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Generac 005030-0, 005028-0, 005031-0 Notes, Liquid-cooled 15, 20 and 25 kW Generators

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

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Section 6 — Notes

Liquid-cooled 15, 20 and 25 kW Generators

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Generac 005030-0, 005028-0, 005031-0 owner manual Notes, Liquid-cooled 15, 20 and 25 kW Generators

Contents

Liquid-cooled, Prepackaged Standby Generators SHOULD ATTEMPT INSTALLATIONOwner’s Manual Model Number 005030-0 15kW 005028-0 20kW 005031-0 25kW‹ HOW TO OBTAIN SERVICE AUTHORIZED SERVICE DEALER LOCATION‹ OPERATION AND MAINTENANCE INTRODUCTIONTable of Contents Liquid-cooled 15, 20 and 25 kW GeneratorsDespite the safe design of this generator GENERAL HAZARDSDANGER Parts of the generator are rotating and/or hotEXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS ‹ STANDARDS INDEX1.4 ENGINEERED TRANSFER SWITCH 2-WIRE START GTS MODE 1.2 TRANSFER SWITCH1.3 AUTOMATIC TRANSFER SWITCH ATS MODE 1.1 GENERATORFigure 1.4 - Low Oil Pressure Switch ‹ 1.8.1 LOW OIL PRESSURE SWITCH‹ 1.8.2 HIGH COOLANT TEMPERATURE SWITCH 1.6 MAIN CIRCUIT BREAKER‹ 1.9.1 UNPACKING PRECAUTIONS ‹ 1.8.6 LOW BATTERY‹ 1.8.3 LOW COOLANT LEVEL SWITCH Figure 1.5- High Coolant Temperature Switch1.12 FUEL CONSUMPTION 1.11 SPECIFICATIONS1.13 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR ‹ 1.11.1 ENGINE1.15 COOLANT RECOMMENDATIONS 1.16 BEFORE INSTALLATIONFigure 1.8 - Reconfigure the Fuel System 1.14 ENGINE OIL RECOMMENDATIONS2.3 GENERATOR MOUNTING AND SUPPORT 2.1 STANDBY GENERATOR INSTALLATION2.2 GENERATOR LOCATION ‹ 2.1.1 NFPA STANDARDS2.7 GROUNDING THE GENERATOR 2.4 BASIC STANDBY ELECTRIC SYSTEM2.6 TOTAL CIRCUIT ISOLATION METHOD 2.5 EMERGENCY CIRCUIT ISOLATION METHOD2.8 GENERATOR AC NEUTRAL CONNECTIONS 2.9 AUTOMATIC TRANSFER SWITCH ATS MODEFigure 2.3 - Connection Diagram ATS Mode If generator wires 23 and 194 are not wired toMAXIMUM WIRE LENGTH 2.10 ENGINEERED TRANSFER SWITCH 2-WIRE START GTS MODEFigure 2.4 - Connection Diagram GTS Mode RECOMMENDED WIREDO NOT SMOKE when near batteries 2.11 BATTERY INSTALLATION‹ 2.11.1 VENTED BATTERIES DO NOT cause flame or spark in battery area, and‹ 2.12.1 PRIOR TO INITIAL START-UP ‹ 2.12.2 TRANSFER SWITCH2.12 PREPARATION BEFORE START-UP ‹ 2.12.3 FUEL SYSTEM‹ 3.1.5 SET EXERCISE TIME SWITCH ‹ 3.1.1 AUTO/OFF/MANUAL SWITCH‹ 3.1.2 FAULT INDICATOR LEDS 3.1 CONTROL CONSOLE COMPONENTS3.3 ENGINE GOVERNOR GAIN ADJUSTMENTS Figure 3.2 - Control Board Dip Switch Location3.5 AUTOMATIC OPERATION Figure 3.3 - “Set Exercise Time” Switch3.4 MANUAL RETRANSFER AND SHUTDOWN 3.6 WEEKLY EXERCISE CYCLEFigure 3.4 - Voltage Regulator 3.7 CONTROL BOARD DIP SWITCH SETTINGS3.8 VOLTAGE REGULATOR ADJUSTMENT If the DIP switch settings are not set correctly4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES 4.2 EXHAUST MANIFOLD PROCEDURE4.3 INTAKE MANIFOLD PROCEDURE Figure 4.1 - Intake Manifold Installation4.5 COOLING SYSTEM 4.4 CYLINDER HEAD PROCEDUREFigure 4.2 - Cylinder Head Installation 4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM DANGER‹ 4.9.1 CLEANING THE GENERATOR 4.9 MISCELLANEOUS MAINTENANCE‹ 4.8.11 CHANGING THE ENGINE AIR CLEANER ‹ 4.9.2 BATTERYPERIODIC REPLACEMENT PARTS ‹ 4.9.3 BATTERY MAINTENANCE‹ 4.9.4 BATTERY REPLACEMENT DANGERTurn off the battery charger turn OFF utility supply to ATS 4.10 SCHEDULED MAINTENANCEService Maintenance Interval Information Remove the negative battery cableTasks MaintenanceLevel LevelLevel MaintenanceLevel LevelCAUSE TROUBLESHOOTING POINTSPROBLEM CORRECTIONSection 6 - Notes Liquid-cooled 15, 20 and 25 kW GeneratorsSection 6 - Notes Liquid-cooled 15, 20 and 25 kW GeneratorsWiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F2183-B Section 7 - Electrical DataLiquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical Data Section 7 - Electrical Data Liquid-cooled 15, 20 and 25 kW GeneratorsSection 7 - Electrical Data Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0F1286-B Section 7 - Electrical DataLiquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical Data Electrical Schematic - 2.5L 25kW unit - Drawing No. 0F1287-B Section 7 - Electrical DataLiquid-cooled 15, 20 and 25 kW Generators Section 7 - Electrical Data Section 8 - Exploded Views and Parts Lists DESCRIPTION 2-PLCS Section 8 - Exploded Views and Parts ListsTO B Liquid-cooled 15Liquid-cooled 15, 20 and 25 kW Generators Section 8 - Exploded Views and Parts ListsDESCRIPTION Enclosure - Drawing No. 0F1645-HSection 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW GeneratorsControl Panel 15kW and 20kW - Drawing No. 0F2267-D Liquid-cooled 15, 20 and 25 kW Generators Section 8 - Exploded Views and Parts ListsDESCRIPTION Control Panel 15kW and 20kW - Drawing No. 0F2267-DSection 8 - Exploded Views and Parts Lists Liquid-cooled 15, 20 and 25 kW GeneratorsControl Panel 25kW - Drawing No. 0E7615-C Liquid-cooled 15, 20 and 25 kW Generators Section 8 - Exploded Views and Parts ListsDESCRIPTION Control Panel 25kW - Drawing No. 0E7615-CSTEPPER Section 8 - Exploded Views and Parts Lists13 17 ONLYDESCRIPTION DESCRIPTIONHEAT SHIELD, EXHAUST MANIFOLD COVER 0E1028A I/NTO ENGINE Section 8 - Exploded Views and Parts ListsLiquid-cooled 15, 20 and 25 kW Generators Section 8 - Exploded Views and Parts ListsDESCRIPTION Fuel System - Drawing No. 0E9980-DSection 8 - Exploded Views and Parts Lists LOCKTIGHTLEADS LOCKTIGHTROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORD ROTOR REPLACEMENT PARTSDESCRIPTION STR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORDDESCRIPTION DESCRIPTIONSCREW HHC M8-1.25 X 60 G8.8 FT ITEM 13 NEOPRENE SECURE WIRE HARNESSDESCRIPTION COATINGTO THERMOSTAT DESCRIPTIONDESCRIPTION ADAPTERSection 9 - Installation Diagram Installation Diagram - Drawing No. 0F1022-ALiquid-cooled 15, 20 and 25 kW Generators PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGSection 10 - Warranty THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING