Generac Power Systems 004090-2, 004091-2, 004092-2, 004093-2, 004094-2 User Manual

...
POWER SYSTEMS, INC.
®
Owner’s Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
(Natural Gas) 004090-2 004091-2 004092-2 004093-2 004094-2 004095-2 004096-2 004097-2 004474-0 (w/TS)
(Liquid Propane Vapor)
004124-1 004125-1 004126-1 004127-1 004128-1 004130-1 004131-1 004475-0 (w/TS)
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
Generac®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.
READ THIS MAN UAL 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.
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:
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.
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
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 DA TA CARD affixed to the unit.
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
Table of Contents
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 1
INTRODUCTION
............................................................
SAFETY RULES ........................................................................2
Section 1
GENERAL INFORMATION ........................................................4
Generator ....................................................................................4
Automatic System Operation ......................................................4
Generator AC Connection Systems............................................4
Main Circuit Breaker....................................................................5
Generator Fuel System ..............................................................5
Engine Protective Devices ..........................................................5
Unpacking....................................................................................6
Generator Specifications ............................................................6
Lifting the Generator ..................................................................7
Engine Specifications..................................................................7
Fuel Consumption ......................................................................7
Lifting the Generator ..................................................................7
Engine Oil Recommendations ....................................................7
Before Installation........................................................................8
Section 2
STANDBY GENERATOR INSTALLATION ................................9
Basic Standby Electric System..............................................................9
Emergency Circuit Isolation Method....................................................10
Total Circuit Isolation Method..............................................................10
Grounding the Generator ....................................................................10
Generator AC Neutral Connections ....................................................10
Transfer Switch Start Signal Connections ..........................................10
Battery Installation ..............................................................................10
Preparation Before Start-Up................................................................11
Section 3
OPERATION ............................................................................12
Using a Standard “GTS”Transfer Switch ..................................12
Control Console Components ..................................................13
Manual Transfer and Startup ....................................................13
Retransfer and Shutdown..........................................................14
Automatic Operation..................................................................14
Weekly Exercise Cycle..............................................................14
Engine Heater ..........................................................................14
Section 3
MAINTENANCE........................................................................15
Maintenance Performed by
Authorized Service Facilities ....................................................15
Overload Protection for Engine DC Electrical System..............15
Checking Fluid Levels ..............................................................15
Maintenance Owner/Operator Can Perform ..............................16
Miscellaneous Maintenance......................................................17
TROUBLESHOOTING..............................................................18
Section 4
NOTES......................................................................................19
Section 5
WIRING DIAGRAMS AND SCHEMATICS..........................20-25
Section 6
EXPLODED VIEWS AND PARTS LISTS............................26-43
Section 7
INSTALLATION DRAWINGS ..............................................44-45
Section 8
WARRANTY.......................................................46 - Back Cover
Figure 1- Water Cooled Emergency Power System
2 Generac®Power Systems, Inc.
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.
GENER
AL 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 in any room or building housing the generator 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 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.
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.
WARNING:
Generac®Power Systems, Inc. 3
• 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.
ELE
CTRICAL 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.
F
IRE HA ZARDS
• 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.
Important Safety Instructions
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
4 Generac®Power Systems, Inc.
GENERATOR
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. Use this generator as a source of electrical power for the operation of 120 and/or 240 volts, single or 3-phase loads, or 120 and/or 208 volts, 3-phase loads.
These models are available. They are rated as follows:
Model 004090: Provides 10,000 watts (10 kW) of 1-phase power. Model 004091: Provides 10,000 watts (10 kW) of 3-phase power. Model 004124: Provides 10,000 watts (10 kW) of 1-phase power. Model 004125: Provides 10,000 watts (10 kW) of 3-phase power. Model 004092: Provides 15,000 watts (15 kW) of 1 phase power. Model 004093: Provides 15,000 watts (15 kW) of 3 phase power. Model 004126: Provides 15,000 watts (15 kW) of 1 phase power. Model 004127: Provides 15,000 watts (15 kW) of 3 phase power. Model 004094: Provides 20,000 watts (20 kW) of 1-phase power. Model 004095: Provides 20,000 watts (20 kW) of 3-phase power. Model 004128: Provides 20,000 watts (20 kW) of 1-phase power. Model 004096: Provides 25,000 watts (25 kW) of 1 phase power. Model 004097: Provides 25,000 watts (25 kW) of 3 phase power. Model 004130: Provides 25,000 watts (25 kW) of 1 phase power. Model 004131: Provides 25,000 watts (25 kW) of 3 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.
WARNING: 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.
AUTOMATIC SYSTEM OPER ATION
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.
When utility source voltage has been restored, the switch re-transfers back to the utility source voltage and the generator then shuts down.
GENERATOR AC CONNECTION SYSTEMS
The generator was shipped from the factory with its sta­tor AC output leads connected in one of the “Delta” con­figurations, as shown in Figure 2. This type of connec­tion system will supply a 120 and/or 240 volts, 1 or 3-phase output as shown in the illustration.
Figure 2 - Generator AC Connection System
If, however, load voltage requires 120/208 volts, 3-phase output, generator will require reconnecting of the sta­tor’s output leads. This task should only be performed by a qualified Generac service technician. Refer to the installation manual (Part No. 079699) for details.
Section 1 - General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 5
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. The “Neutral” leads are the junc­tion of Wires 22 and 33.
Figure 3 - Generator AC Connection System
MAIN CIRCU IT B R EAKER
The generator’s main circuit breaker is included with the unit as shipped from the factory.The breaker for each unit is described as follows:
GENERATOR F U EL 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.
WARNING: 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 P ROTECTIVE 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.
LOW OIL P R ESSURE 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 4).
Figure 4 - Low Oil Pressure Switch
HIGH COOLANT TEMP ER ATURE 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 5).
