Generac Power Systems 005040-1, 005053-1, 005054-0 Description, 1024, SUPPORT,RADIATOR 2.5L FORD

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Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 25 kW Generator

Radiator — Drawing No. 0E9965-D

1

19

18

115

12

2

14

18

		8 10
7		TO BASE OF
7		WATER INLET
25		5
9		5
9
	7	24
		24
		15
	16	3
	16

4 17

6

9

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ITEM	PART NO.	QTY.	DESCRIPTION		ITEM	PART NO.	QTY.	DESCRIPTION
1	0E9769	REF	SUPPORT,RADIATOR 2.5L FORD	14		0F0127	1	HOSE, UPPER RADIATOR 174MM
	0F0779	REF	SUPPORT RADIATOR 2.5L AL					TAL
2	0E9837	1	RADIATOR, 2.5L FORD	15		0E9833	1	HOSE, 2.5L FORD LOWER
3	0F0123	1	VENTURI, 16" FAN 2.5L FORD					RADIATOR
4	0F0118	1	GUARD, FAN 2.5L FORD	16		035461	1	BARBED STR 1/4NPT X 3/8
5	099502	4	CLAMP HOSE #24 B1.06-2.00	17		069860C	1	HOSE OIL DRAIN ASSY 21"
6	0C2454	REF.	SCREW THF M6-1X16 N WA Z/JS	18		0A7275	4	FOAM 1.5 X 1 ADHESIVE BACKING
7	052250	2	TAPE FOAM 1 X 1(17"LG)					(21.5" LG)
8	022097	8	WASHER LOCK M6-1/4	19		031669	4	BOLT CARR 1/4-20 X 1-3/4 JS500
9	022473	12	WASHER FLAT 1/4 ZINC	20		065852	1	SPRING CLIP HOLDER .37-.62
10	022127	8	NUT HEX 1/4-20 STEEL	21		0A2111	1	SCREW SWAGE 10-32 X 5/16 Z/YC
11	046627	1	CAP RADIATOR	24		0C2454	6	SCREW TH-FRM M6-1X16 N WA Z/JS
12	060035	4	SPACER .41 X .75 X .87 ST/ZNC	25		022287	4	SCREW HHC 1/4-20 X 3/4 G5

50 Generac® Power Systems, Inc.

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Contents SHOULD ATTEMPT INSTALLATION Owner’s ManualLiquid-cooled, Prepackaged Standby Generators This manual should remain with the unitAUTHORIZED SERVICE DEALER LOCATION ‹ OPERATION AND MAINTENANCE‹ HOW TO OBTAIN SERVICE INTRODUCTIONTable of Contents Guardian Liquid-cooled 25 kW GeneratorGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot during operation. Exercise care near running gen- eratorsELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.2 TRANSFER SWITCH 1.1 GENERATOR1.3 AUTOMATIC SYSTEM OPERATION 1.4 GENERATOR AC CONNECTION SYSTEMS‹ 1.7.1 LOW OIL PRESSURE SWITCH ‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH‹ 1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch1.10 SPECIFICATIONS ‹ 1.7.6 LOW BATTERY‹ 1.8.1 UNPACKING PRECAUTIONS 1.8 UNPACKING1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR Figure 1.8 - Reconfigure the Fuel System1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR1.15 BEFORE INSTALLATION 2.1 STANDBY GENERATOR INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.3 GENERATOR MOUNTING AND SUPPORT 2.4 BASIC STANDBY ELECTRIC SYSTEM2.2 GENERATOR LOCATION ‹ 2.1.2 OTHER PUBLISHED STANDARDS2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH 2.5 EMERGENCY CIRCUIT ISOLATION METHOD2.6 TOTAL CIRCUIT ISOLATION METHOD 2.7 GROUNDING THE GENERATOR2.10 BATTERY INSTALLATION Pos2 OFF - Standard Prepackaged ATS Application‹ 2.10.1 VENTED BATTERIES Standby generators installed with automatic3.1 ENGINEERED GTS TRANSFER SWITCH ‹ 2.11.2 TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹ 2.11.1 PRIOR TO INITIAL START-UP‹ 3.2.2 FAULT INDICATOR LEDS ‹ 3.2.1 AUTO/OFF/MANUAL SWITCH‹ 3.2.5 SET EXERCISE TIME SWITCH 3.2 CONTROL CONSOLE COMPONENTS3.3 MANUAL TRANSFER AND START-UP 3.4 ENGINE GOVERNOR ADJUSTMENTS‹ 3.2.6 SYSTEM READY LED Figure 3.2 - Engine Governor Adjustment Figure 3.3 - “Set Exercise Time” Switch3.6 AUTOMATIC OPERATION 3.7 WEEKLY EXERCISE CYCLE3.8 CONTROL BOARD DIP SWITCH SETTINGS 4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIESA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHS4.2 EXHAUST MANIFOLD PROCEDURE 4.3 INTAKE MANIFOLD PROCEDURE4.4 CYLINDER HEAD PROCEDURE Figure 4.1 - Intake Manifold Installation4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM 4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.7 CHECKING FLUID LEVELS ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANER Figure 4.4 - Setting the Spark Plug Gap‹ 4.8.8 CHECK FAN BELT ‹ 4.8.9 INSPECT ENGINE GOVERNOR4.9 MISCELLANEOUS MAINTENANCE ‹ 4.9.1 CLEANING THE GENERATOR‹ 4.9.2 BATTERY ‹ 4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationTurn off the battery charger turn OFF utility supply to ATS Remove the negative battery cableLevel MaintenanceTasks Maintenance TROUBLESHOOTING POINTS PROBLEMCAUSE CORRECTIONGenerac Power Systems, Inc 26 Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F1411Section 7 - Electrical Data Generac Power Systems, Inc 28 Generac Power Systems, Inc Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0E9982-B 30 Generac Power Systems, IncGenerac Power Systems, Inc Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-B 32 Generac Power Systems, IncGenerac Power Systems, Inc HARNESS WIRE 34 Generac Power Systems, IncMOUNT BLOCK ENGINEDESCRIPTION PANEL FOR ACCESS GROUND WIRECOVER CABLE FASTENER TO SECUREEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc DESCRIPTION 42 Generac Power Systems, Inc Guardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-ESTEPPER MOTOR UNITS ONLY TO RADIATORSOURCE GENERAC-BOSCH GOV GASKET, 2.5L FORD EXHAUST MANSERPENTINE BELT - 41 3/8 LENGTH BRKT,D.C. ALTERNATORMACHINED0E1028A I/N TO ENGINECOVER 44 Generac Power Systems, IncDESCRIPTION LOCKTIGHT LEADS46 Generac Power Systems, Inc Alternator - Drawing No. 0E8660-CROTOR REPLACEMENT PARTS ROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORDSTR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD CONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER48 Generac Power Systems, Inc SCREW HHC M8-1.25 X 60 G8.8 FTSECURE WIRE HARNESS ITEM 13 NEOPRENECOATING WITH TIE WRAP AS SHOWN50 Generac Power Systems, Inc 1024SUPPORT,RADIATOR 2.5L FORD HOSE, UPPER RADIATOR 174MMSection 9 - Installation Diagram Installation Diagram - Drawing No. 0F1020-AYOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGEPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGGENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI