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Generac Power Systems 005040-0 - page 1
Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! This manual should remain with the unit. Liquid-cooled, Prepac ka ged Standb y Generator s Model Nos. 005040-0, 005040-1 (25kW) 005053-0, 005053-1 (20kW) 005054-0, 005054-1 (15kW) ...
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Generac Power Systems 005040-0 - page 2
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. However , the manufacturer r ...
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Generac Power Systems 005040-0 - page 3
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 ........................................IFC How to Obtain Service .............................. ...
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Generac Power Systems 005040-0 - page 4
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. Many accidents are caused by failing to ...
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Generac Power Systems 005040-0 - page 5
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 . A void contact with bare wires, terminals, connection ...
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Generac Power Systems 005040-0 - page 6
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. The unit has been facto- ry-installed in a weather resistant, all metal enclosure and is intended for ou ...
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Generac Power Systems 005040-0 - page 7
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. If propane (LP) gas is ...
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Generac Power Systems 005040-0 - page 8
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. The first crank cycle is a ...
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Generac Power Systems 005040-0 - page 9
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 (0.18 to 0.5 psi) at all load ranges. F uel pressure for an LP ...
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Generac Power Systems 005040-0 - page 10
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. Use oil having the following SAE viscosity rating, based ...
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Generac Power Systems 005040-0 - page 11
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. 2. 1 .2 O THER P U BLISH ED ST AN D ARDS In addition to NFP A standards, the fol ...
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Generac Power Systems 005040-0 - page 12
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 . If the generator is powering only crit- ical loads, within the wattage/amperage capacity , dur- ing utility power outages, consider using the eme ...
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Generac Power Systems 005040-0 - page 13
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. NOTE: If the generator is installed in conjunction with an engineered GTS type transfer switch, ...
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Generac Power Systems 005040-0 - page 14
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 . Be ...
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Generac Power Systems 005040-0 - page 15
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. A ...
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Generac Power Systems 005040-0 - page 16
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. This ON state indicates the system is fully ready for automatic operation. The system ready LED w ...
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Generac Power Systems 005040-0 - page 17
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. 5. Under full load condition, increase ...
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Generac Power Systems 005040-0 - page 18
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. The generator will now start and run each week at the same time. If DC power to the co ...
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Generac Power Systems 005040-0 - page 19
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. If necessary , clean gasket surfaces on exhaust manifold and cylinder head. 2. ...
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Generac Power Systems 005040-0 - page 20
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. These overcurrent protection devices will open if the circuit is overloaded ...
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Generac Power Systems 005040-0 - page 21
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. Adjust belt tension as required. 4.8.9 I NSPECT ENGIN E ...
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Generac Power Systems 005040-0 - page 22
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. P eriodically clean generator exterior surfaces. A soft brush may be used to ...
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Generac Power Systems 005040-0 - page 23
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. The established intervals in the schedule are the maximum recommended when the unit is used in an average servi ...
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Generac Power Systems 005040-0 - page 24
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 . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) B ...
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Generac Power Systems 005040-0 - page 25
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 . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) B ...
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Generac Power Systems 005040-0 - page 26
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. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. Def ective ...
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Generac Power Systems 005040-0 - page 27
Generac ® Pow er Systems, Inc. 25 Section 6 — Notes Guardian Liquid-cooled 25 kW Generator ...
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Generac Power Systems 005040-0 - page 28
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. 0F1 41 1 ...
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Generac Power Systems 005040-0 - page 29
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. 0F1 41 1 ...
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Generac Power Systems 005040-0 - page 30
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. 0F1 4 1 3 ...
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Generac Power Systems 005040-0 - page 31
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. 0F1 4 1 3 ...
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Generac Power Systems 005040-0 - page 32
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. 0E9982-B ...
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Generac Power Systems 005040-0 - page 33
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. 0E9982-B ...
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Generac Power Systems 005040-0 - page 34
32 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0E9983-B ...
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Generac Power Systems 005040-0 - page 35
Generac ® Pow er Systems, Inc. 33 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0E9983-B ...
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Generac Power Systems 005040-0 - page 36
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 13 3 BO TT O M P ANEL 3 2 12 4 1 11 15 14 13 33 2 3 12 11 36 35 10 10 3 1 6 8 9 3 22 21 27 23 1 25 26 29 3 4 20 24 TO 19 3 3 3 30 H ARNE SS 6 1 7 16 ...
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Generac Power Systems 005040-0 - page 37
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 1.0 G8 YEL CHR 5 022097 1 W ASH ...
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Generac Power Systems 005040-0 - page 38
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 . FA S TENER T O S E CU R E US E D OO R LAT CH N O TE : 2 6 38 11 2 5 31 7 9 24 ...
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Generac Power Systems 005040-0 - page 39
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 2.5L 7 0E9773 1 DOOR REAR ENCL 2.5L FD 8 0E9772 1 BRACE, REA ...
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Generac Power Systems 005040-0 - page 40
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 4 22 3 35 16 36 3 4 0 56 5 12 14 11 6 4 5 4 38 18 39 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 25 kW Generator Control Panel — D ...
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Generac Power Systems 005040-0 - page 41
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. ...
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Generac Power Systems 005040-0 - page 42
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 ...
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Generac Power Systems 005040-0 - page 43
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 1.5L 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 A ...
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Generac Power Systems 005040-0 - page 44
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 18 CAP R ADIAT O R 38 TO 6 2 58 39 S TEPPER M O T O R 17 "A " "A " 6 7 U NIT S O NLY 18 23 20 6 1 Section 8 - Exploded Views and ...
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Generac Power Systems 005040-0 - page 45
ITEM P ART NO . QTY . DESCRIPTION 1 0E9909 REF ENGINE 2.5L FORD 2 0E9739 1 PULLEY , 2.5L FORD W A TER PUMP 3 049814 8 SCREW HHC M10-1.5 X 25 G8.8 4 0F0001 1 CLUTCH, COOLING F AN 2.5L FORD 5 0D3488B 1 SERPENTINE BEL T - 41 3/8" LENGTH 6 0A8584 1 SWITCH,OIL PRESSURE,10PSI,2POL 7 0E0561 1 ASSY W A TER LEVEL SENSOR C/E PL 8 0A6751 1 SW -TMP 245DEG ...
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Generac Power Systems 005040-0 - page 46
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 .P. VAP O R 3 40 1 11 3 40 7 2 6 11 Section 8 - Exploded Views and P arts Guar ...
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Generac Power Systems 005040-0 - page 47
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 M8-1.25 G8 YEL CHR 8 * 0F1570 1 BOD Y CARBURET OR ...
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Generac Power Systems 005040-0 - page 48
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. 0E8660-C ...
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Generac Power Systems 005040-0 - page 49
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 (3.0L FORD & 2.5L FORD) 0E7413A 1 RO TOR 390 40KW 1P DIRECT HSB (3.9L CHR YS ...
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Generac Power Systems 005040-0 - page 50
ITEM P ART NO . QTY . DESCRIPTION 1 0F2912 1 PIPE MUFFLER OUT 2 0F2869 1 PIPE EXHA UST 2.5L FORD 3 0F2823 1 MUFFLER 2.5L FORD 4 036434 2 BOL T U 5/16-18 X 2.09 5 036449 2 SADDLE 2 INCH 6 022129 6 W ASHER LOCK M8-5/16 7 022259 4 NUT HEX 5/16-18 STEEL 8 0E0170A 1 EXHA UST BLANKET 938MM 9 044149 1 GASKET EXHA UST RING 10 0E8816 1 EXHA UST FLANGE 2&quo ...
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Generac Power Systems 005040-0 - page 51
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 M6-1.0 X 10 G8.8 7 022097 5 W ASHER LOCK M6-1/4 8 0E7358 REF SCREW PPPH HI-LO #4-24 X 3/8 9 098783 1 LEVER STEPPER MOT OR ...
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Generac Power Systems 005040-0 - page 52
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 2.5L FORD 5 099502 4 CLAMP HOSE #24 B1.06-2.00 6 0C2454 REF . SCREW THF M6-1X16 N W A Z/JS 7 05225 ...
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Generac Power Systems 005040-0 - page 53
Generac ® Pow er Systems, Inc. 51 Section 9 — Installation Diagram Guardian Liquid-cooled 25 kW Generator Installation Diagram — Drawing No. 0F1 020-A ...
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Generac Power Systems 005040-0 - page 54
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. * In California, new utility , and lawn and g ...
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Generac Power Systems 005040-0 - page 55
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. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered ...
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Generac Power Systems 005040-0 - page 56
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 GUARDIAN® "PR EP ACK A GED EM ERGENCY AUT OMA TIC S T ANDBY GENER A T ORS" F or a period of two years from the date of original sale, Generac P o ...
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