Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number: 005031-2 (25kW) This manual should remain with the unit.
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 written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
Table of Contents Liquid-cooled 25 kW Generators INTRODUCTION ............................................... IFC Section 3 — OPERATION ................................ 12 Read this Manual Thoroughly ..................................... IFC 3.1 Operation and Maintenance ........................................ IFC 3.2 Control Console Components..............................13 How to Obtain Service................................................. IFC 3.3 Manual Transfer and Startup ...............
Important Safety Instructions Liquid-cooled 25 kW Generators be copied and posted in potential hazard areas. Safety should be stressed to all operation operators, potential operators, and service and repair technicians for this equipment. SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe followed during installation and maintenance of the generator and batteries.
Important Safety Instructions Liquid-cooled 25 kW Generators • 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 platform. Work on the equipment only while standing on such insulative mats.
Section 1 - General Information Liquid-cooled 25 kW Generators 1.1 GENERATOR 1.3 This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-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 operation of 120 and/or 240VAC, single-phase loads.
Section 1 - General Information Liquid-cooled 25 kW Generators 1.6 GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is preferred, refer to Section 1.12, 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. 1.7.1 LOW OIL PRESSURE SWITCH This switch is normally-closed (N.C.
Section 1 — General Information Liquid-cooled 25 kW Generators Figure 1.6 - Low Coolant Level Sensor 1.8.2 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 consignor’s memo of loss or damage. 1.9 1.7.
Section 1 — General Information Liquid-cooled 25 kW Generators 1.10.2 GENERATOR Single-phase Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No. of Rotor Poles Driven Speed of Rotor Rotor Excitation System Type of Stator Rotor/Stator Insulation 005031-2 25 120/240 4 1800 Direct excited brush type 4 Wire Class F/H * Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition, and other factors.
Section 2 — Installation Liquid-cooled 25 kW Generators 2.1 attempt to crank or start the engine before Any it has been properly serviced with the recommended oil may result in an engine failure. 1.14 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.
Section 2 — Installation Liquid-cooled 25 kW Generators 2.1.2 OTHER PUBLISHED STANDARDS In addition to NFPA standards, the following information 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 Street, New York, N.Y. 10038. • AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 909 University Avenue, Columbia, MO, 65201. • ASAE EP-364.
Section 2 — Installation Liquid-cooled 25 kW Generators 2.5 EMERGENCY CIRCUIT ISOLATION METHOD Figure 2.2 – Generator Grounding Lug (typical) This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only critical loads, within its wattage/amperage capacity, during utility power outages, consider using the emergency circuit isolation method.
Section 2 — Installation Liquid-cooled 25 kW Generators • The control board WILL monitor all engine conditions and shut down on all the faults listed in this document. Pos2 OFF — ATS Application not dispose of the battery in a fire. The bat Do tery is capable of exploding. • The control board will perform all of the automatic features listed in this document. • The two-wire start connections, wires 178-183, should NOT be connected. NOTE: not open or mutilate the battery.
Section 3 - Operation Liquid-cooled 25 kW Generators When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight. Observe battery polarity when connecting batteries to the generator set.
Section 3 - Operation Liquid-cooled 25 kW Generators • After the engine starts and when the generator AC output voltage and frequency have reached a pre-set value, transfer switch circuits signal the transfer switch main contacts to actuate to the “Standby” power source side. Generator AC output then powers load circuits. • When the utility power source voltage is restored above a pre-set level, transfer switch circuits signal the switch main contacts to move back to their utility power source side.
Section 3 - Operation Liquid-cooled 25 kW Generators Condition System Ready (Green) Low Bat (Red) Low Oil (Red) High Temp (Red) Over Speed (Red) Over Crank (Red) Generator Switch is in the OFF Mode.
Section 3 - Operation Liquid-cooled 25 kW Generators This secondary function is only available with DIP switch two in the OFF position (ATS - automatic transfer switch application). 3.3 Figure 3.2 — Engine Governor Adjustment MANUAL TRANSFER AND START-UP To transfer electrical loads to the Standby (EMERGENCY) power source side and start the engine manually, refer to the Owner’s Manual of the particular transfer switch. 3.
Section 3 - Operation Liquid-cooled 25 kW Generators 3.6 AUTOMATIC OPERATION To set the system for fully automatic operation, proceed 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. 3.7 WEEKLY EXERCISE CYCLE The engine control board will start and run the generator once every seven days for approximately 12 minutes.
Section 4 — Maintenance Liquid-cooled 25 kW Generators 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 3.4. 3.
Section 4 — Maintenance Liquid-cooled 25 kW Generators FIRST 100 OPERATING HOURS 1. Change engine oil and oil filter. After initial change, service engine oil and filter at 150 operating hours or six months, whichever comes first. 2. Retorque cylinder head (see torque specs). 3. Retorque intake and exhaust manifold (see torque specs). EVERY 500 OPERATING HOURS 1. Service air cleaner. 2. Check starter. 3. Check engine DC alternator. EVERY 800 OPERATING HOURS 1.
Section 4 — Maintenance Liquid-cooled 25 kW Generators 4.7.2 The exhaust system parts from this product get 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.
Section 4 — Maintenance Liquid-cooled 25 kW Generators 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 refilling the crankcase with oil, always After check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK. 7. Start engine and check for oil leaks. • Inspect fan belts every three months.
Section 4 — Maintenance Liquid-cooled 25 kW Generators 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 generator 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.
Section 4 — Maintenance Liquid-cooled 25 kW Generators 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.
Section 4 — Maintenance Liquid-cooled 25 kW Generators Maintenance Tasks Level 1 Recommended to be done monthly Task Comp. (DateInitials) Level 2 Required to be done 3 months/ Break-in Task Comp. (DateInitials) Level 3 Required to be done Semiannually Level 4 Task Comp. (DateInitials) Required to be done Annually Task Comp. (DateInitials) 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level.
Section 4 — Maintenance Liquid-cooled 25 kW Generators Maintenance Tasks 13. 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. 14. 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.
Section 5 — Troubleshooting Liquid-cooled 25 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 2. 1. 15 amp fuse blown. Loose or corroded or defective battery cables. Defective starter contactor. Defective starter motor. Dead or Defective Battery. 5 amp fuse blown. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5. Remove, change or replace battery. 6. Replace fuse. 1. Out of fuel.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No.
Section 6 - Electrical Data Liquid-cooled 25 kW Generators Electrical Schematic — 2.5L (25kW unit) — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Mounting Base — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Mounting Base — Drawing No. 0F0104-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART NO. 0F1705 0E8834 0E9911 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0F0796 025507 060619 046526 022131 021991 038805G 050331 050331A 038804J 045771 022129 027482 075763 0E9748A 0F0795 0C2454 065852 045764 QTY.
36 30 32 31 LATCH DETAIL 3 31 32 34 18 17 39 45 38 40 4 4 5 25 9 33 2 STATES FOAM IS ON FAR SIDE STATES FOAM IS ON NEAR SIDE 29 "B" 36 33 25 4 32 4 39 17 10 11 46 SEE LATCH DETAIL 18 17 47 18 48 TYPICAL OF ROOF PANEL THAT REQUIRE INSULATION. SECURE AS SHOWN.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Enclosure — Drawing No. 0F1645-H ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 PART NO.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Control Panel (15kW and 20kW) — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Control Panel (15kW and 20kW) — Drawing No. 0F2267-D ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 PART NO.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Control Panel (25kW) — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Control Panel (25kW) — Drawing No. 0E7615-C ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 41 42 43 44 PART NO.
