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Generac Power Systems 005031-2 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! This manual should remain with the unit. Liquid-cooled, Prepac kaged Standb y Generator s Model Number: 005031-2 (25kW)[...]

  • Page 2

    2 I NTRODUCTION Thank you for purchasing this model of the QuietSource™ standby generator series. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ - ten. However , the manufacturer reserves the right to change, alter or otherwise improve this [...]

  • Page 3

    T able of Cont ents Liquid-cooled 25 kW Generators 1 INTRODUCTION ............................................... IFC Read this Manual Thoroughly ..................................... IFC Operation and Maintenance ........................................ IFC How to Obtain Service ................................................. IFC Authorized Serv[...]

  • Page 4

    2 Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reliably only if it is prop - erly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental r[...]

  • Page 5

    3 • Do not handle any kind of electrical device while standing in water , while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MA Y RESUL T . • If personnel must stand on metal or concrete while install- ing, operating , servicing, adjusting or repairing this equip- ment, place insulative mats over a dry wooden platform. W[...]

  • Page 6

    4 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been facto - ry-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only . Use this [...]

  • Page 7

    5 1.6 GEN ER A T OR F U EL SYST E M 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 F uel System for LP V apor . F uel 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[...]

  • Page 8

    6 Figure 1.6 - Low Coolant Level Sensor 1.7 .4 OVERSPEED SHUTDOWN Should AC frequency exceed about 72 Hz, cir - cuit board action will automatically shutdown the engine. 1.7 .5 OVERCRAN K SH UTDOWN The engine control board uses a cyclic cranking pro - cess when attempting to start the engine. The first crank cycle is a 15- second crank followed by [...]

  • Page 9

    1.1 0.2 GEN ER A T OR * Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an addi- tional 1% for each 10°F above 60°F . Maximum output power of the generator is limited [...]

  • Page 10

    8  Any attempt to crank or start the engine before it has been properly serviced with the r ecom- mended oil may result in an engine failur e. 1.1 4 COOLANT R E COMM EN D A TIONS Use a mixture of half low silicate ethylene glycol base anti-freeze and half deionized water . Cooling system capacity is about 8 U .S. quarts (7.6 liters). Use only de[...]

  • Page 11

    9 2.1.2 O TH ER P U B LISHED ST AN D ARDS In addition to NFP A standards, the following informa- tion pertaining to the installation and use of standby electric systems is available: • Article X, NA TIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New Y ork, N .Y . 10038. • AGRICUL TURAL WIRING HANDBOOK, [...]

  • Page 12

    10 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capac- ity of the generator . If the generator is powering only critical loads, within its wattage/amperage capac- ity , during utility power outages, consider using the emergency circuit isolation method.[...]

  • Page 13

    11 • The control board WILL monitor all engine condi- tions and shut down on all the faults listed in this document. Pos2 OFF — A TS Application • The control board will perform all of the automatic features listed in this document. • The two-wire start connections, wires 178-183, should NOT be connected. NOTE: If the generator is installed[...]

  • Page 14

    12 Section 3 - Operation Liquid-cooled 25 kW Generators When using maintenance -free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the inter - vals specified in Section 4, “Maintenance.” A nega- tive ground system is used. Battery connections are shown on the wiring diagram[...]

  • Page 15

    13 • After the engine starts and when the generator AC output voltage and frequency have reached a pre - set value, transfer switch circuits signal the transfer switch main contacts to actuate to the “Standby” power source side. Generator AC output then powers load circuits. • When the utility power source voltage is restored above a pre - [...]

  • Page 16

    14 3.2.3 1 5 AM P F USE This fuse protects the control console’s DC control circuit against electrical overload and is located inside the control panel. If the fuse has melted open because of an overload, engine cranking and startup cannot occur . If the fuse needs to be replaced, use only an identical 15-amp replacement fuse (type A TO). 3.2.4 5[...]

  • Page 17

    15 Section 3 - Operation Liquid-cooled 25 kW Generators This secondary function is only available with DIP switch two in the OFF position (A TS - automatic transfer switch application). 3.3 MAN U AL TR ANSF ER AN D S T ART -U P T o transfer electrical loads to the Standby (EMERGENCY) power source side and start the engine manually , refer to the Ow[...]

  • Page 18

    16 3.6 AUT OMA TIC OP ER A TION T o set the system for fully automatic operation, pro - ceed as follows: • Check that load circuits are connected to the utility power supply . • Set the AUTO/OFF/MANU AL switch to its AUTO position. • Set the generator main circuit breaker to its ON or CLOSED position. 3.7 WEEKL Y EXERCISE CY CLE The engine co[...]

  • Page 19

    17 Switch P osition 8 — Selects whether the control is in the Normal Mode of operation or T est Mode. In the Normal Mode of operation, pre - determined governor gains are used and the gain trimpots on the control board (Gain, Stability , and Differential) are not active and have no effect on the gains. In T est Mode the gain trimpots are active a[...]

  • Page 20

    18 F IRST 1 00 OP ER A TI NG HOU RS 1. Change engine oil and oil filter . After initial change, service engine oil and filter at 150 operat - ing hours or six months, whichever comes first. 2. Retorque cylinder head (see torque specs). 3. Retorque intake and exhaust manifold (see torque specs). EVER Y 500 OPER A TING HOU RS 1. Service air cleaner .[...]

  • Page 21

    19  The exhaust system parts from this pr oduct get extremely hot and r emains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system. 4.6 O VER L O AD PRO TE CTION FOR ENGI N E DC ELE CTR ICAL SYST E M Engine cranking, start up and runni[...]

  • Page 22

    20 4.8.7 I NSPECT EXHAUS T SY S TEM Inspect the exhaust system at least once every three months. Check all exhaust system pipes, mufflers, clamps, etc. for condition, tightness, leaks, security , damage. 4.8.8 CH E CK F AN B EL T • Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defec- tive belt. • Che[...]

  • Page 23

    21 4.9 M IS CELL AN EOUS MAINTENANCE 4.9.1 CLEAN ING TH E GEN ER A T OR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance. P eriodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacu[...]

  • Page 24

    22 Section 4 — Maintenance Liquid-cooled 25 kW Generators 4.1 0 SCHEDU LED MAI NTENANCE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased [...]

  • Page 25

    23 Section 4 — Maintenance Liquid-cooled 25 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) Break-in Initials) annually Initials) An[...]

  • Page 26

    24 Section 4 — Maintenance Liquid-cooled 25 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) Break-in Initials) annually Initials) An[...]

  • Page 27

    25 Section 5 — T roubleshooting Liquid-cooled 25 kW Generators TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. Defectiv e starter contactor. 3. Replace contactor [...]

  • Page 28

    26 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (1 5kW & 20kW units) —Drawing No. 0F2 1 83-B[...]

  • Page 29

    27 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (1 5kW & 20kW units) —Drawing No. 0F2 1 83-B[...]

  • Page 30

    28 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 2 0kW units) —Drawing No. 0F21 84-B[...]

  • Page 31

    29 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 2 0kW units) —Drawing No. 0F21 84-B[...]

  • Page 32

    30 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1 286-B[...]

  • Page 33

    31 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1 286-B[...]

  • Page 34

    32 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1 28 7 -B[...]

  • Page 35

    33 Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1 28 7 -B[...]

  • Page 36

    34 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW Generators Mounting Base — Drawing No. 0F0 1 04-B[...]

  • Page 37

    35 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW Generators Mounting Base — Drawing No. 0F0 1 04-B ITEM P ART NO . QTY . DESCRIPTION 1 0F1705 1 SUPPORT BA TTER Y TRA Y 2 0E8834 1 HOLD DOWN BA TTERY 3 0E9911 1 ASSEMBL Y BA TTER Y TRA Y 4 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 5 022097 4 W ASHER LOCK M6-1/4 6 026850 2 W ASHER SHAKEP[...]

  • Page 38

    36 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW Generators Enclosure — Drawing No. 0F1 645-H ST A TES FOAM IS ON NEAR SIDE ST A TES FOAM IS ON F AR SIDE 17 LA TCH DET AIL 30 31 31 32 34 32 3 45 18 39 38 40 4 7 47 DET AIL SEE LA TCH 9 "B" 29 46 11 18 17 43 8 13 1 18 SECURE AS SHOWN. REQUIRE INSULA TION. TYPICAL OF ROOF[...]

  • Page 39

    37 ITEM P ART NO . QTY . DESCRIPTION 1 0F0783 1 DUCT INT AKE MID AL 2.5L 2 0F0781 1 DUCT DISCHARGE RH AL 2.5L 3 0F0780 1 DUCT DISCHARGE LH AL 2.5L 4 0C2454 34 SCREW TH-FRM M6-1 X 16 N W A Z/JS 5 0F0779 1 SUPPORT RADIA TOR 2.5L AL 6 0E0072AB 1 AI INSULA TION SIDE REAR CORNER POST RH 7 0E0072A C 1 AI INSULA TION INT AKE DUCT T OP P ANEL 8 0E0072AD 1 [...]

  • Page 40

    38 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW Generators Control Panel (1 5kW and 20kW) — Drawing No. 0F22 67 -D[...]

  • Page 41

    39 ITEM P ART NO . QTY . DESCRIPTION 1 0F0790 1 T OP , CONTROL P ANEL 2 0F0789 1 BACK & BO TTOM, CONTROL P ANEL 3 0F0791 1 P ANEL, FR ONT 2.5L CONTROL PNL 4 0E9704 1 ASSY PCB HSB CONTROLLER 2.5L 5 067680 1 ASSY V OL T AGE REGULA T OR 60HZ 6 0E6875A 2 RELA Y , 12VDC C FORM W/DIODE 7 0C3910 1 XFMR 240/16V 1V A&56V A 8 048468 1 CIRCT BRK 8 X 1[...]

  • Page 42

    40 33 3 2 4 0 3 3 4 1 3 2 6 12 1 6 3 1 3 9 12 2 9 12 24 2 5 12 1 5 14 8 33 24 38 12 2 3 6 3 4 3 5 3 2 21 3 0 41 4 11 17 42 12 12 2 2 0 1 8 4 3 1 27 2 8 5 7 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW Generators Control Panel (2 5kW) — Drawing No. 0E7 6 1 5-C[...]

  • Page 43

    41 ITEM P ART NO . QTY . DESCRIPTION 1 0F0790 1 T OP , CONTROL P ANEL 2 0F0789 1 BACK & BO TTOM, CONTROL P ANEL 3 0F0791 1 P ANEL, FR ONT 2.5L CONTROL PNL 4 0E9704 1 ASSY PCB HSB CONTROLLER 2.5L 5 067680 1 ASSY V OL T AGE REGULA T OR 60HZ 6 0E6875A 2 RELA Y , 12VDC C FORM W/DIODE 7 0C3910 1 XFMR 240/16V 1V A&56V A 8 054450 1 CIRCT BRK 5.5 X[...]

  • Page 44

    42 8 15 66 16 14 1 9 41 3 0 20 27 60 20 3 0 2 9 2 8 5 9 39 5 2 1 9 38 39 20 40 2 25 4 17 1 3 15 1 9 FO R HARNE SS G R OU ND 5 3 22 17 6 8 15 1 9 10 38 22 3 1 0 H S G . 20 3 4 7 45 20 4 9 1 16 39 50 3 4 3 5 65 33 5 7 1 8 3 7 1 8 20 16 38 R ADIAT O R CAP 6 2 TO 5 8 39 S TEPPER MO T O R U NIT S O NLY 17 12 "A " 11 6 7 24 2 3 6 1 Section 7 - [...]

  • Page 45

    43 ITEM P ART NO . QTY . DESCRIPTION 1 0E9909 REF ENGINE 2.5L FORD 2 0E9739 1 PULLEY , 2.5L FORD W A TER PUMP 3 049814 8 SCREW HHC M10-1.5 X 25 G8.8 4 0F0001 1 CLUTCH, COOLING F AN 2.5L FORD 5 0D3488B 1 SERPENTINE BEL T - 40.85" LENGTH 6 0A8584 1 SWITCH,OIL PRESSURE,10PSI,2POL 7 0E0561 1 ASSY W A TER LEVEL SENSOR C/E PL 8 0A6751 1 SW -TMP 245D[...]

  • Page 46

    44 PO RT "OU T 1" 2 2 7 21 TO EN G INE 10 42 CO VER TO VALVE 12 1 3 2 8 1 8 20 33 3 1 3 2 17 3 4 26 6 38 3 0 16 25 24 1 8 4 2 9 15 9 5 27 6 4 C ARB U RET O R A SS Y. 0 E102 8 A ( I/N 1 9 ) CO NVER S I O N 3 5 41 "OU T 2" PO RT L .P. VAP O R 3 40 1 11 3 40 7 2 6 11 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW G[...]

  • Page 47

    45 ITEM P ART NO . QTY . DESCRIPTION 1 0E8456 1 BRACKET FUEL REGULA TOR 2 075580 1 FLANGE FUEL INLET 3 0E9967 1 ASSY FUEL REG 2.5L FRD N/G-L/P 4 039253 4 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 6 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 * 0F1570 1 BOD Y CARBURET OR ASSEMBL Y 9 0A6344 1 BARBED EL 9[...]

  • Page 48

    46 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 7 - Exploded Views and P arts Lists Liquid-cooled 25 kW Generators Alternator — Drawing No. 0F5 092-B[...]

  • Page 49

    47 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 RO T OR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 ROT OR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 ROT OR 390 25KW 1P DIRECT HSB (2.5L FORD) 0F5073A 1 ROT OR 390__30AD1 HSB TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT HSB 2 0F1660A 1 STR 390 15AD HSB (382MM LONG) (2.5L FORD) 0F1658A 1 STR 390 20AD HS[...]

  • Page 50

    ITEM P ART NO . QTY . DESCRIPTION 1 0F2912 1 PIPE MUFFLER OUT 2 0F2869 1 PIPE EXHA UST 2.5L FORD 3 0F2823 1 MUFFLER 2.5L FORD 4 036434 2 BOL T U 5/16-18 X 2.09 5 036449 2 SADDLE 2 INCH 6 022129 6 WASHER LOCK M8-5/16 7 022259 4 NUT HEX 5/16-18 STEEL 8 0E0170A 1 EXHA UST BLANKET 800MM 9 044149 1 GASKET EXHAUST RING 10 0E8816 1 EXHA UST FLANGE 2” PI[...]

  • Page 51

    49 ITEM P ART NO . QTY . DESCRIPTION 1 098290 1 ASM MO TOR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECTOR 3 0F0454 REF HARN GO V 2.5L FORD 4 098942A 1 CO VER CONNECT OR HOUSING 5 098225 2 SCREW PFHST #2 X 5/8 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 W ASHER LOCK M6-1/4 8 0E7358 REF SCREW PPPH HI-LO #4-24 X 3/8 9 098783 1 LEVER STEPPER MO T[...]

  • Page 52

    50 ITEM P ART NO . QTY . DESCRIPTION 1 0E9769 REF SUPPORT RADIA TOR 2.5L FORD 0F0779 REF SUPPORT RADIA T OR 2.5L AL 0E9769A REF SUPPORT RADIA TOR 2.5L FORD ALM 2 0E9837 1 RADIA T OR 2.5L FORD 3 0F0123 1 VENTURI 16” F AN 2.5L FORD 4 0F0118 1 GUARD F AN 2.5L FORD 5 099502 4 CLAMP HOSE #24 B1.06-2.00 6 0C2454 REF . SCREW THF M6-1 X 16 N W A Z/JS 7 0[...]

  • Page 53

    51 Section 8 — Installation Diagram Liquid-cooled 25 kW Generators Installation Diagram — Drawing No. 0F1 022-A[...]

  • Page 54

    52 CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OUR W AR R ANTY R IGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and garden equipment engines must be [...]

  • Page 55

    53 Section 9 – W arranty Liquid-cooled 25 kW Generators EM IS SION CONTROL S Y STEM W AR RANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is[...]

  • Page 56

    Part No. 0F5097 Revision D (07/19/05) Printed in U.S.A. Section 9 – W arranty Liquid-cooled 25 kW Generators GENER AC PO WER SYST EM S " T WO YEAR" LI MITED WARRANT Y FOR QU I ETSO U RCE™ "PR EP ACKAGED EMERGENCY AUT OMA TIC S T ANDBY GENER A T ORS" F or a period of two years from the date of original sale, Generac P ower Sy[...]