Home

Generac 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726

1.
2. Pd esse NOLLO3NNOO HOLIMS HASSNVYL OVHANSO HLAS M3HOS ONILNNOW ZSL HIIS HAL HONA Jed HOJ ate 51 0 1 1 N ISL Q dH d T FI ego n 681 ZEIN Be J 81 c9L ZN V VIN yov1g G oil ez ro a Fo gt 00 in 9 c 76 A de ls 2 M 915 vl L r
3. ONISN3S ALITLLO YSINYOSSNVHL HL SL 9504 d ESL NOILOANNOO HOLIMS 3SIOH3X3 135 ZMS NOLLO3NNOO 3NION3 29 JjsvHd L AOvz Oc L HOLIMS H3dJSNVuH L HOLIMS IWANVW SSO OLNV LMS ONIGNIM NOLLV LIOX3 P jovMOVvdaHd A18N3SSV NOISSSYdNS VS SHaMVaua Z199 NOILOANNOO HAWOLSNO Mov19 MoOv18 YHATIOYLNOO Quvoa HOLIOVdVO L HaldWHOH WH HOIVIS HOLVNHSLIV SV 23 00 i3 ZN N LINN IOH ILINOO HONHSAOD NOD HOLOH HOLVNYSLIV HV VIN Z ZN ZL IL gol e ad QN3931 MOV Ig S c vac Ovid LHL MOV1d ami HOLVNLOV nao 31VNH311V qum AOS MOTISA t OL 395NVHO GASNNN ALVINSNI MOTISA 4 SWALSAS 71 1 802 SHIM MOTISA 2 915 SIN31SAS 1 1 HOS 3HIM 3019 SSN a z Pi 8 T MUS 220 e NOILOANNOO HOLIMS NJ c 435 OVH3N39 SV QquvaNv s 19 15 l 3HIM Z 0 esl LL xs NY a E MC JURA B i cgo VERE agy eL l SIS 95 581 915 ama SL vi 9 4 Vv lt 9 BAR ez ez 9 v v v6L 761 0 T S RSIS 4 os 9 944 3 99 9 ee ero LO sh 291 291 ZL 2 HA uv 7 as 04 6 H Gd S Z amp 0 um r g t 14 SL
4. 1 SINJALSVdNWUO m CI3AUN3S NUDO HLIM NMOHS gt 03 S3HIV3M NUTU 90 6 LdN N UILO3NND2 311549 5 DNT 052 d I NJ SVO WANLYN ONIGNAID39 7 OS 4 il O T Q 8g fi too ee T T 1 11 Hn n ep a 55 u mp 50 S i Li s Kx gt SSS 5 ESS EE 4 SSS 5 Ol Em SF vo E c Oz ze SSF S SH p c 2 lt L cT 9 un 2 V lt lt 4 y p3 rTIOI lt KI 7 p wasa a OS N s E 37 4 7 5 A gt c T WV Zs SSS 7 c 2 SE s L m lt 5 ddh amp P c il i I 2027 m mammam G 3103 N E e N lt V 999 SS322V MOLVviava 1 8862 E P _ 654 rd KATA do 2 dAL Lyle 9v6 zi P dAl ag secum S34d 9 1371100 3313308 00 137105 L1SQVHX3 pe 47 6 08 DNI 19109 LdN v 1i NIVAl EL 33S L0c 90 CI LCE DNI Id LdN SVO JIYANLYN LIINI
5. G 68 1 WDdVA d L31NI bh E M 00 Po T LLULLU LLULLU ENTEN G aa o SNOILOSNNOO 32IAS83S 3NISN3 O S3HONI J Mw SIIND dA 4 Leg rg 591 098 06 INR 219 ot LAAT VIVI IHDI3A Toc re UU UJ JUL UJ UJ D 3 2 0481 Ivg Jn 349344 1109919 3NIT NIVW lt UE Ze 8 Bi nDHLIM TWNOILdO SLINR js LNJALSVdWUO GAVONVLS 1SnvHX3 X314 9 199 8 X 8 9 O22 X 291 SNUISNJAIG SCISNI AVAL AS3LIVG 31 GNNOSS 3AILIV93 OA eI C3NVd TOASLNOO NI G3GIADSNd S3SMIM TWALNOO dD1S 18V1S 1 YJyy OILVWDLOV 3NION3 NV 80937 907 99 90 SINIOd NOILOSNNOO i dn 8nls NUILO3NNUO 2v AO2I S3MIQO3N3 N31V3H 2018 GNV NVIS LSc01 LZTYl L 60 2 el 901 ININdLOO4 3SV8 0951 HOLIMS TWANVW SSO OLNV LMS SZ 3NFINI 3SnH 19 YOLVINDAY 39V L1OA HA AlHWassv NOISSAYdNS VS 5 SI ISNA d SOd ZdlH1S 1VNIIWH3L ESL Quvos LIn2HIO MOVd 3Hd 89d NOILOANNOO dNIDN3 93 SOd dlH1S TVNIIAH3 L ZSL 39018 WHLNAN 292 SOd OZ dINLS TVNINYSL ISL H3 L3WN YNOH WH Haxvaua LINOUYIO 182 ONISN3S ALNILN HINHJSNHIL HL YATIOULNOD HONHSAOD N99 HOLIOVdVO dvo HOLIMS 3SIOH3X3 13S ZMS L1nv4 14 HOLVIS HOLVNH3ITV SV aua9qa1 ONIHV38 OL 1535019 HSf1H8
6. 2 11 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications Section 1 10 and Coolant Section 1 15 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged 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 12 Generac Power Systems Inc 3 1 USING A STANDARD GTS TRANSFER SWITCH When required the pre packaged standby generator can be installed with a standard Generac GTS type engineered automatic transfer switch When a GTS type transfer switch is used it controls automatic operation and automatic transfer as fol lows Solid state circuits in the transfer switch monitor utility power source voltage When utility source voltage drops below a pre set level transfer switch action closes the circuit The
7. INSTALLATION 25 Generac Power Systems Inc
8. 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Scheduled Maintenance Section 4 7 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 4 Figure 4 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 5 0 6 mm 0 020 0 025 inch 26 P ze 7 CAST aS SN 4 5 15 COOLANT CHANGE Every year have Authorized Service Facility drain flush and refill the cooling system See SPECIFICA TIONS Section 1 10 for cooling system recommen dations MAINTENANCE 5 Section 4 Maintenance 4 6 MISCELLANEOUS MAINTENANCE 4 6 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or spon
9. GUARDIAN by Generac Power Systems Inc Owner s Manual Liquid cooled Prepackaged Standby Generators Model Numbers 004721 0 004722 0 004723 0 004724 0 004725 0 004725 1 004725 2 004725 3 004726 0 LLL eee ee Leet N x X A Not intended for use in critical life support applications Ak ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit INTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac Power Systems Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ ten 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 this manual is not understood con tact the nearest Generac Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their defi nitions are
10. a NA s Ig 922 LMS 841 ezz 99 0 WSL p 0 I ost H BA 652 98 03 ON ost Liou 8 6 94 091 662 Sg S8 9 Od v Y VS wv 8 03 23 BF NOILISOd 440 vet eL 99 99 e 1 09 NI NMOHS vi yovga 0 21 09 0 WH vL vL e rL 11 29 581 01 23 L L 6203 J 91 151 dvo ee Generac Power Systems Inc CONTROL PANEL TO CONTROL PANEL TO DC VOLTAGE REGULATOR GOVERNOR CONTROL UNIT TERMINAL STRIP TO 120V 15A UTILITY FED CIRCUIT Section 8 Electrical Data Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ELECTRICAL Electrical Schematic 1 5L Drawing No 0A7182 B DATA WTS ce 12V BATTERY RED 4 BLACK LEGEND EH CONTROL CONTACTOR ACTUATOR CONNECTOR GOVERNOR ACTUATOR 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 Generac Power Systems Inc 29 PARTS qp is 00 Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Governor Assembly Drawing No 0E1331 B 4 ITEM 13 NEOPRENE COATING 6 14 7 WIRE HARNESS 15 SECURE WIRE HARNESS P d WITH TIE WRAP AS SHOWN 7 16 LY amp 17 TO A
11. Generac cannot possibly anticipate every possible cirumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a pro cedure work method or operating technique that Generac does not specifically recommend satisfy your self that it is safe for others Also make sure the proce dure work method or operating technique chosen does not render the generator unsafe 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 are rotating and or hot during operation Exercise care near running gen erators 2 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 for this equipment SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries A GENERAL HAZARDS For safety reasons Genera
12. 2 1 Standby Generator Installation 8 2 4 Generator LoCAOUOD uuu aus ss 9 2 3 Generator Mounting and Support 9 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 TABLE OF CONTENTS Table of Contents Section 3 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 12 3 9 Manual Transfer and Startup 13 3 4 Automatic Operation 13 3 5 Weekly Exercise Cycle 13 20 Bed eee eee 14 Section 4 MAINTENANCE 14 4 1 Maintenance Performed by Authorized service Facilities 14 4 2 Cooling System 15 4 3 Overload Protection for Engine DC Electrical System 15 4 4 Checking Fluid Levels 15 4 5 Maintenance Owner Op
13. 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 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
