Generac Power Systems 04137-0 User Manual

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POWER SYSTEMS, INC

Owner’s Manual

SUARDIAry

by GENERAC- POWER SYSTEMS

Liquid-cooied, Prepackaged

Standby Generators

Models:

04136- 0 (8 kW/Singie-phase) 04137- 0 (8 kW/Three-phase)

INTRODUCTION

Thank you for purchasing the Guardian product

line by Generac Power Systems. This model is a compact, high performance, liquid-cooled, enginedriven generator designed to automatically supply electrical power to operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal

enclosure that is intended exclusively for outdoor

installation.

» READ THIS MANUAL THOROUGHLY

______________

If you do not understand any portion of this manual,

contact Generac or your nearest Generac/Guardian Authorized Dealer for starting, operating and servic ing 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 operation that may be hazardous if performed incorrectly or care lessly. Observe them carefully. Their definitions are as follorvs;

-AEŒ3 A-

After this heading, you can read instructions that, if not strictly complied with, wiil result in personal injury or property damage.

—A WARNING A—

After this heading, you can read instructions that, if not strictly complied with, may result in persona! injury or property damage.

------

M CAUTION M

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 com pliance with the special instructions whUe perform ing the seiwice are essential to preventing accidents.

Four commonlv used safety symbols accompany tire DANGER. WARNING and CAUTION blocks. The type of information each indicates is as follows:

This symbol points out important safety informa

tion that, if not followed, could endanger persona! safety and/or property of you and others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

A This symbol points out potential electrical shock

hazard.

Generac® Power Systems, Inc.

-----------

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 equip ment. 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.

# CONTENTS

________________ ______________________

This manual contains pertinent owner’s informa

tion, including warranty, electrical diagrams, exploded views and lists of repair parts, for the fol

lowing Guardian models;

04136-0 and 04137-0

4 OPERATION AND MAINTENANCE_____________

It is the operator's responsibility to perform all safety

checks, to malce sure that all maintenance for sale operation is performed promptly and to have the equipment checked periodically by a Generac/ Guardian Authorized Dealer. Normal maintenance service and replacement of maintenance parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workman ship within the terms of the warranty. Indirfdual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your generator ensure a ininimumi number of problems and keep operating expenses at a rnlniaium. See your Generac/Guardian

Autiiorized Dealer for service aids and accessories.

^ HOW TO OBTAIN SERVICE_______________________

V.'Tien your generator requires servicing or repairs, simply contact a Generac/Guardian Authorized Dealer for assistance. Sendee technicians are facto ry-trained and are capable of handling all of your sendee needs.

WTien contacting a Generac/Guardian Autlrorized

Dealer or tlie factoiy about parts and service, always supply the complete model number and serial number of your unit as grfen on its data

decal, which is located on your generator.

Model No. Serial No.

AUTHORIZED

DEALER LOCATION

To locate the GENERAC/GUARDIAN AUTHORIZED

DEALER nearest you, please call this number:

1-800-747-1530

DEALER LOCATION INFORMdTION

CNN BE OBTAINED AT THIS NUMBER.

SAFETY RULES

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 and potential operators of this equipment. Mm.

important Safety instructions Guardian Llquid-cooied 8 kW Generators

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

Study these SAf'ETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Oiuner's Manual and with

the unit. The generator can operate safely, effi ciently 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 possi ble circumstance that might involve a hazard. The warnings in this manual, and on tags and decals

afffxed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique Generac does not specificaJly recom mend, you must satisfy yourself that it is safe for

you and others. You also must make sure the pro

cedure. work method or operating technique that

you choose does not render the generator unsafe.

-A0UE33 A-

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 operate or maintain this equipment.

Potentially lethal voltages are generated by

these machines. Ensure ai! 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.

M GEIMERAL HAZARDS M

For safety reasons, Generac recommends

that the installation, inihal start-up and mainte nance of this equipment is carried out by a Generac/Guardian Authorized Dealer.

The engine exhaust fumes contain carbon

monoxicTe, which can be DEADLY. This danger ous gas, If breathed in sufficient concenhations, can cause unconsciousness or even death. This exliaust system must be installed properly, in strict compliance with applicable codes and stan dards. Following installation, you must do noth ing that might render the system unsafe or in

noncompliance with such 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 venti

lating air is critical to comect generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as tliis can seriously affect safe operation of the generator.

When working on this equipment, remain alert at

all times. Never work on the equipment when you are physically or mentally fatigued.

Inspect the generator regularly, and repair or replace all damaged or defective parts irrumedi-

ately. Always use factory-authorized parts.

Turn off the AC power to the batterv' charger

before disconnecting the battery to minimize the chance of equipment damage.

Before performing any maintenance on the gen

erator, disconnect Its battery cables to prevent accidental start-up. Disconnect the cable from tlie battery post indicated by a NEGATIYTD. NEG or H 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 etdaaust gases, fuel leak age, oil leakage, etc.

Generac® Power Systems, Jnc.

Table of Contents

Guardian Liquíd-cooied 8 kW Generators

Introduction

Read This Manual Thoroughly

Contents

Operation and Maintenance

....

....................inside Front Cover

.........................

...........................................................

..............................

IFC IFC

IFC

How, to Obtain Service ....................................IFC

Authorized Dealer Locator Number

Safety Rules

.....

.................................................

..................

.......2

IFC

Section Ì - General Information..................................

1.1 Unpacking/Inspection

1.1.1 Lifting the Generator

1.2

The Generator .................................................4

1.3

Generator AC Connection Systems

Automatic System Operation

1.4 Main Circuit Breaker

1.5 Engine Protective Devices

1.6

....................................

.........................

................

.........................

......................................

..................1...........

1.6.1 Low Oil Pressure Switch....................5

1.6.2

1.6.3

1.6.4

1.6.5

Specifications

1.7

High Coolant

Temperature Switch

..........................

Low Coolant Level Switch ................6

Overspeed Shutdovm Or’ercrank Shutdown

........................

..................................................

1.7.1 Generator............................................6

1.7.2 Engine ................................................6

Fuel Requirements

and Recommendations

.............'..................

1.9 Engine Oil Recommendations.........................7

1.10 The Barterv .....................................................7

2.4 Automatic Transfer Operation

2.5 Sequence of Automatic Operation

.......................

..................

2.6 Engine Heater................................................10

2.7 Weeldy Exercise Cycle .................................10

2.8 Optional GTS Transfer Switch .....................10

2.8.1 Using an Optional GTS Transfer Switch

Section 3 - Maintenance

4 4

4 5 5

3.1 25-Hour Break-in Period

3.2 25-Hour Checkup

3.3 Checldng the Engine Oil Level

3.4 Changing the Engine Oil and Filter ..............12

3.5 Changing the Engine Air Cleaner

3.6 Вatteiy Maintenance

3.7 Cooling System

............................................

3.8 Overload Protection for Engine DC Electrical System

................................

..........

.................................12

..............................

..........................................

....................

.................

.....................................

.......................

12 12 12

13 14

3.9 Fuse................................^...............................14

5 6

6 6

3.10 Engine Coolant

3.11 Miscellaneous Maintenance

3.11.1 Cleaning the Generator

3.11.2 Rodent Protection

3.12 Out of Sendee Procedure

3.12.1 Removal From Service

3.12.2 Return to Service

3.13 Service Schedule

..............................................

.........................

....................

.............................

...............................

.....................

.............................

..........................................

14 15 15 15 15 15 15 16

Section 4 - Troubleshooting

...........................17

4.1 Troubleshooting Guide.................................17

Section 2 - Operation

2.1 Control Console Components

2.1.1 AC Voltmeter

2.1.2 AC Ammeter

2.1.3 AC Frequency Meter

....

.................................8

.........................

.....................................

.......................................

..........................

2.1.4 DC Voltmeter .....................................8

2.1.5 Hourmeter

2.1.6 Auto/Off/Manual Switch

2.1.7 Fault Indicator Lamp

.........................................

...................

.........................

2.1.8 30-amp Fuse.......................................8

2.1.9 Voltage-phase Selector Switch

2.1.10 Set Exercise Time Switch

2.1.11 Main Circuit Breaker .........................8

2.2 Preparation Before Start-up

............................

2.3 Using the Auto/Off/Manual Switch

2.3.1 “Auto" Position

2.3.2 “Off Position

2.3.3 “Manual" Position

.................................

......................................

..............................

.............

.................

................

Section 5- Electrical Data................................18

S 8 8

Section 6 - Exploded Views and

Parts Lists.....................................................22

Section 7 - Installation Drawings

..................

S 8

Section 8 - Warranty

......................................

8 8 9 9

еЗепегас® Power Systems, ¡nc.

ELECTRICAL HAZARDS

Important Safety Instructions

Guardian Liquid-cooled 8 kW Generators

FIRE HAZARDS

SAFETY RULES

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 does the standby generator when it is in operation. Avoid contact with bare wires, ter minals, connections, etc., while the unit is run ning, Ensure all appropriate covers, guards and barriers are in place before operating the genera tor. If you must work around an operating unit, stand on an insulated, diy 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 ELECTRICAX SHOCK my RESULT.

The National Electrical Code (NEC) requires the

frame and emernal electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electri cal system.

ATter installing this standby electrical system, the

generator may crank and start at any time vdthout warning. Wlien this occurs, load circuits are transferred to the STANDBY (generator] power source. To prevent possible injury if such a start and transfer occur, always set the generator’s

Auto/Off/Manual switch to its OFF position before working on equipment.

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 noncon ducting implement, such as a rope or board, to free the victim from the live conductor. If the vic tim is unconscious, apply first aid and get imme diate medical help.

Never wear jewelry when working on this equip ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com

ponents causing injun/.

For fire safety, the generator must be installed

and maintained properly. Installation altvays must 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 estab lished. Also, ensure that the generator is

installed in accordance with the manufacturer's instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncom pliance mth the aforementioned codes, stan

dards, laws and regulations. Keep a fire extinguisher near the generator at ail

times. Extinguishers rated JABC" by the National Fire Protection Association are appropriate for use on the standby electric system. 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

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 tlie generator clean and free from debris.

Although using diesel fuel is safer than using gaso

line or gaseous fluids, which are are extremely EXPLOSIVE, diesel stiU. presents the danger of possible FIRE. Install the fuel supply system according to applicable fuel-gas codes. Before plac

ing the standby electric system into sertlce, fuel

system lines must be properly purged and lecJt tested according to applicable code. After installa

tion, you must inspect the fuel system periodically for leaks. No lealtage is permitted.

Generac® Power Systiems, inc.

GENERAL

INFORMATION

Section 1 — General Information

Guardian Liquid-cooied 8 kW Generators

1,1 UNPACKlNG/iNSPECTiON

After unpacldng, carefully inspect the contents for damage.

« This standby generator set has been factory

installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation.

-A WARNING A-

lf 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 effec tively isolate the electrical system from the util ity distribution system when the generator is operating (NEC 701). Failure to isolate an elec trical system by such means will result in dam age to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy.

If. any loss or damage is noted at time of delivery, have the person(s) making the delivery note all

damage on the freight bill or affix his or her signa ture under the consignor's memo of loss or damage.

If you note loss or damage after delivery, separate the damaged materials and contact the carrier for claim procedures.

“Concealed damage” is understood to mean damage to the contents of a package that is not in evidence at the time of delivery, but is discovered later.

# 1.1.1 LIFTING THE GENERATOR

-A WARNING A-

When lifting or hoisting equipment is used, be

careful not to touch overhead power lines.

The generator's weight of more than 1,500

pounds requires proper tools and equipment, and qualified personnel to be used in all phases of handling and unpacking.

1.2 THE GENERATOR ..

This liquid-cooled, Guardian generator set is

designed to supply electrical power to operate criti cal electrical loads during utility power failure. The unit has a four-pole revolving field (rotor) and uti lizes long-life brushes and slip rings to deliver exci tation current to the rotor windings. The rotor is directly connected to the engine shaft by a highstrength flexible disc. The engine governor holds the diesel engine and rotor speeds at a constant factory setting of approximately 1,860 rpm.

Use this generator as a source of electrical power for tlie operation of 120- and/or 240-volt, singleor three-phase loads; or 120- and/or 208-volt, three-phase loads.

These models are available, rated as follows;

04136- 0: Provides 8,000 watts (8 kW) of single

phase power.

04137- 0: Provides 8,000 rvatts (8 kVV) of three-

phase power.

1.3 GENER.ATORAC CONNECTION SYSTEMS

Ttie three-phase generators are shipped from tlie fac

tory with their stator AC output leads connected in a

12-lead low we configuration (Figure 1.1). This tyq)e of connection system wül supply a 120- and/or 208volt, three-phase output as showm in tire illustration.

If, however, load voltage requires a 120/240-voIt, single- or three-phase output, the stator's output

leads will need to be reconnected (Figure 1.2). This task should be performed only by a qualified

Generac/Guardian Authorized Technician. Refer to the

Guardian Installamn, Start-up and Adjustment

Manual (Part No, 79699) for details.

Figure 1.1 - 12-!ead Low Wye

Generator AC Connection System

Section 1 — Generai Information

Guardian Liquid-cooied 8 kW Generators

GENERAL

INFORMATION

Figure 1.2 - Single- and Three-phase Delta

Generator AC Connection System

Figure 1.3 represents a single-phase, threenvlre

generator AC connection system. The stator assem bly in this system consists of a pair of stationaiy windings with Pan leads brought out of each wincl-

ing. Each single nhnding can supply a 120-volt, 60Hertz AC output. When the two windings are con nected in series, a 240-volt, 60-Hertz AC output results. Typically, the two "hot” leads in the circuit

are Wires 11 and 44. The neutral leads are the

junction of Wires 22 and 33.

Figure 1.3 - Single-phase

Generator AC Connection System

When utility source voltage has been restored, the switch transfers back to the utility source voltage, and the generator then shuts down,

1.5 MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included with

the unit as shipped from the factory. The breaker for each unit is described as follows:

Mode! Number Circuit Breaker Ratinq

04135-0

04137-0 35A-3P-BQ3

35A-2P-BQ2

1.6 ENGINE PROTECTIVE DEVICES

The engine has several safely switches tliat cause it to automatically shut down under the following con

ditions: low oil pressure, high coolant temperature, low coolant level, and engine overspeed or overcrank. See Figure 1.4 for the location of these devices.

4 1.6.1 LOW Oil PRESSURE SWITCH

This switch is normally closed {N.C.] but is held open by engine oil pressure during engine running. Should operating oU pressure drop below apprommately 15 psi, the switch contacts close, and die engine shuts down automatically.

Figure 1.4 - Engine Protective Devices

________________

Low Oil

Pressure Switch

1.4 , AUTOMATIC SYSTEM OPERATION

Wnen this generator, along with its transfer switch,

has been Installed and interconnected, a circuit board in the generator panel continuously 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 genera

tor can power them.

4 1.6.2 HIGH COOLANT TEMPERATURE SWITCH

This normally open (N.O.) thermostatic switch has

a sensing tip that is immersed in captive coolant. Should the coolant temperature exceed approzdmately 124° C (256° F), the switch contacts close, wTich causes the engine to shut clown automatically.

Generac® Power Systems, !nc.

GENERAL

INFORMATION

Section 1 — General information

Guardian Liquid-cooied 8 kW Generators

» 1.6.3 LOW COOLANT LEVEL SWITCH

Should tlie .engine coolant level drop below tloe level of’the high coolant temperature switch, it is possible for the engine to overheat wltlaout automatic shut down. To prevent such overheating without automat ic shut down, the engine has a low coolant level sen sor. If the engine coolant drops too low, the engine

_____________

# 1.6.4 0¥ERSPEE0 SHUTDOWN

______________

The DC control circuit board (inside control panel) senses engine speed from the frequency of the

alternator AC output. Should the alternator output

frequency exceed approximately 72 Hertz (2,160

alternator rpm), circuit board action initiates an automatic engine shutdown.

automatically shuts down.

# 1.6.5 OVERCRANK SHUTDOWN

After 90 seconds of crank-rest cycles (while in Auto mode], this function ends cranking if the engine fails to start in that 90-second span.

1.7 SPECIFICATIONS

♦ 1.7.] GENERATOR

SINGLE-PHASE

Model

Rated Maximum Continuous

AC Power Outnut (kW)*

Rated Voltage (volts) Rated Ma:d.mum Continuous

Current at ... »240 Volts, Single-phase (amps) »240 Volts. Tlcxee-phase (amps)

•208 Volts, Three-phase (amps) NA Power Factor Rated AC Frequency

Number of Rotor Poles

Rotor Speed at No Load Type of Stator Rotor Excitation Svstem Direct Excited Brush-h/pe Svstem Rotor and Stator Insulation

'“Rated p)wer of geneiator is subjeci to and limited by such iactom as ambient leinperature, altitude, engine condition and otiier factoi-s. Engine power will deci-ease about 3.5 percent for eacti 1,000 feet above sea le/el; and also will dettrease an additional 1 percent for each 12° C (10° F) above 15.5° C (60° Fj. Maximum output power of the generator is hmited by maximum engine power.

04136-0

120/240

33.3 NA 24,1

1.0

60 Hertz at 1,800 rpm

1,860 rpm

'Four-wire

Class “F”

♦ 1.7.2 engine’

Make ............................................................................ISM Diesel

Cylinder Arrangement

Displacement.................................................58.2 inches (954 cc)

Bore ............................................................2.95 inches (75 mm)

Stroke..............................................................2.85 inches (72 mm)

Compression Ratio...............................................................23-to-l

Compression Pressure ar 200 rpm

Standard......................................................................426.7 psi

Minimum Limit..........................................................2S4.5 psi

Combustion Chamber Type ..................................Pre-Combustion

Firing Order

Direction of Rotation ...........................................Counterdodvvise

NumAer of Main Bearings

No. of Teeth on Flywheel..........................................................104

Ground Polariw ................................................................Negative

Oil Filter.......................................Full flow, woth byptass valve

Oil Pressure ....................................................................29-71 psi

Crankcase Oil Capacity

With Filter Change Whthout Filter Change

Recoznmended .Engine Oil.................See Section 1,9 (Pcige 7)

Type of Cooling System ....Pressurized, closed recovery

...........................................................................

....................................................

...........................................................

...........................

......................

4.0 U.S. quarts (3.8 L)

3.7 U.S. quarts (3.5 L)

3, in-line

1-2-3

Type of Cooling Fan Cooling System Capacity

Recommended Coolant ..................Use a 50-50 rnimire of low

Type of Fuel System

Recommended Fuel

Fuel Filter......................................................................10 micron

Fuel Injection Pump Injection Spray Angle

Injection Pressure ...........................................................1,707 psi

Fuel Consumption - 60 Hz (gal/h)

25% Load 50%Load 75% Load 100% Load

0.35 0,52 0.63 0.S4

Actual fuel consumption obtained may vary

depending on such variables as applied load, ambi

ent temperature, engine conditions and other environmental factors.

..........................................................

....................

.............................................................

.............................

...........................................

............................................

S Generac^ Power Svstems, !nc.

THREE-PHASE

04137-0

120/208

27.8

0.8

12-'wire Reconnectable

2.5 U.S. gallons (9.5 L)

silicate, ethylene glycol base anti.iTeeze and soft water. See

Section 3.10 (Page 14),

See Section 1.8 (Page 7)

NOTE:

________________

Pusher

Diesel

Bosch “M” Type

20°-21° BTDC

Section 1 - General Information

Guardian Liquid-cooled 8 kW Generators

GENERAL

INFORMATION

.8 FUEL REQUIREMENTS

AND RECOMMENDATIONS

Г-se clean, fresh No. 2D diesel fuel with minimum htane number of 40. It also must conform to merican Society of Testing and Materials (ASTM) pecifications. The iiiel should be stored in sealed

.3ntainers that have low point drains which permit Viter to be drained from the fuel periodically. Never

se any dirty or contaminated fuel.

his unit has a 46-gallon fuel tank. When adding lel, DO NOT overfill the tank. Allow room at the

)p of the tank for fuel expansion.

NOTE:

ppropriate care should be taken in applications here extremely low ambient temperatures are ossible to ensure the temperature of the diesel lel is not allowed to fall below levels where felling” could occur.

-A WARNING A-

y Although using diesel fuel is safer than using A gasoline or gaseous fluids, which are are

extremely EXPLOSIVE, diesel stiil presents the

danger of possible FIRE. The fuel supply system

must be installed according to applicable

fuel-gas codes. After installation, you must

inspect the fuel system periodically for leaks.

No leakage is permitted.

9 ENGINE GIL RECOMMENDATIONS

;e a high-quality detergent oil with American

croleum Institute (API) classification “For Service A’ Detergent oils keep the engine cleaner and Jiice carbon deposits. Use oil having the follovdng ciety of Automotive Engineers (SAE) viscosity' rati, based on the ambient temperature range anticLied before the next oil change:

Temperature

Above 70° F (21° C)

3° to 70° F (-7° to 21° C)

Below 20° F (-7° C)

------

M. CAUTION

Any attempt to crank or start the engine before

^ it has been properly serviced with the recom

mended oil may result in an engine failure.

Oil Grade (Recommended)

SAE 30W SAE 20W

SÀE 10W or 10W-30

A-

1.10 THE BATTERY

Use a 12-volt, automotive-type storage battery (Group 26F) rated 75 amp hours or more and capar bie of a minimum of 530 cold-cranking amps at '17,8° C (0° F). When using a maintenance-free bat tery, it is not necessaiy to check the specific gravity or electrolyte level. Have these procedures per formed at the intervals specified in the service schedule. A negative ground system is used. Battery

connections ai'e shown on the wiring diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

NOTE:

Damage will result if the battery connections are made in reverse.

Your generator is equipped with a battery triclde charger that is active when ypur unit is set up for automatic operation. The trickle charge is designed to help extend the life of your battery by maintain ing the battery when the unit is not running.

-АСШШЭ A-

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture

around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark pro ducing 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.

WARNING

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.

A-

Generac® Power Systems, Inc.

OPERATION

(jo

Section 2 - Operation

Guardian Liquid-cooled 8 kW Generators

2.1 CONTROL CONSOLE COMPONENTS

The components of a liquid-cooled generator con

trol console (Figure 2.1) are as follows:

Figure 2.1 - Control Console

♦ 2.1.1 AC VOLTIVI EIER

The voltmeter displays generator AC output voltage

during operation. Voltage is regulated by a solidstate voltage regulator and is proportional to AC frequency. Refer to your unit's DATA PLATE for rated AC voltage.

# 2.1.5 HGURMETER

This indicates the 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.

» 2.1.6 AUTO/OFF/MANUAL SWITCH

See Section 2.3.

» 2.1.7 FAULT INDICATOR LAMP

This lamp goes ON when one or more of the following

engine faults occurs and when engine shuts down. <> Low oil pressure « High coolant temperature

® Low coolant level ® Overcrank » Overspeed

♦ 2.1.8 30-AiVIP FUSE

This fuse protects the contrcd console’s DC control circuit against electrical overload. If the fuse has melted open because of an overload, engine crank ing and start-up cannot occur. Should you need to replace the fuse, use only an identical 30-amp replacement fuse.

______________

___________________

4 2.1.2 AC AMMETER

This indicates current draw of connected electrical loads during operation. DO NOT EXCEED YOUR

UNIT’S RxCTED MAXIMUM CONTINUOUS CUR RENT. Refer to th,e unit DATA PLATE.

# 2.1.3 AC FREQUENCY METER

This indicates generator AC output frequency in Hertz (cycles per second). Frequency is proportion

al to engine speed. Units vlth a four-pole rotor sup ply 60 Hertz at 1,800 rpm. The frequency reading with no electrical loads connected (no-load condi tion) should be between 61-6.3 Hertz. With full rated wattage/amperage load applied to the gener ator, frequency should not droop below approxi mately 58 Hertz.

♦ 2.1.4 DC VOLTMETER

The generator is equipped with a belt-driven DC

alternator, which maintains batten/ state of charge

when the engine operates. The control module

assembly also incorporates a triclde charge circuit that maintains battery state of charge during non operating periods. Battery voltage should read approximately 12.5 to 14.5 volts DC. A low battery

voltage indicates the battery is discharging.

» 2.1.9 VOLTAGE-PHASE SELECTOR SWITCH

This switch permits you to select either line-to-llne

or line-to-neutral voltage and amperage readings on the console AC voltmeter and ammeter.

♦ 2.1.10 SET EXERCISE TIME SWITCH

This switch allows you to program the generator to

start and exercise automatically.

4 2.1.11 MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included

with the unit as shipped from the factory. See

“Main Circuit Breaker." Section 1.5 (Page 5), for the appropriate breaker.

______________

___________________

2.2 PREPARATION BEFORE START-UP

Before starting the generator, check that oil, coolant and fuel levels are correct (see “Specifications,” Section 1.7, Page 6).

2.3 USING THE AUTO/OFF/MANUAL SWITCH

♦ 2.3.1 "AUTO" POSITION

vSelecting this switch position activates fully automat ic system operation. It also allows the unit to start and exercise the engine every seven days with the set ting of tire exercise timer (see Section 2.7, Page 10).

Gensrac* Power Systems, ine.

Section 2 ~ Operation

Guardian Liquid-cooled 8 kW Generators

OPERATiON

(pix

^ 2.3.2 "OFF" POSITION

This switch position shuts down the engine. This

position also prevents operation.

# 2.3.3 "MANUAL" POSITION

Set the switch to Manual to crank and start the engine. Transfer to standby power will not automaticallv occur unless there is a utility failure.

-A WARMING A-

With the switch set to AUTO, the engine may crank and start at any time without warning.

Such automatic starting normally occurs when utility power source voltage drops below a pre

set level or during the normal exercise cycle. To

prevent possible Injury that might be caused by such sudden starts, always set the switch to OFF and remove the fuse before working on or around the generator or transfer switch. Then, place a "Do Not Operate" tag on the generator panel and on the transfer switch.

2.4

AUTOMATIC TRANSFER OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are set to their “Utility" position, i.e., loads con nected to the utility power source.

2. Be sure tfiat normal utility power source voltage is available to transfer switch terrninal lugs N1 and N2. {See the electrical data in the applicable trans

fer switch manual.)

3. Set the generator’s Auto/Otl/Manuai switch to

AUTO.

4. Set the generator's main circuit breaker to Its ON (or closed) position.

With the preceding steps complete, the generator

will start automatically when utility source voltage

drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to “Sequence of Automatic Operation.”

Upon restoration of utility source voltage above a preset level, generator circuit board action signals the transfer switch to transfer loads back to that power supply. After retransfer, the engine is sig nalled to shut down.

The actual sequence of operation is controlled by

sensors and timers on a control logic circuit board", as follows:

A. Utility Voltage Dropout Sensor

o This sensor monitors utility source voltage. ® If utility source voltage drops below about 60

percent of the nominal supply voltage, the sen sor energizes a 15-second timer.

® Once the timer has expired, the engine v/ill

crank and start.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for about 10 seconds before the load is transferred

to a standby source.

C. Standby Voltage Sensor

» This sensor monitors generator .EC output volt

age. 'Wlien the vtytage has reached 50 percent of the nom.incJ rated voltage, transfer to stand by can occur.

D. Utiliw Voltage Pickup Sensor

® This sensor monitors utillbv power supply volt

age, When that voltage is restored above SO per cent of the nominal source volta.ge, a retrcmsfer, time delay starts timing,

E. Retransfer Time Delay

= This timer runs for about 15 seconds. ® AT end of a 15-second delay, circuit board

acrioii de-energizes transfer relay in the trans

fer switch.

» Retransfer to utility power source tlien occurs.

F. Engine Cool-down Timer

• When the load is transferred back to utility" power source, tihe engine cool-down timer

starts timing,

• The timer will run for about one minute, and the generator will then shut down.

2.5 SEQUENCE OF AUTOMATIC OPERATION

The generator’s control panel houses a control logic

circuit board. This board constantly monitors utllibv* power source voltage. Should tiiat voltage drop

below a preset level, circuit board action will signal

the engine to crank and stmt. .After the engine starts, the circuit board signals the transfer switch

to activate and connect load circuits to the standby power supply (load terminal lugs T1/T2 connect to terminal lugs E1/E2). (See tlie electrical data in tire applicable transfer switch manual.)

Generac® Power Systems, Inc.

OPERATION

-On

Section 2 - Operation

Guardian Liquid-cooled 8 kW Generators

2.6 ENGINE HEATER

Your Generac standby generator comes equipped with a block heater (Figure 2.2) that is similar to the block hea.ters used in automotive applications.

Figure 2.2 - Engine Block Heater

Refer to applicable wring diagram(s) and electrical schematic(s) at the back of this manual for wiring connections.

2.7- WEEKLY EXERCISE CYCLE

The generator wll start and exercise once ever/ seven days. During this weekly exercise, the unit runs for approximately 20 minutes and shuts dotvn. Transfer of loads to generator oucput does not occur during the exercise unless power is lost during the exercise period.

To select the day of the tveek and time of day for

exercising, proceed as follov/s: « Set the Auto/Off/Manual switch to OFF.

« Set generator's main circuit breaker to its OFF (or

open) position.

» Locate 'the rocker swatch on the control panel

identified wdtli the wnrds “Set Exercise Time”

(Figure 2.3).

» Push “Set Exercise Time” swdtch to the ON posi

tion for 20 to 30 seconds and dien release. The swdtch will spring back into its original positLo.n wdien released.

» Wait 30 seconds before setting the Auto/Off/

Manual swdtch to the AUTO position.

NOTE;

The unit -will exercise 20 minutes after it is set.

Example: Set - Noon; Exercise - 12:20 p.m.

-A CAUTION A-

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's main circuit breaker to its ON

(or closed) position.

• The generator is now programmed to start and exercise eveiy seven days thereafter, on the day and at the time of day the swdtch was activched.

0 Place a sign on tlie generator’s control panel and

on the transfer sv/itch that indicates the day and time the generator tvill be exercising.

NOTE:

If the battery terminals are disconnected or the control panel fuse is removed, the exercise timer needs to be reset for automatic exercise operation.

Figure 2.3 - "Set Exercise" Switch on Control Panel

MANUAL

2.8 OPTIONAL GTS TRANSFER SWITCH

This generator can be installed in conjunction wdth

a Generac GTS-type automatic transfer switch, if desired.

The standard ATS-type transfer swdtch has no sensing or controlling circuit boards. Instead, the generator control console houses a control module assembly (CfVLA), which controls all phases of oper ation, including engine start-up and load transfer.

Section 2 — Operation

Guardian Liquid-cooied 8 kW Generators

OPERATION

# 2.8.1 USING AN OPTIONAL GTS

_________

When you use a GTS-type transfer swatch, it con

trols automatic operation and automatic transfer

as follows:

• Solid-state circuits in the transfer switch monitor utility power source voltage.

• When utilitjr source voltage drops below a preset level, transfer swdtch action closes the engine cir cuit. The engine then cranks and starts as con

trolled by the generator's control module circuit board.

* After the engine starts and when the generator

A.C output voltage and frequency have reached a preset value, transfer switch circuits signal the transfer switch main contacts to move to the standby power source side. Generator AC output then pownrs load circuits.

TRANSFER SWITCH

_______________________

® When the utiliW power source voltage is restored

above a preset level and the return to utility timer has timed out. the transfer switch solidstate circuits signal the switch main contacts to move back to their utility power source side.

» The engine cooldown timer stains and times out.

Then, the transfer switch circuit board action

opens the engine run circuit. The engine then

shuts down.

NOTE:

If yonr generator is installed in conjunction

with an optional GTS-type transfer switch, refer

to the applicable transfer switch manual for exact operating parameters and timing sequences.

MAINTENANCE

5izz=:0

Section 3 - Maintenance

Guardian Liquid-cooled 8 kW Generators

3.1 25-HOUR BREAK-IN PERIOD

The first 25 hours of operation constitute the breakn period for the standicy generator. Correctly breakng in the generator is essential to mitiiiriize oil connimption and macdmize engine performance. During he break-in period, observe the ibllowing rules:

. Run the generator at va.rious elecuical loads for

the first 25 hours of operation, to help seat engine piston rings properly.

For the next 75 operating hours, avoid light electrical loads.

' During this period, load the unit at 50 percent or

more of its rated capacity (4,000 watts or more).

Repeated light electrical loads during the break-

in period can cause improper seating of engine piston rings, resulting in blowb\^ and high oil consumption.

. Check the engine crankcase oil level frequently

during the break-in period. It is normal for oil consumption to be high during this period.

, xkfter the 25 hour break-in period is completed,

perform the tasks recommended under "25 Hour Checkup.”

.2 25-HOUR CHECKUP

tlloiving the first 25 hours of operation, contact an

tithorized sendee facility for tlie following mainte-

ince. The generator ovmer is responsible for all targes.

Change the engine crankcase oil and filter. Check all fluid levels (engine coolant, fuel, bat-

ter\" electrolyte fluid).

Inspect cooling system hoses for deterioration

and leaks, all hose clamps for tightness and security.

Check fuel system lines for leaks, tightness and

condition.

Check fuel injection timing, Check/Adjust engine governed speed (frequency). Inspect engine belts for condition, proper tension. Check for correct AC voltage output. Check all generator receptacles and circuit

brealcers for condition and proper operation.

3 CHECKING THE ENGINE

OIL LEVEL

ter the 25-hour break-in period, check the engine oU 'el eveiy" eight hours or operation or at least once ily before using the generator. For oil capacities, see oecltications,” Section 1,7 (Page 6). For engine oil rec-

iinendations. see Section 1,9 (Page 7). To check the

gine oil level, proceed as follows (Figure 3.1):

Remove tlae dipstick and rvlpe it dry rvlth a clean clotli.

S, Generac* Power Systems, !nc.

Install the dipstick cap; then, remove it again. The oil level should be at the dipstick “Full” mark. If necessary, add oil to the “Full” mark

only. DO NOT FILL ABOVE THE “FULL” MARK.

Install the dipstick.

CAUTION M.

-A

Never operate the engine with the oil level below the "Add" mark on the dipstick. Doing this could damage the engine.

Figure 3.1 - Engine OH Servicing Points

Oil Filler

Cap

--------

3.4 CHANGING THE ENGINE GIL AND FILTER

See Section 1.9, “Engine Oil Recommendsfoons” (Page

7), for die proper oil grade for your application.

NOTE;

The engine oil and filter should be changed after the 25-hour break-in period. See the “Service Schedule,” Section 3.13 (Page 16), for subse quent oil and filter changes.

-A

.Any attempt to crank or start the engine before

it has been properly serviced with the recom mended oil may result in an engine failure.

To change tiie oil and filter, proceed as follows: Refer to tlie “Sendee Schedule,” Section 3.13 (Page

16), for engine oU and filter change frequencies.

Drain the oil while the eng,ine is still warm from run ning. This means you should warm up the engine, shut it down and drain It immediately as follows:

1. Remove tlie oil drain hose from its retaining clip,

located on the generator base frame.

2. Loosen and remove tlie oil drain hose cap, locat ed on tlie base frame end of tlie hose. Drain tlie oil completely into a suitable container.

CAUTiON

A-

Section 3 — Maintenance

Guardian Liquid-cooled 8 kW Generators

MAINTENANCE

3. When aJl of the oil has drained, install and tight en the oil drain hose cap.

4. Turn tile oil filter (Figure 3.1) countercloclcwise and remove it. Dispose of the old filter.

5. Apply a light coating of engine oil to the seal of new oil filter. Install tire filter and tighten by hand only. DO NOT OVERTIGHTEN,

6. Remove the oil filler cap (Figure 3.1). Add the rec ommended oil (see Section 1.9, Page 7). DO NOT FILL ABOVE THE DIPSTICK ■‘FULL” MARK.

CAUTION A

-A

After refilling the crankcase with oii, always check the oil level on the dipstick. Never

operate the engine with the oil level below the "Add" mark on the dipstick. Doing this could damage the engine.

--------

7. Start the engine and check for oil leaks.

8. Check the oil level after checking for leaks to ensure that the oil is filled to the proper level.

3.5 CHANGING THE ENGINE

AIR CLEANER

To replace the engine air cleaner, (Generac part

number 70941), simply remove the air cleaner cover and replace the air filter making sure it is

positioned properly before reattaching the cover.

Figure 3.2 - Engine Air Cleaner

AIR CLEANER

3.6 BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule,” Section 3.13 (Page 16). The following procedure should be followed for inspection:

1. Inspect the battery posts and cables for tight ness and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batter ies and, if necessar/, fill wth DISTILLED

WATER ONLY. DO NOT USE TAP WATER IN

BATTERIES.

3. Have the s tate of charge and condition checked.

This should be done mth an automotive-type battery hydrometer or load test.

-АЕВШЗ A-

Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caustic

sulfuric add solution that can cause severe

burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery, if you spill the fluid, flush the affected area immediately with clear water.

Do not use any jumper cables or booster bat

tery to crank and start the generator engine, if the battery has completely discharged, remove it from the generator for recharging.

(TPANSPAREMT ENCLOSURE FOR CLARITY)

See tile “Service Schedule," Section 3.13 (Page 16), for recommended air cleaner maintenance.

-----

Ak WARNING

Be sure the utility power supply is turned off,

or sparking may occur at the battery posts as

you attach the cables and cause an explosion.

Be sure the Auto/Off/Manual switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Generac® Power Systems, inc. 13

---------

MAINTENANCE

AIH OUTLET

Section 3 - Maintenance

Guardian Liquid-cooled 8 kW Generators

Figure 3.3 - Cooling Vent Locations

GJJTHnH

AIR INTAKE

3.7 COOLING SYSTEM

Air Intalce and outlet openings in the generator com partment must be open and unobstructed for contin

ued proper operation. This includes such obstruc tions as high grass, weeds, brush, leaves and snow.

Witiiout sufficient cooling and ventilating air flow, the

engine/generator quiclfly overheats, which causes it

to shut down. (See Figure 3.3 for vent locations.)

