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Generac

Power Systems, Inc.

ITEM

PART NO.

QTY.

DESCRIPTION

0C2267

SCREW HHTT M5-0.8 X 12 BP

064733

RES MTG BRACKET

0D5070A

ASSY 2A 12V UL BATTERY
CHARGER

0D8671

HINGE CONTINUOUS 1.5L CTRL PNL

0E4494

SWITCH ROC DPDT ON-OFF-ON

0E6875A

RELAY 12VDC C FORM W/DIODE

0E7358

SCREW PPPH HI-LO #4-24 X 3/8

0E9704

ASSY PCB HSB CONTROLLER 2.5L

0E9934

CTRL PNL BACK & BOTTOM 2.5L

0E9935

CTRL PNL LH SIDE 2.5L FORD

0E9936

CTRL PNL RH SIDE 2.5L FORD

0E9937

CTRL PNL TOP 2.5L FORD

0E9938

CTRL PNL FRONT 2.5L FORD

023897

WASHER FLAT #10 ZINC

036261

RIVET POP .125 X .275 AL

048468

CIRCT BRK 8 X 1 ETA 46-500-P

057073

JUNCTION BLOCK 3/8-16

067680

ASSY VOLTAGE REGULATOR 60HZ

082573

SWITCH ROC DPST 125V SPD

0C3910

TRANSFORMER 240/16V 1VA & 56VA

029673

DIO BRIDGE 25A 600V

034616

FITTING STRAIGHT 3/4

0E2514

FITTING CONDUIT STR 1-1/2"

0F0581

BRACKET FUSE HOLDER 2.5L FORD

040213

PCB SUPPORT SNAP-IN 1/4"

0F0558

BRACKET PCB SUPPORT 2.5L FORD

0F0598

DECAL FUSES 2.5L CNTRL PANEL

0F0599

DECAL TB1 2.5L CONTROL PANEL

0F0600

DECAL ICT 2.5L CONTROL PANEL

054199

DECAL DANGER HIGH VOLTAGE

049813

NUT HEX M6 X 1.0 G8 YEL CHR

0F0653

DECAL CONTROL HSB 2.5L FORD

022097

WASHER LOCK M6-1/4

0C2212

SCREW PHTT M4-0.7 X 16 ZYC

022264

WASHER LOCK #8-M4

0C2265

SCREW PHTT M4-0.7 X 12 ZYC

ITEM

PART NO.

QTY.

DESCRIPTION

023965

SCREW RHM #8-32 X 3/8

039782

BRKT MTG CB BQ

0D5544

CB 0100A 2P 240V S BQ2 LL (20KW)

0D5541

CB 0070A 2P 240V S BQ2 LL (15KW)

020911

SCREW PPHM M5-0.8 X 30 ZINC

0A8955

SCREW PHM M6-1.0 X 20MM

022152

WASHER LOCK #10

051716

NUT HEX M5-0.8 G8 YEL CHR

023762

WASHER SHAKEPROOF EXT #10
STL

033121

SCREW HHC #10-32 X 1/2

026850

WASHER SHAKEPROOF EXT 1/4
STL

0912970087

ASSY WIRE 14AWG 16" #0 GRN/YEL

022158

NUT HEX #10-32 STEEL

0E7403C

FUSE ATO TYPE 15 AMP (BLUE)

0E7403A

FUSE ATO TYPE 5 AMP (TAN)

0F0526A

HARN CTRL PNL 2.5L FD (NOT
SHOWN)

0A2115

WASHER NYLON .257

022473

WASHER FLAT 1/4-M6 ZINC

048352

RES 5R 5% 25W

55 *

046357

REF

BLOCK TERM 20A 6 X 6 X 1100V

56 *

047822

REF

BLOCK TERM 20A 7 X 6 X 1100V

57 *

0F1467

REF

ASSY WIRE FUSE HOLDER

58 *

0E6881

REF

SOCKET RELAY

59 **

049226

WASHER LOCK M5

60 **

051716

NUT HEX M5-0.8 G8 YEL CHR

61 **

052619

SCREW HHC M5-0.8 X 20 G8.8

62 **

023897

WASHER FLAT #10 ZINC

054199

DECAL DANGER HIGH VOLTAGE

0F6146

HANG TAG 2 WIRE START (NOT
SHOWN)

* PART OF I/N 51, P/N 0F0526A CONTROL PANEL HARNESS.
** NOT SHOWN. HARDWARE FOR ATTACHING WIRES TO I/N 39.

Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 25 kW Generator

Control Panel — Drawing No. 0F1378-F

Содержание 005040-2

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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 A...

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 A...

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 A...

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 A...

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 C...

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 C...

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 C...

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 C...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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: ...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...

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: ...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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