Generac Power Systems 005040-2 Owner's Manual
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Generac Power Systems 005040-2 Owner's Manual

Generac Power Systems 005040-2 Owner's Manual

Liquid-cooled, prepackaged standby generator
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Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number: 005040-2 (25kW)
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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Summary of Contents for Generac Power Systems 005040-2

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

  • Page 2: Introduction

    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.

  • Page 3: Table Of Contents

    INTRODUCTION ...IFC Read this Manual Thoroughly...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Service Dealer Location ...IFC SAFETY RULES ...2 Section 1 — GENERAL INFORMATION ...4 Generator ...4 Transfer Switch ...4 Automatic System Operation ...4 Generator AC Connection Systems...4 Main Circuit Breaker ...4 Generator Fuel System ...5 Engine Protective Devices ...5...

  • Page 4: Safety Rules

    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 –...

  • Page 5: Explosion Hazards

    • 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.

  • Page 6: Section 1 - General Information

    120 and/or 240VAC, single-phase loads. These models are available. They are rated as fol- lows: Model 005040-2: Provides 25,000 watts (25 kW) of single-phase power. If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a trans- fer switch.

  • Page 7: Generator Fuel System

    GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is pre- ferred, refer to Section 1.12, Reconfiguring the Fuel System for LP Vapor. Fuel 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.

  • Page 8: Unpacking

    Section 1 — General Information Guardian Liquid-cooled 25 kW Generator Figure 1.6 - Low Coolant Level Sensor 1.7.4 OVERSPEED SHUTDOWN Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine. 1.7.5 OVERCRANK SHUTDOWN The engine control board uses a cyclic cranking process when attempting to start the engine.

  • Page 9: Fuel Consumption

    (Port 1) of the demand regulator. 4. Remove pipe plug from Port 2. Single-phase 5. Install brass hose fitting into Port 2. 005040-2 6. Install pipe plug into Port 1. 7. Connect carburetor gas hose to brass fitting. 8. Tighten all clamps and plugs.

  • Page 10: Coolant Recommendations

    Section 2 — Installation Guardian Liquid-cooled 25 kW Generator Any attempt to crank or start the engine before it has been properly serviced with the recom- mended oil may result in an engine failure. 1.14 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti-freeze and half deionized water.

  • Page 11: Generator Location

    2.1.2 OTHER PUBLISHED STANDARDS In addition to NFPA standards, the following infor- mation pertaining to the installation and use of standby electric systems is available: • Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038. •...

  • Page 12: Total Circuit Isolation Method

    Section 2 — Installation Guardian Liquid-cooled 25 kW Generator • It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit. • It must be installed between the building’s main distribution panel and the emergency distribution panel.

  • Page 13: Battery Installation

    2.10 BATTERY INSTALLATION DANGER Standby generators installed with automatic transfer switches will crank and start automati- cally 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, do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation.

  • Page 14: Section 3 - Operation

    Section 3 - Operation Guardian Liquid-cooled 25 kW Generator 2.11.1 PRIOR TO INITIAL START-UP Prior to initially starting the generator, it must be properly prepared for use. Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids (oil, coolant, fuel, etc.) may result in an engine failure.

  • Page 15: Control Console Components

    OFF — The generator will not start and run in this position. MANUAL — The control board will start and run the generator whenever the switch is in the manual posi- tion. AUTO — The control board will monitor the two-wire start circuit.

  • Page 16: Manual Transfer And Startup

    Section 3 - Operation Guardian Liquid-cooled 25 kW Generator Condition System Ready (Green) Generator Switch is in the OFF Mode. System Ready for Automatic Start Generator Switch is in the MANUAL Mode Weekly Exerciser is not set Battery Voltage <12V for >1 minute Battery Voltage <6V Unit Shutdown due...

  • Page 17: Retransfer And Shutdown

    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 the stability pot until the unit returns to 60 Hertz (or 50 Hertz in 50 Hertz applications).

  • Page 18: Control Board Dip Switch Settings

    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.

  • Page 19: Exhaust Manifold Procedure

    F. EVERY 800 OPERATING HOURS 1. Retorque cylinder head (see torque specs). 2. Retorque intake and exhaust manifold (see torque specs). 3. Check engine compression. 4. Check valve clearance. EXHAUST MANIFOLD PROCEDURE 1. If necessary, clean gasket surfaces on exhaust manifold and cylinder head.

  • Page 20: Overload Protection For Engine Dc Electrical System

    Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM 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.
  • Page 21 4.8.8 CHECK FAN BELT • 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 INSPECT ENGINE GOVERNOR Visually inspect electronic governor.

  • Page 22: Miscellaneous Maintenance

    Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator MISCELLANEOUS MAINTENANCE 4.9.1 CLEANING THE GENERATOR 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.

  • Page 23: Scheduled Maintenance

    4.10 SCHEDULED MAINTENANCE Following 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 service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to deter- mine the next required maintenance interval.
  • Page 24 Section 4 — Maintenance Guardian Liquid-cooled 25 kW Generator Maintenance Level 1 Tasks Recom- mended to be done monthly 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level.
  • Page 25 Maintenance Level 1 Tasks Recom- mended to be done monthly 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions.

  • Page 26: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Guardian Liquid-cooled 25 kW Generator TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6.

  • Page 27: Section 6 - Notes

    Section 6 — Notes Guardian Liquid-cooled 25 kW Generator Generac ® Power Systems, Inc. 25...

