® POWER SYSTEMS, INC.
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.
Table of Contents Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators INTRODUCTION ............................................................ SAFETY RULES ........................................................................2 Section 1 GENERAL INFORMATION ........................................................4 Generator ....................................................................................4 Automatic System Operation ......................................................
Important Safety Instructions Guardian Liquid-cooled 10 kW, 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.
Important Safety Instructions Guardian Liquid-cooled 10 kW, 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.
Section 1 - General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators GENERATOR AUTOMATIC SYSTEM OPERATION This equipment is an water-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 sound attenuated enclosure and is intended for outdoor installation only.
Section 1 - General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Figure 3 represents a single-phase, 3-wire generator AC connection system. 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.
Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Figure 7 - Control Module Assembly Circuit Board LOW COOLANT LEVEL SWITCH: Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. To prevent such overheating without automatic shut down, the engine has a low coolant level sensor.
Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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.
Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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.
Section 2 — Installation Guardian Liquid-cooled 10 kW, 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 (such as the Generac “GTS” type transfer switch), so as to isolate the electric system from the utility distribution system when the generator is operating.
Section 2 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators EMERGENCY CIRCUIT ISOLATION METHOD Figure 2.2 – Generator Grounding Lug (typical) 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.
Section 2 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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.
Section 3 — Operation Fuel System ▼ ▼ Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical 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. Make sure the generator is properly connected to an approved earth ground.
Section 3 - Operation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators CONTROL CONSOLE COMPONENTS The components of a water-cooled generator control console (Figure 8) are as follows: Figure 8 - Water-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.
Section 3 — Operation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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).
Section 3 — Maintenance Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES CHECKING FLUID LEVELS A. EVERY THREE MONTHS Check engine crankcase oil level (Figure 11) at least every 20 hours of operation, or prior to use. 1.Check battery state of charge and condition. 2.Inspect and test fuel system. 3.Check transfer switch. 4.Inspect exhaust system. 5.Check engine ignition system. 6.Check fan belts. B. ONCE EVERY SIX MONTHS 1.
Section 3 — Maintenance Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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. EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes.
Section 3 — Maintenance Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators CAUTION: 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. COOLANT CHANGE Every year, have Authorized Service Facility drain, flush and refill the cooling system. See SPECIFICATIONS (page 7) for cooling system recommendations.
Section 4 — Troubleshooting Guardian Liquid-cooled 10 kW, 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 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5.
Section 5 - Notes Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803C FUSE 20 Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (1-Phase) — Drawing No. 0A2802A Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (3-Phase) — Drawing No. 0A2804C 22 Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A2805B Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (3-Phase) — Drawing No. 0A7176A 24 Generac® Power Systems, Inc.
Section 6 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A7182A Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Enclosure — Drawing No. 0C1404A 26 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Enclosure — Drawing No. 0C1404A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART NO. A2110 A2115 A3133A A3133B A3133C A3133D A3359 A3360 C1245 C1245A A3449 A4822 A4823 A4824 A4825 A4826 C1193 A4831 A4832 C1067 C1067A C1068 C8817 C1244 A9955 C1053Z 22097 QTY.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel — Drawing No. 0C8847B 28 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel — Drawing No. 0C8847B 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. QTY.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1406B 30 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1406B ITEM 1 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. QTY.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1405A ITEM 1 3 4 5 6 7 8 9 10 12 13 14 15 PART NO. QTY. DESCRIPTION 0A9955 070936 070936C 039253 022145 022129 045771 071956 051730 057821 021991 027482 0A2308 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.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Muffler — Drawing No. 0C1408B 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.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Circuit Breaker — Drawing No. 0A3371B ITEM 1 2* 3 4 5 6 7 8 PART NO. QTY.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – CMA Assembly — Drawing No. 081086D ITEM PART NO. QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13* 074100 1 076009A 1 072566 080882 074978 047822 075476 083264 022985 022264 051787 079847 0A8504 0A8504A 022661V 4 4 1 1 2 1 4 4 2 1 1 1 .083' DESCRIPTION ASSY HOME STDBY LOGIC (MODELS 921, 863, 865) PP LOGIC ASM 50/60HZ (MODEL 9428) NUT SPACER .
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Governor Assembly — Drawing No. 0A7216A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO.QTY. DESCRIPTION 098290 098941A 098958A 098942A 098225 043146 022097 064256 098783 037398 0A7041 0A7106 074031 029333A 022507 022473 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.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Battery — Drawing No. 098922E 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 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.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A9348B 38 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A9348B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 PART NO. QTY. 098671 098681 098675 098936 0A5336A 0A1659 071912 022152 051713 022129 098672 098673 098674 098682 098683 098684 098676 098677 098678 097620 098937 097621 0A5382 075591 052813 0A5601 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 DESCRIPTION ITEM PART NO. QTY.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Natural Gas Fuel System — Drawing No. 0A9349E 40 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Natural Gas Fuel System — Drawing No. 0A9349E 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.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642J 42 Generac® Power Systems, Inc.
Section 7 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642J 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 30 31 32 33 34 35 36 37 38 39 PART NO.
Section 8 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1450 44 Generac® Power Systems, Inc.
Section 8 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1450 Generac® Power Systems, Inc.
Section 9 — Notes Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 46 Generac® Power Systems, Inc.
Section 9 — Notes Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Generac® Power Systems, Inc.
Section 9 – Warranty Guardian Liquid-cooled 10 kW, 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.
Section 9 – Warranty Guardian Liquid-cooled 10 kW, 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.
Section 9 – Warranty Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators GENERAC’S STANDARD ONE-YEAR LIMITED WARRANTY FOR STANDBY POWER SYSTEMS For a period of one year or 1,500 hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc.