Owner`s manual | Earthquake Sound Cinenova 7 Stereo Amplifier User Manual

®
POWER SYSTEMS, INC.
Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
(Natural Gas)
004188-1
004370-2
004474-1
(Liquid Propane Vapor)
004189-1
004371-2
004475-1
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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 were both accurate and current at the time the manual was written.
However, the manufacturer reserves the right to change,
alter or otherwise improve this product(s) at any time
without prior notice.
READ THIS MANUAL THOROUGHLY
If you do not understand any portion of this manual,
contact Generac or your 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 you to special instruction about a particular service or operation
that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:
After this heading, you can read instructions that, if
not strictly complied with, will result in personal injury
or property damage.
The operator is responsible for proper and safe use of
the equipment. We strongly recommend that the operator read this Owner's Manual and thoroughly understand all instructions before using this equipment. We
also strongly recommend instructing other users to
properly start and operate the unit. This prepares them
if they need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment
checked periodically by a Generac Authorized Service
Dealer. Normal maintenance service and replacement of
parts are the responsibility of the owner/operator and,
as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual
operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of your generator ensure a
minimum number of problems and keep operating
expenses at a minimum. See your 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
After this heading, you can read instructions that, if not
strictly complied with, may result in personal injury or
property damage.
After this heading, you can read instructions that, if not
strictly complied with, could result in damage to equipment and/or property.
NOTE:
When your generator requires servicing or repairs, simply contact a Generac Authorized Service Dealer for
assistance. Service technicians are factory-trained and
are capable of handling all of your service needs.
When contacting a Generac Authorized Service Dealer
or the factory about parts and service, always supply the
complete model number of your unit as given on the
front cover of this manual or on the DATA CARD affixed
to the unit.
After this heading, you can read explanatory statements that require special emphasis.
These safety warnings cannot eliminate the hazards that
they indicate. Common sense and strict compliance with
the special instructions while performing the service are
essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type of
information each indicates is as follows:
This symbol points out important safety information
that, if not followed, could endanger personal safety
and/or property of you and others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the GENERAC AUTHORIZED SERVICE
DEALER nearest you, please call this number:
1-800-333-1322
OR
Locate us on the web at:
www.generac.com
Generac® Power Systems, Inc.
Table of Contents
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
INTRODUCTION ....................................IFC
SAFETY RULES..........................................2
Section 3
OPERATION ..........................................11
Using a Standard “GTS” Transfer Switch ................11
Section 1
Control Console Components ..................................12
GENERAL INFORMATION ......................4
Manual Transfer and Startup ..................................13
Generator ..................................................................4
Retransfer and Shutdown ........................................13
Transfer Switch ........................................................4
Automatic Operation ................................................13
Automatic System Operation ....................................4
Weekly Exercise Cycle ..............................................13
Generator AC Connection Systems ............................4
Engine Heater ..........................................................14
Main Circuit Breaker ................................................5
Section 4
Generator Fuel System ..............................................5
MAINTENANCE ....................................14
Engine Protective Devices ..........................................5
Unpacking..................................................................6
Lifting the Generator..................................................6
Maintenance Performed by
Authorized Service Facilities ....................................14
Specifications ............................................................6
Overload Protection for Engine DC
Electrical System ....................................................14
Fuel Consumption......................................................7
Checking Fluid Levels ..............................................14
Torque Specifications ................................................7
Maintenance Owner/Operator Can Perform..............15
Engine Oil Recommendations ....................................7
Miscellaneous Maintenance......................................17
Coolant Recommendations ........................................7
Section 5
Before Installation......................................................7
TROUBLESHOOTING ............................18
Section 2
STANDBY GENERATOR INSTALLATION..8
Generator Location ....................................................8
Section 6
SCHEDULED MAINTENANCE ................19
Generator Mounting and Support ..............................9
Section 7
Basic Standby Electric System ..................................9
WIRING DIAGRAMS AND
SCHEMATICS ........................................22
Emergency Circuit Isolation Method ..........................9
Total Circuit Isolation Method....................................9
Grounding the Generator ..........................................9
Section 8
Transfer Switch Start Signal Connections ..............10
EXPLODED VIEWS AND
PARTS LISTS ........................................27
Battery Installation ..................................................10
Section 9
Generator AC Neutral Connections ..........................10
Preparation Before Start-Up ....................................11
INSTALLATION DRAWINGS ..................52
Section 10
WARRANTY ...........................................56
Generac® Power Systems, Inc.
1
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
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.
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is
properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.
Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in
this
manual,
and
on
tags
and
decals
affixed to the unit are, therefore, not all-inclusive. If you
use a procedure, work method or operating technique
that Generac does not specifically recommend, you
must satisfy yourself that it is safe for you and others.
You also must make sure the procedure, work method
or operating technique that you choose 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 maintain this
equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running generators.
2
Generac® Power Systems, Inc.
GENERAL HAZARDS
• For safety reasons, Generac recommends that this
equipment be installed, serviced and repaired by a
Generac Authorized Service Dealer or other competent, qualified electrician or installation technician
who is familiar with applicable codes, standards and
regulations. The operator also must comply with all
such codes, standards and 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 generator is installed, operated and serviced in accordance
with the manufacturer’s instructions and recommendations. Following installation, you must not do anything that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide
gas, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason, adequate ventilation must be provided. 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, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove
any drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases
and to ensure correct generator operation. Do not
alter the 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 uncluttered. Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all
times. Never work on the equipment when you are
physically or mentally fatigued.
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 dangerous electrical voltages and can cause fatal electrical
shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the
standby generator. Avoid contact with bare wires, terminals, connections, etc., on the generator as well as
the transfer switch, if applicable. Ensure all appropriate covers, guards and barriers are in place before
operating the generator. If you must work 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 conductive parts of the generator to be connected to an
approved earth ground and/or grounding rods. This
grounding will help prevent dangerous electrical
shock that might be caused by a ground fault condition in the generator set or by static electricity. Never
disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are
positively turned off at their source. Failure to do so
will result in hazardous and possibly fatal electrical
shock.
• Connecting this unit to an electrical system normally
supplied by an electric utility shall be by means of a
transfer switch so as to isolate the generator electric
system from the electric utility distribution system
when the generator is operating. Failure to isolate the
two electric system power sources from each other by
such means will result in damage to the generator
and may also result in injury or death to utility power
workers due to backfeed of electrical energy.
• Generators installed with an automatic transfer
switch will crank and start automatically when normal (utility) source voltage is removed or is below an
acceptable preset level. To prevent such automatic
start-up and possible injury to personnel, disable the
generator’s automatic start circuit (battery cables,
etc.) before working on or around the unit. Then,
place a “Do Not Operate” tag on the generator control
panel and on the transfer switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this
is not possible, attempt to free the victim from the
live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement, such
as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid
and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
FIRE HAZARDS
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher
properly charged and be familiar with its use. If you
have any question pertaining to fire extinguishers,
consult your local fire department.
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 several types of fuels. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled
with care. Comply with all laws regulating the storage
and handling of fuels. Inspect the unit’s fuel system
frequently and correct any leaks immediately. Fuel
supply lines must be properly installed, purged and
leak tested according to applicable fuel-gas codes
before placing this equipment into service.
• Diesel fuels are highly FLAMMABLE. Gaseous fluids
such as natural gas and liquid propane (LP) gas are
extremely EXPLOSIVE. Natural gas is lighter than air,
and LP gas is heavier than air; install leak detectors
accordingly.
Generac® Power Systems, Inc.
3
Section 1 - General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
GENERATOR
AUTOMATIC SYSTEM OPERATION
This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical
power that operates critical electrical loads during utility power failure. The unit has been factory-installed in
a weather resistant, all metal enclosure and is intended
for outdoor installation only. Use this generator as a
source of electrical power for the operation of 120
and/or 240 volts, single phase loads.
When this generator, along with its transfer switch, has
been installed and interconnected, a circuit board in the
generator panel constantly monitors utility power
source voltage. Should that voltage drop below a preset
value, and remain at such a low state for a preset
amount of time, the generator cranks and starts. After
the generator starts, the transfer switch transfers load
circuits so the generator can power them.
These models are available. They are rated as follows:
When utility source voltage has been restored, the
switch re-transfers back to the utility source voltage and
the generator then shuts down.
Model 004188: Provides 15,000 watts (15 kW) of 1 phase power.
Model 004189: Provides 15,000 watts (15 kW) of 1 phase power.
Model 004370: Provides 20,000 watts (20 kW) of 1-phase power.
Model 004371: Provides 20,000 watts (20 kW) of 1-phase power.
Model 004474: Provides 25,000 watts (25 kW) of 1 phase power.
Model 004475: Provides 25,000 watts (25 kW) of 1 phase power.
If this generator is used to power electrical load
circuits normally powered by a utility power
source, you are 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 results in damage to the
generator and may also result in injury or even
death to utility power workers due to backfeed
of electrical energy.
GENERATOR AC CONNECTION SYSTEMS
The generator was shipped from the factory with its stator AC output leads connected in a single-phase, 3-wire
generator AC connection system (Figure 1.1). The stator
assembly in this system consists of a pair of stationary
windings, with two leads brought out of each winding.
Each single winding can supply 120 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
TRANSFER SWITCH
This Guardian system includes a matched automatic
transfer switch which is intended to be used in conjunction with your Guardian generator. It is supplied in
either a NEMA 1 enclosure (15 kW models 004188, and
004189, and 20 kW models 004370, and 004371) or a
NEMA 3R enclosure (25 kW models 004474 and
004475). The NEMA 1 enclosure is intended for indoor
use only. The NEMA 3R enclosure is weather proof and
can be used indoors or outdoors. Follow these rules:
• Install the transfer switch on a firm, sturdy supporting structure.
• To prevent switch distortion, level the switch if necessary. This can be done by placing washers between
the switch enclosure and the mounting surface.
• Never install the switch where water or any corrosive
substance might drip onto the enclosure.
• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and corrosive
vapors.
4
Generac® Power Systems, Inc.
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.
GENERATOR FUEL SYSTEM
Your unit has been factory tested and adjusted using a
natural gas fuel system. If propane (LP) gas is preferred,
contact an authorized service dealer.
