Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 owner manual

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1.5MAIN CIRCUIT BREAKER

Section 1 - General Information

Guardian Liquid-cooled 25 kW Generator

1.5MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included with the unit as shipped from the factory. The breaker for each unit is described in Figure 1.2.

1.6GENERATOR FUEL SYSTEM

This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is pre- ferred, refer to Section 1.12, Reconfiguring the Fuel System for LP Vapor.

Fuel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

A seperate gas line and regulator may be needed to assure proper gas pressure to the generator. Improper gas pressure can cause hard starting and affect engine durability.

Gaseous fuels such as natural and LP

!(propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.

1.7ENGINE PROTECTIVE DEVICES

The engine has several safety switches which cause the engine to automatically shut down under the fol- lowing conditions: low oil pressure, high coolant tem- perature, engine overspeed, low coolant level or over- crank (Figure 1.3).

Figure 1.3 - Engine Protective Devices

‹1.7.1 LOW OIL PRESSURE SWITCH

This switch is normally-closed (N.C.) but is held open by engine oil pressure during engine running. Should operating oil pressure drop below about 8-10 psi (55-68 kPa), the switch contacts close and the engine shuts down automatically (Figure 1.4).

Figure 1.4 - Low Oil Pressure Switch

‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH

Normally open (N.O.) thermostatic switch has sens- ing tip which is immersed in captive coolant. Should coolant temperature exceed about 230°F (110°C), the switch contacts close, which causes the engine to shut down automatically (Figure 1.5).

Figure 1.5- High Coolant Temperature Switch

‹1.7.3 LOW COOLANT LEVEL SWITCH

Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating without automatic shut down, the engine has a low coolant level sensor. If the engine coolant drops too low, the engine automatical- ly shuts down (Figure 1.6 on page 6).

Generac® Power Systems, Inc. 5

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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 SERVICEINTRODUCTION Table of ContentsDespite the safe design of this generator GENERAL HAZARDSParts of the generator are rotating and/or hot ‹STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.4GENERATOR AC CONNECTION SYSTEMS 1.2TRANSFER SWITCH1.1GENERATOR 1.3AUTOMATIC 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 SWITCH1.8UNPACKING 1.10 SPECIFICATIONS‹1.7.6 LOW BATTERY ‹1.8.1 UNPACKING PRECAUTIONS‹ 1.10.2 GENERATOR 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPORFigure 1.8 — Reconfigure the Fuel System 1.11 FUEL CONSUMPTION1.14 COOLANT RECOMMENDATIONS 1.15 BEFORE INSTALLATION2.1STANDBY GENERATOR INSTALLATION 1.13 ENGINE OIL RECOMMENDATIONS‹2.1.2 OTHER PUBLISHED STANDARDS 2.3GENERATOR MOUNTING AND SUPPORT2.4BASIC STANDBY ELECTRIC SYSTEM 2.2GENERATOR LOCATION2.7GROUNDING THE GENERATOR 2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.6TOTAL CIRCUIT ISOLATION METHODStandby generators installed with automatic 2.10BATTERY INSTALLATIONPos2 OFF — Standard Prepackaged ATS Application ‹2.10.1 VENTED BATTERIES‹2.11.1 PRIOR TO INITIAL START-UP 3.1ENGINEERED GTS TRANSFER SWITCH‹2.11.2 TRANSFER SWITCH 2.11 PREPARATION BEFORE START-UP3.2CONTROL CONSOLE COMPONENTS ‹3.2.2 FAULT INDICATOR LEDS‹3.2.1 AUTO/OFF/MANUAL SWITCH ‹3.2.5 SET EXERCISE TIME SWITCH3.3MANUAL TRANSFER AND START-UP 3.4ENGINE GOVERNOR ADJUSTMENTS‹3.2.6 SYSTEM READY LED 3.7WEEKLY EXERCISE CYCLE Figure 3.2 — Engine Governor AdjustmentFigure 3.3 - “Set Exercise Time” Switch 3.6AUTOMATIC OPERATIONC. ONCE ANNUALLY 3.8CONTROL BOARD DIP SWITCH SETTINGSA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHSFigure 4.1 — Intake Manifold Installation 4.2EXHAUST MANIFOLD PROCEDURE4.3INTAKE MANIFOLD PROCEDURE 4.4CYLINDER HEAD PROCEDURE4.7CHECKING FLUID LEVELS 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.6OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM‹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 4.9MISCELLANEOUS MAINTENANCE‹4.9.1 CLEANING THE GENERATOR ‹4.9.2 BATTERYService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCELevel MaintenanceTasks Maintenance CORRECTION TROUBLESHOOTING POINTSPROBLEM CAUSESection 6 — Notes Section 7 - Electrical Data 26 Generac Power Systems, IncSection 7 - Electrical Data 28 Generac Power Systems, Inc Section 7 - Electrical Data 30 Generac Power Systems, Inc Section 7 - Electrical Data 32 Generac Power Systems, Inc Section 7 - Electrical Data MOUNT PART NO ITEMDESCRIPTION 31 7 11 Enclosure — Drawing No. 0E9720-D 54 36 30 0C2267 40 Generac Power Systems, Inc 0C2267 Engine — Drawing No. 0E9918-E 42 Generac Power Systems, Inc0E9909 0E1028A I/N 0E8456 LOCKTIGHT 0F1659A Muffler — Drawing No. 0F2930-B Stepper Motor — Drawing No. 0E9979-C Radiator — Drawing No. 0E9965-D Installation Diagram — Drawing No. 0F1020-A Section 9 — Installation DiagramCALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES 1-800-333-1322EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYP.O. BOX 297 • WHITEWATER, WI WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC