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Generac 005030-0, 005028-0, 005031-0 owner manual Owner’s Manual, Should Attempt Installation

Models: 005028-0 005030-0, 005028-0, 005031-0

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Owner’s Manual

Liquid-cooled, Prepackaged

Standby Generators

Model Number 005030-0 (15kW) 005028-0 (20kW) 005031-0 (25kW)

This manual should remain with the unit.

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

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Generac 005030-0, 005028-0, 005031-0 owner manual Owner’s Manual, Liquid-cooled, Prepackaged Standby Generators

Contents

Owner’s Manual SHOULD ATTEMPT INSTALLATIONLiquid-cooled, Prepackaged Standby Generators Model Number 005030-0 15kW 005028-0 20kW 005031-0 25kW‹ OPERATION AND MAINTENANCE AUTHORIZED SERVICE DEALER LOCATION‹ HOW TO OBTAIN SERVICE INTRODUCTIONLiquid-cooled 15, 20 and 25 kW Generators Table of ContentsDANGER GENERAL HAZARDSDespite the safe design of this generator Parts of the generator are rotating and/or hotFIRE HAZARDS ELECTRICAL HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.3 AUTOMATIC TRANSFER SWITCH ATS MODE 1.2 TRANSFER SWITCH1.4 ENGINEERED TRANSFER SWITCH 2-WIRE START GTS MODE 1.1 GENERATOR‹ 1.8.2 HIGH COOLANT TEMPERATURE SWITCH ‹ 1.8.1 LOW OIL PRESSURE SWITCHFigure 1.4 - Low Oil Pressure Switch 1.6 MAIN CIRCUIT BREAKER‹ 1.8.3 LOW COOLANT LEVEL SWITCH ‹ 1.8.6 LOW BATTERY‹ 1.9.1 UNPACKING PRECAUTIONS Figure 1.5- High Coolant Temperature Switch1.13 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR 1.11 SPECIFICATIONS1.12 FUEL CONSUMPTION ‹ 1.11.1 ENGINEFigure 1.8 - Reconfigure the Fuel System 1.16 BEFORE INSTALLATION1.15 COOLANT RECOMMENDATIONS 1.14 ENGINE OIL RECOMMENDATIONS2.2 GENERATOR LOCATION 2.1 STANDBY GENERATOR INSTALLATION2.3 GENERATOR MOUNTING AND SUPPORT ‹ 2.1.1 NFPA STANDARDS2.6 TOTAL CIRCUIT ISOLATION METHOD 2.4 BASIC STANDBY ELECTRIC SYSTEM2.7 GROUNDING THE GENERATOR 2.5 EMERGENCY CIRCUIT ISOLATION METHODFigure 2.3 - Connection Diagram ATS Mode 2.9 AUTOMATIC TRANSFER SWITCH ATS MODE2.8 GENERATOR AC NEUTRAL CONNECTIONS If generator wires 23 and 194 are not wired toFigure 2.4 - Connection Diagram GTS Mode 2.10 ENGINEERED TRANSFER SWITCH 2-WIRE START GTS MODEMAXIMUM WIRE LENGTH RECOMMENDED WIRE‹ 2.11.1 VENTED BATTERIES 2.11 BATTERY INSTALLATIONDO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area, and2.12 PREPARATION BEFORE START-UP ‹ 2.12.2 TRANSFER SWITCH‹ 2.12.1 PRIOR TO INITIAL START-UP ‹ 2.12.3 FUEL SYSTEM‹ 3.1.2 FAULT INDICATOR LEDS ‹ 3.1.1 AUTO/OFF/MANUAL SWITCH‹ 3.1.5 SET EXERCISE TIME SWITCH 3.1 CONTROL CONSOLE COMPONENTSFigure 3.2 - Control Board Dip Switch Location 3.3 ENGINE GOVERNOR GAIN ADJUSTMENTS3.4 MANUAL RETRANSFER AND SHUTDOWN Figure 3.3 - “Set Exercise Time” Switch3.5 AUTOMATIC OPERATION 3.6 WEEKLY EXERCISE CYCLE3.8 VOLTAGE REGULATOR ADJUSTMENT 3.7 CONTROL BOARD DIP SWITCH SETTINGSFigure 3.4 - Voltage Regulator If the DIP switch settings are not set correctly4.3 INTAKE MANIFOLD PROCEDURE 4.2 EXHAUST MANIFOLD