Figure 5 - High Coolant Temperature Switch
Section 1 - General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
MODEL CIRCUIT BREAKER RATING
004090-2, 004124-1 50 amp BQ2 breaker 004091-2, 004125-1 40 amp BQ3 breaker 004092-2, 004128-1 90 amp BQ2 breaker 004093-2 70 amp BQ3 breaker 004094-2, 004126-1 70 amp BQ2 breaker 004095-2, 004127-1 60 amp BQ3 breaker 004096-2, 004130-1 125 amp BQ2 breaker 004097-2, 004131-1 90 amp BQ3 breaker 004474-0, 004475-0 125 amp BQ2 breaker
6 Generac®Power Systems, Inc.
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. If the engine coolant drops too low, the engine automatically shuts down (Figure 6).
Figure 6 - Low Coolant Level Sensor
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 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 7 - Control Module Assembly Circuit Board
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. 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 15 amps.
UNPACKING
UNPACKING PRECAUTIONS:
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.
Section 1 — General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
SPECIFICATIONS
GENERATOR SPECIFICATIONS
3-Phase 1-Phase
Mode
l 004097 004095 004093 004091 004096 004094 004092 004090
004131 004127 004125 004130 004126 004128 004124 *Rated Max. Cont. AC Power Output (kW) 25 20 15 10 25 20 15 10 Rated V oltage (volts) 120/208 120/240 Rated Max. Cont. Current @ 240 V, 1Ø N/A N/A N/A N/A 104.2 83.3 62.5 41.6 Current @ 208 V, 3Ø 86.8 69.5 52.1 34.7 N/A N/A N/A N/A No.of Rotor Poles 2 4 2 4 Driven Speed of Rotor 3600 3600 1800 1800 3600 3600 1800 1800 Rotor Excitation System Direct excited brush type system Type of Stator 12 wire reconnectable Rotor/Stator Insulation Class F
† Models 004474 & 004475 has same specifications as models 004096 & 004130 below.
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.
LIFTI NG TH E GEN ERATOR
WARNING: 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
ENGINE SP ECIF ICATIONS
Make................................................................................Mitsubishi
Displacement ................................................92 inches
3
(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. quar ts (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 CONSUM PTION
Models 004096, 004097, 004130, 004131, 004474, 004475
Using Natural Gas....................................441 cu. ft. per hour
Using LP Gas ........................175 cubic ft.(4.8 gal.) per hour
Models 004094, 004095, 004126, 004127
Using Natural Gas....................................359 cu. ft. per hour
Using LP Gas........................143 cubic ft. (4.0 gal.) per hour
Model 004092, 004093, 004128
Using Natural Gas....................................277 cu. ft. per hour
Using LP Gas ........................110 cubic ft.(3.1 gal.) per hour
Models 004090, 004091, 004124, 004125
Using Natural Gas....................................195 cu. ft. per hour
Using LP Gas..........................77 cubic ft. (2.2 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 SP ECIF ICATIONS
Cylinder Head......................................15 (+ 90° + 90°) ft.lb.
Intake Manifold..........................................................13 ft.lb.
Exhaust Manifold ......................................................13 ft.lb.
ENGINE OI L R ECOMMEN DATIONS
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:
CAUTION: Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.
Section 1 — General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 7
Temperature Oil Grade (Recommended)
Above 80° F (27° C) SAE 30W or 15W-40
32° to 80° F (-1° to 27° C) SAE 20W-20 or 15W-40
Below 32° F (0° C) SAE 10W or 15W-40
8 Generac®Power Systems, Inc.
BEFORE I NSTALLATION
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.
Section 1 — General Information
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 9
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 #46622) 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, ST A TIONARY 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.
OTHER PUBLISH ED STANDARDS
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.
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
Section 2 — Installation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
STAN DBY GENER ATOR 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. 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.
10 Generac®Power Systems, Inc.
EMERGENCY CIRCU IT 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.
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 CI RCU IT 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.
GROUNDI NG TH E GEN ERATOR
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)
GENERATOR AC NEUTRAL CONN ECTIONS
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 of 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.
BAT TERY 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
Section 2 — Installation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 11
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.
PREPARATION BEFORE START-UP
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.
PRIOR TO INITIAL START-UP
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,” and the “Service Schedule” on Page 17.
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.
Section 2 — Installation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
12 Generac®Power Systems, Inc.
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.
If the unit has been idle for a long period of time, or if the fuel lines or system components have been removed and reinstalled, the fuel system may require bleeding to remove air from the system. Air in the fuel system causes hard starting and rough operation. All fuel system lines must be installed and must be tight. A loose line may show no sign of leakage, but may draw air into the system.
Use a suitable container to catch the fuel that will spill during system bleeding process. Clean up all spilled fuel after bleeding.
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.
Check the oil level in the generator gearbox (If so equipped, contact sales for availability.) prior to initial use and at the intervals indicated by the “Service Schedule.” The recommended oil is SAE 90 gear lubri­cant.
Also, if the engine is equipped with a mechanical gover­nor, make sure the governor is properly lubricated with clean engine oil.
Engine Coolant
Have the engine cooling system properly filled with the recommended coolant mixture. Check the system for leaks and other problems. See “Specifications” (Page 7) and “Coolant” (Page 8).
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).
Electrical System
Make sure the generator is properly connected to an approved earth ground.
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” TR ANSFER 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.
Section 3 — Operation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 13
CONTROL CONSOLE COMPONENTS
The components of a water-cooled generator control console (Figure 8) are as follows:
Figure 8 - Water-Cooled Generator Panel
AC VOLTM ETER:
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). F requency 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 59-61 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.
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/MAN UAL 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.
DANGER! 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 LAM P:
Lamp goes ON when one or more of the following engine faults occurs and when engine shuts down.
• Low oil pressure • Overcrank
• High coolant temperature • Overspeed
• Low coolant level
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)
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 AN D 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.
Section 3 - Operation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
14 Generac®Power Systems, Inc.
RETRANSFER AN D SH UTDOWN
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.
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.
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 9).
• 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.
CAUTION: 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 9 - “Set Exercise” Switch
ENGINE H EATER
Your Generac standby generator comes equipped with a block heater (Figure 10), similar to the block heaters used in automotive applications.
