Generac Power Systems Portable Generator 005040 0 005040 1 005053 0 005053 1 005054 0 005054 1 User Manual

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!!  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
®
Generac Power Systems, Inc.  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
2
Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
Generac Power Systems, Inc.  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
4
Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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).  
®
Generac Power Systems, Inc.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
6
Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
Generac Power Systems, Inc.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
8
Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
Generac Power Systems, Inc.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
10 Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
Generac Power Systems, Inc. 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
12 Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
Generac Power Systems, Inc. 13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
®
14 Generac Power Systems, Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.