-A WARNING A-

The exhaust system of this product gets extreme

ly hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

3.8

OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM

Engine cranlting, start-up and running are con trolled by a solid-state engine controller circuit board. Battery voltage is delivered to that circuit board via a 30-arnp fuse. These overcuiTent protec tion devices will open if the circuit is overloaded,

-A CAUTION A"

A !f a circuit breaker opens or a fuse element melts,

you should find the cause of the overioad before

resetting the circuit breaker or replacing the fuse.

3.9 FUSE

The generator panel's 30-amp fuse (Figure 2.1, Page

8) protects the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel. If the fuse element has melted

open, you cannot crank or start the engine. You siiould replace the fuse using only an identical 30amp replacement.

3.10 ENGINE COOLANT

Check the coolant level in the coolant recovery bot tle at least once daily or prior to use. Add the rec

ommended coolant rruxture (see Section 1.7.2, Page

6) as necessary; the bottle should he kept half full. If desired, you may add a high quality rust inliibitor to the recommended ,50-,50 coolant rruxture. If added consistently, the recommended rnixture will protect the unit against freezing temperatures.

Periodically remove the radiator pressure cap to make sure the coolant recover}' system is function ing properly. Coolant should be at the bottom of tire radiator filler neck. If the coolant level is low, inspect the gasket in the radiator pressure cap. Replace the cap, if necessary'. To have the pressure cap tested, contact a Generac/Guardian

Authorized Dealer, inspect the cooling system and

coolant recovery system for leaks.

-A A-

Do not remove the radiator pressure cap while

the engine is hot or serious burns from boiling

liquid or steam could result. Ethylene glycol base antifreeze is poisonous.

Do not use your mouth to siphon coolant from the radiator, recovery bottle or any container, Wash your hands thoroughly after handling. Never store used antifreeze in an open contain er because animals are attracted to the smell and taste of antifreeze even though it is poi sonous to them.

-A CAUTION A-

Do not use any chromate base rust inhibitor with

ethylene glycol base antifreeze, or chromium hydroxide ("green slime") will form and cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base antifreeze. Using any high silicate antifreeze boosters or additives also will cause overheating.

We also recommend that you DO NOT use any

soluble oil inhibitor for this equipment.

Section 3 — Maintenance

Guardian liquid-cooled 8 kW Generators

MAINTENANCE

3.11 MISCELLANEOUS MAINTENANCE

# 5.11.1 CLEANING THE GENERATOR

Keep your generator as clean and as diy^ as possi ble. Dirt and moisture that accumulate on internal generator windings have an adverse effect on insu lation resistance.

Periodically, clean the generator’s exterior surfaces.

soft brush may be used to loosen caked on dirt.

You can use a vacuum system or clr/, low pressure

air to remove any accumulations of dirt. The gener ator is housed inside an all-weather enclosure: clean the enclosure with a soft, damp cloth or sponge and water.

Once each year, have tlie generator cleaned and inspected t3V a Generac/Guardian Authorized Dealer. Sertdce technicians wall use diy, low pres sure air to clean internal windings. Parts Inside the control console should be cleaned and inspected at this time as w^ell.

F'ina.lly, have the insulation resistance of stator and

rotor wdndings checked. If insulation resistances are

excessively low. the generator may require diydng.

^ 3.11.2 RODENT PROTECTION

____________________

The intrusion of rodents into the generator set can cause a wide range of problems, from failure of the unit to start, to personal injury and, in extreme circumsta.nces, short circuit or fire. .Although the unit wms designed to limit this problem, you can take further precautions to help minimize both the chance of rodent entry and the extent of any dam age, You should inspect the unit at regular inter vals for signs of rodent intrusion. In addition, ensure that all access doors are tightly closed and secured at all times. If you detect intrusion and/or damage, contact your nearest Generac Authorized Service Dealer immediately.

_____________

3.12 GUT OF SERVICE PROCEDURE

♦ 5.12.1 REMOVAL FROM SERVICE

If you cannot exercise the generator even/ seven days, and it is to be out of sertdce longer than 90 days, prepare the generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line and allow the unit to shut dowm.

_______________

3. Once the unit has shut downs, it will signal a fault on the control panel.

4. Set tlie Auto/Off/Manual switch to OFF and turn off the utility powder to tlie transfer switch.

5. While ttie engine is still warm from n.m,ning, drain the oil completely. Reiill the cranitcase witli the

recommended oil (see Section 1.9, Page 7).

6. Attach a tag to tlie engine indicating the viscos ity and classification of the oil in the crankcase.

7. Remove the battery and store it in a cool, dry room on a wooden boa.rd. Never store the batter>' on any concrete or earthen floor.

8. Clean and wipe the entire generator.

# 5.12.2 RETURN TO SERVICE______________________

To return the unit to sendee after storage, proceed as follows:

1. Verify that utility' power is turned off to the transfer switch and that the Auto/Off/Manual switch is set to OFF.

2. Check the tag on the engine for oil viscosify and classi,fication. Verify that the correct recom mended oil is used in engine (see Section 1.9. Page 7). If necessa.r>i clradn and refill with the proper oil.

3. Check the barterv. Fill all ceils to the proper level witli distilled water. DO NOT USE TAP

WATER IN THE BATTERY. Remove the batteiy

before charging. Recharge the batteiy' to 100 percent state of charge, or. if defective, replace the batteiy' with a 12-volt DC Group 26F battery rated for 75 amp hours (part # 77483).

4. Clean and wipe the entire generator.

5. Reconnect the battery. Obsen'e battery pokirity.

Damage will occur if tlie battery is connected incorrectly.

6. Open the fuel shutoff valve.

7. Start the unit by moving the Auto/Off/Manual switch to MANUAL. Allow the unit to warm up thoroughly.

8. Stop the unit and set tlie Auto/Off/Manual switch to OFF.

9. Turn on the utility power to the transfer switch.

10. Set the Auto/Off/Manual switc.h to AUTO.

11. Your generator is now ready for sendee.

Generac® Power Systems, Inc. 1 5

Section 3 - Maintenance

MAINTEMANCE

Guardian Liquîd-cooied 3 kW Generators

|3J3 SERVICE SCHEDULE

ATTENTiON: !t is recommended that a!! service work

be performed by your nearest Generac/Guardian Authorized Dealer.

SYSTEM/COMPONENT

X = Action R = Replace/Adjust as Needed * = Notify Dealer

if R.epair is Needed.

■FUEL

Fuel level

;

Fuel lines, connections

and filters*

LUBRICATION

Oil level

; Oil

1 Oil filter

: Oil line leakage* 1 X

! COOLING

Engine cooling -system*

; Coolant level

Coolant* X 1 Enclosure louvers X : EXHAUST

Eichaust svstem Retorque Exhaust Manifold* X

BATTERY

Electrolyte fluid level Charge and condition

FAN BELT

Tension and condition*

ENGINE

Retorque cylinder head*

Retorque intake manifold*

Starter motor* X DC alternator* X

Air cleaner X R 1

Compression*

Valve clearance*

Governor* X

SafeA detdces* Iniection svstem*

GENERAL

Overall condition Exercise svstem

COMPLETE TUNE-UP*

inspect

X i

X i 1 j AFTER 25-H BRE.AK-IN, W X ! R 1 X i W, EVERT 250 H / 6 M

X X

X X ! R

TO BE COMPLETED BY A GENERAC/

GUARDIAN AUTHORIZED DEALER

PROCEDURE

Change

R i

R R

Clean

FREQUENCY

D = DaiN W = Weekly M = Monthly Y = Y'early H = Hours

AFTER 25-H BRE.AK-IN,

D / BEFORE USE

AVTER 25-H BRE.MÎ-IN,

EVERY 250 H / 6 M

EVERY 8 H /D

AFTER 25-H BRE.AK-IN.

EVERY 250 H / 6 M

AFTER 25-H BREAK-IN,

EVERY 250 H / 6 M

: EVERY 100 H

AFTER 25-H BREAK-IN,

EVERY iOO H / M

AFTER 25-H BRE-.AK-IN,

D / BEFORE USE EVERY 500 H / Y

EVERY 250 H / 6 M

EVERY 100 H / M FIRST 100 H ANE

EVERY 800 H

1 AFTER 25-H BREAK-IN, ! EYERY 250 H / 6 M

FIRST 100 H AND

EVERY 800 H

FIRST 100 H AND

EVERY 800 H EVERY 500 H

EVERY 500 H ARiD Y

EVERY 500 H EVERY 800 H EVERY 800 H

AFTER 25-H BRE-AK-IN,

EVERY 250 H/6 M

EVERY 6 M EVERY 3 M

AFTER 25-H BREAGIN, W

4.1 TROUBLESHOOTING GUIDE

Section 4 — Troubleshooting

Guardian Liquid-cooled 8 kW Generators

TROUBLESHOOTING

PROBLEM

CAUSE CORRECTION

The engine will not crank. 1. Fuse blown

2. Loose, corroded or defective battery cables

3. Defective starter contactor

4. Defective starter motor

5. Dead Battery

The engine cranks but will not start.

1. Out of fuel

2. ' Defective fuel solenoid (FS)

3. Open #14 wire from engine control board

4. Dirty/Blocked air filter

5. Amto/Off/Manual Switch in OFF position

The engine starts hard

and runs rough.

1. Air cleaner plugged or damaged

2. Dlrty/Blocked air filter

The engine starts, but then

shuts doLTO.

1. Engine oil level low

2. Defective low oil pressure switch

3. Defective high temperature switch

4. Defective control board

5. Low coolcmt level

6. Defective low coolant switch

7. Engine temperature high

8. Loss of AC sensing to control boa.rd

1. Replace fuse.

2. Tighten, clean or replace as necessary.

3. *

4. *

5. Charge or replace battery.

1. Replenish fuel.

2. *

3. *

4. Clean or replace as required.

5. Reset to AUTO or IvLwMUAL.

1. Check, clea.n or replace air cleaner.

2. Clean or replace as required.

1. Check oil and add oil as needed.

2 * O .1.