14. Mow 8 L qat oF 915 rl eL 0 ove ama ex ce el E LHL 31vVNH3LTV n 0 8 1 918 681 B uy z 0 0 N bo ec 50 19 tHL B 00 OL 8 1 Noa O O v vr da dau 2 00 OL 19 p LL 0 MOTT3A 915 l 21 YL ama e Ove Z30113 ldo 915 915 0 ama vi 0 QN SIS vi a O ASVHd L AOvrc OcL SL Y NOLLO3NNOO LAdLNO B v v S gt 5 EL 4 lu e EN 58 9 99 got SL e lo L ld wu UW 0 l O qaq sei 961 VSL U MOV IH vScc 5 an OLNY gz LL fa 440 bo ama ost vst H co 6 581 Y g LMS 9 1 1 15 5 a yovia ee no 73 62 ama 581 90 8 1 ict MOTI3A e 652 UIS 3ONVHO a a 915 8 1 A HO LWNLOW die e os 1 PP ais 719 091 ama YONYSAOD OL LL 0 8 1 ez 291 O N acne 652 95 SIS SL 8L ZL 9L SL vL L OLO 8 2 9 S v EC 9 S r C ama 92413 9 NS anig 62c S YA v dod 1 915 SIS ELECTRICAL DATA lt ee Generac Power Systems Inc Section 8 Electrical Data Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ie i ELECTRICAL Wiring Diagram 1 5L Engine Drawing No 0 0343 0 01 WLS WTS FS 48 0 49 13 14 T 15 14 13 m lt 4 fn 16 85 13 7 5
15. No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John otreet New York N Y 10038 AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 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 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air always is available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit INSTALLATION Hh Section 2 Installation Install the generator on high ground where water l
16. 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 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS 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 as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All generators covered by this manual produce dan
17. 1 5 liters Cylinder 4 in line Valve Overhead Cam Firing Order eese 1 3 4 2 Number of Main Bearings eene 5 Compression Ratio l a 9 to 1 No of Teeth on Flywheel enne 104 Ignition Timing at 1800 rpm 35 degrees BTDC at 3600 rpm 43 degrees BTDC Spark Plug Gap sees 0 020 0 025 inch Recommended Spark Plugs Champion esses RN11YC4 Oil Pressure 30 50 psi Crankcase Oil 3 0 U S quarts 2 8 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery Cooling Fan essen Pusher Type Cooling System Capacity 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base 1 11 FUEL CONSUMPTION 25 kW Models Using Natural Gas 441 cu ft per hour Using LP Gas 175 cubic ft 4 8 gal per hour 20 kW Models Using Natural Gas 359 cu f
18. 2 CHECK BATTERY Check battery fluid level each week as outlined under Check Fluid Levels Check battery cables for condition tightness cor rosion or damage Clean tighten or replace as necessary 4 5 3 EXERCISE SYSTEM otart the generator engine at least once every seven days and let it run at least 20 minutes See Section 3 5 Weekly Exercise Cycle Generac Power Systems Inc 1 5 OPERATION Section 4 Maintenance J gt Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 4 5 4 INSPECT 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 4 5 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels in Section 4 4 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coolant leaks 4 5 7 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 4 5 8 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway bet
19. DEG GASKET INLET MANIFOLD MANIFOLD INTAKE MACHINED ASSY WATER LEVEL SENSOR C E PL SW TMP 245 DEG 3 8 NPT BARBED EL 90 3 8 NPT X 5 8 PLUG STD PIPE 3 8 STEEL SQ HD Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Engine Drawing No 0E1228 E PART NO 061012 039253 0A5110 0A7006 025507 022500B 0A8584 036277 042574 026073A 0A6701 039414 0A5568 051769 0A4804 0A4804A 0A4800 0A4800A 0A5839 0A1354B 0A4839 055816 049811 0E1936 0A2628 0A5275 0A5586 0A4814 0445310244 0C1852 0912970066 070928 069860C 069811 075443 po Ba cl cl cl cl PARTS qea OG DESCRIPTION PLUG STD PIPE 1 8 SCKT HD SCREW HHC 8 1 25 X 20 G8 8 PIPE WATER INLET O RING 1 1 16 X 1 5 16 X 1 8 WASHER SHAKEPROOF EXT 7 16 SIL SPACER 41 X 75 X 25 ST ZNC SWITCH OIL PRESSURE ELBOW 90D STREET 1 8 ADAPTOR 1 8 NPTF 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 BUILT PRIOR TO 11 20 02 PULLEY CRANKSHAFT 1800 RPM BUILT AFTER 11 20 02 PULLEY CRANKSHAFT 3600 RPM BUILT PRIOR TO 11 20 02 PULLEY CRANKSHAFT 3600 RPM BUILT AFTER 11 20 02 BRACKET ALT SUPPRT DC ALTERNATOR 12V ARM ADJUST ALTERNATOR SCREW HHC M6 1 0 X 70 G8 8 WASHER FLAT M6 F
20. 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 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 49 Section 10 Warranty WARRANTY Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators GENERAC POWER SYSTEMS STANDARD TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection a
21. 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 EARTH STRAP PANEL SUPPORT PANEL BRACKET SCREW TH FRM M6 1 X 16 N WA Z JS SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC LUG SLDLSS 2 8 X 17 64 CU NUT HEX M6 X 1 0 G8 YEL CHR WASHER SHAKEPROOF EXT 1 4 STL 1 1 2 BUTTON PLUG Generac Power Systems Inc 31 LISTS ace Section 9 Exploded Views and Parts gt Guardian Liquid cooled 15 kW and 20 kW Generators Standard Compartment Drawing No 0E0771 D PANEL FOR ACCESS COVER CABLE WELD STUD UNDER ROOF FASTENER TO SECURE USE DOOR LATCH GROUND WIRE USE LOCTITE ON NUTS ITEM 26 21 WAWA 1 4 x AN i NUN ANA i i x ARN AN A NANA YAY WAY AYA YY AAA ANNA A EN MS Ah LAC M 32 Generac Power Systems Inc CONDOR N 008666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 051716 022152 0912970064 023762 0912970063 022264 067035 022127 0C2634A 022473 022097 0D2023 0C2164 037337 0D2023 0D8664A 0D8664B Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW and 20 kW Generators Standard Compartment Drawing No 0E0771 D DESCRIPTION ROOF ACSTC amp STND CMPRTMNT 1 5L DUC
22. GAS L P V 12 029032 1 HOSE 9 32 ID 6 5 13 0A5547 1 COVER AIR CLEANER 14 048031C 4 CLAMP HOSE BAND 1 4 15 0D1509 1 DECAL INLET PRESSURE 16 0 0591 1 ADAPTER CARB TO AIR CLNR 17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 1 4 20 NYLK 19 0E1028 1 CARBURETOR ASSY 1 5L 20 059401 1 CARBURETOR GASKET 21 091526 4 SCREW 5 0 8 X 12 ZNC 22 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0D8492Q 1 DECAL EMISSION CTRL 1 5 NG 2004 10 15KW NATURAL GAS 0D8492R 1 DECAL EMISSION CTRL 1 5 LP 2004 10 15KW LP VAPOR UNITS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0 0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0 0590 1 VENTURI 18MM 33 005133 1 O RING 29 82 X 2 62 34 0 0665 1 SCREW THROTTLE PIN STOP 35 0 1108 1 THROTTLE ARM REWORK 36 033138 1 SCREW HHM 10 32 X 5 8 37 022152 1 WASHER LOCK 10 38 0 0645 1 LEVER THROTTLE STOP 39 063463A 1 BARBED STR 3 8NPT X 1 2 WWS 40 0E1558 1 HOSE LPG amp NAT GAS 1 2 ID 23 LG 41 057823 2 CLAMP HOSE 10 56 1 06 42 0E1111 1 PLATE GAS REGULATOR MOUNTING 43 042907 2 SCREW HHC 8 1 25 X 16 G8 8 44 0C2454 2 SCREW TH FRM M6 1 X 16 N WA Z JS PARTS ib ues OG gt SHOWN IN OTHER VIEW INCLUDED IN ITEM 19 CARBURETOR ASY Generac Power Systems Inc 43 CG Sectio
23. If propane LP requirements gas is preferred contact an authorized service dealer Refer to Secion 1 12 Section 1 General Information Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators GENERAL INFORMATION Figure 1 2 Main Circuit Breaker Model Rating Phase Actual Current 004721 004722 15 000 1 62 5 004723 004724 20 000 1 83 3 004725 004726 25 000 1 104 2 C B Rating over rating Circuit Breaker 7O 112 70A BQ2 90 108 90A BQ2 125 120 125A BQ2 Amp Rating of CB structured under model Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas and at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel being used Fuel pressure for both natural gas and liquid propane set ups should be 11 inches to 14 inches of water column 0 6 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure 11 14 to the gen erator Low gas pressure can cause hard starting and could affect engine durability waRnNING amp 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 1 7 ENGINE PROTECTIVE DEVICES The engi