Figure 10 - Engine Block Heater
Refer to applicable wiring diagram(s) and electrical schematic(s) at back of manual for wiring connections.
Section 3 — Operation
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 15
MAINTENANCE PER FOR M ED BY AUTHORIZED SERVICE FACILITI ES
A. EVERY THREE MONTHS
1.Check battery state of charge and condition.
2.Inspect and test fuel system.
3.Check transfer switch.
4.Inspect exhaust system.
5.Check engine ignition system.
6.Check fan belts.
B. ONCE EVERY SIX MONTHS
1.Test Engine Safety Devices (low oil pressure, low coolant level, high coolant temperature).
C. ONCE ANNUALLY
1.Test engine governor; adjust or repair, if needed.
2.Clean, inspect generator.
3.Flush cooling system.
D. FIRST 100 OPER ATING 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.)
E. EVERY 500 OPERATING HOU RS
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.
OVERLOAD PROTECTION FOR ENGI NE 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.
CAUTION! 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 FLUI D LEVELS
CHECK ENGINE OI L
Check engine crankcase oil level (Figure 11) 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.
• 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 11 - Oil Dipstick and Oil Fill Cap
c
ap
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 7
• 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 Facility. Inspect cooling system and coolant recovery system for leaks.
K
Section 3 — Maintenance
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
OIL FILL CAP
OIL DIPSTIC
16 Generac®Power Systems, Inc.
MAINTENANCE OWNER/OPER ATOR CAN PERFORM
CHECK ENGINE OI L 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. See page 14, “Weekly Exercise Cycle”.
INSPECT COOLING SYSTEM
• Inspect engine cooling system at least once each month.
• Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found.
• Check hose clamps for tightness.
CHECK ENGINE COOLANT LEVEL
See “Checking Fluid Levels” on page 15.
PERFOR M VISUAL INSP ECTION
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 ENGIN E 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.
CHANGING ENGIN E OI L
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 12) counterclockwise and remove. Dispose of old filter.
Figure 12 - 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 (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)
Section 3 — Maintenance
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
OIL FILTER
Generac®Power Systems, Inc. 17
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.
MISCELLANEOUS MAI NTENANCE
CLEANING TH E GEN ERATOR
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 Facility. That facility 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 REPLACEMENT
Generac uses these different types of vented batteries on units ranging up to 400 kW. When replacing batteries, use the same number and the type of battery that follows:
Note:
The BCI number should be located directly on the battery. For more information, see “Specifications.”
Section 3 — Maintenance
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac P/N BCI Group No. CCA
58665 27F 700 @ 0 deg. F 61915 4DLT 810 @ 0 deg. F 61104 8D 1155 @ 0 deg.F
Section 4 — Troubleshooting
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
PROBLEM CAUSE CORRECTION
Engine won’t crank. 1. 30 amp fuse blown. 1. Replace fuse.
2. Loose or corroded or defective 2. Tighten, clean or replace battery cables as necessary.
3. Defective starter contactor. 3. Replace contactor.
4. Defective starter motor. 4. Replace starter motor.
5. Dead or Defective Battery. 5. Remove, change or replace battery.
Engine cranks but won't start 1. Out of fuel. 1. Replenish fuel.
2. Fuel solenoid (FS) is defective 2. Replace solenoid.
3. Open Wire #14 from Engine Control 3. Reconnect wire.
circuit board
4. Spark plugs defective. 4. Clean, regap or replace plugs.
Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or 1. Clean or replace as needed.
damaged.
2. Plugged fuel line. 2. Unclog fuel line.
3. Defective spark plugs. 3. Clean, regap or replace plugs.
Engine starts then shuts down. 1. Engine oil level is low. 1. Check oil and add oil as needed.
2. Engine is overheated. 2. Check cooling system for leaks.
3. Defective Low Oil Pressure Switch 3. Replace switch.
4. Defective Coolant Temperature Switch 4. Replace switch.
5. Defective Control Module circuit board. 5. Replace board.
6. Coolant Level is Low. 6. Repair leak - Add coolant.
7. Defective Low Coolant Level Switch 7. Replace Switch.
Auto/Off/Manual Switch at OFF, 1. Defective Auto/Off/Manual switch 1. Replace switch. engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire.
Auto/Off/Manual switch and Control Module circuit board.
3. Defective Control Module circuit board 3. Replace board.
No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.
2. Check circuit breaker & fuses. 2. Reset and replace, if necessary.
3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.
4. Generator internal failure. 4. Contact an Authorized Generac facility.
5. Ther mal circuit breaker open. 5. Auto-reset - Wait 5 min. and attempt restart.
PERIODIC R EP LACEM ENT PARTS
Part Name Generacs Part Number
Oil Filter # 0A45310244 Radiator Cap # 046627 Air Cleaner # 059402 Spark Plug # 0A45310275
TROUBLESHOOTING POINTS
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Section 5 - Notes
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
20 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
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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
22 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
Generac®Power Systems, Inc. 23
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
24 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
Generac®Power Systems, Inc. 25
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
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
Generac®Power Systems, Inc. 27
ITEM PART NO. QTY. DESCRIPTION
1 A2110 32 1/4"-20-1/2" FASTENER 2 A2115 32 1/4" NYLON WASHER 3 A3133A 4 SLIP HINGE, MALE L.H.
A3133B 4 SLIP HINGE, FEMALE L.H. A3133C 2 SLIP HINGE, MALE R.H.
A3133D 2 SLIP HINGE, FEMALE R.H. 4 A3359 24 BHSCS M6 x 16 S.S. 5 A3360 24 SHAKEPROOF, INT M6 S.S. 6 C1245 1 PANEL, TOP SIDE L.H.
