Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Nos. 005040-0, 005040-1 (25kW)
005053-0, 005053-1 (20kW)
005054-0, 005054-1 (15kW)
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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Table of Contents
Guardian Liquid-cooled 25 kW Generator
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
1.1 Generator..............................................................4
1.2 Transfer Switch ....................................................4
1.3 Automatic System Operation ................................4
1.4 Generator AC Connection Systems........................4
1.5 Main Circuit Breaker ............................................5
1.6 Generator Fuel System..........................................5
1.7 Engine Protective Devices......................................5
1.8 Unpacking ............................................................6
1.9 Lifting the Generator ............................................6
1.10 Specifications ........................................................6
1.11 Fuel Consumption ................................................7
1.12 Reconfiguring the Fuel System for LP Vapor..........7
1.13 Engine Oil Recommendations ..............................8
1.14 Coolant Recommendations....................................8
1.15 Before Installation ................................................8
Section 2 — INSTALLATION ............................8
2.1 Standby Generator Installation ............................8
2.2 Generator Location................................................9
2.3 Generator Mounting and Support ........................9
2.4 Basic Standby Electric System..............................9
2.5 Emergency Circuit Isolation Method....................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 Preparation Before Start-Up................................12
Section 3 — OPERATION ................................12
3.1 Engineered GTS Transfer Switch........................12
3.2 Control Console Components..............................13
3.3 Manual Transfer and Startup..............................14
3.4 Engine Governor Adjustments ............................14
3.5 Retransfer and Shutdown....................................15
3.6 Automatic Operation ..........................................15
3.7 Weekly Exercise Cycle..........................................15
3.8 Control Board DIP Switch Settings ....................16
Section 4 — MAINTENANCE ..........................16
4.1 Maintenance Performed by Authorized
Service Facilities..................................................16
4.2 Exhaust Manifold Procedure ..............................17
4.3 Intake Manifold Procedure ..................................17
4.4 Cylinder Head Procedure ....................................17
4.5 Cooling System....................................................17
4.6 Overload Protection for Engine DC
Electrical System ................................................18
4.7 Checking Fluid Levels ........................................18
4.8 Maintenance Owner/Operator
Can Perform........................................................18
4.9 Miscellaneous Maintenance ................................20
4.10 Scheduled Maintenance ......................................21
Section 5 — TROUBLESHOOTING ..................24
Section 6 — NOTES ........................................25
Section 7 — ELECTRICAL DATA ....................26
Section 8 — EXPLODED VIEWS AND
PARTS LISTS ..............................34
Section 9 — INSTALLATION DIAGRAM ..........51
Section 10 — WARRANTY...............................52
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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 – This manual contains important instructions that should be
followed during installation and maintenance of the generator and batteries.
!
!
!
GENERAL HAZARDS
!
!
WARNING:
• For safety reasons, Generac recommends that this equip-
ment be installed, serviced and repaired by a Generac
Authorized Service Dealer or other competent, qualified
electrician or installation technician who is familiar with
applicable codes, standards and regulations. The operator
also must comply with all such codes, standards and regu-
lations.
• Installation, operation, servicing and repair of this (and
related) equipment must always comply with applicable
codes, standards, laws and regulations. Adhere strictly to
local, state and national electrical and building codes.
Comply with regulations the Occupational Safety and
Health Administration (OSHA) has established. Also,
ensure that the generator is installed, operated and serv-
iced in accordance with the manufacturer’s instructions
and recommendations. Following installation, do nothing
that might render the unit unsafe or in noncompliance with
the aforementioned codes, standards, laws and regula-
tions.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
!
!
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The gen-
erator can operate safely, efficiently and reliably only if
it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fun-
damental rules or precautions.
Generac cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this man-
ual, and on tags and decals affixed to the unit are, there-
fore, not all-inclusive. If using a procedure, work
method or operating technique that Generac does not
specifically recommend, ensure that it is safe for others.
Also make sure the procedure, work method or operat-
ing technique chosen does not render the generator
unsafe.
• The engine exhaust fumes contain carbon monoxide gas,
which can be DEADLY. This dangerous gas, if breathed in
sufficient concentrations, can cause unconsciousness or
even 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 unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air
is critical to prevent buildup of explosive gases and to
ensure correct generator operation. Do not alter the instal-
lation or permit even partial blockage of ventilation provi-
sions, as this can seriously affect safe operation of the gen-
erator.
• Keep the area around the generator clean and uncluttered.
Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
• Inspect the generator regularly, and promptly repair or
replace all worn, damaged or defective parts using only fac-
tory-approved parts.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
!
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate or main-
tain this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
• Before performing any maintenance on the generator, dis-
connect its battery cables to prevent accidental start-up.
Disconnect the cable from the battery post indicated by a
NEGATIVE, NEG or (–) first. Reconnect that cable last.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running gen-
erators.
!
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and may
result in dangerous operating conditions from leaking
exhaust gases, fuel leakage, oil leakage, etc.
®
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Important Safety Instructions
Guardian Liquid-cooled 25 kW Generator
ELECTRICAL HAZARDS
FIRE 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.
• 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.
• 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.
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.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric shock, 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQ-
or may get caught in moving components causing injury.
UIDS CODE, available same as Item 1.
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Section 1 - General Information
Guardian Liquid-cooled 25 kW Generator
• Protect 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 Authorized Dealer.
1.1 GENERATOR
This equipment is a liquid-cooled, engine-driven gen-
erator set. The generator is designed to supply elec-
trical power that operates critical electrical loads
during utility power failure. The unit has been facto-
ry-installed in a weather resistant, all metal enclosure
and is intended for outdoor installation only. Use this
generator as a source of electrical power for the oper-
ation of 120 and/or 240VAC, single-phase loads.
1.3 AUTOMATIC SYSTEM OPERATION
When this generator, along with a transfer switch, has
been installed and interconnected, a circuit board in
the generator panel constantly monitors utility power
source voltage. Should that voltage drop below a pre-
set value, and remain at such a low state for a preset
amount of time, the generator cranks and starts. After
the generator starts, the transfer switch transfers load
circuits so the generator can power them.
These models are available. They are rated as fol-
lows:
Model 005040-0: Provides 25,000 watts (25 kW) of single-phase
power.
Model 005053-0: Provides 20,000 watts (20 kW) of single-phase
power.
When utility source voltage has been restored, the
switch re-transfers back to the utility source voltage
and the generator then shuts down.
Model 005054-0: Provides 15,000 watts (15 kW) of single-phase
power.
Please reference the transfer switch manual for spe-
cific information.
1.4 GENERATOR AC CONNECTION
If this generator is used to power electrical
load circuits normally powered by a utility
power source, it is required by code to install
SYSTEMS
!
The generator was shipped from the factory with its
stator AC output leads connected in a single-phase,
3-wire generator AC connection system (Figure 1.1).
The stator assembly in this system consists of a pair
of stationary windings, with two leads brought out of
each winding. Each single winding can supply 120
VAC, 60 Hertz. When the two windings are connected
in series, a 240 VAC, 60 Hertz AC output results.
Typically the two “hot” leads in the circuit are Wires
No. 11 and 44. The “Neutral” leads are the junction
of Wires 22 and 33.
a transfer switch. The transfer switch must
effectively isolate the electric system from the
utility distribution system when the generator
is operating (NEC 701). Failure to isolate an
electrical system by such means results in
damage to the generator and may also result
in injury or even death to utility power work-
ers due to backfeed of electrical energy.
1.2 TRANSFER SWITCH
This generator system is intended to be used with a
matched automatic transfer. It may be supplied in
either a NEMA 1 enclosure or a NEMA 3R enclosure.
The NEMA 1 enclosure is intended for indoor use
only. The NEMA 3R enclosure is weather proof and
can be used indoors or outdoors. Follow these rules:
Figure 1.1 - Generator AC Connection System
• Install the transfer switch on a firm, sturdy sup-
porting structure.
0
• To prevent switch distortion, level the switch if nec-
essary. This can be done by placing washers
between the switch enclosure and the mounting
surface.
NEUTRAL
• Never install the switch where water or any corro-
sive substance might drip onto the enclosure.
Figure 1.2 - Main Circuit Breaker
Model
005040-0
005053-0
005054-0
Rating
25,000 W
20,000 W
15,000
Phase
Actual Current
C/B Rating*
% over rating
120%
Circuit Breaker
125A BQ2
1
1
1
104.2 A
125 A
83.3 A
62.5
100 A
70 A
120%
120%
100A BQ2
70A BQ2
* Amp Rating of C/B structured under model.
®
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Section 1 - General Information
Guardian Liquid-cooled 25 kW Generator
1.7.1 LOW OIL PRESSURE SWITCH
‹
1.5 MAIN CIRCUIT BREAKER
The generator’s main circuit breaker is included with
the unit as shipped from the factory. The breaker for
each unit is described in Figure 1.2.
This switch is normally-closed (N.C.) but is held open
by engine oil pressure during engine running. Should
operating oil pressure drop below about 8-10 psi
(55-68 kPa), the switch contacts close and the engine
shuts down automatically (Figure 1.4).
1.6 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.
Figure 1.4 - Low Oil Pressure Switch
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.
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
NOTE:
A seperate gas line and regulator may be needed
to assure proper gas pressure to the generator.
Improper gas pressure can cause hard starting and
affect engine durability.
1.7.2 HIGH COOLANT TEMPERATURE SWITCH
‹
Normally open (N.O.) thermostatic switch has sens-
ing tip which is immersed in captive coolant. Should
coolant temperature exceed about 230°F (110°C), the
switch contacts close, which causes the engine to
shut down automatically (Figure 1.5).
Gaseous fuels such as natural and LP
(propane) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause
!
an explosion. No leakage of fuel is permitted.
Natural gas, which is lighter than air, tends to
collect in high areas. LP gas is heavier than air
and tends to settle in low areas.
Figure 1.5- High Coolant Temperature Switch
1.7 ENGINE PROTECTIVE 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 coolant level or over-
crank (Figure 1.3).
Figure 1.3 - Engine Protective Devices
1.7.3 LOW COOLANT LEVEL SWITCH
‹
Should engine coolant level drop below the level of
the high coolant temperature switch, it is possible for
the engine to overheat without automatic shutdown.
To prevent such overheating without automatic shut
down, the engine has a low coolant level sensor. If the
engine coolant drops too low, the engine automatical-
ly shuts down (Figure 1.6 on page 6).
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Section 1 — General Information
Guardian Liquid-cooled 25 kW Generator
Figure 1.6 - Low Coolant Level Sensor
1.8.2 INSPECTION
‹
Upon delivery, carefully inspect the generator for any
damage that may have occurred during shipment. If
loss or damage is noted at the time of delivery, have
the person(s) making delivery note all damage on the
freight bill or affix their signature under the consign-
or’s memo of loss or damage.
1.9 LIFTING THE GENERATOR
1.7.4 OVERSPEED SHUTDOWN
Should AC frequency exceed about 72 Hz, circuit
board action will automatically shutdown the engine.
‹
When lifting or hoisting equipment is used,
be careful not to touch overhead power lines.
