Generac 005031-2 1.8UNPACKING, 1.9LIFTING THE GENERATOR, Specifications, ‹1.7.6 LOW BATTERY

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Figure 1.6 - Low Coolant Level Sensor

Section 1 — General Information

Liquid-cooled 25 kW Generators

Figure 1.6 - Low Coolant Level Sensor

‹ 1.8.2 INSPECTION

‹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 low battery voltage alarm is latched, cranking is terminated, and the low battery LED stays on.

‹1.7.7 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.

1.8UNPACKING

‹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.

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.

1.9LIFTING THE GENERATOR

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

Make

Ford

Displacement

153 inches3 (2.5 liters)

Cylinder Arrangement

4, in-line

Valve Arrangement

Overhead Cam

Firing Order

1-3-4-2

Number of Main Bearings

5

Compression Ratio

9.37 to 1

No. of Teeth on Crank

36-1

Ignition Timing (Waste Spark System)

at 1800 rpm (NG)

36 degrees BTDC

Ignition Timing (Waste Spark System)

at 1800 rpm (LP vapor)

28` degrees BTDC

Spark Plug Gap

0.044 inch

Recommended Spark Plugs

 

Motorcraft

AWSF-52-C

Oil Pressure

30-50 psi

Crankcase Oil Capacity

4.5 U.S. quarts (4.26 liters)

Recommended Engine Oil

SAE 15W-40

Type of Cooling System

Pressurized, closed recovery

Cooling Fan

Pusher Type

Cooling System Capacity

2 U.S. gallons (7.6 liters)

Recommended Coolant

Use a 50-50 mixture of ethylene

glycol base and deionized water.

Home standby control board assembly part num- ber 0E9704 must be used on 1800 rpm genera- tors.

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Contents SHOULD ATTEMPT INSTALLATION Liquid-cooled,Prepackaged Standby GeneratorsModel Number 005031-225kW This manual should remain with the unitAUTHORIZED SERVICE DEALER LOCATION ‹OPERATION AND MAINTENANCE‹HOW TO OBTAIN SERVICE INTRODUCTIONINTRODUCTION WARNING   GENERAL HAZARDSELECTRICAL HAZARDS ‹STANDARDS INDEX FIRE HAZARDS EXPLOSION HAZARDS 1.2TRANSFER SWITCH 1.1GENERATOR1.3ATS MODE AUTOMATIC OPERATION 1.4GENERATOR AC CONNECTION SYSTEMS‹1.7.1 LOW OIL PRESSURE SWITCH ‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH‹1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch1.10 SPECIFICATIONS ‹1.7.6 LOW BATTERY‹1.8.1 UNPACKING PRECAUTIONS 1.8UNPACKING1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR Figure 1.8 - Reconfigure the Fuel System1.11 FUEL CONSUMPTION 1.13 ENGINE OIL RECOMMENDATIONS2.1STANDBY GENERATOR INSTALLATION 1.15 BEFORE INSTALLATION1.14 COOLANT RECOMMENDATIONS ‹2.1.1 NFPA STANDARDS2.2GENERATOR LOCATION 2.3GENERATOR MOUNTING AND SUPPORT2.4BASIC STANDBY ELECTRIC SYSTEM ‹2.1.2 OTHER PUBLISHED STANDARDS2.9USING A “GTS” TRANSFER SWITCH 2.5EMERGENCY CIRCUIT ISOLATION METHOD2.6TOTAL CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATOR‹2.10.1 VENTED BATTERIES 2.10 BATTERY INSTALLATIONPos2 OFF — ATS Application 3.1GTS TRANSFER SWITCH ‹2.11.2 TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹2.11.4 GENERATOR SET LUBRICATION‹3.2.1 AUTO/OFF/MANUAL SWITCH ‹3.2.2 FAULT INDICATOR LEDS3.2CONTROL CONSOLE COMPONENTS GTS Mode Operation‹3.2.5 SET EXERCISE TIME SWITCH ‹3.2.3 15 AMP FUSE‹3.2.4 5 AMP FUSE ‹3.2.6 SYSTEM READY LED3.4ENGINE GOVERNOR GAIN ADJUSTMENTS 3.3MANUAL TRANSFER AND START-UP3.5MANUAL RETRANSFER AND SHUTDOWN Figure 3.2 - Engine Governor Adjustment3.8CONTROL BOARD DIP SWITCH SETTINGS Figure 3.3 - “Set Exercise Time” Switch3.6AUTOMATIC OPERATION 3.7WEEKLY EXERCISE CYCLE3.9VOLTAGE REGULATOR ADJUSTMENT ‹EVERY THREE MONTHS‹ONCE EVERY SIX MONTHS ‹ONCE ANNUALLY4.2EXHAUST MANIFOLD PROCEDURE 4.3INTAKE MANIFOLD PROCEDURE4.4CYLINDER HEAD PROCEDURE Figure 4.1 - Intake Manifold Installation4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM ‹4.7.2 BATTERY FLUID‹4.8.2 CHECK BATTERY 4.6OVERLOAD PROTECTION FOR‹4.8.11 CHANGING THE ENGINE AIR CLEANER Figure 4.4 - Setting the Spark Plug Gap‹4.8.7 INSPECT EXHAUST SYSTEM ‹4.8.8 CHECK FAN BELT4.9MISCELLANEOUS MAINTENANCE ‹4.9.1 CLEANING THE GENERATOR‹4.9.2 BATTERY ‹4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationTasks Level TROUBLESHOOTING POINTS PROBLEMCAUSE 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 Section 7 - Exploded Views and Parts Lists FOR HARNESS GROUND STEPPERONLY 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