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GE EER2001 Convection Oven User Manual

1. 1 Move DIP switch 8 to the TEST mode OFF posi r tion 2 Set all three potentiometers pots fully counter Oo kc clockwise rS 3 Under no load condition increase the GAIN pot DIP SWITCH GAIN as much as possible without causing instability STABILITY 4 Apply 1 4 1 2 3 4 and full load to the unit DIFFERENTIAL Decrease the GAIN pot if there is instability at any pas OFF LN DESCRIPTION P o Under full load condition increase the stability Eu VE pot until the unit returns to 60 Hertz or 50 Hertz 6 6 CYL 4 CYL BE CYLINDERS in 50 Hertz applications TEST NORMAI PERATING MODE 16 OPERATION Section 5 Operation Liquid cooled 15 20 and 25 kW Generators gt 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 small amount causes oscillations at some load 8 Leave DIP switch 8 in TEST mode 3 4 MANUAL RETRANSFER AND SHUTDOWN When utility power source voltage has been restored electrical loads may be transferred back to that source and the generator can be shut down as fol lows Verify that utility power su
2. 4 4 1 Maintenance Performed by Authorized 14 Engineered Transfer Switch 2 wire Start SCI VICE Facilite m 19 GTS Mode j 4 4 2 Exhaust Manifold Procedure 19 1 5 Generator AC Connection oystems EINER 4 4 3 Intake Manifold Procedure 19 1 6 Main Circuit Breaker 4444 5 4 4 Cylinder Head Procedure 20 1 7 Generator Fuel System 5 4 5 Cooling DUSICHL 20 1 8 Engine Protective 5 4 6 Overload Protection for Engine DC 1 9 Unpacking G 5ysli rl 20 1 10 Lifting Generator 6 Mas E 20 1 11 Specifications 7 4 8 Maintenance Owner Operator I PCO tit onde 21 1 12 Fuel Consumption 7 4 9 Miscellaneous Maintenance 22 1 13 Reconfiguring the Fuel System for LP 7 4 10 Scheduled Maintenance 24 1 14 Engine Oil Recommendations 8 Section 5 TROUBLESHOOTING 27 1 15 Coolant 8
3. essere 9 37 to 1 No of Teeth on Crank essen 36 1 Ignition Timing Waste Spark System at 1800 rpm NG 36 degrees BTDC at 1800 rpm LP vapor 28 degrees BTDC Spark Plug Gap esee 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 Cooling System Capacity 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and deionized water warninc amp A Home standby control board assembly part number 0E9704 must be used on 1800 rpm gen erators 1 11 2 GENERATOR Single phase Single phase Model 00503 1 0 005028 0 25 20 Rated Max Cont AC Power Output kW Rated Voltage volts No of Rotor Poles e ____ Driven Speed of Rotor rpm 1800 1800 1800 Rotor Excitation System Type of Stator Rotor Insulation stator Insulation Section 1 General Information Liquid cooled 15 20 and 25 kW Generators 1 12 FUEL CONSUMPTION 15 kW Models Using Natural Gas
4. 236 cu ft per hour Using CE 206 usss 92 cu ft per hour 20 kW Models Using Natural Gas 307 cu ft per hour Using LP 122 25 kW Models Using Natural Gas 441 cu ft per hour Using LP Gas eee 175 cu ft per hour Fuel consumption is given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot or LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Fuel 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 Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges 1 15 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR NOTE All models are configured for natural gas NG from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off Single phase 005030 0 15 120 240 120 240 120 240 4 4 4 Direct excited brush type Direct excited brush type Direct excited brush type 4 Wire Class F Rated power of generator is subject to and limited by such factors as ambient temperature alt
5. 8 1 16 Before Installation 22 2000222 8 28 Section 2 INSTALLATION 9 Section 7 ELECTRICAL DATA 30 2 1 Standby Generator Installation 9 Section 8 ICI AND 38 2 2 Generator Location 9 2 9 Generator Mounting and Support 9 Section 9 INSTALLATION DIAGRAM 95 2 4 Basic Standby Electric System 10 Section 10 WARRANTY 96 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 11 2 9 Automatic Transfer Switch ATS Mode 11 2 10 Engineered Transfer Switch 2 wire Start u E 12 2 11 Battery Installation 13 2 12 Preparation Before Start Up 14 SAFETY RULES Important Safety Instructions Liquid cooled 15 20 and 25 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipm
6. TO SET TIME PLA ANUAL SWITCH TO AUTO POSITION THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR HOLD SET EXERCISE TIME SWITCH IN ON POSITION FOR THREE OUTDOOR INSTALLATION ONLY ND RELEASE SEE OWNER S MANUAL FOR COMPLETE DETAILS ISER 15 NOW SET ALL FIVE RED LED S WILL FLASH FOR 10 SECONDS 5 USE OF SYNTHETIC OIL IS RECOMMENDED 0 2629 5 1 1 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 6 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engine With OFF selected operation will not be possible A A A With switch set to AUTO engine can crank and start suddenly without warning Such automat ic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on trol console 5 1 2 FAULT INDICATOR LEDS SEE CHART ON PAGE 16 These red LEDs turn ON when one or more of the fol lowing engine faults occurs and the engine shuts down Low Oil Pressure Overcrank Low Battery Overspeed Engine Speed Signal Fault High Coolant Tempe
7. OMLNOD NI 184915 31DW38 CNV NAM eee Lave 1 5399 14 9 55 Section 10 Warranty WARRANTY Liquid cooled 15 20 and 25 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer PURCHASE
8. tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging MAINTENANCE 2 9 Section 4 Maintenance waRnNING amp A Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply to the battery 2 charger is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 9 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 60R 525 0 deg F NOTE The BCI number should be located directly on the battery PERIODIC REPLACEMENT PARTS Part Name Oil Filter Motorcraft FL 400 S supplied with engine Radiator Cap Air Cleaner Spark Plug Battery 23 Section 4 Maintenance MAINTENANCE Liquid cooled 15 20 and 25 kW Generators S 4 10 SCHEDULED MAINTENANCE 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 performed more frequently if the unit is used in a severe application Use calendar time from
9. purged and leak tested according to applicable fuel gas codes before placing this equipment into service Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be used as installation guide for this equipment 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLE UM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELEC TRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND C
10. EVERY 500 OPERATING HOURS Service air cleaner Check starter Check engine DC alternator EVERY 800 OPERATING HOURS Retorque cylinder head see torque specs Retorque intake and exhaust manifold see torque specs 3 Check engine compression 4 Check valve clearance 2 EXHAUST MANIFOLD PROCEDURE If necessary clean gasket surfaces on exhaust manifold and cylinder head 2 Install exhaust manifold and exhaust manifold gasket 3 Install fasteners PP rot ae CSS eee NOTE Exhaust manifold fasteners must be tightened in two stages 4 Tighten fasteners to 20 30 N m 15 22 Ib ft dur ing the first stage o Retighten fasteners to 60 80 N m 44 59 Ib ft during the second stage 4 5 INTAKE MANIFOLD PROCEDURE 1 Clean and inspect the mounting surfaces of the intake manifold and the cylinder head Both sur faces must be clean and flat Figure 4 1 2 Clean and lightly oil the manifold bolt stud threads Figure 4 1 Intake Manifold Installation FASTENER TORQUE SEQUENCE 00283 19 MAINTENANCE 2D Section 4 Maintenance 3 Install a new lower intake manifold gasket 4 Position 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 First pass 7 10 N m 5 7 lb ft Final pass 26 38 N m 19 28 lb ft 4 CYLINDER HEAD PROCEDURE Position he
11. attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insu lation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris These generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the units fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed
12. 0 0123 0 0118 099502 0C2454 052250 022097 022473 022127 046627 060035 0 0127 NON LAAA AAA AN Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Radiator Drawing No 0E9965 F REF REF REF m JJ II OO DESCRIPTION SUPPORT RADIATOR 2 5L FORD SUPPORT RADIATOR 2 5L AL SUPPORT RADIATOR 2 5L FORD ALM RADIATOR 2 5L FORD VENTURI 16 FAN 2 5L FORD GUARD FAN 2 5L FORD CLAMP HOSE 24 1 06 2 00 SCREW THF M6 1 X 16 N WA Z JS TAPE FOAM 1 X 1 21 LG WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC NUT HEX 1 4 20 STEEL CAP RADIATOR SPACER 41 X 75 X 87 ST ZNC HOSE UPPER RADIATOR 174MM TAL 5 10 5 a TO THERMOSTAT Pa ADAPTER 9 TO BASE OF WATER INLET TUBE ON BLOCK PART NO 0E9833 035461 069860C 0A7275 031669 065852 0A2111 0C2454 022287 077992 050275 QTY REF DESCRIPTION HOSE 2 5L FORD LOWER RADIATOR BARBED STR 1 4 NPT X 3 8 HOSE OIL DRAIN ASSY 21 FOAM 1 5 X 1 ADHESIVE BACKING 21 5 LG BOLT CARR 1 4 20 X 1 3 4 JS500 SPRING CLIP HOLDER 37 62 SCREW SWAGE 10 32 X 5 16 Z YC SCREW TH FRM M6 1 X 16 N WA 7 15 SCREW 1 4 20 X 3 4 G5 NUT HEX LOCK M6 1 0 SS NY INS DECAL WARNING FAN INSTALLATION Section 9 Installation Diagram Liquid cooled 15 20 and 25 kW
13. 022129 REF 027482 1 075763 1 0E9748A 1 0 0795 3 0C2454 33 065852 1 045764 1 JJ 24 CO T dm BO c TI Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Mounting Base Drawing No 0F0104 B DESCRIPTION SUPPORT BATTERY TRAY HOLD DOWN BATTERY ASSEMBLY BATTERY TRAY NUT HEX M6 X 1 0 G8 YEL CHR WASHER LOCK M6 1 4 WASHER SHAKEPROOF EXT 1 4 STL LUG SLDLSS 2 8 X 17 64 CU WASHER FLAT 1 4 M6 ZINC SCREW HHC M6 1 0 X 16 G8 8 NUT FLANGED HEX M12 1 75 DAMPENER VIBRATION 40 BLUE SPACER 49 X 62 X 1 87 PWDR ZNC DAMPENER VIBRATION WASHER FLAT M12 SCREW HHC M12 1 75 X 80 G8 8 ASSY WIRE 0 12 00 SCREW M6 1 0 X 20 BP BATT 12VDC 75 AH 26 NOT SHOWN BRACKET CONTROL PANEL SUPPORT WASHER SHAKEPROOF EXT 7 16 STL SCREW SHC M10 1 50 X 40 G12 9 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC EARTH STRAP CABLE BLK 1 X 41 50 BATTERY POST COVER BLACK BATTERY POST COVER RED CABLE BATT RED 1 X 40 50 NUT HEX M8 1 25 G8 YEL CHR WASHER LOCK M8 5 16 WASHER SHAKEPROOF EXT 5 16 STL BOOT BATTERY CABLE ASSY MTG BASE 2 5L AL ENCL SUPPORT CONTROL PANEL 2 5L SCREW THF M6 1 X 16 N WA Z JS SPRING CLIP HOLDER 37 62 SCREW HHTT M4 0 7 X 8 BP age LISTS 39 C STATES FOAM IS ON NEAR SIDE STATES FOAM IS ON SIDE 00 TYPICAL OF ROOF PANEL THAT REQUIRE INSUL
