Generac Power Systems 005053-0, 005053-1 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.

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Contents Liquid-cooled, Prepackaged Standby Generators SHOULD ATTEMPT INSTALLATIONOwner’s Manual This manual should remain with the unit‹ HOW TO OBTAIN SERVICE AUTHORIZED SERVICE DEALER LOCATION‹ OPERATION AND MAINTENANCE INTRODUCTIONTable of Contents Guardian Liquid-cooled 25 kW GeneratorParts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator during operation. Exercise care near running gen- eratorsEXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS ‹ STANDARDS INDEX1.3 AUTOMATIC SYSTEM OPERATION 1.2 TRANSFER SWITCH1.1 GENERATOR 1.4 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 Figure 1.4 - Low Oil Pressure Switch‹ 1.8.1 UNPACKING PRECAUTIONS 1.10 SPECIFICATIONS‹ 1.7.6 LOW BATTERY 1.8 UNPACKING1.11 FUEL CONSUMPTION 1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 - Reconfigure the Fuel System ‹ 1.10.2 GENERATOR1.13 ENGINE OIL RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1 STANDBY GENERATOR INSTALLATION 1.14 COOLANT RECOMMENDATIONS2.2 GENERATOR LOCATION 2.3 GENERATOR MOUNTING AND SUPPORT2.4 BASIC STANDBY ELECTRIC SYSTEM ‹ 2.1.2 OTHER PUBLISHED STANDARDS2.6 TOTAL CIRCUIT ISOLATION METHOD 2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5 EMERGENCY CIRCUIT ISOLATION METHOD 2.7 GROUNDING THE GENERATOR‹ 2.10.1 VENTED BATTERIES 2.10 BATTERY INSTALLATIONPos2 OFF - Standard Prepackaged ATS Application Standby generators installed with automatic2.11 PREPARATION BEFORE START-UP 3.1 ENGINEERED GTS TRANSFER SWITCH‹ 2.11.2 TRANSFER SWITCH ‹ 2.11.1 PRIOR TO INITIAL START-UP‹ 3.2.5 SET EXERCISE TIME SWITCH ‹ 3.2.2 FAULT INDICATOR LEDS‹ 3.2.1 AUTO/OFF/MANUAL SWITCH 3.2 CONTROL CONSOLE COMPONENTS‹ 3.2.6 SYSTEM READY LED 3.4 ENGINE GOVERNOR ADJUSTMENTS3.3 MANUAL TRANSFER AND START-UP 3.6 AUTOMATIC OPERATION Figure 3.2 - Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.7 WEEKLY EXERCISE CYCLEA. EVERY THREE MONTHS 3.8 CONTROL BOARD DIP SWITCH SETTINGS4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES B. ONCE EVERY SIX MONTHS4.4 CYLINDER HEAD PROCEDURE 4.2 EXHAUST MANIFOLD PROCEDURE4.3 INTAKE MANIFOLD PROCEDURE Figure 4.1 - Intake Manifold Installation4.7 CHECKING FLUID LEVELS 4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM ‹ 4.8.8 CHECK FAN BELT ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 - Setting the Spark Plug Gap ‹ 4.8.9 INSPECT ENGINE GOVERNOR‹ 4.9.2 BATTERY 4.9 MISCELLANEOUS MAINTENANCE‹ 4.9.1 CLEANING THE GENERATOR ‹ 4.9.3 BATTERY MAINTENANCETurn off the battery charger turn OFF utility supply to ATS 4.10 SCHEDULED MAINTENANCEService Maintenance Interval Information Remove the negative battery cableTasks MaintenanceLevel Maintenance CAUSE TROUBLESHOOTING POINTSPROBLEM CORRECTIONGenerac Power Systems, Inc Section 7 - Electrical Data Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F141126 Generac Power Systems, Inc 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, IncGenerac Power Systems, Inc Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-B 32 Generac Power Systems, IncGenerac Power Systems, Inc MOUNT HARNESS WIRE34 Generac Power Systems, Inc BLOCK ENGINEDESCRIPTION COVER CABLE PANEL FOR ACCESSGROUND WIRE FASTENER TO SECUREEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc Section 8 - Exploded Views and Parts STEPPER MOTOR UNITS ONLY 42 Generac Power Systems, IncGuardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-E TO RADIATORSERPENTINE BELT - 41 3/8 LENGTH SOURCE GENERAC-BOSCH GOVGASKET, 2.5L FORD EXHAUST MAN BRKT,D.C. ALTERNATORMACHINEDCOVER 0E1028A I/NTO ENGINE 44 Generac Power Systems, IncGuardian Liquid-cooled 25 kW Generator 46 Generac Power Systems, Inc LOCKTIGHTLEADS Alternator - Drawing No. 0E8660-CSTR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD ROTOR REPLACEMENT PARTSROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD CONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER48 Generac Power Systems, Inc SCREW HHC M8-1.25 X 60 G8.8 FTCOATING SECURE WIRE HARNESSITEM 13 NEOPRENE WITH TIE WRAP AS SHOWNSUPPORT,RADIATOR 2.5L FORD 50 Generac Power Systems, Inc1024 HOSE, UPPER RADIATOR 174MMSection 9 - Installation Diagram Installation Diagram - Drawing No. 0F1020-APURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANWARRANTY SCHEDULE GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI