Generac 005031-2 Preparation Before Start-Up, 3.1GTS TRANSFER SWITCH, ‹2.11.5 ENGINE COOLANT

Page 14
‹2.11.4 GENERATOR SET LUBRICATION

Section 3 - Operation

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.

‹2.11.4 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 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 “Safety 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

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.”

‹2.11.5 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.

‹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 according to code. No fuel leakage is permitted.

12

3.1GTS TRANSFER SWITCH

When required, the pre-packaged standby genera- tor can be installed 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.

Image 14
Contents Model Number 005031-225kW SHOULD ATTEMPT INSTALLATIONLiquid-cooled,Prepackaged Standby Generators This manual should remain with the unit‹HOW TO OBTAIN SERVICE AUTHORIZED SERVICE DEALER LOCATION‹OPERATION AND MAINTENANCE INTRODUCTIONINTRODUCTION WARNING   GENERAL HAZARDSELECTRICAL HAZARDS ‹STANDARDS INDEX FIRE HAZARDS EXPLOSION HAZARDS 1.3ATS MODE AUTOMATIC OPERATION 1.2TRANSFER SWITCH1.1GENERATOR 1.4GENERATOR AC CONNECTION SYSTEMS‹1.7.3 LOW COOLANT LEVEL SWITCH ‹1.7.1 LOW OIL PRESSURE SWITCH‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH Figure 1.4 - Low Oil Pressure Switch‹1.8.1 UNPACKING PRECAUTIONS 1.10 SPECIFICATIONS‹1.7.6 LOW BATTERY 1.8UNPACKING1.11 FUEL CONSUMPTION 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 - Reconfigure the Fuel System 1.13 ENGINE OIL RECOMMENDATIONS1.14 COOLANT RECOMMENDATIONS 2.1STANDBY GENERATOR INSTALLATION1.15 BEFORE INSTALLATION ‹2.1.1 NFPA STANDARDS2.4BASIC STANDBY ELECTRIC SYSTEM 2.2GENERATOR LOCATION2.3GENERATOR MOUNTING AND SUPPORT ‹2.1.2 OTHER PUBLISHED STANDARDS2.6TOTAL CIRCUIT ISOLATION METHOD 2.9USING A “GTS” TRANSFER SWITCH2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATOR‹2.10.1 VENTED BATTERIES 2.10 BATTERY INSTALLATIONPos2 OFF — ATS Application 2.11 PREPARATION BEFORE START-UP 3.1GTS TRANSFER SWITCH‹2.11.2 TRANSFER SWITCH ‹2.11.4 GENERATOR SET LUBRICATION3.2CONTROL CONSOLE COMPONENTS ‹3.2.1 AUTO/OFF/MANUAL SWITCH‹3.2.2 FAULT INDICATOR LEDS GTS Mode Operation‹3.2.4 5 AMP FUSE ‹3.2.5 SET EXERCISE TIME SWITCH‹3.2.3 15 AMP FUSE ‹3.2.6 SYSTEM READY LED3.5MANUAL RETRANSFER AND SHUTDOWN 3.4ENGINE GOVERNOR GAIN ADJUSTMENTS3.3MANUAL TRANSFER AND START-UP Figure 3.2 - Engine Governor Adjustment3.6AUTOMATIC OPERATION 3.8CONTROL BOARD DIP SWITCH SETTINGSFigure 3.3 - “Set Exercise Time” Switch 3.7WEEKLY EXERCISE CYCLE‹ONCE EVERY SIX MONTHS 3.9VOLTAGE REGULATOR ADJUSTMENT‹EVERY THREE MONTHS ‹ONCE ANNUALLY4.4CYLINDER HEAD PROCEDURE 4.2EXHAUST MANIFOLD PROCEDURE4.3INTAKE MANIFOLD PROCEDURE Figure 4.1 - Intake Manifold Installation‹4.8.2 CHECK BATTERY 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM‹4.7.2 BATTERY FLUID 4.6OVERLOAD PROTECTION FOR‹4.8.7 INSPECT EXHAUST SYSTEM ‹4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 - Setting the Spark Plug Gap ‹4.8.8 CHECK FAN BELT‹4.9.2 BATTERY 4.9MISCELLANEOUS MAINTENANCE‹4.9.1 CLEANING THE GENERATOR ‹4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationTasks Level CAUSE TROUBLESHOOTING POINTSPROBLEM CORRECTIONSection 6 - Electrical Data Section 6 - Electrical Data Section 6 - Electrical Data Liquid-cooled25 kW GeneratorsSection 6 - Electrical Data Section 6 - Electrical Data Liquid-cooled25 kW GeneratorsSection 6 - Electrical Data Section 6 - Electrical Data Liquid-cooled25 kW GeneratorsSection 6 - Electrical Data Section 7 - Exploded Views and Parts Lists DESCRIPTION Mounting Base - Drawing No. 0F0104-B38 3 45 39 32 18 LATCH DETAIL Enclosure - Drawing No. 0F1645-H Section 7 - Exploded Views and Parts Lists 0F0790 Control Panel 25kW - Drawing No. 0E7615-C Control Panel 25kW - Drawing No. 0E7615-C ONLY FOR HARNESS GROUNDSTEPPER RADIATOREngine - Drawing No. 0E9918-F COVER Fuel System - Drawing No. 0E9980-D LOCKTIGHT LEADS0F1659A Muffler - Drawing No. 0F2930-C Stepper Motor - Drawing No. 0E9979-C ADAPTER Radiator - Drawing No. 0E9965-FTO THERMOSTAT Section 8 - Installation Diagram CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING