Generac Power Systems 005040-2 owner manual Troubleshooting Points, Problem Cause Correction

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Section 5 — Troubleshooting

Guardian Liquid-cooled 25 kW Generator

TROUBLESHOOTING POINTS

PROBLEM

CAUSE

CORRECTION

Engine won’t crank.

1.

15 amp fuse blown.

1.

Replace fuse.

 

2.

Loose or corroded or defective

2.

Tighten, clean or replace

 

 

battery cables.

 

battery cables as necessary.

 

3.

Defective starter contactor.

3.

Replace contactor.

 

4.

Defective starter motor.

4.

Replace starter motor.

 

5.

Dead or Defective Battery.

5.

Remove, change or replace battery.

 

6.

5 amp fuse blown.

6.

Replace fuse.

 

 

 

 

 

Engine cranks but won't start

1.

Out of fuel.

1.

Replenish fuel.

 

2.

Fuel solenoid (FS) is defective

2.

Replace solenoid.

 

3.

Open Wire #14A from Engine Control

3.

Reconnect wire.

 

 

circuit board.

 

 

 

4.

Spark plugs defective.

4.

Clean, regap or replace plugs.

 

 

 

 

 

Engine starts hard, runs rough.

1.

Flame arrestor (air cleaner) plugged or

1.

Clean or replace as needed.

 

 

damaged.

 

 

 

2.

Plugged fuel line.

2.

Unclog fuel line.

 

3.

Defective spark plugs.

3.

Clean, regap or replace plugs.

 

 

 

 

 

Engine starts then shuts down.

1.

Engine oil level is low.

1.

Check oil and add oil as needed.

 

2.

Engine is overheated.

2.

Check cooling system for leaks.

 

3.

Defective Low Oil Pressure Switch

3.

Replace switch.

 

4.

Defective Coolant Temperature Switch

4.

Replace switch.

 

5.

Defective Control Module circuit board.

5.

Replace board.

 

6.

Coolant Level is Low.

6.

Repair leak - Add coolant.

 

7.

Defective Low Coolant Level Switch

7.

Replace Switch.

 

 

 

 

AUTO/OFF/MANUAL Switch at OFF,

1. Defective AUTO/OFF/MANUAL switch

1.

Replace switch.

engine continues to run

2. Open/disconnected wire #15A between

2.

Reconnect/close wire.

 

 

AUTO/OFF/MANUAL switch and Control

 

 

 

 

Module circuit board.

 

 

 

3.

Defective Control Module circuit board

3.

Replace board.

 

 

 

 

No AC output from generator.

1. Check main line circuit breaker.

1.

Reset to ON or CLOSED.

 

2.

Check circuit breaker & fuses.

2.

Reset and replace, if necessary.

 

3.

Transfer switch set to NORMAL position

3.

Set to GENERATOR position.

 

4.

Generator internal failure.

4.

Contact an Authorized Generac Service Dealer.

 

5.

Thermal circuit breaker open.

5.

Auto-reset - Wait 5 min. and

 

 

 

 

attempt restart.

24 Generac® Power Systems, Inc.

Image 26
Contents This manual should remain with the unit ‹ HOW to Obtain Service Authorized Service Dealer Location‹ Operation and Maintenance IntroductionTable of Contents General Hazards Fire Hazards ‹ Standards IndexAutomatic System Operation Transfer SwitchGenerator Generator AC Connection Systems‹ 1.7.3 LOW Coolant Level Switch ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.2 High Coolant Temperature Switch Generator Fuel SystemLifting the Generator SpecificationsUnpacking ‹ 1.10.2 Generator Fuel ConsumptionEngine OIL Recommendations ‹ 2.1.1 Nfpa Standards Before InstallationCoolant Recommendations Generator Mounting Support Basic Standby Electric SystemGenerator Location Emergency Circuit Isolation MethodGenerator AC Neutral Connections Using AN Engineered GTS Transfer SwitchTotal Circuit Isolation Method Grounding the Generator‹ 2.10.1 Vented Batteries Battery InstallationPreparation Before START-UP Engineered GTS Transfer Switch ‹ 3.2.5 SET Exercise Time Switch ‹ 3.2.2 Fault Indicator Leds‹ 3.2.1 AUTO/OFF/MANUAL Switch Control Console ComponentsManual Transfer START-UP Engine Governor Adjustments ‹ 3.2.6 System Ready LEDRetransfer and Shutdown Automatic OperationWeekly Exercise Cycle Control Board DIP Switch Settings Cylinder Head Procedure Exhaust Manifold ProcedureIntake Manifold Procedure Cooling SystemOverload Protection for Engine DC Electrical System Checking Fluid Levels‹ 4.8.9 Inspect Engine Governor ‹ 4.8.11 Changing the Engine AIR Cleaner‹ 4.8.8 Check FAN Belt ‹ 4.8.10 Changing Engine OIL‹ 4.9.3 Battery Maintenance Miscellaneous Maintenance‹ 4.9.1 Cleaning the Generator ‹ 4.9.4 Battery ReplacementScheduled Maintenance Service Maintenance Interval InformationLevel Maintenance Level Troubleshooting Points Problem Cause CorrectionGuardian Liquid-cooled 25 kW Generator Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Mount Battery Post Cover RED Hold Down Battery 2.5L FordBattery Post Cover Black Boot Battery CablePanel for Access Cover Access GEN Assy Wire 14AWG 7.5 #0 GRN/YELAssembly Cover Access Roof ACO & STD Encl 2.5L54 36 Assy Wire Fuse Holder Assy 2A 12V UL BatterySwitch ROC Dpst 125V SPD Screw Hhtt M5-0.8 X 12 BPGenerac Power Systems, Inc Ctrl PNL TOP 2.5L Ford STL Only Motor Units STARTER, 12 Volt Tank Coolant RecoveryEngine 2.5L Ford NUT HEX M10-1.5 G8 YEL CHRTo Engine GASKET, AIR Cleaner Adapter Body Carburetor AssemblyCover AIR Cleaner Bracket Fuel RegulatorLocktight Rotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 390 15KW 1P Direct HSB 2.5L FordRotor 390 20KW 1P Direct HSB 2.5L Ford Rotor 39030AD1 HSB TecumMuffler 2.5L Ford Pipe Muffler OUTPipe Exhaust 2.5L Ford Saddle 2 InchASM Motor Stepper Housing Governor ConnectorCover Connector Housing Harn GOV 2.5L FordHOSE, 2.5L Ford Lower Support Radiator 2.5L AL TALRADIATOR, 2.5L Ford VENTURI, 16 FAN 2.5L Ford RadiatorInstallation Diagram PURCHASER’S/OWNER’S Warranty Responsibilities Your Warranty Rights and ObligationsMANUFACTURER’S Emission Control System Warranty Coverage Emission Control System Warranty Emission Related Parts Include the FollowingWarranty Schedule