Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 General Hazards

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! GENERAL HAZARDS !

Important Safety Instructions

Guardian Liquid-cooled 25 kW Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

!operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be

!followed during installation and maintenance of the generator and batteries.

!

!

!WARNING: !

The engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

!

WARNING:

!

 

 

 

This product contains or emits chemicals

 

 

known to the state of California to cause

 

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The gen- erator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fun- damental rules or precautions.

! GENERAL HAZARDS !

For safety reasons, Generac recommends that this equip- ment be installed, serviced and repaired by a Generac Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regu- lations.

Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed, operated and serv- iced in accordance with the manufacturer’s instructions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regula- tions.

Generac cannot anticipate every possible circumstance that might involve a hazard. The warnings in this man- ual, and on tags and decals affixed to the unit are, there- fore, not all-inclusive. If using a procedure, work method or operating technique that Generac does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operat- ing technique chosen does not render the generator unsafe.

Despite the safe design of this generator,Parts of the generator are rotating and/or hot DANGER

Despite the safe design of this generator,

! operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or main- tain this equipment.

Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot

! during operation. Exercise care near running gen- erators.

The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the instal- lation or permit even partial blockage of ventilation provi- sions, as this can seriously affect safe operation of the gen- erator.

Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.

When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only fac- tory-approved parts.

Before performing any maintenance on the generator, dis- connect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

2 Generac® Power Systems, Inc.

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Contents SHOULD ATTEMPT INSTALLATION Owner’s ManualLiquid-cooled,Prepackaged Standby Generators This manual should remain with the unitAUTHORIZED SERVICE DEALER LOCATION ‹OPERATION AND MAINTENANCE‹HOW TO OBTAIN SERVICE INTRODUCTIONTable of Contents INTRODUCTIONDespite the safe design of this generator GENERAL HAZARDSParts of the generator are rotating and/or hot ELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹STANDARDS INDEX1.2TRANSFER SWITCH 1.1GENERATOR1.3AUTOMATIC SYSTEM OPERATION 1.4GENERATOR 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 Switch1.10 SPECIFICATIONS ‹1.7.6 LOW BATTERY‹1.8.1 UNPACKING PRECAUTIONS 1.8UNPACKING1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR Figure 1.8 — Reconfigure the Fuel System1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR1.15 BEFORE INSTALLATION 2.1STANDBY GENERATOR INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.3GENERATOR MOUNTING AND SUPPORT 2.4BASIC STANDBY ELECTRIC SYSTEM2.2GENERATOR LOCATION ‹2.1.2 OTHER PUBLISHED STANDARDS2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH 2.5EMERGENCY CIRCUIT ISOLATION METHOD2.6TOTAL CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATOR2.10BATTERY INSTALLATION Pos2 OFF — Standard Prepackaged ATS Application‹2.10.1 VENTED BATTERIES Standby generators installed with automatic3.1ENGINEERED GTS TRANSFER SWITCH ‹2.11.2 TRANSFER SWITCH2.11 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 3.2CONTROL CONSOLE COMPONENTS3.3MANUAL TRANSFER AND START-UP 3.4ENGINE GOVERNOR ADJUSTMENTS‹3.2.6 SYSTEM READY LED Figure 3.2 — Engine Governor Adjustment Figure 3.3 - “Set Exercise Time” Switch3.6AUTOMATIC OPERATION 3.7WEEKLY EXERCISE CYCLE3.8CONTROL BOARD DIP SWITCH SETTINGS A. EVERY THREE MONTHSB. ONCE EVERY SIX MONTHS C. ONCE ANNUALLY4.2EXHAUST MANIFOLD PROCEDURE 4.3INTAKE MANIFOLD PROCEDURE4.4CYLINDER HEAD PROCEDURE Figure 4.1 — Intake Manifold Installation4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM 4.6OVERLOAD PROTECTION FORENGINE DC ELECTRICAL SYSTEM 4.7CHECKING 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 GOVERNOR4.9MISCELLANEOUS MAINTENANCE ‹4.9.1 CLEANING THE GENERATOR‹4.9.2 BATTERY ‹4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationLevel MaintenanceTasks Maintenance TROUBLESHOOTING POINTS PROBLEMCAUSE 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 PART NO ITEMDESCRIPTION 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-AYOUR WARRANTY RIGHTS AND OBLIGATIONS PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES1-800-333-1322 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWINGGENERAC POWER SYSTEMS, INC P.O. BOX 297 • WHITEWATER, WI