Generac Power Systems 005040-0, 005040-1, 005053-0, 005053-1, 005054-0, 005054-1 0E9909

Page 45
0E9909

Section 8 - Exploded Views and Parts

Guardian Liquid-cooled 25 kW Generator

Engine — Drawing No. 0E9918-E

ITEM

PART NO.

QTY.

DESCRIPTION

 

ITEM

PART NO.

QTY.

DESCRIPTION

1

0E9909

REF

ENGINE 2.5L FORD

33

0E9680

1

GASKET, 2.5L FORD EXHAUST MAN.

2

0E9739

1

PULLEY, 2.5L FORD WATER PUMP

34

0E9609

1

MANIFOLD, EXHAUST ( MACHINED)

3

049814

8

SCREW HHC M10-1.5 X 25 G8.8

35

0E9930

1

HEAT SHIELD, EXHAUST MANIFOLD

4

0F0001

1

CLUTCH, COOLING FAN 2.5L FORD

36

049821

3

SCREW SHC M8-1.25 X 30 G12.9

5

0D3488B

1

SERPENTINE BELT - 41 3/8" LENGTH

37

0E9747

1

STARTER, 12 VOLT

6

0A8584

1

SWITCH,OIL PRESSURE,10PSI,2POL

38

043116

5

SCREW HHC M6-1.0 X 12 G8.8

7

0E0561

1

ASSY WATER LEVEL SENSOR C/E

39

022473

6

WASHER FLAT 1/4-M6 ZINC

PL

 

 

 

40

045772

2

NUT HEX M10-1.5 G8 YEL CHR

8

0A6751

1

SW-TMP 245DEG 3/8NPT

41

064416

2

SCREW HHC M10-1.5 X 45 G8.8

9

035579

1

BUSHING REDUCER 1/4 TO 1/8

42

0F0252

1

SPRING BUSHING

10

026925

1

PLUG STD PIPE 3/8 STEEL SQ HD

43

0E9868

1

ALTERNATOR, D.C

11

0E9611

1

MANIFOLD, INTAKE (MACHINED)

44

0F0035

1

BRKT,D.C. ALTERNATOR(MACHINED)

 

 

 

(STEPPER MOTOR)

45

026082

1

SCREW HHC 3/8-16 X 2-1/4 G5

 

0E9611A

1

MANIFOLD INTAKE MACH BOSCH32

46

0E9928

1

TENSIONER, D.C. ALTERNATOR

 

 

 

(BOSCH GOV.) (NOT SHOWN)

47

0F0383

1

HOSE,2.5L FORD COOLANT BY-

12

0E9681

1

GASKET, 2.5L FORD INTAKE MAN.

 

 

 

 

PASS

13

039253

4

SCREW HHC M8-1.25 X 20 G8.8

48

057823

2

CLAMP HOSE #10 .56-1.06

14

097962

4

SCREW SHC M6-1.0 X 25 G12.9 ZP

49

0E9737

1

LOWER HOSE ADAPTER,2.5L FORD

15

022145

8

WASHER FLAT 5/16-M8 ZINC

50

0F0393

1

O-RING 1-3/16 X 1-7/16 X 1/8

16

022097

11

WASHER LOCK M6-1/4

51

045757

2

SCREW HHC M6-1.0 X 25 G8.8

17

022129

16

WASHER LOCK M8-5/16

52

069860C

1

HOSE OIL DRAIN ASSY 21"

18

043107

11

SCREW HHC M8-1.25 X 25 G8.8

53

048031J

REF

HOSE CLAMP BAND 5/8"

19

022131

19

WASHER FLAT 3/8-M10 ZINC

54

055596

1

BARBED STR 3/8NPT X 3/8

20

046526

30

WASHER LOCK M10

55

077456

1

ADAPTER M12-1.75 3/8NPT

21

052625

2

SCREW SHC M10-1.5 X 35 G12.9

56

052677

1

WASHER NYLON .50 X .87 X .06

22

0E9708

2

ENGINE FOOT, 2.5L FORD

57

049813

1

NUT HEX M6 X 1.0 G8 YEL CHR

23

0E9738

1

DIPSTICK, 2.5L FORD

58

0E9738A

1

DIPSTICK TUBE, 2.5L FORD

24

0E9929

1

BRACKET, DIPSTICK TUBE

59

0F1132

1

COVER, R/H SIDE ENGINE

25

0F0230

1

FAN 16" COOLING

 

 

 

 

ADAPTOR

26

0E9834

1

HARNESS, 2.5L FORD ENGINE

60

0F1133

1

COVER, L/H SIDE ENGINE ADAPTOR

 

 

 

(GENERAC & GUARDIAN) (NOT

61

059355

8

SCREW SHC M10-1.50 X 50 G12.9

 

 

 

SHOWN)

62

076749

1

TANK COOLANT RECOVERY

 

0E9834A

1

HARNESS,2.5L FORD (QUIET

63

029032

1

HOSE 9/32 ID (39"LG)

 

 

 

SOURCE) (GENERAC-BOSCH GOV.)

64

0F1433

1

BRACKET,2.5L FORD WATER

 

 

 

(NOT SHOWN)

 

 

 

 

BOTTLE

27

0D5417

6

SCREW HHC M10-1.0 X 25 G10.9

65

070007

3

WASHER FLAT M6 SS

28

0E5048B

1

FLEXPLATE 2.5L FORD

66

070005

3

WASHER LOCK M6 SS

29

0E9655

1

ADAPT CASTING MACH 2.5L FORD

67

080826

3

SCREW HHC M6-1.0 X 12 SS

30

057192

4

SCREW SHC M10-1.5 X 30 G12.9

68

045771

1

NUT HEX M8-1.25 G8 YEL CHR

31

060619

2

SCREW SHC M10-1.50 X 40 G12.9

69

048031C

2

CLAMP HOSE BAND 1/4

32

0E8940

1

SPACER FLEXPLATE HSB

 

 

 

 

 

Generac® Power Systems, Inc. 43

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Contents Owner’s Manual SHOULD ATTEMPT INSTALLATIONLiquid-cooled,Prepackaged Standby Generators This manual should remain with the unit‹OPERATION AND MAINTENANCE AUTHORIZED SERVICE DEALER LOCATION‹HOW TO OBTAIN SERVICE INTRODUCTIONINTRODUCTION Table of ContentsGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot FIRE HAZARDS ELECTRICAL HAZARDSEXPLOSION HAZARDS ‹STANDARDS INDEX1.1GENERATOR 1.2TRANSFER SWITCH1.3AUTOMATIC SYSTEM OPERATION 1.4GENERATOR AC CONNECTION SYSTEMS‹1.7.2 HIGH COOLANT TEMPERATURE SWITCH ‹1.7.1 LOW OIL PRESSURE SWITCH‹1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch‹1.7.6 LOW BATTERY 1.10 SPECIFICATIONS‹1.8.1 UNPACKING PRECAUTIONS 1.8UNPACKINGFigure 1.8 — Reconfigure the Fuel System 1.12RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR2.1STANDBY GENERATOR INSTALLATION 1.15 BEFORE INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.4BASIC STANDBY ELECTRIC SYSTEM 2.3GENERATOR MOUNTING AND SUPPORT2.2GENERATOR LOCATION ‹2.1.2 OTHER PUBLISHED STANDARDS2.5EMERGENCY CIRCUIT ISOLATION METHOD 2.9USING AN ENGINEERED “GTS” TRANSFER SWITCH2.6TOTAL CIRCUIT ISOLATION METHOD 2.7GROUNDING THE GENERATORPos2 OFF — Standard Prepackaged ATS Application 2.10BATTERY INSTALLATION‹2.10.1 VENTED BATTERIES Standby generators installed with automatic‹2.11.2 TRANSFER SWITCH 3.1ENGINEERED GTS TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹2.11.1 PRIOR TO INITIAL START-UP‹3.2.1 AUTO/OFF/MANUAL SWITCH ‹3.2.2 FAULT INDICATOR LEDS‹3.2.5 SET EXERCISE TIME SWITCH 3.2CONTROL CONSOLE COMPONENTS3.4ENGINE GOVERNOR ADJUSTMENTS 3.3MANUAL TRANSFER AND START-UP‹3.2.6 SYSTEM READY LED Figure 3.3 - “Set Exercise Time” Switch Figure 3.2 — Engine Governor Adjustment3.6AUTOMATIC OPERATION 3.7WEEKLY EXERCISE CYCLEA. EVERY THREE MONTHS 3.8CONTROL BOARD DIP SWITCH SETTINGSB. ONCE EVERY SIX MONTHS C. ONCE ANNUALLY4.3INTAKE MANIFOLD PROCEDURE 4.2EXHAUST MANIFOLD PROCEDURE4.4CYLINDER HEAD PROCEDURE Figure 4.1 — Intake Manifold Installation4.6OVERLOAD PROTECTION FOR 4.8MAINTENANCE OWNER/ OPERATOR CAN PERFORMENGINE DC ELECTRICAL SYSTEM 4.7CHECKING FLUID LEVELSFigure 4.4 – Setting the Spark Plug Gap ‹4.8.11 CHANGING THE ENGINE AIR CLEANER‹4.8.8 CHECK FAN BELT ‹4.8.9 INSPECT ENGINE GOVERNOR‹4.9.1 CLEANING THE GENERATOR 4.9MISCELLANEOUS MAINTENANCE‹4.9.2 BATTERY ‹4.9.3 BATTERY MAINTENANCEService Maintenance Interval Information 4.10 SCHEDULED MAINTENANCEMaintenance LevelTasks Maintenance PROBLEM TROUBLESHOOTING POINTSCAUSE CORRECTIONSection 6 — Notes Section 7 - Electrical Data 26 Generac Power Systems, IncSection 7 - Electrical Data 28 Generac Power Systems, Inc Section 7 - Electrical Data 30 Generac Power Systems, Inc Section 7 - Electrical Data 32 Generac Power Systems, Inc Section 7 - Electrical Data MOUNT ITEM PART NODESCRIPTION 31 7 11 Enclosure — Drawing No. 0E9720-D 54 36 30 0C2267 40 Generac Power Systems, Inc 0C2267 Engine — Drawing No. 0E9918-E 42 Generac Power Systems, Inc0E9909 0E1028A I/N 0E8456 LOCKTIGHT 0F1659A Muffler — Drawing No. 0F2930-B Stepper Motor — Drawing No. 0E9979-C Radiator — Drawing No. 0E9965-D Installation Diagram — Drawing No. 0F1020-A Section 9 — Installation DiagramPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES YOUR WARRANTY RIGHTS AND OBLIGATIONS1-800-333-1322 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING WARRANTY SCHEDULEGENERAC POWER SYSTEMS, INC P.O. BOX 297 • WHITEWATER, WI
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