  • Page 28: Section 7 - Electrical Data

    Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1411-A 26 Generac ® Power Systems, Inc.
  • Page 29 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1411-A Generac ® Power Systems, Inc. 27...
  • Page 30 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1413-A 28 Generac ® Power Systems, Inc.
  • Page 31 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1413-A ® Generac Power Systems, Inc. 29...
  • Page 32 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0E9982-C 30 Generac ® Power Systems, Inc.
  • Page 33 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0E9982-C Generac ® Power Systems, Inc. 31...
  • Page 34 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0E9983-C ® 32 Generac Power Systems, Inc.
  • Page 35 Section 7 - Electrical Data Guardian Liquid-cooled 25 kW Generator Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0E9983-C Generac ® Power Systems, Inc. 33...

  • Page 36: Section 8 - Exploded Views And Parts Lists

    Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Mounting Base — Drawing No. 0E9964-E 34 Generac ® Power Systems, Inc.
  • Page 37 ITEM PART NO. QTY. 0D9336 0E9939 0C2454 049813 022097 026850 055414 022473 047411 052860 052251 052257 052252 052259 052891 0536210261 074906 077483 0E9941 025507 059980 046526 022131 021991 038805J 050331 050331A 038804J 045771 022129 027482 075763 0E9748 0E9940 065852 024469 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Mounting Base —...
  • Page 38 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Enclosure — Drawing No. 0E9720-J 29 2 36 Generac ® Power Systems, Inc. "Y" "Y" 29 2 WELD STUD UNDER ROOF PANEL FOR ACCESS COVER CABLE 35 3 33 3 NOTE: USE DOOR LATCH...
  • Page 39 ITEM PART NO. QTY. 0E9768 (A) 0E9862 (A) 0E9769 (A) 0D8660 (A) 0A7568 (A) 0E9771 (A) 0E9773 (A) 0E9772 0E9770 (A) 10 * 067042 0C2454 033530 051716 022152 0912970063 023762 0912970064 022264 067035 022127 0C2634A 022473 022097 0D2023 25 ** 0F3390 037337 0E0072G...
  • Page 40 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Control Panel — Drawing No. 0E9719-G 38 Generac ® Power Systems, Inc.
  • Page 41 ITEM PART NO. QTY. DESCRIPTION 0C2267 SCREW HHTT M5-0.8 X 12 BP 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...
  • Page 42 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Control Panel — Drawing No. 0F1378-F 40 Generac ® Power Systems, Inc.
  • Page 43 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...
  • Page 44 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Engine — Drawing No. 0E9918-F 42 Generac ® Power Systems, Inc.
  • Page 45 ITEM PART NO. QTY. DESCRIPTION 0E9909 ENGINE 2.5L FORD 0E9739 PULLEY, 2.5L FORD WATER PUMP 049814 SCREW HHC M10-1.5 X 25 G8.8 0F0001 CLUTCH, COOLING FAN 2.5L FORD 0D3488B SERPENTINE BELT - 40.85" LENGTH 0A8584 SWITCH,OIL PRESSURE,10PSI,2POL 0E0561 ASSY WATER LEVEL SENSOR C/E 0A6751 SW-TMP 245DEG 3/8NPT 035579...
  • Page 46 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Fuel System — Drawing No. 0E9980-D 44 Generac ® Power Systems, Inc.
  • Page 47 ITEM PART NO. QTY. 0E8456 075580 0E9967 039253 022145 022129 045771 0F1570 0A6344 0F3994 REF. 0E1056 0F0397 0A5547 048031C 0D1509 16 * 0E0591 059402 037561 0E1028A 059401 21 * 091526 22 * 049226 026307 062522 022127 022259 050279 0A6125 0C2454 0E1104 0E0668 0E0590A...
  • Page 48 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Alternator — Drawing No. 0F5092-A 46 Generac ® Power Systems, Inc.
  • Page 49 ITEM PART NO. QTY. 0F1659A 0F1657A 0F1655A 0F5073A 0E7413A 0F1660A 0F1658A 0F1656A 0F5074A 0E7412A 0E5706 0E5048 0E5048B 0E5048A 0E6668 0E6076 046526 051755 04576100BK 04576100BF 043123 051779 0E7587 023365 0C3993 057192 0A2602 042558 0A2601 022264 038150 077043F 077043F ROTOR REPLACEMENT PARTS 047248 070892 Section 8 - Exploded Views and Parts...
  • Page 50 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Muffler — Drawing No. 0F2930-B ITEM PART NO. QTY. DESCRIPTION 0F2912 PIPE MUFFLER OUT 0F2869 PIPE EXHAUST 2.5L FORD 0F2823 MUFFLER 2.5L FORD 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH 022129...
  • Page 51 TO "A" CARBURETOR ARM (REF.) ITEM PART NO. QTY. 098290 098941A 0F0454 098942A 098225 043146 022097 0E7358 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Stepper Motor — Drawing No. 0E9979-C "A"...
  • Page 52 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generator Radiator — Drawing No. 0E9965-D ITEM PART NO. QTY. DESCRIPTION 0E9769 SUPPORT,RADIATOR 2.5L FORD 0F0779 SUPPORT RADIATOR 2.5L AL 0E9837 RADIATOR, 2.5L FORD 0F0123 VENTURI, 16" FAN 2.5L FORD 0F0118 GUARD, FAN 2.5L FORD 099502...

  • Page 53: Section 9 - Installation Diagram

    Section 9 — Installation Diagram Guardian Liquid-cooled 25 kW Generator Installation Diagram — Drawing No. 0F1020-A Generac ® Power Systems, Inc. 51...

  • Page 54: Section 10 - Warranty

    YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards.

  • Page 55: Emission Control System Warranty

    Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con- tinue for 24 consecutive months thereafter.
  • Page 56 "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective.

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