Instruction/ maintenance manual of the product 005053-1 Generac Power Systems
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Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! This manual should remain with the unit. Liquid-cooled, Prepac ka ged Standb y Generator s Model Nos.
Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the Guardian Elite standby generator series by Generac P ower Systems, Inc.. 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.
T able of Contents Guardian Liquid-cooled 25 kW Generator Generac ® Pow er Systems, Inc. 1 INTRODUCTION ................................................ IFC Read this Manual Thoroughly ......................................IFC Operation and Maintenance .
2 Generac ® Pow er Systems, Inc. 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.
Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous volt- ages to the transfer switch as well as the standby generator .
4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure.
Generac ® Pow er Systems, Inc. 5 1.5 MAI N CI RCU IT B R EAKER The generator’s main circuit breaker is included with the unit as shipped from the factory . The breaker for each unit is described in Figure 1.2. 1.6 GEN ER A T OR F U EL SY S TEM This unit has been factory tested and adjusted using a natural gas fuel system.
6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor 1.7 .4 O VERSPEED SH UTDOWN Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine. 1.7 .5 O VERCRAN K SH UTDOWN The engine control board uses a cyclic cranking process when attempting to start the engine.
1.1 1 F U EL C ONSU M PTION 25 kW Models Using Natural Gas ........................................441 cu. ft. per hour Using LP Gas ..............................175 cubic ft.(4.8 gal.) per hour F uel pressure for a natural gas set up should be five inches to 14 inches of water column (0.
8 Generac ® Pow er Systems, Inc. 1.1 3 ENGI N E OI L R E C OM M EN D A TIONS The unit has been filled with 15W -40 engine oil at the factory . Use a high- quality detergent oil classified “F or Service CC, SD , SE, SF .” Detergent oils keep the engine cleaner and reduce carbon deposits.
Generac ® Pow er Systems, Inc. 9 • NFP A No. 68, GUIDE FOR EXPLOSION VENTING • NFP A No. 70, NA TIONAL ELECTRICAL CODE. • NFP A No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE. • NFP A No. 10, INST ALLA TION, MAINTENANCE AND USE OF PORT ABLE FIRE EXTINGUISHERS.
10 Generac ® Pow er Systems, Inc. 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator .
Generac ® Pow er Systems, Inc. 11 Pos2 OFF — Standard Prepackaged A TS Application • The control board will perform all of the automat- ic features listed in this document. • The two -wire start connections, wires 178-183, should NOT be connected.
12 Generac ® Pow er Systems, Inc. Section 3 - Operation Guardian Liquid-cooled 25 kW Generator 2.1 1 P R EP AR A TION B EFOR E ST ART -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 .
Generac ® Pow er Systems, Inc. 13 GT S Mode Operation When in GTS mode, the control board will respond as follows based on the generator A UTO/OFF/MANU- AL switch position. OFF — The generator will not start and run in this position. MANU AL — The control board will start and run the generator whenever the switch is in the manual posi- tion.
14 Generac ® Pow er Systems, Inc. 3.2.6 SY S TEM READ Y LED The System Ready LED (green) has two main pro- poses. First, the LED will be ON when the A UTO/OFF/MANU AL switch is in the A UTO position, utility is present, and there are no system alarms.
Generac ® Pow er Systems, Inc. 15 Section 3 - Operation Guardian Liquid-cooled 25 kW Generator 3. Under no load condition, increase the GAIN pot as much as possible without causing instability . 4. Apply 1/4, 1/2, 3/4 and full load to the unit. Decrease the GAIN pot if there is instability at any load point.
16 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator At this time all five red LEDs will flash for approxi- mately 10 seconds, then the engine will start and run for it ’s 12 minute exercise period, then shut down.
Generac ® Pow er Systems, Inc. 17 F . EVER Y 800 OPER A TI NG HOU RS 1. Retorque cylinder head (see torque specs). 2. Retorque intake and exhaust manifold (see torque specs). 3. Check engine compression. 4. Check valve clearance. 4.2 EXHAUS T MAN I FOLD P ROCEDU R E 1.
18 Generac ® Pow er Systems, Inc. 4.6 O VER L O AD P RO TECTION FOR ENGI N E DC ELE CTR ICAL SY STEM Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via a 15 amp fuse.
Generac ® Pow er Systems, Inc. 19 4.8.8 CH E CK F AN B EL T • Inspect fan belts every three months. Replace any damaged, deteriorated, worn or otherwise defec- tive belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch.
20 Generac ® Pow er Systems, Inc. 4.9 M IS CELL AN EOUS MAINTENANCE 4.9.1 CLEAN ING TH E GEN ER A T OR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance.
Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator 4.1 0 S CH EDU LED MAI NTENANCE F ollowing is a recommended maintenance schedule for Generac small standby and residential generator sets.
22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp. to be done Comp . Required Comp .
Generac ® Pow er Systems, Inc. 23 Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp. to be done Comp . Required Comp .
24 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Guardian Liquid-cooled 25 kW Generator TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or def ective 2.
Generac ® Pow er Systems, Inc. 25 Section 6 — Notes Guardian Liquid-cooled 25 kW Generator.
26 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (1 5kW & 20kW units) —Drawing No.
Generac ® Pow er Systems, Inc. 27 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (1 5kW & 20kW units) —Drawing No.
28 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L Engine (15kW & 2 0kW units) —Drawing No.
Generac ® Pow er Systems, Inc. 29 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L Engine (15kW & 2 0kW units) —Drawing No.
30 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No.
Generac ® Pow er Systems, Inc. 31 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No.
32 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No.
Generac ® Pow er Systems, Inc. 33 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No.
34 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 25 kW Generator Mounting Base — Drawing No. 0E9964-E 28 E N G INE BLOCK 5 CARRIER R EAR BEARIN G 14 15.
Generac ® Pow er Systems, Inc. 35 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 25 kW Generator Mounting Base — Drawing No. 0E9964-E ITEM P ART NO . QTY . DESCRIPTION 1 0D9336 3 P ANEL BRACKET 2 0E9939 2 CTRL PNL SUPPORT 2.5L FORD 3 0C2454 24 SCREW TH-FRM M6-1 X 16 N W A Z/JS 4 049813 1 NUT HEX M6 X 1.
36 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 25 kW Generator Enclosure — Drawing No. 0E9 7 20-D 35 N U T S ITEM #2 6. US E L OC TITE ON PANEL F O R A CC E SS CO VER C ABL E WELD S T U D U NDER R OOF 17 G R OU ND WIRE .
Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0E9768 1 ROOF A CO & STD ENCL 2.5L 2 0E9862 1 DUCT , DISCHARGE MID 2.5L 3 0E9769 1 SUPPORT ,RADIA T OR 2.5L FORD 4 0D8660 2 BRA CE SIDE 1.5L MITSU 5 0A7568 2 DOORWELDMENT 1.5EPS 6 0E9771 1 CORNER POST ,REAR RH SIDE 2.
38 Generac ® Pow er Systems, Inc. 6 TO "A" 15 4 19 5 3 2 44 40 14 1 14 26 10 14 1 24 2 9 33 3 1 50 5 2 41 33 4 48 13 27 36 5 4 "A" 23 65 3 7 35 2 7 3 35 9 3 4 43 3 4 21 35 17 30 3.
Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 1 0C2267 16 SCREW HHTT M5-0.8 X 12 BP 3 0D5070A 1 ASSY 2A 12V UL BA TTER Y CHARGER 4 0D8671 1 HINGE CONTINUOUS 1.5L CTRL PNL 5 0E4494 1 SWITCH ROC DPDT ON-OFF-ON 6 0E6875A 2 RELA Y , 12VDC C FORM W/DIODE 7 0E7358 4 SCREW PPPH HI-LO #4-24 X 3/8 8 0E9704 1 ASSY PCB HSB CONTROLLER 2.
40 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 25 kW Generator Control Panel — Drawing No. 0F1 37 8-D.
Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0C2267 16 SCREW HHTT M5-0.8 X 12 BP 2 064733 2 RES MTG BRACKET 3 0D5070A 1 ASSY 2A 12V UL BA TTER Y CHARGER 4 0D8671 1 HINGE CONTINUOUS 1.
5 1 15 16 14 19 41 30 20 60 27 20 30 29 28 20 59 39 52 38 19 39 40 2 25 4 17 15 G R OU ND FO R HARNE SS 19 5 3 22 17 68 15 19 10 38 22 20 HSG . 20 3 4 7 46 4 45 19 0 3 49 48 1 16 39 50 3 4 35 65 33 18.
ITEM P ART NO . QTY . DESCRIPTION 1 0E9909 REF ENGINE 2.5L FORD 2 0E9739 1 PULLEY , 2.5L FORD W A TER PUMP 3 049814 8 SCREW HHC M10-1.5 X 25 G8.8 4 0F0001 1 CLUTCH, COOLING F AN 2.
44 Generac ® Pow er Systems, Inc. PO RT "OU T 1" 2 2 7 21 TO EN G INE 10 42 CO VER TO VALVE 12 13 28 1 8 20 33 3 1 3 2 17 3 4 26 6 38 30 16 25 24 18 4 29 15 9 5 27 6 4 C ARB U RET O R A SS Y. 0 E1028A ( I/N 19 ) CO NVER S I O N 35 41 "OU T 2" PO RT L .
Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 0E8456 1 BRACKET FUEL REGULA T OR 2 075580 1 FLANGE FUEL INLET 3 0E9967 1 ASSY FUEL REG 2.5L FRD N/G-L/P 4 039253 4 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 6 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.
46 Generac ® Pow er Systems, Inc. 3 LOC KTI G HT LOC KTI G HT 7 1 5 17 8 7 6 18 4 16 L EAD S 5 2 9 13* 21 19 20 14 10 11 12 30 1 3 1 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 25 kW Generator Alternator — Drawing No.
Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 RO T OR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 RO T OR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 RO T OR 390 25KW 1P DIRECT HSB (2.5L FORD) 0E5093A 1 RO TOR 390 30KW 1P DIRECT HSB (3.
ITEM P ART NO . QTY . DESCRIPTION 1 0F2912 1 PIPE MUFFLER OUT 2 0F2869 1 PIPE EXHA UST 2.5L FORD 3 0F2823 1 MUFFLER 2.5L FORD 4 036434 2 BOL T U 5/16-18 X 2.
ITEM P ART NO . QTY . DESCRIPTION 1 098290 1 ASM MOT OR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECT OR 3 0F0454 REF HARN GOV 2.5L FORD 4 098942A 1 CO VER CONNECT OR HOUSING 5 098225 2 SCREW PFHST #2 X 5/8 6 043146 3 SCREW HHC M6-1.
50 Generac ® Pow er Systems, Inc. ITEM P ART NO . QTY . DESCRIPTION 1 0E9769 REF SUPPORT ,RADIA T OR 2.5L FORD 0F0779 REF SUPPOR T RADIA TOR 2.5L AL 2 0E9837 1 RADIA T OR, 2.5L FORD 3 0F0123 1 VENTURI, 16" F AN 2.5L FORD 4 0F0118 1 GU ARD , F AN 2.
Generac ® Pow er Systems, Inc. 51 Section 9 — Installation Diagram Guardian Liquid-cooled 25 kW Generator Installation Diagram — Drawing No. 0F1 020-A.
52 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OU R W ARR ANT Y RIGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine.
Generac ® Pow er Systems, Inc. 53 EM IS SION CONTROL S Y STEM W AR R ANTY Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines.
Part No. 0F1005 Revision C (12/15/04) Printed in U.S.A . Section 1 0 – W arranty Guardian Liquid-cooled 25 kW Generator GENER AC PO WER SY S TEMS "T WO YEAR" LIM ITED W ARR ANTY FOR GUARDI.
An important point after buying a device Generac Power Systems 005053-1 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac Power Systems 005053-1 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac Power Systems 005053-1 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac Power Systems 005053-1 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac Power Systems 005053-1 will certainly help you make a decision on the purchase.
If you already are a holder of Generac Power Systems 005053-1, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac Power Systems 005053-1.
However, one of the most important roles played by the user manual is to help in solving problems with Generac Power Systems 005053-1. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac Power Systems 005053-1 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
