Page 24
Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
Maintenance | Level 1 | | Level 2 | | Level 3 | | Level 4 | |
Tasks | Recom- | Task | Required | Task | Required | Task | | Task |
| mended | Comp. | to be done | Comp. | to be done | Comp. | Required | Comp. |
| to be done | (Date- | 3 months/ | (Date- | Semi- | (Date- | to be done | (Date- |
| monthly | Initials) | Break-in | Initials) | annually | Initials) | Annually | Initials) |
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 as necessary.
4.Check the engine coolant
thermal protection level. Correct as necessary.
5.Check the natural gas delivery system on gas
engine driven units. Tighten connections as necessary.
6. Check the air inlets and outlets for debris. Clean as necessary.
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. Correct 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 corrosion. Correct as necessary.
12.Test the engine and
transfer switch safety devices. Correct and/or adjust as necessary.
22 Generac® Power Systems, Inc.
Contents
SHOULD ATTEMPT INSTALLATION
Owner’s Manual
Liquid-cooled, Prepackaged Standby Generators
This manual should remain with the unit
AUTHORIZED SERVICE DEALER LOCATION
OPERATION AND MAINTENANCE
HOW TO OBTAIN SERVICE
INTRODUCTION
Table of Contents
Guardian Liquid-cooled 25 kW Generator
GENERAL HAZARDS
Despite the safe design of this generator
Parts of the generator are rotating and/or hot
during operation. Exercise care near running gen- erators
ELECTRICAL HAZARDS
FIRE HAZARDS
EXPLOSION HAZARDS
STANDARDS INDEX
1.2 TRANSFER SWITCH
1.1 GENERATOR
1.3 AUTOMATIC SYSTEM OPERATION
1.4 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
Figure 1.4 - Low Oil Pressure Switch
1.10 SPECIFICATIONS
1.7.6 LOW BATTERY
1.8.1 UNPACKING PRECAUTIONS
1.8 UNPACKING
1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR
Figure 1.8 - Reconfigure the Fuel System
1.11 FUEL CONSUMPTION
1.10.2 GENERATOR
1.15 BEFORE INSTALLATION
2.1 STANDBY GENERATOR INSTALLATION
1.13 ENGINE OIL RECOMMENDATIONS
1.14 COOLANT RECOMMENDATIONS
2.3 GENERATOR MOUNTING AND SUPPORT
2.4 BASIC STANDBY ELECTRIC SYSTEM
2.2 GENERATOR LOCATION
2.1.2 OTHER PUBLISHED STANDARDS
2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH
2.5 EMERGENCY CIRCUIT ISOLATION METHOD
2.6 TOTAL CIRCUIT ISOLATION METHOD
2.7 GROUNDING THE GENERATOR
2.10 BATTERY INSTALLATION
Pos2 OFF - Standard Prepackaged ATS Application
2.10.1 VENTED BATTERIES
Standby generators installed with automatic
3.1 ENGINEERED GTS TRANSFER SWITCH
2.11.2 TRANSFER SWITCH
2.11 PREPARATION BEFORE START-UP
2.11.1 PRIOR TO INITIAL START-UP
3.2.2 FAULT INDICATOR LEDS
3.2.1 AUTO/OFF/MANUAL SWITCH
3.2.5 SET EXERCISE TIME SWITCH
3.2 CONTROL CONSOLE COMPONENTS
3.4 ENGINE GOVERNOR ADJUSTMENTS
3.3 MANUAL TRANSFER AND START-UP
3.2.6 SYSTEM READY LED
Figure 3.2 - Engine Governor Adjustment
Figure 3.3 - “Set Exercise Time” Switch
3.6 AUTOMATIC OPERATION
3.7 WEEKLY EXERCISE CYCLE
3.8 CONTROL BOARD DIP SWITCH SETTINGS
4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES
A. EVERY THREE MONTHS
B. ONCE EVERY SIX MONTHS
4.2 EXHAUST MANIFOLD PROCEDURE
4.3 INTAKE MANIFOLD PROCEDURE
4.4 CYLINDER HEAD PROCEDURE
Figure 4.1 - Intake Manifold Installation
4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM
4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM
4.7 CHECKING FLUID LEVELS
4.8.11 CHANGING THE ENGINE AIR CLEANER
Figure 4.4 - Setting the Spark Plug Gap
4.8.8 CHECK FAN BELT
4.8.9 INSPECT ENGINE GOVERNOR
4.9 MISCELLANEOUS MAINTENANCE
4.9.1 CLEANING THE GENERATOR
4.9.2 BATTERY
4.9.3 BATTERY MAINTENANCE
4.10 SCHEDULED MAINTENANCE
Service Maintenance Interval Information
Turn off the battery charger turn OFF utility supply to ATS
Remove the negative battery cable
Maintenance
Level
Tasks
Maintenance
TROUBLESHOOTING POINTS
PROBLEM
CAUSE
CORRECTION
Generac Power Systems, Inc
Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F1411
26 Generac Power Systems, Inc
Section 7 - Electrical Data
Generac Power Systems, Inc
28 Generac Power Systems, Inc
Generac Power Systems, Inc
Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0E9982-B
30 Generac Power Systems, Inc
Generac Power Systems, Inc
Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-B
32 Generac Power Systems, Inc
Generac Power Systems, Inc
HARNESS WIRE
34 Generac Power Systems, Inc
MOUNT
BLOCK ENGINE
DESCRIPTION
PANEL FOR ACCESS
GROUND WIRE
COVER CABLE
FASTENER TO SECURE
Enclosure - Drawing No. 0E9720-D
38 Generac Power Systems, Inc
HINGE CONTINUOUS 1.5L CTRL PNL
40 Generac Power Systems, Inc
DESCRIPTION
42 Generac Power Systems, Inc
Guardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-E
STEPPER MOTOR UNITS ONLY
TO RADIATOR
SOURCE GENERAC-BOSCH GOV
GASKET, 2.5L FORD EXHAUST MAN
SERPENTINE BELT - 41 3/8 LENGTH
BRKT,D.C. ALTERNATORMACHINED
0E1028A I/N
TO ENGINE
COVER
44 Generac Power Systems, Inc
DESCRIPTION
LOCKTIGHT
LEADS
46 Generac Power Systems, Inc
Alternator - Drawing No. 0E8660-C
ROTOR REPLACEMENT PARTS
ROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD
STR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD
CONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER
48 Generac Power Systems, Inc
SCREW HHC M8-1.25 X 60 G8.8 FT
SECURE WIRE HARNESS
ITEM 13 NEOPRENE
COATING
WITH TIE WRAP AS SHOWN
50 Generac Power Systems, Inc
1024
SUPPORT,RADIATOR 2.5L FORD
HOSE, UPPER RADIATOR 174MM
Section 9 - Installation Diagram
Installation Diagram - Drawing No. 0F1020-A
YOUR WARRANTY RIGHTS AND OBLIGATIONS
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
EMISSION CONTROL SYSTEM WARRANTY
EMISSION RELATED PARTS INCLUDE THE FOLLOWING
GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN
WARRANTY SCHEDULE
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING
GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI