Generac Power Systems 005040-2 owner manual General Hazards

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Important Safety Instructions

Guardian Liquid-cooled 25 kW Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

!operation be copied and posted in potential hazard areas. Safety 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.

!

WARNING:

!

 

 

 

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 genera- tor can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many acci- dents are caused by failing to follow simple and funda- mental rules or precautions.

Generac cannot anticipate every possible circumstance 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 operat- ing technique that Generac does not specifically recom- mend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the generator unsafe.

DANGER

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 main- tain this equipment.

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.

Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly 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 serv- iced 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 regulations.

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.

Adequate, 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.

Parts of the generator are rotating and/or hot

!during operation. Exercise care near running gen- erators.

!GENERAL HAZARDS !

For safety reasons, Generac recommends that this equip- ment be installed, serviced and repaired by a Generac 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.

ELECTRICAL HAZARDS

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 the transfer switch, if applica- ble. 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.

2 Generac® Power Systems, Inc.

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Contents This manual should remain with the unit Authorized Service Dealer Location ‹ Operation and Maintenance‹ HOW to Obtain Service IntroductionTable of Contents General Hazards Fire Hazards ‹ Standards IndexTransfer Switch GeneratorAutomatic System Operation Generator AC Connection Systems‹ 1.7.1 LOW OIL Pressure Switch ‹ 1.7.2 High Coolant Temperature Switch‹ 1.7.3 LOW Coolant Level Switch Generator Fuel SystemUnpacking SpecificationsLifting the Generator Engine OIL Recommendations Fuel Consumption‹ 1.10.2 Generator Coolant Recommendations Before Installation‹ 2.1.1 Nfpa Standards Basic Standby Electric System Generator LocationGenerator Mounting Support Emergency Circuit Isolation MethodUsing AN Engineered GTS Transfer Switch Total Circuit Isolation MethodGenerator AC Neutral Connections Grounding the GeneratorPreparation Before START-UP Battery Installation‹ 2.10.1 Vented Batteries Engineered GTS Transfer Switch ‹ 3.2.2 Fault Indicator Leds ‹ 3.2.1 AUTO/OFF/MANUAL Switch‹ 3.2.5 SET Exercise Time Switch Control Console ComponentsManual Transfer START-UP Engine Governor Adjustments ‹ 3.2.6 System Ready LEDWeekly Exercise Cycle Automatic OperationRetransfer and Shutdown Control Board DIP Switch Settings Exhaust Manifold Procedure Intake Manifold ProcedureCylinder Head Procedure Cooling SystemOverload Protection for Engine DC Electrical System Checking Fluid Levels‹ 4.8.11 Changing the Engine AIR Cleaner ‹ 4.8.8 Check FAN Belt‹ 4.8.9 Inspect Engine Governor ‹ 4.8.10 Changing Engine OILMiscellaneous Maintenance ‹ 4.9.1 Cleaning the Generator‹ 4.9.3 Battery Maintenance ‹ 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 Hold Down Battery 2.5L Ford Battery Post Cover BlackBattery Post Cover RED Boot Battery CablePanel for Access Assy Wire 14AWG 7.5 #0 GRN/YEL Assembly Cover AccessCover Access GEN Roof ACO & STD Encl 2.5L54 36 Assy 2A 12V UL Battery Switch ROC Dpst 125V SPDAssy Wire Fuse Holder Screw Hhtt M5-0.8 X 12 BPGenerac Power Systems, Inc Ctrl PNL TOP 2.5L Ford STL Only Motor Units Tank Coolant Recovery Engine 2.5L FordSTARTER, 12 Volt NUT HEX M10-1.5 G8 YEL CHRTo Engine Body Carburetor Assembly Cover AIR CleanerGASKET, AIR Cleaner Adapter Bracket Fuel RegulatorLocktight Rotor 390 15KW 1P Direct HSB 2.5L Ford Rotor 390 20KW 1P Direct HSB 2.5L FordRotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 39030AD1 HSB TecumPipe Muffler OUT Pipe Exhaust 2.5L FordMuffler 2.5L Ford Saddle 2 InchHousing Governor Connector Cover Connector HousingASM Motor Stepper Harn GOV 2.5L FordSupport Radiator 2.5L AL TAL RADIATOR, 2.5L FordHOSE, 2.5L Ford Lower VENTURI, 16 FAN 2.5L Ford RadiatorInstallation Diagram MANUFACTURER’S Emission Control System Warranty Coverage Your Warranty Rights and ObligationsPURCHASER’S/OWNER’S Warranty Responsibilities Emission Control System Warranty Emission Related Parts Include the FollowingWarranty Schedule