® 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.