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Generac 005028-0 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 ka ged Standb y Generator s Model Number 005030-0 (15kW) 005028-0 (20kW) 005031-0 (25kW)[...]

  • Page 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 pro[...]

  • Page 3

    T able of Contents Liquid-cooled 1 5, 20 and 2 5 kW Generators 1 INTRODUCTION ................................................ IFC Read this Manual Thoroughly ......................................IFC Operation and Maintenance ........................................IFC How to Obtain Service ................................................IFC Autho[...]

  • 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 gen- erator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fun- damental [...]

  • Page 5

    3 ELE CTR ICAL HA Z AR DS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous volt- ages to the transfer switch as well as the standby generator . A void contact with bare wires, terminals, connections, etc., on the generator as wel[...]

  • Page 6

    4 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical 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 th[...]

  • Page 7

    5 Figure 1.1 - Generator AC Connection System 1.6 MAI N CI RCU IT B R EAKER 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. 1.7 GEN ER A T OR F U EL SY S TEM This unit has been factory tested and adjusted using a natural gas fuel system. If propane [...]

  • Page 8

    6 Figure 1.5- High Coolant T emperature Switch 1.8.3 L O W C OOL ANT LEVEL SWIT CH 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. T o prevent such overheating without automatic shut down, the engine has a low coolant level sensor . If the[...]

  • Page 9

    1.1 1 SP ECIF ICA TIONS 1.1 1.1 ENGIN E Make ......................................................................................F ord Displacement ............................................153 inches 3 (2.5 liters) Cylinder Arrangement ......................................................4, in-line V alve Arr angement ........................[...]

  • Page 10

    8 2. Remove the carburetor fuel hose from the outlet port (P ort 1) of the demand regulator (F igure 1.8). 3. Remove the brass hose fitting from the outlet port (P ort 1) of the demand regulator . 4. Remove pipe plug from P ort 2. 5. Install brass hose fitting into P ort 2. 6. Install pipe plug into P ort 1. 7. Connect carburetor gas hose to brass [...]

  • Page 11

    9 2.1 S T AN DB Y GEN ER A T OR I NS T ALL A TION Connecting this generator to an electrical sys- tem normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distri- bution system when the generator is operating. Failure to isolate the electric system by these means will[...]

  • Page 12

    10 2.4 B ASIC S T AN DBY ELE CTRIC SYST E M Figure 2.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the ST ANDBY GENERA TOR output are connected to an approved transfer switch. The trans- fer switch is required by electrical code and serves the following functions: • P ermits the LOAD circuits to[...]

  • Page 13

    11 2.8 GEN ER A T OR AC NEUTR AL CO N N EC T I O N S The manufacturer uses an UNGROUNDED AC neu- tral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the exces- sive current opens the load circuit breaker or col- lapses the generator field. The actual result d[...]

  • Page 14

    12 2.1 0 ENGI N EER ED TR ANSF ER SWIT CH (2-WI R E S T ART G T S MODE) When required, the pre -packaged standby generator can be installed with an engineered W T ype transfer switch which controls utility voltage sensing, weekly exercising and load transferring . When P osition 2 of the eight -position DIP switch, which is located on the generator[...]

  • Page 15

    13 Transfer Switch terminals N1 and N2 (also called Utility 1 and Utility 2) are the input utility AC power connections to the Transfer Switch. T ransfer Switch terminals T1 and T2 (also called Load 1 and Load 2) are the transfer switch AC output power terminals that go to the load circuit distribution panel. Transfer Switch terminals E1 and E2 are[...]

  • Page 16

    14 The recommended battery is Group 26, 12VDC, 550 CCA/75 AH minimum. All batteries must be at 100 percent state - of- charge before they are installed on the generator . When using maintenance -free batteries, it is not nec- essary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Sec[...]

  • Page 17

    15 Section 3 - Operation Liquid-cooled 1 5, 20 and 2 5 kW Generators 3.1 C ONTROL CONS OLE C OM PON ENTS The components of a home standby generator control console (Figure 3.1) are as follows: Figure 3.1 - Generator Control Console 3.1.1 AUT O/OF F/MANUAL SWIT CH Use this three -position switch as follows: • Set the switch to A UTO for fully auto[...]

  • Page 18

    16 3.3 ENGI N E G OVERNOR GAI N ADJ US TM ENTS Engine speed governing is also controlled by the engine control board. The engine governor has been set by the factory during final testing of the generator and should not be adjusted. If, however , adjustments are necessary , the following procedure should be followed (Figure 3.2 and Section 3.7): 1. [...]

  • Page 19

    17 6. Reduce load to 3/4, 1/2, 1/4 and no load. Decrease the stability pot if there is instability at any load point. 7. Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot. If it is set too high, it may introduce oscillations at some load. It can be set to zero (full CCW) if a [...]

  • Page 20

    18 3.7 C ONTROL BO AR D DI P SWIT CH S E TTIN G S Located on the control board is an eight position DIP switch (see Figure 3.2). The eight different switches, are used to configure the control board for the spe- cific engine and governor being used and are pre - set at the factory . If the DIP switch settings are not set corr ectly , the generator [...]

  • Page 21

    19 7. T urn the voltage regulator’s VOL T AGE ADJUST pot to obtain a line -to -line voltage of: A. 240 V AC if the generator has been configured for 60 Hertz operation. B. 200 V AC if the generator has been configured for 50 Hertz operation. 8. If the RED REGULA TOR LED is flashing, adjust the ST ABILITY pot in either direction until the flashing[...]

  • Page 22

    20 3. Install a new lower intake manifold gasket. 4. P osition the lower intake manifold to the cylinder head. 5. Install retaining bolts/studs finger tight. 6. Tighten all bolts/studs to specifications in the tightening sequence shown: • F irst pass = 7=10 N-m (5-7 lb -ft). • F inal pass = 26-38 N-m (19-28 lb -ft). 4.4 CYLI N DER H EAD P ROCED[...]

  • Page 23

    21 4 .7 .2 B A TT E R Y FL UID Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa- tors in all battery cells. If fluid level is low , add dis- tilled water to cover tops of separators. DO NOT USE T AP W A TER IN BA TTERY . 4.7 .3 ENGI NE COOLANT Check coolant level in coolant recovery bottle. See Specificat[...]

  • Page 24

    22 5. Apply light coating of new engine oil to seal of new oil filter . Install FIL TER and tighten by hand only . DO NOT OVER TIGHTEN . 6. Remove OIL FILL CAP . Add recommended oil (see SPECIFICA TIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL ” MARK. Crankcase oil capacity is 4.0 U .S. quarts (3.8 liters). After refilling the crankcase with oil,[...]

  • Page 25

    23 4.9.3 BA TTER Y MAI NTENANCE The battery should be inspected per Section 4.7, Scheduled Maintenance. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary . 2. Check the battery fluid level of unsealed batteries and, if necessary , fill with [...]

  • Page 26

    24 Section 4 — Maintenance Liquid-cooled 1 5, 20 and 2 5 kW Generators 4.1 0 S CH EDU 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 t[...]

  • Page 27

    25 Section 4 — Maintenance Liquid-cooled 1 5, 20 and 2 5 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 [...]

  • Page 28

    26 Section 4 — Maintenance Liquid-cooled 1 5, 20 and 2 5 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 [...]

  • Page 29

    27 Section 5 — T roubleshooting Liquid-cooled 1 5, 20 and 2 5 kW Generators TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blo wn. 1. Replace fuse. 2. Loose or corroded or def ective 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. Def ective starter contactor . 3. Rep[...]

  • Page 30

    28 Section 6 — Notes Liquid-cooled 1 5, 20 and 2 5 kW Generators[...]

  • Page 31

    29 Section 6 — Notes Liquid-cooled 1 5, 20 and 2 5 kW Generators[...]

  • Page 32

    30 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Wiring Diagram — 2.5L Engine (1 5kW & 20kW units) —Drawing No. 0F2 1 83-B[...]

  • Page 33

    31 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Wiring Diagram — 2.5L Engine (1 5kW & 20kW units) —Drawing No. 0F2 1 83-B[...]

  • Page 34

    32 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Electrical Schematic — 2.5L Engine (15kW & 2 0kW units) —Drawing No. 0F21 84-B[...]

  • Page 35

    33 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Electrical Schematic — 2.5L Engine (15kW & 2 0kW units) —Drawing No. 0F21 84-B[...]

  • Page 36

    34 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1 286-B[...]

  • Page 37

    35 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0F1 286-B[...]

  • Page 38

    36 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1 28 7 -B[...]

  • Page 39

    37 Section 7 - Electrical Data Liquid-cooled 1 5, 20 and 2 5 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0F1 28 7 -B[...]

  • Page 40

    38 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 kW Generators Mounting Base — Drawing No. 0F0 1 04-B[...]

  • Page 41

    39 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 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 DO WN BA TTER Y 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[...]

  • Page 42

    40 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 kW Generators Enclosure — Drawing No. 0F1 645-H S TAT E S FOAM I S ON NEAR S IDE S TAT E S FOAM I S ON F AR S IDE 17 LA TCH DET AIL 3 0 3 1 3 1 3 2 3 4 3 2 3 45 1 8 39 38 40 4 7 47 DET AIL S EE LA TCH 9 "B" 2 9 46 11 1 8 17 4 3 8 1 3 1 1 8 S ECURE A S S HOWN. R[...]

  • Page 43

    41 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 T OR 2.5L AL 6 0E0072AB 1 AI INSULA TION SIDE REAR CORNER POST RH 7 0E0072A C 1 AI INSULA TION INT AKE DUCT TOP P ANEL 8 0E0072AD 1 [...]

  • Page 44

    42 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 kW Generators Control Panel (1 5kW and 20kW) — Drawing No. 0F22 67 -D[...]

  • Page 45

    43 ITEM P ART NO . QTY . DESCRIPTION 1 0F0790 1 TOP , CONTROL P ANEL 2 0F0789 1 BACK & BO TT OM, CONTROL P ANEL 3 0F0791 1 P ANEL, FRONT 2.5L CONTR OL PNL 4 0E9704 1 ASSY PCB HSB CONTROLLER 2.5L 5 067680 1 ASSY V OL T A GE 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 [...]