14. 12 SCREW HHC M8 1 25 X 60 08 8 FT 8 OE0170A 1 EXHAUST BLANKET 800MM 20 022145 5 WASHER FLAT 5 16 M8 ZINC 9 044149 1 GASKET EXHAUST RING 21 022131 2 WASHER FLAT 3 8 10 ZINC 10 0E8816 1 EXHAUST FLANGE 2 PIPE 22 085917 2 WASHER LOCK 3 8 SS Hl OF 2925 2 STRAP MUFFLER 23 002611 2 SCREWHHC 3 8 16 X 1 3 4 SS 120 0F 2926 1 BRACKET MUFFLER 24 052858 1 NUT TOP LOCK FL M8 1 25 ITEM CONDOR PART NO 098290 098941A 0 0454 098942 098225 043146 022097 0 7358 098783 037398 0 1326 0 7106 074031 029333A 022507 022473 064526 0E1694 CARBURETOR ARM Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Stepper Motor Drawing No 0E9979 C INTAKE MANIFOLD REF DESCRIPTION ASM MOTOR STEPPER HOUSING GOVERNOR CONNECTOR HARN GOV 2 5L FORD COVER CONNECTOR HOUSING SCREW PFHST 2 X 5 8 SCREW M6 1 0 X 10 68 8 WASHER LOCK M6 1 4 SCREW PPPH HI LO 4 24 X 3 8 LEVER STEPPER MOTOR NUT LOCK HEX 10 32 NYL INS ASSY CARBURETOR LINKAGE ROD BRACKET STEPPER MOTOR LIQUID NEOPRENE TIE WRAP 7 4 19 BLK UL SCREW HHC 1 4 20 X 1 2 G5 WASHER FLAT 1 4 ZINC SCREW TAP HWH 6 25 X 3 8 ZINC SPRING ANTI LASH ITEM 13 NEOPRENE COATING SECURE WIRE HARNESS age WITH TIE WRAP AS SHOWN LISTS 53 PARTS ITEM PART NO QTY CON MD CO 11 12 14 54 LISTS 0E9769 0F0779 NA AA ANANAS 0E9769A 0E9837
15. 15A STARTER CONTACTOR EG ND 3 0 COIL PACK COOLANT SENSORS 4 85 S CRANK SENSOR 5 FS FUEL SOLENOID F6 6 HIGH COOLANT TEMP SWITCH DISTRIBUTOR 12V 7 JI CONNECTOR 1 DN NOT USED 3 LOS LOW DIL PRESSURE SWITCH CRANK SENSIR IN 9 0 m SM STARTER MOTOR CRANK SENSE RET 110 79 4 L 4 STEPPER MOTOR NOT USED 11 WLS COOLANT LEVEL SWITCH EG FIK 12 13 15A 4 14 158 DIL 49 lisas DISTRIBUTOR RET 16 DISTR 17 DEG PM 18 DEG ENABLE L19 LOW DIL PRESS 20 86 CRANK SHIELD 21 0 CHIL 22 B 23 258 LOS 86 71 0 ELT EC XE WLS 85 gt WWW gt 0 li 37 dg As Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators 0 Mounting Base Drawing No 0 0104 85 19 REAR BEARING 35 CARRIER 42 TO ENGINE 20 24 2024 BLOCK E TO STARTER 7 BOLT TO STARTER CONTACTOR M a p AC HARNESS 32 20 TO ENGINE MOUNT 16 7 17 38 CONDOR WD PART NO QTY 0F1705 0 8834 0 9911 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0 0796 025507 060619 046526 022131 021991 0388056 050331 REF 0503314 REF 038804J 1 045771 REF
16. 25 kW Generators ELECTRICAL DATA Wiring Diagram 2 5L Engine 25kW unit Drawing No 021286 CUNTRUL PANEL LEGEND AVR AUTOMATIC VOLTAGE REGULATOR B C BATTERY CHARGER BRI BRIDGE RECTIFIER CB CIRCUIT BREAKER EXCITATION gos 13 Fl i Poe wo F1 FUSE POWER CISA TYPED NOT USED 1 Fe FUSE B C COA TYPE NOT USE 2 Je CONNECTOR CUN PCB iar 3 w1 J3 CONNECTOR 3 CON PCB 0 0 4 We RLI RELAY 1 START RELAY KLe RELAY 2 CENGINE RUM SW AUID UFF MANUAL SWITCH SWe SET EXERCISER SWITCH TERMINAL BLICK 1 TRI TRANSFORMER 1 56 VA 240 16 VAC WHITE W3 5 W3 GREEN W4 6 W4 POD 42 NOT USED 1 START RELAY 56 FUELCRUN RELAY 3 14 2 WIRE STRKD 4 183 MOMENT OPEN T 5 ES15FEF 2 WIRE 6 178 NAN AUTO INPUT 7 515A 16VAC SENSECD 8 224 ALARM RELAY 9 mm RELAY 10 23 NAN INPUT 11 239 SENSED 1 2 225 NOT USED T 3 1 4150 NOTE ALL VIRES ARE ue 18 AWG UL LISTED UNLESS OTHERWISE NOTED AS SHOWN DOOR OGROUNDING WIRE ER d d IL CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMLY GENERATOR MAINLINE BREAKER 040 DUIPUT TD TRANSFER SWITCH TBI INTERCONNECT TERMINAL BLOCK l NEUTRAL BLOCK __ Section 7 Electrical Data Liqu
17. CLAMP HOSE 10 56 1 06 49 0E9737 1 LOWER HOSE ADAPTER 2 5L FORD 50 0F0393 1 O RING 1 3 16 X 1 7 16 X 1 8 51 045757 2 SCREW HHC M6 1 0 X 25 G8 8 52 069860C 1 HOSE OIL DRAIN ASSY 21 53 048031 HOSE CLAMP BAND 5 8 54 055596 1 BARBED STR 3 8NPT X 3 8 55 077456 1 ADAPTER M12 1 75 3 8 56 052677 1 WASHER NYLON 50 X 87 X 06 57 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 58 0E9738A 1 DIPSTICK TUBE 2 5L FORD 59 0F1132 1 COVER R H SIDE ENGINE ADAPTOR 60 0F1133 1 COVER L H SIDE ENGINE ADAPTOR 61 059355 8 SCREW SHC M10 1 50 X 50 G12 9 62 076749 1 TANK COOLANT RECOVERY 63 029032 1 HOSE 9 32 ID 39 LG 64 0F 1433 1 BRACKET 2 5L FORD WATER BOTTLE 65 070007 3 WASHER FLAT M6 SS 66 070005 3 WASHER LOCK M6 SS 67 080826 3 SCREW HHC M6 1 0 X 12 SS 68 045771 1 NUT HEX M8 1 25 G8 YEL CHR 69 048031 2 CLAMP HOSE BAND 1 4 NOTE TORQUE TO 44 FT LBS PARTS Ce LISTS 47 Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Fuel System Drawing No 0E9980 D 6L N I V820130 ASSV NOISH3ANOO dOdVA dl JNION3 OL d3AO9 JA VA OL 48 ITEM PART NO QTY 1 0 8456 1 2 075580 1 3 0 9967 1 4 039253 4 5 022145 2 6 022129 6 7 045771 2 8 0F1570 1 9 0A6344 1 10 0 3994 REF 11 0 1056 1 12 0 0397 1 13 0A5547 1 14 048031 2 15 001509 1 16 0 0591 1 17 059402 1 18 037561 1 19 0 1028 1 20 059401 1 217 091526 4 227 049226 4 23 0263
18. and run the generator When the 2 Wire start signal is removed the control board will imme diately stop the generator 2 11 BATTERY INSTALLATION A DIG A Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel do not connect battery cables until certain that normal source voltage at the transfer switch is correct the generator main line circuit breaker is switched to OFF the AUTO OFF MANUAL switch on the control con sole is switched to OFF the 15A and 5A fuses have been removed from the control console utility fed supply to battery charger terminals N1 and N2 is removed and the system is ready to be placed into operation Ensure that the 5A and 15A fuses in the control panel are removed when connecting or disconnecting battery cables Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery INSTALLATION Section 2 Ins
19. limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state P O BOX 297 WHITEWATER WI 53190 Revision 2 05 Part No OF1007 Revision F 07 25 05 Printed in U S A
20. not strictly complied with may result in personal injury or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa A tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator reads this Owner s Manual and thoroughly understands all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all
21. s Ne TBI AS UTILITY FROM T SM EE 6A 29 TBI A4 TRANSFER COIL RELAY 6 194 TB1 A3 TRANSFER CDIL RELAY NB N urea GE MEM E Y CUSTOMER CONNECTION amp ALTERNATOR LEGEND BRUSH ASSEMLY GENERATOR MAINLINE CIRCUIT BREAKER 13 CA4QV OUTPUT TO TRANSFER SWITCH INTERCONNECT TERMINAL BLUCK NEUTRAL BLICK 155 3e Section 7 Electrical Data Liquid cooled 15 20 and 25 kW Generators ELECTRICAL Electrical Schematic 2 5L Engine 15kW amp 20kW units Drawing No 0F2184 B lt ENGINE WIRING LEGEND PCB Jl ALT D C CHARGE ALTERNATOR IEG Hav 1 BAT 12VDC BATTERY MG 2 15A STARTER CONTACTOR KGW 3 0 COIL PACK COOLANT SENSORS 4 85 S CRANK SENSOR EGO 5 FS FUEL SOLENOID EGY 6 HCT HIGH COOLANT TEMP SWITCH DISTRIBUTOR 12V 7 JL CONECTOR 1 ON PCD NOT USED 3 LOS LOW DIL PRESSURE SWITCH CRANK SENSOR IN 9 0 m SM STARTER CRANK SENSE RET 10 79 140 STM STEPPER NOT USED 1 1 NLS COOLANT LEVEL SWITCH IEG FIK 12 WC 13 154 oil 9 114 158 ain his 2544 L DISTRIBUTOR RET 1 6 DISTR INPUT 17 DEG PVN 18 DEG ENABLE 1 9 LOW OIL PRESS 20 CRANK SHIFLD 21 o CHIL 2 22 H B 423 258 LOS C Y WLS 85 5 gt W gt 0 4 Section 7 Electrical Data Liquid cooled 15 20 and
22. safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized service Dealer Normal maintenance service adjust ments and replacement of parts are the responsibility of the owner operator and as such are not consid ered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by an Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact an Authorized Service Dealer for assistance service technicians are factory trained and are capa ble of handling all service needs When contacting an Authorized Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER please call this number
23. thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such
24. where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A required mini mum allowance of space to any solid structure is three feet Five feet allowance of space is recom mended Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE 2 5 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides INSTALLATION Section 2 Installation Liquid cooled 15 20 and 25 kW Generators 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply a
25. 07 1 24 062522 1 25 022127 1 26 022259 2 27 050279 1 28 0A6125 2 29 0C2454 3 30 0 1104 1 31 0 0668 1 32 0 0590 1 33 0C5133 1 34 0 0665 1 35 0 1108 1 36 033138 1 37 022152 1 38 0 0645 1 39 034339 1 40 059194 1 41 057823 2 42 0 0382 1 INCLUDED IN ITEM 19 CARBURETOR ASSY Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Fuel System Drawing No 0E9980 D DESCRIPTION BRACKET FUEL REGULATOR FLANGE FUEL INLET ASSY FUEL REG 2 5L FRD N G L P SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 NUT HEX M8 1 25 G8 YEL CHR BODY CARBURETOR ASSEMBLY BARBED EL 90 1 8 NPT X 3 8 PCV VALVE 2 5L FORD FUEL HOSE ASSM NAT GAS L P V HOSE CRANKCASE BREATHER COVER AIR CLEANER CLAMP HOSE BAND 1 4 DECAL INLET PRESSURE ADAPTER CARB TO AIR CLNR FILTER ELEMENT NUT WING 1 4 20 NYLK CARBURETOR ASSY 2 51 FORD CARBURETOR GASKET SCREW PPHM M5 0 8 X 12 ZNC WASHER LOCK M5 ELBOW 90D STREET 3 4 STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL NUT HEX 5 16 18 STEEL DECAL FUEL INLET NG STUD 5 16 18 X 1 25 F THR SCREW TH FRM M6 1 X 16 N WA Z JS GASKET AIR CLEANER ADAPTER O RING 2 028 1 38 X 1 50 X 06 VENTURI 20MM 0 RING 29 82 X 2 62 SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM 410 32 X 5 8 WASHER LOCK 410 LEVER THROTTLE STOP BARBED EL 90 3 8 NPT X 5 8 HOSE 5 8 ID LPG amp NG 24 LG CLAMP HOSE 10 56 1 06 HOSE 3 8 90 DEG 2