The generators weight of more than 900
pounds requires proper tools, equipment, and
qualified personnel to be used in all phases of
handling and unpacking.
!
‹
1.7.5 OVERCRANK SHUTDOWN
The engine control board uses a cyclic cranking
process when attempting to start the engine. The first
crank cycle is a 15-second crank followed by a seven-
second rest. This is followed by five more crank
cycles each with a seven second crank followed by a
seven-second rest.
1.10 SPECIFICATIONS
1.10.1 ENGINE
‹
Make ......................................................................................Ford
Displacement ............................................153 inches3 (2.5 liters)
Cylinder Arrangement......................................................4, in-line
Valve Arrangement................................................Overhead Cam
Firing Order........................................................................1-3-4-2
Number of Main Bearings............................................................5
Compression Ratio..........................................................9.37 to 1
No. of Teeth on Flywheel ........................................................164
Ignition Timing (Waste Spark System)
If the engine fails to start after all six attempts, the start
attempt is stopped and the overcrank LED turns on.
‹
1.7.6 LOW BATTERY
The engine control board continually monitors the
battery voltage and turns on the low battery LED if
the battery voltage falls below 12 VDC for one minute.
Low battery voltage is a non-latching alarm, which
will automatically clear if the battery voltage rises
above 12 VDC.
at 1800 rpm ..................................................36 degrees BTDC
Spark Plug Gap ............................................................0.044 inch
Recommended Spark Plugs
1.7.7 15A DC FUSE
‹
This fuse is located inside the control panel. It pro-
tects the panel wiring and components from damag-
ing overload. The unit will not start or crank if the
fuse is blown. Replace the fuse with one of the same
size, type, and rating.
Motorcraft ................................................................AWSF-52-C
Oil Pressure....................................................................30-50 psi
Crankcase Oil Capacity......................4.5 U.S. quarts (4.26 liters)
Recommended Engine Oil........................................SAE 15W-40
Type of Cooling System ..................Pressurized, closed recovery
Cooling Fan ..............................................................Pusher Type
Cooling System Capacity ......................2 U.S. gallons (7.6 liters)
1.8 UNPACKING
1.8.1 UNPACKING PRECAUTIONS
‹
Recommended Coolant ............Use a 50-50 mixture of ethylene
glycol base and deionized water.
Handle shipping cartons and crates with care. Use
care to avoid damage from dropping, bumping, colli-
sion, etc. Store and unpack cartons with the proper
side up, as noted on the shipping carton.
Home standby control board assembly part
number 0E9704 must be used on 1800 rpm gen-
!
erators.
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Section 1 — General Information
Guardian Liquid-cooled 25 kW Generator
1.10.2 GENERATOR
‹
Single-phase
Single-phase
Single-phase
Model
005040-0
*25
005053-0
20
005054-0
15
Rated Max. Cont.
AC Power Output (kW)
Rated voltage (volts)
No. of Rotor Poles
Driven Speed of Rotor
Rotor Excitation System
Type of Stator
120/240
4
1800
120/240
4
1800
4
1800
Direct excited brush type
Direct excited brush type
Direct excited brush type
4 Wire
Class F
Class H
4 Wire
Class F
Class H
4 Wire
Class F
Class H
Rotor Insulation
Stator Insulation
* Rated power of generator is subject to and limited by such factors as ambient temperature, altitude, engine condition,
and other factors. Engine power will decrease about 3.5% for each 1000 feet above sea level and will decrease an addi-
tional 1% for each 10°F above 60°F. Maximum output power of the generator is limited by maximum engine power.
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.
1.11 FUEL CONSUMPTION
25 kW Models
Using Natural Gas ........................................441 cu. ft. per hour
Using LP Gas..............................175 cubic ft.(4.8 gal.) per hour
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.
9. Make sure fuel supply is of the proper pressure
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).
Fuel pressure for an LP vapor set up should be 11
inches to 14 inches of water column (0.4 to 0.5
psi) at all load ranges.
11. Reverse the procedure to convert back to natural
gas.
NOTE:
Figure 1.8 — Reconfigure the Fuel System
Fuel consumption is given at rated maximum con-
tinuous power output when using natural gas
rated at 1000 Btu per cubic foot; or LP gas rated
2520 Btu per cubic foot. Actual fuel consumption
obtained may vary depending on such variables as
applied load, ambient temperature, engine condi-
tions and other environmental factors.
Port 1
Port 2
FUEL HOSE
FUEL HOSE
BRASS HOSE
FITTING
BRASS HOSE
FITTING
PLUG
PLUG
OUT
PORT 1
OUT
PORT 2
FUEL INLET
1.12 RECONFIGURING THE FUEL
SYSTEM FOR LP VAPOR
NOTE:
NG FUEL SYSTEM
All models are configured for natural gas from the
factory.
LP FUEL SYSTEM
NOTE:
To reconfigure the fuel system from NG to LP vapor,
follow these steps:
Port 1 is for NG only and Port 2 is for LP vapor
only. No provision for dual fuel has been made.
1. Turn the main gas supply off.
DANGER
2. Remove the carburetor fuel hose from the outlet
port (Port 1) of the demand regulator (Figure
1.8).
Serious injury or damage may occur if not
configured properly. Please consult an author-
ized Generac Service Dealer with any ques-
3. Remove the brass hose fitting from the outlet port
!
(Port 1) of the demand regulator.
tions.
4. Remove pipe plug from Port 2.
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Section 2 — Installation
Guardian Liquid-cooled 25 kW Generator
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 controls all phases
of operation, including engine start up and load
transfer.
1.13 ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the
factory. Use a high-quality detergent oil classified “For
Service CC, SD, SE, SF.” Detergent oils keep the
engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the
next oil change:
2.1 STANDBY GENERATOR
INSTALLATION
Temperature
Above 80° F (27° C)
32° to 80° F (-1° to 27° C)
Below 32° F (0° C)
Oil Grade (Recommended)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
SAE 10W or 15W-40
DANGER
Connecting this generator to an electrical sys-
tem normally supplied by an electric utility
shall be by means of a transfer switch, so as
to isolate the electric system from the utility
distribution system when the generator is
operating. Failure to isolate the electric sys-
tem by these means will result in damage to
the generator and may also result in injury or
death to utility workers due to backfeed of
electrical energy.
Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil may result in an engine fail-
ure.
!
1.14 COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base
anti-freeze and half deionized water. Cooling system
capacity is about 8 U.S. quarts (7.6 liters). Use only
deionized water and only low silicate anti-freeze. If
desired, add a high quality rust inhibitor to the rec-
ommended coolant mixture. When adding coolant,
always add the recommended 50-50 mixture.
If an open bottom is used, the engine-genera-
tor must be installed over non-combustible
materials and should be located such that com-
bustible materials are not capable of accumu-
lating under the generator set.
Only qualified, competent installation contractors or
electricians thoroughly familiar with applicable
codes, standards and regulations should install this
standby electric power system. The installation must
comply strictly with all codes, standards and regula-
tions pertaining to the installation.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or
chromiumhydroxide (“green slime”) forms and
!
will cause overheating. Engines that have
been operated with a chromate base rust
inhibitor must be chemically cleaned before
adding ethylene glycol base anti-freeze. Using
any high silicate anti-freeze boosters or addi-
tives will also cause overheating. DO NOT use
any soluble oil inhibitor for this equipment.
After the system has been installed, do nothing
that might render the installation in noncompli-
ance with such codes, standards and regula-
tions.
!
NOTE:
For more information about the installation of a
standby system contact a Generac Authorized
Service Dealer.
1.15 BEFORE INSTALLATION
Before installing this equipment, check the ratings of
both the generator and the transfer switch. Read
“Emergency Isolation Method” and “Total Circuit
Isolation Method” in Sections 2.5 and 2.6.
2.1.1 NFPA STANDARDS
‹
The following published standards booklets pertain-
ing to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
The generator’s rated wattage/amperage capacity
must be adequate to handle all electrical loads that
the unit will power. It may be necessary to group the
critical (essential) loads together and wire them into
a separate “emergency” distribution panel.
• NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
This generator can be installed in conjunction with
an engineered Generac “GTS” type transfer switch, if
necessary.
®
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Section 2 — Installation
Guardian Liquid-cooled 25 kW Generator
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
2.3 GENERATOR MOUNTING AND
SUPPORT
Retain the generator compartment to a concrete slab
with 1/4-inch masonry type anchor bolts. Be sure the
bolts are long enough to retain the compartment. The
slab should be at least six inches thick and should
extend beyond the enclosure to a distance of at least
three inches on all sides.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
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:
2.4 BASIC STANDBY ELECTRIC
SYSTEM
• Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYS-
TEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
Figure 2.1 shows a schematic diagram of a basic
standby electric system. Both the UTILITY power
supply and the STANDBY GENERATOR output are
connected to an approved transfer switch. The trans-
fer switch is required by electrical code and serves
the following functions:
• Permits the LOAD circuits to be connected to only
one power supply at a time.
• Prevents electrical backfeed between the generator
and the UTILITY power circuits.
Notice that both the STANDBY and the UTILITY
power supplies to the transfer switch are protected
against overload by a main line circuit breaker.
Figure 2.1 – Basic Standby Electric System
2.2 GENERATOR LOCATION
Install the generator set, in its protective enclosure
outdoors, where adequate cooling and ventilating air
always is available. Consider these factors:
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drift-
ing, consider using a windbreak to protect the unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator
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
direction, face the generator air inlet openings into
the prevailing winds.
• Install the generator as close as possible to the
transfer switch. This reduces the length of wiring
and conduit.
NOTE:
Generac recommends the use of a Generac Power
Systems transfer switch in conjunction with this
generator.
• Install the generator 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.
®
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Section 2 — Installation
Guardian Liquid-cooled 25 kW Generator
Figure 2.2 – Generator Grounding Lug (typical)
2.5 EMERGENCY CIRCUIT ISOLATION
METHOD
This prevents overloading the generator by keeping
electrical loads below the wattage/amperage capacity
of the generator. If the generator is powering only crit-
ical loads, within the wattage/amperage capacity, dur-
ing utility power outages, consider using the emer-
gency circuit isolation method.
Critical electrical loads are grouped together and
wired into a separate “Emergency Distribution
Panel.” Load circuits powered by that panel are with-
in the wattage/amperage capacity of the generator set.
The transfer switch must meet the following require-
ments:
2.8 GENERATOR AC NEUTRAL
• 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.
CONNECTIONS
Generac uses an UNGROUNDED AC neutral.
Grounding 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 generator field. The actual result depends on the
electrical characteristics of the particular installed
generator.
2.6 TOTAL CIRCUIT ISOLATION
METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, the “Total
Circuit Isolation Method” may be used. The following
apply to the transfer switch in this type of system.
2.9 USING AN ENGINEERED “GTS”
TRANSFER SWITCH
When required, the pre-packaged standby generator
can be installed with an engineered Generac “GTS”
type automatic transfer switch.
• Ampere rating of the transfer switch must equal
the ampere rating of the normal incoming utility
service.
• The transfer switch is installed between the utility
service entrance and the building distribution
panel.