PROCEDURE4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES Figure 4.1 - Intake Manifold InstallationFigure 4.2 - Cylinder Head Installation 4.4 CYLINDER HEAD PROCEDURE4.5 COOLING SYSTEM 4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEMDANGER 4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM‹ 4.8.11 CHANGING THE ENGINE AIR CLEANER 4.9 MISCELLANEOUS MAINTENANCE‹ 4.9.1 CLEANING THE GENERATOR ‹ 4.9.2 BATTERY‹ 4.9.4 BATTERY REPLACEMENT ‹ 4.9.3 BATTERY MAINTENANCEPERIODIC REPLACEMENT PARTS DANGERService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCETurn off the battery charger turn OFF utility supply to ATS Remove the negative battery cableLevel MaintenanceTasks LevelLevel MaintenanceLevel LevelPROBLEM TROUBLESHOOTING POINTSCAUSE CORRECTIONLiquid-cooled 15, 20 and 25 kW Generators Section 6 - NotesLiquid-cooled 15, 20 and 25 kW Generators Section 6 - NotesSection 7 - Electrical Data Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F2183-BLiquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical DataSection 7 - Electrical Data Section 7 - Electrical Data Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0F1286-BLiquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical Data Section 7 - Electrical Data Electrical Schematic - 2.5L 25kW unit - Drawing No. 0F1287-BLiquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical Data Section 8 - Exploded Views and Parts Lists DESCRIPTION TO B Section 8 - Exploded Views and Parts Lists2-PLCS Liquid-cooled 15DESCRIPTION Section 8 - Exploded Views and Parts ListsLiquid-cooled 15, 20 and 25 kW Generators Enclosure - Drawing No. 0F1645-HLiquid-cooled 15, 20 and 25 kW Generators Section 8 - Exploded Views and Parts ListsControl Panel 15kW and 20kW - Drawing No. 0F2267-D DESCRIPTION Section 8 - Exploded Views and Parts ListsLiquid-cooled 15, 20 and 25 kW Generators Control Panel 15kW and 20kW - Drawing No. 0F2267-DLiquid-cooled 15, 20 and 25 kW Generators Section 8 - Exploded Views and Parts ListsControl Panel 25kW - Drawing No. 0E7615-C DESCRIPTION Section 8 - Exploded Views and Parts ListsLiquid-cooled 15, 20 and 25 kW Generators Control Panel 25kW - Drawing No. 0E7615-C13 17 Section 8 - Exploded Views and Parts ListsSTEPPER ONLYDESCRIPTION DESCRIPTIONHEAT SHIELD, EXHAUST MANIFOLD TO ENGINE 0E1028A I/NCOVER Section 8 - Exploded Views and Parts ListsDESCRIPTION Section 8 - Exploded Views and Parts ListsLiquid-cooled 15, 20 and 25 kW Generators Fuel System - Drawing No. 0E9980-DLEADS LOCKTIGHTSection 8 - Exploded Views and Parts Lists LOCKTIGHTDESCRIPTION ROTOR REPLACEMENT PARTSROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD STR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORDDESCRIPTION DESCRIPTIONSCREW HHC M8-1.25 X 60 G8.8 FT DESCRIPTION SECURE WIRE HARNESSITEM 13 NEOPRENE COATINGDESCRIPTION DESCRIPTIONTO THERMOSTAT ADAPTERInstallation Diagram - Drawing No. 0F1022-A Section 9 - Installation DiagramLiquid-cooled 15, 20 and 25 kW Generators MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYSection 10 - Warranty THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING