Generac Power Systems 005054-0, 005053-1, 005053-0, 005054-1 Emission Control System Warranty

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EMISSION CONTROL SYSTEM WARRANTY

Section 10 – Warranty

Guardian Liquid-cooled 25 kW Generator

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:

(a)Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con- tinue for 24 consecutive months thereafter.

(b)General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to each subsequent purchaser/owner that each of its engines is ...

(1)Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and

(2)Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war- ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man- ufacturer’s application for certification.

(c)The ECS Warranty only pertains to emissions-related parts on your engine, as follows:

(1)Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2)Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3)Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection

(4)below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

(4)Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Dealer.

(5)When the engine is inspected by a Generac Authorized Warranty Service Dealer, the owner shall not be held responsi- ble for diagnostic costs if the repair is deemed warrantable.

(6)Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.

(7)Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts.

(8)Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac ECS Warranty obligations.

(9)Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

3)

Ignition System including:

1.2) LPG/Natural Gas carburetion assembly and its internal

 

a) Spark plug

components.

 

b) Ignition module

a) Fuel controller (if so equipped)

4)

Catalytic Muffler Assembly (if so equipped) including:

b) Mixer and its gaskets (if so equipped)

 

a) Muffler gasket

c) Carburetor and its gaskets (if so equipped)

 

b) Exhaust manifold

d) Primary gas regulator (if so equipped)

5)

Crankcase Breather Assembly including:

 

e) LP liquid vaporizer (if so equipped)

a) Breather connection tube

2) Air Induction System including:

 

a) Intake pipe/manifold

 

b) Air cleaner

 

*Generac engine types covered by this warranty statement include the following:

1)Prepackaged Standby Generator

2)Auxiliary Power Unit (APU) Generator

3)Standby Generator

Part 2

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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