Generac Power Systems 005054-0, 005053-1, 005053-0, 005054-1 Description, Exploded Views and Parts

Page 43
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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 25 kW Generator Control Panel — Drawing No. 0F1378-D

ITEM

PART NO.

QTY.

DESCRIPTION

1

0C2267

16

SCREW HHTT M5-0.8 X 12 BP

2

064733

2

RES MTG BRACKET

3

0D5070A

1

ASSY 2A 12V UL BATTERY

 

 

 

CHARGER

4

0D8671

1

HINGE CONTINUOUS 1.5L CTRL PNL

5

0E4494

1

SWITCH ROC DPDT ON-OFF-ON

6

0E6875A

2

RELAY 12VDC C FORM W/DIODE

7

0E7358

4

SCREW PPPH HI-LO #4-24 X 3/8

8

0E9704

1

ASSY PCB HSB CONTROLLER 2.5L

9

0E9934

1

CTRL PNL BACK & BOTTOM 2.5L

10

0E9935

1

CTRL PNL LH SIDE 2.5L FORD

11

0E9936

1

CTRL PNL RH SIDE 2.5L FORD

12

0E9937

1

CTRL PNL TOP 2.5L FORD

13

0E9938

1

CTRL PNL FRONT 2.5L FORD

14

023897

19

WASHER FLAT #10 ZINC

15

036261

4

RIVET POP .125 X .275 AL

16

048468

1

CIRCT BRK 8 X 1 ETA 46-500-P

17

057073

1

JUNCTION BLOCK 3/8-16

18

067680

1

ASSY VOLTAGE REGULATOR 60HZ

19

082573

1

SWITCH ROC DPST 125V SPD

20

0C3910

1

TRANSFORMER 240/16V 1VA & 56VA

21

029673

1

DIO BRIDGE 25A 600V

22

034616

1

FITTING STRAIGHT 3/4

23

0E2514

1

FITTING CONDUIT STR 1-1/2"

24

0F0581

1

BRACKET FUSE HOLDER 2.5L FORD

25

040213

2

PCB SUPPORT SNAP-IN 1/4"

26

0F0558

1

BRACKET PCB SUPPORT 2.5L FORD

27

0F0598

1

DECAL FUSES 2.5L CNTRL PANEL

28

0F0599

1

DECAL TB1 2.5L CONTROL PANEL

29

0F0600

1

DECAL ICT 2.5L CONTROL PANEL

30

054199

1

DECAL DANGER HIGH VOLTAGE

31

049813

1

NUT HEX M6 X 1.0 G8 YEL CHR

32

0F0653

1

DECAL CONTROL HSB 2.5L FORD

33

022097

3

WASHER LOCK M6-1/4

34

0C2212

9

SCREW PHTT M4-0.7 X 16 ZYC

ITEM

PART NO.

QTY.

DESCRIPTION

35

022264

22

WASHER LOCK #8-M4

36

0C2265

13

SCREW PHTT M4-0.7 X 12 ZYC

37

023965

2

SCREW RHM #8-32 X 3/8

38

039782

1

BRKT MTG CB BQ

39

0D5544

1

CB 0100A 2P 240V S BQ2 LL (20KW)

 

0D5541

1

CB 0070A 2P 240V S BQ2 LL (15KW)

40

020911

2

SCREW PPHM M5-0.8 X 30 ZINC

41

0A8955

2

SCREW PHM M6-1.0 X 20MM

42

022152

3

WASHER LOCK #10

43

051716

2

NUT HEX M5-0.8 G8 YEL CHR

44

023762

1

WASHER SHAKEPROOF EXT #10

 

 

 

STL

45

033121

1

SCREW HHC #10-32 X 1/2

46

026850

1

WASHER SHAKEPROOF EXT 1/4

 

 

 

STL

47

0912970087

1

ASSY WIRE 14AWG 16" #0 GRN/YEL

48

022158

1

NUT HEX #10-32 STEEL

49

0E7403C

1

FUSE ATO TYPE 15 AMP (BLUE)

50

0E7403A

1

FUSE ATO TYPE 5 AMP (TAN)

51

0F0526A

1

HARN CTRL PNL 2.5L FD (NOT

 

 

 

SHOWN)

52

0A2115

2

WASHER NYLON .257

53

022473

2

WASHER FLAT 1/4-M6 ZINC

54

048352

1

RES 5R 5% 25W

55 *

046357

REF

BLOCK TERM 20A 6 X 6 X 1100V

56 *

047822

REF

BLOCK TERM 20A 7 X 6 X 1100V

57 *

0F1467

REF

ASSY WIRE FUSE HOLDER

58 *

0E6881

REF

SOCKET RELAY

59 **

049226

2

WASHER LOCK M5

60 **

051716

2

NUT HEX M5-0.8 G8 YEL CHR

61 **

052619

2

SCREW HHC M5-0.8 X 20 G8.8

62 **

023897

4

WASHER FLAT #10 ZINC

*PART OF I/N 51, P/N 0F0526A CONTROL PANEL HARNESS.

