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Generac Power Systems 004188-1 Portable Generator User Manual

1. R813 0 R SWING P d N BOTH SIDES 2 E ut R SWING 1 1774 CX 69 8 ESESE RADIATOR SSS FILL COVER N 914 756 E36 01 29 8 Ex 1535 N 60 41 N E LAN VIEW bw AIR DUI 6 845 33 3 251 37 41 1 4 NPI f CONNECT ION 25 22 gt c D PG 10614 21 tages lt 152 6701 26 61 215 0 6 MOUNTING HOLE EX p 473 42 3 6 PLCS C10 91 18 61 18 6 137 1500 5 4 59 11 RIGHT SIDE VIEW 54 Generac Power Systems Inc oo 1 CUNTRUL PANEL AT THIS END SHOWN HIDDEN Section 9 Installation Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Installation Drawing 25 kW Drawing 0C1450 INSTALLATIO NNNNNNNNNNNN Air Intake U
2. LLU ULL ULULULU RRSRPRPRh ULUULU ULUUUL LLL ULL 5 654 L OO 74 Lee o LJ RA DIAI R END VIEW Generac Power Systems Inc 55 Section 10 Warranty WARRANTY Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 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 EMISSI
3. 6 Fuel Consumption 7 Torg e u u u a uuu da riders dne 7 Engine Oil Recommendations 7 Coolant Recommendations 7 Before Installation T Section 2 STANDBY GENERATOR INSTALLATION 8 Generator 0 Susan ie 8 Generator Mounting and 9 Basic Standby Electric System 9 Emergency Circuit Isolation Method 9 Total Circuit Isolation Method 9 Grounding the GenDeralor teta 9 Generator AC Neutral Connections 10 Transfer Switch Start Signal Connections 10 Battery Installation 10 Preparation Before Start Up 11 TABLE OF CONTENTS Table of Contents Section 3 OPERATION uu uu uu u o u 299 00005009 11 Using a Standard GTS Transfer Switch 11 Control Console Components 12 Manual Transfer and Startup 13 Retransfer and Shutdown 13 Automatic Operation 13 Weekly Exercise 15 LOSIE
4. 441 cu ft per hour Using LP Gas 175 cubic ft 4 8 gal per hour Models 004370 004371 Using Natural Gas 359 cu ft per hour Using LP 143 cubic ft 4 0 gal per hour Models 004188 004189 Using Natural Gas 277 Cu ft per hour Using LP Gas 110 cubic ft 3 1 gal per hour NOTE 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 conditions and other environmental factors TORQUE SPECIFICATIONS Cylinder Head 15 90 90 ft lb Intake Manifold 13 Exhaust Manifold 13 ft Ib Section 1 General Information ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the fac tory Use a high quality detergent oil classified For Service CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient tem perature range anticipated before the next oil change Tempera
5. N Section 8 Exploded Views Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Radiator 15 amp 20 kW Drawing No 0A7206 D PART NO QTY DESCRIPTION 0A6272 1 SUPPORT RADIATOR 0A5734 1 RADIATOR 1 5L 0A6237 1 VENTURI 1 5L MODINE 0A6238 1 GUARD FAN 1 5L MODINE 084918 1 HEATER ENGINE 0500W 120V 050967 1 HOSE 5 8 ID RIA 250F 12 057823 4 CLAMP HOSE 10 56 1 06 099502 4 CLAMP HOSE 24 B1 06 2 00 083709 2 CLAMP WIRE HOSE 573 551 052250 1 TAPE FOAM 1 X 1 14 042568 4 SCREW HHC M6 1 0 X 20 G8 8 022097 13 WASHER LOCK M6 1 4 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 022473 11 WASHER FLAT 1 4 ZINC 084427 1 BRACKET HEATER 050967 1 HOSE 5 8 ID RIA 250F 18 075443 6 SCREW CRMPTIT 1 4 20 X 5 8 056892 4 SCREW CRIMPTITE 10 24 X 3 8 0A6284 1 HOSE LOWER RADIATR 0A6258 1 HOSE UPPER RADIATR 029032 1 HOSE 9 32 ID 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 060035 4 SPACER 41 X 75 X 87 ST ZNC 022127 5 NUT HEX 1 4 20 STEEL 022145 4 WASHER FLAT 5 16 ZINC 022129 4 WASHER LOCK 8 5 16 045771 4 NUT HEX M8 1 25 G8 YEL CHR 042907 4 SCREW HHC 8 1 25 16 G8 8 076749 1 TANK COOLANT RECOVERY 080712 1 BRACKET COOLANT RECOVERY TANK 0 7215 1 SCREW SWAGE 1 4 20 X 5 8 N WA 5500 0A7275 6 1 5 X 1 ADHESIVE BACKING 0 2111 2 SCREW SWAGE 10 32 X 5 16 Z YC 065852 2 SPRING CLIP HOLDER 37 62 LISTS Generac Power Systems Inc 35 dg As Sec
6. ZN VIN GEC YZZ LHL 141 3LYNX3LIY 76 C CN IN 1 vVS SIS G3SNNN 31 106 1 MOTI3A 51431545 1 1 802 504 MOTT3A SWALSAS 1 1 0 2 X04 3018 ISN HOLIMS MOLIO3l3JS 3SVHd HOLIMS H3JSNV HL QSVONVIS 304 SS 1 15 Z U 0 0 LL 21 Q3 ll GIS 95 cal 91 11 84 gl NOILISOd 330 NMOHS 1 0 00000000 JSVHd AOvZ OZI NOILO3NNOO M3NOLSn2 00 m 2 191 0 NOILO3NNOO 3NION3 624 24 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ELECTRICAL DATA lt Wiring Diagram 1 5 Gas Engine Drawing 0 7176 YOLOANNOOD YOLVALOV YOLVNLOV YONYSAOSD L 3339 3jLIHM 49v 18 H3 Addillv8 2 18 C 034 44 13 OL 1971110 G34 ALMILA VSL AOZL OL 5 35 13 41 SIM HOLIMS 1 SIM YOLOW 3311 WS HOLIMS 34155349 10 501 ONnOSD 099 dION3IOS 1304 54 1 ANIONS YOLVNYSLIV 20 vod 9011081915149 50 JOLOVINOO TJOSLNOO 22 ON 394 AINO IVMVSOHLIM 794711 44815
7. ND LLULLU LU LU LLL LU LU VVVVV U DPDDDD LLL DL 2 3 4 NATURA E 575 34 5 C NNNNNNNINNNNNNNNNNNNNNNNNNNNNNNNNNNNNIN E 1050 4 616 24 2 PANEL END VIE 4 9459 L 14 91 RADIATOR INLET CSHUWN HIDDEN 210 LO 3 Air Intake NANAAAAAAAAAAAAAAAAAAAAAANAAAAAANAAAAANA Air Intake LUUUUU VU
8. SN GEN POVVER SYSTEMS INC Owner s Manual GENERAG FR CO NN E FR I N C T E gt 2 TR YO SS 7 gt 222 Dn rT a5 s Serssgro GO 2585 2 2 5 9 lt gt gy2ooogooo soootooo 9 o S 5 S 5 9 lt 2 WW o 111111 010110 10000200017 TTA Q 7770 i lt lt 5 5 5 9 lt lt a gt lt L Ce O H U lt Ce c U Ce O V c lt Ce U LLI Lit LL lt C gt c O This manual should remain with the unit INTRODUCTION Thank you for purchasing this model of the standby gen erator set product line by Generac Power Systems Every effort was expended to make sure that the infor mation and instructions in this manual were both accu rate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of th
9. 8 n I m ino aly e j HI lJ y 18 6 621 18 1 911 819 01 1 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Section 9 Installation Installation Drawing 15 amp 20 kW INSTALLATION S32V ld v 0 ONILAIT VIG 1 11 86 1 53 1 SAALAWITIIW SNHISN3WIQ 119 40115 3GISNI 404 44100484 NOTLVOTSICOW W3ISAS 1404 TIVWS SNOTLOANNOD dA 801S 30151 esl dN 135 S3ADO 315 8 13404 310 061921 061118 pores 0221162 AV31 AYALLVE Sv3dav dn anis 021 52 Generac Power Systems Inc Section 9 Installation INSTALLATIO Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Installation Drawing 15 amp 20 kW Drawing No 0A7214 C m eu w e CLEFT SIDE A lt 5 U 24 L L 2 oo A lt O gt zu 20 OJ x qe 0 2 lt et ee ae LY A D J lt lt lt gt s t C AZ I lt DZ LJ LJ Ta g aa x IH 2 3 4a 5 L o yo lt 2 in lt e2 LJ lt gt 2 Yano I an 4 x AM Z lt 0 mF 89 x lt
10. 1 3NVd 10 1 09 815 AVNIW 91 3NVd 8 vi vp OL S8 S8 S8 SIG 25 Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ELECTRICAL DATA j Electrical Schematic 1 5L Gas Engine Drawing No 0A7182 B WTS TO CONTROL PANEL TERMINAL STRIP e e e 12V BATTERY RED x BLACK wur LEGEND GREEN CC CONTROL CONTACTOR DCA DC ALTERNATOR EH ENGINE HEATER FS FUEL SOLENOID GRD GROUND ISC IGNITION SYSTEM CONTACT LOS LOW OIL SWITCH SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH WLS WATER LEVEL SWITCH TO DC VOLTAGE REGULATOR FED CIRCUIT TO 120V 15A UTILITY GOVERNOR CONTROL UNIT GOVERNOR ACTUATOR 1371110 OV 2 q33 TO CONTROL PANEL ACTUATOR CONNECTOR ee Generac Power Systems Inc Section 8 Exploded Views Parts Qi Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Enclosure 15 and 20 kW Drawing No 0A7188 D 0 15 Y Note Use door latch lt fastener to secure Ground Wire Note Use door latch fastener to secure Ground Wire ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 1 97575 2 BRACE SIDE 10 3
11. 1 16 FOR PRE PACK TRANSFER c SWITCH CONNECTION deer 23 E em 125456789 10 11 12 13 14 15 16 17 176 USE BLUE WIRE FOR 240V L L SYSTEMS 194 25 229 0 IE YELLOW WIRE FOR 208V L L SYSTEMS LI 85 1194 14 178 RED T2 INSULATE UNUSED WIRE 1 ma s s 229 t 15C LEM 0 14 85 e O 2 14 LEGEND AMMETER 5 ALTERNATOR STATOR BVM BATTERY VOLTMETER 1 2 CIRCUIT BREAKER 11 2 CURRENT TRANSFORMER F1 FUSE 30 AMPS 2 FUSE 7 5 AMPS IN LINE HM HOUR METER HZ FREQUENCY METER L LIGHT FAULT INDICATOR PCB CIRCUIT BOARD CONTROLLER PSW PHASE SELECTOR SWITCH SA SUPRESSION ASSEMBLY SW AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH 1 2 5 TERMINAL BLOCKS 67 TR1 TRANSFORMER UTILITY SENSING 24VA VOLTMETER VR VOLTAGE REGULATOR GCB GOVERNOR CONTROL BOARD ee Generac Power Systems Inc Section 7 Electrical Data Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ELECTRICAL Wiring Diagram Control Panel 1 Phase Drawing 0A2803 D i DATA ALTERNATE 1 BLUE RED 224 22 176 BLACK BLACK 11 1 5 15 11 1 0 15 178 1 57 cs 44 58 O CT2 O OCHO 9 EE 4
12. 41872 sS lt nO Fa TM aT 654 m 25 3 41 p wo 5 Lm pss Lj d gt 23 x 1 No 0 a Air Intake Generac Power Systems Inc 53 INSTALLATIO Lec 61 Section 9 Installation Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Installation Drawing 25 kW Drawing No 0C1450