Section 1 - General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Figure 1.2 - Main Circuit Breaker
Model
Rating
Phase
004188
004189
004370
004371
004474
004475
15,000
15,000
20,000
20,000
25,000
25,000
1
1
1
1
1
1
Actual Current
C/B Rating*
62.5
62.5
83.3
83.3
104.2
104.2
* Amp Rating of C/B structured
70
70
90
90
125
125
under model.
% over rating
Circuit Breaker
112%
112%
108%
108%
120%
120%
70A BQ2
70A BQ2
90A BQ2
90A BQ2
125A BQ2
125A BQ2
Figure 1.4 - Low Oil Pressure Switch
Gaseous fuels such as natural and LP (propane)
gas are highly explosive. Even the slightest
spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural
gas, which is lighter than air, tends to collect in
high areas. LP gas is heavier than air and tends
to settle in low areas.
ENGINE PROTECTIVE DEVICES
The engine has several safety switches which cause the
engine to automatically shut down under the following
conditions: low oil pressure, high coolant temperature,
engine overspeed, low coolant level or overcrank (Figure
1.3).
Figure 1.3 - Engine Protective Devices
HIGH COOLANT TEMPERATURE SWITCH
Normally open (N.O.) thermostatic switch has sensing
tip which is immersed in captive coolant. Should
coolant temperature exceed about 230°F (110°C), the
switch contacts close, which causes the engine to shut
down automatically (Figure 1.5).
Figure 1.5- High Coolant Temperature Switch
LOW COOLANT LEVEL SWITCH
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).
Should engine coolant level drop below the level of the
high coolant temperature switch, it is possible for the
engine to overheat without automatic shutdown. To
prevent such overheating without automatic shut down,
the engine has a low coolant level sensor. If the engine
coolant drops too low, the engine automatically shuts
down (Figure 1.6).
Generac® Power Systems, Inc.
5
Section 1 — General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Figure 1.6 - Low Coolant Level Sensor
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 normally uses an AGC fuse rated at 30 amps.
UNPACKING
UNPACKING PRECAUTIONS
OVERSPEED SHUTDOWN
The CMA circuit board on liquid cooled units receives
AC frequency (rpm) signals directly from the stator AC
power windings, via sensing leads S15 and S16. Should
AC frequency exceed about 72 Hz, circuit board action
will automatically shutdown the engine (Figure 1.7).
*Rated power of generator is subject to and limited
by such factors as ambient temperature, altitude,
engine condition, and other factors. Engine power
will decrease about 3.5% for each 1000 feet above
sea level and will decrease an additional 1% for each
10°F above 60°F. Maximum output power of the generator is limited by maximum engine power.
Figure 1.7 - Control Module Assembly
Circuit Board
Handle shipping cartons and crates with care. Use care
to avoid damage from dropping, bumping, collision, etc.
Store and unpack cartons with the proper side up, as
noted on the shipping carton.
INSPECTION
After unpacking, carefully inspect the generator for any
damage that may have occurred during shipment. If
loss or damage is noted at the time of delivery, have the
person(s) making delivery note all damage on the freight
bill or affix his signature under the consignor’s memo of
loss or damage.
LIFTING THE GENERATOR
When lifting or hoisting equipment is used, be
careful not to touch overhead power lines. The
generators weight of more than 900 pounds
requires proper tools, equipment, and qualified
personnel to be used in all phases of handling
and unpacking.
SPECIFICATIONS
GENERATOR SPECIFICATIONS
Model
OVERCRANK SHUTDOWN
After 90 seconds of crank-rest cycles, this function ends
cranking if the engine fails to start in that 90-second
span.
6
Generac® Power Systems, Inc.
*Rated Max. Cont.
AC Power Output (kW)
Rated voltage (volts)
No. of Rotor Poles
Driven Speed of Rotor
Rotor Excitation System
Type of Stator
Rotor/Stator Insulation
1-Phase
4370
4371
20
4474
4475
25
4188
4189
15
120/240
2
4
3600
3600
1800
Direct excited brush type
4 Wire
Class F
Section 1 — General Information
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
ENGINE SPECIFICATIONS
Make ..................................................................................Mitsubishi
Displacement ....................................................92 inches3 (1.5 liters)
Cylinder Arrangement ..........................................................4, in-line
Valve Arrangement ....................................................Overhead Cam
Firing Order ............................................................................1-3-4-2
Number of Main Bearings ................................................................5
Compression Ratio....................................................................9 to 1
No. of Teeth on Flywheel ..............................................................104
Ignition Timing
at 1800 rpm ........................................................35 degrees BTDC
at 3600 rpm ........................................................43 degrees BTDC
Spark Plug Gap ......................................................0.020-0.025 inch
Recommended Spark Plugs
Champion ........................................................................RN11YC4
Oil Pressure ........................................................................30-50 psi
Crankcase Oil Capacity ............................4.0 U.S. quarts (3.8 liters)
Recommended Engine Oil ............................................SAE 15W-40
Type of Cooling System ......................Pressurized, closed recovery
Cooling Fan ....................................................................Pusher Type
Cooling System Capacity............................2 U.S. gallons (7.6 liters)
Recommended Coolant ................................Use a 50-50 mixture of
ethylene glycol base.
FUEL CONSUMPTION
Models 004474, 004475
Using Natural Gas ..............................................441 cu. ft. per hour
Using LP Gas ..................................175 cubic ft.(4.8 gal.) per hour
Models 004370, 004371
Using Natural Gas ..............................................359 cu. ft. per hour
Using LP Gas ..................................143 cubic ft. (4.0 gal.) per hour
Models 004188, 004189
Using Natural Gas ..............................................277 cu. ft. per hour
Using LP Gas ..................................110 cubic ft.(3.1 gal.) per hour
NOTE:
Fuel consumption is given at rated maximum continuous power output when using natural gas rated
at 1000 Btu per cubic foot; or LP gas rated 2520 Btu
per cubic foot. Actual fuel consumption obtained
may vary depending on such variables as applied
load, ambient temperature, engine conditions and
other environmental factors.
TORQUE SPECIFICATIONS
Cylinder Head ..................................................15 (+ 90° + 90°) ft.lb.
Intake Manifold ......................................................................13 ft.lb.
Exhaust Manifold ..................................................................13 ft.lb.
ENGINE OIL RECOMMENDATIONS
The unit has been filled with 15W-40 engine oil at the factory. Use a high-quality detergent oil classified “For
Service CC, SD, SE, SF.” Detergent oils keep the engine
cleaner and reduce carbon deposits. Use oil having the
following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:
Temperature
Above 80° F (27° C)
32° to 80° F (-1° to 27° C)
Below 32° F (0° C)
Oil Grade (Recommended)
SAE 30W or 15W-40
SAE 20W-20 or 15W-40
SAE 10W or 15W-40
Any attempt to crank or start the engine before
it has been properly serviced with the recommended oil may result in an engine failure.
COOLANT RECOMMENDATIONS
Use a mixture of half low silicate ethylene glycol base
anti-freeze and half soft water. Cooling system capacity
is about 8 U.S. quarts (7.6 liters). Use only soft water
and only low silicate anti-freeze. If desired, add a high
quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.
Do not use any chromate base rust inhibitor
with ethylene glycol base anti-freeze or chromiumhydroxide (“green slime”) forms and will
cause overheating. Engines that have been operated with a chromate base rust inhibitor must be
chemically cleaned before adding ethylene glycol
base anti-freeze. Using any high silicate antifreeze boosters or additives will also cause overheating. We also recommend that you DO NOT
use any soluble oil inhibitor for this equipment.
BEFORE INSTALLATION
Before installing this equipment, check the ratings of both
the generator and the transfer switch. Read “Emergency
Isolation Method” and “Total Circuit Isolation Method” in
the installation manual (Part No. 079699).
The generator’s rated wattage/amperage capacity must
be adequate to handle all electrical loads that the unit
will power. You may have to group the critical (essential)
loads together and wire them into a separate “emergency” distribution panel.
This generator can be installed in conjunction with a
standard Generac “GTS” type transfer switch, if desired.
The standard transfer switch has no sensing or controlling circuit boards. Instead, the generator control
console houses a “Control Module Assembly”, which
controls all phases of operation, including engine start
up and load transfer.
Generac® Power Systems, Inc.
7
Section 2 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
STANDBY GENERATOR INSTALLATION
Connecting this generator to an electrical system 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 system by these means will result in
damage to the generator and may also result in injury or death to utility workers due to backfeed of
electrical energy.
OTHER PUBLISHED STANDARDS
If an open bottom is used, the engine-generator is
to be installed over non-combustible materials
and should be located such that combustible
materials are not capable of accumulating under
the generator set.
Only 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 regulations pertaining to the installation.
After the system has been installed, you must not
do anything that might render the installation in
noncompliance with such codes, standards and
regulations.
NOTE:
For more information about the installation of a standby system, you can order Engine-Generator Standby
Electric Power Systems Installer’s Guide and
Reference Manual (part #046622) from your Generac
Authorized Service Dealer.
NFPA STANDARDS
The following published standards booklets pertaining
to standby electric systems are available form the
National Fire Protection Association (NFPA),
Batterymarch Park, Quincy, MA 02269:
• NFPA No. 37, STATIONARY COMBUSTION ENGINES
AND GAS TURBINES.
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS
FOR HEALTH CARE FACILITIES.
• NFPA No. 220, STANDARD TYPES OF BUILDING
CONSTRUCTION
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING
• NFPA No. 70, NATIONAL ELECTRICAL CODE.
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE.
• NFPA No. 10, INSTALLATION, MAINTENANCE AND
USE OF PORTABLE FIRE EXTINGUISHERS.
8
Generac® Power Systems, Inc.
In addition to NFPA standards, the following information 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
Street, New York, N.Y. 10038.
• AGRICULTURAL WIRING HANDBOOK, obtainable
from the Food and Energy Council, 909 University
Avenue, Columbia, MO, 65201.
• ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER,
available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.
• A52.1, AMERICAN NATIONAL STANDARD FOR
CHIMNEYS, FIREPLACES AND VENTING SYSTEMS, available from the American National
Standard Institute, 1430 Broadway, New York, N.Y.
10018.
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 drifting,
you may need to consider using a windbreak to protect the unit.
• Install the generator on high ground where water levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator for
maintenance and servicing. A good rule is to allow 3
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 REGULATE THE DISTANCE.