30 42 41 20 30 19 20 29 27 60 39 59 28 38 19 20 14 39 16 52 40 25 38 4 10 13 2 0 17 15 22 31 5 19 45 19 3 47 FOR HARNESS GROUND 20 HSG. 20 3 68 34 17 22 15 1 50 35 49 39 16 65 33 15 8 66 67 18 20 12 61 37 "A" 57 16 11 18 62 17 58 38 TO RADIATOR CAP 39 24 23 STEPPER MOTOR UNITS ONLY Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Engine — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Engine — Drawing No. 0E9918-F ITEM PART NO. QTY.
44 12 TO VALVE 1 COVER 17 20 28 TO ENGINE 10 32 31 8 33 18 42 30 6 26 7 35 22 21 38 34 16 24 25 13 9 41 PORT "OUT 2" 3 11 4 15 29 CARBURETOR ASSY. 0E1028A (I/N 19) L.P. VAPOR CONVERSION 40 5 27 1 4 6 3 40 11 2 PORT "OUT 1" 6 7 Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Fuel System — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Fuel System — Drawing No. 0E9980-D ITEM 1 2 3 4 5 6 7 8* 9 10 11 12 13 14 15 16 * 17 18 19 20 21 * 22 * 23 24 25 26 27 28 29 30* 31* 32* 33* 34* 35* 36* 37* 38* 39* 40 41 42 PART NO.
Section 7 - Exploded Views and Parts Lists 12 8 7 5 18 46 LOCKTIGHT 15 7 17 1 4 16 31 30 LEADS 2 6 9 21 13 LOCKTIGHT 3 10 11 20 19 14 Liquid-cooled 25 kW Generators Alternator — Drawing No.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Alternator — Drawing No. 0F5092-B ITEM PART NO. QTY.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Muffler — Drawing No. 0F2930-C 1 5 4 24 6 7 11 3 17 19 20 13 15 20 12 11 20 5 7 4 6 18 6 15 14 16 9 8 10 2 21 22 23 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 48 PART NO. 0F2912 0F2869 0F2823 036434 036449 022129 022259 0E0170A 044149 0E8816 0F2925 0F2926 QTY. 1 1 1 2 2 6 4 1 1 1 2 1 DESCRIPTION PIPE MUFFLER OUT PIPE EXHAUST 2.5L FORD MUFFLER 2.5L FORD BOLT U 5/16-18 X 2.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Stepper Motor — Drawing No. 0E9979-C 5 4 3 ITEM (13) NEOPRENE COATING 2 1 14 6 7 10 WIRE HARNESS 15 12 9 "A" 10 7 CARBURETOR ARM (REF.) 6 SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN. 7 16 17 TO "A" INTAKE MANIFOLD (REF.) 11 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NO. 098290 098941A 0F0454 098942A 098225 043146 022097 0E7358 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694 QTY.
Section 7 - Exploded Views and Parts Lists Liquid-cooled 25 kW Generators Radiator — Drawing No. 0E9965-F 1 19 18 12 5 11 2 14 26 TO THERMOSTAT ADAPTER 5 9 18 7 8 10 5 25 5 TO BASE OF WATER INLET TUBE (ON BLOCK) 9 7 24 15 3 16 9 1 2 3 4 5 6 7 8 9 10 11 12 14 50 PART NO. QTY. 0E9769 0F0779 0E9769A REF REF REF 0E9837 0F0123 0F0118 099502 0C2454 052250 022097 022473 022127 046627 060035 0F0127 1 1 1 4 REF. 2 8 12 8 1 4 1 DESCRIPTION SUPPORT RADIATOR 2.5L FORD SUPPORT RADIATOR 2.
Section 8 — Installation Diagram Liquid-cooled 25 kW Generators Installation Diagram — Drawing No.
Section 9 – Warranty Liquid-cooled 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.
Section 9 – Warranty Liquid-cooled 25 kW Generators 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 continue for 24 consecutive months thereafter.
Section 9 – Warranty Liquid-cooled 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.