4. *

5. Check coolant level, repair leaks

and refill.

6. *

7. Check engine cooling airflow.

R ^

The Auto/Off/Manual switch is set to OFF, but the engine

continues to run.

There is no AC output from

tlie generator.

There is no transfer to

standby after utility source failure.

*Contact your nearest Generac/Guardian Authorized Dealer for assistance.

1. Defective switch

2. Defective control board

1. Generator main line circuit breaker open

2, Generator internal failure

1. Generator main line circuit breaker open

2. Defective transfer svfitch coil

3. Defective transfer relay

4. Transfer relay circuit open

5. Defective control logic board

1. * 0

1, Reset circuit breaker

to ON (or closed].

2. *

1. Reset circuit breaker to ON (or closed).

2. *

3. *

5. *

Generac* Power Systems, Inc. '1 *7

oWiTi'l fCTOW

_r ELECTRICAL

DATA

Section 5 — Electrical Data

Guardian Liquid-cooled 8 kW Generators Wiring Diagram (Control Pane!) - Drawing No. C2516-A

Section 5 - Electrica! Data

Guardian Liquid-coded 8 kW Generators

Electrical Schematic (Control Panel) - Drawing No. C2669-A

WiTm nrmT]

ELECTRICAL

DATA

Tini {HPi piFoinn

ELECTRICAL

DATA

-L

Section 5 — Electrical Data

Guardian Liquid-cooled 8 kW Generators Wiring Diagram (1.0 Liter Engine) - Drawing No. C4954-

On \A/ r

hWT- HIGH G/ATEH TEMP.

lOS- low oil press SW.

SC - STARTER CONTACTOR SM - STARTER MOTOR SWT- SENDER VVATER TEMP

WLS- WATER LEVEL SENSOR

5\/^t:i=rr»5=;. Inc.

Section 5 — Electrical Data

Guardian Liquid-cooled 8 kW Generators

Electrical Schematic (1,0 Liter Engine) - Drawing No. C4955-

CUSTOMER 120V/i5A UTILITY CONNECTIDN

niFoTri rifiJoTir

ELECTRICAL

DATA

EZL

■rr \ 'iZy

BLACK-

DCA

DCR

lDS

S W T

WLS

- DC ALTERMATDR

- DC vdltagl regulator

“ lNCINE Hl_A i EK

- ^UEL SHIJTOF“ SQlENGID

- FUEL PUMP

- Glow plug

- HIGH WATER TEMP,

- SWITCH, caw GIL PRESSURE

- STARTER CGMTACTuR

- starter METER

- SLMDER water temp

- WATER _EVEL SENSaP

Generac” Power Systems. Inc. ST

^PARTS

LISTS

Section 5 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators Compartment - Drawing No. C2436-B

2S CBenerac® Power Systems, Inc.

Section 6 — Exploded Views and Paris Lists

Guardian Liquid-cooled 8 kW Generators

Compartment - Drawing No. C2436-B

’’EM

PART NO.

*02433 1 CORNER POST, LH. REAR

*02434

A3443

3 4 A3444 1 5 A3445 6 A3446

A3447 1

A7198 1

A3449 2 DOOR, SIDE

A3451 12 A7197 1 13 A3453 14 A3454

*02435

*C2435A 1 DUCT, LH. REAR CORNER

C2755A

C2755B 1 DOOR, REAR (INSUL.)

C2755C

C2755D

C2755E

C2755F

C2755N VENTURI, TOP (INSUL.)

QTY.

DESCRIPTION

ITEM

CORNER POST, RH. REAR 25

1 1 PANEL. REAR BOTTOM

PANEL, REAR TOP PANEL. SIDE

PANEL, RH. SIDE BOTTOM

26 27

28 CORNER POST, LH. FRONT 29 CORNER POST, RH. FRONT

1 PANEL, FRONT TOP

PANEL, FRONT

1 DOOR, REAR

1 TOR ROOF 34

DUCT, RH. REAR CORNER 35

POST

36 POST

1 PANEL, REAR BOTTOM 38

(INSUL.) 39

DOOR, FRONT (INSUL.)

2 CORNER POST, FRONT

(INSUL.)

1 DOOR, LEFT SIDE (INSUL.) 4 PANEL, SIDE (INSUL.)

FOR REF. ONLY (SEE 02438 CONTROL PANEL FOR

DE \lLSi

PART NO. QTY.

DESCRIPTION

C2755P 1 ROOF, TOP (INSUL.) C2755M C2755G 1 C2755H 1

1 DOOR, RIGHT SIDE (INSUL)

AIR DUCT, BOTTOM (INSUL.) AIR DUCT. FRONT RH,

(INSUL.) C2755J C2755K

AIR DUCT, LH. SIDE (INSUL.)

AIR DUCT, FRONT LH.

(INSUL.) C2755L 1 22473

AIR DUCT, RH. SIDE (INSUL.)

50 FLAT WASHER-M6-1/4" 22097 32 LOCK WASHER-M6-1/4" 22127 6 49813 42568 18

NUT. HEX-1 M"-20 NUT, HEX-M6-1.0

CAPSCR..HEX HD.-M6-1,0 x 20

LONG 67577 22413 67042 78115 A3133A 2 A3133B A3133C A3133D A3359 40 A3360 40

SPEED NUO1/4"-20

16 16 CAPSCR., HEX HD,-1/4"-20 x 1

LATCH & CAM

WASHER. SELF LOCK/DOME

HINGE, SLIP-MALE L.H.

HINGE, SLIP-FEMALE L.H.

HINGE, SLIP-MALE R.H.

HINGE, SLIP-FEMALE R.H,

BHSCS-M6 X 16 S.S.

SHAKEPROOF, INT.-M6 S.S.

ör-iVA/pan S V «=; ft {= m «=:. inrt.

.PARTS

LISTS

Section 6 — Exoioded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators Controi Pane! - Drawing No. C2438-3

iS^^ooo.;

1©;

»67680 VOLT. RlG, shown IN THIS VIEW IS USED ON 30 UNIT DMLY

2^4 Generac® Power Systems, Inc.

Section 6 - Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators

Control Pane! - Drawing No. C2438-8

:'E!V! PART NO,

C2430 1 CONTROL PANEL BACK/

QTY. DESCRIPTION ITEM PART NO.

BOTTOM

2 C2719

SILKSCREEN-CONTROL 37

1 '

PANEL 38

3 C2431

C2431A

83048

CONTROL PANEL L.H, SIDE 39

1 1 CONTROL PANEL R.H, SIDE

VOLTAGE REGULATOR

1-PHASE 60HZ

67680

VOLTAGE REGULATOR

3-PHASE BOHZ 43

C2434

CORNER POST, RH REAR 45

(PANEL SUPPORT) 46

6 C2433

CORNER POST, LH REAR 47

(PANEL SUPPORT

7 77906 1 CIRCUIT BREAKER-MAIN 48

(35A-2P-BQ2) 49

57906

CIRCUIT BREAKER-MAIN (35A-3P-BQ3)

S C2435 1 DUCT. R.H. R.R, CORNER 53

75589 1 BRACKET, VOLTAGE

REGULATOR

76039

11 51716 2

12 90426

90427

13 14 40295

40292

C2435A

SCREW, PPHM M5-.8 x 40MM HEX NUT M5-0.8 PPHMS #10-32 X 3/8“ S.S.

FLAT WASHER #10

LOCK WASHER #10 58 C2428

HEX NUT #10-32

DUCT, LH REAR ICORNER

POST)

17 C2515 1 HARNESS, CONTROL 61

PANEL “P“ 18 29333 4 TIE WRAP T LG. 19 76061 1

81988 1

21 82573

DECAL. TERMINAL STRIP 64

DECAL SET EXERCISE TIME 65

SWITCH ROCKE.R(SET EXERCISE TIME) 67 C2265 9

22 76020

64009 LIGHT FAULT INDICATOR

24 61945

A2560

C5454

26 27 22473

55349

58568

SWITCH-AUTO/MANUAL/OFF

SWITCH, VOLTAGE SELECTOR 1 RELAY IP 50A/12V 1 CABLE, NYLON CONTROL

PANEL

WASHER. FLAT 1/4"

1 INSULATOR

2 CURRENT TRANSFORMER

50/5 n PHASE) CURRENT TRANSFORMER

73 36935 75 76 77 78 79

50/5 (3 PHASE)

70081

70043

31 32 32300

49939 RECTIFIER

33 34

22668

1 HOUR METER 1 VOLTMETER DC (BATTERY)

HOLDER, FUSE

FUSE. 30A.

30 81 82 22473 83

70042 1

35 36 700-^5 1

71668 70370 1 30468 71938A 1

23762 1 22097 22

C1914A 48766 56967 2 79246

48468 1

22155 22142

52 22145

33121

22152

23897

22158

57 A2419

24 SWG FASTENER 1/4"-20 x

34616

57335

46669 7 57907 1

C2484 2

22264 7 39782

75545 1

61979

68 69 57073

33530 2

22129

22259 54199 C2512 75595 A7215

C2473 22287

22127

DESCRIPTION

QTY.