Section 2 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
GENERATOR MOUNTING AND SUPPORT
Retain the generator compartment to a concrete slab
with 1/4-inch masonry type anchor bolts. Be sure the
bolts are long enough to retain the compartment. The
slab should be at least 6 inches thick and should extend
beyond the enclosure to a distance of at least 3 inches
on all sides. See pages 54-55 for generator major
dimensions.
BASIC STANDBY ELECTRIC SYSTEM
Figure 2.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and
the STANDBY (generator) output are connected to an
approved transfer switch. The transfer switch is
required by electrical code and serves the following
functions:
• Permits the LOAD circuits to be connected to only one
power supply at a time.
• Prevents electrical backfeed between the generator
and the UTILITY power circuits.
Notice that both the STANDBY and the UTILITY power
supplies to the transfer switch are protected against
overload by a main line circuit breaker.
NOTE:
Generac recommends the use of a Generac power
systems “GTS” type transfer switch in conjunction
with this generator.
Figure 2.1 – Basic Standby Electric System
Critical electrical loads are grouped together and wired
into a separate “Emergency Distribution Panel.” Load
circuits powered by that panel are within the
wattage/amperage capacity of the generator set. When
this method is used, it is difficult to overload the generator. The transfer switch must meet the following
requirements:
• It must have an ampere rating equal to the total
amperage rating of the emergency distribution panel
circuit.
• Have it installed between the building’s main distribution panel and the emergency distribution panel.
TOTAL CIRCUIT ISOLATION METHOD
When a generator capable of powering all electrical
loads in the circuit is to be installed, you may use the
“Total Circuit Isolation Method.” It is possible for the
generator 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 equal the
ampere rating of the normal incoming utility service.
• The transfer switch is installed between the utility
service entrance and the building distribution panel.
GROUNDING THE GENERATOR
The National Electrical Code requires the frame and
external electrically conductive parts of this equipment
to be properly connected to an approved earth ground
and/or grounding rods. For that purpose, a GROUND
LUG (Figure 2.2) is provided on the generator mounting
base. Consult a qualified electrician for grounding
requirements in your area. Grounding procedures must
meet local regulations.
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 condition in
the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that
often builds up in ungrounded devices.
Figure 2.2 – Generator Grounding Lug (typical)
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 critical
loads, within the wattage/amperage capacity, during utility power outages, you might consider using the emergency circuit isolation method.
Generac® Power Systems, Inc.
9
Section 2 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
GENERATOR AC NEUTRAL CONNECTIONS
Generac uses an UNGROUNDED AC neutral.
Grounding is recommended only at the main service
entrance. If the neutral wire is grounded and one of the
phase loads becomes grounded, the excessive current
opens the load circuit breaker or collapses the generator field. The actual result depends on the electrical
characteristics of the particular installed generator.
TRANSFER SWITCH START SIGNAL
CONNECTIONS
If your generator is to be installed with an automatic
transfer switch, such as a Generac GTS-type switch, it
will be necessary to connect the two-wire start
control system.
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection, which
is located in the right hand corner inside the control
panel. Match wires 178 and 183 in the transfer switch
to 178 and 183 on the terminal strip in the control
panel. The conductors for the two-wire start circuit
must be in their own conduit.
BATTERY INSTALLATION
Standby generators installed with automatic
transfer switches will crank and start automatically when normal (utility) source voltage is removed
or is below an acceptable preset level. To prevent
such automatic start-up and possible injury to personnel, do not connect battery cables until you
are certain that normal source voltage at the
transfer switch is correct and you are ready to
place the system 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.
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 you spill the fluid, flush the affected
area immediately with clear water.
Do not dispose of the battery in a fire. The battery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
The battery represents a risk of high short circuit
current. When working on the battery, always
remove watches, rings or other metal objects, and
only use tools that have insulated handles.
VENTED BATTERIES
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures
are to be observed:
• Wear full eye protection and protective clothing,
• Where electrolyte contacts the skin, wash it off
immediately with water,
• Where electrolyte contacts the eyes, flush thoroughly
and immediately with water and seek medical attention, and
• Spilled electrolyte is to be washed down with an acidneutralizing agent. A common practice is to use a
solution of one pound (500 grams) bicarbonate of
soda to one gallon (4 liters) of water. The bicarbonate
of soda solution is to be added until the evidence of
reaction (foaming) has ceased. The resulting liquid is
to be flushed with water and the area dried.
Lead acid batteries present a risk of fire because
they generate hydrogen gas. The following procedure are to be followed:
• DO NOT SMOKE when near batteries,
• DO NOT cause flame or spark in battery area, and
• Discharge static electricity from body before touching
batteries by first touching a grounded metal surface.
Servicing of batteries is to be performed or supervised
by personnel knowledgeable of batteries and the
required precautions. Keep unauthorized personnel
away from batteries.
For recommended batteries, see “Specifications.” All
batteries must be at 100 percent state-of-charge before
they are installed on the generator.
When using maintenance-free batteries, it is not necessary 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 batteries 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.
10 Generac® Power Systems, Inc.
Section 3 - Operation
The instructions in this section assume that the standby 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.
Have the engine cooling system properly filled with the
recommended coolant mixture. Check the system for
leaks and other problems. See “Specifications” and
“Coolant” (Page 7).
▼
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 4, “Maintenance.”
Transfer Switch
▼
If this generator is used to supply power to any electrical system normally powered by an electric utility, the
National Electrical Code requires that a transfer switch
be installed. The transfer switch prevents electrical
backfeed between two different electrical systems.
(For additional information, see the applicable transfer
switch manual for this unit.) The transfer switch, as
well as the generator and other standby components,
must be properly located and mounted in strict compliance with applicable codes, standards and regulations.
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” (Page
7) for more information.
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” (Page 7)
and “Engine Oil Recommendations” (Page 8).
NOTE:
This engine is shipped from the manufacturer with
15W-40 oil. This oil should be changed after 30
hours of operation.
Engine Coolant
Belt Tension
Check the engine fan belt tension and condition prior to
placing the unit into service and at recommended
intervals. Belt tension is correct when a force of approximately 22 pounds (10 kg), applied midway between
pulleys, deflects the belt about 3/8- to 5/8-inch
(10 to 16 mm).
▼
PRIOR TO INITIAL START-UP
▼
PREPARATION BEFORE START-UP
▼
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Electrical System
Make sure the generator is properly connected to an
approved earth ground and/or ground rod.
Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use.
Check to ensure that there are no loose electrical connections. Restrain any loose wires to keep them clear of
any moving generator set components.
USING A STANDARD “GTS” TRANSFER
SWITCH
When required, the pre-packaged standby generator
can be installed with a standard Generac “GTS” type
automatic transfer switch.
When you use a standard GTS type transfer switch, it
controls automatic operation and automatic transfer as
follows:
• Solid state circuits in the transfer switch monitor utility power source voltage.
• When utility source voltage drops below a pre-set level,
transfer switch action closes the circuit. The 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 output 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 your generator is installed in conjunction with a
standard GTS type transfer switch, refer to the applicable transfer switch manual for exact operating
parameters and timing sequences.
Generac® Power Systems, Inc. 11
Section 3 — Operation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
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
HOURMETER
Indicates time the engine-generator has operated, in
hours and tenths of hours. Use the hourmeter along
with the periodic maintenance schedule for your generator set.
AUTO/OFF/MANUAL SWITCH
Use this 3-position switch as follows:
• Set the switch to “Auto” for fully automatic operation.
See “Automatic Operation”.
• Set switch to “Manual” position to crank and start the
generator engine.
• Set switch to “Off” position to shut down an operating engine. With “Off” selected, operation will not be
possible.
30 AMP
FUSE
AC VOLTMETER
The voltmeter displays generator AC output voltage during operation. Voltage is regulated by a solid state voltage regulator and is proportional to AC frequency. Refer
to your unit’s DATA PLATE for rated AC voltage.
AC AMMETER
Indicated current draw of connected electrical loads
during operation. DO NOT EXCEED YOUR UNIT’S
RATED MAXIMUM CONTINUOUS CURRENT. Refer to
the unit DATA PLATE.
AC FREQUENCY METER
Indicates generator AC output frequency in “Hertz”
(cycles per second). Frequency is proportional to engine
speed. Units with a 4-pole rotor supplies 60 Hertz at
1800 rpm. Units with a 2-pole rotor supplies 60 Hz at
3600 rpm. Frequency reading with no electrical loads
connected (no-load condition) should be between 60-62
Hertz.
DC VOLTMETER
The generator is equipped with a belt-driven DC
alternator, which maintains battery state of charge when
the engine operates. The Control Module Assembly also
incorporates a trickle charge circuit which maintains
battery state of charge during non-operating periods.
Battery voltage should read about 12.5 to 14.5 volts DC.
A low battery voltage indicates the battery is
discharging.
12 Generac® Power Systems, Inc.
With switch set to "auto", engine can crank and
start suddenly without warning. Such automatic
start up normally occurs when utility 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.
FAULT INDICATOR LAMP
Lamp goes ON when one or more of the following
engine faults occurs and when engine shuts down.
• Low oil pressure
• High coolant temperature
• Low coolant level
• Overcrank
• Overspeed
30 AMP FUSE
Fuse protects the control console’s DC control circuit
against electrical overload. If the fuse has melted open
because of an overload, engine cranking and startup
cannot occur. Should you need to replace the fuse, use
only an identical 30-amp replacement fuse. (Type AGC)
7.5 AMP INLINE FUSE
This inline fuse is connected in the 15A line that runs
between the Auto/Off/Manual switch and position 10 of
the 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.
Section 3 - Operation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
NOTE:
This fuse will not remove the + battery input power
from the PCB when it opens. This means the exercise
timer will not be reset. If this fuse does open, carefully check the wiring to the start, fuel, field boost
and transfer outputs before replacing the fuse.
METER READING SELECTOR SWITCH:
Switch permits you to select either line-to-line or
line-to-neutral voltage and amperage readings on the
console AC voltmeter and AC ammeter.
SET EXERCISE TIME SWITCH:
Switch allows you to program the generator to start and
exercise automatically. “See Weekly Exercise Cycle.”
MANUAL TRANSFER AND START UP
To transfer electrical loads to the “Standby” (generator)
power source side and start the engine manually, refer
to the Owner’s Manual of your particular transfer
switch.