**NOT SHOWN. HARDWARE FOR ATTACHING WIRES TO I/N 39.

Generac® Power Systems, Inc. 41

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Contents This manual should remain with the unit SHOULD ATTEMPT INSTALLATIONOwner’s Manual Liquid-cooled, Prepackaged Standby GeneratorsINTRODUCTION AUTHORIZED SERVICE DEALER LOCATION‹ OPERATION AND MAINTENANCE ‹ HOW TO OBTAIN SERVICEGuardian Liquid-cooled 25 kW Generator Table of Contentsduring operation. Exercise care near running gen- erators GENERAL HAZARDSDespite the safe design of this generator Parts of the generator are rotating and/or hot‹ STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.4 GENERATOR AC CONNECTION SYSTEMS 1.2 TRANSFER SWITCH1.1 GENERATOR 1.3 AUTOMATIC SYSTEM OPERATIONFigure 1.4 - Low Oil Pressure Switch ‹ 1.7.1 LOW OIL PRESSURE SWITCH‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹ 1.7.3 LOW COOLANT LEVEL SWITCH1.8 UNPACKING 1.10 SPECIFICATIONS‹ 1.7.6 LOW BATTERY ‹ 1.8.1 UNPACKING PRECAUTIONS‹ 1.10.2 GENERATOR 1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 - Reconfigure the Fuel System 1.11 FUEL CONSUMPTION1.14 COOLANT RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1 STANDBY GENERATOR INSTALLATION 1.13 ENGINE OIL RECOMMENDATIONS‹ 2.1.2 OTHER PUBLISHED STANDARDS 2.3 GENERATOR MOUNTING AND SUPPORT2.4 BASIC STANDBY ELECTRIC SYSTEM 2.2 GENERATOR LOCATION2.7 GROUNDING THE GENERATOR 2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5 EMERGENCY CIRCUIT ISOLATION METHOD 2.6 TOTAL CIRCUIT ISOLATION METHODStandby generators installed with automatic 2.10 BATTERY INSTALLATIONPos2 OFF - Standard Prepackaged ATS Application ‹ 2.10.1 VENTED BATTERIES‹ 2.11.1 PRIOR TO INITIAL START-UP 3.1 ENGINEERED GTS TRANSFER SWITCH‹ 2.11.2 TRANSFER SWITCH 2.11 PREPARATION BEFORE START-UP3.2 CONTROL CONSOLE COMPONENTS ‹ 3.2.2 FAULT INDICATOR LEDS‹ 3.2.1 AUTO/OFF/MANUAL SWITCH ‹ 3.2.5 SET EXERCISE TIME SWITCH3.3 MANUAL TRANSFER AND START-UP 3.4 ENGINE GOVERNOR ADJUSTMENTS‹ 3.2.6 SYSTEM READY LED 3.7 WEEKLY EXERCISE CYCLE Figure 3.2 - Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.6 AUTOMATIC OPERATIONB. ONCE EVERY SIX MONTHS 3.8 CONTROL BOARD DIP SWITCH SETTINGS4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A. EVERY THREE MONTHSFigure 4.1 - Intake Manifold Installation 4.2 EXHAUST MANIFOLD PROCEDURE4.3 INTAKE MANIFOLD PROCEDURE 4.4 CYLINDER HEAD PROCEDURE4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM 4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.7 CHECKING FLUID LEVELS ‹ 4.8.9 INSPECT ENGINE GOVERNOR ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANERFigure 4.4 - Setting the Spark Plug Gap ‹ 4.8.8 CHECK FAN BELT‹ 4.9.3 BATTERY MAINTENANCE 4.9 MISCELLANEOUS MAINTENANCE‹ 4.9.1 CLEANING THE GENERATOR ‹ 4.9.2 BATTERYRemove the negative battery cable 4.10 SCHEDULED MAINTENANCEService Maintenance Interval Information Turn off the battery charger turn OFF utility supply to ATSLevel MaintenanceTasks Maintenance CORRECTION TROUBLESHOOTING POINTSPROBLEM CAUSEGuardian Liquid-cooled 25 kW Generator 26 Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F1411Section 7 - Electrical Data Section 7 - Electrical Data 28 Generac Power Systems, Inc Section 7 - Electrical Data 30 Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0E9982-BSection 7 - Electrical Data 32 Generac Power Systems, Inc Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-BSection 7 - Electrical Data BLOCK ENGINE HARNESS WIRE34 Generac Power Systems, Inc MOUNTDESCRIPTION FASTENER TO SECURE PANEL FOR ACCESSGROUND WIRE COVER CABLEEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc DESCRIPTION TO RADIATOR 42 Generac Power Systems, IncGuardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-E STEPPER MOTOR UNITS ONLYBRKT,D.C. ALTERNATORMACHINED SOURCE GENERAC-BOSCH GOVGASKET, 2.5L FORD EXHAUST MAN SERPENTINE BELT - 41 3/8 LENGTH44 Generac Power Systems, Inc 0E1028A I/NTO ENGINE COVERFuel System - Drawing No. 0E9980-D Alternator - Drawing No. 0E8660-C LOCKTIGHTLEADS 46 Generac Power Systems, IncCONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER ROTOR REPLACEMENT PARTSROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD STR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORDSCREW HHC M8-1.25 X 60 G8.8 FT 48 Generac Power Systems, IncWITH TIE WRAP AS SHOWN SECURE WIRE HARNESSITEM 13 NEOPRENE COATINGHOSE, UPPER RADIATOR 174MM 50 Generac Power Systems, Inc1024 SUPPORT,RADIATOR 2.5L FORDInstallation Diagram - Drawing No. 0F1020-A Section 9 - Installation DiagramCALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYGENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING
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