C1245A 1 PANEL,TOP SIDE R.H. 7 A3449 2 DOOR, SIDE 8 A4822 1 PANEL, FRONT 9 A4823 2 PANEL, SIDE BOTTOM
10 A4824 1 PANEL, REAR 11 A4825 1 CORNER POST, REAR L.H. 12 A4826 1 CORNER POST, REAR R.H. 13 C1193 1 TOP, ENCLOSURE 14 A4831 1 DOOR, REAR 15 A4832 2 DUCT 16 C1067 1 RADIATOR, SUPPORT-L.H. 17 C1067A 1 RADIATOR, SUPPORT-R.H. 18 C1068 1 SUPPORT, MUFFLER 19 C8817 1 TOP-CONTROL PANEL-SAE 20 C1244 1 FRONT AIR DUCT 21 A9955 1 BASE, MOUNTING 22 C1053Z 1 KIT, INSULATION 1.5L 23 22097 16 LOCKWASHER, 1/4"-M6
ITEM PART NO. QTY. DESCRIPTION
24 22129 12 LOCKWASHER, 5/16"-M8 25 22127 4 NUT, 1/2"-20 26 22145 12 FLAT WASHER, 5/16"-M8 27 89961 24ft. FOAM STRIP, 3/4" x 1/4" 28 22473 20 FLAT WASHER, 1/4"-M6 29 82570 1 PLUG BUTTON 4" 30 39253 12 HHCS, M8-1.25 x 20 31 42568 14 HHCS, M6-1.0 x 20LG 35 49813 4 NUT, HEX M6-1.0 37 37337 4 HEX NUT JAM-3/8"-24 38 A6807 1 LATCH & CAM (REWORK) 39 57042 2 LATCH AND CAM 40 67577 4 SPEED NUT 1/4"-20 42 22413 4 1/4"-20 x 1 HHCS 43 C1053B 1 INSULATION, PANEL TOP 44 C1053A 2 INSULATION, DOOR 45 C1053E 1 INSULATION, PANEL, FRONT R.H. 46 C1053F 1 INSULATION, PANEL, FRONT L.H. 47 C1063G 1 INSULATION, DUCT, FRONT 48 C1053H 1 INSULATION, PANEL, FRONT TOP 49 C1053D 2 INSULATION, PANEL, SIDE 50 C1053J 1 INSULATION, PANEL, REAR 51 C1053K 1 INSULATION, DUCT, L.H. SIDE 52 C1053L 1 INSULATION, DUCT, R.H. SIDE 53 C1053M 1 INSULATION, DOOR, REAR 54 78115 14 WASHER, SELF LOC/DOME 55 30486 2 RUBBER GROMMET
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
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 PART NO. QTY. DESCRIPTION
1 0C5077 1 SUPPORT, CONTROL PANEL L.H. 2 075589 1 BRA CKET, VOLTAGE REGULATOR 3 0A1775 1 CONTRLPANEL-BACK 4 0C5078 1 SUPPORT CONTROL PANEL R.H. 5 0C4224A 1 SILKSCREEN, PANEL (SAE) 6 057073 1 BLOCK JUNCTION 3/8-16 7 022985 4 WASHER FLAT #6 ZINC 8 081988 1 DECAL EXERCISE INFO
9 070043 1 VOLTMETER AC 0-300 10 070055 1 AMMETER AC 0-100 11 070042 1 FREQUENCY METER 55-65HZ 12 070081 1 HOURMETER 13 076037 1 VOLTMETER DC 8-18V 14 022152 10 WASHER, LOCK #10 15 022158 10 NUT, HEX #10-32 STEEL 16 061945 1 SWITCH 6A AMP/V SELECTOR 17 032300 1 HOLDER, FUSE 18 022668 1 FUSE 30A X AGC30 HLDR22669 HKP 19 076020 1 SWITCH DPDT 15/10 SP ON-OFF-ON 20 083048 1 ASY POTTED REG WOFIN 21 0A2077 1 CIRCT BRK 125X2 120/240V 22 075476 14 SCREW, PPHM-M4-0.7 x 16MM 23 022264 14 WASHER, LOCK-M4 24 0A3968 1 CAPACITOR, FILTER ASSY. 25 039782 1 BRACKET CIRCT BRK MOUNTING 26 0C2323 2 SCREW TAPTITE PH 6-32X5/8 ZYC 27 076039 2 SCREW PPHM M5-0.8 X 40 28 051756 3 SCREW HHC M10-1.5 X 20 G8.8 29 048476 1 CIRCT BRK 4.5X1 AUT30KW CNT45K 30 022237 1 WASHER LOCK 3/8 31 022097 8 WASHER LOCK M6-1/4 32 022473 8 WASHER FLAT 1/4 ZINC 33 082573 1 SWITCH DPST 5 125V SPD RCKR 34 043116 4 SCREW HHC M6-1.0 X 12 G8.8
ITEM PART NO. QTY. DESCRIPTION
35 056739 1 RELAY SOLENOID 12VDC PNL MNT 36 072252 2 GROMMET 1.37 X .06 X 1.00 37 063212 1 GROMMET 1.75 X .12 X 1.50 38 058318 2 TRANSFRM 150A TO 5A 5VA 39 033121 2 SCREW HHM 10-32 X 1/2 40 049226 4 WASHER LOCK M5 41 023897 10 WASHER FLAT #10 ZINC 42 075595 1 ASSM.,CMA BOX 43 049811 8 WASHER FLAT M6 44 072355 2 HHCS M6-1X12-A/C-.HD 45 055440 1 SCREW HHC M5-0.8 X 25 G8.8 46 022241 1 NUT HEX 3/8-16 STEEL 48 022155 2 WASHER LOCK #6 49 098647 1 ASSY L.C. ELECT GOV 50 057335 1 BLOCK TERM 20A 20 X 6 X 1100V 51 021480 1 DECAL TERMINAL STRIP 52 048766 1 BLOCK TERM 20A 2 X 6 X 1100V 53 058589 1 DECAL WARN ENG START
54* 070882 1 ASSY SUPPRESSION
55 0A7215 10 SCREW SW 1/4-20X5/8 N WA JS500 56 076040 2 SCREW PPHM M5-0.8 X 16 57 049813 8 NUT HEX M6-1.0 G8 YEL CHR
58 061979 1 BUS BAR 59* 0A2833 1 HARNESS PNL "PP" 1P 60* 0A6821 1 HARNESS WIRING (1.5L)
61 064009 1 LIGHT 12VDC .02A LED RED PILOT
62 064009 1 DECAL, TRANS.SWITCH CONN.
