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Generac

®

Power Systems, Inc.

INTRODUCTION

Thank you for purchasing this model of the Guardian
Elite standby generator series by Generac Power
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 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 Generac Authorized Service Dealer
for starting, 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:

After this heading, read instructions that, if not
strictly complied with, will result in serious person-
al injury, including death, or property damage.

After this heading, read instructions that, if not
strictly complied with, may result in personal injury
or property damage.

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-
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. Generac strongly recommends that
the operator reads this Owner's Manual and thor-
oughly understands all instructions before using this
equipment. Generac also strongly 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 safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Generac
Authorized Service Dealer. Normal maintenance serv-
ice adjustments and replacement of parts are the
responsibility of the owner/operator and, as such, are
not considered defects in materials or workmanship
within the terms of the warranty. Individual operating
habits and usage contribute to the need for mainte-
nance service.

Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See a Generac Authorized
Service Dealer for service aids and accessories.

Operating instructions presented in this manual
assume that the standby electric system has been
installed by a Generac 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 a Generac Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.

When contacting a Generac 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.

‹

‹

!

DANGER

‹

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

OR

Locate us on the web at:

www.generac.com

Summary of Contents for 005040-2

Page 1: ...Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Number 005040 2 25kW...

Page 2: ...tential 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 Gene...

Page 3: ...od 9 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Using an Engineered GTS Transfer Switch 10 2 10 Battery Installation 11 2 11 Prepa...

Page 4: ...ven 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...

Page 5: ...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 t...

Page 6: ...ect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors If a transfer switch is not included one may be pur chased separately from a Generac Autho...

Page 7: ...cally 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 Figure 1 3 Engine Protective Devices 1 7 1 LOW OI...

Page 8: ...ck cartons with the proper side up as noted on the shipping carton 1 8 2 INSPECTION Upon delivery carefully inspect the generator for any damage that may have occurred during shipment If loss or damag...

Page 9: ...2 5 Install brass hose fitting into Port 2 6 Install pipe plug into Port 1 7 Connect carburetor gas hose to brass fitting 8 Tighten all clamps and plugs 9 Make sure fuel supply is of the proper pressu...

Page 10: ...ll phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION Connecting this generator to an electrical sys tem normally supplied by an electric utility shall...

Page 11: ...enerator 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 3 GENERATOR MOUNTING AND SUPPORT Retain the generator c...

Page 12: ...ng is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the excessive current opens the load circuit breaker or collapses the ge...

Page 13: ...g 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 electr...

Page 14: ...em for leaks and other problems See Specifications and Coolant 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals B...

Page 15: ...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 c...

Page 16: ...the factory during final testing of the generator and should not be adjusted If however adjustments are necessary the following procedure should be followed Figure 3 2 and Section 3 8 1 Move dip swit...

Page 17: ...sfer switch using whatever means provided such as a utility main line circuit breaker The utility power source now powers the loads 3 6 AUTOMATIC OPERATION To set the system for fully automatic operat...

Page 18: ...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 ATS Switch Positio...

Page 19: ...ts 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 Figure 4 1 Intake Manifold Installation 4 4 CYLINDER HEAD PROCEDURE 1 Positio...

Page 20: ...iodically 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...

Page 21: ...f old filter 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...

Page 22: ...9 3 BATTERY MAINTENANCE The battery should be inspected per Section 4 7 Scheduled Maintenance The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tight...

Page 23: ...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...

Page 24: ...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 outlets for debris Clean as necessary 7 Check the b...

Page 25: ...d 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 conne...

Page 26: ...gs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil...

Page 27: ...Generac Power Systems Inc 25 Section 6 Notes Guardian Liquid cooled 25 kW Generator...

Page 28: ...26 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine 15kW 20kW units Drawing No 0F1411 A...

Page 29: ...Generac Power Systems Inc 27 Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine 15kW 20kW units Drawing No 0F1411 A...

Page 30: ...28 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Electrical Schematic 2 5L Engine 15kW 20kW units Drawing No 0F1413 A...

Page 31: ...Generac Power Systems Inc 29 Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Electrical Schematic 2 5L Engine 15kW 20kW units Drawing No 0F1413 A...

Page 32: ...30 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine 25kW unit Drawing No 0E9982 C...

Page 33: ...Generac Power Systems Inc 31 Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Wiring Diagram 2 5L Engine 25kW unit Drawing No 0E9982 C...

Page 34: ...32 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Electrical Schematic 2 5L 25kW unit Drawing No 0E9983 C...

Page 35: ...Generac Power Systems Inc 33 Section 7 Electrical Data Guardian Liquid cooled 25 kW Generator Electrical Schematic 2 5L 25kW unit Drawing No 0E9983 C...

Page 36: ...25 kW Generator Mounting Base Drawing No 0E9964 E 28 ENGINE BLOCK 5 CARRIER REAR BEARING 14 15 13 3 BOTTOM PANEL 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 34...

Page 37: ...4 052259 4 WASHER FLAT M12 15 052891 4 SCREW HHC M12 1 75 X 80 G8 8 16 0536210261 1 ASSY WIRE 0 12 00 17 074906 1 SCREW HHTT M6 1 0 X 20 BP 18 077483 REF BATT 12VDC 75 AH 26 NOT SHOWN 19 0E9941 1 HOLD...