24. Retorque intake and exhaust manifold See Torque Specs Section 1 13 3 Check engine compression 4 Check valve clearance Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 4 2 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See Section 7 for installation drawings and vent locations waRNING amp 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 4 5 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution amp If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 4 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 1 at le
25. always supply the complete model number of the unit as given on the front cover of this manual or on the DATA LABEL affixed to the unit AUTHORIZED SERVICE DEALER LOCATION locate the nearest GENERAC AUTHORIZED SERVICE DEALER 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 ALOR E 4 12 Transfer SWIICh 4 1 3 Automatic System Operation 4 1 4 Generator AC Connection Systems 4 15 Main Circuit Breaker 4 1 6 Generator Fuel System 4 1 7 Engine Protective Devices 5 LO 6 1 9 Lifting the Generator 6 1 10 Specifications 7 1 11 Fuel Consumption 1 12 Reconfiguring the Fuel System 7 1 13 Torque Specifications 8 1 14 Engine Oil Recommendations 8 1 15 Coolant Recommendations 8 1 16 Before Installation 8 Section 2 INSTALLATION 8
26. amp 1 4 S 9 L d 6 y amu OO N INTAKE MANIFOLD A CARBURETOR ARM REF REF e I ORS dil a ITEM PART NO QTY DESCRIPTION 1 098290 I ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A REF CONNECTOR INTERFACE ASSEMBLY 4 098942A COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM 2 X 5 8 SELF TAP 6 043146 3 SCREW HHC M6 1 0 X 10 G8 8 7 022097 5 WASHER LOCK 6 1 4 8 084543A I SCREW PHM M3 0 5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 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 17 064526 I SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH Generac Power Systems Inc CONDOR WY PART NO 0D8656 027482 070936 070936C 039253 022145 022129 045771 071956 051730 021991 0D9335 0D9336 002454 047411 022097 022473 055414 049813 026850 0A1694 QTY 1 2 2 2 8 12 16 4 4 4 1 2 2 16 1 1 1 1 5 1 2 Section 9 Exploded Views and Parts PARTS Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators a LISTS Mounting Base Drawing No 0E0768 B 0 DESCRIPTION BASE MOUNTING 1 5L STNRD amp ACSTC WASHER SHAKEPROOF EXT 5 16 STL DAMPENER VIBRATION VIB ISO 70 75 DURO SCREW HHC 8 1 25 20 G8 8 WASHER
27. connected in the 15A line that runs between the Auto Off Manual switch and position 10 of the 76009A PCB 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 NOTE This fuse will not remove the positive battery input power from the PCB when it opens This means the exercise timer will not be reset If this fuse does open carefully check the wiring to the start fuel field boost and transfer outputs before replacing the fuse 5 2 6 SET EXERCISE TIME SWITCH This switch allows for programming the generator to start and exercise automatically See Weekly Exercise Cycle Section 3 5 3 5 MANUAL TRANSFER AND START UP To transfer electrical loads to the STANDBY GEN ERATOR power source side and start the engine manually refer to the Owner s Manual of the particu lar transfer switch 3 4 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed as follows Check that load circuits are connected to the utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 5 5 WEEKLY EXERCISE CYCLE The generator will start and exercise once every seven 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 exe
28. engine then cranks and starts as controlled by the pre packaged generator s Control Module circuit board After the engine starts and when the generator AC output voltage and frequency have reached a pre set value transfer switch circuits signal the transfer switch main contacts to actuate to the STANDBY power source side Generator AC out put then powers load circuits When the utility power source voltage is restored above a pre set level transfer switch solid state circuits signal the switch main contacts to move back to 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 applicable transfer switch manual for exact oper ating parameters and timing sequences 3 2 CONTROL CONSOLE COMPONENTS The components of a liquid cooled generator control console Figure 3 1 are as follows Figure 3 1 Liquid Cooled Generator Panel FUSE FAULT Q HOUR METER AUTO SET OFF EXERCISE MANUAL by Generac Power Systems Inc OPERATION Section 3 Operation Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators J gt 3 2 1 HOURMETER Indicates time the engine generator has operated in hours and tenths of hours Use the
29. the block heaters used in automotive applications The block heater is wired to a grounded plug Figure 3 3 Engine Block Heater 14 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Refer to applicable wiring diagram s and electrical schematic s at back of manual for wiring connec tions Customer supplies a 120V 15 Utility fed cir cuit for the block heater 4 1 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 1 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 l Change engine oil and oil filter After initial change service engine oil and filter at 150 oper ating hours or six months whichever comes first 2 Retorque cylinder head See Torque Specs section 1 13 3 Retorque intake and exhaust manifold See Torque Specs Section 1 13 E EVERY 500 OPERATING HOURS Service air cleaner 2 Check starter 3 Check engine DC alternator F EVERY 800 OPERATING HOURS l Retorque cylinder head See Torque Specs Section 1 13 2
30. 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas RE AES Figure 1 8 Reconfigure the Fuel System Port 1 Port 2 e FUEL HOSE FUEL HOSE E BRASS HOSE BRASS HOSE FITTING FITTING A A I Jj NG FUEL SYSTEM LP FUEL SYSTEM Generac Power Systems Inc 7 INSTALLATION Im Section 2 Installation NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for simultaneous fuels has been made DIG A Serious injury or damage may occur if not con figured properly Please consult an authorized Generac Service Dealer with any questions 1 13 TORQUE SPECIFICATIONS Cylinder 15 90 90 ft lb Intake Manifold eenn n 13 Exhaust Manifold eene 13 ft lb 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For oervice CC SD SE SE Detergent oils keep the engine cleaner and reduce carbon deposits Use oi
31. 3 1 ogy V V oL DE dO OW 5 s 8250 A 3 1 75 PCB OPERATION LED S LED 1 is RED The LED is on when utility sensing is NOT available to the circuit board This LED will function only when the Auto Off Manual switch is set in the Auto position 6 Generac Power Systems Inc Section 1 General Information Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators LED 2 is YELLOW This LED is on when the circuit board battery charger is on This LED will cycle on and off with the battery charger 4 85 hours on the 4 85 hours off LED 3 is GREEN This LED will flash when the cir cuit board has load voltage available to it This LED will function when voltage is available across T1 and T2 1 76 OVERCRANK SHUTDOWN After 90 seconds of crank rest cycles this function ends cranking if the engine fails to start in that 90 second span 1 76 DC FUSE This clearly labeled fuse is located on the front panel of the control system It protects the panel wiring and components 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
32. 4 Maintenance Generac Power Systems Inc 11 OPERATION Section 3 Operation J gt Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any elec trical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 2 11 3 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 Section 1 10 for more information 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications Section 1 10 and Engine Oil Recommendations Section 1 14 NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation
33. 51716 022152 0912970064 023762 0912970063 022264 067035 078115 0C2634A 022473 022097 022127 0D8663 0D8665 0 00720 0 0072 0E0072Q 0E0072C 0 0072 0 0072 0 0072 OE0072L OE0072N 0E0072G 0E0072J OE0072F 0 0072 0 0072 OE0072H 0D2023 0C2164 037337 0D8664A 0D8664B QTY Section 9 Exploded Views and Parts Guardian Liquid cooled 25 kW Generators Acoustic Compartment Drawing No 0E0772 E DESCRIPTION ROOF ACSTC amp STND CMPRTMNT 1 5L DUCT CENTER 1 5L SUPPORT RADIATOR 1 5L MITSU BRACE SIDE 1 5L MITSU DOOR WELDMENT 1 5 EPS CORNER POST REAR RH SIDE 1 5L DOOR REAR COMPARTMENT 1 5L BRACE REAR 1 5L MITSU CORNER POST REAR LH SIDE 1 5L LATCH amp CAM SCREW TH FRM M6 1 X 16 N WA Z JS SCREW PHM 10 32 X 5 8 ZINC NUT HEX 5 0 8 G8 YEL CHR WASHER LOCK 10 ASSEMBLY BASE DOOR GROUND WIRE WASHER SHAKEPROOF EXT 10 STL GRD WIRE ASS Y 99HSB WASHER LOCK 8 4 SCREW PPHM 8 32 X 5 16 WASHER SELF LOCKING DOME ASSEMBLY COVER ACCESS WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL BAFFLE CNTRL PNL 1 5L ACOUSTIC BAFFLE DOOR 1 5L ACOUSTIC UNIT ACSTC INSLTN 1 5L DUCT RH PNL ACSTC INSLTN 1 5L DUCT LH PNL ACSTC INSLTN 1 5L RAD SUPPORT ACSTC INSLTN 1 5L DUCT FNT PNL ACSTC INSLTN 1 5L ROOF PANEL ACSTC INSLTN 1 5L SIDE DR PNL ACSTC INSLTN 1 5L SIDE DR PNL ACSTC INSLTN 1 5L SIDE BRC PNL ACSTC INSLTN 1 5L DR BAFFLE PL ACSTC INSLTN 1 5L RR CRNR TOP ACSTC INSLTN 1 5L RR CRNR BOT
34. 6 Te 3 85 LZ 95 L1 LLLI IT CONTROL _ 1 LLLI PANEL a CONNECTION 9 S Z 7 8 9 10 11 12 O O O O O DEUTSCH 10 14 1000 O 11 14 5 E a 1 Oo k N 1 LEGEND CC CONTROL CONTACTOR DIS DISTRIBUTOR d2 V DCA DC ALTERNATOR E BATTE HY EH ENGINE HEATER GRD FS FUEL SOLENOID EH GRD GROUND LOS LOW OIL PRESSURE SWITCH TO 120V 15A SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH UTILITY FED WHITE WLS WATER LEVEL SENSOR CIRCUIT GREEN TO ELECTRONIC GOVERNOR GOVERNOR CONTROLLER ACTUATOR CONNECTOR Generac Power Systems Inc 27 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Wiring Diagram 1 5L Guardian Drawing No 0E1525 Section 8 Electrical Data ELECTRICAL gt YOLVINDAY ADVLIOA YA SQHVO8 1 EZ LSL YOLVOIGNI LINVA LHOM SZ 3503 13
35. A6284 1 HOSE LOWER RADIATR 20 0A6258 1 HOSE UPPER RADIATR 21 029032 1 HOSE 9 32 ID 36 LG 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 4 NUT HEX 1 4 20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE 38 87 28 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS 29 076749 1 TANK COOLANT RECOVERY 30 0E0726 1 BRACKET WATER BOTTLE 1 5L MIT 31 035461 1 BARBED STR 1 4 NPT X 3 8 32 0A7275 3 FOAM 1 5 1 ADH BAK 33 0 2111 2 SCREW SWAGE 10 32 5 16 Z YC 34 065852 2 SPRING CLIP HOLDER 37 62 35 047290A 1 ASSY RAD DRAIN HOSE FAN GUARD KIT 0E3596 NOT USED WITH LEVEL ONE GUARDING age LISTS Generac Power Systems Inc 41 Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Fuel System Drawing No 0E0774 D NATURAL GAS A lt gt A 42 Generac Power Systems Inc Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Fuel System Drawing No 0E0774 D ITEM PART NO QTY DESCRIPTION 1 0 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0 1006 1 ASSY REGULATOR 1 5L N G OR LPV 4 039253 2 SCREW HHC 8 1 25 X 20 G8 8 5 022145 2 WASHER FLAT 5 16 ZINC 6 022129 6 WASHER LOCK M8 5 16 7 045771 2 NUT HEX M8 1 25 G8 YEL CHR 8 0A7040 1 BRACKET RAD HOSE 9 032552 1 BARBED EL 90 5 16 X 1 8 NPT 10 029032 1 HOSE 9 32 ID 11 11 0E1056 1 FUEL HOSE ASSM NAT
36. AN COOLING 15 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 4NPT BRASS SCREW CRMPTIT 1 4 20 X 5 8 Generac Power Systems Inc 39 n Section 9 Exploded Views and Parts 0 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators KO Radiator Drawing No 0E0769 G TO ENGINE BYPASS ON INTAKE MANIFOLD I TO THERMOSTAT MIDWAY UP ENGINE BLOCK ADAPTER TO WATER INLET TUBE TO BASE OF WATER INLET 32 35 BOTTOM ONLY 40 Generac Power Systems Inc Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Radiator Drawing No 0E0769 G ITEM PART NO QTY DESCRIPTION 1 0D8657 1 SUPPORT RADIATOR 1 5L MITSU 2 0A5734 1 RADIATOR 1 5L 3 0A6237 1 VENTURI 1 5L MODINE 4 0A6238 1 GUARD FAN 1 5L MODINE 5 084918 1 HEATER ENGINE 0500W 120V 6 050967 1 HOSE 5 8 ID RIA 250F 12 7 048031C 4 CLAMP HOSE BAND 1 4 8 099502 4 CLAMP HOSE 24 B1 06 2 00 9 083709 1 CLAMP WIRE HOSE 573 551 10 052250 2 TAPE FOAM 1 X 1 12 LG 11 047411 4 SCREW HHC M6 1 0 X 16 G8 8 12 022097 8 WASHER LOCK M6 1 4 13 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 14 022473 9 WASHER FLAT 1 4 ZINC 15 084427 1 BRACKET HEATER 16 050967 1 HOSE 5 8 ID RIA 250F 18 17 075443 6 SCREW CRMPTIT 1 4 20 X 5 8 18 056892 4 SCREW CRIMPTITE 10 24 X 3 8 19 0
37. 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 ofa 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 generator s 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 shut 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 l
38. D ASSY STATOR 20KW 1PH GJK ASSY STATOR 25KW 1PH ASSY STATOR 25KW 1PH D ASSY STATOR 25KW 3PH D BEARING CARRIER REAR ASSY HOLDER BRUSH SCREW PPHM M4 0 7 X 16 COVER REAR BEARING CARRIER BOLT STATOR X 16 LG SCREW RHM 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 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 45 STARTER SOLENOID Section 9 Exploded Views and Parts Ce Ps Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators KO Battery Drawing No 0E0770 A 2 Dm ITEM PART NO QTY DESCRIPTION 1 077483 1 BATT 12VDC 75 AH 26 2 038804D 1 CABLE BATT RED 4 X 20 00 3 038805B 1 CABLE BATT BLK 4 X 23 00 4 0742600131 1 ASSY WIRE 16 RED 1 6 5 022131 1 WASHER FLAT 3 8 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC 10 1 25 X 20 G8 8 8 075763 3 BOOT BATTERY CABLE 9 0D8668 1 BRACKET BATTERY HOLD DOWN 1 5 13 050331A 1 BATTERY POST COVER RED 14 050331 1 BATTERY POSTCOVER BLACK 15 002454 2 SCREW TH FRM M6 1X16 N WA Z JS 16 025507 1 WASHER S
39. Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Engine Drawing No 0E1228 E lt 93 JuvMadvH L7 2 38 Generac Power Systems Inc PART NO 0 4531 022473 0 45310258 0 4355 0 2632 022097 022507 052212 046526 022131 002499 055993 045772 023586 020692 0 7005 052243 0 4772 070901 051735 056768 022145 022129 022259 052213 047411 052830 045771 058306 030795 0 2711 048665 075885 0 45310257 0E1100 0E0561 0A6751 034339 026925 5 c ro ro ro eo r Samo JN O1 DESCRIPTION ENGINE 1 5L WASHER FLAT 1 4 ZINC GASKET EXHAUST MANIFOLD MANIFOLD EXHAUST HEAT SHIELD EXH 1 5L 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 FOOT 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 M8 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 M8 1 25 G8 YEL CHR SCREW SHC M8 1 25 X 25 612 9 SCREW HHC 5 16 18 X 1 G5 ADAPTER THERMOSTAT GASKET THERMOSTAT THERMOSTAT 195
40. HAKEPROOF EXT 7 16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 46 Generac Power Systems Inc TO ENGINE BLOCK Z ITEM PART NO 0A4355 0E2844 036434 036449 0E0109 001318 0D8657 0E0170 0D9437 060366 039253 022145 022129 045771 0 8974 027837 po aA T A D WO G Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators PARTS Ce LISTS Muffler Drawing No 0E0773 A 0 DESCRIPTION MANIFOLD EXHAUST 1 5L NIPPLE TOE 1 5NPTX5 5 BLK IRON BOLT U 5 16 18 X 2 09 SADDLE 2 INCH PIPE EXHAUST 1 5L STNDRD amp ACSTC FLEX PIPE EXHAUST SUPPORT RADIATOR 1 5L MITSU BLANKET EXHAUST 1 5L MITSU MUFFLER 1 5L ACOUSTIC amp STANDARD STRAP MUFFLER 6 DIA 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 CAP 2 SCREW RHM 1 4 20 X 2 1 4 Generac Power Systems Inc 47 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 e
41. LTER 5 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 DIPSTICK FULL 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 4 5 11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 4 3 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Figure 4 3 Engine Air Cleaner Air Cleaner 5524 eee EX Keg be Be o 9 Doors Removed for Clarity See the Scheduled Maintenance Section 4 7 for air cleaner maintenance 4 5 12 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 4 7
42. T ACSTC INSLTN 1 5L REAR DR PNL ACSTC INSLTN 1 5L REAR BRC PNL ACSTC INSLTN 1 5L BAFFLE PANEL ACSTC INSLTN 1 5L CNTRL SUPPT GASKET CLIP ON SELF GRIPPING LATCH AND CAM NUT HEX JAM 3 8 24 SS DUCT LH SIDE 1 5L DUCT RH SIDE 1 5L Generac Power Systems Inc age LISTS 35 n Section 9 Exploded Views and Parts LISTS Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators KO Control Panel Drawing No 0E0778 G 36 Generac Power Systems Inc PART NO 0D9322 0D9332 0D9325A 0D9330 0C1457 064009 032300 022676 0E4494 082573 083048 083264 076009A 0E0331 056739 049350 047822 048766 057335 098647 0E1454 0E1459 072566 080882 0 8955 022097 022473 002212 023762 _ MDM O N A A HS HS HS nlla N o DESCRIPTION PANEL BACK amp BOTTOM GUARDIAN PANEL LH SIDE GUARDIAN amp SPRN PANEL FRONT CONTROL GUARDIAN W SILKSC PANEL RH SIDE C PANEL SML BRK HOURMETER LIGHT 12VDC 02A LED RED PILOT HOLDER FUSE FUSE 15A X 15 SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD ASSEMBLY REGULATOR POTTED TFMR ASM CMA 240 12V PP LOGIC ASM 50 60HZ HARNESS CONTROL PANEL PP GUARDIAN RELAY SOLENOID 12VDC PNL MNT CIRCT BRK 4 X 1 ETA 46 500 P BLOCK TERM 20A 7 X 6 X 1100V BLOCK TERM 20A 2 X 6 X 1100V BLOCK TERM 20A 20 X 6 X 1100V ASSY L C ELECT GOV DECAL CUST CONNT PRE PACK1 5L DECAL TERMINAL S
43. T CENTER 1 5L SUPPORT RADIATOR 1 5L MITSU BRACE SIDE 1 5L MITSU DOORWELDMENT 1 5EPS CORNER POST REAR RH SIDE 1 5L DOOR REAR COMPARTMENT 1 5L BRACE REAR 1 5L MITSU CORNER POST REAR LH SIDE 1 5L LATCH amp CAM SCREW TH FRM M6 1 X 16 N WA Z JS SCREW PHM 10 32 X 5 8 ZINC NUT HEX 5 0 8 G8 YEL CHR WASHER LOCK 10 ASSEMBLY BASE DOOR GROUND WIRE WASHER SHAKEPROOF EXT 10 STL GRD WIRE ASS Y 99HSB WASHER LOCK 8 4 SCREW PPHM 8 32 X 5 16 NUT HEX 1 4 20 STEEL ASSEMBLY COVER ACCESS WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 GASKET CLIP ON SELF GRIPPING LATCH AND CAM NUT HEX JAM 3 8 24 SS GASKET CLIP ON SELF GRIPPING DUCT LH SIDE 1 5L DUCT RH SIDE 1 5L age LISTS Generac Power Systems Inc 33 LISTS aca Section 9 Exploded Views and Parts Guardian Liquid cooled 25 kW Generators Acoustic Compartment Drawing No 0E0772 E O Lu l Lu cO 3 NUT 037337 LL C LL aM cn 3 3g a 0 P LE lt 6 5 i S G Oo 2c T QD D 2 2 8 2 LN gt S ae 28 o LO cose N Sg E 7 lt lt T Yt e O ui 5 aS Es u C N N 9 i gt lt On lt gt b Q 2 e id c j C lt ns FITTZZYZ77 77777777 21 34 Generac Power Systems Inc CONDOR N 008666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 0
44. TRIP PRE PACK NUT SPACER 250 PCB SCREW PPH TAPPING 6 X 5 8 SS SCREW PHM M6 1 0 X 20MM WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW PHTT M4 0 7 X 16 ZYC WASHER SHAKEPROOF EXT 10 SIL Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators PARTS Ce LISTS Control Panel Drawing No 0E0778 G O ITEM PART NO QTY DESCRIPTION 30 0C2267 14 SCREW HHTT 5 0 8 X 12 BP 31 023897 15 WASHER FLAT 10 ZINC 32 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0 2514 1 STRAIGHT WIRE CONNECTOR 1 1 2 36 0 1354 1 REGULATOR DC ALT 37 074908 4 SCREW HHTT M5 0 8 X 10 BP 38 020911 4 SCREW PPHM M5 0 8 X 30 ZINC 39 051713 5 WASHER FLAT 5 40 049226 5 WASHER LOCK M5 41 051716 5 NUT M5 0 8 G8 YEL CHR 42 036261 4 RIVET POP 125 X 129 133 30 43 0D9334 1 PANEL TOP 44 061979 1 BUS BAR 45 022237 1 WASHER LOCK 3 8 46 022241 1 NUT HEX 3 8 16 STEEL 47 057073 1 JUNCTION BLOCK 3 8 16 48 055440 1 SCREW HHC 5 0 8 X 25 G8 8 49 0D8671 1 HINGE CONTINUOUS 1 5L CNTL PNL 50 0912970080 1 WIRE ASSEMBLY 51 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 52 033121 1 SCREW HHC 10 32 X 1 2 53 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 54 022158 1 NUT HEX 10 32 STEEL 55 022152 1 WASHER LOCK 10 56 0A3968 1 CAPACITOR FILTER ASY 57 002323 2 SCREW PHTT 6 32 X 5 8 ZYC 58 0E3783 1 DECAL WARNING REMOVE FUSE NOT SHOWN Generac Power Systems Inc 37 Section 9
45. When using maintenance free batteries it is not nec essary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in Section 4 Maintenance A negative ground system is used Battery connections are shown on the wiring diagrams Make sure all batter ies are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the stand by generator has been properly installed serviced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on Pages 2 and 3 as well as all other safety information in this manual before attempting to operate this and related equipment 2 11 1 PRIOR TO INITIAL START UP caution amp Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section
46. 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 gener ator to be overloaded when this isolation method is employed The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must be equal to or greater than the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution panel 2 7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations 10 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi tion in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded d
47. ac Guardian small standby and residential gen erator 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 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 utility supply to engine water heater Turn off the battery charger by turning off utility supply to the transfer switch Remove the negative battery
48. 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 Section 4 Maintenance MAINTENANCE Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 5 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 to be done Comp to be done Comp Required to be done Date 3months Date Date 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 lo
49. as follows A After this heading read instructions that if not strictly complied with will result in personal injury or property damage wanNiNG 4 After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution amp 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 compli ance 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 informa A tion that if not followed could endanger personal safety 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 Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also st
50. ast 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 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 Section 1 14 for recom mended oils MAINTENANCE 2 0 Figure 4 1 Dipstick and Section 4 Maintenance 4 4 2 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 separators DO NOT USE TAP WATER IN BATTERY 4 4 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Section 1 10 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 radiator pressure cap Replace cap if necessary To have pressure cap tested contact an authorized Generac Service Dealer Inspect cooling system and coolant recovery system for leaks 4 5 MAINTENANCE OWNER OPERATOR CAN PERFORM 451 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels in Section 4 4 4 5
51. ause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac accord
52. c 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 Installation operation servicing and repair of this and related equipment must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the 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 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
53. c shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatical ly shuts down Figure 1 6 on page 6 Generac Power Systems Inc 5 1 7 4 OVERSPEED SHUTDOWN The Pre pack circuit board on liquid cooled units receives AC frequency rpm signals directly from the stator AC power windings via sensing leads 515 and 516 Should AC frequency exceed about 72 Hz cir cuit board action will automatically shutdown the engine Figure 1 7 Rated power of generator is subject to and limit ed by such factors as ambient temperature alti tude 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 generator is limited by maximum engine power Figure 1 7 Control Module Assembly Circuit Board us UN LI i oO 2 ms T T 118 LEDS LUE hess i AM DE ANN Mw BES E B isss P semus a pu sm 5 g c9 Qu ME Roo O OO SO How k li CUT R83 R55 18 2002 GENERAC POWER SYSTEMS ASSY 076009 gu a a E
54. 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 80 hours of operation after purchase of the unit and requires approximatelu 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer 3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually 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 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify
55. cables until the NORMAL source voltage at the transfer switch is correct and the system is ready to be put 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 battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery 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 the fluid is spilled flush the affected area immediately with clear water warnings amp Do not dispose of the battery a fire The bat tery is capable of exploding Do not open or mutilate the battery Released A electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short cir cuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 10 1 VENTED BATTERIES caution amp The electrolyte is a dilute sulfuric acid that is A harmfu
56. eing performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or conse quential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 531 90 Part No 0E1151 Revision J 06 28 04 Printed in U S A
57. en disconnected wire 15A between AUTO OFF MANUAL switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker amp fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open ee Generac Power Systems Inc CORRECTION 1 2 Es e Fog Te Du Uc o D Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replenish 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 five min and attempt restart Section 6 Notes NOTES Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Generac Power Systems Inc 23 NOTES Section 6 Notes Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 24 Generac Power Systems Inc
58. erac 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 either 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 obl
59. erator POFIOPHY 15 4 6 Miscellaneous Maintenance 17 4 7 Scheduled Maintenance 19 Section 5 TROUBLESHOOTING 22 5 1 Troubleshooting Points 22 Section 6 NOTES 23 Section 7 INSTALLATION DIAGRAM 25 Section 8 ELECTRICAL DATA 26 Section 9 EXPLODED VIEWS AND PARTS LISTS 30 Section 10 WARRANTY 48 Generac Power Systems Inc 1 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 A A A 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 A A This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The genera tor can operate safely efficiently and reliably only if it is properly installed operated and maintained Many acci dents are caused by failing to follow simple and funda mental rules or precautions
60. erators 1 16 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 generators rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power The critical essential loads may need to be grouped together and wired into a sepa rate 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 con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 STANDBY GENERATOR INSTALLATION Connecting this generator to an electrical sys AN tem normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric sys tem by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy If an open bottom is used the engine genera f tor is to be installed over non combustible materials and s
61. esults in damage to the generator and may also result in injury or even death to utility power work ers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system may include a matched auto matic transfer switch which is intended to be used in conjunction with the Guardian generator It is sup plied in either a NEMA 1 enclosure 15 kW model 004721 20 kW models 004723 or a NEMA 3R enclosure 25 kW models 004725 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 Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors Failure to utilize a Generac Guardian transfer switch with this generator will void the warranty ea Generac Power Systems Inc Section 1 General Information Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 1 3 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 utili
62. evels 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 five feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REG ULATE THE DISTANCE 2 5 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least six inches thick and should extend beyond the enclosure to a distance of at least three inches on all sides See Section 7 Installation Diagram 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY generator output are con nected 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 t
63. evices Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG 2 8 GENERATOR AC NEUTRAL CONNECTIONS Generac Power Systems uses an UNGROUNDED AC neutral Grounding is recommended only at the main service entrance If the neutral wire is grounded and one of the phase loads becomes grounded the exces sive current opens the load circuit breaker or col lapses the generator field The actual result depends on the electrical characteristics of the particular installed generator 2 9 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 is 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 trans fer 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 Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 2 10 BATTERY INSTALLATION A DIG A Standby generators installed with automatic transfer switches will crank and start automati cally when NORMAL UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel do not connect battery
64. eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immediately with clear water A Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging 18 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators warninc amp A Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 6 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery that follows BCI Group No CCA 26 268 525 0 deg F NOTE The BCI number should be located directly on the battery PERIODIC REPLACEMENT PARTS Part Name Generac s Part Number Oil Filter 0A45310244 Radiator Cap 046627 Air Cleaner 059402 Spark Plug 0A45310275 Section 4 Maintenance Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators MAINTENANCE 4 7 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for Gener
65. ge and water Apply a coat of automotive type wax once a year to help pre vent corrosion Once each year have the generator cleaned and inspected by an Authorized Service Dealer That deal er will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 6 2 BATTERY lead acid storage batteries discharge when not in use Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use 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 bat tery 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 charging The ga
66. he UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Figure 2 1 Basic Standby Electric System MAIN LINE CIRCUIT BREAKER UTILITY POWER SUPPLY TO LOAD CIRCUITS Sa t CIRCUIT Generac Power Systems Inc s INSTALLATION 13 Section 2 Installation NOTE Generac recommends the use of a Generac Power Systems GTS type transfer switch in conjunc tion with this generator 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only crit ical loads within the wattage amperage capacity dur ing utility power outages consider using the emer gency circuit isolation method Critical electrical loads are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set When this method is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements It must have an ampere rating equal to or greater than the total amperage rating of the emergency distribution panel circuit Have it installed between the buildings main dis tribution panel and the emergency distribution panel 2 6 TOTAL CIRCUIT ISOLATION METHOD When
67. hould be located such that com bustible materials are not capable of accumu lating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standards and regula tions pertaining to the installation This genset must be installed on a level surface The base frame must be level within 1 2 inch all around caution amp After the system has been installed do nothing that might render the installation in noncompli ance with such codes standards and regula tions Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators NOTE For more information about the installation of a standby system order Engine Generator Standby Electric Power Systems Installer s Guide and Reference Manual part 046622 from a Generac Authorized Service Dealer 2 1 1 NFPA STANDARDS The following published standards booklets pertain ing to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING
68. hourmeter along with the periodic maintenance schedule for the gen erator set 3 2 2 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Section 3 4 Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an oper ating engine With OFF selected operation will not be possible A With switch set to AUTO engine can crank and start suddenly without warning Such automatic start up normally occurs when utili ty source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on control console 5 2 5 FAULT INDICATOR LAMP The 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 5 2 4 15 AMP FUSE The 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 replacement of the fuse is necessary use only an identical 15 amp fuse Type part number 022676 3 2 5 7 5 AMP INLINE FUSE This inline fuse is
69. igations 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 53190 Part 1 48 Generac Power Systems Inc Section 10 Warranty Guardian 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 c
70. ing 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 diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an
71. is 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 1 1 GENERATOR This equipment is a liquid cooled engine driven gen erator set The generator is designed to supply elec trical power that operates critical electrical loads during utility power failure The unit has been facto ry installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the oper ation of 120 and or 240 volts single phase loads These models are available They are rated as follows Models 0047210 and 0047220 Provides 15 000 watts 15 kW of single phase power Models 0047230 and 0047240 Provides 20 000 watts 20 kW of single phase power Models 0047250 0047251 0047252 0047253 and 0047260 Provides 25 000 watts 25 kW of sin gle phase power warninc If this generator is used to power electrical A load circuits normally powered by a utility power source it is required by code to install a transfer switch The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means r
72. ive 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 Consult the local fire department for any questions pertaining to fire extinguishers EXPLOSION HAZARDS 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 All fuel types are potentially FLAM MABLE and or EXPLOSIVE and should be handled with care Comply with all 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 th
73. l 4 Recom Task Required Task Required Task Task mended Comp to be done Comp Ito be done Comp Required Comp to be done Date 3months Date Date tobedone Date monthly Initials Break in Initials annually Initials Annually Initials 10 hrs 50 hrs 100 hrs Generac Power Systems Inc 21 TROUBLESHOOTING Section 5 Troubleshooting Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators 5 1 TROUBLESHOOTING POINTS CAUSE 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 T Co O O1 15 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 1 Defective AUTO OFF MANUAL switch Op
74. l having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change Oil Grade Recommended SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 Temperature Above 80 F 27 C 32 to 80 F 1 to 27 C Below 32 F 0 C caution amp Any attempt to crank start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is about 8 U S quarts 7 6 liters Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution amp Do not use any chromate base rust inhibitor A with ethylene glycol base anti freeze or chromi umhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating Generac Power Systems also recommends that any soluble oil inhibitor is NOT used for this equipment 8 Generac Power Systems Inc Guardian Liquid cooled 15 kW 20 kW and 25 kW Gen
75. l to the skin and eyes It is electrically conductive and corrosive The following proce dures 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 flush thor oughly and immediately with water and seek med ical attention and INSTALLATION Hh Section 2 Installation e Spilled electrolyte is to be washed down with acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbon ate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire 4 because they generate hydrogen gas The fol lowing procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause or spark in battery area and Discharge static electricity from body before touch ing batteries by first touching a grounded metal surface Servicing of batteries is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries For recommended batteries see Specifications batteries must be at 100 percent state of charge before they are installed on the generator
76. n 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators KO Alternator Drawing No 0A9348 F ee C i eo NI O OS WA WMA Wh re 4 Wks To Blower m d 44 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 049226 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 0A5382 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 0A7043 5 31 049808 5 32 058589 1 33 023365 4 35 0A8830 4 36 072080 1 USED ON PRE PACKAGED UNITS ONLY Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Alternator 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 3PH D ASSY STATOR 15KW 1PH GJK ASSY STATOR 20KW 1PH A ASSY STATOR 20KW 1PH