RETRANSFER AND SHUTDOWN
When utility power source voltage has been restored,
electrical loads may be transferred back to that source
and the generator can be shut down as follows:
• Verify that utility power supply voltage to the transfer
switch has been positively turned “Off,” using whatever means provided (such as utility main line circuit
breaker).
• Set the generator’s main circuit breaker to its “Off” or
“Open” position.
• Let the generator engine run at no-load for a few minutes, to stabilize internal unit temperatures.
• On the generator console, set the Auto-Off-Manual
switch to “Off”. Wait for engine to come to a complete
stop.
• For transfer to utility position, refer to the Owner’s
Manual of your particular transfer switch.
• Turn on the utility power supply to the transfer
switch, using whatever means provided (such as a
utility main line circuit breaker). The utility power
source now powers the loads.
WEEKLY EXERCISE CYCLE
The generator will start and exercise once every 7 days.
During this weekly exercise, the unit runs for about 20
minutes and shuts down. Transfer of loads to generator output does not occur during the exercise.
To select day and time for exercising, proceed as
follows:
• Set the Auto/Off/Manual switch to OFF.
• Set generator main circuit breaker to OFF or OPEN.
• Locate the rocker switch on the control panel identified 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.
If you switch the Auto/Off/Manual switch too
soon, the engine may start. If engine does start,
it will shut down automatically in about two (2)
minutes.
• Set the generator main circuit breaker to its ON or
CLOSED position.
• Generator is now programmed to start and exercise
every 7 days thereafter, on day and time of day the
switch was actuated.
• Place a sign on the generator control panel and the
transfer switch, indicating the day and time the
generator will be exercising.
NOTE:
If battery terminals are disconnected or control
panel fuse is removed, the exercise timer needs to be
reset for correct automatic exercise operation.
Figure 3.2 - “Set Exercise” Switch
AUTOMATIC OPERATION
To set the system for fully automatic operation, proceed
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.
Generac® Power Systems, Inc. 13
Section 4 — Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
ENGINE HEATER
Your Generac standby generator comes equipped with a
block heater (Figure 4.1), similar to the block heaters
used in automotive applications. The block heater is
wired to a grounded plug.
Figure 4.1 - Engine Block Heater
E. EVERY 500 OPERATING HOURS
1.Service air cleaner.
2.Check starter.
3.Check engine DC alternator.
F. EVERY 800 OPERATING HOURS
1.Retorque cylinder head. (See Torque Specs, page 7.)
2.Retorque intake and exhaust manifold. (See Torque
Specs, page 7.)
3.Check engine compression.
4.Check valve clearance.
COOLING SYSTEM
Air intake and outlet openings in the generator compartment must be open and unobstructed for continued
proper operation. This includes such obstructions as
high grass, weeds, brush, leaves and snot.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it to
shut down. (See Section 9 for installation drawings and
vent locations.)
Refer to applicable wiring diagram(s) and electrical
schematic(s) at back of manual for wiring connections.
Customer supplies a 120V 15A Utility fed circuit for the
block heater.
MAINTENANCE PERFORMED BY
AUTHORIZED SERVICE FACILITIES
A. EVERY THREE MONTHS
1.Check battery state of charge and condition.
2.Inspect and test fuel system.
3.Check transfer switch.
4.Inspect exhaust system.
5.Check engine ignition system.
6.Check fan belts.
The exhaust system parts from this product get
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc. must remain
clear of the exhaust. Such materials may ignite
and burn from the heat of the exhaust system.
OVERLOAD PROTECTION FOR ENGINE DC
ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled by
a solid state Engine Controller circuit board. Battery
voltage is delivered to that circuit board via a 30 amp
fuse. These overcurrent protection devices will open if
the circuit is overloaded.
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
1.Change engine oil and oil filter. (After initial change,
service engine oil and filter at 150 operating hours
or 6 months, whichever comes first.)
2.Retorque cylinder head. (See Torque Specs, page 7.)
3.Retorque intake and exhaust manifold. (See Torque
Specs, page 7.)
14 Generac® Power Systems, Inc.
If a circuit breaker opens or a fuse element
melts, you should find the cause of the overload
before resetting the circuit breaker or replacing
the fuse.
CHECKING FLUID LEVELS
CHECK ENGINE OIL
Check engine crankcase oil level (Figure 4.2) at least
every 20 hours of operation, or prior to use.
• Remove oil dipstick and wipe dry with a clean,
lint-free cloth.
• Install oil dipstick, then remove again.
• Oil should be between FULL and ADD marks.
Section 4 — Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
• If oil level is below the dipstick ADD mark, remove oil
fill cap. Add the recommended oil to bring oil level
up to the FULL mark. DO NOT FILL ABOVE THE
“FULL” MARK. See page 6 for recommended oils.
Figure 4.2 - Oil Dipstick and Oil Fill Cap
EXERCISE SYSTEM
Start the generator engine at least once every seven days
and let it run at least 20 minutes. See page 14, “Weekly
Exercise Cycle”.
INSPECT COOLING SYSTEM
OIL DIPSTICK
• Inspect engine cooling system at least once each
month.
• Check hoses for damage, deterioration, leaks, etc.
Correct any discrepancies found.
• Check hose clamps for tightness.
CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels” on page 15.
PERFORM VISUAL INSPECTION
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.
ENGINE COOLANT
Check coolant level in coolant recovery bottle. See
Specifications, page 8
• 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.
MAINTENANCE OWNER/OPERATOR CAN
PERFORM
CHECK ENGINE OIL LEVEL
Refer to “Checking Fluid Levels” on page 15.
CHECK BATTERY
• Check battery fluid level each week as outlined under
“Check Fluid Levels”.
• Check battery cables for condition, tightness, corrosion or damage. Clean, tighten or replace as
necessary.
Complete a thorough visual inspection of the entire
engine-generator monthly. Look for obvious damage,
loose, missing or corroded nuts, bolts and other fasteners. Look for fuel, oil or coolant leaks.
INSPECT EXHAUST SYSTEM
Inspect the exhaust system at least once every three
months. Check all exhaust system pipes, mufflers,
clamps, etc. for condition, tightness, leaks, security,
damage.
CHECK FAN BELT
• Inspect fan belts every three months. Replace any
damaged, deteriorated, worn or otherwise defective
belt.
• Check fan belt tension. Thumb pressure, exerted
midway between pulleys, should deflect about 3/8 to
3/4 inch. Adjust belt tension as required.
INSPECT ENGINE GOVERNOR
Visually inspect electronic governor.
DANGER: Do not attempt to adjust the governor. Only qualified service facilities should adjust
the governor. Excessively high operating speeds
are dangerous and increase the risk of personal
injury. Low speeds impose a heavy load on the
engine when adequate engine power is not
available and may shorten engine life. Correct
rated frequency and voltage are supplied only at
the proper governed speed. Some connected
electrical load devices may be damaged by incorrect frequency and/or voltage. Only qualified
service technicians should adjust the governed
speed.
Generac® Power Systems, Inc. 15
Section 4 — Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Figure 4.4 – Engine Air Cleaner
CHANGING ENGINE OIL
Refer to maintenance performed by authorized service
facilities for engine oil and filter change frequencies.
Drain the oil while the engine is still warm from running. 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 4.3) counterclockwise and
remove. Dispose of old filter.
Figure 4.3 - Oil Filter
See the “Service Schedule,” Section 6, for air cleaner
maintenance.
SPARK PLUGS
Reset the spark plug gap or replace the spark plugs as
necessary. See Section 6.
OIL FILTER
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).
After refilling the crankcase with oil, always
check oil level on dipstick. NEVER OPERATE
ENGINE WITH OIL BELOW THE DIPSTICK “ADD”
MARK.
7. Start engine and check for oil leaks.
CHANGING THE ENGINE AIR CLEANER
To replace the engine air cleaner, (part number 59402),
simply remove the air cleaner cover and replace the air
filter making sure it is positioned properly before reattaching the cover (Figure 4.4).
16 Generac® Power Systems, Inc.
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 commercial solvent. Do not blast the spark plugs to
clean.
2. Remove the spark plugs and check the condition.
Replace the spark plugs if worn or if reuse is questionable. See the “Service Schedule,” Section 6, for
recommended inspection.
3. Check the spark plug gap using a wire feeler gauge.
Adjust the gap to 0.5-0.6 mm (0.020-0.025 inch) by
carefully bending the ground electrode (Figure 4.5).
Figure 4.5 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.5-0.6 mm
(0.020-0.025 inch)
COOLANT CHANGE
Every year, have Authorized Service Facility drain, flush
and refill the cooling system. See SPECIFICATIONS
(page 8) for cooling system recommendations.
Section 4 — Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
MISCELLANEOUS MAINTENANCE
CLEANING THE GENERATOR
Keep your generator as clean and as dry as possible.
Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance.
Periodically clean generator exterior surfaces. A soft
brush may be used to loosen caked on dirt. You can use
a vacuum system or dry, low pressure air to remove any
accumulations of dirt. The generator is housed inside
an all-weather enclosure, clean the enclosure with a
soft, damp cloth or sponge and water.
Once each year have the generator cleaned and inspected by an Authorized Service Dealer. That dealer will use
dry, low pressure air to clean internal windings. Parts
inside the control console should be cleaned and
inspected at this time as well.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
BATTERY
All lead-acid storage batteries discharge when not in
use. Refer to specific instructions and warnings that
accompany your 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 you spill
any battery fluid, 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 gas can form an explosive mixture
around the battery for several hours after charging.
Any spark, heat or flames can ignite the gas and
cause an explosion which can shatter the battery,
causing blindness or other serious injury.
BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule,” Section 6. The following procedure should
be followed for inspection:
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 battery hydrometer.
Storage batteries give off explosive hydrogen gas.
This gas can form an explosive mixture around
the battery for several hours after charging. The
slightest spark can ignite the gas and cause an
explosion. Such an explosion can shatter the 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.
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 you spill the fluid, flush the affected
area immediately with clear water.
Do not use any jumper cables or booster battery
to crank and start the generator engine. If the
battery has completely discharged, remove it from
the generator for recharging.
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 you
attach the cables and cause an explosion.
BATTERY REPLACEMENT
When replacing batteries, use the same number and the
type of battery that follows:
BCI Group No.
26/26R
CCA
525 @ 0 deg. F
Note:
The BCI number should be located directly
on the battery.