13. 20 12 14 BOB 4 PO n Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Enclosure 25kW Drawing No 0C1404 D DESCRIPTION SCREW SWAGE 1 4 20 X 1 2 7 WASHER NYLON 250 HINGE SLIP MALE LH HINGE SLIP FEMALE LH HINGE SLIP MALE RH HINGE SLIP FEMALE RH SCREW BHSC M6 1 0 X 16 SS SHAKEPROOF INT 6 55 PANEL TOP SIDE LH PANELTOP SIDE RH DOOR SIDE PANEL FRONT PANEL SIDE BOTTOM PANEL REAR CORNER POST REAR LH CORNER POST REAR RH TOP ENCLOSURE 1 5 SAE DOOR REAR DUCT SUPPORT RADIATOR LH SUPPORT RADIATOR RH SUPPORT MUFFLER 1 5L TOP CONTROL PANEL SAE DUCT FRONT 1 5L SAE BASE MOUNTING WASHER LOCK M6 1 4 WASHER LOCK M8 5 16 NUT HEX 1 4 20 STEEL WASHER FLAT 5 16 ZINC FOAM STRIP 3 4 X 1 4 WASHER FLAT 1 4 ZINC PLUG PLASTIC 4 PLUG BTTN 425 SCREW HHC 8 1 25 X 20 G8 8 SCREW M6 1 0 X 20 68 8 DECAL CAUTION HOT SURFACES BRACE REAR DOOR NUT HEX JAM 3 8 24 SS LATCH AND CAM LATCH AND CAM NUT SPEED 1 4 20 SCREW HHC 1 4 20 X 1 G5 INSULATION PANEL TOP INSULATION PANEL SIDE DOOR INSULATION PANEL FRONT RH INSULATION PANEL FRONT LH INSULATION DUCT FRONT INSULATION PANEL FRONT TOP INSULATION PANEL DUCT SIDE TOP INSULATION PANEL REAR INSULATION DUCT LH SIDE INSULATION DUCT RH SIDE INSULATION DOOR REAR WASHER SELF LOC DOME GROMMET 7 16 X 1 16 X 1 4 INSULATION PANEL DUCT SIDE
14. 14 Section 4 MAINTENANCE 14 Maintenance Performed by Authorized Service Facilities 14 Overload Protection for Engine DC Electrical SySUSDWI eee aste 14 Clie Choa 0 0116 LEVELS 14 Maintenance Owner Operator Can Perform 15 Miscellaneous Maintenance 17 Section 5 TROUBLESHOOTING 18 Section 6 SCHEDULED MAINTENANCE 19 Section 7 WIRING DIAGRAMS AND SCHEMATICS i es 22 Section 8 EXPLODED VIEWS AND PARIS LISTS 2 sssscspusss 27 Section 9 INSTALLATION DRAWINGS 52 Section 10 WARRANTY o sus 56 Generac Power Systems Inc M SAFETY RULES Important Safety Instructions Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe WARNING 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 Bec
15. Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY a POWER SUPPLY 8 SWITCH TO LOAD CIRCUITS STANDBY GENERATOR n OUTPUT DS 1 MAIN LINE CIRCUIT BREAKER EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping elec trical loads below the wattage amperage capacity of the generator If the generator is powering only critical loads within the wattage amperage capacity during util ity power outages consider using the emergency circuit isolation method INSTALLATION Section 2 Installation Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are within the wattage amperage capacity of the generator set When this method is used it is difficult to overload the gener ator The transfer switch must meet the following requirements It must have an ampere rating equal to the total amperage rating of the emergency distribution panel circuit Have it installed between the building s main distri bution panel and the emergency distribution panel TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the genera tor to be overloaded when this isolation method is employed The following apply to the transfer switch in th
16. Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging waRNING amp 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 gen erator can crank and start as soon as the battery cables are connected 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 9 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 26R 525 0 deg F Note The BCI number should be located directly on the battery Generac Power Systems Inc 17 TROUBLESHOOTING PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down Auto Off Manual Switch at OFF engine continues to run No AC output from generator 1 2 3 4 5 1 Part Name Oil Filter Radiator Cap Air Cleaner opark Plug TROUBLESHOOTING POINTS CAUSE Section 5 Troubleshooting Guardian Liqui
17. 045771 8 NUT M8 1 25 G8 YEL CHR 042907 8 SCREW HHC 8 1 25 X 16 08 8 076749 1 TANK COOLANT RECOVERY 080712 1 BRACKET COOLANT RECOVERY TANK 0A7215 1 SCREW SW 1 4 20 X 5 8 N WA 5500 030486 2 GROMMET 7 16 X 1 16 X 1 4 0A2111 2 SCREW SWAGE 10 32 X 5 16 Z YC 065852 2 NUT SPRINGCLIP 37 62 0 1067 1 SUPPORT RADIATOR RH 0C1067 1 SUPPORT RADIATOR LH 0C1480 1 BRACKET COOLANT BOTTLE LISTS Generac Power Systems Inc 37 Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Mounting Base 15 20 kW Drawing 0A7187 A 5 5 20 5 ENGINE NC A MOUNTING RACKET 6 BENE 5 j 6 2 8 REAR BEARING d CARRIER 7 je 6 ITEM PART NO QTY DESCRIPTION 1 C2632 1 BASE MOUNTING 3 70936 2 ISOLATOR VIBRATION 4 70936C 2 ISOLATOR VIBRATION 5 39253 8 CAPSCREW HEX HEAD M8 1 25 x 20MM 6 22145 12 FLAT WASHER M8 7 22129 12 LOCK WASHER M8 8 45771 12 NUT HEX M8 1 25 9 71956 4 WASHER VIBRATION ISOLATOR 10 51730 2 CAPSCREW HEAD M8 1 25 x 60 12 57821 2 CAPSCREW HEX HEAD M8 1 25 x 40MM 13 21991 1 STRAP GROUNDING 14 27482 1 WASHER STAR 5 16 15 A2308 1 PLUG BUTTON 38 Generac Power Systems Inc 049955 070936 070936 039253 022145 022129 045771 071956 051730 057821 021991 027482 032308 Section 8 E
18. EXHAUST 45 DEG MUFFLER 1 6 1 5L SAE STRAP MUFFLER 6 DIA SCREW HHC 8 X 1 25 X 20MM WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR CAP RAIN 2 LISTS Generac Power Systems Inc 41 n Section 8 Exploded Views and Parts LISTS Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Circuit Breaker Drawing 008294 6 2 5 ITEM PART NO QTY DESCRIPTION 1 0A2106 1 SILKSCREEN P PANEL 2 0A2952 1 COVER BQ CIRCUIT BREAKER 3 039782 1 BRACKET MOUNTING CIRCUIT BREAKER 4 048373 1 CIRCUIT BREAKER 70 X 2 240V 39782 BRKT 039766 1 CIRCUIT BREAKER 90 X 2 240V 39782 BRKT 0A2077 1 CIRCUIT BREAKER 125 X 2 120 240V 39783 BRKT 5 023965 2 SCREW RHM 48 39 X 3 8 6 022264 2 WASHER LOCK 8 M4 42 Generac Power Systems Inc ITEM PART QTY 1 074100 1 076009A 1 072566 080882 074978 047822 075476 083264 022985 022264 051787 079847 P 3 12 DESCRIPTION ASSY HOME STDBY LOGIC MODELS 921 863 865 PP LOGIC ASM 50 60HZ MODEL 9428 NUT SPACER 250 PCB SCREW PPH TAPPING 6X5 8 SS DECAL TERMINAL STRIP BLOCK TERM 20A 7 X 6 X 1100V SCREW PPHM M4 0 7 X 16 TRANSFORMER ASM CMA 240 12V WASHER FLAT 6 ZINC WASHER LOCK M4 SCREW HHC 4 0 7 X 16 G8 8 BOX CMA Section 8 Exp
19. Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped 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 57 Section 10 Warranty WARRANTY Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 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 Guar
20. NE 1 516 816 CUSTOMER CONNECTION 120 240V 1 PHASE 93 1 E1 TO E2 240 E1 TO 00 120V E2 TO 00 299 BLACK 13 es BRUSH HOLDER H STANDARD GENERAC 4 E 01111 TRANSFER SWITCH S f 1 i 544 544 58 17 57 ss S16 BRUSH WITH RED LEAD 44 H 0 CLOSEST TO BEARING B BLUE Generac Power Systems Inc 23 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ind e m c 9 un ELECTRICAL No 0A2802 B ing Draw Phase Electrical Schematic Control Panel 1 DATA QHVO8 10 1 HONHJAOD 829 INIT NI SdWv 94 3504 SNISN3S ALIMILA 5 LHL OC 3504 901911934 ONIGNIM NOILVLIOXS H3LJALIOA OV 009 30010 ca SQNVOS8 IVNINH3L C181 HJAHOJSNVML LN3HNHOO 2110 HOLIMS 3SIOM3X3 135 ZMS SM3MV3MH8G 2182 HOLIMS 440 1 IMS MOLlOVdVvO dvd 55 NOISSSYdNS YS 1 WAG YATIONLNOD GYVOd LINDYIO God MOLVIS MOLVNMNHALTIV SV MOLVOIQNI LINV4S LHON L1 MOLOM MOLVNM3ITV MV H3L3A 0344 ZH M3L3AWV OV y C81 NOILO3NNOO 935079 S31VOIQNI X 0 HOLIMS 4335 NY aL 39 OV
21. as a step otepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc A ELECTRICAL HAZARDS generators covered by this manual produce dan gerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the standby generator Avoid contact with bare wires ter minals connections etc on the generator as well as the transfer switch if applicable Ensure all appropri ate 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 people must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC Article 250 requires the frame and external electrically conduc tive parts of the generator to be connected to an approved earth ground and or grounding rods This rounding will help prevent dangerous electrical shock that might be caused by a ground fault condi tion
22. clip 4 Turn OIL FILTER Figure 4 3 counterclockwise and remove Dispose of old filter Figure 4 3 Filter St am i 4 OIL FILTER o Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIP STICK FULD MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters caution amp After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 59402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reat taching the cover Figure 4 4 16 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Figure 4 4 Engine Air Cleaner AIR CLEANER al jess SN J c S3 E Sl Soo 0 DOORS REMOVED FOR CLARITY See the Service Schedule Section 6
23. for air cleaner maintenance SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 6 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 ques tionable See the Service Schedule Section 6 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 5 0 6 mm 0 020 0 025 inch by carefully bending the ground electrode Figure 4 5 Figure 4 5 Setting the Spark Plug Gap SET PLUG GAP AT 0 5 0 6 mm 0 020 0 025 inch f G COOLANT CHANGE Every year have Authorized Service Facility drain flush and refill the cooling system See SPECIFICATIONS for cooling system recommendations Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resist ance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacu um system or dry low pressure air to remove any accu mulations of dirt The generator
24. generator as close as possible to the trans fer switch This reduces the length of wiring and con duit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REGU LATE THE DISTANCE Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 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 6 inches thick and should extend beyond the enclosure to a distance of at least 3 inches on all sides See pages 54 55 for generator major dimensions BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic stand by electric system Both the UTILITY power supply and the STANDBY generator output are connected to an approved transfer switch The transfer 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 NOTE Generac recommends the use of a Generac power systems GTS type transfer switch in conjunction with this generator Figure 2 1
25. 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 oroblems 21 Return the unit to standby setup for operation when required MAINTENANCE 2 0 Section 6 Scheduled Maintenance Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Level 1 Level 2 Level 3 Level 4 Hecom Task Required Task Required Task Task mended Comp be done Comp be done Comp Required Comp to be done Date 3months Date Date Ito be done Date monthly Initials Break in Initials annually Initials Annually Initials 10 hrs 50 hrs 100 hrs Generac Power Systems Inc 21 Section 7 Electrical Data Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ELECTRICAL DATA j Wiring Diagram Control Panel 1 Phase Drawing No 0A2803 D o UTILITY 1 t NIA BLACK A 15 UTILITY 2 5 gt 2 LOAD 1
26. in the generator set or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum elec trical current ampacity to which they will be sub jected Before installing or servicing this and related equip ment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and possibly fatal electrical shock Connecting this unit to an electrical system normally supplied 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 damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when nor mal 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 generators automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immedi ately sh
27. 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 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 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 297 WHITEWATER WI 53190 Revision 10 01 04 Part No 006444 Revision 01 05 05 Printed in U S A
28. is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspect ed by an Authorized Service Dealer That dealer 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 Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 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 avail able observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine 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 battery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while chargin
29. months Replace damaged deteriorated worn or otherwise defective belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 3 4 inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating 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 shorten 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 frequency and or voltage Only qualified service technicians should adjust the governed speed Generac Power Systems Inc 15 OPERATION OD CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Section 4 Maintenance 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
30. should be performed only by an authorized Generac Service Dealer 3 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 or following each 50 hours of operation of the unit and 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 Amid 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 or following each 100 hours of operation of the unit and 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 Generac Power Systems Inc 19 gt Section 6 Scheduled Maintenance MAINTENANCE Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 2 0 10 Check the engine 11 12 Disable the unit from Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp done Comp be done Comp Required to done Date 3 months Date Semi Dat
31. tion pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John otreet New York N Y 10038 AGRICULTURAL WIRING HANDBOOR obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road 51 Joseph MI 49085 452 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 GENERATOR LOCATION Install the generator set in its protective enclosure out doors 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 drifting consider using a windbreak to protect the unit nstall the generator on high ground where water lev els will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow 3 feet of space on all sides Where strong prevailing winds blow from one direc tion face the generator air inlet openings into the pre vailing winds nstall the
32. 0 operating hours or 6 months whichever comes first 2 Retorque cylinder head See Torque Specs 3 Retorque intake and exhaust manifold See Torque Specs 14 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators E EVERY 500 OPERATING HOURS Service air cleaner 2 Check starter 3 Check engine DC alternator F EVERY 800 OPERATING HOURS 1 Retorque cylinder head See Torque Specs 2 Retorque intake and exhaust manifold Torque opecs 3 Check engine compression 4 Check valve clearance COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snot Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See Section 9 for installation drawings and vent locations wanNiNG The exhaust system parts from this product get f 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 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 30 amp fus
33. 00 4 Wire Class F Type of Stator Rotor Stator Insulation Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ENGINE SPECIFICATIONS 2 O uu x Mitsubishi Displacement 92 inches 1 5 liters Cylinder Arrangement 4 in line Valve Arrangement Overhead Cam 811 916 9 1 3 4 2 Number of Bearings serene 5 Compression 9 to 1 No of Teeth on Flywheel eere 104 Ignition Timing al T800 TOM RETE 35 degrees BTDC 822000 43 degrees BTDC Spark Plug Gap 0 020 0 025 inch Recommended Spark Plugs 91111118 o RR RR RH RN11YC4 30 50 psi Crankcase Oil Capacity 4 0 U S quarts 3 8 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery RE Pusher Type Cooling System Capacity 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base FUEL CONSUMPTION Models 004474 004475 Using Natural Gas
34. 020692 0A7005 052243 0A4772 070901 051735 056768 022145 022129 022259 052213 047411 052830 045771 058306 030795 0 2711 048665 075885 0 45310257 0 4682 057522 ENGINE 1 5L CLAMP HOSE 28 1 32 2 25 PIPE FLEX EXHAUST GASKET EXHAUST MANIFOLD MANIFOLD EXHAUST SHIELD HEAT EXHAUST WASHER LOCK M6 1 4 SCREW HHC 1 4 20 X 1 2 G5 SCREW HHC M10 1 25 X 25 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 ZINC STAMPING ENG SPACER 41 X 75 X 12 STL ZNC NUT HEX M10 1 5 G8 YEL CHR SCREW SHC 5 16 18 X 2 G8 8 NZ STARTER 12V SPACER 56 X 1 X 37 ST ZNC SCREW HHC M10 1 5 X 60 G8 8 ENGINE PLATE SLEEVE DOWEL BLHSG SCREW HHC M10 1 5 X 70 G8 8 SCREW HHC M10 1 5 X 90 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK 8 5 16 NUT HEX 5 16 18 STEEL SCREW HHC M10 1 25 X 20 G8 8 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M10 1 25 X 45 G8 8 NUT HEX 8 1 25 G8 YEL CHR SCREW SHC 8 1 25 X 25 612 9 SCREW HHC 5 16 18 X 1 G5 ADAPTER THERMOSTAT GASKET THERMOSTAT THERMOSTAT 195 DEG GASKET INLET MANIFOLD MANIFOLD INTAKE SENSOR COOLANT LEVEL Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Engine Compartment Drawing 0 7642 PARTS 00 ITEM PART DESCRIPTION 0A6751 034339 0D4788 061012 039253 0A5110 0A7006 025507 022500B 0A8584 036277 042574 026073A 0A6701 039414 0A5568 051769 0A4804 0A4800 0A5839 0A1354B 0A4
35. 2990 6 BUMPER 2 3769 2 DOOR ENCLOSURE 11 C2164 1 LATCH 3 A3768 1 DOOR ENCLOSURE 13 29107 6 GROMMET 3 16 7 8 4 A5314 1 TOP ENCLOSURE 14 A1694 5 BUTTON PLUG 1 1 2 5 67042 2 LATCH 15 91297 063 3 GROUND WIRE ASSEMBLY 6 22264 6 LOCK WASHER 8 16 91297 064 3 GROUND WIRE ASSEMBLY 7 67035 6 SCREW PAN HEAD MACH 48 32 x 17 49813 3 HEX NUT M6 x 1 0 5 16 18 70005 3 LOCK WASHER M6 8 82570 2 PLUG 4 19 49811 3 FLAT WASHER M6 9 7215 10 SWAGE FASTENER W NYLON WASHER Generac Power Systems Inc 27 dg Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Enclosure 25kW Drawing 0C1404 D y wi AS 2 D E N z co CE A gt a O O HP Bo Generac Power Systems Inc 0 2110 0 2115 0A3133A 0A3133B 0A3133C 0A3133D 0A3359 0A3360 001245 0C1245A 0A3449 0 4822 0 4823 0 4824 0 4825 0 4826 0C1193 0A4831 0A4832 0C1067 0 1067 0 1068 0 8817 0 1244 049955 022097 022129 022127 022145 089961 022473 082570 039253 042568 003397 003785 037337 0 2164 067042 067577 022413 0C1053B 0C1053A 0C1053E 0C1053F 0C1053G 0C1053H 0C1053D 0C1053J 0C1053K 0C1053L 0C1053M 078115 030486 0C1053C Ko N 24 FT
36. 6 197 0 9611 FUSE 7 5AXBK AGC7 5NX WASHER LOCK 1 4 M6 WASHER FLAT 1 4 M6 REGULATOR DC ALT HHCS M6 1 0 x 12MM SOLENOID RELAY 12VDC Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators PARTS Ce LISTS SHOWN ON THIS ASSEMBLY SEE CHART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 31 LISTS Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Control Panel 25kW Drawing 0C8847 D VIEW ON VIEW ON C VIEW ON G Xe RANA 5 8X9 v gem 1 2 INSIDE PANEL FACE 32 Generac Power Systems Inc O WD PART NO QTY 0C5077 075589 0A1775 0C5078 0C4224A 057073 022985 081988 070043 070055 070042 070081 076037 022152 022158 061945 032300 022668 076020 083048 0A2077 075476 022264 0A3968 039782 0C2323 076039 051756 048476 022237 022097 022473 082573 043116 056739 072252 c cl N RA 00 56 c DESCRIPTION SUPPORT CONTROL PANEL LH BRACKET VOLTAGE REGULATOR CONTROL PANEL BACK SUPPORT CONTROL PANEL RH SILKSCREEN PANEL SAE BLOCK JUNCTION 3 8 16 WASHER FLAT 6 ZINC DECAL EXERCISE INFO VOLTMETER AC 0 300 AMMETER AC 0 100 FREQUENCY M
37. 839 055816 049811 075614 0A2628 0A5275 0A5586 0A4814 0445310244 0C1852 0912970066 070928 069860C 069811 0A5317 022473 1 1 1 1 6 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 2 SW TMP 245DEG 3 8NPT BARBED EL 90 3 8NPT X 5 8 PLUG STD PIPE 3 8 STEEL SQ HD PLUG STD PIPE 1 8 SCKT HD SCREW HHC 8 1 25 X 20 G8 8 PIPE WATER INLET O RING 1 1 16X1 5 16X1 8 WASHER SHAKEPROOF EXT 7 16 STL SPACER 41X 75X 25 ST ZNC SWITCH OIL PRESSURE ELBOW 90D STREET 1 8 ADAPTOR 1 8NPTF TO 1 8 28 PLUG STD PIPE 1 4 STEEL SQ HD SCREW HHC M10 1 5 X 110 G8 8 SCREW HHC 8 1 25 X 35 G8 8 SCREW HHC M12 1 25 X 55 G8 8 WASHER LOCK M12 PULLEY CRANKSHAFT 1800 RPM PULLEY CRANKSHAFT 3600 RPM BRACKET ALT SUPPRT DC ALTERNATOR 12V ARM ADJUST ALTERNATOR SCREW HHC M6 1 0 X 70 G8 8 WASHER FLAT M6 FAN ENG PUSHER 6 880 PULLEY FAN 95 DIA V BELT 3 8 X 32 1 8 1 5L V BELT 3 8 X 28 9 1 5L SPACER PULLEY FILTER OIL ADAPTER DRAIN OIL GROUND WIRE STARTER CLAMP HOSE OIL DRAIN HOSE ASM OIL DRAIN CAP HEX 1 4 BRASS NAMEPLATE ENGINE WASHER FLAT 1 4 ZINC Generac Power Systems Inc 51 Lote 2 1 6 1 06421 91 61 21 809 NOILOANNOD 13043 10011 d 1 v T L LJ 2 1 611 1709 NMDC er 03 370 510 x9 N lt 2 a 3 zr ww pH 7 1 68 1
38. 9226 4 6 051713 4 7 022129 4 8 098672 1 098673 1 098674 1 098682 1 098683 1 098684 1 098676 1 098677 1 098678 1 097620 1 098937 1 097621 1 9 0 5382 1 10 075591 1 11 075476 4 12 0A5601 1 13 075554B 4 14 0A9375 4 15 022152 4 16 097146 1 17 042558 1 18 0A5061 1 19 0 4989 1 20 053557 1 21 051769 6 22 049541 4 23 046526 4 24 045772 4 26 087599 1 27 077043 1 28 022131 4 29 072578 1 30 0 7043 5 31 049808 5 32 058589 1 33 023365 4 35 0 8830 4 36 072080 1 USED ON PRE PACKAGED UNITS ONLY Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Generator Drawing No 0A9348 F DESCRIPTION ASSY ROTOR 10KW ASSY ROTOR 15KW ASSY ROTOR 20KW ASSY ROTOR 25KW HOUSING BLOWER SCREEN AIR OUTLET SCREW PPHM M5 0 8 X 8 SS WASHER LOCK M5 WASHER FLAT M5 WASHER LOCK M8 5 16 ASSY STATOR 10KW A ASSY STATOR 10KW D ASSY STATOR 10KW GJK ASSY STATOR 15KW 1PH A ASSY STATOR 15KW D ASSY STATOR 15KW 1PH GJK ASSY STATOR 20KW 1PH A ASSY STATOR 20KW 1PH D ASSY STATOR 20KW 1PH GJK ASSY STATOR 25KW 1PH A ASSY STATOR 25KW 1PH D ASSY STATOR 25KW 3PH D BEARING CARRIER REAR ASSY HOLDER BRUSH SCREW PPHM 4 0 7 X 16 COVER REAR BEARING CARRIER BOLT STATOR X 16 LG SCREW 10 24 X 2 WASHER LOCK 10 FAN amp RING GEAR ASSEM KEY SQ 3 8 X 1 STEEL SPACER FLEX PLATE PLATE FLEX SCREW HHC M12 1 75 X 40 G8 8 WASHER LOCK M12 SCREW HHC M10 1 5
39. BOTTOM NOTE THESE PARTS ARE INCLUDED IN KIT 0C1053Z LISTS Generac Power Systems Inc 29 PARTS Section 8 Exploded Views and Parts Exploded View Control Panel 15 and 20 kW Drawing No 0A2872 F Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ALO v ALO A lO W4ASSV SSdNSVH JAIM NOTLV TIVISNI 082908 WVADVIT ONIAIM 33S A18 vl ALO ALO 21 ALO 21 9 lt 82 0 851220 261220 N d 86220 N d 35 AINO SLINN NO 9351 SI MJIA SIHL NI NAUHS Sad LIA 089298 AINO 91 ND 04501 SI NI NADHS Dad LIA vZO0vZg8 Generac Power Systems Inc O WD PART NO QTY 098062 075589 0A1775 098063 0A2106 057073 022985 070080 070043 070055 070042 070081 076037 022152 022158 061945 032300 022668 076020 074074 067680 075476 022264 022237 051715 0C2428 076039 051756 048476 054450 022241 022097 022473 0A1354A 043116 056739 _ Exploded View Control Panel 15 and 20 kW Drawing 0A2872 F 0 DESCRIPTION ITEM PART NO QTY DESCRIPTION SUPPORT CONTROL PANEL L H 36 0C2512 GROMMET 1 16 1 3 8 BRACKET VOLTAGE REGULATOR 37 0 2513 GROMMET 1 8 1 3 4 CONTROL PANEL BACK 38 061395 TRANSFORMER CURRENT 100 5 SUPPORT CONTROL
40. C M5 0 8 X 25 G8 8 NUT HEX 3 8 16 STEEL WASHER LOCK 6 ASSEMBLY L C ELECT GOV BLOCK TERM 20A 20 X 6 X 1100V DECAL TERMINAL STRIP BLOCK TERM 20A 2 X 6 X 1100V DECAL WARN ENG START ASSEMBLY SUPPRESSION SCREW SW 1 4 20 X 5 8 5500 SCREW PPHM M5 0 8 X 16 NUT HEX M6 1 0 G8 YEL CHR BUS BAR HARNESS PNL PP 1P HARNESS WIRING 1 5L LIGHT 12VDC 02A LED RED PILOT DECAL TRAN SWITCH CONN REGULATOR DC ALT SCREW PHTT M4 0 7 X 16 ZYC HINGE CONTROL PANEL SS M6 X 1 0 X 12 CONTROL PANEL TOP SAE FUSE amp HOLDER LITTLE 7 5A FUSE 7 5A X BK AGC7 5NX NOT SHOWN ON THIS ASSEMBLY PART OF CONTROL PANEL WIRE HARNESS Generac Power Systems Inc 33 dg Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Radiator 15 amp 20 kW Drawing No 0A7206 D 8 D lt e C ES Q di x 8 5 C co 2 Se 5 D gt ps lt 5 o gt C co x e rT a Ope lt O lt el oes N co CN 9 u A co 4 2 M dic iB p 2 Bottom only UNM 7 um 24 JN CN CN CN 34 Generac Power Systems Inc
41. ETER 55 65HZ HOURMETER VOLTMETER DC 8 18V WASHER LOCK 10 NUT HEX 410 32 STEEL SWITCH 6A AMP V SELECTOR HOLDER FUSE FUSE 30A X AGC30 HLDR22669 HKP SWITCH DPDT 15 10 SP ON OFF ON ASSEMBLY POTTED REG WOFIN CIRCT BRK 125X2 120 240V SCREW PPHM 4 0 7 X 16 WASHER LOCK 8 4 ASSEMBLY CAPACITOR FILTER BRACKET CIRCT BRK MOUNTING SCREW PHTT 6 32 X 5 8 ZYC SCREW PPHM M5 0 8 X 40 SCREW 10 1 5 X 20 68 8 CIRCT 4 5 X 1 AUTSOKW 45 WASHER LOCK 3 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC SWITCH DPST 5 125V SPD RCKR SCREW HHC M6 1 0 X 12 G8 8 RELAY SOLENOID 12VDC PNL MNT GROMMET 1 37 X 06 X 1 00 67 68 69 Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Control Panel 25kW Drawing No 0C8847 D PART NO QTY 063212 058318 033121 049226 023897 075595 049811 072355 055440 022241 022155 098647 057335 021480 048766 058589 070882 0 7215 076040 049813 061979 0 2833 0 6821 064009 064828 1354 0C2212 0C3826 0C4427 0C8817 0D5324 0A9611 N L ee lt ono n JJ T PARTS 00 DESCRIPTION GROMMET 1 75 X 12 X 1 50 TRANSFRM 150A TO 5A 5VA SCREW HHC 10 32 X 1 2 WASHER LOCK M5 WASHER FLAT 10 ZINC ASSEMBLY CMA BOX WASHER FLAT M6 SCREW M6 1 X 12 SEMS SCREW HH
42. Liquid cooled 15 kW 20 kW and 25 kW Generators WARRANTY 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 Subsectio
43. No 0C1667 F DESCRIPTION WELDMENT MOUNTING BASE FLANGE FUEL INLET NIPPLE CLOSE 3 4 X 1 375 SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR SOLENOID GAS FUEL BUSHING REDUCER 3 4 TO 3 8 ASSY HOSE NG LPV 31 COVER AIR CLEANER REGULATOR NATURAL GAS EM REGULATOR L P GAS EM NIPPLE PIPE 3 8 NPT X 4 BL IRON ADAPTOR CARBURETOR FILTER ELEMENT NUT WING 1 4 20 NYLK CARBURETOR CA55 EM CARBURETOR GASKET SCREW PRHM 10 24 X 1 2 WASHER LOCK 10 WASHER FLAT 10 ZINC 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 5 F THR BARBED STR 1 8 NPT X 5 16 CLAMP HOSE BAND 1 4 HOSE 9 32 6 5 HOSE 9 32 ID 11 BARBED EL 90 5 16 X 1 8 NPT MANIFOLD INTAKE 1 5 MACH PART SCREW HHC 8 1 25 16 G8 8 CLAMP VINYL 1 06 X 406 Z BRACKET RAD HOSE DECAL EMISSION 10 15KW NATURAL GAS UNITS DECAL EMISSION 10 15KW LP VAPOR UNITS LISTS Generac Power Systems Inc 49 Section 8 Exploded Views and Parts LISTS Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Engine Compartment Drawing 0 7642 WATERPUMP HARDWARE Generac Power Systems Inc ITEM PART DESCRIPTION O 0 4531 035685 075546 0 45310258 0 4355 0 6699 022097 022507 052212 046526 022131 0C2499 055993 045772 023586
44. ON 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 Facility 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 Facility 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 ei
45. OOLANT LOW COOLANT TEMPERATURE LEVEL SWITCH SWITCH 0f i LOW OIL xm PRESSURE Ap SWITCH E 21 oo r RSS 2 55 55 lt 9 LOW OIL PRESSURE SWITCH 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 Figure 1 4 Low Oil Pressure Switch HIGH COOLANT TEMPERATURE SWITCH Normally open N O thermostatic switch has sensing 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 Figure 1 5 High Coolant Temperature Switch 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 pre vent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatically shuts down Figure 1 6 Genera
46. OOT BATTERY CABLE 44 Generac Power Systems Inc Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Governor Assembly Drawing No 0A7216 B 0 ITEM 13 NEOPRENE COATING 6 T SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN 9 O 9 INTAKE MANIFOLD Me Ss 1 REF 10 V 9 es CARB ARM 11 din t ITEM PART NO QTY DESCRIPTION 098290 ASM MOTOR STEPPER 2 098941 HOUSING GOVERNOR CONNECTOR 3 098958A CONNECTOR INTERFACE ASSEMBLY 4 098942A COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM 82 X 5 8 SELF TAP 6 043146 3 SCREW HHC M6 1 0 X 10 G8 8 7 022097 5 WASHER LOCK M6 1 4 8 064526 2 SCREW HWH 46 25 X 3 8 ZINC 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0 7041 ASSEMBLY CARBURATOR LINKAGE 12 0A7106 BRACKET STEPPER MOTOR 13 074031 LIQUID NEOPRENE 14 029333A TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC Generac Power Systems Inc 45 Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Generator Drawing 0A9348 F To Engine Crankshaft NN S QQ Waka To Blower ee 46 Generac Power Systems Inc ITEM PART NO QTY 1 098671 1 098681 1 098675 1 098936 1 2 0 5336 1 3 0 1659 1 4 071912 4 5 04
