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2

Generac

®

Power 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 genera-

tor can operate safely, efficiently and reliably only if it is
properly installed, operated and maintained. Many acci-
dents are caused by failing to follow simple and funda-
mental rules or precautions.

Generac cannot anticipate every possible circumstance 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 operat-
ing technique that Generac does not specifically recom-
mend, ensure that it is safe for others. Also make sure the
procedure, work method or operating technique chosen
does not render the generator unsafe.

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
and 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 are rotating and/or hot
during operation. Exercise care near running gen-
erators.

GENERAL HAZARDS

• For safety reasons, Generac recommends that this equip-

ment be installed, serviced and repaired by a Generac
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 regulations.

• The engine exhaust fumes contain carbon monoxide gas,

which can be DEADLY. This dangerous gas, if breathed in
sufficient concentrations, can cause unconsciousness or
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 installation or
permit even partial blockage of ventilation provisions, as
this can seriously affect safe operation of the generator.

• 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 leakage, oil leakage, etc.

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 applica-
ble. 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.

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!

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DANGER

Important Safety Instructions

Guardian Liquid-cooled 25 kW Generator

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 equipment.

!

!

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.

!

!

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.

WARNING:

!

!

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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