  • Page 46

    44 33 32 4 0 3 34 13 2 6 12 1 6 31 39 12 2 9 12 24 2 5 12 1 5 14 8 33 24 38 12 2 3 6 34 35 32 21 30 41 4 11 17 42 12 12 2 2 0 1 8 4 3 1 27 2 8 5 7 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 kW Generators Control Panel (2 5kW) — Drawing No. 0E7 6 1 5-C[...]

  • Page 47

    45 ITEM P ART NO . QTY . DESCRIPTION 1 0F0790 1 TOP , CONTROL P ANEL 2 0F0789 1 BACK & BO TT OM, CONTROL P ANEL 3 0F0791 1 P ANEL, FRONT 2.5L CONTR OL PNL 4 0E9704 1 ASSY PCB HSB CONTROLLER 2.5L 5 067680 1 ASSY V OL T A GE 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 [...]

  • Page 48

    8 15 66 16 14 19 41 30 20 27 60 20 30 29 28 59 39 5 2 19 38 39 20 40 2 25 4 17 13 15 19 FO R HARNE SS G R OU ND 5 3 22 17 68 15 19 10 38 22 3 1 0 HSG . 20 3 4 7 45 20 49 1 16 39 50 34 35 65 33 5 7 18 3 7 18 20 16 38 R ADIAT O R CAP 6 2 TO 58 39 S TEPPER MO T O R U NIT S O NLY 17 12 "A " 11 6 7 24 23 6 1 Section 8 - Exploded Views and P ar[...]

  • Page 49

    ITEM P AR T 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 245DEG[...]

  • Page 50

    48 PO RT "OU T 1" 2 2 7 21 TO EN G INE 10 42 CO VER TO VALVE 12 13 28 1 8 20 33 3 1 3 2 17 3 4 26 6 38 30 16 25 24 18 4 29 15 9 5 27 6 4 C ARB U RET O R A SS Y. 0 E1028A ( I/N 19 ) CO NVER S I O N 35 41 "OU T 2" PO RT L .P. VAP O R 3 40 1 11 3 40 7 2 6 11 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 [...]

  • Page 51

    49 ITEM P ART NO . QTY . DESCRIPTION 1 0E8456 1 BRA CKET FUEL REGULA T OR 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 CARBURETOR ASSEMBL Y 9 0A6344 1 BARBED EL [...]

  • Page 52

    50 3 LOC KTI G HT LOC KTI G HT 7 1 5 17 8 7 6 18 4 16 L EAD S 5 2 9 13* 21 19 20 14 10 11 12 30 1 3 1 Section 8 - Exploded Views and P arts Lists Liquid-cooled 1 5, 20 and 2 5 kW Generators Alternator — Drawing No. 0E8660-C[...]

  • Page 53

    51 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 R O T OR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 R O T OR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 R O T OR 390 25KW 1P DIRECT HSB (2.5L FORD) 0E5093A 1 R O T OR 390 30KW 1P DIRECT HSB (3.0L FORD & 2.5L FORD) 0E7413A 1 R O T OR 390 40KW 1P DIRECT HSB (3.9L CHR YSLER) 2 0F1660A 1 STR 390 [...]

  • Page 54

    ITEM P AR T 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 W ASHER LOCK M8-5/16 7 022259 4 NUT HEX 5/16-18 STEEL 8 0E0170A 1 EXHAUST BLANKET 800MM 9 044149 1 GASKET EXHA UST RING 10 0E8816 1 EXHA UST FLANGE 2&quo[...]

  • Page 55

    ITEM P ART NO . QTY . DESCRIPTION 1 098290 1 ASM MOT OR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECTOR 3 0F0454 REF HARN GOV 2.5L FORD 4 098942A 1 CO VER CONNECTOR 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 MOT OR 10[...]

  • Page 56

    54 ITEM P AR T NO . QTY . DESCRIPTION 1 0E9769 REF SUPPORT RADIA T OR 2.5L FORD 0F0779 REF SUPPOR T RADIA TOR 2.5L AL 0E9769A REF SUPPOR T RADIA T OR 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 GU ARD 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 [...]

  • Page 57

    55 Section 9 — Installation Diagram Liquid-cooled 1 5, 20 and 2 5 kW Generators Installation Diagram — Drawing No. 0F1 022-A[...]

  • Page 58

    56 CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OU R W ARR ANT Y RIGHTS 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 59

    57 EM IS SION CONTROL S Y STEM W AR R ANTY 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 purchased by/delivered to its original, end-use purcha[...]

  • Page 60

    Part No. 0F1007 Revision F (07/25/05) Printed in U.S.A. Section 1 0 – W arranty Liquid-cooled 1 5, 20 and 2 5 kW Generators GENER AC PO WER SY STEMS "TWO YEAR" LIMITED WARR ANTY FOR QU I E TS OU RCE™ "PR EP A CKAGED EMERGENCY AUT OMA TIC ST ANDBY GENER A T ORS" F or a period of two years from the date of original sale, Gener[...]