In this application, the engineered GTS is responsi-
ble for utility sensing, weekly exercising, and load
transferring.
Position two of the eight-position dip switch is used to
turn over this control to the engineered GTS.
2.7 GROUNDING THE GENERATOR
The National Electrical Code requires the frame and
external electrically conductive parts of this equip-
ment to be properly connected to an approved earth
ground and/or grounding rods. For that purpose, a
GROUND LUG (Figure 2.2) is provided on the gener-
ator mounting base. Consult a qualified electrician
for grounding requirements in the area. Grounding
procedures must meet local regulations.
In order for the battery charger to work, it is neces-
sary to provide a fused 240 VAC utility source to the
N1 and N2 terminals in the control panel.
Pos2 ON — Engineered GTS Application
• The control board will NOT monitor utility.
• The control board will NOT perform a weekly exer-
cise. (The five red LEDs will flash one at a time in
this mode.)
DANGER
• The control board will NOT activate the transfer
Do not connect the ground wire to any pipe
that carries a flammable or explosive substance
– FIRE or an EXPLOSION may result.
output.
• The control board WILL monitor all engine condi-
tions and shut down on all the faults listed in this
document.
Proper grounding helps protect personnel against
electrical shock in the event of a ground fault condi-
tion in the generator or in connected electrical
devices. In addition, grounding helps dissipate static
electricity that often builds up in ungrounded devices.
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Section 2 — Installation
Guardian Liquid-cooled 25 kW Generator
The battery represents a risk of high short cir-
Pos2 OFF — Standard Prepackaged ATS
Application
• The control board will perform all of the automat-
ic features listed in this document.
• The two-wire start connections, wires 178-183,
should NOT be connected.
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
‹
NOTE:
If the generator is installed in conjunction with an
engineered GTS type transfer switch, refer to the
applicable transfer switch manual for exact oper-
ating parameters and timing sequences.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following proce-
dures are to be observed:
!
2.10 BATTERY INSTALLATION
DANGER
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
Standby generators installed with automatic
transfer switches will crank and start automati-
• Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek med-
ical attention, and
!
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. Ensure
that the 5A and 15A fuses in the control panel
are removed when connecting or disconnecting
battery cables.
• Spilled electrolyte is to be washed down with an
acid-neutralizing agent. A common practice is to
use a solution of one pound (500 grams) bicarbon-
ate of soda to one gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The fol-
lowing procedure are to be followed:
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touch-
ing batteries by first touching a grounded metal
surface.
Servicing of batteries is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
Battery electrolyte fluid is an extremely corro-
sive sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
!
The recommended battery is Group 26, 525 CCA/75
AH minimum at 0° F (-17.8° C). All batteries must be
at 100 percent state-of-charge before they are
installed on the generator.
When using maintenance-free batteries, it is not nec-
essary to check the specific gravity or electrolyte level.
Have these procedures performed at the intervals
specified in Section 4, “Maintenance.” A negative
ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batter-
ies are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries to
the generator set.
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
!
NOTE:
Damage will result if the battery connections are
made in reverse.
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Section 3 - Operation
Guardian Liquid-cooled 25 kW Generator
‹
2.11.5 ENGINE COOLANT
2.11 PREPARATION BEFORE START-UP
The instructions in this section assume that the
standby generator has been properly installed, serv-
iced, tested, adjusted and otherwise prepared for use
by a competent, qualified installation contractor. Be
sure to read the “Safety Rules” on pages 2 and 3, as
well as all other safety information in this manual,
before attempting to operate this (and related) equip-
ment.
Have the engine cooling system properly filled with
the recommended coolant mixture. Check the system
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. Belt tension is correct when a force of
approximately 22 pounds (10 kg), applied midway
between pulleys, deflects the belt about 3/8- to 5/8-
inches (10 to 16 mm).
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.
‹
2.11.7 ELECTRICAL SYSTEM
!
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
Make sure the generator battery is fully charged,
properly installed and interconnected, and ready for
use.
Before starting the generator for the first time, the
installer must complete the following procedures. For
follow-up maintenance information and/or service
intervals, please refer to Section 4, “Maintenance.”
Check to ensure that there are no loose electrical con-
nections. Restrain any loose wires to keep them clear
of any moving generator set components.
‹
2.11.2 TRANSFER SWITCH
3.1 ENGINEERED GTS TRANSFER
If this generator is used to supply power to any elec-
trical system normally powered by an electric utility,
the National Electrical Code requires that a transfer
switch be installed. The transfer switch prevents elec-
trical backfeed between two different electrical sys-
tems, (for additional information, see the applicable
transfer switch manual for this unit). The transfer
switch, as well as the generator and other standby
components, must be properly located and mounted
in strict compliance with applicable codes, standards
and regulations.
SWITCH
When required, the pre-packaged standby generator
can be installed with an engineered Generac “GTS”
type automatic transfer switch. Set dip switch on
engine control PCB to GTS-type.
When using an engineered GTS type transfer switch,
it controls automatic operation and automatic trans-
fer as follows:
• Solid state circuits in the transfer switch monitor
utility power source voltage.
• When utility source voltage drops below a pre-set
level, transfer switch action signals the generator
to start. The engine then cranks and starts as con-
trolled by the pre-packaged generator’s Control
Module circuit board.
• After the engine starts and when the generator AC
output voltage and frequency have reached a
pre-set value, transfer switch circuits signal the
transfer switch main contacts to actuate to the
“Standby” power source side. Generator AC output
then powers load circuits.
‹
2.11.3 FUEL SYSTEM
Make sure the fuel supply system to the generator (a)
delivers the correct fuel at the correct pressure and
volume and, (b) is properly purged and leak tested
according to code. No fuel leakage is permitted.
‹
2.11.4 GENERATOR SET LUBRICATION
Check the engine crankcase oil level before operating
and add oil to the proper level – the dipstick “FULL”
mark. Never operate the engine with the oil level
below the dipstick “ADD” mark. See “Specifications”
and “Engine Oil Recommendations”.
• When the utility power source voltage is restored
above a pre-set level, transfer switch circuits signal
the switch main contacts to move back to their util-
ity power source side.
NOTE:
This engine is shipped from the manufacturer
with 15W-40 oil. This oil should be changed after
30 hours of operation.
• Following re-transfer back to the utility power
source side, transfer switch circuit board action
signals the generator to stop. Engine then shuts
down.
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Section 3 - Operation
Guardian Liquid-cooled 25 kW Generator
GTS Mode Operation
When in GTS mode, the control board will respond
as follows based on the generator AUTO/OFF/MANU-
AL switch position.
DANGER
With switch set to AUTO, engine can crank
and start suddenly without warning. Such
automatic start up normally occurs when utili-
ty source voltage drops below a pre-set level.
To prevent possible injury that might be
caused by such sudden starts, set AUTO/OFF/
MANUAL switch to OFF before working on or
around the unit. Then, place a “DO NOT
OPERATE” tag on control console.
!
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. When a two-wire start is issued, the con-
trol board will immediately start and run the genera-
tor. Whe the two-wire start is removed the control
board will immediately stop the generator.
3.2.2 FAULT INDICATOR LEDS
‹
(SEE CHART ON PAGE 14)
These LEDs turn ON when one or more of the follow-
ing engine faults occurs and the engine shuts down.
NOTE:
• Low Oil Pressure
• Overcrank
• Low Battery
• Overspeed/Engine Speed Signal Fault
• High Coolant Temperature/Low Coolant Level
See Section 1.7 for further explanation of engine pro-
tection functions.
If the generator is installed in conjunction with an
engineered GTS type transfer switch, refer to the
applicable transfer switch manual for exact oper-
ating parameters and timing sequences.
For proper battery charger operation, it will be nec-
essary to supply a fused 240VAC utility fed supply to
terminals N1 and N2 in the control panel.
3.2.3 15 AMP FUSE
‹
3.2 CONTROL CONSOLE
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 cranking and startup
cannot occur. If the fuse needs to be replaced, use
only an identical 15-amp replacement fuse (type
ATO).
COMPONENTS
The components of a home standby generator control
console (Figure 3.1) are as follows:
Figure 3.1 - Home Standby Generator Panel
0F0653
CAUTION
AUTO
RISK OF ELECTRICAL SHOCK. DO NOT REMOVE COVER. NO USER SERVICEABLE
PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.
OFF
3.2.4 5 AMP FUSE
‹
OFF
ON
CAUTION
This fuse protects the battery charger against electri-
cal overload and is located inside the control panel. If
the fuse needs to be replaced, use only an identical 5-
amp replacement fuse (type ATO).
SET
EXERCISE
TIME
MANUAL
FOR STAND-BY SERVICE CONNECT OUTPUT OF GENERATOR TO SUITABLY RATED
TRANSFER SWITCH IN ACCORDANCE WITH CANADIAN ELECTRICAL CODE, PART I.
TO SET EXERCISER TIME
SYSTEM READY
LOW BATTERY
ATTENTION: POUR L'ALIMENTATION DE RESERVE, CONNECTER LA SORTIE DE LA
ICE A UN COMMUTATEUR DE CALIBRE APPROPRIE, CONFO
CANADIEN DE L'ECTRICITE, PREMIERE PARTIE.
1) PLACE AUTO/OFF/MANUAL SWITCH
TO AUTO POSITION.
2) HOLD "SET EXERCISE TIME"
SWITCH IN "ON" POSITION FOR
THREE SECONDS AND RELEASE.
THE EXERCISER IS NOW SET. ALL
FIVE RED LED'S WILL FLASH FOR
10 SECONDS. THEN THE UNIT WILL
START, RUN THROUGH THE EXERCISE
CYCLE AND SHUTDOWN.
LOW OIL PRESSURE
LOW COOLANT LEVEL
HI COOLANT TEMPERATURE
OVER SPEED
WARNING
NOTE:
OVER CRANK
N AUTOMATICALLY START AT ANYTIME WITHOUT NOTICE.
INJURY REMOVE NEGATIVE BATTERY CABLE PRIOR TO SE
T
LED INDICATORS:
FLASHING GREEN LED
FLASHING RED LED'S
=
NO UTILITY SENSE
EXERCISER NOT SET
This fuse will not remove the + battery input
power from the PCB when it opens. This means
the exercise timer will not be reset.
5
=
(IN AUTO MODE ONLY) SOLID GREEN LED
RED LED'S INDIVIDUAL FAULT
=
SYSTEM READY, UTILITY POWER ON
=
WARNING
(SEE OWNER'S MANUAL FOR COMPLETE DETAILS)
USE OF SYNTHETIC OIL IS RECOMMENDED
THIS EMERGENCY POWER SYSTEM IS DESIGNED EXCLUSIVELY FOR
OUTDOOR INSTALLATION ONLY!
3.2.5 SET EXERCISE TIME SWITCH
This switch allows programming the generator to
start and exercise automatically. “See Weekly
Exercise Cycle.”
‹
3.2.1 AUTO/OFF/MANUAL SWITCH
Use this three-position switch as follows:
‹
• Set the switch to AUTO for fully automatic opera-
tion. See “Automatic Operation” (Section 3.5).
• Set switch to MANUAL position to crank and start
the generator engine.
• Set switch to OFF position to shut down an oper-
ating engine. With OFF selected, operation will not
be possible.
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Section 3 - Operation
Guardian Liquid-cooled 25 kW Generator
Condition
System
Ready (Green)
Low
Bat (Red)
Low
Oil (Red)
High
Temp (Red)
Over
Speed (Red)
Over
Crank (Red)
Switch Position
Manual
Auto
Off
Generator Switch is
in the OFF Mode.
OFF
ON
OFF
X
X
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
O
System Ready for
Automatic Start
X
X
O
Generator Switch is
in the MANUAL Mode
OFF
OFF
OFF
OFF
O
O
O
Weekly Exerciser
is not set
Flashing
Flashing
Flashing
Flashing
Flashing
O
O
O
O
(-----------------------------------1 sec rate---------------------------------------)
Battery Voltage <12V
for >1 minute
X
ON
(Non-latching)
Battery Voltage <6V
X
ON
X
O
O
O
O
Unit Shutdown due
to Low Oil Pressure
OFF
ON
Unit Shutdown due
to High Temperature
OFF
OFF
OFF
X
X
X
X
ON
O
O
O
O
O
O
O
O
Unit Shutdown due
to Engine Overspeed
ON
Unit Failed to Start
during it’s Crank Cycle
ON
Utility Voltage is
<45% of Nominal
Flashing
1 sec rate
Engine Speed Signal Fault
OFF
OFF
X
X
Flashing
O
O
O
O
Control Board is
in GTS Mode
The five RED LED’s will turn on one at a time
O
X = indicates that the LED can be ON or OFF depending on the operating conditions.
3.2.6 SYSTEM READY LED
‹
3.3 MANUAL TRANSFER AND
START-UP
The System Ready LED (green) has two main pro-
poses. First, the LED will be ON when the
AUTO/OFF/MANUAL switch is in the AUTO position,
utility is present, and there are no system alarms.
This ON state indicates the system is fully ready for
automatic operation.
To transfer electrical loads to the Standby (EMER-
GENCY) power source side and start the engine man-
ually, refer to the Owner’s Manual of the particular
transfer switch.
The system ready LED will be OFF when the switch
is in the manual or OFF positions.
3.4 ENGINE GOVERNOR
ADJUSTMENTS
The system ready LED is also used to indicate the
presence of utility sensing at the PCB when the switch
is either in the AUTO or MANUAL modes. The LED
will flash at the rate of 1/2 second on, 1/2 second off
if the utility sensing level is below the transfer back
threshold.
Engine speed governing is also controlled by the
engine control board. The engine governor has been
set by 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):
This secondary function is only available with dip
switch two in the OFF position (ATS - automatic
transfer switch application).
1. Move dip switch 8 to the test mode (OFF posi-
tion).
2. Set all three potentiometers (pots) fully counter-
clockwise.
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Section 3 - Operation
Guardian Liquid-cooled 25 kW Generator
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.
• Let the generator engine run at no-load for a few
minutes, to stabilize internal unit temperatures.
• On the generator console, set the Auto/Off/ Manual
switch to Off. Wait for engine to come to a complete
stop.
5. Under full load condition, increase the stability
pot until the unit returns to 60 Hertz (or 50 Hertz
in 50 Hertz applications).
6. Reduce load to 3/4, 1/2, 1/4 and no load.
Decrease the stability pot if there is instability at
any load point.
• For transfer to utility position, refer to the Owner’s
Manual of the particular transfer switch.
• Turn on the utility power supply to the transfer
switch, using whatever means provided (such as a
utility main line circuit breaker). The utility power
source now powers the loads.
7. Adjust differential pot to make the recovery to
load changes even faster and minimize load
change undershoot and overshoot. If it is set too
high, it may introduce oscillations at some load.
It can be set to zero (full CCW) if a small amount
causes oscillations at some load.
3.6 AUTOMATIC OPERATION
To set the system for fully automatic operation, pro-
ceed as follows:
• Check that load circuits are connected to the
utility power supply.
• Set the AUTO/OFF/MANUAL switch to its AUTO
Figure 3.2 — Engine Governor Adjustment
position.
• Set the generator main circuit breaker to its ON or
CLOSED position.
3.7 WEEKLY EXERCISE CYCLE
The engine control board will start and run the gen-
erator once every seven days for approximately 12
minutes. If utility should fail during this exercise
period, the engine control board will transfer the load
to the generator output and continue to run until util-
ity returns.
On the day, and at the time of day chosen for the gen-
erator to exercise, set the weekly exercise cycle as fol-
lows:
1. Place the AUTO/OFF/MANUAL switch in the auto
position (Figure 3.3).
2. Press and hold the “Set Exercise” switch for five
seconds, then release.
Figure 3.3 - “Set Exercise Time” Switch
0F0653
AUTO
RISK OF ELECTRICAL
PARTS INSIDE. R
OFF
OFF
ON
SET
EXERCISE
TIME
MANUAL
3.5 RETRANSFER AND SHUTDOWN
When utility power source voltage has been restored,
electrical loads may be transferred back to that
source and the generator can be shut down as fol-
lows:
FOR STAND-BY SERV
TRANSFER SWITCH IN
TO SET EXERCISER TIME
SYSTEM READY
LOW BATTERY
ATTENTION: POUR L'
ICE A UN COM
CAN
1) PLACE AUTO/OFF/MANUAL SWITCH
TO AUTO POSITION.
2) HOLD "SET EXERCISE TIME"
SWITCH IN "ON" POSITION FOR
THREE SECONDS AND RELEASE.
THE EXERCISER IS NOW SET. ALL
FIVE RED LED'S WILL FLASH FOR
10 SECONDS. THEN THE UNIT WILL
START, RUN THROUGH THE EXERCISE
CYCLE AND SHUTDOWN.
LOW OIL PRESSURE
LOW COOLANT LEVEL
HI COOLANT TEMPERATURE
OVER SPEED
• Verify that utility power supply voltage to the trans-
fer switch has been positively turned Off, using
whatever means provided (such as utility main line
circuit breaker).
OVER CRANK
N AUTOMATICA
INJURY REMO
LED INDICATORS:
FLASHING GREEN LED = NO UTILITY SENSE
5 FLASHING RED LED'S = EXERCISER NOT SET
(IN AUTO MODE ONLY) SOLID GREEN LED = SYSTEM READY, UTILITY POWER ON
RED LED'S = INDIVIDUAL FAULT
• Set the generator’s main circuit breaker to its Off
(SEE OWNER'S MANUAL FOR COMPLETE DETAILS)
or Open position.
®
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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.
Switch Position 4 — Selects the type of fuel being
used and is factory pre-set for natural gas (NG).
Switch Position 5 — Selects the engine displacement
and is factory pre-set for a 2.5 liter (2.5L) engine.
Switch Position 6 — Selects the number of engine
cylinders and is factory pre-set for four cylinders.
If DC power to the control board is lost, the weekly
exercise setting will be lost. This is indicated by all
five red LEDs continually flashing. In this state the
generator will still start and run in manual mode, or
automatically start and run if utility is lost while in
Auto mode, but it will not perform a weekly exercise
cycle.
Switch Position 7 — Selects the direction of rotation
of the governor stepper motor and is factory pre-set
for CCW rotation (rotation is observed looking at the
stepper shaft as it move from closed throttle to open
throttle).
Switch Position 8 — Selects whether the control is
in the Normal Mode of operation or Test Mode. In the
Normal Mode of operation, pre-determined governor
gains are used and the gain trimpots on the control
board (Gain, Stability, and Differential) are not active
and have no effect on the gains. In Test Mode the gain
trimpots are active and can be adjusted. See Section
3.4.
If a failure occurs while running in this mode, the five
red LEDs will stop flashing, the individual fault LED
will turn on and the engine will shut down. Once the
AUTO/OFF/MANUAL switch has been switch to OFF,
the individual fault LED will turn OFF and the five
red LEDs will begin flashing to show exercise has still
not been set.
3.8 CONTROL BOARD DIP SWITCH
4.1 MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
SETTINGS
Located on the control board is an eight position DIP
switch (see Figure 3.2). The eight different switches,
are used to configure the control board for the spe-
cific engine and governor being used and are pre-set
at the factory.
A. EVERY THREE MONTHS
1. Check battery condition.
2. Inspect and test fuel system.
3. Check transfer switch.
4. Inspect exhaust system.
5. Check engine ignition system.
6. Check fan belts.
If the DIP switch settings are not set correctly,
the generator may not start or operate correct-
!
ly.
B. ONCE EVERY SIX MONTHS
1. Test Engine Safety Devices (low oil pressure, low
coolant level, high coolant temperature).
240 VAC can be present within the control
panel.
C. ONCE ANNUALLY
1. Test engine governor; adjust or repair, if needed.
2. Clean, inspect generator.
If it is necessary to select an alternate switch position,
move the AUTO/OFF/MANUAL switch to the OFF
position. Remove the 5 amp and 15 amp fuses in the
generator control panel. Move the DIP switch position
that needs to be changed to its new position. Wait five
seconds, then re-install the 5 and 15 amp fuses.
3. Flush cooling system.
D. FIRST 100 OPERATING HOURS
1. Change engine oil and oil filter. After initial
change, service engine oil and filter at 150 oper-
ating hours or six months, whichever comes first.
2. Retorque cylinder head (see torque specs).
3. Retorque intake and exhaust manifold (see
torque specs).
The ON position is marked on the switch and the fac-
tory settings are also shown in Figure 3.3.
Switch Position 1 — Selects the 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).
E. EVERY 500 OPERATING HOURS
Switch Position 3 — Selects the type of governor
control used and is factory pre-set for stepper motor
control.
1. Service air cleaner.
2. Check starter.
3. Check engine DC alternator.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
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.
4.4 CYLINDER HEAD PROCEDURE
1. Position head gasket on the block (Figure 4.2).
2. Position cylinder head to cylinder block.
3. Install 10 cylinder head bolts in numerical
sequence. Tighten to 70 N-m (52 lb-ft) in
sequence. Retighten to 70 N-m (52 lb-ft) in
sequence. Then turn all head bolts an additional
90 - 100 degrees in sequence.
4.2 EXHAUST MANIFOLD PROCEDURE
1. If necessary, clean gasket surfaces on exhaust
manifold and cylinder head.
Figure 4.2 — Cylinder Head Installation
2. Install exhaust manifold and exhaust manifold
gasket.
3. Install fasteners.
NOTE:
Exhaust manifold fasteners must be tightened in
two stages.
4. Tighten fasteners to 20-30 N-m (15-22 lb-ft) dur-
ing the first stage.
5. Retighten fasteners to 60-80 N-m (44-59 lb-ft)
during the second stage.
4.3 INTAKE MANIFOLD PROCEDURE
1. Clean and inspect the mounting surfaces of the
intake manifold and the cylinder head. Both sur-
faces must be clean and flat (Figure 4.1).
2. Clean and lightly oil the manifold bolt/stud
threads.
3. Install a new lower intake manifold gasket.
4. Position the lower intake manifold to the cylinder
head.
5. Install retaining bolts/studs finger tight.
6. Tighten all bolts/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
4.5 COOLING SYSTEM
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down. (See the installation diagram.)
The exhaust system parts from this product get
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
4.7.3 ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications.
‹
4.6 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. These overcurrent protection devices
will open if the circuit is overloaded.
• Add recommended coolant mixture as necessary.
• Periodically 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 level is low, inspect gasket in radiator
pressure cap. Replace cap, if necessary. To have
pressure cap tested, contact an authorized
Generac Service Dealer. Inspect cooling system
and coolant recovery system for leaks.
If a circuit breaker opens or a fuse element
melts, find the cause of the overload before
resetting the circuit breaker or replacing the
!
fuse.
4.8 MAINTENANCE OWNER/
OPERATOR CAN PERFORM
4.7 CHECKING FLUID LEVELS
4.7.1 CHECK ENGINE OIL
‹
4.8.1 CHECK ENGINE OIL LEVEL
‹
Check engine crankcase oil level (Figure 4.3) at least
every 20 hours of operation, or prior to use.
Refer to “Checking Fluid Levels”.
• Remove oil dipstick and wipe dry with a clean,
lint-free cloth.
4.8.2 CHECK BATTERY
• See “Checking Fluid Levels”.
• Check battery cables for condition, tightness, cor-
rosion or damage. Clean, tighten or replace as
necessary.
‹
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
• If oil level is below the dipstick ADD mark, remove
oil fill cap. Add the recommended oil to bring oil
level up to the FULL mark. DO NOT FILL ABOVE
THE “FULL” MARK. See “Engine Oil Recommen-
dations” for recommended oils.
4.8.3 EXERCISE SYSTEM
Start the generator engine at least once every seven
days and let it run at least 20 minutes. See “Weekly
Exercise Cycle”.
‹
Figure 4.3 - Oil Dipstick and Oil Fill Cap
Engine
Air Cleaner
4.8.4 INSPECT COOLING SYSTEM
• Inspect engine cooling system. See “Maintenance
Schedule”.
‹
Oil Fill Cap
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
Oil Dipstick
4.8.5 CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels”.
‹
Oil
Filter
4.8.6 PERFORM VISUAL INSPECTION
‹
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fas-
teners. Look for fuel, oil or coolant leaks.
4.7.2 BATTERY FLUID
‹
4.8.7 INSPECT EXHAUST SYSTEM
‹
Check battery electrolyte fluid based on the
Maintenance Schedule. Fluid should cover separa-
tors in all battery cells. If fluid level is low, add dis-
tilled water to cover tops of separators. DO NOT USE
TAP WATER IN BATTERY.
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
7. Start engine and check for oil leaks.
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.
4.8.11 CHANGING THE ENGINE AIR CLEANER
‹
To replace the engine air cleaner, (part number
059402), simply remove the air cleaner cover and
replace the air filter making sure it is positioned
properly before reattaching the cover (Figure 4.1).
See the “Service Schedule,” for air cleaner mainte-
nance.
4.8.9 INSPECT ENGINE GOVERNOR
‹
Visually inspect electronic governor.
4.8.12 SPARK PLUGS
‹
Reset the spark plug gap or replace the spark plugs
as necessary (Figure 4.4). See Section 6.
DANGER
DANGER: Do not attempt to adjust the gover-
nor. Only qualified service facilities should
adjust the governor. Excessively high operat-
1. Clean the area around the base of the spark plugs
to keep dirt and debris out of the engine. Clean by
scraping or washing using a wire brush and com-
mercial solvent. Do not blast the spark plugs to
clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is
questionable. See the “Service Schedule,” Section
6, for recommended inspection.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 1.07-1.17 mm (0.042-
0.046 inch) by carefully bending the ground elec-
trode (Figure 4.2).
!
ing speeds are dangerous and increase the
risk of personal injury. Low speeds impose a
heavy load on the engine when adequate
engine power is not available and may short-
en engine life. Correct rated frequency and
voltage are supplied only at the proper gov-
erned speed. Some connected electrical load
devices may be damaged by incorrect fre-
quency and/or voltage. Only qualified service
technicians should adjust the governed speed.
4.8.10 CHANGING ENGINE OIL
Refer to maintenance performed by authorized service
facilities for engine oil and filter change frequencies.
‹
Figure 4.4 – Setting the Spark Plug Gap
SET PLUG GAP AT 1.07 - 1.17 mm
(0.042 - 0.046 inch)
Drain the oil while the engine is still warm from run-
ning. This means warm up the engine, shut it down
and drain immediately as follows:
1. Remove OIL DRAIN HOSE from its retaining clip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain
oil completely into suitable container.
3. When all oil has drained, install and tighten OIL
DRAIN HOSE CAP, and re-install into its retaining
clip.
4. Turn OIL FILTER (Figure 4.1) counterclockwise
and remove. Properly dispose of 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). DO NOT FILL ABOVE THE
DIPSTICK “FULL” MARK. Crankcase oil capacity
is 4.0 U.S. quarts (3.8 liters).
4.8.13 COOLANT CHANGE
‹
Every year, have an Authorized Service Facility drain,
flush and refill the cooling system. See
“Specifications” for cooling system recommenda-
tions.
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK
!
“ADD” MARK.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with DISTILLED WATER
ONLY. DO NOT USE TAP WATER IN BATTERIES.
3. Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
4.9 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.
DANGER
Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. Use a
vacuum system or dry, low pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure, clean the enclosure
with a soft, damp cloth or sponge and water.
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks or any spark
producing tools or equipment near the battery.
Once each year have the generator cleaned and
inspected by an Authorized Service Dealer. That deal-
er will use dry, low pressure air to clean internal
windings. Parts inside the control console should be
cleaned and inspected at this time as well.
Battery electrolyte fluid is an extremely corro-
!
sive sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
4.9.2 BATTERY
‹
All lead-acid storage batteries discharge when not in
use. Refer to specific instructions and warnings that
accompany the battery. If such information is not
available, observe the following precautions when
handling a battery:
Do not use any jumper cables or booster bat-
tery to crank and start the generator engine. If
the battery has completely discharged, remove
it from the generator for recharging.
!
!
• DO NOT use jumper cables and a booster battery
to crank or start the generator engine.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position, before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
• DO NOT recharge a weak battery while it is
installed in the generator. Remove battery from
generator and recharge in a well-ventilated area,
away from fuel vapors, sparks, heat or flames.
• Battery electrolyte fluid is an extremely caustic
sulfuric solution that can cause severe burns. DO
NOT permit fluid to contact eyes, skin, clothing,
painted surfaces, wiring insulation, etc. If any bat-
tery fluid is spilled, flush the affected area with
clear water immediately.
Be sure the utility power supply is turned off,
or sparking may occur at the battery posts as
the cables are attached and cause an explosion.
4.9.4 BATTERY REPLACEMENT
When replacing batteries, use the same number and
the type of battery that follows:
‹
• Always wear safety glasses, rubber apron and
gloves when handling a battery.
BCI Group No.
CCA
• Batteries give off explosive hydrogen gas while
charging. The gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.
26
525 @ 0 deg. F
NOTE:
The BCI number should be located directly
on the battery.
PERIODIC REPLACEMENT PARTS
4.9.3 BATTERY MAINTENANCE
The battery should be inspected per Section 4.7,
Scheduled Maintenance. The following procedure
should be followed for inspection:
‹
Part Name
Generac’s Part Number
Oil Filter
Motorcraft FL-400-S (supplied with engine)
Radiator Cap
Air Cleaner
Spark Plug
Battery
# 046627
# 059402
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
Motorcraft AWSF-52-C (supplied with engine)
# 077483
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
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.
Service Maintenance Interval Information:
The various service maintenance intervals are designated by interval numbers as follows:
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-
tial problem areas.
Performed monthly this requires approximately .5 man-hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
•
Disable the generator set from starting and/or connecting to the load by setting the control panel
AUTO/OFF/MANUAL switch to the OFF position.
•
•
•
Remove the 5 amp and 15 amp control panel fuses.
Turn off the battery charger (turn OFF utility supply to ATS).
Remove the negative 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 all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.
2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
Performed ONLY ONCE following the first three months of operation after purchase of the unit and requires
approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an authorized Generac Service Dealer.
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
Performed semi-annually this requires approximately 1.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an authorized Generac Service Dealer.
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and
to identify any potential problem areas.
Performed annually this requires approximately 4.0 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and should be performed only by an authorized Generac Service Dealer.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
Maintenance
Tasks
Level 1
Recom-
mended
Level 2
Required
Level 3
Required
Level 4
Task
Task
Task
Task
Comp.
Comp. to be done Comp. to be done Comp.
Required
to be done (Date-
monthly Initials)
3 months/
Break-in
(Date-
Initials)
Semi-
annually
(Date-
Initials)
to be done (Date-
Annually Initials)
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. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
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 battery
electrolyte level if
accessible. Adjust as
necessary.
8. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper
operation. Correct as
necessary.
9. Check the unit wiring for
loose connections,
corrosion, and damage.
Correct as necessary.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
®
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Section 4 — Maintenance
Guardian Liquid-cooled 25 kW Generator
Maintenance
Tasks
Level 1
Recom-
mended
Level 2
Required
Level 3
Required
Level 4
Task
Task
Task
Task
Comp.
Comp. to be done Comp. to be done Comp.
Required
to be done (Date-
monthly Initials)
3 months/
Break-in
(Date-
Initials)
Semi-
annually
(Date-
Initials)
to be done (Date-
Annually Initials)
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. 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 connections or
components, and abnormal
operating conditions.
Correct as necessary.
15. Change the engine oil.
16. Replace the engine oil
filter(s).
17. Replace the engine air
filter(s).
18. Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.
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Section 5 — Troubleshooting
Guardian Liquid-cooled 25 kW Generator
TROUBLESHOOTING POINTS
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 15 amp fuse blown.
1. Replace fuse.
2. Loose or corroded or defective
battery cables.
2. Tighten, clean or replace
battery cables as necessary.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
6. 5 amp fuse blown.
3. Replace contactor.
4. Replace starter motor.
5. Remove, change or replace battery.
6. Replace fuse.
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14A from Engine Control
circuit board.
1. Replenish fuel.
2. Replace solenoid.
3. Reconnect wire.
4. Spark plugs defective.
4. Clean, regap or replace plugs.
1. Clean or replace as needed.
Engine starts hard, runs rough.
Engine starts then shuts down.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
1. Engine oil level is low.
2. Engine is overheated.
3. Defective Low Oil Pressure Switch
4. Defective Coolant Temperature Switch
5. Defective Control Module circuit board.
6. Coolant Level is Low.
1. Check oil and add oil as needed.
2. Check cooling system for leaks.
3. Replace switch.
4. Replace switch.
5. Replace board.
6. Repair leak - Add coolant.
7. Replace Switch.
7. Defective Low Coolant Level Switch
AUTO/OFF/MANUAL Switch at OFF, 1. Defective AUTO/OFF/MANUAL switch
1. Replace switch.
engine continues to run
2. Open/disconnected wire #15A between
AUTO/OFF/MANUAL switch and Control
Module circuit board.
