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Generac

®

Power Systems, Inc.

3

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 applicable.
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.

• 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 plat-
form. Work on the equipment only while standing on such
insulative mats.

• The National Electrical Code (NEC), Article 250 requires

the frame and external electrically conductive parts of the
generator to be connected to an approved earth ground
and/or grounding rods. This grounding will help prevent
dangerous electrical shock that might be caused by a
ground fault condition in the generator set or by static elec-
tricity. Never disconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables and cord sets

must be adequate to handle the maximum electrical current
(ampacity) to which they will be subjected.

• Before installing or servicing this (and related) equipment,

make sure that all power voltage supplies are positively
turned off at their source. Failure to do so will result in haz-
ardous and possibly fatal electrical shock.

• Connecting this unit to an electrical system normally sup-

plied by an electric utility shall be by means of a transfer
switch so as to isolate the generator electric system from
the electric utility distribution system when the generator is
operating. Failure to isolate the two electric system power
sources from each other by such means will result in dam-
age to the generator and may also result in injury or death
to utility power workers due to backfeed of electrical ener-
gy.

• Generators installed with an automatic transfer switch will

crank and start automatically when NORMAL (UTILITY)
source voltage is removed or is below an acceptable preset
level. To prevent such automatic start-up and possible
injury to personnel, disable the generator’s automatic start
circuit (battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on the genera-
tor control panel and on the transfer switch.

• In case of accident caused by electric shock, immediately

shut down the source of electrical power. If this is not pos-
sible, attempt to free the victim from the live conductor.

AVOID DIRECT CONTACT WITH THE VICTIM.

Use a

nonconducting implement, such as a dry rope or board, to
free the victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate medical
help.

• Never wear jewelry when working on this equipment.

Jewelry 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 tetra-chloride type extinguisher. Its
fumes are toxic, and the liquid can deteriorate wiring insu-
lation. Keep the extinguisher properly charged and be
familiar with its use. If there are any questions pertaining
to fire extinguishers, consult the local fire department.

EXPLOSION HAZARDS

• Do not smoke around the generator. Wipe up any fuel or oil

spills immediately. Ensure that no combustible materials
are left in the generator compartment, or on or near the
generator, as FIRE or EXPLOSION may result. Keep the
area surrounding the generator clean and free from debris.

• Generac generator sets may operate using one of several

types of fuels. All fuel types are potentially FLAMMABLE
and/or EXPLOSIVE and should be handled with care.
Comply with all laws regulating the storage and handling of
fuels. Inspect the unit’s fuel system frequently and correct
any leaks immediately. Fuel supply lines must be properly
installed, purged and leak tested according to applicable
fuel-gas codes before placing this equipment into service.

• Gaseous fluids such as natural gas and liquid propane (LP)

gas are extremely EXPLOSIVE. Natural gas is lighter than
air, and LP gas is heavier than air; install leak detectors
accordingly.

STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and
laws, the published information listed below may be used as
installation guide for this equipment.

1.

NFPA No. 37, STATIONARY COMBUSTION ENGINES
AND GAS TURBINES, available from the National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA
02210.

2.

NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES, available same as Item 1.

3.

NFPA No. 54, NATIONAL FUEL GAS CODE, available
same as Item 1. 

4.

NFPA No. 58, AMERICAN NATIONAL STANDARD FOR
STORAGE AND HANDLING OF LIQUEFIED PETROLE-
UM GAS, available same as Item 1.

5.

NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELEC-
TRIC CODE, available same as Item 1.

6.

Article X, NATIONAL BUILDING CODE, available from
the American Insurance Association, 85 John Street, New
York, N.Y. 10038.

7.

AGRICULTURAL WIRING HANDBOOK, available from the
Food and Energy Council, 909 University Avenue,
Columbia, MO 65201.

8.

ASAE EP-3634, INSTALLATION AND MAINTENANCE OF
FARM STANDBY ELECTRICAL SYSTEMS, available from
the American Society of Agricultural Engineers, 2950
Niles Road, St. Joseph, MI 49085.

9.

NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQ-
UIDS CODE, available same as Item 1.

‹

Important Safety Instructions

Guardian Liquid-cooled 25 kW Generator

Содержание 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1

Страница 1: ...FIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Nos 005040 0 005040 1 25kW 005053 0 005053 1 20k...

Страница 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...

Страница 3: ...d 10 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...

Страница 4: ...ng that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dan...

Страница 5: ...not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conduct...

Страница 6: ...urface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and co...

Страница 7: ...VE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low cool...

Страница 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...

Страница 9: ...re and type for configuration 10 Move dip switch position 4 on the control board to the off position LP vapor see Figure 3 2 and Section 3 8 11 Reverse the procedure to convert back to natural gas Fig...

Страница 10: ...witch if necessary The standard prepackaged transfer switch does not have sensing or controlling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which cont...

Страница 11: ...for maintenance and servicing A required mini mum allowance of space to any solid structure is three feet Five feet allowance of space is recom mended Where strong prevailing winds blow from one dire...

Страница 12: ...in the area Grounding procedures must meet local regulations Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper groundin...

Страница 13: ...of high short cir cuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 10 1 VENTED BATTERIES The electrolyte is...

Страница 14: ...ine Oil Recommendations NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine cooling system pr...

Страница 15: ...1 7 for further explanation of engine pro tection functions 3 2 3 15 AMP FUSE This fuse protects the control console s DC control circuit against electrical overload and is located inside the control...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 B...

Страница 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 B...

Страница 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 B...

Страница 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 B...

Страница 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...

Страница 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...

Страница 38: ...9720 D 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 26 38 11 25 31 7 9 24 10 4 2 15 26 25 19 8 29 2 11 16 14 1...

Страница 39: ...4 20 STEEL 21 0C2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1 4 ZINC 23 022097 1 WASHER LOCK M6 1 4 24 0D2023 2 GASKET CLIP ON SELF GRIPPING 89 LG 25 0C2164 1 LATCH AND CAM 26 037337 6 NUT...

Страница 40: ...14 26 10 14 1 24 29 33 31 50 52 41 33 4 48 13 27 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 0 56 5 12 14 11 64 54 38 18 39 Section 8 Exploded Views and Parts Guardian Liqu...

Страница 41: ...CAL CONTROL HSB 2 5L FORD 33 022097 3 WASHER LOCK M6 1 4 34 0C2212 13 SCREW PHTT M4 0 7 X 16 ZYC 35 022264 20 WASHER LOCK 8 M4 36 0C2265 5 SCREW PHTT M4 0 7 X 12 ZYC ITEM PART NO QTY DESCRIPTION 37 02...

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

Страница 43: ...EX M6 X 1 0 G8 YEL CHR 32 0F0653 1 DECAL CONTROL HSB 2 5L FORD 33 022097 3 WASHER LOCK M6 1 4 34 0C2212 9 SCREW PHTT M4 0 7 X 16 ZYC ITEM PART NO QTY DESCRIPTION 35 022264 22 WASHER LOCK 8 M4 36 0C226...

Страница 44: ...9 5 3 22 17 68 15 19 10 38 22 20 HSG 20 3 47 46 4 45 19 0 3 49 48 1 16 39 50 34 35 65 33 18 18 CAP RADIATOR 38 TO 62 58 39 STEPPER MOTOR 17 A A 67 UNITS ONLY 18 23 20 61 Section 8 Exploded Views and P...

Страница 45: ...8940 1 SPACER FLEXPLATE HSB ITEM PART NO QTY DESCRIPTION 33 0E9680 1 GASKET 2 5L FORD EXHAUST MAN 34 0E9609 1 MANIFOLD EXHAUST MACHINED 35 0E9930 1 HEAT SHIELD EXHAUST MANIFOLD 36 049821 3 SCREW SHC M...

Страница 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...

Страница 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...

Страница 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...

Страница 49: ...Y 3 0L HSB LG GEAR 6 0E6076 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 04576100B...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 56: ...e 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 fuels oils coolants or lack...

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