63 0A1354A 1 REGULATOR - DC ALT
64 0C2212 6 SCREW TAPTITE PH M4-0.7X16 ZYC
65 0C3826 2 HINGE, CONTROL PANEL
66 0C4427 8 M6X1.0X12 T.H.M.S SS
67 0C8817 1 TOP, CONTROL PANEL (SAE)
*NOT SHOWN ON THIS ASSEMBLY
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
Generac®Power Systems, Inc. 29
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
Generac®Power Systems, Inc. 31
ITEM PART NO. QTY. DESCRIPTION
1 0A4822 1 PANEL FRONT 2 0A5734 1 RADIATOR 1.5L 3 0A6237 1 VENTURI 1.5L 4 0A6238 1 GUARD FAN 5 084918 1 HEATER 500W 1020 6 050967 12" HOSE RES 5/8 RIA 250F 7 057823 4 CLAMP HOSE #10 .56 - 1.06 8 099502 4 CLAMP HOSE #24 1.06 - 2.00
9 083709 2 CLAMP WIRE HOSE .573 - .551 11 042568 6 SCREW HHC M6-1.0 X 20 G8.8 12 022097 15 WASHER LOCK M6-1/4 13 049813 2 NUT HEX M6 -1.0 G8 YEL CHR 14 022473 11 WASHER FLAT M6-1/4 ZINC 15 084427 1 BRACKET HEATER 16 050967 18" HOSE RES 5/8 RIA 250F 17 075443 6 CRMPTIT 1/4-20 X 5/8 18 056892 4 CRMPTIT 10-24 X 3/8 19 0A6284 1 HOSE LOWER RADIATOR 20 0A6258 1 HOSE UPPER RADIATOR 21 029032 1 HOSE 9/32 ID 22 031669 4 BOLT CARR 1/4-20 X 1-3/4 JS500 23 060035 4 SPACER .41 X .75 X .87 ST/ZNC 24 022127 5 NUT HEX 1/4-20 STEEL 25 022145 12 WASHER FLAT 5/16 ZINC 26 022129 12 WASHER LOCK M8-5/16 27 045771 12 NUT HEX M8-1.25 G8 YEL CHR 28 042907 12 SCREW HHC M8-1.25 X 16 G8.8 29 076749 1 TANK COOLANT RECOVERY 30 080712 1 BRACKET COOLANT RECOVERY TANK 31 0A7215 1 SCREW SW 1/4-20X5/8 N WA JS500 32 030486 2 GROMMET 7/16 X 1/16 X 1/4 33 0A2111 2 SCREW SWAGE 10-32 X 5/16 Z/YC 34 065852 2 NUT SPRINGCLIP .37 - .62 35 0C1067A 1 SUPPORT RADIATOR RH 36 0C1067 1 SUPPORT RADIATOR LH 37 0C1480 1 BRACKET COOLANT BOTTLE
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 PART NO. QTY. DESCRIPTION
1 0A9955 1 BASE MOUNTING 3 070936 2 DAMPENER VIBRATION 4 070936C 2 DAMPENER VIBRATION 5 039253 8 SCREW HHC M8-1.25 X 20 G8.8 6 022145 12 WASHER FLAT 5/16 ZINC 7 022129 12 WASHER LOCK M8-5/16 8 045771 12 NUT HEX M8-1.25 G8 YEL CHR
9 071956 4 WASHER FLAT M8 10 051730 2 SCREW HHC M8-1.25 X 60 G8.8 12 057821 2 SCREW HHC M8-1.25 X 40 G8.8 13 021991 1 EARTH STRAP 14 027482 2 WASHER SHAKEPROOF EXT 5/16 STL 15 0A2308 1 PLUG BUTTON 2" DIA
32 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. 0C1405A
Generac®Power Systems, Inc. 33
ITEM PART NO. QTY. DESCRIPTION
1 0A4355 1 MANIFOLD EXHAUST 1.5L
2 0C1636 1 NIPPLE TOE 1.5 NPT X 6.5 BL IRON
3 036434 4 BOLT U 5/16-18 X 2.09
036449 4 SADDLE 2 INCH 4 0C1330 1 PIPE EXHAUST 5 0C1318 1 FLEX PIPE EXHAUST 6 0C1068 1 SUPPORT MUFFLER 1.5L 7 0C1412 1 ELBOW EXHAUST 45 DEG 8 0A5728 1 MUFFLER 1.6/1.5L SAE 9 060366 2 STRAP MUFFLER 6" DIA
10 066889 4 SCREW HHC M8 X 1.25 X 20MM 11 022145 4 WASHER FLAT 5/16 ZINC 12 022129 4 WASHER LOCK M8-5/16 13 045771 4 NUT HEX M8-1.25 G8 YEL CHR 14 0A8974 1 CAP RAIN 2"
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 PART NO. QTY. DESCRIPTION
1 0A2103 1 SILKSCREEN "A" PANEL
0A2104 1 SILKSCREEN "B" PANEL 0A2105 1 SILKSCREEN "C" PANEL 0A2106 1 SILKSCREEN "P" PANEL
2* 0A2052 1 COVER BQ CIRCUIT BREAKER
3 033130 - SCREW HHM #8-32 X 1/4 4 022264 - WASHER LOCK M4 5 039783 1 BRACKET MOUNTING CIRCT BRK 6 080522 1 CIRCT BRK 20 X 3 INACTIVE
047585 1 CIRCT BRK 30 X 3 240V MT PL 057906 1 CIRCT BRK 35 X 3 240V 056783 1 CIRCT BRK 40X3 240V 049942 1 CIRCT BRK 50X3 W/MOUNT PL ITE 040533 1 CIRCT BRK 60X3 240V 049135 1 CIRCT BRK 70 X 3 240V 062812 1 CIR BKR 80-A 3P BQ3 053691 1 CIRCT BRK 90 X 3 ITE BQ3-B090
040532 1 CIRCT BRK 100X3 240V 39783 BR 7 039782 1 BRACKET MOUNTING CIRCT BRK 8 076640 1 CIRCT BRK 20 X 2 ITE BQ2-B020
057903 1 CIRCT BRK 25 X 2 240V ITE
057472 1 CIRCT BRK 30 X 2 240V ITE
077906 1 CIRCT BRK 35X2 W/39782 BRACKET
043240 1 CIRCT BRK 40X2 240V
ITEM PART NO. QTY. DESCRIPTION
057905 1 CIRCT BRK 45X2 240V 039765 1 CIRCT BRK 50X2 240V 39782 BRKT 048373 1 CIRCT BRK 70X2 240V 063452 1 CIRCT BRK 80X2 240V 039766 1 CIRCT BRK 90X2 240V 048374 1 CIRCT BRK 100X2 240V 0A2077 1 CIRCT BRK 125X2 120/240V
9 056967 3 PLUG PLASTIC .375 10 053640 4 SCREW RHM #8-32 X 3-1/4 11 038150 4 WASHER FLAT #8 ZINC 12 022471 4 NUT HEX #8-32 STEEL
13** 0A2670 1 COVER,CIR.BRKR. 480V