2. Reconnect/close wire.
3. Defective Control Module circuit board
3. Replace board.
No AC output from generator.
1. Check main line circuit breaker.
2. Check circuit breaker & fuses.
3. Transfer switch set to NORMAL position
4. Generator internal failure.
1. Reset to ON or CLOSED.
2. Reset and replace, if necessary.
3. Set to GENERATOR position.
4. Contact an Authorized Generac Service Dealer.
5. Thermal circuit breaker open.
5. Auto-reset - Wait 5 min. and
attempt restart.
®
24 Generac Power Systems, Inc.
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Section 6 — Notes
Guardian Liquid-cooled 25 kW Generator
®
Generac Power Systems, Inc. 25
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1411
®
26 Generac Power Systems, Inc.
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Wiring Diagram — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1411
®
Generac Power Systems, Inc. 27
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1413
®
28 Generac Power Systems, Inc.
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Electrical Schematic — 2.5L Engine (15kW & 20kW units) —Drawing No. 0F1413
®
Generac Power Systems, Inc. 29
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0E9982-B
®
30 Generac Power Systems, Inc.
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Wiring Diagram — 2.5L Engine (25kW unit) —Drawing No. 0E9982-B
®
Generac Power Systems, Inc. 31
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0E9983-B
®
32 Generac Power Systems, Inc.
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Section 7 - Electrical Data
Guardian Liquid-cooled 25 kW Generator
Electrical Schematic — 2.5L (25kW unit) — Drawing No. 0E9983-B
®
Generac Power Systems, Inc. 33
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Mounting Base — Drawing No. 0E9964-E
®
34 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Mounting Base — Drawing No. 0E9964-E
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
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
3
2
24
1
1
2
1
1
1
4
4
4
4
4
4
1
1
REF
1
3
1
1
1
1
1
REF
REF
1
REF
REF
1
1
1
1
1
PANEL BRACKET
CTRL PNL SUPPORT 2.5L FORD
SCREW TH-FRM M6-1 X 16 N WA Z/JS
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER LOCK M6-1/4
WASHER SHAKEPROOF EXT 1/4 STL
LUG SLDLSS #2-#8 X 17/64 CU
WASHER FLAT 1/4-M6 ZINC
SCREW HHC M6-1.0 X 16 G8.8
NUT FLANGED HEX M12-1.75
DAMPENER VIBRATION 40 BLUE
SPACER .49 X .62 X 1.87 PWDR/ZNC
DAMPENER VIBRATION
WASHER FLAT M12
SCREW HHC M12-1.75 X 80 G8.8
ASSY WIRE #0 12.00"
SCREW HHTT M6-1.0 X 20 BP
BATT 12VDC 75-AH 26 (NOT SHOWN)
HOLD DOWN BATTERY 2.5L FORD
WASHER SHAKEPROOF EXT 7/16 STL
SCREW HHC M10-1.5 X 25 G10.9
WASHER LOCK M10
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
WASHER FLAT 3/8-M10 ZINC
EARTH STRAP
CABLE BATT BLK #1 X 30.00
BATTERY POST COVER (BLACK)
BATTERY POST COVER (RED)
CABLE BATT RED #1 X 40.50
NUT HEX M8-1.25 G8 YEL CHR
WASHER LOCK M8-5/16
WASHER SHAKEPROOF EXT 5/16 STL
BOOT BATTERY CABLE
ASSY MTG BASE 2.5L FORD
TRAY BATTERY 2.5L FORD
SPRING CLIP HOLDER .37-.62
SCREW HHTT #10-32 X 3/8 CZ
1
®
Generac Power Systems, Inc. 35
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Enclosure — Drawing No. 0E9720-D
WELD STUD UNDER ROOF
PANEL FOR ACCESS
COVER CABLE
21
36
1
13
14
29
15
11
4
41
2
16
"Y"
26
34
37
11
40
10
26
"Y"
22
23
20
17
18
10
35
35
19
11
33
4
29
15
11
9
11
8
17
26
10
15
19
24
18
6
3
25
26
2
30
24
19
17
NOTE:
USE DOOR LATCH
10
32
25
FASTENER TO SECURE
GROUND WIRE.
38
5
NOTE:
7
11
®
36 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Enclosure — Drawing No. 0E9720-D
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0E9768
0E9862
0E9769
0D8660
0A7568
0E9771
0E9773
0E9772
0E9770
067042
0C2454
033530
051716
022152
0912970064
023762
1
1
1
2
2
1
1
1
1
2
34
3
3
3
3
3
3
6
6
1
1
1
1
2
1
6
2
2
2
2
1
2
2
1
2
1
2
1
2
1
1
ROOF ACO & STD ENCL 2.5L
DUCT, DISCHARGE MID 2.5L
SUPPORT,RADIATOR 2.5L FORD
BRACE SIDE 1.5L MITSU
DOORWELDMENT 1.5EPS
CORNER POST,REAR RH SIDE 2.5L
DOOR REAR ENCL 2.5L FD
BRACE, REAR 2.5L FORD
CORNER POST,REAR LH SIDE 2.5L
LATCH & CAM
SCREW TH-FRM M6-1X16 N WA Z/JS
SCREW PHM #10-32 X 5/8 ZINC
NUT HEX M5-0.8 G8 YEL CHR
WASHER LOCK #10
ASSEMBLY BASE-DOOR GROUND WIRE
WASHER SHAKEPROOF EXT #10 STL
GRD WIRE ASS'Y 99HSB
WASHER LOCK #8-M4
SCREW PPHM #8-32 X 5/16
NUT HEX 1/4-20 STEEL
ASSEMBLY COVER ACCESS
WASHER FLAT 1/4 ZINC
WASHER LOCK M6-1/4
GASKET CLIP-ON SELF GRIPPING (89"LG)
LATCH AND CAM
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
0912970063
022264
067035
022127
0C2634A
022473
022097
0D2023
0C2164
037337
NUT HEX JAM 3/8-24 SS
0E0072G
0E0072J
0E0072L
0E0072M
0D2023
0E0072P
0E0072Q
0E0072S
0E0072T
0E0072U
0E0072V
0E0072W
0E0072X
0E9861
0E9860
ACSTC INSLTN 1.5L RR CRNR TOP
ACSTC INSLTN 1.5L RR CRNR BOTT
ACSTC INSLTN 1.5L SIDE BRC PNL
ACSTC INSLTN 1.5L SIDE DR PNL
TRIM VINYL SELF GRIPPING (80"LG)
ACSTC INSLTN 1.5L SIDE DR PNL
ACSTC INSLTN 1.5L RAD SUPPORT
ACSTC INSLTN 2.5L ROOF
ACSTC INSLTN 2.5L DUCT L&RH SD
INSUL ACO 2.5L EXH ROOF PANEL
ACSTC INSLTN 2.5L DUCT FRNT SD
ACSTC INSLTN 2.5L REAR DOOR
ACSTC INSLTN 2.5 RR CRNR PNL S
DUCT, DISCHARGE RH SIDE 2.5L
DUCT, DISCHARGE LH SIDE 2.5L
®
Generac Power Systems, Inc. 37
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Control Panel — Drawing No. 0E9719-E
®
38 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Control Panel — Drawing No. 0E9719-E
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
3
0C2267
0D5070A
16
1
SCREW HHTT M5-0.8 X 12 BP
ASSY 2A 12V UL BATTERY
CHARGER
37
38
39
40
41
42
43
44
023965
039782
0A2077
020911
0A8955
022152
051716
023762
2
1
1
2
2
3
2
1
SCREW RHM #8-32 X 3/8
BRKT MTG CB BQ
CB 0125A 2P 240V S BQ2 LL
SCREW PPHM M5-0.8 X 30 ZINC
SCREW PHM M6-1.0 X 20MM
WASHER LOCK #10
NUT HEX M5-0.8 G8 YEL CHR
WASHER SHAKEPROOF EXT #10
STL
SCREW HHC #10-32 X 1/2
WASHER SHAKEPROOF EXT 1/4
STL
ASSY WIRE 14AWG 16" #0 GRN/YEL
NUT HEX #10-32 STEEL
FUSE ATO TYPE 15 AMP (BLUE)
FUSE ATO TYPE 5 AMP (TAN)
HARN CTRL PNL 2.5L FD (NOT
SHOWN)
4
5
6
7
8
0D8671
0E4494
0E6875A
0E7358
0E9704
0E9934
0E9935
0E9936
0E9937
0E9938
023897
036261
054450
057073
067680
082573
0C3910
029673
034616
0E2514
0F0581
040213
0F0558
0F0598
0F0599
0F0600
054199
049813
0F0653
022097
0C2212
022264
0C2265
1
1
2
4
1
1
1
1
1
1
19
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
13
20
5
HINGE CONTINUOUS 1.5L CTRL PNL
SWITCH ROC DPDT ON-OFF-ON
RELAY, 12VDC C FORM W/DIODE
SCREW PPPH HI-LO #4-24 X 3/8
ASSY PCB HSB CONTROLLER 2.5L
CTRL PNL BACK & BOTTOM 2.5L
CTRL PNL LH SIDE 2.5L FORD
CTRL PNL RH SIDE 2.5L FORD
CTRL PNL TOP 2.5L FORD
CTRL PNL FRONT 2.5L FORD
WASHER FLAT #10 ZINC
RIVET POP .125 X .275 AL
CIRCT BRK 5.5 X 1 ETA 46-500-P
JUNCTION BLOCK 3/8-16
ASSY VOLTAGE REGULATOR 60HZ
SWITCH ROC DPST 125V SPD
TRANSFORMER 240/16V 1VA & 56VA
DIO BRIDGE 25A 600V
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
45
46
033121
026850
1
1
47
48
49
50
51
0912970087
022158
0E7403C
0E7403A
0F0526
1
1
1
1
1
52
53
54
55
56
57 *
58 *
59 *
60 *
61 **
62 **
63 **
64 **
65
0A2115
022473
038150
0C2428
022155
052619
023897
049226
051716
046357
047822
0F1467
0E6881
0A9457
2
2
5
2
2
2
4
2
2
REF
REF
REF
REF
1
WASHER NYLON .257
WASHER FLAT 1/4-M6 ZINC
WASHER FLAT #8 ZINC
SCREW PHTT #6-32 X 1/2 ZYC
WASHER LOCK #6
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
WASHER LOCK M5
NUT HEX M5-0.8 G8 YEL CHR
BLOCK TERM 20A 6 X 6 X 1100V
BLOCK TERM 20A 7 X 6 X 1100V
ASSY WIRE FUSE HOLDER
SOCKET RELAY
FITTING STRAIGHT 3/4
FITTING CONDUIT STR 1-1/2"
BRACKET FUSE HOLDER 2.5L FORD
PCB SUPPORT SNAP-IN 1/4"
BRACKET PCB SUPPORT 2.5L FORD
DECAL FUSES 2.5L CNTRL PANEL
DECAL TB1 2.5L CONTROL PANEL
DECAL ICT 2.5L CONTROL PANEL
DECAL DANGER HIGH VOLTAGE
NUT HEX M6 X 1.0 G8 YEL CHR
DECAL CONTROL HSB 2.5L FORD
WASHER LOCK M6-1/4
DECAL NEUTRAL
SCREW PHTT M4-0.7 X 16 ZYC
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 12 ZYC
* NOT SHOWN. HARDWARE FOR ATTACHING WIRES TO I/N 39.