Page 38: ...0E9720 J 35 NUTS ITEM 26 USE LOCTITE ON PANEL FOR ACCESS COVER CABLE WELD STUD UNDER ROOF 17 GROUND WIRE FASTENER TO SECURE USE DOOR LATCH NOTE 6 18 38 11 31 7 9 24 1 4 26 2 18 8 29 2 12 11 14 13 10 5...

Page 39: ...72J 2 ACSTC INSLTN 1 5L RR CRNR BOTTOM 29 0E0072L 2 ACSTC INSLTN 1 5L SIDE BRC PNL 30 0E0072M 2 ACSTC INSLTN 1 5L SIDE DR PNL 31 0D2023 1 TRIM VINYL SELF GRIPPING 80 LG 33 0E0072Q 2 ACSTC INSLTN 1 5L...

Page 40: ...4 26 10 14 1 29 24 31 33 52 50 41 33 4 48 13 27 66 36 54 A 23 65 37 35 2 7 3 35 9 34 43 34 21 35 17 30 34 22 3 35 16 36 34 5 56 0 12 14 11 64 54 38 18 39 Section 8 Exploded Views and Parts Guardian Li...

Page 41: ...13 SCREW PHTT M4 0 7 X 16 ZYC 35 022264 22 WASHER LOCK 8 M4 36 0C2265 7 SCREW PHTT M4 0 7 X 12 ZYC 37 023965 2 SCREW RHM 8 32 X 3 8 38 039782 1 BRKT MTG CB BQ ITEM PART NO QTY DESCRIPTION 39 0A2077 1...

Page 42: ...40 Generac Power Systems Inc Section 8 Exploded Views and Parts Guardian Liquid cooled 25 kW Generator Control Panel Drawing No 0F1378 F...

Page 43: ...CONTROL HSB 2 5L FORD 33 022097 3 WASHER LOCK M6 1 4 34 0C2212 9 SCREW PHTT M4 0 7 X 16 ZYC 35 022264 22 WASHER LOCK 8 M4 36 0C2265 13 SCREW PHTT M4 0 7 X 12 ZYC ITEM PART NO QTY DESCRIPTION 37 023965...

Page 44: ...ND 5 3 22 17 68 15 19 10 38 22 31 0 HSG 20 3 47 45 20 49 1 16 39 50 34 35 65 33 57 18 37 18 20 16 38 RADIATOR CAP 62 TO 58 39 STEPPER MOTOR UNITS ONLY 17 12 A 11 67 24 23 61 Section 8 Exploded Views a...

Page 45: ...E9680 1 GASKET 2 5L FORD EXHAUST MAN 34 0E9609 1 MANIFOLD EXHAUST MACHINED 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 ST...

Page 46: ...LVE 12 13 28 1 8 20 33 31 32 17 34 26 6 38 30 16 25 24 18 4 29 15 9 5 27 6 4 CARBURETOR ASSY 0E1028A I N 19 CONVERSION 35 41 OUT 2 PORT L P VAPOR 3 40 1 11 3 40 7 2 6 11 Section 8 Exploded Views and P...

Page 47: ...CARBURETOR GASKET 21 091526 4 SCREW PPHM M5 0 8 X 12 ZNC 22 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022...

Page 48: ...Power Systems Inc 3 LOCKTIGHT LOCKTIGHT 7 15 17 8 7 6 18 4 16 LEADS 5 2 9 13 21 19 20 14 10 11 12 30 1 31 Section 8 Exploded Views and Parts Guardian Liquid cooled 25 kW Generator Alternator Drawing N...

Page 49: ...1 REVCOR FAN 10 75 X 2 W PRESS DIS 7 046526 8 WASHER LOCK M10 8 051755 4 SCREW HHC M10 1 5 X 16 G8 8 9 04576100BK 4 STUD M14 2 0 X 490 G5 ZINC 3 0L FORD 2 5L FORD 04576100BF 4 STUD M14 2 0 X 540 G5 Z...

Page 50: ...C M6 1 0 X 16 G8 8 14 022097 4 WASHER LOCK M6 1 4 15 022473 8 WASHER FLAT 1 4 M6 ZINC 16 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 17 039253 2 SCREW HHC M8 1 25 X 20 G8 8 18 045771 2 NUT HEX M8 1 25 G8 YEL...

Page 51: ...1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 1 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZI...

Page 52: ...060035 4 SPACER 41 X 75 X 87 ST ZNC ITEM PART NO QTY DESCRIPTION 14 0F0127 1 HOSE UPPER RADIATOR 174MM TAL 15 0E9833 1 HOSE 2 5L FORD LOWER RADIATOR 16 035461 1 BARBED STR 1 4NPT X 3 8 17 069860C 1 HO...

Page 53: ...Generac Power Systems Inc 51 Section 9 Installation Diagram Guardian Liquid cooled 25 kW Generator Installation Diagram Drawing No 0F1020 A...

Page 54: ...enerac 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 u...

Page 55: ...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 replaceme...

Page 56: ...losures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminated...

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