26. 1 800 333 1322 OR Locate us on the web at WWW generac com Table of Contents 5 Liquid cooled 15 20 and 25 kW Generators INTRODUCTION IFC Section OPERATION 15 Read this Manual IFC 3 1 Control Console Components 15 Operation and Maintenance IFC 3 2 Manual Transfer and Startup 15 How to ODIAN DOE VICE 12 22 09 5 902990 099 0900e Dto IFC 3 9 Engine Governor Gain Adjustments 16 Authorized Service Dealer Location IFC 3 4 Manual Retransfer and Shutdown 17 SAFETY 2 3 5 Automatic Operation 17 Standards o pite uma IER o eEe qa Sape 3 3 6 Weekly Exercise Cycle 17 Section 1 GENERAL INFORMATION 4 3 7 Control Board DIP Switch Settings 18 1 1 Generator 0040 4 3 8 Voltage Regulator 1 18 1 2 Transfer Switch sse 4 Section 4 MAINTENANCE 19 1 3 ATS Mode Automatic
27. 11518 2544 L DISTRIBUTOR RET 1 6 DISTR INPUT p DEG PM 1 8 DEG ENABLE T19 LOW DIL PRESS te 0 86 CRANK SHIELD L21 0 CHIL t Fee COIL G 2328 255 GROUND o BB 8 ws 371 Section 7 Electrical Data Liquid cooled 15 20 and 25 kW Generators ELECTRICAL DATA Electrical Schematic 2 5L Engine 15kW amp 20kW units Drawing No 0F2184 B F2 CONTROL PANEL LEGEND 13 F1 AVR AUTOMATIC VOLTAGE REGULATOR B C BATTERY CHARGER BRI BRIDGE RECTIFIER CBe CIRCUIT BREAKER EXCITATION Fl FUSE BAT PUWER 15 TYPE PCB 554 Fo FUSE B C SA ATO TYPE NOT USED 1 Je CONNECTOR 2 CON PCR NOT USED 2 J8 CONNECTOR 3 ON PCD 3 W1 RI RESISTOR 5 CHM 25 WATT 4 We TR1 RL RELAY 1 START RELAY IEW 5 1 N1 RL RELAY 2 ENGINE RUN 6 W4 n MS SWI AUTO OFF MANUAL SWITCH SW SET EXERCISER SWITCH ce v4 154 TERMINAL BLOCK m ds een 15 TRANSFORMER 1 56 VA 240 16 VAC FUELCRUN RELAY 3 144 WIRE 4 183 MOMENT OPEN 5 15E 2 WIRE START 2 6 178 NAN AUTO INPUT 7 154 SENSECL 8 224 ALARM RELAY 9 XFER RELAY 1 O 23 WW INPUT 7 1 1 239 12 225 NOT USED 1 3 00 8 4 0 DOOR 69 0 NI TB1 A6 UTILITY FROM T SW 144 14 wr 15 15 5
28. 5L PVC LISTS age 49 Section 8 Exploded Views and Parts Lists LISTS 0 Liquid cooled 15 20 and 25 kW Generators KO Alternator Drawing No 0 8660 LOCKTIGHT C Vy O O 5Q ITEM ROTOR REPLACEMENT PARTS 30 31 PART NO 0F1659A 0F1657A 0F1655A 0E5093A 0E7413A OF1660A OF 1658A OF 1656A 0E5094A 0E7412A 0E5706 0 5048 0 5048 0 5048 0 6668 0 6076 046526 051755 04576100 04576100BF 043123 051779 0E7587 023365 0C3993 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F 047248 070892 QTY LK L REF REF REF ARAB p p RAR Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Alternator Drawing No 0E8660 C DESCRIPTION ROTOR 390 15KW 1P DIRECT HSB 2 5L FORD ROTOR 390 20KW 1P DIRECT HSB 2 5L FORD ROTOR 390 25KW 1P DIRECT HSB 2 5L FORD ROTOR 390 30KW 1P DIRECT HSB 3 0L FORD 4 2 5L ROTOR 390 40KW 1P DIRECT HSB 3 9L CHRYSLER STR 390 15AD HSB 382MM LONG 2 5L FORD STR 390 20AD HSB 382MM LONG 2 5L FORD STR 390 25AD HSB 382MM LONG 2 5L FORD STR 390 35AD1 HSB 382MM LONG 3 0L FORD amp 2 5L FORD STR 390 40AD HSB 433MM LONG 3 9L CHRYSLER REAR BEARING CARRIER 390 DRCT FLEXPLATE 3 0L FORD FLEXPLATE 3 9L HSB FLEXPLATE 2 5L FORD FLYWHEEL ASSY 3 0L HSB LG GE
29. 632 0 2629 0 7193 0 6146 po Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Control Panel 15kW and 20kW Drawing No 0F2267 D DESCRIPTION TOP CONTROL PANEL BACK amp BOTTOM CONTROL PANEL PANEL FRONT 2 5L CONTROL PNL ASSY PCB HSB CONTROLLER 2 5L ASSY VOLTAGE REGULATOR 60HZ RELAY 12VDC C FORM W DIODE XFMR 240 16V 1VA amp 56VA CIRCT BRK 8 X 1 ETA 46 500 P ASSY PCB 2A 12V UL BATT CHRGR JUNCTION BLOCK 3 8 16 PCB SUPPORT SNAP IN 1 4 SCREW M4 0 7 X 12 ZYC DIO BRIDGE 25A 600V BRACKET CB SIEMENS BQ BRKT CB MTG BACK CB 0070A 2P 240V S BQ2 LL CB 0100A 2P 240V S BQ2 LL ADPTR LH SIDE WICKMAN 178 6192 ADPTR RH SIDE WICKMAN 178 6191 HOLDER FUSE WICKMANN 178 6150 FUSE ATO TYPE 5 AMP TAN FUSE ATO TYPE 15 AMP BLUE FITTING CONDUIT STR 1 1 2 SCREW PPHM M5 0 8 X 30 ZINC WASHER FLAT 10 ZINC WASHER LOCK 10 NUT HEX M5 0 8 G8 YEL CHR SWITCH ROC DPST 125V SPD SWITCH ROC DPDT ON OFF ON BLOCK TERM 20A 14 X 6 X 1100V SCREW 6 32 X 3 8 ZYC SCREW PHTT M4 0 7 X 16 ZYC SCREW HHC M6 1 0 X 16 68 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW PPPH HI LO 4 24 X 3 8 RES MTG BRACKET HARNESS C PNL 2 5L QS 15 amp 20KW NOT SHOWN SOCKET RELAY RES 5R 5 25W DECAL AVR COVER DECAL WARNING ELECTRICAL SHOCK DECAL TERMINAL BLOCK DECAL CONTROL HSB DECAL WARNINGS HSB HANG TAG 2 WIRE
30. AR REVCOR FAN 10 75 X 2 W PRESS DIS WASHER LOCK M10 SCREW HHC M10 1 5 X 16 G8 8 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD amp 2 5L FORD STUD M14 2 0 X 540 G5 ZINC 3 9L CHRYSLER WASHER LOCK M14 NUT HEX M14 2 0 G8 YEL CHR ASSY BRUSH HOLDER 390 HSB WASHER SHAKEPROOF INT 48 SCREW HHTT M4 0 7 X 25 BP SCREW SHC M10 1 5 X 30 G12 9 WASHER FLAT 688 ID X 3 25 OD KEY SQ 3 8 X 1 STEEL SCREW HHC M16 2 0 X 45 G8 8 WASHER LOCK 8 4 WASHER FLAT 48 ZINC CONDUIT FLEX 1 1 4 30 LG 3 0L FORD amp 3 9L CHRYSLER CONDUIT FLEX 1 1 4 18 LG 2 5L FORD BALL BEARING 45 MM SLIP RING MACHINED age LISTS 51 Section 8 Exploded Views and Parts Lists Ce Liquid cooled 15 20 25 kW Generators KO Muffler Drawing No 0F2930 C 1 rae EN A d pas a x QE eae 10 5 b o oc vM pL n SOP 1 S lt OE UELLE Bo 11 fs 2 IS A ITEM PARTNO QTY DESCRIPTION ITEM PARTNO QTY DESCRIPTION 12 OF2012 1 PIPE MUFFLER OUT 13 042568 4 SCREWHHC M 1 0 X 20 98 8 2 OF2869 1 PIPE EXHAUST 2 5L FORD 14 022097 4 WASHER LOCK M6 1 4 3 0F 2828 1 MUFFLER 2 5L FORD 15 022473 8 WASHER FLAT 1 4 6 ZINC 4 036434 2 BOLT U 5 16 18 X 2 09 16 049813 4 NUTHEX M6 X 1 0 G8 YEL CHR 5 036449 2 SADDLE 2 INCH 17 039253 2 SCREW HHC 8 1 25 X 20 G8 8 6 092129 6 WASHER LOCK 8 5 16 18 045771 2 NUT HEX M8 1 25 G8 YEL CHR 7 022259 4 NUT HEX 5 16 18 STEEL 19 4010
31. ATION SECURE AS SHOWN Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Enclosure Drawing No 0F1645 H SEE LATCH LATCH DETAIL ITEM PART NO 1 0 0783 2 0 0781 3 0 0780 4 0C2454 5 0F0779 6 0 0072 7 0 0072 8 0 0072 9 0 5912 10 0 0787 11 089961 12 0 2115 13 0 0072 14 165 15 0 0165 17 022097 18 022473 19 0 7570 20 0 7571 21 070015 22 0 7662 23 0F0164A 24 0 0164 25 002023 26 078115 27 0 2179 28 0 0788 29 0 7829 30 0D3037A 31 0C7781 32 0 0786 33 0 00720 34 0D3037 35 0 0072 36 OE0072AF 37 0 0072 38 0 0782 39 026850 40 0912970064 41 0912970063 42 049813 43 0 0784 44 0 0785 45 0 8665 46 0 8837 47 359 48 0 8404 Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Enclosure Drawing No 0F1645 H DESCRIPTION DUCT INTAKE MID AL 2 5L DUCT DISCHARGE RH AL 2 5L DUCT DISCHARGE LH AL 2 5L SCREW TH FRM M6 1 X 16 N WA Z JS SUPPORT RADIATOR 2 5L AL Al INSULATION SIDE REAR CORNER POST RH Al INSULATION INTAKE DUCT TOP PANEL Al INSULATION LH SIDE REAR CORNER POST PANEL BOTTOM DOOR SIDE AL SUPPORT RH SIDE AL 2 5L FOAM STRIP 3 4 WIDE X 3 16 THK 40 LG WASHER NYLON 257 Al NSULATION LH SIDE REAR CORNER POST PANEL HINGE TYPE B W STUDS SOCKET HINGE TYPE B W STUDS PIN WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC GAS SP
32. BQ2 Amp Rating of C B structured under model a Figure 1 1 Generator AC Connection System 12 BLACK 2 WHITE VOLTS NEUTRAL Q y RLACK 240 VOLTS CIRCUIT BREAKER 16 MAIN CIRCUIT BREAKER 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 GENERATOR FUEL SYSTEM 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 13 Reconfiguring the Fuel System for LP Vapor Fuel 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 Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability wanNiNG Gaseous fuels such as natural and LP propane gas are highly explosive Even the slightest spark can ignite such fuels and cause an explo sion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 8 ENGINE PROTECTIVE DEVICES The engine has several safety swit
33. Generators Installation Diagram Drawing No 0F1022 A 13NVd 553999 gt MAIA ACIS INIddlO04 3SV8 98778 29vI V1IVaSAD INISdIDDUJ 3SV8 1 8682 9 6 NDILO3NNDO 1303 1 9 N 8 7 1 S 88 DNI L ZTv 901 LJANI 13014 LOv I 89 GE Nm Ho E3 q IILI LHDISH TINSI3AD L 2Z 2 856 310 33S AM3IIV8 IAA eI 39NV3IV3 19 Q V3H33Al L 88 89 SE EZ9I 1994 l3NVd 1041 0 V V J310N 335 T 3LLN 33S 19 31 TIVB3AD AECL 89 81 dAL p L ST 81 02 S3 H dAl L 92 lv 8 01 S3 H L E9 021 LS3HONIJ WW SLIN 50 G 7261 61v 1IND viva 1371100 3314404 M O 72 1 lt 13315 8 6 NIV3G 710 E 1 7 590 TWWANLYN 137 1 ISNUIILO3NNU23 33IASN3S 3NIDN3 S3 DH DNILNNOW L S2v2 919 dfl 8n1S 0 68 8 2 HE 1 28 n 8E 2 S 09 43093844 1102412 3NITNIVW 11984 92 49 96 31VIDWWDOOV TIIM AYAL 7 2679 X 0 87 941 X SOZ SNDISN3WIGQ 3015 AVAL AN311V8 W31SAS 3 11993 LWA 21 713
34. INE GOVERNOR GAIN ADJUSTMENTS 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 err If however adjustments are necessary the following procedure should be followed Figure 3 2 and Section 3 7 iod B ziw g g fs HF E gB 1 I lt J x p e H 06000000 O O O
35. J2 CONNECTOR 2 ON PCB NOT USED 2 J3 CONNECTOR 3 CON PCB 3 W1 RLI RELAY 1 START RELAY 04 4 We TR1 RL2 RELAY 2 ENGINE RUM 5 W3 NI SW1 AUTO OFF MANUAL SWITCH REN 6 4 WE He SW SET EXERCISER SWITCH TERMINAL BLOCK mee we ISA TRANSFORMER 1 56 VA 240 16 VAC START RELAY H 55 FUELCRUN RELAY 3 144 2 WIRE 4 183 MOMENT OPEN 5 15E 2 WIRE START 2 6 178 NAN AUTO INPUT 7 154 16VAC SESECD 8 224 ALARM RELAY 9 XFER RELAY 10 23 MAN INPUT 7 1 1 239 SENSED 1 2 225 NOT USED 1 3 00 8 1 4 0 DOOR 62 0 NI TBI A6 UTILITY FROM T SW 144 14 qT 15 15 5 Ne TBI AS UTILITY FROM T SW CC 6A 23 4 TRANSFER COIL RELAY 33 194 TB1 A3 TRANSFER COIL RELAY NB _ m 26 183 TB1 A2 REMOTE START CCID 15 178 H 181 A1 REMOTE START m x EN CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMLY GENERATOR CBl MAINLINE CIRCUIT BREAKER 13 DUTPUT TO TRANSFER SWITCH INTERCONNECT TERMINAL BLOCK NEUTRAL BLICK 15 36 Section 7 Electrical Data Liquid cooled 15 20 and 25 kW Generators f ELECTRICAL Electrical Schematic 2 5L 25kW unit Drawing No 0F1287 B lt DATA ENGINE WIRING LEGEND PCB Jl ALT D C CHARGE ALTERNATOR DEG Hav 1 BAT 12VDC BATTERY RO 12
36. MBUSTION ENGINES AND GAS TURBINES NFPA 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS INSTALLATION Section 2 Installation 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John otreet New York N Y 10038 AGRICULTURAL WIRING HANDBOOR obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available from the American National otandard Institute 1430 Broadway New York N Y 10018 2 20 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit
37. OMBUSTIBLE LIQ UIDS CODE available same as Item 1 3 GENERAL INFORMATION 1 1 GENERATOR 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 this generator as a source of electrical power for the oper ation of 120 and or 240VAC single phase loads These models are available They are rated as follows Model 005031 0 Provides 25 000 watts 25 kW of single phase power Model 005028 0 Provides 20 000 watts 20 kW of single phase power Model 005030 0 Provides 15 000 watts 15 kW of single phase power warninc amp A If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electric system from the utility distri bution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the genera tor and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system is intended to be used with a matched automatic transfer switch It may be supp
38. PSI 2POL ASSY WATER LEVEL SENSOR C E PL SW TMP 245DEG 3 8NPT BUSHING REDUCER 1 4 TO 1 8 PLUG STD PIPE 3 8 STEEL SQ HD MANIFOLD INTAKE MACHINED STEPPER MOTOR MANIFOLD INTAKE MACH BOSCH32 BOSCH GOV NOT SHOWN GASKET 2 5L FORD INTAKE MAN SCREW HHC 8 1 25 X 20 G8 8 SCREW SHC M6 1 0 X 25 G12 9 ZP WASHER FLAT 5 16 M8 ZINC WASHER LOCK M6 1 4 WASHER LOCK 8 5 16 SCREW HHC 8 1 25 X 25 G8 8 WASHER FLAT 3 8 M10 ZINC WASHER LOCK M10 SCREW SHC M10 1 5 X 35 G12 9 ENGINE FOOT 2 5L FORD DIPSTICK 2 5L FORD BRACKET DIPSTICK TUBE FAN 16 COOLING HARNESS 2 5L FORD ENGINE NOT SHOWN HARNESS 2 5L FORD BOSCH GOV NOT SHOWN SCREW HHC M10 1 0 X 25 G10 9 FLEXPLATE 2 5L FORD ADAPT CASTING MACH 2 5L FORD SCREW SHC M10 1 5 X 30 G12 9 SCREW SHC M10 1 50 X 40 G12 9 SPACER FLEXPLATE HSB GASKET 2 5L FORD EXHAUST MAN MANIFOLD EXHAUST MACHINED Engine Drawing No 0E9918 F O ITEM PART NO QTY DESCRIPTION 35 0E9930 1 HEAT SHIELD EXHAUST MANIFOLD 36 049821 3 SCREW SHC M8 1 25 X 30 G12 9 37 0E9747 1 STARTER 12 VOLT 38 043116 5 SCREW HHC M6 1 0 X 12 G8 8 39 022473 6 WASHER FLAT 1 4 M6 ZINC 40 045772 2 NUT HEX M10 1 5 G8 YEL CHR 41 064416 2 SCREW HHC M10 1 5 X 45 G8 8 42 0 0252 1 SPRING BUSHING 43 0E9868 1 ALTERNATOR D C 44 0 0035 1 BRKT D C ALTERNATOR MACHINED 45 026082 1 SCREW HHC 3 8 16 X 2 1 4 G5 46 0E9928 1 TENSIONER D C ALTERNATOR 47 0 0383 1 HOSE 2 5L FORD COOLANT BY PASS 48 057823 2
39. R S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Dealer as soon as a prob lem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer To locate the Generac Authorized Warranty Service Dealer nearest you call our toll free number 1 800 555 1522 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also th
40. RELAY 9 mm RELAY 4110 23 MAN 11 239 SENSEC2 12 225 NOT USED 1 3 02 1 4160 SET EXERCISER SWITCH TERMINAL BLDCK 1 0 SWI AUTD DFF MANUAL SWITCH C 1 TRANSFORMER 1 56 VA 240 16 VAC NOTE ALL WIRES ARE ANG 18 AWG UL LISTED UNLESS OTHERWISE NOTED AS SHOWN DOOR OGROUNDING WIRE L 1 ol gt mo e CUSTOMER CONNECTION amp ALTERNATOR LEGEND BA BRUSH ASSEMLY GENERATOR MAINLINE CIRCUIT BREAKER C4QV OUTPUT TO TRANSFER SWITCH TBI INTERCONNECT TERMINAL BLOCK l NB NEUTRAL BLOCK __ 3Q Section 7 Electrical Data Liquid cooled 15 20 and 25 kW Generators 25 ELECTRICAL Wiring Diagram 2 5L Engine 15kW amp 20kW units Drawing 0F2183 B lt ENGINE WIRING LEGEND ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY STARTER CONTACTOR P COIL PACK C CRANK SENSOR FS FUEL SOLENOID GND1 GROUND 1 GND2 GROUND 2 HIGH COOLANT TEMP SWITCH JL CONNECTOR 1 ON LOS LOW OIL PRESSURE SWITCH SM STARTER MOTOR STM STEPPER MOTOR WLS COOLANT LEVEL SWITCH POB a DEG 101 1 gt 4 2 16 154 DEG GND 3 COLANT SENSORS 4 85 IG OV 5 DEG 49 x c DISTRIBUTOR 12V 7 NOT USED 8 CRANK SENSOR IN 9 0 CRANK SENSE RET H10 79 NOT USED 1 DEG FIBK 12 1 318 isa fN RI coi 1 416 15 9
41. RING BALL STUD GAS SPRING MOUNT NUT HEX 5 16 18 LOCK SCREW WING M6 1 00 X 25 HINGE TYPE A W STUDS SOCKET HINGE TYPE A W STUDS PIN GASKET CLIP ON SELF GRIPPING 84 LG WASHER SELF LOCKING DOME KIT SAE FOAM 2 5L QUIET SOURCE ROOF 2 5L FORD AL DOOR PANEL LATCH 1 4 TURN NONLOCKING PAWL DOOR HSB SUPPORT LH SIDE AL 2 5L Al INSULATION RAD SUPPORT PANEL LATCH QUARTER TURN LOCKING Al INSULATION SIDE BRACE PANEL RH Al INSULATION SIDE BRACE PANEL LH Al INSULATION ROOF PANEL DUCT DISCHARGE MID AL 2 5L WASHER SHAKEPROOF EXT 1 4 STL ASSY WIRE 14AWG 7 5 0 GRN YEL ASSY WIRE 14AWG 7 5 0 GRN YEL NUT HEX M6 X 1 0 G8 YEL CHR CORNER POST REAR LH SIDE AL CORNER POST REAR RH SIDE AL BRACKET STIFFENER LH FRONT DOOR BATTERY COMPARTMENT SCREW BHSC M6 1 0 X 16 SS BRACKET STIFFENER RH FRONT ALL ITEMS NOTATED WITH Al ARE COMPONENTS OF 0F2179 LISTS age 41 Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Control Panel 15kW and 20kW Drawing No 0F2267 D ae ITEM CONDOR N 15KW 20KW PART NO 0 0790 0 0789 0 0791 0 9704 067680 0 6875 003910 048468 0D5070A 057073 040213 0C2265 029673 0 0793 0 7890 0D5541 0D5544 0 1264 0F 1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 0C2699 0C2212 047411 022097 022473 0 7358 064733 0 0798 0 6881 048352 001127 001229 0 2
42. SHER FLAT 10 ZINC WASHER LOCK 10 NUT HEX M5 0 8 G8 YEL CHR SWITCH ROC DPST 125V SPD SWITCH ROC DPDT ON OFF ON BLOCK TERM 20A 14 X 6 X 1100V SCREW PHTT 6 32 X 3 8 270 SCREW PHTT M4 0 7 X 16 ZYC SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW PPPH HI LO 4 24 X 3 8 HARNESS CTRL PNL 2 5L FORD AL NOT SHOWN SOCKET RELAY DECAL AVR COVER DECAL WARNING ELECTRICAL SHOCK DECAL TERMINAL BLOCK DECAL CONTROL HSB DECAL WARNINGS HSB HANG TAG 2 WIRE START NOT SHOWN LISTS age 45 LISTS Section 8 Exploded Views and Parts Lists 0 Liquid cooled 15 20 and 25 kW Generators Engine Drawing No 0 9918 MOTOR UNITS STEPPER ONLY FOR HARNESS ITEM NOOB WD PART NO 0E9909 0E9739 049814 0 0001 0D3488B 0A8584 0 0561 6751 035579 026925 0 9611 0E9611A 0 9681 039253 097962 022145 022097 022129 043107 022131 046526 052625 0 9708 0 9738 0 9929 0 0230 0 9834 0 9834 005417 0 5048 0 9655 057192 060619 0 8940 0 9680 0 9609 1 8 1 1 1 1 OD Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators DESCRIPTION ENGINE 2 5L FORD PULLEY 2 5L FORD WATER PUMP SCREW HHC M10 1 5 X 25 G8 8 CLUTCH COOLING FAN 2 5L FORD SERPENTINE BELT 40 85 LENGTH SWITCH OIL PRESSURE 10
43. START NOT SHOWN LISTS age 43 Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Control Panel 25kW Drawing No 0E7615 C ITEM CONDOR N PART NO 0 0790 0 0789 0 0791 0 9704 067680 0 6875 003910 054450 0D5070A 057073 040213 0C2265 029673 0 0793 0 7890 0A2077 0 1264 0F 1263 0F1262 0E7403A 0E7403C 0E2514 020911 023897 022152 051716 082573 0E4494 0C4167 0C2699 0C2212 047411 022097 022473 0 7358 0 0798 0 6881 001127 001229 0 2632 0 2629 0 7193 0 6146 po Section 8 Exploded Views and Parts Lists Liquid cooled 15 20 and 25 kW Generators Control Panel 25kW Drawing No 0E7615 C DESCRIPTION TOP CONTROL PANEL BACK amp BOTTOM CONTROL PANEL PANEL FRONT 2 5L CONTROL PNL ASSY PCB HSB CONTROLLER 2 5L ASSY VOLTAGE REGULATOR 60HZ RELAY 12VDC C FORM W DIODE XFMR 240 16V 1VA amp 56VA CIRCT BRK 5 5 X 1 ETA 46 500 P ASSY PCB 2A 12V UL BATT CHRGR JUNCTION BLOCK 3 8 16 PCB SUPPORT SNAP IN 1 4 SCREW M4 0 7 X 12 ZYC DIO BRIDGE 25A 600V BRACKET CB SIEMENS BQ BRKT CB MTG BACK CB 0125A 2P 240V S BQ2 LL ADPTR LH SIDE WICKMAN 178 6192 ADPTR RH SIDE WICKMAN 178 6191 HOLDER FUSE WICKMANN 178 6150 FUSE ATO TYPE 5 AMP TAN FUSE ATO TYPE 15 AMP BLUE FITTING CONDUIT STR 1 1 2 SCREW PPHM 5 0 8 X 30 ZINC WA
44. The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire f because they generate hydrogen gas The fol lowing procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries 43 INSTALLATION Section 2 Installation Liquid cooled 15 20 and 25 kW Generators 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 Section 4 Maintenance A negative ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in r
45. WOUIETSOURCE 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 caution amp ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION INTRODUCTION 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 product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAU TION and NOTE blocks are used to alert personnel to special instructions about a particular service or oper ation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A 1091 A After this heading read instructions that if not strictly complied with will result in serious person al injury including death or property damage wanNiNG amp After this heading read instructions that if
46. Y SHALL NOT APPLY TO THE FOLLOWING Quietsource generators that utilize non Generac replacement parts Quietsource generators utilizing non Generac automatic transfer switches Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Any Quietsource generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental co
47. ad gasket on the block Figure 4 2 Position cylinder head to cylinder block Install 10 cylinder head bolts in numerical sequence Tighten to 70 N m 52 lb ft in sequence Retighten to 70 N m 52 lb ft in sequence Then turn all head bolts an additional 90 100 degrees in sequence o gt Figure 4 2 Cylinder Head Installation CYLINDER HEAD GASKET CYLINDER sj EN E E j om f 1 e fi f B 2 k bye EL ka 00024 4 5 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram eo Liquid cooled 15 20 and 25 kW Generators WARNING amp The exhaust system parts from this product get its extremely hot and remains 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 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board a 15 amp fuse These overcurre
48. arbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness even death For that reason adequate ventilation must be provided Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the instal lation or permit even partial blockage of ventilation provi sions as this can seriously affect safe operation of the gen erator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only fac tory approved parts Before performing any maintenance on the generator dis connect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakag
49. ase as fre quency drops set the UNDERFREQUENCY ADJUST pot fully CW C To obtain a constant voltage regulation as fre quency decreases set the UNDERFREQUENCY ADJUST pot fully CCW 10 With the electrical load still applied check the REGULATOR LED for flashing If the LED is flashing adjust the STABILITY pot until the flash ing stops 11 If better response is needed adjust the GAIN pot clockwise CW as needed Then if needed cor rect for stability by adjusting the STABILITY pot 12 Turn OFF the electrical loads 13 Verify that all the voltage regulators LED s are ON 14 Turn OFF the generator 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS Check battery condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY Test engine governor adjust or repair if needed Clean inspect generator Flush cooling system ui o Gee T ee ES MAINTENANCE 2 9 Section 4 Maintenance D FIRST 100 OPERATING HOURS 1 Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or six months whichever comes first 2 Retorque cylinder head see torque specs Retorque intake and exhaust manifold see torque specs
50. cal loads from the generator initial adjustments are done under no load con ditions Figure 3 4 Voltage Regulator VOLTAGE ADJUST gt GAIN gt STABILITY UNDERFREQUENCY 6 ADJUST d REGULATOR SENSING gt EXCITATION gt 2 Connect an accurate voltmeter fre quency meter to the generator s AC output leads 3 On the voltage regulator set the potentiometers as follows A Turn the Voltage Adjust pot fully counterclock wise CCW B Set the GAIN pot to its centered mid position C Set the STABILITY pot to its centered mid position D DO NOT adjust the UNDERFREQUENCY ADJUST pot 4 Start the engine Let it stabilize and warm up at no load o Verify that the three voltage regulator s LED s are ON 6 Check the reading on the AC frequency meter Liquid cooled 15 20 and 25 kW Generators 7 Turn the voltage regulators VOLTAGE ADJUST pot to obtain a line to line voltage of A 240 VAC if the generator has been configured for 60 Hertz operation B 200 if the generator has been configured for 50 Hertz operation 8 If the RED REGULATOR LED is flashing adjust the STABILITY pot in either direction until the flashing stops 9 Apply an electrical load and check the engine speed recovery A Adjust the UNDERFEQUENCY ADJUST pot CCW to reduce load during engine recovery B For flat regulation no voltage decre
51. ched to OFF the individual fault LED will turn OFF and the five red LEDs will begin flashing to show exercise has still not been set 17 OPERATION Section 5 Operation gt Liquid cooled 15 20 and 25 kW Generators 5 7 CONTROL BOARD DIP SWITCH SETTINGS 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 caution amp If the DIP switch settings are not set correctly A the generator may not start or operate correct ly warninc amp A 240 VAC can be present within the control panel If it is necessary to select an alternate switch position move the AUTO OFF MANUAL switch to the OFF position Remove the 15 amp fuse in the generator control panel Move the DIP switch position that needs to be changed to its new position Wait five sec onds then re install the 15 amp fuse The ON position is marked on the switch and is shown in Figure 3 2 Switch Position 1 Selects the generator alternator output frequency and is factory pre set for 60 Hz Switch Position 2 Selects the type of transfer switch and is factory pre set for an automatic trans fer switch 5 Switch Position 3 Selects the type of governor control used and is factory pre set for stepper motor operation Switch Position 4 Selects t
52. ches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Section 1 General Information Liquid cooled 15 20 and 25 kW Generators Figure 1 3 Engine Protective Devices HIGH COOLANT LOW COOLANT LOW OIL LEVEL SWITCH PRESSURE E SWITCH 4 y y Z 1 81 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 8 2 HIGH COOLANT TEMPERATURE SWITCH Normally open N O thermostatic switch has sens ing tip which is immersed in captive coolant Should coolant temperature exceed about 230 F 110 C the switch contacts close which causes the engine to shut down automatically Figure 1 5 Figure 1 5 High Coolant Temperature Switch 1 8 5 LOW COOLANT LEVEL SWITCH 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 To prevent such o
53. ctrical 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 result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy A open bottom is used the engine genera f tor must be installed over non combustible materials and should be located such that com bustible materials are not capable of accumu lating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standards and regula tions pertaining to the installation caution amp After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regula tions NOTE For more information about the installation of a standby system contact an Authorized Service Dealer 211 STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA No 37 STATIONARY CO
54. d circuits to the generator so the generator can power them When the utility source voltage has been restored the transfer switch re transfers the load cir cuits back to the utility source voltage and the gener ator shuts down 1 4 ENGINEERED TRANSFER SWITCH 2 WIRE START GTS MODE When required the pre packaged standby generator can be installed with an engineered W type transfer switch which controls utility voltage sensing weekly exercising and load transferring UTILITY voltage sensing weekly exercising and load transferring is then under the control of the Engineered W type transfer switch GTS Mode 1 5 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase 3 wire generator AC connection system Figure 1 1 The stator assembly in this system consists of a pair of stationary windings with two leads brought out of each winding Each single winding can supply 120 VAC 60 Hertz When the two windings are connected in series a 240 VAC 60 Hertz AC output results Typically the two hot leads in the circuit are Wires No 11 and 44 The Neutral leads are the junction of Wires 22 and 33 Figure 1 2 Main Circuit Breaker Model Rating Phase Actual Current 005031 0 25 000 W 1 104 2 A 005028 0 20 000 W 1 83 3 A 005030 0 15 000 W 1 62 5 C B Rating 2e over rating Circuit Breaker 125 12096 125A BQ2 100A 12096 100A BQ2 70A 11296 70A
55. d capable persons to install operate or main tain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator rotating and or hot during operation Exercise care near running gen erators followed during installation and maintenance of the generator and batteries GENERAL HAZARDS For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by an Authorized Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regu lations Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed operated and serv iced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain c
56. e Generac Power Systems Inc Two Year Limited Warranty which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Dealer When requesting warranty serv ice evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 55190 Part 1 56 Section 10 Warranty Liquid cooled 15 20 and 25 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months
57. e oil leakage etc Important Safety Instructions SAFETY RULES Liquid cooled 15 20 and 25 kW Generators ELECTRICAL HAZARDS 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 Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT If personnel must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden plat form Work on the equipment only while standing on such insulative mats The National Electrical Code NEC Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static elec tricity Never disconnect
58. e switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact an Authorized Service Dealer Auto reset Wait 5 min and attempt restart 27 5 es Section 6 Notes Liquid cooled 15 20 and 25 kW Generators Section 6 Notes Liquid cooled 15 20 and 25 kW Generators NOTES e Section 7 Electrical Data Liquid cooled 15 20 and 25 kW Generators ELECTRICAL _ ue Wiring Diagram 2 5L Engine 15kW amp 20kW units Drawing 0F2183 B CUNTRUL PANEL LEGEND AVR AUTOMATIC VOLTAGE REGULATOR B C BATTERY CHARGER BRI BRIDGE RECTIFIER CB CIRCUIT BREAKER EXCITATION FL FUSE POWER 15 TYPE Fe FUSE B C 5A TYPE CONNECTOR CON PCB 3 CONNECTOR 3 CON PCB ES NOT USED 1 NOT USED 2 77 UJ NNNM 8 3 W1 R1 RESISTOR 5 OHM 25 WATT RED 4 We RLI RELAY 1 START RELAY RL2 RELAY 2 ENGINE RUM WHITE W3 W3 GREEN W4 6 W4 POB UZ NOT USED 1 START RELAY 564 FUELCRUN RELAY 3 144 WIRE START 4 193 MONENT OPEN 5 16 152 gt VIRE START 6 178 manvauTo 7 18154 8 224 ALARM
59. e transfer switch must meet the following requirements 10 It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit It must be installed between the buildings main distribution panel and the emergency distribution panel 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed the Total Circuit Isolation Method may be used The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution panel 2 7 GROUNDING THE GENERATOR A GROUNDING LUG Figure 2 2 is provided on the generator mounting base for the purpose of ground ing the frame and the external electrically conductive parts of the equipment to an approved earth ground and or grounding rods where required by the National Electrical Code Consult a qualified electri cian for grounding requirements in the area Grounding procedures must meet local regulations 1091 A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the ge
60. ent SAVE THESE INSTRUCTIONS This manual contains important instructions that should be WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm 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 rules or precautions The manufacturer cannot anticipate every possible cir cumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufac turer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique chosen does not render the generator unsafe A Dia A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible an
61. everse 2 12 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed serv iced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equip ment 2 12 1 PRIOR TO INITIAL START UP caution amp y Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 12 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems for additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be prope