HERTZ METER 60HZ AC AMMETER 0-200 AC VOLTMETER 0-500

WASHER, MICA STEP, WASHER NYLON

VOLTAGE REGULATOR, D.C. WASHER, EXTERNAL SHAKEPROOF WASHER. LOCK 1/4" HINGE CONTROL PANEL

BLOCK TERMINAL (2)

PLUG, PLASTIC .37

HHCS M6-1.0 X 16 LG. W/LOCK WASHER CIRCUIT BREAKER 8A #6 LOCK WASHER HHCS 5/16”-18 X 3/4"

WASHER FLAT 5/16"-M8 #10-32 X 1./2" LG. HEX HD

MACH. SCREW #10 LOCK V/ASHER

#10 FLAT WASHER

#10-32 HEX NUT

1/2" LG. SWG FASTENER #6-32 x 1/2" LG. STRAIGHT CONNECTOR

TERMINAL BLOCK

JUMPER, TERMINAL BLOCK

RESISTOR, 10 OHM

BRACKET, PANEL SUPPORT WASHER. LOCK M4 BRACKET, CIRCUIT BREAKER

COVER, CIRCUIT BREAKER SWG FASTENER M4-0.7 x 12 LG. BAR, BUS NEUTRAL STAR

STUD, JUNCTION BOX

PHMS #10-32 X 5,/8"

WASHER, LOCK 5/16"-M8

PPHMS #10-32 X 3/4"

HEX NUT 5/16"-18

DECAL, HIGH VOLTAGE

WIRE CONNECTOR 1"

CMA, BOX SW FASTENER 1,''4"-20 x 5/8"

W.A/VASHER BRACE, TOP REAR

2 HHCS, 1/4"-20 X 3/4"

FLAT WASHER, 04"

HEX NUT 1/4--20

Generac® Power Systems, Inc. S5

.PARTS

LISTS

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators

Engine Common Parts - Drawing No. C5009-B

o o

o a

lD [X

SB Generac'’ Power Systems, Inc.

Section 6 - Exploded Views and Parts Lists

Guardian Liquid-cooled S kW Generators

Engine Common Parts - Drawing No. C5009-B

.PARTS

LISTS

ITEM

PART NO.

72501 2 MOUNT, ENGINE 70936

75672

o 4

51769 4 WASHER. LOCK Ml 2 46 46233

57642 1

/ 46526 1

42909

22129

77909 1

QTY. DESCRIPTION ITEM

2 DAMPENER, VIBRATION 4

HHCS Ml2-1.25 X 40MM

V-BELT30-1/8" LONG HHCS M10-1.5 X 40MM WASHER. LOCK M10 49

HHCS M8-1,25 X 30MM WASHER, LOCK M8

BRACKET, ALTERNATOR

11 22145 1 WASHER, FLAT M8 53

45771

22097

13 14 57058 2

77910

16X 47411

17 50311

A1354

39294

20 59399A 1

NUT, HEX M8-1.25

14 WASHER. LOCK M6

HHCS M6-1.0 X 55MM

FAN, ENGINE

HHCS M6-1.0 X 16MM 58

SPACER 59

DC ALTERNATOR

CLAMP, HOSE #44

INTAKE HOSE 21 35685 1 CLAMP. HOSE #28 63 22 23

70941 1 C4206

FILTER, AIR

ENGINE HARNESS

PART NO.

44 52221 45 30096

74819 40173

52221

52221 1 HOSE 5/16" X 205MM LONG 52221

22097

52219

52 '

50S67 1 HOSE 5/8" I.D. X 18" 50967

57823 6

72573

69860E

22507 53667 2 42574 1 ADAPTOR

84033

99236 68-44114

64’

42907 5

24 C4695 1 BRACKET. FUEL PUMP 67 69811

65852

71952 1 WASHER, LOCK 69

26 27 71912

75673

75674 1

A4119 1 FUEL PUMP ASSEMBLY 74

84918

42907 3

75692 1 SHIELD, HEAT

45757

22261

74808

37 52233

39450 2 90 DEG. ELBOW BARB

74823

68736-3

6S736-A

28739

70928

1 CLAMP, SPRING

PPHMS M5-0.8 X 8MM 70

-j

MANIFOLD EXHAUST GASKET EXHAUST ADAPTOR

BLOCK HEATER HHCS M8-1.25 X 16MM 76

6 HHCS M6-1.0 X 16MM 77 1

STAR WASHER M8

CONNECTOR. ADAPTOR 80

CONNECTOR, ADAPTOR TEE

CLAMP, HOSE 82 87458

HOSE 3/16" I.D.

HOSE 3/16" I.D. MOUNT

TIE WRAP

3 CLAMP, HOSE

78 81

84 357-70939 1 85

72 73

84432 57522 57824 46852 79929 77444 1 77913 35468

51730 71956 A7803 66246

87469

661-70939

QTY.

DESCRIPTION

HOSE 5/16“ I.D. X 170MM LONG

FITTING, BARBED STRAIGHT

CONNECTOR FITTING CLAMP, HOSE

1 HOSE 5/16" X 570MM LONG

1 HOSE 5/16" X 120MM LONG

WASHER, LOCK 1/4"

1 FITTING, BARBED STRAIGHT

HOSE 5/8" I.D. X 14"

CLAMP, HOSE #10

FITTING, OIL

HOSE. DRAIN HHCS 1/4“-20 X 1./2”

SENDER, WATER TEMP.

1 FITTING, BARBED STRAIGHT

3/4“ NPT X 5/8" SWITCH, OIL PRESSURE

ASSEMBLY. GROUND STRAP

HHCS M8-1.25 X 16MM 1 CAP, HEX 1/xT DÍA. 1

ADAPTOR, SENSOR 1 WATER LEVEL SENSOR

CLAMP, HOSE 316

1 TAPTITE #10-32 X 1/4"

TEE 1 X 1 X

UPPER RADIATOR HOSE

LOWER RADIATOR HOSE

1 1 3/8" X 1/4" REDUCER

BUSHING

HHCS M8-1.25 X 60

4 4

WASHER, FLAT M8

1" PRE-ALARM TEE

WTS PREHEAT & SHUT DOWN

230 DEG. 5/8" O.D.TUBE

THERMOSTAT 5/8" TUBE

GASKET EXHAUST ISM FUEL FILTER ASSEMBLY ISM

rORGUE FT. LBS,

* NOT SHOWN

Generac* Power Systems, inc.

^PARTS

LISTS

Section 6 - Exploded Views and Parts Lists

Guardian Liquid-cooled 3 kW Generators

Generator - Drawing No. A4671-B

3<4 j 0

SS Generaci Power Systems, ine.

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators

Generator - Drawing No. A4671-B

iEM PART NO. QTY,

1 77900 1 2 42558 1 3 48189 2

87714A

5 74243 1

72512 4

S 7 22097

8 WASHER. LOCK-M6 27* 8 22473 8 9 77043C 1

10 76019A 1

69804A 1

14 69892

■ 5

70992 1

98323 17 75554 18

22129

1 PLATE. COVER

¿1

19 47411 4

134-70939

21 20747

DESCRIPTION ROTOR ASSEMBLY-8KW 22

KEY

ITEM PART NO.

46526

23 22131 PIN, DOWEL 24 73450B 1 HOUSING, BLOWER 25 ■

49814

QTY.

DESCRIPTION

WASHER, LOCK

7 WASHER

PLATE, ENGINE

•o

CAPSCREW, HEX HEAD-MI 0-

SCREEN, AIR OUTLET 1.5 X25MM LONG

CAPSCREW. HEX HEAD-M6-

26^^' 51756

CAPSCREW, HEX HEAD-M10-

1.00 X 8MM LONG 1.5 X 20M.M LONG

42907

CAPSCREW, HEX HEAD-M8-

WASHER, FLAT-M6 1.25 X 16MM LONG

FLEX CONDUIT-3/4" l.D.x 10"

28 73451

ASSEMBLY, FLYWHEEL & LONG RING GEAR STATOR ASSEMBLY-8KW

29**

62963

CAPSCREW, HEX HEAD-MI 0CARRIER. REAR BEARING 1,25 X 30MM LONG GASKET. REAR BEARING 30 CARRIER

31 53557

72578

1 SPACER. ATR SHAFT 1

BOLT, HEX HEAD-MI2-1,75 x ARRESTER, FLAME 40MM LONG

BOLT, STATOR

33 73A54A

WASHER, LOCK-M8 34*

51769 75789

WASHER, LOCK-MI2

PLATE. COUPLING

12 SOCKET HEAD CAPSCREW.

CAPSCREW, HEX HEAD-M6- 5/16-18 x3,/4"

1.00 X 16MM MOTOR, STARTER 36 SCREW, SOCKET-HEAD M10- 37

35 73452

73455 63212

1.5 X 35MM LONG (391 821308

1 HUB, DRIVE

-i

1 FAN

GROMMET RUBBER

SENSOR, RPM

=MON-GUARDiAN UNIT

TORQUE FT LBS,

/far* 5^\

^PARTS

LISTS

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators CMA Assembly - Drawing No. S1086-C

/ /V

/ /

/' /■'

..x /,

'-'t“-/-A,

■'vT'-' \ /X\ X

/ /

in /

<7>

—. ’"x

\ \ ' /

\ 'x\ /'

\V /'

1/'

-mMM\

‘

./ \ '

—

------

, ^X/

...V—^

.. /

/ / ^ /'■

Cvl

/ CO /

J i

/ /

30 CSenerac® Power Systems, Inc.

,'/ / /

V / /

03'

LO,

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators

CMA Assembiy - Drawing No. 81086-C

ТЕМ PART NO.

76009A 1

72566

О 80882

74978 1

47822

75476

83264 8 22985 4 9 22264

10 51787 11

79847

QTY.

