® 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 ............................................................IFC 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 - Low Coolant Level Sensor 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 6).
Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Figure 8 - Control Module Assembly Circuit Board SPECIFICATIONS ENGINE SPECIFICATIONS OVERCRANK SHUTDOWN: After 90 seconds of crank-rest cycles, this function ends cranking if the engine fails to start in that 90-second span. 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.
Section 1 — General Information Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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.
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 — Installation ▼ Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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.
Section 3 - Operation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 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.
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 4 — 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 4 — 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 4 — Maintenance Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators 6.Remove OIL FILL CAP (Figure 11, page 15). Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” MARK. Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters) CAUTION: 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.
Section 5 — 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 6 — Scheduled Maintenance Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Following is a recommended maintenance schedule for Generac small standby and residential generator sets from 8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
Section 6 — Scheduled Maintenance Guardian Liquid-cooled 10 kW, 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.
Section 6 — Scheduled Maintenance Guardian Liquid-cooled 10 kW, 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) 14.
Section 7 - Electrical Data Guardian Liquid-cooled 10 kW, 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 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (1-Phase) — Drawing No. 0A2802-B Generac® Power Systems, Inc.
Section 7 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (3-Phase) — Drawing No. 0A2804-D 24 Generac® Power Systems, Inc.
Section 7 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A2805-C Generac® Power Systems, Inc.
Section 7 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7176-A 26 Generac® Power Systems, Inc.
Section 7 - Electrical Data Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Electrical Schematic — 1.5L Gas Engine — Drawing No. 0A7182-A Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Enclosure — Drawing No. 0C1404-B 28 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Enclosure — Drawing No. 0C1404-A 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 PART NO. QTY.
1Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel — Drawing No. 0C8847-C 30 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel — 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 ITEM PART NO. QTY.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1406-B 32 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1406-B 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 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1405-A 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 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Muffler — 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.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Circuit Breaker — Drawing No. 0A3371-B ITEM 1 2* 3 4 5 6 7 8 PART NO. QTY.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 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 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 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 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 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 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Governor Assembly — Drawing No. 0A7216-A 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 064526 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 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A9348-B 40 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A9348-B 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 8 - 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. 0A9349-E 42 Generac® Power Systems, Inc.
Section 8 - 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. 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.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642-J 44 Generac® Power Systems, Inc.
Section 8 - Exploded Views and Parts Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642-J 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 9 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1450 46 Generac® Power Systems, Inc.
Section 9 — Installation Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1450 Generac® Power Systems, Inc.
Section 10 – 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 10 – 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 10 – 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.