62. he type of fuel being used and is factory pre set for natural gas Switch Position 5 Selects the engine displacement and is factory pre set for a 2 5 liter 2 5L engine Switch Position 6 Selects the number of engine cylinders and is factory pre set for four cylinders Switch Position 7 Selects the direction of rotation of the governor stepper motor and is factory pre set for CCW rotation rotation is observed looking at the stepper shaft as it moves from closed throttle to open throttle Switch Position 8 Selects whether the control is in the Normal Mode of operation or Test 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 Test Mode the gain trimpots are active and can be adjusted See Section 3 3 5 8 VOLTAGE REGULATOR ADJUSTMENT Four adjustment potentiometers are provided on the voltage regulator installed in the control panel Figure 3 4 These are a voltage adjust b gain c stabili ty and d underfrequency adjust The voltage regula tor potentiometers have been factory set and SHOULD NOT be adjusted If however adjustments are necessary contact the local Dealer to implement the following procedure wanNiNG A High voltage is present inside the control panel during this procedure 1 Disconnect all electri
63. id cooled 15 20 and 25 kW Generators EE ELECTRICAL Wiring Diagram 2 5L Engine 25kW unit Drawing No 021286 lt DATA lt ENGINE WIRING LEGEND ALT D C CHARGE ALTERNATOR BAT 12VDC BATTERY STARTER CONTACTOR COIL PACK C CRANK SENSOR FS FUEL SOLENOID GND1 GROUND 1 GND2 GROUND 2 HIGH COOLANT TEMP SWITCH CONNECTOR 1 CON PCB LOS LOW PRESSURE SWITCH SM STARTER MOTOR Fibra DEG 121 e M 2 26 154 DEG GND 3 COOLANT SENSORS 4 85 600 5 DEG 5 S DISTRIBUTIR 12V 7 8 CRANK SENSOR IN 9 0 m CRANK SENSE RET Li j Fo NH USED F1 1 0 7 le SIM STEPPER MUTOR h 4388 154 WLS COOLANT LEVEL SWITCH coi 1 418 152 a 15018254414 DISTRIBUTOR 1 6 DISTR INPUT 17 DEG PY 1 8 JEG ENABLE 119 LOW DIL PRESS 20 86 CRANK SHIELD 121 0 CHIL t9 22 CHIL 2 3 25 _ GROUND w s 35 Section 7 Electrical Data Liquid cooled 15 20 and 25 kW Generators ELECTRICAL 5 Electrical Schematic 2 5L 25kW unit Drawing No 021287 PZ CONTROL PANEL LEGEND 13 F4 econ AVR AUTOMATIC VOLTAGE REGULATOR s B C BATTERY CHARGER BRI BRIDGE RECTIFIER CIRCUIT BREAKER EXCITATION F1 FUSE POWER 15 TYPE J3 Fo FUSE B C SA TYPE NOT USED 1
64. ill use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 9 2 BATTERY lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any bat tery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindne
65. it APU Generator 3 Standby Generator Part 2 57 Section 10 Warranty WARRANTY Liquid cooled 15 20 and 25 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR QUIETSOURCE PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Quietsource generator will be free from defects in material and workmanship for the items and period set forth below Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or an Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Quietsource prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANT
66. itch AC output power terminals that go to the load circuit distribution panel Transfer owitch terminals 1 and E2 are the AC power termi nals that come from the generator s main alternator Figure 2 3 Connection Diagram ATS Mode FROM UTILITY MAIN LINE CIRCUIT BREAKER OR FUSE FUSE N1N2 T1 N2 2 FUSE TO LOAD FEEDER CIRCUITS LOAD DISTRIBUTION PANEL GENERATOR TRANSFER SWITCH E1 E2 194 D L 194 HS 23 23 18 E1 E2 N2 N1 11 INSTALLATION Section 2 Installation 2 10 ENGINEERED TRANSFER SWITCH 2 WIRE START GTS MODE When required the pre packaged standby generator can be installed with an engineered W Type transfer switch which controls utility voltage sensing weekly exercising and load transferring When Position 2 of the eight position DIP switch which is located on the generator circuit board See Figure 3 2 is in the ON position then utility voltage sensing weekly exercising and load transferring is under the control of the Engineered W Type transfer switch GTS Mode Generator DIP Switch Position 2 ON 2 Wire Start GTS Mode The generator control board will NOT monitor the utility The generator control board will NOT perform a weekly exercise The five red LEDs will flash one at a time in GTS mode The generator control board wil
67. itch transfers the load circuits to the generator so the generator can power them When the utility source voltage has been restored the transfer switch re transfers the load cir cuits back to the utility source voltage and the gener ator shuts down INSTALLATION Section 2 Installation The HS Type transfer switch is controlled by the gen erator circuit board via control wires 23 and 194 Wire 23 connects the relay driver output collector of an transistor on the generator circuit board to the low side Terminal 23 of the transfer relay coil in the transfer switch Wire 194 connects positive battery voltage from the generator circuit board to the high side Terminal 194 of the transfer relay coil in the transfer switch caution If generator wires 23 and 194 are not wired to the correct terminals in the transfer switch the circuit board in the generator control panel will be damaged In order for the generator utility voltage sensing and battery charging functions to work it is necessary to provide a 5 amp fused 240Vac utility source connec tion from the transfer switch main N1 and N2 termi nals to the generator control panel N1 and N2 termi nals See Figure 2 3 Transfer Switch terminals N1 and N2 also called Utility 1 and Utility 2 are the input utility AC power connections to the Transfer Switch Transfer Switch terminals T1 and T2 also called Load 1 and Load 2 are the transfer sw
68. itude engine condition and other fac tors Engine power will decrease about 3 5 for each 1000 feet above sea level and will decrease an additional 196 for each 10 F above 60 F Maximum output power of the generator is limited by maximum engine power 7 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration not to exceed 14 inch es water column 10 Move DIP switch position 4 on the control board to the off position LP vapor see Figure 3 2 and Section 3 7 11 Reverse the procedure to convert back to natural gas gt SS S Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 FUEL HOSE FUEL HOSE BRASS HOSE BRASS HOSE PLUG FITTING FITTING OUT OUT PORT 1 PORT 2 PLUG FUEL INLET Q Q NG FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made A NE A Serious injury or damage may occur if not con figured properly Please consu
69. l NOT activate the transfer output The generator control board WILL monitor all engine conditions and shut down on all the faults listed in this document For the W Type transfer switch to control utility volt age sensing weekly exercising and load transferring suitable wiring must also be connected from the transfer switch 178 and 183 2 Wire Start terminals to the corresponding generator 178 and 183 2 Wire Liquid cooled 15 20 and 25 kW Generators Start terminals Recommended wire gauge sizes for the 2 Wire Start wiring depend on the length of the wire see wiring length chart MAXIMUM WIRE LENGTH RECOMMENDED WIRE SIZE No 18 AWG No 16 AWG No 14 AWG No 12 AWG 460 feet 140m 461 to 730 feet 223m 731 to 1 160 feet 354m 1 161 to 1 850 feet 565m Route the 2 Wire Start control wires through suitable approved conduit which is separate from the AC power leads Connection of wire 178 to wire 183 by relay contact closure action volt free switch contacts in the transfer switch must result in generator engine cranking and startup See Figure 2 4 caution amp A Do NOT connect battery voltage utility voltage N1 N2 or load voltage T1 T2 to either the 178 or the 183 2 Wire start terminals as this will damage the generator control board In order for the generator battery charging function to work it is necessary to provide 5 amp fused 240Vac utility source connection from the tra
70. lant recovery bottle See opecifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an Authorized Service Dealer Inspect cooling system and coolant recov ery system for leaks 4 8 MAINTENANCE OWNER OPERATOR CAN PERFORM 4 8 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels 4 8 2 CHECK BATTERY See Checking Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 4 8 5 EXERCISE SYSTEM otart the generator engine at least once every seven days and let it run at least 12 minutes See Weekly Exercise Cycle 4 8 4 INSPECT COOLING SYSTEM Inspect engine cooling system Maintenance ochedule Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 8 5 CHECK ENGINE COOLANT LEVEL oee Checking Fluid Levels MAINTENANCE 2 9 Section 4 Maintenance 4 8 06 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded n
71. lied in either a NEMA 1 enclosure or a NEMA 3R enclo sure The NEMA 1 enclosure is intended for indoor use only The NEMA 3R enclosure is weather proof and can be used indoors or outdoors Follow these rules Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors Section 1 General Information Liquid cooled 15 20 and 25 kW Generators If a transfer switch is not included one may be pur chased separately from an Authorized Dealer 1 5 AUTOMATIC TRANSFER SWITCH ATS MODE When this generator along with an H5 Type automat ic transfer switch has been installed and connected a circuit board in the generator control panel con stantly monitors the utility voltage and controls the operation of the transfer switch In ATS Mode utility voltage sensing weekly exercis ing and load transferring is under the control of the generator should the utility voltage drop below a preset value and remain at this low voltage for a preset amount of time the generator cranks and starts After the gen erator starts the transfer switch transfers the loa
72. lt an Authorized Service Dealer with any questions 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Temperature Above 80 F 27 C Oil Grade Recommended SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 32 to 80 F 1 to 27 C Below 32 F 0 C Section 1 General Information Liquid cooled 15 20 and 25 kW Generators NOTE Synthetic oil is highly recommended when the generator will be operating in ambient tempera tures which regularly exceed 90 F and or fall below 30 caution amp Any attempt to crank or start the engine before A it has been properly serviced with the recom mended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS 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 deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution amp A Do not use any chromate base rust i
73. nd the STANDBY GENERATOR output are connected to an approved transfer switch The trans fer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER SWITCH TO LOAD CIRCUITS STANDBY GENERATOR J OUTPUT MAIN LINE CIRCUIT BREAKER NOTE The manufacturer recommends the use of a Generac Power Systems transfer switch in con junction with this generator 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within its wattage amperage capacity dur ing utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel The generator only supplies electrical circuits connected to the emergency distribution panel during utility power outages Load circuits powered by that panel must be within the wattage amperage capacity of the generator set Th
74. nected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components Liquid cooled 15 20 and 25 kW Generators 3 1 CONTROL CONSOLE COMPONENTS The components of a home standby generator control console Figure 3 1 are as follows Figure 3 1 Generator Control Console omew O A CAUTION OVER SPEED LOW COOL LEVEL 5 COOL TEMP RISK OF ELECTRICAL SHOCK DO NOT REMOVE COVER NO USER SERVICEABLE LOW OIL PRESS PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL LOW BATTERY LED INDICATORS SYSTEM READY A CAUTION Ay FLASHING GREEN LED NO UTILITY SENSE pee N AUTO MODE ONLY eee READY UTILITY POWER ON FOR STAND BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATED RED LED S INDIVIDUAL FAULT TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE PART I FOR CI amp TTENTION POUR L ALIMENTATION DE RESERVE CONNECTER LA SORTIE DE L AUTO A UN COMMUTATEUR DE CALIBRE APPROPRIE CONFORMENENT AU DODE CANADIEN DE L ECTRICITE PREMIERE PARTIE I OFF WARNING CAN AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE PERMA ON MALAY REMOVE FUSE ON CONTROL PANEL AND NEGATIVE BATTER CABLE FIOR T SERVICING EXERCISE PS _4 WARNING
75. nerator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG Liquid cooled 15 20 and 25 kW Generators 2 8 GENERATOR AC NEUTRAL CONNECTIONS 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 depends on the electrical characteristics of the particular installed generator 2 9 AUTOMATIC TRANSFER SWITCH ATS MODE When this generator along with an H5 Type automat ic transfer switch has been installed and connected a circuit board in the generator control panel con stantly monitors the utility voltage and controls the operation of the transfer switch To implement this mode of operation Position 2 of the eight position DIP switch which is located on the generator circuit board see Figure 3 2 must be in the OFF position In ATS Mode utility voltage sensing weekly exercising and load transferring is under the control of the generator Should the utility voltage drop below a preset value and remain at this low voltage for a preset amount of time the generator cranks and starts After the gen erator starts the transfer sw
76. ngine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule Section 6 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 07 1 17 mm 0 042 0 046 inch by carefully bending the ground elec trode Figure 4 2 Figure 4 4 Setting the Spark Plug Gap SET PLUG GAP AT 1 07 1 17 mm 0 042 0 inch CR 5 JZ SN ee Liquid cooled 15 20 and 25 kW Generators 4 8 15 COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See Specifications for cooling system recommenda tions 4 9 MISCELLANEOUS MAINTENANCE 4 9 1 CLEANING THE GENERATOR 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 Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer That deal er w
77. nhibitor with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating DO NOT use any solu ble oil inhibitor for this equipment 1 16 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in the installation manual Part No 079699 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power It may be necessary to group the critical essential loads together and wire them into a separate emergency distribution panel This generator can be installed in conjunction with an engineered transfer switch if necessary see Section 2 10 The standard prepackaged transfer switch ATS mode does not have sensing or controlling circuit boards Instead the generator control console hous es a Printed Circuit Board Assembly which con trols all phases of operation including engine start up and load transfer Liquid cooled 15 20 and 25 kW Generators 21 STANDBY GENERATOR INSTALLATION A A Connecting this generator to an ele
78. nsequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above
79. nsfer switch main N1 and N2 terminals to the generator control panel N1 and N2 terminals See Figure 2 4 Figure 2 4 Connection Diagram GTS Mode FROM UTILITY MAIN LINE CIRCUIT BREAKER OR FUSE FUSE N1 INI N2 FUSE W TYPE TRANSFER SWITCH TO LOAD FEEDER CIRCUITS LOAD DISTRIBUTION PANEL GENERATOR Liquid cooled 15 20 and 25 kW Generators Transfer Switch terminals N1 and N2 also called Utility 1 and Utility 2 are the input utility AC power connections to the Transfer Switch Transfer 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 owitch terminals 1 and E2 are the AC power termi nals that come from the generator s main alternator When in GTS mode the control board will respond as follows based on the generator AUTO OFF MANU AL switch position OFF The generator will not start and run in this position MANUAL The generator control board will start and run the generator whenever the switch is in the manual position AUTO The generator control board will monitor the 2 Wire start circuit terminals 178 and 183 in the generator control panel When a 2 Wire start signal is issued by the W type engineered transfer switch via a relay contact closure that connects wire 178 to wire 183 the generator control board will immedi ately start
80. nt protection devices will open if the circuit is overloaded caution amp If a circuit breaker opens or a fuse element A melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 CHECKING FLUID LEVELS 4 7 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 3 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommen dations for recommended oils Figure 4 3 Oil Dipstick and Oil Fill Cap Engine Cil Fill Cap Air Cleaner VAN AVAVA 000000 KOO Y N NAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAS NS IVAVAVAVAVAVAVAVAVAVA AA N 7 AAA 2 5 lt IIT KO Liquid cooled 15 20 and 25 kW Generators 4 7 2 BATTERY FLUID 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 TAP WATER IN BATTERY 4 75 ENGINE COOLANT Check coolant level in coo
81. p Date 3 months Date Date to be done Date Initials Initials Initials Initials 1 Disable the unit from operating per the first page warning Adjust as necessary level Adjust as necessary 4 Check the engine coolant le Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and mI necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessary 10 Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary 11 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary 25 Section 4 Maintenance MAINTENANCE Liquid cooled 15 20 and 25 kW Generators S 13 14 15 16 17 18 19 20 21 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to be done Comp to be done Comp Required to be done Date 3 months Date Date
82. part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Dealer 5 When the engine is inspected by a Generac Authorized Warranty Service Dealer the owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac au
83. pply voltage to the trans fer switch has been positively turned Off using whatever means provided such as utility main line circuit breaker Set the generator s main circuit breaker to its Off or Open position Let the generator engine run at no load for a few minutes to stabilize internal unit temperatures On the generator console set the Auto Off Manual switch to Off Wait for engine to come to a complete stop For transfer to utility position refer to the Owner s Manual of the particular transfer switch Turn on the utility power supply to the transfer switch using whatever means provided such asa utility main line circuit breaker The utility power source now powers the loads 3 5 AUTOMATIC OPERATION To 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 MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 6 WEEKLY EXERCISE CYCLE The engine control board will start and run the gen erator once every seven days for approximately 12 minutes If utility should fail during this exercise period the engine control board will transfer the load to the generator output and continue to run until util ity returns On the day and at the time of day chosen for the gen erator to exercise set the weekly exercise cycle as fol low
84. rature Low Coolant Level OPERATION See Section 1 7 for further explanation of engine pro tection functions Section 3 Operation 5 1 5 15 AMP FUSE 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 3 1 4 5 AMP FUSE This fuse protects the battery charger against electri cal overload and is located inside the control panel If the fuse needs to be replaced use only an identical 5 amp replacement fuse type ATO NOTE This fuse will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset 5 1 5 SET EXERCISE TIME SWITCH This switch allows programming the generator to start and exercise automatically See Weekly Exercise Cycle see Figure 3 3 and Section 3 6 3 1 6 SYSTEM READY LED The System Ready LED green has two main pur poses First the LED will be ON when the AUTO OFF MANUAL switch is in the AUTO position utility is present and there are no system alarms This ON state indicates the system is fully ready for automatic operation The system ready LED will be OFF when the switch is in the MANUAL or OFF positions The system ready LED is also used to indicate the p