47. PANEL R H 058318 TRANSFORMER CURRENT 150 5 SILKSCREEN P PANEL 39 033121 2 HEX HD MACH SCR 10 32 x 1 2 BLOCK JUNCTION 40 049226 2 LOCK WASHER M5 WASHER FLAT 6 41 023897 6 WASHER FLAT 10 5 INSULATOR 42 075595 1 BOX ASSEMBLY VOLTMETER AC 0 300 43 077438 4 SCREW PHM M6 x 1 0 x 12MM AMMETER AC 0 100 44 082573 1 ROCKER SWITCH DPST METER FREQUENCY 55 65HZ 45 055440 1 HHCS 5 0 8 x 25MM HOURMETER 47 0C2212 6 4 7 x 16 SWAGEFORM PPH METER VOLT DC 8 18V 50 057335 1 TERMINAL BLOCK 20 PCS 6 PANEL WASHER LOCK 10 51 0A7230 1 DECAL TERMINAL STRIP NUT HEX 10 32 52 048766 1 BLOCK TERMINAL 2 PCS 6 PANEL SWITCH SELECTOR AMP VOLT 55 0A7215 14 1 4 20 X 5 8 LG SWAGEFORM HOLDER FUSE 56 057593 4 MOUNT CABLE TIE FUSE AGC 30 57 028739 4 WRAP TIE 4 LONG SWITCH TOGGLE DPDT 58 061979 1 BUS BAR ASSEM POTTED REG WOFIN 59 0 2833 1 HARNESS PANEL PP VOLTAGE REG ASSEM B amp D 60 0A2833A 1 HARNESS PANEL PP SCREW 4 0 7 x 16MM 61 064009 1 PILOT LIGHT RED 14 V WASHER LOCK 8 4 63 081988 1 DECAL EXERCISE INFO WASHER LOCK 3 8 65 086381 2 CAPLUG BPF 1 4 NUT HEX M4 0 7 67 036903 2 SCREW PPHM 6 32 x 5 8 LG 6 32 x 5 8 SWAGEFORM PPH 68 022155 2 WASHER LOCK 6 SCREW 5 0 8 x 40MM 69 098647 1 STEPPER MOTOR KIT HHCS M10 1 5 x 20 70 076040 2 PPHMS 5 0 8 x 16MM CIRCUIT BREAKER 4 5 71 049226 2 WASHER LOCK M5 CIRCUIT BREAKER 5 5 qa 005324 1 FUSE amp HOLDER LITTLE 7 5A HEX NUT 3 8 1
48. X 35 G8 8 WASHER LOCK M10 NUT HEX M10 1 5 G8 YEL CHR PLUG PLASTIC 3 8 NPT FLEX CONDUIT 1 BLACK NOT SHOWN WASHER FLAT 3 8 M10 ZINC SPACER ROTOR SHAFT SCREW HHC M12 1 25 X 25 G8 8 WASHER FLAT M12 DECAL WARN ENG START WASHER SHAKEPROOF INT 8 WASHER FLAT 34 ID X 75 OD DECAL DANGER STANBY UNITS PARTS LISTS OG Generac Power Systems Inc 47 LISTS n Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Gaseous Fuel System Drawing 0 1667 9 6277 227 0 N Oo o 2 of N Gs 18 37 wa 33 NATURAL GAS VERSION 31 30 Generac Power Systems Inc L P VAPOR VERSION SHOWN OTHER VIEW PART NO 075580 026915 039253 022145 022129 045771 0 2666 046747 003714 0A5547 001475 0A9911 0A7989 0 6593 059402 037561 059403 059401 076011 022152 023897 062522 022127 022259 050279 028717 052219 048031 029032 029032 032552 034682 042907 0559340 0 7040 008492 008492 DB HS HS HS Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Gaseous Fuel System Drawing
49. age 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 This generator can be installed in conjunction with a standard Generac GTS type transfer switch if desired The standard transfer switch has no sensing or control ling circuit boards Instead the generator control con sole houses a Control Module Assembly which con trols all phases of operation including engine start up and load transfer Generac Power Systems Inc 7 INSTALLATION Section 2 Installation Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators STANDBY GENERATOR INSTALLATION Connecting this generator to electrical system normally supplied by 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 system 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 caution amp an open bottom is used the engine generator is to be installed over non combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set Only q
50. are connected to the utility power supply Set the Auto Off Manual switch to its Auto position Set the generator main circuit breaker to its or Closed position OPERATION OD Section 3 Operation WEEKLY EXERCISE CYCLE The generator will start and exercise once every 7 days During this weekly exercise the unit runs for about 20 minutes and shuts down Transfer of loads to generator output does not occur during the exercise To select day and time for exercising proceed as follows Set the Auto Off Manual switch to OFF Set generator main circuit breaker to OFF or OPEN Locate the rocker switch on the control panel identi fied with the words Set Exercise Time Figure 3 2 Push Set Exercise Time switch to ON position for 20 to 30 seconds and then release Switch will spring back into its original position when released Wait 30 seconds before setting the Auto Off Manual switch to AUTO position caution If the Auto Off Manual switch is switched too soon the engine may start If engine does start it will shut down automatically in about two 2 minutes Set the generator main circuit breaker to its ON or CLOSED position Generator is now programmed to start and exercise every 7 days thereafter on day and time of day the switch was actuated Place a sign on the generator control panel and the transfer switch indicating the day and time the g
51. at 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 FAULT INDICATOR LAMP Lamp goes ON when one or more of the following engine faults occurs and when engine shuts down Overcrank Overspeed Low oil pressure High coolant temperature Low coolant level 30 FUSE Fuse protects the control console s DC control circuit against electrical overload 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 30 amp replacement fuse Type AGC 7 5 AMP INLINE FUSE This inline fuse is connected in the 15A line that runs between the Auto Off Manual switch and position 10 of the 76009 This fuse protects the start fuel field boost and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outputs Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators NOTE This fuse will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset If this fuse does open care fully check the wiring to the start fuel field boost and transfer outputs before replacing the fuse METER READING SELECTOR SWITCH This switch permits selection of either line to line or line to neutral voltage and amperage readings
52. c Power Systems Inc 5 Section 1 General Information Figure 1 6 Low Coolant Level Sensor 9 OVERSPEED SHUTDOWN The CMA circuit board on liquid cooled units receives AC frequency rpm signals directly from the stator AC power windings via sensing leads 515 and 16 Should AC frequency exceed about 72 Hz circuit board action will automatically shutdown the engine Figure 1 7 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 additional 1 for each 10 F above 60 F Maximum output power of the gen erator is limited by maximum engine power Figure 1 7 Control Module Assembly Circuit Board PO emp jf CO i Oe Ug pe 00003 1554 303 t 1 2 x a 5 Sl l fl i ii 1 P 22 an 32 aay REESE 5 Be aE b OVERCRANK SHUTDOWN After 90 seconds of crank rest cycles this function ends cranking if the engine fails to start in that 90 second span 6 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators DC FUSE This clearly labeled fuse is located on the front pane
53. d 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 A Battery electrolyte fluid is an extremely caustic 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 10 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators amp A 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 be toxic and harmful to the skin and eyes A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles VENTED BATTERIES caution amp The electrolyte is dilute sulfuric acid that is harmful to the skin and eyes It is electrically con ductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes fl
54. d cooled 15 kW 20 kW and 25 kW Generators PERIODIC REPLACEMENT PARTS 046627 059402 30 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Defective Battery Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective Auto Off Manual switch Open disconnected wire 15 between Auto Off Manual switch and Control Module circuit board 3 Defective Control Module circuit board gt Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open 18 Generac Power Systems Inc 0445310275 Generac s Part Number 0445310244 CORRECTION 1 2 3 4 9 Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Repl
55. dian 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 e Steel enclosures that are rusting due to t
56. e be done monthly Initials Break in Initials annually Initials Annually operating per the first page warning Check the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant thermal protection level Correct as necessary Check the natural gas delivery system on gas engine driven units Tighten connections as necessary Check the air inlets and fel f necessary Check the battery electrolyte level if accessible Adjust as necessary f fe cables and charger for loose connections corrosion and proper operation Correct as necessary Check the unit wiring for loose connections corrosion and damage Correct as necessary accessory drive belts for wear weather cracking and damage Replace as necessary Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary Test the engine and transfer switch safety devices Correct and or adjust as necessary eo Generac Power Systems Inc Task Comp Date Initials Maintenance Tasks 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
57. e These overcurrent protection devices will open if the circuit is overloaded caution amp If a circuit breaker opens or fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 4 2 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 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 Recommenations Figure 4 2 Oil Dipstick and Oil Fill Cap 9 BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separa tors DO NOT USE TAP WATER IN BATTERY ENGINE COOLANT Check coolant level in coolant recovery bottle See opecifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap 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 radiat