77. nd testing by Generac or a Generac Authorized Warranty Service Dealer is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All trans portation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators 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 maintenance is required Engine All Components Alternator All Components Transfer System All Components warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Generac Guardian generators utilizing non Generac Guardian automatic transfer switches Any Generac Guardian generators used as rental or trailer mounted applications 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 n
78. ne has several safety switches which cause the engine to automatically shut down under the fol lowing conditions low oil pressure high coolant tem perature engine overspeed low coolant level or over crank Figure 1 3 Figure 1 3 Engine Protective Devices HIGH COOLANT LOW COOLANT TEMPERATURE LEVEL SWITCH SWITCH LOW OIL e LP a 4 N 1 7 1 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 Pressure Switch 1 7 2 HIGH COOLANT TEMPERATURE SWITCH This 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 1 73 LOW COOLANT LEVEL SWITCH Should engine coolant level drop below the level of the high coolant temperature switch it is possible for the engine to overheat without automatic shutdown To prevent such overheating without automati
79. ngines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service 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 Gen
80. normally uses an AGC fuse rated at 15 amps part number 022676 1 8 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 8 2 INSPECTION After unpacking carefully inspect the generator for any damage that may have occurred during ship ment If loss or damage is noted at the time of deliv ery have the person s making delivery note all dam age on the freight bill or affix their signature under the consignor s memo of loss or damage 1 9 LIFTING THE GENERATOR warninc amp When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR SPECIFICATIONS Single Phase Model 004725 004723 004721 004726 004724 004722 Rated Max Cont 20 20 15 AC Power Output kW Rated voltage volts 120 240 No of Rotor Poles 4 Driven Speed of Rotor 3600 3600 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor Stator Insulation Class F 1 10 2 ENGINE SPECIFICATIONS Mitsubishi Displacement 92 inches
81. ormally exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent 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 replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are b
82. ose 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 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 Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary 19 Perform a 5 minute no load operational run of the unit looking for any post service oroblems 20 Return the unit to standby setup for operation when required MAINTENANCE 2 0 Section 4 Maintenance Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Level 1 Level 2 Level 3 Leve
83. r cise 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 iden tified 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 Generac Power Systems Inc 1 MAINTENANCE Section 4 Maintenance caution amp 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 exer cise every seven days thereafter on day and time of day the switch was actuated Placea sign on the generator control panel and the transfer switch indicating the day and time the generator will be exercising NOTE If battery terminals are disconnected the exercise timer needs to be reset for correct automatic exer cise operation Figure 3 2 Set Exercise Switch N 7 SET EXERCISE TIME ON FAULT AUTO INDICATOR Ge Q MANUAL 3 6 ENGINE HEATER This standby generator comes equipped with a block heater Figure 3 3 similar to
84. rongly recommends 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 operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance serv ice and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship 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 ensure 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 Generac 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 contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all of servicing needs When contacting a Generac Authorized Service Dealer about parts and service
85. s 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 Generac Power Systems Inc 17 MAINTENANCE S O Section 4 Maintenance 4 6 3 BATTERY MAINTENANCE The battery should be inspected per the Scheduled Maintenance Section 4 7 The following procedure should be followed for inspection 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 DX A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact
86. t per hour Using LP Gas 143 cubic ft 4 0 gal per hour 15 kW Models Using Natural Gas 277 Cu ft per hour Using LP Gas 110 cubic ft 3 1 gal per hour Section 1 General Information Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators NOTE Fuel consumption is given at rated maximum con tinuous power output when using natural gas rated at 1000 Btu per cubic foot and LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors Fuel pressure for both natural gas and liquid propane set ups should be 11 inches to 14 inches of water column 0 6 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper as pressure 11 14 to the gen erator Low gas pressure can cause hard starting and could affect engine durability 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP follow these steps 1 Turn the main gas supply 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port
87. ty power source voltage Should that voltage drop below a pre set value and remain at such a low state for a preset amount of time the generator cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can power them When utility source voltage has been restored the switch re transfers back to the utility source voltage and the generator then shuts down Please reference the transfer switch manual for spe cific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase three 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 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit as shipped from the factory The breaker for each unit is described in Figure 1 2 at the top of page 5 1 6 GENERATOR FUEL SYSTEM The generator has been factory tested and adjusted using a natural gas fuel system
88. ween pulleys should deflect about 3 8 to 3 4 inch Adjust belt tension as required 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A DANGER Do not attempt to adjust the gover A nor Only qualified service facilities should adjust the governor Excessively high operat ing speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may short en engine life Correct rated frequency and voltage are supplied only at the proper gov erned speed Some connected electrical load devices may be damaged by incorrect fre quency and or voltage Only qualified service technicians should adjust the governed speed 16 Generac Power Systems Inc 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized serv ice facilities for engine oil and filter change frequen cies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into its retaining clip 4 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose of old filter Figure 4 2 Oil Filter OIL FI

Generac 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726

Contents

Download Pdf Manuals

Related Search

Related Contents