85. resence of utility sensing at the PCB when the switch is either in the AUTO or MANUAL modes The LED will flash at the rate of 1 2 second on 1 2 second off if the utility sensing level is below the transfer back threshold This secondary function is only available with DIP switch two in the OFF position ATS automatic transfer switch application 5 2 MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby EMER GENCY power source side and start the engine man ually refer to the Owner s Manual of the particular transfer switch 75 OPERATION Section 5 Operation gt Liquid cooled 15 20 and 25 kW Generators Condition System Low Low High Over Over Ready Green Bat Red Oil Red Temp Red Speed Red Crank Red Manual Auto Off Generator Switch is OFF X OFF OFF OFF OFF in the OFF Mode Automatic Start Generator Switch is OFF X OFF OFF OFF OFF in the MANUAL Mode X Weekly Exerciser Flashing Flashing Flashing Flashing Flashing is not set 1 sec rate Battery Voltage 12 2V X ON for gt 1 minute Non latching or o Tolo Battery Voltage 6V Unit Shutdown due OFF to Low Oil Pressure Unit Shutdown due to High Coolant Temperature or Low Coolant Level Unit Shutdown due to Engine Overspeed Unit Failed to Start during its Crank Cycle Utility Voltage is Flashing lt 45 of Nominal 1 sec rate Engine Speed Signal Fault OFF Control Board is in GTS Mode 5 5 ENG
86. rly located and mounted in strict compliance with applicable codes standards and regulations 2 12 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and volume and b is properly purged and leak tested according to code No fuel leakage is permitted 2 12 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 12 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant 2 12 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inches 10 to 16 mm 2 12 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged properly installed and intercon
87. s 1 Place the AUTO OFF MANUAL switch in the AUTO position Figure 3 3 2 Press and hold the Set Exercise Time switch for five seconds then release At this time all five red LEDs will flash for approxi mately 10 seconds then the engine will start and run for its 12 minute exercise period then shut down The generator will now start and run each week at the same time Figure 3 3 Set Exercise Time Switch RED LED S INDIVIDUAL FAULT SEE OWNER S MANUAL FOR COMPLETE LED DETAILS AUTO OFF OFF ON SET MANUAL EXERCISE TIME TOSETEXERCISERTIME 1 PLACE AUTO OFF MANUAL SWITCH TO AUTO POSITION 2 HOLD SET EXERCISE TIME SWITCH IN ON POSITION FOR THREE SECONDS AND RELEASE SEE OWNER S MANUAL FOR COMPLETE DETAILS THE EXERCISER IS NOW SET ALL FIVE RED LED S WILL FLASH FOR 10 SECONDS THEN THE UNIT WILL START RUN THROUGH THE EXERCISE CYCLE AND SHUTDOWN If DC power to the control board is lost the weekly exercise setting will be lost This is indicated by all five red LEDs continually flashing In this state the generator will still start and run in MANUAL mode or automatically start and run if utility is lost while in AUTO mode but it will not perform a weekly exercise cycle If a failure occurs while running in this mode the five red LEDs will stop flashing the individual fault LED will turn on and the engine will shut down Once the AUTO OFF MANUAL switch has been swit
88. ss or other serious injury Liquid cooled 15 20 and 25 kW Generators 4 9 5 BATTERY MAINTENANCE The battery should be inspected per Section 4 7 ocheduled 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 DISTILLED WATER ONLY Do not use tap water in batteries 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water A Do not use any jumper cables or booster bat
89. t down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 4 1 counterclockwise and remove Properly dispose of old filter 21 MAINTENANCE 2D Section 4 Maintenance 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters caution A After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 4 8 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 1 See the Service Schedule for air cleaner mainte nance 4 8 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary Figure 4 4 See Section 6 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the e
90. tallation Battery electrolyte fluid is extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water WARNING A Do not dispose of the battery in a fire The bat tery is capable of exploding Do not open mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short cir cuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 11 1 VENTED BATTERIES caution amp A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures are to be observed Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thor oughly and immediately with water and seek med ical attention and Spilled electrolyte is to be washed down with acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbon ate of soda to one gallon 4 liters of water
91. tart or crank if the fuse is blown Replace the fuse with one of the same size type and rating 19 UNPACKING 1 9 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 1 9 2 INSPECTION 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 10 LIFTING THE GENERATOR amp 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 111 SPECIFICATIONS 1 11 1 ENGINE rc Ford Displacement 153 inches 2 5 liters Cylinder 4 in line Valve Overhead Cam o 1 3 4 2 Number of Main 5 400 5 Compression Ratio
92. the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in haz ardous and possibly fatal electrical shock Connecting this unit to an electrical system normally sup plied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in dam age to the generator and may also result in injury or death to utility power workers due to backfeed of electrical ener gy Generators installed with an automatic transfer switch will crank and start automatically when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the genera tor control panel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible
93. the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten tial problem areas Performed monthly this requires approximately 5 man hours per unit to complete This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the 5 amp and 15 amp control panel fuses Turn off the battery charger turn OFF utility supply to ATS Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to assure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any poten
94. thorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Un
95. tial problem areas Performed ONLY ONCE following the first three months of operation after purchase of the unit and requires approximately 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually this requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer 4 Amid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually this requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an Authorized Service Dealer ea Section 4 Maintenance Liquid cooled 15 20 and 25 kW Generators MAINTENANCE 2 9 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task Task mended Comp to be done Comp be done Comp Required Com
96. to be done monthl Initials Initials Initials Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Change the engine oil 1 filter s filter s Replace the engine fuel filter s on diesel engine driven units and re prime the fuel system Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a 5 minute no load operational run of the unit looking for any post service oroblems Return the unit to standby required ee Task Comp Date Initials Section 5 Troubleshooting Liquid cooled 15 20 and 25 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won t crank 1 15 amp fuse blown 2 Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery 5 amp fuse blown co Out of fuel 2 Fuel solenoid FS is defective 3 Open Wire 14A from Engine Control circuit board 4 Spark plugs defective Engine cranks but
97. uts bolts and other fas teners Look for fuel oil or coolant leaks 4 8 7 INSPECT EXHAUST SYSTEM 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 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required 4 8 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A 191 A A Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed 4 8 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine is still warm from run ning This means warm up the engine shut i
98. verheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatical ly shuts down Figure 1 6 Figure 1 6 Low Coolant Level Sensor 1 8 4 OVERSPEED SHUTDOWN Should AC frequency exceed about 72 Hz circuit board action will automatically shutdown the engine 1 8 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 Section 1 General Information Liquid cooled 15 20 and 25 kW Generators 1 8 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 If battery voltage goes below 6 VDC during cranking the low battery voltage alarm is latched cranking is terminated and the low battery LED stays on 1 8 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 s
99. won t start Engine starts hard runs rough 1 Flame arrestor air cleaner plugged or damaged 2 Plugged fuel line 3 Defective spark plugs Engine starts then shuts down Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch WD AUTO OFF MANUAL Switch at OFF 1 Defective AUTO OFF MANUAL switch engine continues to run 2 Open disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board 3 Defective Control Module circuit board No AC output from generator 1 Main line circuit breaker open 2 Circuit breakers amp fuses open 3 Transfer switch set to NORMAL position 4 Generator internal failure 5 Thermal circuit breaker open TROUBLESHOOTING CORRECTION 1 2 co Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replace fuse Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replac

GE EER2001 Convection Oven User Manual

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