58. e current opens the load circuit breaker or collapses the genera tor field The actual result depends on the electrical characteristics of the particular installed generator TRANSFER SWITCH START SIGNAL CONNECTIONS If the generator is to be installed with an automatic transfer switch such as a Generac GTS type switch it will be necessary to connect the two wire start control system Connect the two wire start signal from the automatic transfer switch to the automatic start connection which is located in the right hand corner inside the control panel Match wires 178 and 183 in the transfer switch to 178 and 183 on the terminal strip in the control panel The conductors for the two wire start circuit must be in their own conduit BATTERY INSTALLATION A DIG A A Standby generators installed with automatic transfer switches will crank and start automatical ly when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to per sonnel 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 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 bat tery an
59. ectrical load circuits normally powered by a utility power source it is required by code to install a transfer switch The transfer switch must effectively iso late the electric system from the utility distribu tion 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 workers due to backfeed of electrical ener TRANSFER SWITCH This Guardian system includes a matched automatic transfer switch which is intended to be used in con junction with a Guardian generator It is supplied in either a NEMA 1 enclosure 15 kW models 004188 and 004189 and 20 kW models 004370 and 004371 or a NEMA 3R enclosure 25 kW models 004474 and 004475 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 of 1 phase power of 1 phase power of 1 phase power 25 kW 25 kW Install the transfer switch on a firm sturdy support ing structure To prevent switch distortion level the switch if neces sary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any corrosive substance might drip onto the enclosure Protect the switch at all times against excessive mois ture dust dirt lint construction grit and corrosi
60. enerator will be exercising NOTE If battery terminals are disconnected or control panel fuse is removed the exercise timer needs to be reset for correct automatic exercise operation Figure 3 2 Set Exercise Switch SET EXERCISE TIME ON FAULT AUTO INDICATOR De MANUAL Generac Power Systems Inc 13 MAINTENANCE Section 4 Maintenance ENGINE HEATER The Generac standby generator comes equipped with a block heater Figure 4 1 similar to the block heaters used in automotive applications The block heater is wired to a grounded plug Figure 4 1 Engine Block Heater Refer to applicable wiring diagram s and electrical schematic s at back of manual for wiring connections Customer supplies a 120V 15A Utility fed circuit for the block heater MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A EVERY THREE MONTHS 1 Check battery state of charge and condition 2 Inspect and test fuel system 3 Check transfer switch 4 Inspect exhaust system 5 Check engine ignition system 6 Check fan belts B ONCE EVERY SIX MONTHS l Test Engine Safety Devices low oil pressure low coolant level high coolant temperature C ONCE ANNUALLY 1 Test engine governor adjust or repair if needed 2 Clean inspect generator 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 15
61. enish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact an Authorized Generac facility Auto reset Wait 5 min and attempt restart Section 6 Scheduled Maintenance Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators MAINTENANCE 2 0 Following is a recommended maintenance schedule for Generac Guardian small standby and residential genera tor 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 mainte nance interval to determine 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
62. g 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 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 6 The following procedure should be followed for inspection MAINTENANCE 5 Section 4 Maintenance 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 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 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 bat tery 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 Battery electrolyte fluid is extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc
63. gnostic 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 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a
64. he 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 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 e 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 e 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
65. ight Observe battery polarity when connecting batteries to the generator set Note Damage will result if the battery connections are made in reverse Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators PREPARATION BEFORE START UP The instructions in this section assume that the stand by generator has been properly installed serviced test ed adjusted and otherwise prepared for use by a com petent 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 equipment PRIOR TO INITIAL START UP amp Prior to initially starting the generator it must properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quanti ties of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service inter vals please refer to Section 4 Maintenance gt Transfer Switch If this generator is used to supply power to any electri cal system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents electrical backfeed between two different e
66. is manual is not understood contact the nearest Generac Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and tags decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or oper ation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage warning After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety information that if not followed could endanger personal safet
67. is type of system 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 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equipment 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 generator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations Do not connect the ground wire to pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against elec trical shock in the event of a ground fault condition in the generator or in connected electrical devices In addi tion grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG Generac Power Systems Inc s INSTALLATION Section 2 Installation GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED 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 excessiv
68. l laws regulating the storage and handling of fuels Inspect the units 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 Diesel fuels are highly FLAMMABLE 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 Generac Power Systems Inc 3 Section 1 General Information GENERATOR This equipment is a liquid cooled engine driven gener ator set The generator is designed to supply electrical power that operates critical electrical loads during util ity power failure The unit has been factory 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 operation of 120 and or 240 volts single phase loads These models are available They are rated as follows Model 004188 Provides 15 000 watts 15 KW of 1 phase power Model 004189 Provides 15 000 watts 15 KW of 1 phase power Model 004370 Provides 20 000 watts 20 KW Model 004371 Provides 20 000 watts 20 kW Model 004474 Provides 25 000 watts 25 kW Model 004475 Provides 25 000 watts 25 kW of 1 phase power waRNING amp If this generator is used to power el
69. l of the control system It protects the panel wiring and com ponents from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating Generac normally uses an AGC fuse rated at 30 amps UNPACKING UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping collision etc Store and unpack cartons with the proper side up as noted on the shipping carton INSPECTION After unpacking 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 his signature under the consignor s memo of loss or damage LIFTING THE GENERATOR warninc A 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 SPECIFICATIONS GENERATOR SPECIFICATIONS 1 Phase 4474 4370 4188 4475 4371 4189 120 240 3600 3600 Model Rated Max Cont AC Power Output kW Rated voltage volts No of Rotor Poles Driven Speed of Rotor Rotor Excitation System Direct excited brush type 4 18
