voltage Adjust pot fully counterclock wise CCW
78. osion Correct as necessary 12 Test the engine and transfer switch safety devices Correct nal adjust as nece 23 Section 4 Maintenance MAINTENANCE Liquid cooled 25 kW Generators S 13 14 17 18 19 20 21 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Required Required mended to be done to be done Required to be done 3 months to be done Initiate an automatic start and transfer of the unit to Site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions orrect as necessary hange the engine oi LL J a i Replace the engine oil filter Replace the engine air Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service D OVIS Return the unit to standby setup for operation when GUTE Sei Section 5 Troubleshooting Liquid cooled 25 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won t crank 1 15 amp luse
79. rease an addi tional 1 for each 10 F above 60 F Maximum output power of the generator is limited by maximum engine power 1 11 FUEL CONSUMPTION 25 kW Models Using Natural Gas nsnnnnenenneeeeeeeerenereneeen 441 cu ft per hour Using LP G38 n aaa 175 cubic ft 4 8 gal per hour NOTE Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot or LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges 1 12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR NOTE All models are configured for natural gas NG from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 3 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Section 1 General Information GENERAL Liquid cooled 25 kW Generators INFORMATION 4 Remove pipe plug from Port 2
80. rmally sup plied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the genera tor is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when NORMAL UTILITY source voltage is removed or is below an acceptable pre set level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the genera tor control panel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HA
81. rol 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 preventan 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 operation when required 2 A 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 approximatelu 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 bu an Authorized 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 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 Service Dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when requir
82. ry or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows A This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard ZAN This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator reads this Owner s Manual and thoroughly understands all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for
83. safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service adjust ments and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capa ble of handling all service needs When contacting an Authorized Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR Locate us on the web at www generac
84. sion Such an explosion can shat ter 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 A Battery electrolyte fluid is an extremely corro sive 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 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 WARNING A 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 utility power supply to the battery Charger is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 9 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows gt aroub No 26 60R 525 0 deg F NOTE The BCI number should be located directly on the battery Motorcraft FL 400 ne Hadiato OU park P
85. sions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Dealer as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Au
86. stment ANTTTTT a lt B L kal S 28 ii ma titan WS e usss IONICS ee eoo SS e CH SE Ek H ig ETE a HE sou T H EI eee 00000000 a e e e o e e e e o e ee e e e e oe e e e oe e e e e L EN H CT w 8 S 2 e NO DA EES L 8 Sr JJ WH e Z _ aol dt HI n ET JIJ Hi SAUER bCB OEdYO2 KEN YSTIOMLNOD AGBONVLS JWOH A DIP SWITCH GAIN STABILITY DIFFERENTIAL POS OFF ON DESCRIPTION I 6 FREQ HZ 0 1 0 0 2 ATS GTS TRANSFER SW TYPE 3 BOSCH STEPPER GOVERNOR TYPE 4 BS NG FUEL TYPE gt 3 9L 2 3 3 0L ENGINE TYPE 6 6 CYL 4 CYL OF CYLINDERS 7 CCW CW STEPPER ROTATION 8 TEST NORMAL OPERATING MODE 3 5 MANUAL RETRANSFER AND SHUTDOWN When utility power source voltage has been restored electrical loads may be transferred back to that source and the generator can be shut down as fol lows Verify that utility power supply voltage to the trans fer switch has been positively turned Off using whatever means provided such as utility main line circuit breaker Set the generator s main circuit breaker to its Off or Open position Let the generator engine run at no load for a few minutes to stabilize internal unit temperatures On the generator console set the Auto Off Manual switch to Off Wait for engine to come to a complete stop For transfer to utility position refer
87. tch enclosure and the mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors If a transfer switch is not included one may be pur chased separately from an Authorized Dealer Section 1 General Information 1 3 ATS MODE AUTOMATIC OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator control panel constantly monitors utility power source voltage Should that voltage drop below a preset value and remain at such a low state for a pre set amount of time the generator cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can power them When utility source voltage has been restored the switch re transfers back to the utility source voltage and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase 3 wire generator AC connection system Figure 1 1 The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can supply 120 VAC 60 Hertz When the
88. the transfer switch if appli cable Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If personnel must stand on metal or concrete while install ing operating servicing adjusting or repairing this equip ment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insula tive mats The National Electrical Code NEC Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static elec tricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in haz ardous and possibly fatal electrical shock Connecting this unit to an electrical system no
89. thorized Warranty Service Dealer To locate the Generac Authorized Warranty Service Dealer nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Power Systems Inc Two Year Limited Warranty which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Dealer When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 52 Section 9 Warranty Liquid cooled 25 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emiss
90. tion Liquid cooled 25 kW Generators caution amp Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 1 14 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half deionized water Cooling system capacity is about 8 U S quarts 7 6 liters Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution amp A Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro miumhydroxide green slime forms and will cause overheating Engines that have been oper ated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause over heating DO NOT use any soluble oil inhibitor for this equipment 1 15 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in the installation manual Part No 079699 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power It may be ne
91. to the Owner s Manual of the particular transfer switch Turn on the utility power supply to the transfer switch using whatever means provided such as a utility main line circuit breaker The utility power source now powers the loads 15 OPERATION Section 3 Operation J gt Liquid cooled 25 kW Generators 3 6 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed as follows e Check that load circuits are connected to the utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 7 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the generator to exercise set the weekly exercise cycle as follows 1 Place the AUTO OFF MANUAL switch in the AUTO position Figure 3 3 2 Press and hold the Set Exercise Time switch for five seconds then release At this time all five red LEDs will flash for approxi mately 10 seconds then the engine will start and run for its 12 minute exercise period then shut down The generator will now start and run each week at the same time Figure 3 3 Set Ex
92. two windings are connected in series a 240 VAC 60 Hertz AC output results Typically the two hot leads in the circuit are Wires No 11 and 44 The Neutral leads are the junction of Wires 22 and 33 Figure 1 1 Generator AC Connection System re rn 19 De RED em pm 240 VOLTS CIRCUIT BREAKER 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for each unit is described in Figure 1 2 Figure 1 2 Main Circuit Breaker Model Ratin Phase Actual Current C B Rating over ratin Circuit Breaker 005031 2 25 000 W 1 104 2A 125A 120 125A BQ2 Amp Rating of C B structured under model 1 6 GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is pre ferred refer to Section 1 12 Reconfiguring the Fuel System for LP Vapor Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A separate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability WARNING A Gaseous fuels such as natural and LP propan
93. uires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gen erator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations A DI A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against elec trical shock in the event of a ground fault condition in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices 10 Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG 2 8 GENERATOR AC NEUTRAL CONNECTIONS The manufacturer uses an UNGROUNDED AC neu tral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the exces sive current opens the load circuit breaker or col lapses the generator field The actual result depends on the electrical characteristics of the particular installed generator WARNING amp Failure to connect the generator neutral proper ly will result in unbalanced line to neutral volt ages Resulting high voltages will cause equip ment damage

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