** PART OF I/N 51, P/N 0F0526 CONTROL PANEL HARNESS.
®
Generac Power Systems, Inc. 39
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Control Panel — Drawing No. 0F1378-D
®
40 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Control Panel — Drawing No. 0F1378-D
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
0C2267
064733
0D5070A
16
2
1
SCREW HHTT M5-0.8 X 12 BP
RES MTG BRACKET
ASSY 2A 12V UL BATTERY
35
36
37
38
39
022264
0C2265
023965
039782
0D5544
0D5541
020911
0A8955
022152
051716
023762
22
13
2
1
1
1
2
2
3
WASHER LOCK #8-M4
SCREW PHTT M4-0.7 X 12 ZYC
SCREW RHM #8-32 X 3/8
BRKT MTG CB BQ
CB 0100A 2P 240V S BQ2 LL (20KW)
CB 0070A 2P 240V S BQ2 LL (15KW)
SCREW PPHM M5-0.8 X 30 ZINC
SCREW PHM M6-1.0 X 20MM
WASHER LOCK #10
NUT HEX M5-0.8 G8 YEL CHR
WASHER SHAKEPROOF EXT #10
STL
SCREW HHC #10-32 X 1/2
WASHER SHAKEPROOF EXT 1/4
STL
ASSY WIRE 14AWG 16" #0 GRN/YEL
NUT HEX #10-32 STEEL
FUSE ATO TYPE 15 AMP (BLUE)
FUSE ATO TYPE 5 AMP (TAN)
HARN CTRL PNL 2.5L FD (NOT
SHOWN)
WASHER NYLON .257
WASHER FLAT 1/4-M6 ZINC
RES 5R 5% 25W
CHARGER
4
5
6
7
8
0D8671
0E4494
0E6875A
0E7358
0E9704
0E9934
0E9935
0E9936
0E9937
0E9938
023897
036261
048468
057073
067680
082573
0C3910
029673
034616
0E2514
0F0581
040213
0F0558
0F0598
0F0599
0F0600
054199
049813
0F0653
022097
0C2212
1
1
2
4
1
1
1
1
1
1
19
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
9
HINGE CONTINUOUS 1.5L CTRL PNL
SWITCH ROC DPDT ON-OFF-ON
RELAY 12VDC C FORM W/DIODE
SCREW PPPH HI-LO #4-24 X 3/8
ASSY PCB HSB CONTROLLER 2.5L
CTRL PNL BACK & BOTTOM 2.5L
CTRL PNL LH SIDE 2.5L FORD
CTRL PNL RH SIDE 2.5L FORD
CTRL PNL TOP 2.5L FORD
CTRL PNL FRONT 2.5L FORD
WASHER FLAT #10 ZINC
RIVET POP .125 X .275 AL
CIRCT BRK 8 X 1 ETA 46-500-P
JUNCTION BLOCK 3/8-16
ASSY VOLTAGE REGULATOR 60HZ
SWITCH ROC DPST 125V SPD
TRANSFORMER 240/16V 1VA & 56VA
DIO BRIDGE 25A 600V
40
41
42
43
44
9
2
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
45
46
033121
026850
1
1
47
48
49
50
51
0912970087
022158
0E7403C
0E7403A
0F0526A
1
1
1
1
1
52
53
54
0A2115
022473
048352
046357
047822
0F1467
0E6881
049226
051716
052619
023897
2
2
1
REF
REF
REF
REF
2
FITTING STRAIGHT 3/4
FITTING CONDUIT STR 1-1/2"
BRACKET FUSE HOLDER 2.5L FORD
PCB SUPPORT SNAP-IN 1/4"
BRACKET PCB SUPPORT 2.5L FORD
DECAL FUSES 2.5L CNTRL PANEL
DECAL TB1 2.5L CONTROL PANEL
DECAL ICT 2.5L CONTROL PANEL
DECAL DANGER HIGH VOLTAGE
NUT HEX M6 X 1.0 G8 YEL CHR
DECAL CONTROL HSB 2.5L FORD
WASHER LOCK M6-1/4
55 *
56 *
57 *
58 *
59 **
60 **
61 **
62 **
BLOCK TERM 20A 6 X 6 X 1100V
BLOCK TERM 20A 7 X 6 X 1100V
ASSY WIRE FUSE HOLDER
SOCKET RELAY
WASHER LOCK M5
2
2
4
NUT HEX M5-0.8 G8 YEL CHR
SCREW HHC M5-0.8 X 20 G8.8
WASHER FLAT #10 ZINC
* PART OF I/N 51, P/N 0F0526A CONTROL PANEL HARNESS.
** NOT SHOWN. HARDWARE FOR ATTACHING WIRES TO I/N 39.
SCREW PHTT M4-0.7 X 16 ZYC
®
Generac Power Systems, Inc. 41
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Engine — Drawing No. 0E9918-E
®
42 Generac Power Systems, Inc.
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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
2
3
4
5
6
7
0E9909
0E9739
049814
0F0001
0D3488B
0A8584
0E0561
REF
ENGINE 2.5L FORD
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
0E9680
0E9609
0E9930
049821
0E9747
043116
022473
045772
064416
0F0252
0E9868
0F0035
026082
0E9928
0F0383
1
1
1
3
1
5
6
2
2
1
1
1
1
1
1
GASKET, 2.5L FORD EXHAUST MAN.
MANIFOLD, EXHAUST ( MACHINED)
HEAT SHIELD, EXHAUST MANIFOLD
SCREW SHC M8-1.25 X 30 G12.9
STARTER, 12 VOLT
SCREW HHC M6-1.0 X 12 G8.8
WASHER FLAT 1/4-M6 ZINC
NUT HEX M10-1.5 G8 YEL CHR
SCREW HHC M10-1.5 X 45 G8.8
SPRING BUSHING
1
8
1
1
1
1
PULLEY, 2.5L FORD WATER PUMP
SCREW HHC M10-1.5 X 25 G8.8
CLUTCH, COOLING FAN 2.5L FORD
SERPENTINE BELT - 41 3/8" LENGTH
SWITCH,OIL PRESSURE,10PSI,2POL
ASSY WATER LEVEL SENSOR C/E
PL
8
9
10
11
0A6751
035579
026925
0E9611
1
1
1
1
SW-TMP 245DEG 3/8NPT
BUSHING REDUCER 1/4 TO 1/8
PLUG STD PIPE 3/8 STEEL SQ HD
MANIFOLD, INTAKE (MACHINED)
(STEPPER MOTOR)
MANIFOLD INTAKE MACH BOSCH32
(BOSCH GOV.) (NOT SHOWN)
GASKET, 2.5L FORD INTAKE MAN.
SCREW HHC M8-1.25 X 20 G8.8
SCREW SHC M6-1.0 X 25 G12.9 ZP
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M6-1/4
ALTERNATOR, D.C
BRKT,D.C. ALTERNATOR(MACHINED)
SCREW HHC 3/8-16 X 2-1/4 G5
TENSIONER, D.C. ALTERNATOR
HOSE,2.5L FORD COOLANT BY-
PASS
CLAMP HOSE #10 .56-1.06
LOWER HOSE ADAPTER,2.5L FORD
O-RING 1-3/16 X 1-7/16 X 1/8
SCREW HHC M6-1.0 X 25 G8.8
HOSE OIL DRAIN ASSY 21"
HOSE CLAMP BAND 5/8"
BARBED STR 3/8NPT X 3/8
ADAPTER M12-1.75 3/8NPT
WASHER NYLON .50 X .87 X .06
NUT HEX M6 X 1.0 G8 YEL CHR
DIPSTICK TUBE, 2.5L FORD
COVER, R/H SIDE ENGINE
ADAPTOR
COVER, L/H SIDE ENGINE ADAPTOR
SCREW SHC M10-1.50 X 50 G12.9
TANK COOLANT RECOVERY
HOSE 9/32 ID (39"LG)
0E9611A
1
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
0E9681
039253
097962
022145
022097
022129
043107
022131
046526
052625
0E9708
0E9738
0E9929
0F0230
0E9834
1
4
4
48
49
50
51
52
53
54
55
56
57
58
59
057823
0E9737
0F0393
045757
069860C
048031J
055596
077456
052677
049813
0E9738A
0F1132
2
1
1
2
1
REF
1
1
1
1
8
11
16
11
19
30
2
2
1
1
1
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 25 G8.8
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK M10
SCREW SHC M10-1.5 X 35 G12.9
ENGINE FOOT, 2.5L FORD
DIPSTICK, 2.5L FORD
BRACKET, DIPSTICK TUBE
FAN 16" COOLING
HARNESS, 2.5L FORD ENGINE
(GENERAC & GUARDIAN) (NOT
SHOWN)
1
1
1
60
61
62
63
64
0F1133
059355
076749
029032
0F1433
1
8
1
1
1
0E9834A
1
HARNESS,2.5L FORD (QUIET
SOURCE) (GENERAC-BOSCH GOV.)
(NOT SHOWN)
BRACKET,2.5L FORD WATER
BOTTLE
27
28
29
30
31
32
0D5417
0E5048B
0E9655
057192
060619
0E8940
6
1
1
4
2
1
SCREW HHC M10-1.0 X 25 G10.9
FLEXPLATE 2.5L FORD
ADAPT CASTING MACH 2.5L FORD
SCREW SHC M10-1.5 X 30 G12.9
SCREW SHC M10-1.50 X 40 G12.9
SPACER FLEXPLATE HSB
65
66
67
68
69
070007
070005
080826
045771
048031C
3
3
3
1
2
WASHER FLAT M6 SS
WASHER LOCK M6 SS
SCREW HHC M6-1.0 X 12 SS
NUT HEX M8-1.25 G8 YEL CHR
CLAMP HOSE BAND 1/4
®
Generac Power Systems, Inc. 43
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Fuel System — Drawing No. 0E9980-D
®
44 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Fuel System — Drawing No. 0E9980-D
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8 *
9
0E8456
075580
0E9967
039253
022145
022129
045771
0F1570
0A6344
0F3994
0E1056
0F0397
0A5547
048031C
0D1509
0E0591
059402
037561
0E1028A
059401
091526
049226
026307
062522
022127
022259
050279
0A6125
0C2454
0E1104
0E0668
0E0590A
0C5133
0E0665
0E1108
033138
022152
0E0645
034339
059194
057823
0F0382
1
1
1
4
2
6
2
1
1
REF.
1
1
1
2
1
1
1
1
1
1
4
4
1
1
1
2
1
2
3
1
1
1
1
1
BRACKET FUEL REGULATOR
FLANGE FUEL INLET
ASSY FUEL REG 2.5L FRD N/G-L/P
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
BODY CARBURETOR ASSEMBLY
BARBED EL 90 1/8 NPT X 3/8
PCV VALVE 2.5L FORD
FUEL HOSE ASSM. NAT. GAS/L.P.V.