70. lectrical systems 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 compli ance with applicable codes standards and regulations gt Fuel System Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is permitted See Specifications for more information gt 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 NOTE This engine is shipped from the manufacturer with 15 40 oil This oil should be changed after 30 hours of operation OPERATION OD Section 3 Operation gt Engine Coolant Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications and Coolant 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 approx imately 22 pounds 10 kg applied midway between pulleys deflects the belt ab
71. loded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View CMA Assembly Drawing No 081086 D ITEM PARTNO 12 0A8504 1 0 8504 1 19 022661 083 14 038057 2 15 058443 2 16 081224 1 17 079682 1 18 086093 2 19 083736 1 20 051715 2 21 077401 1 SHOWN VU MM 18 PARTS 00 DESCRIPTION DECAL CMA LABEL DECAL CMA LABEL TUBING SHRINK 19 ID RED GROMMET 7 8 X 1 16 X 3 4 SCREW CRIMPTITE 1 4 20 X 5 8 DECAL MFG NAMEPLATE HARNESS CMA WIRE DECAL CMA WARNING DECAL CSA GTS NUT HEX M4 0 7 G8 YEL CHR COVER SILKSCREEN CMA Generac Power Systems Inc 43 PARTS O WD LISTS PART NO 077483 038804D 038805B 0742600131 022131 046526 052213 059567 078121 022145 022129 022259 050331A 050331 075763 Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Battery Drawing No 098922 E QTY 1 1 1 1 1 1 1 2 1 2 2 2 1 1 3 TO STARTER TO ENGINE BLOCK DESCRIPTION 12VDC 75 AH 26 26R CABLE RED 4 X 20 00 CABLE BLK 4 X 23 00 ASSY WIRE 16 RED 1 6 WASHER FLAT 3 8 ZINC WASHER LOCK M10 SCREW HHC M10 1 25 X 20 G8 8 BOLT BATTERY HOLD DOWN BAR BATTERY HOLDDOWN WASHER FLAT M8 5 16 ZINC WASHER LOCK 5 16 NUT HEX 5 16 18 STEEL BATTERY POST COVER RED BATTERY POSTCOVER BLACK B
72. n 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 Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi ble for dia
73. ome familiar with this Owner s Manual and with the unit The gener ator 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 utilized does not render the generator unsafe DIG A 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 A 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 Parts of the generator rotating and or hot during operation Exercise care near running gen erators e Generac Power Systems Inc operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians f
74. on the console AC voltmeter and AC ammeter SET EXERCISE TIME SWITCH This switch allows for programming the generator to start and exercise automatically Weekly Exercise Cycle MANUAL TRANSFER AND START UP To transfer electrical loads to the Standby generator power source side and start the engine manually refer to the Owner s Manual of the particular transfer switch 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 follows Verify that utility power supply voltage to the transfer switch has been positively turned Off using what ever means provided such as utility main line circuit breaker Set the generator s main circuit breaker to its Off or Open position Let the generator engine run at no load for a few min utes 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 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 AUTOMATIC OPERATION To set the system for fully automatic operation proceed as follows Check that load circuits
75. or 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 MAINTENANCE OWNER OPERATOR CAN PERFORM 9 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels CHECK BATTERY Check battery fluid level each week as outlined under Check Fluid Levels Check battery cables for condition tightness corro sion or damage Clean tighten or replace as necessary MAINTENANCE S Section 4 Maintenance EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See Weekly Exercise Cycle 5 COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels 9 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 fasten ers Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage CHECK FAN BELT Inspect fan belts every three
76. or 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 For safety reasons Generac recommends that this equipment be installed serviced and repaired by a Generac Authorized Service Dealer or other compe tent 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 regulations nstallation 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 gener ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations 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 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 ade quate ventilation must be provided Exhaust gases must be piped
77. out 3 8 to 5 8 inch 10 to 16 mm gt 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 prop erly installed and interconnected and ready for use 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 USING A STANDARD GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with a standard Generac GTS type automatic transfer switch When using a standard GTS type transfer switch it con trols automatic operation and automatic transfer as fol lows Solid state circuits in the transfer switch monitor util ity power source voltage When utility source voltage drops below a pre set level transfer switch action closes the circuit The engine then cranks and starts as controlled by the pre pack aged 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 When the utility power source voltage is restored above a pre set level transfer switch solid state cir cuits signal the switch main contacts to move back to
78. plies 60 Hertz at 1800 rpm Units with a 2 pole rotor supplies 60 Hz at 3600 rpm Frequency reading with no electrical loads connected no load condition should be between 60 62 Hertz DC VOLTMETER The generator is equipped with a belt driven DC alternator which maintains battery state of charge when the engine operates The Control Module Assembly also incorporates a trickle charge circuit which maintains battery state of charge during non operating periods Battery voltage should read about 12 5 to 14 5 volts DC A low battery voltage indicates the battery is discharging 12 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators HOURMETER Indicates time the engine generator has operated in hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for the genera tor set AUTO OFF MANUAL SWITCH Use this 3 position switch as follows Set the switch to Auto for fully automatic operation See Automatic Operation Set switch to Manual position to crank and start the generator engine Set switch to Off position to shut down an operat ing engine With Off selected operation will not be possible A A With switch set to auto engine crank start suddenly without warning Such automatic start up normally occurs when utility source volt age drops below a pre set level To prevent possi ble injury th
79. poten tial problem areas Performed monthly or following each 10 hours of operation of the unit and 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 control panel fuse Turn off the battery charger 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 or the first hours 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
80. rac Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs con tact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a Generac Authorized Service Dealer about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA CARD affixed to the unit AUTHORIZED SERVICE DEALER LOCATION To locate the GENERAC AUTHORIZED SERVICE DEALER nearest you please call this number 1 800 333 1322 OR Locate us on the web at WWW generac com Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators INTRODUCTION IFC SAFETY RULES 2 Section 1 GENERAL INFORMATION 4 1 Mr 58140 4 222001 0 S 4 Automatic System Operation 4 Generator AC Connection Systems 4 Main Circuit Breaker 5 Generator Fuel System 5 Engine Protective Devices 5 il ii 6 dpi 6
81. rom the factory The breaker for each unit is described in Figure 1 2 at the top of page 5 GENERATOR FUEL SYSTEM This unit has been factory tested and adjusted using a natural gas fuel system If propane LP gas is preferred contact an authorized service dealer Section 1 General Information Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Figure 1 2 Main Circuit Breaker GENERAL INFORMATION Model Rating Phase Actual Current C B Rating 2o over rating Circuit Breaker 004188 15 000 1 62 5 7O 112 70 2 004189 15 000 1 62 5 70 112 70 2 004370 20 000 1 83 3 90 108 90A 2 004371 20 000 1 83 3 90 108 90A 2 004474 25 000 1 104 2 125 120 125 2 004475 25 000 1 104 2 125 120 125 2 Amp Rating of C B structured under model wanNiNG 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 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 Figure 1 3 Engine Protective Devices HIGH C
82. safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict compliance with applicable codes and standards 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 ventilat ing air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and unclut tered Remove any materials that could become haz ardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Important Safety Instructions SAFETY RULES Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Before performing any maintenance on the generator disconnect 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 Never use the generator or any of its parts