Generac® Power Systems, Inc. 17
Section 5 — Troubleshooting
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
PERIODIC REPLACEMENT PARTS
Part Name
Oil Filter
Radiator Cap
Air Cleaner
Spark Plug
Generac’s Part Number
# 0A45310244
# 046627
# 059402
# 0A45310275
TROUBLESHOOTING POINTS
PROBLEM
CAUSE
CORRECTION
Engine won’t crank.
1. 30 amp fuse blown.
2. Loose or corroded or defective
battery cables.
3. Defective starter contactor.
4. Defective starter motor.
5. Dead or Defective Battery.
1. Replace fuse.
2. Tighten, clean or replace
battery cables as necessary.
3. Replace contactor.
4. Replace starter motor.
5. Remove, change or replace battery.
Engine cranks but won't start
1. Out of fuel.
2. Fuel solenoid (FS) is defective
3. Open Wire #14 from Engine Control
circuit board.
4. Spark plugs defective.
1. Replenish fuel.
2. Replace solenoid.
3. Reconnect wire.
Engine starts hard, runs rough.
4. Clean, regap or replace plugs.
1. Flame arrestor (air cleaner) plugged or
damaged.
2. Plugged fuel line.
3. Defective spark plugs.
2. Unclog fuel line.
3. Clean, regap or replace plugs.
Engine starts then shuts down.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
Auto/Off/Manual Switch at OFF,
engine continues to run
1. Defective Auto/Off/Manual switch
2. Open/disconnected wire #15A between
Auto/Off/Manual switch and Control
Module circuit board.
3. Defective Control Module circuit board
1. Replace switch.
2. Reconnect/close wire.
1.
2.
3.
4.
1.
2.
3.
4.
No AC output from generator.
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
Check main line circuit breaker.
Check circuit breaker & fuses.
Transfer switch set to NORMAL position
Generator internal failure.
5. Thermal circuit breaker open.
18 Generac® Power Systems, Inc.
1. Clean or replace as needed.
Check oil and add oil as needed.
Check cooling system for leaks.
Replace switch.
Replace switch.
Replace board.
Repair leak - Add coolant.
Replace Switch.
3. Replace board.
Reset to ON or CLOSED.
Reset and replace, if necessary.
Set to GENERATOR position.
Contact an Authorized Generac
facility.
5. Auto-reset - Wait 5 min. and
attempt restart.
Section 6 — Scheduled Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Following is a recommended maintenance schedule for Generac Guardian small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an
average service application. They will need to be decreased (performed more frequently) if the unit is used in a
severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to 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 potential problem areas.
Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 manhours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to prevent
the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
•
Disable the generator set from starting and/or connecting to the load by setting the control panel
Auto-Off-Manual switch to the “OFF” position.
•
Remove the control panel fuse.
•
Turn off the battery charger.
•
Remove the negative battery cable.
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition 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 30 hours of operation after purchase of
the unit and requires approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge
to accomplish and 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 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 6 — Scheduled Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
1. Disable the unit from
operating per the first page
warning.
2. Check the engine oil level.
Adjust as necessary.
3. Check the engine coolant
level. Adjust as necessary.
4. Check the engine coolant
thermal protection level.
Correct as necessary.
5. Check the natural gas
delivery system on gas
engine driven units.
Tighten connections as
necessary.
6. Check the air inlets and
outlets for debris. Clean as
necessary.
7. Check the battery
electrolyte level if
accessible. Adjust as
necessary.
8. Check the battery posts,
cables, and charger for
loose connections,
corrosion, and proper
operation. Correct as
necessary.
9. Check the unit wiring for
loose connections,
corrosion, and damage.
Correct as necessary.
10. Check the engine
accessory drive belts for
wear, weather cracking,
and damage. Replace as
necessary.
11. Visually inspect the unit
looking for leaks, wear or
damage, loose connections
or components, and
corrosion. Correct as
necessary.
12. Test the engine and
transfer switch safety
devices. Correct and/or
adjust as necessary.
20 Generac® Power Systems, Inc.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 hrs.
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually/
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Task
Comp.
(DateInitials)
Section 6 — Scheduled Maintenance
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Maintenance
Tasks
Level 1
Recommended
to be done
monthly/
10 hrs.
Level 2
Task
Comp.
(DateInitials)
Required
to be done
3 months/
Break-in
30 hrs.
Level 3
Task
Comp.
(DateInitials)
Required
to be done
Semiannually/
50 hrs.
Level 4
Task
Comp.
(DateInitials)
Required
to be done
Annually/
100 hrs.
Task
Comp.
(DateInitials)
13. Initiate an automatic start
and transfer of the unit to
site load and exercise it for
at least 1 hour looking for
leaks, loose connections
or components, and
abnormal operating
conditions. Correct as
necessary.
14. Start and exercise the unit
at full rated load (use a
load bank if the site load is
not enough) for at least 2
hours looking for leaks,
loose connections or
components, and abnormal
operating conditions.
Correct as necessary.
15. Change the engine oil.
16. Replace the engine oil
filter(s).
17. Replace the engine air
filter(s).
18. Replace the engine fuel
filter(s) on diesel engine
driven units and re-prime
the fuel system.
19. Check the engine spark
plugs on gas engine driven
units. Clean and re-gap or
replace as necessary.
20. Perform a 5 minute no-load
operational run of the unit
looking for any post service
problems.
21. Return the unit to standby
setup for operation when
required.
Generac® Power Systems, Inc. 21
Section 7 - Electrical Data
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803-D
22 Generac® Power Systems, Inc.
Section 7 - Electrical Data
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803-D
Generac® Power Systems, Inc. 23
Section 7 - Electrical Data
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Electrical Schematic — Control Panel (1-Phase) — Drawing No. 0A2802-B
24 Generac® Power Systems, Inc.
Section 7 - Electrical Data
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
(AC OUTLET)
Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7176-A
Generac® Power Systems, Inc. 25
Section 7 - Electrical Data
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Electrical Schematic — 1.5L Gas Engine — Drawing No. 0A7182-A
FED CIRCUIT (AC OUTLET)
26 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Enclosure (15 and 20 kW) — Drawing No. A7188-D
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
97575
A3769
A3768
A5314
67042
22264
67035
2
2
1
1
2
6
6
8
9
82570
A7215
2
10
BRACE, SIDE
DOOR, ENCLOSURE
DOOR, ENCLOSURE
TOP, ENCLOSURE
LATCH
LOCK WASHER, #8
SCREW, PAN HEAD MACH.-#8-32 x
5/16"
PLUG-4"
SWAGE FASTENER-W/NYLON WASHER
ITEM
10
11
13
14
15
16
17
18
19
PART NO. QTY. DESCRIPTION
32990
C2164
29107
A1694
91297-063
91297-064
49813
70005
49811
6
1
6
5
3
3
3
3
3
BUMPER
LATCH
GROMMET 3/16"-7/8"
BUTTON-PLUG 1-1/2"
GROUND WIRE ASSEMBLY
GROUND WIRE ASSEMBLY
HEX NUT M6 x 1.0
LOCK WASHER M6
FLAT WASHER M6
Generac® Power Systems, Inc. 27
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Enclosure (25kW) — Drawing No. 0C1404-B
28 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Enclosure (25kW) — Drawing No. 0C1404-B
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
30
31
32
36
37
38
39
40
42
43*
44*
45*
46*
47*
48*
49*
50*
51*
52*
53*
54
55
PART NO.
0A2110
0A2115
0A3133A
0A3133B
0A3133C
0A3133D
0A3359
0A3360
0C1245
0C1245A
0A3449
0A4822
0A4823
0A4824
0A4825
0A4826
0C1193
0A4831
0A4832
0C1067
0C1067A
0C1068
0C8817
0C1244
0A9955
022097
022129
022127
022145
089961
022473
082570
039253
042568
0D3397
0D3785
037337
0A6807
057042
067577
022413
0C1053B
0C1053A
0C1053E
0C1053F
0C1053G
0C1053H
0C1053D
0C1053J
0C1053K
0C1053L
0C1053M
078115
030486
QTY.
32
32
4
4
2
2
24
24
1
1
2
1
2
1
1
1
1
1
2
1
1
1
1
1
1
16
12
4
12
24ft.
20
1
12
14
2
1
4
1
2
4
4
1
2
1
1
1
1
2
1
1
1
1
14
2
DESCRIPTION
SCREW SWAGE 1/4-20 X 1/2 Z/YC
WASHER NYLON .250
HINGE SLIP MALE LH
HINGE SLIP FEMALE LH
HINGE SLIP MALE RH
HINGE SLIP FEMALE RH
SCREW BHSC M6-1.0 X 16 SS
SHAKEPROOF INT M6 SS
PANEL TOP SIDE LH
PANELTOP SIDE RH
DOOR SIDE
PANEL FRONT
PANEL SIDE BOTTOM
PANEL REAR
CORNER POST REAR LH
CORNER POST REAR RH
TOP ENCLOSURE 1.5 SAE
DOOR REAR
DUCT
SUPPORT RADIATOR LH
SUPPORT RADIATOR RH
SUPPORT MUFFLER 1.5L
TOP CONTROL PANEL SAE
DUCT FRONT 1.5L SAE
BASE MOUNTING
WASHER LOCK M6-1/4
WASHER LOCK M8-5/16
NUT HEX 1/4-20 STEEL
WASHER FLAT 5/16 ZINC
FOAM STRIP 3/4 X 1/4
WASHER FLAT 1/4 ZINC
PLUG PLASTIC 4 PLUG BTTN #425
SCREW HHC M8-1.25 X 20 G8.8
SCREW HHC M6-1.0 X 20 G8.8
DECAL CAUTION HOT SURFACES
BRACE REAR DOOR
NUT HEX JAM 3/8-24 SS
LATCH REWORK 48.5MM
LATCH AND CAM
NUT SPEED 1/4-20
SCREW HHC 1/4-20 X 1 G5
INSULATION PANEL TOP
PANEL SIDE DOOR
INSULATION PANEL FRONT R.H.
INSULATION PANEL FRONT L.H.
INSULATION DUCT FRONT
INSULATION PANEL FRONT TOP
INSULATION PANEL DUCT SIDE TOP
INSULATION PANEL, REAR
INSULATION DUCT L.H. SIDE
INSULATION DUCT R.H. SIDE
INSULATION DOOR REAR
WASHER SELF LOC/DOME
GROMMET 7/16 X 1/16 X 1/4
* NOTE: THESE PARTS ARE INCLUDED IN KIT 0C1053Z.