14 0A2820 1 MCB 16A 3P 480V B-TR
0A2821 1 MCB 25A 3P 480V B-TR 0A2822 1 MCB 32A 3P 480V B-TR 0A2828 1 MCB 40A 3P 480V B-TR
* USE WITH ITEM 14 ONLY ** USE WITH ITEM 8 ONLY
34 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 – Circuit Breaker — Drawing No. 0A3371B
Generac®Power Systems, Inc. 35
ITEM PART NO. QTY. DESCRIPTION
1 074100 1 ASSY HOME STDBY LOGIC
(MODELS 921, 863, 865)
076009A 1 PP LOGIC ASM 50/60HZ
(MODEL 9428) 2 072566 4 NUT SPACER .250 PCB 3 080882 4 SCREW PPH TAPPING #6X5/8 SS 4 074978 1 DECAL TERMINAL STRIP 5 047822 1 BLOCK TERM 20A 7 X 6 X 1100V 6 075476 2 SCREW PPHM M4-0.7 X 16 7 083264 1 TRANSFORMER ASM CMA 240/12V 8 022985 4 WASHER FLAT #6 ZINC 9 022264 4 WASHER LOCK M4
10 051787 2 SCREW HHC M4-0.7 X 16 G8.8 11 079847 1 BOX CMA 12 0A8504 1 DECAL, CMA LABEL
0A8504A 1 DECAL, CMA LABEL
13* 022661V .083' TUBING SHRINK 19"ID RED
ITEM PART NO. QTY. DESCRIPTION
14 038057 2 GROMMET 7/8 X 1/16 X 3/4 15 058443 2 SCREW CRIMPTITE 1/4-20 X 5/8 16 081224 1 DECAL MFG NAMEPLATE
17* 079682 1 HARNESS CMA WIRE
18 086093 2 DECAL CMA WARNING 19 083736 1 DECAL CSA GTS 20 051715 2 NUT HEX M4-0.7 G8 YEL CHR 21 077401 1 COVER SILKSCREEN CMA
* NOT SHOWN
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. DESCRIPTION
1 098290 1 ASM MOTOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECTOR 3 098958A 1 CONNECTOR INTERFACE ASSEMBLY 4 098942A 1 COVER CONNECTOR HOUSING 5 098225 2 SCREW FHM #2 X 5/8 SELF TAP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 WASHER LOCK M6-1/4 8 064256 2 SCREW HHM #6-32 X 3/8 SELF TAP
9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX #10-32 NYL INS 11 0A7041 1 ASSEMBLY CARBURATOR LINKAGE 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 - LIQUID NEOPRENE 14 029333A 1 TIE WRAP 7" BLACK 15 022507 2 SCREW HHC 1/4-20 X 1/2 G5 16 022473 2 WASHER FLAT 1/4 ZINC
36 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 – Governor Assembly — Drawing No. 0A7216A
Generac®Power Systems, Inc. 37
ITEM PART NO. QTY. DESCRIPTION
1 077483 1 BATT 12VDC 75-AH 26 2 038804D 1 CABLE BATT RED #4 X 20.00 3 038805B 1 CABLE BATT BLK #4 X 23.00 4 0742600131 1 ASSY,WIRE#16 RED 1.6 5 022131 1 WASHER FLAT 3/8 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 059567 2 BOLT BATTERY HOLD DOWN
9 078121 1 BAR BATTERY HOLDDOWN 10 022145 2 WASHER FLAT M8-5/16 ZINC 11 022129 2 WASHER LOCK 5/16 12 022259 2 NUT HEX 5/16-18 STEEL 13 050331A 1 BATTERY POST COVER (RED+) 14 050331 1 BATTERY POSTCOVER (BLACK-) 15 075763 3 BOOT, BATTERY CABLE
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
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
Generac®Power Systems, Inc. 39
ITEM PART NO. QTY. DESCRIPTION
1 098671 1 ASSY ROTOR 10KW
098681 1 ASSY ROTOR 15KW 098675 1 ASSY ROTOR 20KW
098936 1 ASSY ROTOR 25KW 2 0A5336A 1 HOUSING BLOWER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 5 022152 4 LOCK W ASHER-#10 6 051713 4 WASHER FLAT M5 7 022129 4 WASHER LOCK M8-5/16 8 098672 1 ASSY STATOR 10KW A
098673 1 ASSY STATOR 10KW D
098674 1 ASSY STATOR 10KW GJK
098682 1 ASSY STATOR 15KW 1PH A
098683 1 ASSY STATOR 15KW 3PH D
098684 1 ASSY STATOR 15KW 1PH GJK
098676 1 ASSY STATOR 20KW 1PH A
098677 1 ASSY STATOR 20KW 1PH A
098678 1 ASSY STATOR 20KW 1PH GJK
097620 1 ASSY STATOR 25KW 1PH A
098937 1 ASSY STATOR 25KW 1PH D
097621 1 ASSY STATOR 25KW 1PH D 9 0A5382 1 BEARING CARRIER REAR
10 075591 1 HOLDER, BRUSH ASSEM. 11 052813 4 SCREW HHC M4-0.7 X 20 G8.8 12 0A5601 1 COVER, REAR BEARING CARRIER
ITEM PART NO. QTY. DESCRIPTION
13 075554B 4 BOLT,STATOR X 16"LG 14 0A9375 4 SCREW RHM #10-24 X 2 15 022152 4 WASHER LOCK #10 16 097146 1 FAN & RING GEAR ASSEM. 17 042558 1 KEY SQ 3/8 X 1 STEEL 18 0A5061 1 SPACER-FLEX PLATE 19 0A4989 1 PLATE, FLEX 20 052213 1 SCREW HHC M10-1.25 X 20 G8.8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10-1.5 X 35 G8.8 23 046526 4 WASHER LOCK M10 24 045772 4 NUT HEX M10-1.5 G8 YEL CHR
25** 082130B 1 ASSY MPU SPEED SENSOR 48"
26* 087599 1 PLUG PLASTIC 3/8 CAPLUG #2
27 077043E 1 FLEX CONDUIT 1" BLCK