HOSE CRANKCASE BREATHER
COVER AIR CLEANER
10
11
12
13
14
15
16 *
17
18
19
20
21 *
22 *
23
24
25
26
27
28
29
30*
31*
32*
33*
34*
35*
36*
37*
38*
39*
40
41
42
CLAMP HOSE BAND 1/4
DECAL INLET PRESSURE
ADAPTER CARB. TO AIR CLNR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
CARBURETOR ASSY. 2.5L FORD
CARBURETOR GASKET
SCREW PPHM M5-0.8 X 12 ZNC
WASHER LOCK M5
ELBOW 90D STREET 3/4
STUD TH 1/4-20 X 3 G2 ZNC FULL
NUT HEX 1/4-20 STEEL
NUT HEX 5/16-18 STEEL
DECAL FUEL INLET NG
STUD 5/16-18 X 1.25 F THR
SCREW TH-FRM M6-1 X 16 N WA Z/JS
GASKET, AIR CLEANER ADAPTER
O-RING 2-028 1.38 X 1.50 X .06
VENTURI 20MM
0-RING 29.82 X 2.62
SCREW THROTTLE PIN STOP
THROTTLE ARM REWORK
SCREW HHM #10-32 X 5/8
WASHER LOCK #10
LEVER,THROTTLE STOP
BARBED EL 90 3/8 NPT X 5/8
HOSE 5/8 ID LPG & NG (24" LG)
CLAMP HOSE #10 .56 - 1.06
HOSE 3/8" 90 DEG 2.5L PVC
1
1
1
1
1
1
2
1
* INCLUDED IN ITEM 19 (CARBURETOR ASSY )
®
Generac Power Systems, Inc. 45
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Alternator — Drawing No. 0E8660-C
®
46 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Alternator — Drawing No. 0E8660-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
0F1659A
0F1657A
0F1655A
0E5093A
0E7413A
0F1660A
0F1658A
0F1656A
0E5094A
0E7412A
0E5706
1
1
1
1
1
1
1
1
1
1
1
REF
REF
REF
1
1
8
4
4
ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)
ROTOR 390 30KW 1P DIRECT HSB (3.0L FORD & 2.5L FORD)
ROTOR 390 40KW 1P DIRECT HSB (3.9L CHRYSLER)
STR 390 15AD HSB (382MM LONG)(2.5L FORD)
STR 390 20AD HSB (382MM LONG)(2.5L FORD)
STR 390 25AD HSB (382MM LONG)(2.5L FORD)
STR 390 35AD1 HSB (382MM LONG)(3.0L FORD & 2.5L FORD)
STR 390 40AD HSB (433MM LONG)(3.9L CHRYSLER)
REAR BEARING CARRIER 390/DRCT
FLEXPLATE 3.0L FORD
FLEXPLATE 3.9L HSB
FLEXPLATE 2.5L FORD
FLYWHEEL ASSY 3.0L HSB LG GEAR
REVCOR FAN 10.75 X 2 W/PRESS DIS
WASHER LOCK M10
2
3
4
0E5048
0E5048A
0E5048B
0E6668
0E6076
046526
5
6
7
8
9
051755
SCREW HHC M10-1.5 X 16 G8.8
04576100BK
04576100BF
043123
STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)
STUD M14-2.0 X 540 G5 ZINC (3.9L CHRYSLER)
WASHER LOCK M14
4
4
10
11
12
13
14
15
16
17
18
19
20
21
051779
0E7587
023365
0C3993
057192
0A2602
042558
0A2601
022264
4
1
1
4
4
1
1
1
4
4
1
1
NUT HEX M14-2.0 G8 YEL CHR
ASSY BRUSH HOLDER 390/HSB
WASHER SHAKEPROOF INT #8
SCREW HHTT M4-0.7 X 25 BP
SCREW SHC M10-1.5 X 30 G12.9
WASHER FLAT .688 ID X 3.25 OD
KEY SQ 3/8 X 1 STEEL
SCREW HHC M16-2.0 X 45 G8.8
WASHER LOCK #8-M4
WASHER FLAT #8 ZINC
CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER)
CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD)
038150
077043F
077043F
ROTOR REPLACEMENT PARTS
30
31
047248
070892
1
1
BALL BEARING-45 MM
SLIP RING -MACHINED-
®
Generac Power Systems, Inc. 47
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Muffler — Drawing No. 0F2930-B
1
4
24
5
6
7
11
13
3
15
17
20
20
12
19
11
20
6
18
4
5
6
7
15
14
16
9
8
10
2
21
22
23
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
0F2912
0F2869
0F2823
036434
036449
022129
022259
0E0170A
044149
0E8816
0F2925
0F2926
1
1
1
2
2
6
4
1
1
1
2
1
PIPE MUFFLER OUT
13
14
15
16
17
18
19
20
21
22
23
24
047411
022097
022473
049813
039253
045771
0A4010
022145
022131
085917
0D2611
052858
4
4
8
4
2
2
1
5
2
2
2
1
SCREW HHC M6-1.0 X 16 G8.8
WASHER LOCK M6-1/4
PIPE EXHAUST 2.5L FORD
MUFFLER 2.5L FORD
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
EXHAUST BLANKET 938MM
GASKET EXHAUST RING
EXHAUST FLANGE 2" PIPE
STRAP MUFFLER
WASHER FLAT 1/4-M6 ZINC
NUT HEX M6 X 1.0 G8 YEL CHR
SCREW HHC M8-1.25 X 20 G8.8
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M8-1.25 X 60 G8.8 FT
WASHER FLAT 5/16-M8 ZINC
WASHER FLAT 3/8-M10 ZINC
WASHER LOCK 3/8 SS
10
11
12
SCREW HHC 3/8-16 X 1-3/4 SS
NUT TOP LOCK FL M8-1.25
BRACKET, MUFFLER
®
48 Generac Power Systems, Inc.
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Stepper Motor — Drawing No. 0E9979-C
5
4
3
ITEM (13) NEOPRENE
COATING
2
1
14
6
7
10
WIRE HARNESS
15
SECURE WIRE HARNESS
WITH TIE WRAP AS SHOWN.
12
7
9
"A"
16
17
INTAKE MANIFOLD
(REF.)
10
7
6
CARBURETOR ARM
(REF.)
11
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
098290
098941A
0F0454
098942A
098225
043146
022097
0E7358
098783
037398
0E1326
0A7106
074031
029333A
022507
022473
064526
0E1694
1
1
REF
1
2
3
5
REF
1
2
1
1
AR
1
2
2
ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
HARN GOV 2.5L FORD
COVER CONNECTOR HOUSING
SCREW PFHST #2 X 5/8
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW PPPH HI-LO #4-24 X 3/8
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSY. CARBURETOR LINKAGE ROD
BRACKET STEPPER MOTOR
LIQUID NEOPRENE
TIE WRAP 7.4"X.19" BLK UL
SCREW HHC 1/4-20 X 1/2 G5
WASHER FLAT 1/4 ZINC
1
1
SCREW TAP HWH #6-25 X 3/8 ZINC
SPRING,ANTI LASH
®
Generac Power Systems, Inc. 49
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Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 25 kW Generator
Radiator — Drawing No. 0E9965-D
1
19
18
5
11
12
2
14
18
10
TO BASE OF
WATER INLET
7
25
5
9
7
24
15
3
16
4
17
6
9
10
24
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0E9769
0F0779
0E9837
0F0123
0F0118
099502
0C2454
052250
022097
022473
022127
046627
060035
REF
REF
1
1
1
4
REF.
2
8
12
8
SUPPORT,RADIATOR 2.5L FORD
SUPPORT RADIATOR 2.5L AL
RADIATOR, 2.5L FORD
VENTURI, 16" FAN 2.5L FORD
GUARD, FAN 2.5L FORD
CLAMP HOSE #24 B1.06-2.00
SCREW THF M6-1X16 N WA Z/JS
TAPE FOAM 1 X 1(17"LG)
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
NUT HEX 1/4-20 STEEL
CAP RADIATOR
SPACER .41 X .75 X .87 ST/ZNC
14
15
0F0127
0E9833
1
1
HOSE, UPPER RADIATOR 174MM
TAL
HOSE, 2.5L FORD LOWER
RADIATOR
BARBED STR 1/4NPT X 3/8
HOSE OIL DRAIN ASSY 21"
FOAM 1.5 X 1 ADHESIVE BACKING
(21.5" LG)
BOLT CARR 1/4-20 X 1-3/4 JS500
SPRING CLIP HOLDER .37-.62
SCREW SWAGE 10-32 X 5/16 Z/YC
SCREW TH-FRM M6-1X16 N WA Z/JS
SCREW HHC 1/4-20 X 3/4 G5
2
3
4
5
6
7
8
9
16
17
18
035461
069860C
0A7275
1
1
4
19
20
21
24
25
031669
065852
0A2111
0C2454
022287
4
1
1
6
4
10
11
12
1
4
®
50 Generac Power Systems, Inc.
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Section 9 — Installation Diagram
Guardian Liquid-cooled 25 kW Generator
Installation Diagram — Drawing No. 0F1020-A
®
Generac Power Systems, Inc. 51
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Section 10 – Warranty
Guardian Liquid-cooled 25 kW Generator
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
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. Generac will warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi-
cation or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will
repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur-
ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance
on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac 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 use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to a Generac Authorized Warranty Service Dealer as soon as a prob-
lem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer.
To locate the Generac Authorized Warranty Service Dealer nearest you, call our toll-free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Power
Systems, Inc., Two Year Limited Warranty” which is enclosed herewith on a separate sheet, also provided to you by Generac.
The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between
the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac
Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights
and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Dealer. When requesting warranty serv-
ice, evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol-
lowing address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
®
52 Generac Power Systems, Inc.
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Section 10 – Warranty
Guardian Liquid-cooled 25 kW Generator
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.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its
authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war-
ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man-
ufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according 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 replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Dealer.
(5) When the engine is inspected by a Generac Authorized Warranty Service Dealer, the owner shall not be held responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
3) Ignition System including:
a) Spark plug
b) Ignition module
1.2) LPG/Natural Gas carburetion assembly and its internal
components.
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
®
Generac Power Systems, Inc. 53
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Section 10 – Warranty
Guardian Liquid-cooled 25 kW Generator
GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®
"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. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian
Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and
prepaid by the purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby genera-
tors sold and rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and main-
tenance is required):
Engine - All Components
Alternator - All Components
Transfer System - All Components
Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the
responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be
repaired promptly by the owner.
All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate
Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Guardian generators that utilize non-Guardian/Generac replacement parts.
• Guardian generators utilizing non-Guardian/Generac automatic transfer switches.
• Repairs performed by individuals other than Guardian/Generac authorized dealers.
• Any Guardian generators used as rental or trailer mounted applications.
• Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Steel enclosures 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 fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all
mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not
cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace-
ment of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
®
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Revision (10/01/04)
Part No. 0F1005
Revision C (12/15/04)
Printed in U.S.A.
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