Generac® Power Systems, Inc. 29
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Control Panel (15 and 20 kW) — Drawing No. 0A2872-F
30 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Control Panel (15 and 20 kW) — Drawing No. 0A2872-F
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
PART NO.QTY.
DESCRIPTION
098062
075589
0A1775
098063
0A2106
057073
022985
070080
070043
070055
070042
070081
076037
022152
022158
061945
032300
022668
076020
074074
067680
075476
022264
022237
051715
0C2428
076039
051756
048476
054450
022241
022097
022473
0A1354A
043116
056739
SUPPORT, CONTROL PANEL, L.H.
BRACKET, VOLTAGE REGULATOR
CONTROL, PANEL-BACK
SUPPORT, CONTROL PANEL R.H.
SILKSCREEN, "P" PANEL
BLOCK, JUNCTION
WASHER, FLAT #6
INSULATOR
VOLTMETER, AC 0-300
AMMETER, AC 0-100
METER, FREQUENCY 55-65HZ
HOURMETER
METER, VOLT DC 8-18V
WASHER, LOCK #10
NUT, HEX #10-32
SWITCH, SELECTOR AMP/VOLT
HOLDER, FUSE
FUSE, AGC-30
SWITCH, TOGGLE DPDT
ASSEM. POTTED REG. WOFIN
VOLTAGE REG. ASSEM. B&D
SCREW, PPHM M4-0.7 x 16MM
WASHER, LOCK #8-M4
WASHER, LOCK 3/8"
NUT, HEX M4-0.7
6-32 x 5/8" SWAGEFORM PPH
SCREW, PPHM-M5-0.8 x 40MM
HHCS M10-1.5 x 20
CIRCUIT BREAKER 4.5A.
CIRCUIT BREAKER 5.5A.
HEX NUT 3/8"-16
WASHER, LOCK 1/4-M6
WASHER, FLAT 1/4-M6
REGULATOR-DC ALT.
HHCS, M6-1.0 x 12MM
SOLENOID RELAY 12VDC
1
1
1
1
1
1
**
2
1
1
1
1
1
**
**
1
1
1
1
**
**
**
**
1
**
2
**
**
1
1
1
8
8
1
4
1
ITEM
36
37
38
39
40
41
42
43
44
45
47
50
51
52
55
56
57
58
59*
60*
61
63
65
67
68
69
70
71
72***
73***
PART NO.QTY.
DESCRIPTION
0C2512
0C2513
061395
058318
033121
049226
023897
075595
077438
082573
055440
0C2212
057335
0A7230
048766
0A7215
057593
028739
061979
0A2833
0A2833A
064009
081988
086381
036903
022155
098647
076040
049226
0D5324
0A9611
GROMMET 1/16-1-3/8
GROMMET 1/8-1-3/4
TRANSFORMER, CURRENT 100/5
TRANSFORMER, CURRENT 150/5
HEX HD. MACH. SCR. 10-32 x 1/2"
LOCK WASHER, M5
WASHER, FLAT #10-M5
CMA BOX ASSEMBLY
SCREW, PHM M6 x 1.0 x 12MM
ROCKER SWITCH DPST
HHCS M5-0.8 x 25MM
M4-.7 x 16 SWAGEFORM PPH
TERMINAL BLOCK 20 PCS #6 PANEL
DECAL, TERMINAL STRIP
BLOCK, TERMINAL 2 PCS #6 PANEL
1/4"-20 X 5/8" LG. SWAGEFORM
MOUNT, CABLE TIE
WRAP, TIE-4" LONG
BUS, BAR
HARNESS, PANEL "PP" IP
HARNESS, PANEL "PP" 3P
PILOT LIGHT RED 14-V.
DECAL-EXERCISE INFO
CAPLUG, BPF-1/4"
SCREW, PPHM 6-32 x 5/8 LG
WASHER, LOCK #6
STEPPER MOTOR KIT
PPHMS, M5-0.8 x 16MM
WASHER, LOCK M5
FUSE & HOLDER LITTLE 7.5A
FUSE 7.5AXBK/AGC7.5NX
1
2
**
**
2
2
6
1
4
1
1
6
1
1
1
14
4
4
1
1
1
1
1
2
2
2
1
2
2
1
REF
*NOT SHOWN ON THIS ASSEMBLY
**SEE CHART
***PART OF CONTROL PANEL WIRE HARNESS
Generac® Power Systems, Inc. 31
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Control Panel (25kW) — Drawing No. 0C8847-C
32 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Control Panel (25kW) — Drawing No. 0C8847-C
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
PART NO.QTY.
DESCRIPTION
0C5077
075589
0A1775
0C5078
0C4224A
057073
022985
081988
070043
070055
070042
070081
076037
022152
022158
061945
032300
022668
076020
083048
0A2077
075476
022264
0A3968
039782
0C2323
076039
051756
048476
022237
022097
022473
082573
043116
056739
072252
SUPPORT, CONTROL PANEL L.H.
BRACKET, VOLTAGE REGULATOR
CONTRLPANEL-BACK
SUPPORT CONTROL PANEL R.H.
SILKSCREEN, PANEL (SAE)
BLOCK JUNCTION 3/8-16
WASHER FLAT #6 ZINC
DECAL EXERCISE INFO
VOLTMETER AC 0-300
AMMETER AC 0-100
FREQUENCY METER 55-65HZ
HOURMETER
VOLTMETER DC 8-18V
WASHER, LOCK #10
NUT, HEX #10-32 STEEL
SWITCH 6A AMP/V SELECTOR
HOLDER, FUSE
FUSE 30A X AGC30 HLDR22669 HKP
SWITCH DPDT 15/10 SP ON-OFF-ON
ASY POTTED REG WOFIN
CIRCT BRK 125X2 120/240V
SCREW, PPHM-M4-0.7 x 16MM
WASHER, LOCK-M4
CAPACITOR, FILTER ASSY.
BRACKET CIRCT BRK MOUNTING
SCREW TAPTITE PH 6-32X5/8 ZYC
SCREW PPHM M5-0.8 X 40
SCREW HHC M10-1.5 X 20 G8.8
CIRCT BRK 4.5X1 AUT30KW CNT45K
WASHER LOCK 3/8
WASHER LOCK M6-1/4
WASHER FLAT 1/4 ZINC
SWITCH DPST 5 125V SPD RCKR
SCREW HHC M6-1.0 X 12 G8.8
RELAY SOLENOID 12VDC PNL MNT
GROMMET 1.37 X .06 X 1.00
1
1
1
1
1
1
4
1
1
1
1
1
1
10
10
1
1
1
1
1
1
14
14
1
1
2
2
3
1
1
8
8
1
4
1
2
ITEM
37
38
39
40
41
42
43
44
45
46
48
49
50
51
52
53
54*
55
56
57
58
59*
60*
61
62
63
64
65
66
67
68**
69**
PART NO.QTY.
DESCRIPTION
063212
058318
033121
049226
023897
075595
049811
072355
055440
022241
022155
098647
057335
021480
048766
058589
070882
0A7215
076040
049813
061979
0A2833
0A6821
064009
064009
0A1354A
0C2212
0C3826
0C4427
0C8817
0D5324
0A9611
GROMMET 1.75 X .12 X 1.50
TRANSFRM 150A TO 5A 5VA
SCREW HHM 10-32 X 1/2
WASHER LOCK M5
WASHER FLAT #10 ZINC
ASSM.,CMA BOX
WASHER FLAT M6
HHCS M6-1X12-A/C-.HD
SCREW HHC M5-0.8 X 25 G8.8
NUT HEX 3/8-16 STEEL
WASHER LOCK #6
ASSY L.C. ELECT GOV
BLOCK TERM 20A 20 X 6 X 1100V
DECAL TERMINAL STRIP
BLOCK TERM 20A 2 X 6 X 1100V
DECAL WARN ENG START
ASSY SUPPRESSION
SCREW SW 1/4-20X5/8 N WA JS500
SCREW PPHM M5-0.8 X 16
NUT HEX M6-1.0 G8 YEL CHR
BUS BAR
HARNESS PNL "PP" 1P
HARNESS WIRING (1.5L)
LIGHT 12VDC .02A LED RED PILOT
DECAL, TRANS. SWITCH CONN.
REGULATOR - DC ALT
SCREW TAPTITE PH M4-0.7X16 ZYC
HINGE, CONTROL PANEL
M6X1.0X12 T.H.M.S SS
TOP, CONTROL PANEL (SAE)
FUSE & HOLDER LITTLE 7.5A
FUSE 7.5AXBK/AGC7.5NX
1
2
2
4
10
1
8
2
1
1
2
1
1
1
1
1
1
10
2
8
1
1
1
1
1
1
6
2
8
1
1
REF
* NOT SHOWN ON THIS ASSEMBLY
** PART OF CONTROL PANEL WIRE HARNESS
Generac® Power Systems, Inc. 33
To engine bypass
21
6
9
7
7
32
"A"
23
8
8
11
5
20
To thermostat
adapter
7
16
14
7
8
14
12
8
10
19
32
3
(Bottom only)
25
26
27
24
To water inlet tube
(Midway up engine block)
12
13
8
17
To base of
water inlet
tube (On block)
2
10
"A"
29
31
33
3
12
4
24
14
30
12
4
18
17
34
33
11
Section 8 - Exploded Views and Parts
9
12
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Radiator (15 & 20 kW) — Drawing No. A7206-C
34 Generac® Power Systems, Inc.
1
22
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Radiator (15 & 20 kW) — Drawing No. A7206-C
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PART NO.
0A6272
0A5734
0A6237
0A6238
084918
050967
057823
099502
083709
052250
042568
022097
049813
022473
084427
050967
075443
056892
0A6284
0A6258
029032
031669
060035
022127
022145
022129
045771
042907
076749
080712
0A7215
0A7275
0A2111
065852
QTY.