(NOT SHOWN) 28 022131 4 WASHER FLAT 3/8 ZINC 29 072578 1 SPACER ROTOR SHAFT 30 0A7043 5 SCREW HHC M12-1.25 X 25 G8.8 31 049808 5 WASHER FLAT M12 32 058589 1 DECAL-WARNING 33 023365 4 WASHER SHAKEPROOF INT #8 35 0A8830 4 WASHER FLAT .34ID X .75OD
* USED ON PRE-PACKAGED UNITS ONLY
** USED ON "C" OPTION PANEL UNITS ONLY
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
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
Generac®Power Systems, Inc. 41
ITEM PART NO. QTY. DESCRIPTION
1 0C2632 1 WELDMENT MOUNTING BASE 2 075580 2 FLANGE FUEL INLET 3 026915 3 NIPPLE CLOSE 3/4 X 1.375 4 039253 4 SCREW HHC-M8-1.25 X 20 5 022145 5 WASHER FLAT 5/16 ZINC 6 022129 7 WASHER LOCK M8-5/16 7 045771 4 NUT HEX M8-1.25 G8 YEL CHR 8 0A2666 2 SOLENOID GAS FUEL
9 046747 1 BUSHING REDUCER 3/4 TO 3/8 11 0C3714 1 ASSY HOSE NG/LPV.31" 13 0A5547 1 COVER AIR CLEANER 14 0C1475 1 REGULATOR NATURAL GAS EM
0A9911 1 REGULATOR L.P. GAS EM 15 0A7989 1 NIPPLE PIPE 3/8 NPT X 4 BLK IRON 16 0A6593 1 ADAPTOR CARBURETOR 17 059402 1 FILTER ELEMENT 18 037561 1 NUT WING 1/4-20 NYLK 19 059403 1 CARBURETOR, CA55 EM 20 059401 1 GASKET CARBURETOR 21 034154 4 SCREW PHM 10-24 X 1/2 CAD 22 022152 4 WASHER LOCK #10 23 023897 4 WASHER FLAT #10 ZINC 24 062522 1 STUD THR 1/4-20X3 F THR G2 ZNC 25 022127 1 NUT HEX 1/4-20 STEEL 26 022259 2 NUT HEX 5/16-18 STEEL 27 050280 1 DECAL FUEL INLET LPG 28 0A6125 2 STUD 5/16-18 X 1.25 F THR 29 052219 1 BARBED STR 1/8NPT X 5/16 30 048031C 3 CLAMP HOSE BAND 1/4 31 029032 6-1/2" HOSE 9/32 ID 32 029032 11" HOSE 9/32 ID 33 032552 1 BARBED EL 90 5/16 X 1/8NPT 34 0A4682 1 MANIFOLD INTAKE 1.5 35 042907 1 SCREW HHC M8-1.25 X 16 G8.8 36 055934D 1 CLAMP VINYL 1.06 X .406 Z 37 0A7040 1 BRACKET-RADIATOR HOSE 38 0C3153 1 TORX PLUS BHS M8 X 30
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
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
Generac®Power Systems, Inc. 43
ITEM PART NO. QTY. DESCRIPTION
1 0A4531 1 ENGINE-1.5L 2 035685 1 CLAMP HOSE #28 1.32 - 2.25 3 075546A 1 PIPE-FLEX EXHAUST 4 0A45310258 1 GASKET-EXHAUST MANIFOLD 5 0A4355 1 MANIFOLD-EXHAUST 6 0A6699 1 SHIELD HEAT EXHAUST 7 022097 8 WASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5
9 052212 4 SCREW HHC M10-1.25 X 25 G8.8 10 046526 14 WASHER-LOCK-M10 11 022131 16 WASHER FLAT 3/8 ZINC 12 0C2499 2 STAMPING ENG FOOT 13 055993 1 SPACER .41 X .75 X .12 STL/ZNC 14 045772 4 NUT HEX M10-1.5 G8 YEL CHR 15 023586 2 SCREW SHC 5/16-18 X 2 G8.8 NZ 16 020692 1 STARTER-12V 17 0A7005 2 SPACER .56 X 1 X .37 ST/ZNC 18 052243 1 SCREW HHC M10-1.5 X 60 G8.8 19 0A4772 1 ENGINE PLATE 20 070901 2 SLEEVE DOWEL BLHSG 21 051735 3 SCREW HHC M10-1.5 X 70 G8.8 22 056768 2 SCREW HHC M10-1.5 X 90 G8.8 23 022145 2 WASHER FLAT 5/16 ZINC 24 022129 23 WASHER LOCK M8-5/16 25 022259 2 NUT HEX 5/16-18 STEEL 26 052213 1 SCREW HHC M10-1.25 X 20 G8.8 27 047411 2 SCREW HHC M6-1.0 X 16 G8.8 28 052830 2 SCREW HHC M10-1.25 X 45 G8.8 30 045771 10 NUT HEX M8-1.25 G8 YEL CHR 31 058306 5 SCREW SHC M8-1.25 X 25 G12.9 32 030795 2 SCREW HHC 5/16-18 X 1 G5 33 0A2711A 1 ADAPTER-THERMOSTAT 34 048665 1 GASKET THERMOSTAT 35 075885 1 THERMOSTAT 195 DEG 36 0A45310257 1 GASKET INLET MANIFOLD 37 0A4682 1 MANIFOLD-INTAKE 38 057522 1 SENSOR COOLANT LEVEL 39 0A6751 1 SW-TMP 245DEG 3/8NPT
ITEM PART NO. QTY. DESCRIPTION
40 034339 1 BARBED EL 90 3/8NPT X 5/8 41 026925 1 PLUG STD PIPE 3/8 STEEL SQ HD 42 061012 1 PLUG STD PIPE 1/8 SCKT HD 43 039253 6 SCREW HHC M8-1.25 X 20 G8.8 44 0A5110 1 PIPE WATER-INLET 45 0A7006 1 O-RING 1-1/16X1-5/16X1/8 46 025507 2 WASHER SHAKEPROOF EXT 7/16 STL 47 022500B 2 SPACER .41X.75X.25 ST/ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1/8 50 042574 1 ADAPTOR 1/8NPTF TO 1/8-28 51 026073A 1 PLUG STD PIPE 1/4 STEEL SQ HD 52 0A6701 1 SCREW HHC M10-1.5 X 110 G8.8 53 039414 1 SCREW HHC M8-1.25 X 35 G8.8 54 0A5568 1 SCREW HHC M12-1.25 X 55 G8.8 55 051769 1 WASHER LOCK M12 56 0A4804 1 PULLEY-CRANKSHAFT (1800 RPM)
0A4800 1 PULLEY-CRANKSHAFT (3600 RPM) 57 0A5839 1 BRACKET - ALT SUPPRT 58 0A1354B 1 DC ALTERNATOR-12V 59 0A4839 1 ARM ADJUST ALTERNATOR 60 055816 4 SCREW HHC M6-1.0 X 70 G8.8 61 049811 4 WASHER FLAT M6 62 075614 1 FAN ENG PUSHER 6/380 63 0A2628 1 PULLEY - FAN 95 DIA 64 0A5275 1 V-BELT 3/8 X 32-1/8 1.5L
0A5586 1 V-BELT 3/8 X 28.9 1.5L 65 0A4814 1 SPACER PULLEY 66 0A45310244 1 FILTER OIL 67 0C1852 1 ADAPTER DRAIN OIL 68 0912970066 1 GROUND WIRE (STARTER) 69 070928 1 CLAMP HOSE - OIL DRAIN 70 069860C 1 HOSE ASM.-OIL DRAIN 71 069811 1 CAP HEX 1/4NPT BRASS 72 0A5317 1 NAMEPLATE ENGINE 73 022473 2 WASHER FLAT 1/4 ZINC
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
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. 45
Section 8 — 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 — Notes
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 47
Section 9 — Notes
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
48 Generac®Power Systems, Inc.
CALIFOR NIA EM ISSION CONTROL WARR ANT Y STATEM ENT
YOUR WARRANT Y R IGHTS AND OB LIGATIONS
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 R ESPONSIBILITIES:
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 WARRANT Y DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 8
WAUKESHA, WI 53187
Part 1
Section 9 – Warranty
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
Generac®Power Systems, Inc. 49
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 war-
ranted 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 responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an 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:
*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
Section 9 – Warranty
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators
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
Part No. C8840 Revision 0 (04/25/01) Printed in U.S.A.
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. (Generac) will, at its option, repair or replace any part which, upon examination by Generac or a Generac/Guardian Authorized W arranty Service Facility, 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/Guardian Authorized Warranty Service Facility. 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 generators used in “Standby” applications, as Standby has been defined by Generac, provided said generators have been initially installed and inspected on-site by a Generac/Guardian Authorized Service Dealer or branch thereof.
WARRANTY SCHEDULE
YEAR ONE – 100 percent coverage on mileage*, labor and parts listed:
• Engine – All components
• Alternator – All components
• Transfer System – All components
*Travel allowance is limited to 300 miles or 7.5 hours, whichever occurs first, and applies only to permanently wired and mounted units.
All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate Manual.
Units that have been resold are not covered under the Generac warranty, as this warranty is not transferable.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Costs of normal maintenance, adjustments, installation and start-up.
2. Units sold, rated or used for “Prime Power” applications as Prime Power has been defined by Generac. Contact a dis­tributor for Prime Power definition and warranty.
3. Failures due to (a) normal wear and tear, or (b) accident, misuse, abuse, negligence or improper installation.
4. Products that are modified or altered in a manner not authorized by Generac in writing.
5. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective parts.
6. Failure due to misapplication.
7. Telephone, telegraph, teletype or other communication expenses.
8. Living or travel expenses of persons performing service, except as specifically included within the terms of a specific unit warranty.
9. Rental equipment used while warranty repairs are being performed.
10. Overtime labor.
11. Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLA CE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. SPECIFICALL Y, GENERAC MAKES NO OTHER WARRANTIES AS TO 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 PARTS 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. Purchaser/owner agrees to make no claims against Generac based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
GENERAC®POWER SYSTEMS, INC.
P.O. BOX 8
WAUKESHA, WI 53187
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