Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 Problem, Cause

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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 INTRODUCTIONParts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator EXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS ‹STANDARDS INDEX1.3AUTOMATIC SYSTEM OPERATION 1.2TRANSFER SWITCH1.1GENERATOR 1.4GENERATOR 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 1.8UNPACKING1.11 FUEL CONSUMPTION 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 — Reconfigure the Fuel System ‹ 1.10.2 GENERATOR1.13 ENGINE OIL RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1STANDBY GENERATOR INSTALLATION 1.14 COOLANT RECOMMENDATIONS2.2GENERATOR LOCATION 2.3GENERATOR MOUNTING AND SUPPORT2.4BASIC STANDBY ELECTRIC SYSTEM ‹2.1.2 OTHER PUBLISHED STANDARDS2.6TOTAL CIRCUIT ISOLATION METHOD 2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATOR‹2.10.1 VENTED BATTERIES 2.10BATTERY INSTALLATIONPos2 OFF — Standard Prepackaged ATS Application Standby generators installed with automatic2.11 PREPARATION BEFORE START-UP 3.1ENGINEERED 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 3.2CONTROL CONSOLE COMPONENTS‹3.2.6 SYSTEM READY LED 3.4ENGINE GOVERNOR ADJUSTMENTS3.3MANUAL TRANSFER AND START-UP 3.6AUTOMATIC OPERATION Figure 3.2 — Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.7WEEKLY EXERCISE CYCLEB. ONCE EVERY SIX MONTHS 3.8CONTROL BOARD DIP SWITCH SETTINGSA. EVERY THREE MONTHS C. ONCE ANNUALLY4.4CYLINDER HEAD PROCEDURE 4.2EXHAUST MANIFOLD PROCEDURE4.3INTAKE MANIFOLD PROCEDURE Figure 4.1 — Intake Manifold InstallationENGINE DC ELECTRICAL SYSTEM 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.6OVERLOAD PROTECTION FOR 4.7CHECKING FLUID LEVELS‹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 4.9MISCELLANEOUS MAINTENANCE‹4.9.1 CLEANING THE GENERATOR ‹4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationTasks MaintenanceLevel Maintenance CAUSE TROUBLESHOOTING POINTSPROBLEM CORRECTIONSection 6 — Notes 26 Generac Power Systems, Inc Section 7 - Electrical DataGenerac Power Systems, Inc. 28 Generac Power Systems, Inc Generac Power Systems, Inc 30 Generac Power Systems, Inc Generac Power Systems, Inc. 32 Generac Power Systems, Inc Generac Power Systems, Inc. MOUNT DESCRIPTION ITEMPART NO 31 7 11 Enclosure — Drawing No. 0E9720-D 54 36 30 0C2267 40 Generac Power Systems, Inc 0C2267 42 Generac Power Systems, Inc Engine — Drawing No. 0E9918-E0E9909 0E1028A I/N 0E8456 LOCKTIGHT 0F1659A Muffler — Drawing No. 0F2930-B Stepper Motor — Drawing No. 0E9979-C Radiator — Drawing No. 0E9965-D Section 9 — Installation Diagram Installation Diagram — Drawing No. 0F1020-A1-800-333-1322 YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGGENERAC POWER SYSTEMS, INC WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING P.O. BOX 297 • WHITEWATER, WI