1
1
1
1
1
12"
4
4
2
14'
4
13
2
11
1
18"
6
4
1
1
1
4
4
5
4
4
4
4
1
1
1
6'
2
2
DESCRIPTION
SUPPORT RADIATOR
RADIATOR 1.5L
VENTURI 1.5L MODINE
GUARD FAN 1.5L MODINE
HEATER ENGINE 0500W 120V
HOSE 5/8 ID RIA 250F
CLAMP HOSE #10 .56 - 1.06
CLAMP HOSE #24 B1.06 - 2.00
CLAMP WIRE HOSE .573 - .551
TAPE FOAM 1 X 1
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
NUT HEX M6 X 1.0 G8 YEL CHR
WASHER FLAT 1/4 ZINC
BRACKET HEATER
HOSE 5/8 ID RIA 250F
CRIMPTITE 1/4-20 X 5/8
CRIMPTITE 10-24 X 3/8
HOSE - LOWER RADIATR
HOSE - UPPER RADIATR
HOSE 9/32 ID
BOLT CARR 1/4-20 X 1-3/4 JS500
SPACER .41 X .75 X .87 ST/ZNC
NUT HEX 1/4-20 STEEL
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M8-1.25 X 16 G8.8
TANK COOLANT RECOVERY
BRACKET COOLANT RECOVERY TANK
SCREW SWAGE 1/4-20 X 5/8 N WA JS500
FOAM 1.5 X 1 ADHESIVE BACKING
SCREW SWAGE 10-32 X 5/16 Z/YC
SPRING CLIP HOLDER .37-.62
Generac® Power Systems, Inc. 35
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Radiator (25 kW) — Drawing No. 0C1406-B
36 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Radiator (25 kW) — Drawing No. 0C1406-B
ITEM
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
PART NO.
0A5734
0A6237
0A6238
084918
050967
057823
099502
083709
042568
022097
049813
022473
084427
050967
075443
056892
0A6284
0A6258
029032
031669
060035
022127
022145
022129
045771
042907
076749
080712
0A7215
030486
0A2111
065852
0C1067A
0C1067
0C1480
QTY.
1
1
1
1
12"
4
4
2
6
15
2
11
1
18"
6
4
1
1
1
4
4
5
12
12
12
12
1
1
1
2
2
2
1
1
1
DESCRIPTION
RADIATOR 1.5L
VENTURI 1.5L
GUARD FAN
HEATER 500W 1020
HOSE RES 5/8 RIA 250F
CLAMP HOSE #10 .56 - 1.06
CLAMP HOSE #24 1.06 - 2.00
CLAMP WIRE HOSE .573 - .551
SCREW HHC M6-1.0 X 20 G8.8
WASHER LOCK M6-1/4
NUT HEX M6 -1.0 G8 YEL CHR
WASHER FLAT M6-1/4 ZINC
BRACKET HEATER
HOSE RES 5/8 RIA 250F
CRMPTIT 1/4-20 X 5/8
CRMPTIT 10-24 X 3/8
HOSE LOWER RADIATOR
HOSE UPPER RADIATOR
HOSE 9/32 ID
BOLT CARR 1/4-20 X 1-3/4 JS500
SPACER .41 X .75 X .87 ST/ZNC
NUT HEX 1/4-20 STEEL
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SCREW HHC M8-1.25 X 16 G8.8
TANK COOLANT RECOVERY
BRACKET COOLANT RECOVERY TANK
SCREW SW 1/4-20X5/8 N WA JS500
GROMMET 7/16 X 1/16 X 1/4
SCREW SWAGE 10-32 X 5/16 Z/YC
NUT SPRINGCLIP .37 - .62
SUPPORT RADIATOR RH
SUPPORT RADIATOR LH
BRACKET COOLANT BOTTLE
Generac® Power Systems, Inc. 37
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Mounting Base (15 & 20 kW) — Drawing No. A7187-A
ITEM
1
3
4
5
6
7
8
9
10
12
13
14
15
PART NO.
C2632
70936
70936C
39253
22145
22129
45771
71956
51730
57821
21991
27482
A2308
QTY.
1
2
2
8
12
12
12
4
2
2
1
1
1
DESCRIPTION
BASE, MOUNTING
ISOLATOR-VIBRATION
ISOLATOR, VIBRATION
CAPSCREW, HEX HEAD-M8-1.25 x 20MM
FLAT WASHER-M8
LOCK WASHER-M8
NUT, HEX-M8-1.25
WASHER, VIBRATION ISOLATOR
CAPSCREW, HEX HEAD-M8-1.25 x 60MM
CAPSCREW, HEX HEAD-M8-1.25 x 40MM
STRAP, GROUNDING
WASHER-STAR 5/16"
PLUG-BUTTON
38 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Mounting Base (25 kW) — Drawing No. 0C1405-A
ITEM
1
3
4
5
6
7
8
9
10
12
13
14
15
PART NO.
0A9955
070936
070936C
039253
022145
022129
045771
071956
051730
057821
021991
027482
0A2308
QTY.
1
2
2
8
12
12
12
4
2
2
1
2
1
DESCRIPTION
BASE MOUNTING
DAMPENER VIBRATION
DAMPENER VIBRATION
SCREW HHC M8-1.25 X 20 G8.8
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
WASHER FLAT M8
SCREW HHC M8-1.25 X 60 G8.8
SCREW HHC M8-1.25 X 40 G8.8
EARTH STRAP
WASHER SHAKEPROOF EXT 5/16 STL
PLUG BUTTON 2" DIA
Generac® Power Systems, Inc. 39
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Muffler (15 & 20 kW) — Drawing No. A7618-B
3
5
1
4
2
12
11
12
9
10
9
8
9
13
13
7
6
15
14
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO.
020689
060366
059933
080761
059939
075546A
036434
022259
022129
036449
076032
039253
045771
0C3683
0A7215
QTY.
1
1
1
1
1
1
1
2
6
1
1
4
4
1
4
DESCRIPTION
MUFFLER W/RAIN SHLD
MUFFLR STRAP 6IN DIA
ELBOW 90 DEG 2 NPT
NIPPLE TOE 2 NPT X 4.5 BLK IRON
RAIN CAP 2.37 I.D.
PIPE FLEX EXHAUST
BOLT U 5/16-18 X 2.09
NUT HEX 5/16-18 STEEL
WASHER LOCK M8-5/16
SADDLE 2 INCH
CHANNEL MUFFLER SUPPORT
SCREW HHC M8-1.25 X 20 G8.8
NUT HEX M8-1.25 G8 YEL CHR
GUARD MUFFLER (1.5L)
SCREW SW 1/4-20 X 5/8 N WA JS500
40 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Muffler (25 kW) — Drawing No. 0C1408-B
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO.
0A4355
0C1636
036434
036449
0C1330
0C1318
0C1068
0C1412
0A5728
060366
066889
022145
022129
045771
0A8974
QTY.
1
1
4
4
1
1
1
1
1
2
4
4
4
4
1
DESCRIPTION
MANIFOLD EXHAUST 1.5L
NIPPLE TOE 1.5 NPT X 6.5 BL IRON
BOLT U 5/16-18 X 2.09
SADDLE 2 INCH
PIPE EXHAUST
FLEX PIPE EXHAUST
SUPPORT MUFFLER 1.5L
ELBOW EXHAUST 45 DEG
MUFFLER 1.6/1.5L SAE
STRAP MUFFLER 6" DIA
SCREW HHC M8 X 1.25 X 20MM
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
CAP RAIN 2"
Generac® Power Systems, Inc. 41
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Circuit Breaker — Drawing No. 0D8294
1
4
3
6
2
5
ITEM
1
2
3
4
5
6
PART NO.
0A2106
0A2952
039782
048373
039766
0A2077
023965
022264
QTY.
1
1
1
1
1
1
2
2
DESCRIPTION
SILKSCREEN "P" PANEL
COVER BQ CIRCUIT BREAKER
BRACKET MOUNTING CIRCUIT BREAKER
CIRCUIT BREAKER 70 X 2 240V 39782 BRKT
CIRCUIT BREAKER 90 X 2 240V 39782 BRKT
CIRCUIT BREAKER 125 X 2 120/240V 39783 BRKT
SCREW RHM #8-32 X 3/8
WASHER LOCK #8-M4
42 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – CMA Assembly — Drawing No. 081086-D
ITEM PART NO. QTY.
1
2
3
4
5
6
7
8
9
10
11
074100
1
076009A
1
072566
080882
074978
047822
075476
083264
022985
022264
051787
079847
4
4
1
1
2
1
4
4
2
1
DESCRIPTION
ASSY HOME STDBY LOGIC
(MODELS 921, 863, 865)
PP LOGIC ASM 50/60HZ
(MODEL 9428)
NUT SPACER .250 PCB
SCREW PPH TAPPING #6X5/8 SS
DECAL TERMINAL STRIP
BLOCK TERM 20A 7 X 6 X 1100V
SCREW PPHM M4-0.7 X 16
TRANSFORMER ASM CMA 240/12V
WASHER FLAT #6 ZINC
WASHER LOCK M4
SCREW HHC M4-0.7 X 16 G8.8
BOX CMA
ITEM PART NO. QTY.
12
13*
14
15
16
17*
18
19
20
21
0A8504
0A8504A
022661V
038057
058443
081224
079682
086093
083736
051715
077401
1
1
.083'
2
2
1
1
2
1
2
1
DESCRIPTION
DECAL, CMA LABEL
DECAL, CMA LABEL
TUBING SHRINK 19"ID RED
GROMMET 7/8 X 1/16 X 3/4
SCREW CRIMPTITE 1/4-20 X 5/8
DECAL MFG NAMEPLATE
HARNESS CMA WIRE
DECAL CMA WARNING
DECAL CSA GTS
NUT HEX M4-0.7 G8 YEL CHR
COVER SILKSCREEN CMA
* NOT SHOWN
Generac® Power Systems, Inc. 43
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Battery — Drawing No. 098922-E
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO.
077483
038804D
038805B
0742600131
022131
046526
052213
059567
078121
022145
022129
022259
050331A
050331
075763
QTY.
1
1
1
1
1
1
1
2
1
2
2
2
1
1
3
DESCRIPTION
BATT 12VDC 75-AH 26/26R
CABLE BATT RED #4 X 20.00
CABLE BATT BLK #4 X 23.00
ASSY,WIRE#16 RED 1.6
WASHER FLAT 3/8 ZINC
WASHER LOCK M10
SCREW HHC M10-1.25 X 20 G8.8
BOLT BATTERY HOLD DOWN
BAR BATTERY HOLDDOWN
WASHER FLAT M8-5/16 ZINC
WASHER LOCK 5/16
NUT HEX 5/16-18 STEEL
BATTERY POST COVER (RED+)
BATTERY POSTCOVER (BLACK-)
BOOT, BATTERY CABLE
44 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Governor Assembly — Drawing No. 0A7216-A
ITEM
PART NO.
