Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 1.8UNPACKING

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Figure 1.6 - Low Coolant Level Sensor

Section 1 — General Information

Guardian Liquid-cooled 25 kW Generator

Figure 1.6 - Low Coolant Level Sensor

‹ 1.8.2 INSPECTION

‹1.7.4 OVERSPEED SHUTDOWN

Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine.

‹1.7.5 OVERCRANK SHUTDOWN

The engine control board uses a cyclic cranking process when attempting to start the engine. The first crank cycle is a 15-second crank followed by a seven- second rest. This is followed by five more crank cycles each with a seven second crank followed by a seven-second rest.

If the engine fails to start after all six attempts, the start attempt is stopped and the overcrank LED turns on.

‹1.7.6 LOW BATTERY

The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 12 VDC for one minute. Low battery voltage is a non-latching alarm, which will automatically clear if the battery voltage rises above 12 VDC.

‹1.7.7 15A DC FUSE

This fuse is located inside the control panel. It pro- tects the panel wiring and components from damag- ing overload. The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating.

1.8UNPACKING

‹1.8.1 UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, colli- sion, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton.

Upon delivery, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consign- or’s memo of loss or damage.

1.9LIFTING THE GENERATOR

When lifting or hoisting equipment is used,

!be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.

1.10 SPECIFICATIONS

‹ 1.10.1 ENGINE

Make

 

Ford

Displacement

153 inches3 (2.5 liters)

Cylinder Arrangement

 

4, in-line

Valve Arrangement

Overhead Cam

Firing Order

1-3-4-2

Number of Main Bearings

5

Compression Ratio

 

9.37 to 1

No. of Teeth on Flywheel

164

Ignition Timing (Waste Spark System)

at 1800 rpm

36 degrees BTDC

Spark Plug Gap

 

0.044 inch

Recommended Spark Plugs

 

 

 

Motorcraft

 

AWSF-52-C

Oil Pressure

 

30-50 psi

Crankcase Oil Capacity

4.5 U.S. quarts (4.26 liters)

Recommended Engine Oil

SAE 15W-40

Type of Cooling System

Pressurized, closed recovery

Cooling Fan

 

Pusher Type

Cooling System Capacity

2 U.S. gallons (7.6 liters)

Recommended Coolant

Use a 50-50 mixture of ethylene

 

 

 

glycol base and deionized water.

 

 

 

 

 

 

Home standby control board assembly part

!number 0E9704 must be used on 1800 rpm gen- erators.

6 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 INTRODUCTIONParts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator 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 COMPONENTS‹3.2.6 SYSTEM READY LED 3.4ENGINE GOVERNOR ADJUSTMENTS3.3MANUAL TRANSFER AND START-UP 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 InformationTasks MaintenanceLevel 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 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-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