83. t ZA UA 2 CA Z ZA Z 2 227 27 2 2 M e 2722 C gt gt Eu CAA C 2 MO Op 6 X 2202 220 2272 2 A Cu A 2 ZZ p P di Sy ZA x lt C 7 SS CA ZA 29722 C Qul C CA SS CD 260 CLA lt lt CZ N SS 0729 UC gU N RN X 42 gt S AE 6 SSO CZ a 0727 y Quum C p d s a N l ES Te NN A d DESCRIPTION MUFFLER W RAIN SHLD MUFFLR STRAP 6IN DIA ELBOW 90 DEG 2 NPT NIPPLE TOE 2 NPT X 4 5 BLK IRON RAIN 2 37 PIPE FLEX EXHAUST BOLT U 5 16 18 X 2 09 NUT HEX 5 16 18 STEEL WASHER LOCK 8 5 16 SADDLE 2 INCH CHANNEL MUFFLER SUPPORT SCREW HHC 8 1 25 X 20 G8 8 NUT HEX M8 1 25 G8 YEL CHR GUARD MUFFLER 1 5L SCREW SW 1 4 20 X 5 8 N WA JS500 40 Generac Power Systems Inc CON O 11 12 13 14 PART NO 0A4355 0C1636 036434 036449 0C1330 0C1318 0C1068 0C1412 0A5728 060366 066889 022145 022129 045771 0A8974 QTY a A B A D B BR Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View 25 kW Drawing No 0C1408 B DESCRIPTION MANIFOLD EXHAUST 1 5L NIPPLE TOE 1 5 NPT X 6 5 BL IRON BOLT 5 16 18 X 2 09 SADDLE 2 INCH PIPE EXHAUST FLEX PIPE EXHAUST SUPPORT MUFFLER 1 5L ELBOW
84. their utility power source side Following re transfer back to the utility power source side transfer switch circuit board action opens the circuit Engine then shuts down NOTE If the generator is installed in conjunction with a standard GTS type transfer switch refer to the appli cable transfer switch manual for exact operating parameters and timing sequences Generac Power Systems Inc 11 OPERATION OD CONTROL CONSOLE COMPONENTS The components of a liquid cooled generator control console Figure 3 1 are as follows Section 3 Operation Figure 3 1 Liquid Cooled Generator Panel AC AC AMMETER VOLTMETER AC FREQUENCY METER DC VOLTMETER HOURMETER SET EL EXERCISE M TIME FAULT FUSE OFF METER READING SWITCH Pas 3 SELECTOR SWITCH AUTO OFF MANUAL 30 SWITCH LAMP FUSE VOLTMETER The voltmeter displays generator AC output voltage dur ing operation Voltage is regulated by a solid state volt age regulator and is proportional to AC frequency Refer to the units DATA PLATE for rated AC voltage AC AMMETER Indicated current draw of connected electrical loads during operation DO NOT EXCEED THE UNIT S RATED MAXIMUM CONTINUOUS CURRENT Refer to the unit DATA PLATE FREQUENCY METER Indicates generator AC output frequency in Hertz cycles per second Frequency is proportional to engine speed Units with a 4 pole rotor sup
85. ther your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 555 1522 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 Limited Warranties for Generac Power Systems Inc 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 impor tant rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility 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 55190 Part 1 56 Generac Power Systems Inc Section 10 Warranty Guardian
86. tion 8 Exploded Views and Parts 0 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 0 Exploded View Radiator 25 kW Drawing 0C1406 C N y DS a O gt G N a 0 N o S gt 22 O a c N A amp 2 2 g p a Nee y lt O 2 adapter 29 A To base of water inlet 36 Generac Power Systems Inc Section 8 Exploded Views Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Radiator 25 kW Drawing No 0C1406 C PART NO QTY DESCRIPTION 0A5734 1 RADIATOR 1 5L 0A6237 1 VENTURI 1 5L 0A6238 1 GUARD 084918 1 HEATER 500W 1020 050967 12 HOSE RES 5 8 RIA 250F 057823 4 CLAMP HOSE 10 56 1 06 099502 4 CLAMP HOSE 24 1 06 2 00 083709 2 CLAMP WIRE HOSE 573 551 042568 6 SCREW M6 1 0 X 20 68 8 022097 11 WASHER LOCK M6 1 4 049813 2 NUT HEX M6 1 0 G8 YEL CHR 022473 7 WASHER FLAT M6 1 4 ZINC 084427 1 BRACKET HEATER 050967 18 HOSE RES 5 8 RIA 250F 075443 6 CRMPTIT 1 4 20 X 5 8 056892 4 CRMPTIT 10 24 X 3 8 0A6284 1 HOSE LOWER RADIATOR 0A6258 1 HOSE UPPER RADIATOR 029032 1 HOSE 9 32 ID 022127 1 NUT HEX 1 4 20 STEEL 022145 8 WASHER FLAT 5 16 ZINC 022129 8 WASHER LOCK 8 5 16
87. ture Above 80 F 27 C Oil Grade Recommended SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 32 to 80 F 1 to 27 C Below 32 F 0 C caution Any attempt to crank or start the engine before it has been properly serviced with the recommend ed oil may result in an engine failure COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and half soft water Cooling system capacity is about 8 U S quarts 7 6 liters Use only soft water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mix ture When adding coolant always add the recommend ed 50 50 mixture amp Do not use chromate base rust inhibitor with ethylene glycol base anti freeze or chromiumhy droxide green slime forms and will cause over heating 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 additives will also cause overheating DO NOT use any soluble oil inhibitor for this equipment 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 the installation manual Part No 079699 The generator s rated watt
88. ualified 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 regulations per taining to the installation caution amp After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regulations NOTE For more information about the installation of a stand by system order Engine Generator Standby Electric Power Systems Installer s Guide and Reference Manual part 046622 from the Generac Authorized Service Dealer STANDARDS The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 8 Generac Power Systems Inc 9 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following informa
89. ush thoroughly and immediately with water and seek medical atten tion and e 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 bicarbonate 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 following proce dure are to be followed DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area and Discharge static electricity from body before touching batteries by first touching a grounded metal surface Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries For recommended batteries see Specifications batteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not neces sary to check the specific gravity or electrolyte level Have these procedures performed at the intervals spec ified in Section 4 Maintenance A negative ground sys tem is used Battery connections are shown on the wiring diagrams Make sure all batteries are correctly connected and terminals are t
90. ut down the source of electrical power If this is not possible 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 Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS 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 insulation 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 Z Properly ventilate any room or building housing the generator to prevent build up of explosive gas 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 sev eral types of fuels fuel types are potentially FLAM MABLE and or EXPLOSIVE and should be handled with care Comply with al
91. ve vapors Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators AUTOMATIC SYSTEM OPERATION When this generator along with its 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 preset 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 When utility source voltage has been restored the switch re transfers back to the utility source voltage and the generator then shuts down GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its sta tor 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 volts AC 60 Hertz When the two windings are connected in series a 240 volts 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 Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped f
92. xploded Views and Parts Qi Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Mounting Base 25 kW Drawing No 0C1405 A 0 8 MOUNTING BRACKET DESCRIPTION BASE MOUNTING DAMPENER VIBRATION DAMPENER VIBRATION SCREW HHC 8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR WASHER FLAT M8 SCREW HHC 8 1 25 X 60 G8 8 SCREW HHC 8 1 25 X 40 G8 8 EARTH STRAP WASHER SHAKEPROOF EXT 5 16 STL PLUG BUTTON 2 DIA Generac Power Systems Inc PARTS ITEM CONDOR co 10 11 12 13 14 15 OG LISTS PART NO 020689 060366 059933 080761 059939 075546A 036434 022259 022129 036449 076032 039253 045771 003683 0 7215 Section 8 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Exploded View Muffler 15 amp 20 kW Drawing No 0A7618 B QTY B A a O PO Jet 2 ge 2 Pd CA 2 27 27 CA 226 222 7 me EZ EZ AEF 2 C 2 C2 27 A C 27 28722 LD 7 2272 a 2 ZA 292 272 Br dd f f V U Hu 7 20 L 02722 ps NY po CZ C C Pl p 2 FZ CZ Pd ZA 29 27 lt 273 2 272 CT lt 20 620 22 272 072 22 ZA 6772 4 fs P P g
93. y and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment We strongly recommend that the opera tor read this Owner s Manual and thoroughly under stand all instructions before using this equipment We also strongly recommend instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe oper ation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or work manship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See a Generac Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by a Gene

Generac Power Systems 004188-1 Portable Generator User Manual

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