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
098290
098941A
098958A
098942A
098225
043146
022097
064526
098783
037398
0A70410SRV
0A7106
074031
029333A
022507
022473
1
1
1
1
2
3
5
2
1
2
1
1
1
2
2
DESCRIPTION
ASM MOTOR STEPPER
HOUSING GOVERNOR CONNECTOR
CONNECTOR INTERFACE ASSEMBLY
COVER CONNECTOR HOUSING
SCREW FHM #2 X 5/8 SELF TAP
SCREW HHC M6-1.0 X 10 G8.8
WASHER LOCK M6-1/4
SCREW HHM #6-32 X 3/8 SELF TAP
LEVER STEPPER MOTOR
NUT LOCK HEX #10-32 NYL INS
ASSEMBLY CARBURATOR LINKAGE
BRACKET STEPPER MOTOR
LIQUID NEOPRENE
TIE WRAP 7" BLACK
SCREW HHC 1/4-20 X 1/2 G5
WASHER FLAT 1/4 ZINC
Generac® Power Systems, Inc. 45
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Generator — Drawing No. 0A9348-C
46 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Generator — Drawing No. 0A9348-C
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25**
26*
27
28
29
30
31
32
33
35
PART NO.
098671
098681
098675
098936
0A5336A
0A1659
071912
022152
051713
022129
098672
098673
098674
098682
098683
098684
098676
098677
098678
097620
098937
097621
0A5382
075591
075476
0A5601
075554B
0A9375
022152
097146
042558
0A5061
0A4989
052213
051769
049541
046526
045772
082130B
087599
077043E
022131
072578
0A7043
049808
058589
023365
0A8830
QTY.
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
4
4
4
1
1
1
1
1
6
4
4
4
1
1
1
4
1
5
5
1
4
4
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
LOCK WASHER-#10
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 A
ASSY STATOR 20KW 1PH GJK
ASSY STATOR 25KW 1PH A
ASSY STATOR 25KW 1PH D
ASSY STATOR 25KW 1PH 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 & RING GEAR ASSEM.
KEY SQ 3/8 X 1 STEEL
SPACER-FLEX PLATE
PLATE, FLEX
SCREW HHC M10-1.25 X 20 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
ASSY MPU SPEED SENSOR 48"
PLUG PLASTIC 3/8 CAPLUG #2
FLEX CONDUIT 1" BLACK (NOT SHOWN)
WASHER FLAT 3/8 ZINC
SPACER ROTOR SHAFT
SCREW HHC M12-1.25 X 25 G8.8
WASHER FLAT M12
DECAL-WARNING
WASHER SHAKEPROOF INT #8
WASHER FLAT .34 ID X .75 OD
* USED ON PRE-PACKAGED UNITS ONLY
** USED ON "C" OPTION PANEL UNITS ONLY
Generac® Power Systems, Inc. 47
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Gaseous Fuel System — Drawing No. 0A9349-E
48 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Gaseous Fuel System — Drawing No. 0A9349-E
ITEM
1
2
3
4
5
6
7
8
9
11
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PART NO.
QTY.
DESCRIPTION
0C2632
075580
026915
039253
022145
022129
045771
0A2666
046747
0C3714
0A5547
0C1475
0A9911
0A7989
0A6593
059402
037561
059403
059401
034154
022152
023897
062522
022127
022259
050280
0A6125
052219
048031C
029032
029032
032552
0A4682
042907
055934D
0A7040
0C3153
1
2
3
4
5
7
4
2
1
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
2
1
2
1
3
6-1/2"
11"
1
1
1
1
1
1
WELDMENT MOUNTING BASE
FLANGE FUEL INLET
NIPPLE CLOSE 3/4 X 1.375
SCREW HHC-M8-1.25 X 20
WASHER FLAT 5/16 ZINC
WASHER LOCK M8-5/16
NUT HEX M8-1.25 G8 YEL CHR
SOLENOID GAS FUEL
BUSHING REDUCER 3/4 TO 3/8
ASSY HOSE NG/LPV.31"
COVER AIR CLEANER
REGULATOR NATURAL GAS EM
REGULATOR L.P. GAS EM
NIPPLE PIPE 3/8 NPT X 4 BLK IRON
ADAPTOR CARBURETOR
FILTER ELEMENT
NUT WING 1/4-20 NYLK
CARBURETOR, CA55 EM
GASKET CARBURETOR
SCREW PHM 10-24 X 1/2 CAD
WASHER LOCK #10
WASHER FLAT #10 ZINC
STUD THR 1/4-20X3 F THR G2 ZNC
NUT HEX 1/4-20 STEEL
NUT HEX 5/16-18 STEEL
DECAL FUEL INLET LPG
STUD 5/16-18 X 1.25 F THR
BARBED STR 1/8NPT X 5/16
CLAMP HOSE BAND 1/4
HOSE 9/32 ID
HOSE 9/32 ID
BARBED EL 90 5/16 X 1/8NPT
MANIFOLD INTAKE 1.5
SCREW HHC M8-1.25 X 16 G8.8
CLAMP VINYL 1.06 X .406 Z
BRACKET-RADIATOR HOSE
TORX PLUS BHS M8 X 30
Generac® Power Systems, Inc. 49
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Engine Compartment — Drawing No. 0A7642-J
50 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Exploded View – Engine Compartment — Drawing No. 0A7642-J
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
33
34
35
36
37
38
0A4531
035685
075546A
0A45310258
0A4355
0A6699
022097
022507
052212
046526
022131
0C2499
055993
045772
023586
020692
0A7005
052243
0A4772
070901
051735
056768
022145
022129
022259
052213
047411
052830
045771
058306
030795
0A2711A
048665
075885
0A45310257
0A4682
057522
1
1
1
1
1
1
8
2
4
14
16
2
1
4
2
1
2
1
1
2
3
2
2
23
2
1
2
2
10
5
2
1
1
1
1
1
1
ENGINE-1.5L
CLAMP HOSE #28 1.32 - 2.25
PIPE-FLEX EXHAUST
GASKET-EXHAUST MANIFOLD
MANIFOLD-EXHAUST
SHIELD HEAT EXHAUST
WASHER LOCK M6-1/4
SCREW HHC 1/4-20 X 1/2 G5
SCREW HHC M10-1.25 X 25 G8.8
WASHER-LOCK-M10
WASHER FLAT 3/8 ZINC
STAMPING ENG 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 G12.9
SCREW HHC 5/16-18 X 1 G5
ADAPTER-THERMOSTAT
GASKET THERMOSTAT
THERMOSTAT 195 DEG
GASKET INLET MANIFOLD
MANIFOLD-INTAKE
SENSOR COOLANT LEVEL
ITEM PART NO. QTY. DESCRIPTION
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
0A6751
034339
0D4788
061012
039253
0A5110
0A7006
025507
022500B
0A8584
036277
042574
026073A
0A6701
039414
0A5568
051769
0A4804
0A4800
0A5839
0A1354B
0A4839
055816
049811
075614
0A2628
0A5275
0A5586
0A4814
0A45310244
0C1852
0912970066
070928
069860C
069811
0A5317
022473
1
1
1
1
6
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
SW-TMP 245DEG 3/8NPT
BARBED EL 90 3/8NPT X 5/8
PLUG STD PIPE 3/8 STEEL SQ HD
PLUG STD PIPE 1/8 SCKT HD
SCREW HHC M8-1.25 X 20 G8.8
PIPE WATER-INLET
O-RING 1-1/16X1-5/16X1/8
WASHER SHAKEPROOF EXT 7/16 STL
SPACER .41X.75X.25 ST/ZNC
SWITCH OIL PRESSURE
ELBOW 90D STREET 1/8
ADAPTOR 1/8NPTF TO 1/8-28
PLUG STD PIPE 1/4 STEEL SQ HD
SCREW HHC M10-1.5 X 110 G8.8
SCREW HHC M8-1.25 X 35 G8.8
SCREW HHC M12-1.25 X 55 G8.8
WASHER LOCK M12
PULLEY-CRANKSHAFT (1800 RPM)
PULLEY-CRANKSHAFT (3600 RPM)
BRACKET - ALT SUPPRT
DC ALTERNATOR-12V
ARM ADJUST ALTERNATOR
SCREW HHC M6-1.0 X 70 G8.8
WASHER FLAT M6
FAN ENG PUSHER 6/380
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
NAMEPLATE ENGINE
WASHER FLAT 1/4 ZINC
Generac® Power Systems, Inc. 51
Section 9 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Installation Drawing 15 & 20 kW – Drawing No. A7214-C
52 Generac® Power Systems, Inc.
Section 9 — Installation
Air
Intake
Air Intake
Air Outlet
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Installation Drawing 15 & 20 kW – Drawing No. A7214-C
Generac® Power Systems, Inc. 53
Section 9 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Installation Drawing 25 kW – Drawing No. 0C1450
54 Generac® Power Systems, Inc.
Section 9 — Installation
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
Installation Drawing 25 kW – Drawing No. 0C1450
Air Intake
Air Intake
Air Intake
Generac® Power Systems, Inc. 55
Section 10 – Warranty
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification 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, during such warranty period, any emission-related component or system on your engine is found to be defective in materials or
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance
on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unapproved 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 problem 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:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac 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 important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, 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 following address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
56 Generac® Power Systems, Inc.
Section 10 – Warranty
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
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 continue for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its
authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
1.2) LPG/Natural Gas carburetion assembly and its internal
components.
a) Fuel controller (if so equipped)
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
3) Ignition System including:
a) Spark plug
b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
5) Crankcase Breather Assembly including:
a) Breather connection tube
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
Generac® Power Systems, Inc. 57
Section 10 – Warranty
Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators
GENERAC POWER SYSTEMS "TWO YEAR" STANDARD WARRANTY FOR GUARDIAN®
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"
For a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, Generac Power
Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and 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 transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to
Generac Guardian prepackaged emergency automatic standby 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
All 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.
• 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 normally 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 being 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 consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part No. 0D6444
Revision 0 (11/14/01)
Printed in U.S.A.
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