DESCRIPTION

BOARD. CIRCUIT-DC 12

CONTROL/CRAMK LATCH

STANDOFF, CIRCUIT BOARD SUPPORT

SCREW, PPH TAPPING #6 x 13*

5/8"

DECAL, TERMINAL STRIP

BLOCK. TERMINAL STRIP 16

SCREW, PPHM M4-0.7 x 16MM 17*

TRANSFORMER 24VA. 12 SEC

WASHER, FLAT M4

WASHER, LOCK M4

2 HHCS M4-0.7 X 16

BOX. CMA

ITEM

PART NO. QTY.

A8504 A850-1A 22661V .083’ HEAT SHRINK RED ,19

14 15

38057 2 584A3 2 8122-i 1 DECAL, MFG NAMEPLATE

79682 1 WIRE HARNESS 18 19

86093 2 DECAL, CMA WARNING

83736 1

20 51715 21

74495

77^01

‘NOT SHOWN

DESCRIPTION

DECAL. COVER-CMA (MODEL

921. 863,865)

DECAL. COVER-CMA (MODEL 94281

GROMMET CRIMPTITE

DECAL, CSA NUT, HEX M4-0.7

2 1 COVER, CMA BOX (921,863,

865, 9428)

COVER, SILKSCREENED

.PARTS

LISTS

Section 5 - Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators Mounting Bass - Drawing No. C2655-B

(

>li

:,_i

32 Generac® Powpr Systems, inc.

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators

Mounting Base - Drawing No. C266S-B

TEM

PART NO.

A1492

2 A7200

A7307

A7726 A7727

5 7

AA285

QTY. DESCRIPTION

1 FUEL CAP KELCH200751

BASE FRAME ASSEMBLY

BRACKET, FRONT FRAME

ALT MNT ASSEMBLY, R-SiDE

ALT, MNT. ASSEMBLY. L-SIDE

1 2

BRACKET, ENGINE MOUNT

8 21538G 2 FUEL DIP PIPE, 250MM

21973A 10 11 12

26847

26924

A57^6

GAUGE, FUEL LEVEL 281

2 BREATHER

90 DEG. ST ELBOW 3/8 NPT

BRACKET, RADIATOR

SUPPORT

35472

13 14 59502 1 6 70936 17

52221 1 5/16 I.D. HOSE X 800MM 36 63831 2 PIPE PLUG 1-1/4^' SO, HD.

HOSE CLAMP, SIZE #6

BARBED 90 DEG.1/4 x 9/16

4 VIBRATION ISOLATOR

PART NO.

67982

ITEM

21 35468

23 42568 24

49813 9 M6-1.0 HEX FIN. NUT

25 22473

22097

26 27

39253 38 M8-1.25 X 20 HHCS 45771

28 29 22145 50

22129

¿9814

32 46526 4

A4160

34 68-44114 1

22261

QTY.

DESCRIPTION

BARBED STRAIGHT, 5/16 x 3/8

REDUCER BUSHING 3/8 x 1/4

M6-1.0 X 20 HHCS

1/4 SAE FLAT WASHER

25 1/4 SPLIT LOCKV'/ASHER

M8-1.25 HEX FIN. FULL NUT 5/16 SAE FLAT WASHER

38 5/16 SPLIT LOCK WASHER

Ml0-1,5 X 25 HHCS M10 SPLIT LOCK WASHER

BRACKET, ENGINE HEATER

ASSEMBLY, GROUND STRAP

1 STAR WASHER. M8

Generac* Power Systems, Inc. 33

^PARTS

LISTS

Section 6 - Exploded Views and Parts Lists

Guardian Liquid-coded 8 kW Generators Radiator - Drawing No. A7836-

c/^

\ / iT' Cr''.

./'LV / :

vD'

1>-

\ \

-o\

--^3i"0vr ^Vvs'.'TOj

'ji'AA.'A v'f> a;

U J

34 Generac* Power Systems, Inc.

At A'AiAtAT.O'.

c . _ /

'LTi

;X)

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooied 8 kW Generators

Radiator - Drawing No. A7886-

..PARTS

LISTS

PART MO. QTY.

'EM

1 A3483

A3484 1 BRACKET, RADIATOR LH SIDE

¿L

A3487 1 VENTURI

A3488

A3826

A4353

46627 1 RADIATOR CAP

77444 1 UPPER RADIATOR HOSE

77913

83709

DESCRlPTiON

BRACKET, RADIATOR RH SIDE

1 AIR DUCT 1 GUARD FAN 1

RADIATOR REWORK DRAWING

LOWER RADIATOR HOSE

SPRING CLAMP. #9

ITEM

1 1

15 16

18 19

PART NO.

29032 76749

80712

42907

22145

22129

45771 57824 75443 79929

QTY. DESCRIPTION 1 5/16” l.D, X 36" HOSE

COOLANT RECOVERY ВОТ

1 1 BRACKET, COOLANT BOT1

M8-1.25X16

FLAT WASHER - M8

LOCK WASHER - M8

HEX NUT - M8-1.25

HOSE CLAMP N0.16

CRIMPTITE 1/4-20 X 5/S

TEE 1 X 1 X 5/8

TLE WE

Generac* Power Systems, inc. 35

Section 5 — Exploded Views and Parts Lists

Guardian Liquid-cooied 8 kW Generators Exhaust - Drawing No. A4674-A

WRAP FLEX EXHAUST FROM A TO B WITH EXHAUST INSULATION P/N 82361, SECURE EACH END OF INSULATION

'EiVI

PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

A3591 1 FLEX EXHAUST -8KW

TRAILER

A3904 1

A3905

22129

22145 6 22259 7

240.05

8 53413

3S Generac® Power SystemSj inc.

EXHAUST ELBOW, 1.5"

SILENCER, 1,0L-8KW TRAILER 1 r

4 LOCK WASHER - 5/16”-M8 12

FLAT WASHER - 5/16"-M8

4 4

HEX NUT - ,5/16"-18

U-BOLT - 1-3/4” X 5/16-18

2 SADDLE - 1-5/8-1.80 * NOT SHOWN

77767A 2 MUFFLER MOUNTING BAND -

7” O.D.

10' 82361 8,5 FT. EXHAUST INSULATION

42561 75674

13 22129 4

HOSE CLAMP, #36

GASKET, EXHAUST ADAPTOR

5/16 SPLIT LOCK WASHER

14 43107 4 M8-1.25 X 25MM HHCS

Section 6 — Exploded Views and Parts Lists

Guardian Liquid-cooled 8 kW Generators

Battery - Drawing No. A4675-A

T' ‘ 1

I o Engine

Unde n

dai

^ t e n,

I o Sdo.nTen

Connecton

, 'j

ITEM PART NO, QTY. DESCRIPTION

1277483

38804Y 1 38805H 1 CABLE, BATTERY - BLACK-23”

3 4

22250 1 51769 1 WASHER, LOCK - 7/16 10

68485 1

BATTERY. GROUP 26 CABLE, BATTERY - RED-35”

WASHER, FLAT - 7/16 CAPSCREW. HEX HEAD, M12-

1.25 X 20MM

ITEM PART NO. QTY. DESCRIPTION

J-BOLTS, BATTERY HOLD DOWN BAR, HOLD-DOWN

WASHER, FLAT - 5/16

WASHER, LOCK - 5/16

NUT, HEX - 5/16-18

59567 2

78121

22145

22129 22259 2

Generac^ Power Systems, inc. 3“7

INSTALLATION

FUEL 1‘ANK FITTING

F i TT i NG DESCRIPT i ON

FUEL SUPPLY FUEL RETURN

3 C 'UEL FILL D FUEL LEVEL GAUGE E

PLUG (.RUPTURED BAS.IN SWITCH)

□ UTER TANK '/EMT G PLUG (LOW -UEL LEVEL SWITCH) И :nner tank vent

Section 7 — Installation Drawings

Guardian Liquid-cooled 8 kW Generators insiallation Drawing - Drawing No. C25I8-A

MOUNTING HOLES

2)12,49 [0,53] b HOLES ON BOTTOM

R^73.5 rRi5.S4]__

DOOR SLING A,

593 Cil.l4] ROOF AIR DISCHARGE

134.5 CT.cbj

974 [56.54]

ROOF AIR

DISCHARGE

600 C23.62] ; \

L-" TYP ^

TYP \ Л

ISOO C-!7,S4]

TOP GR plan VIEl

I SHOWN WlTHOur ENGiNE a. ALiERNAiOR;

3S Generac® Power SystamSj Inc.

Section 7 Installation Drawings

Guardian Liquid-cooled 8 kW Generators

Installation Drawing - Drawing No. C2518-A .

ENGINE SERVICE CnNNEC^iENS FUEu SUPPLY = 3/S' Npv COUPLING

FUEL RETURN = 3/8' NPI' COUPLING □;L DRAIN = SEE NGTE 1i

NGTES^

INSTALLATIQN DRAWING FOR MODEL NO, Q4I55-0

DESCRiPTinM = SDOOS DIRECT EXCITATION ALTERNATDR WITH

METER L CONTROL PANEL.

/3a STANDARD BLOCK HEATER REQUIRES lEOV AC CONNECTION

(CFTIGNAL BATTERY HEATER AVAILABLE)

MX, AC LOAD LEAD CONDUIT

/'5a 13 VOLT NEGATIVE GROUND SYSTEM

,s BATTERY TRAY INSIDE DIMENSIDNS: 307 X 183 [8.

/61. 38 <!.5') i, D, PLEX EXHAUST PIPES, /JÀ DOORS MUST EE OPENED 90 DEG, TO BE REMOVED,

/8a MAIN LINE CIRCUIT BREAKER,

M 46 gallon CAPACITY DIESEL EUEL TANK,

/’ n\ OUTER RUPTURE BASIN,

,3 1\ FLEXIBLE OIL DRAIN HOSE SERVICEABLE FRCM RIGRp SIDE

DOER.

1, OL DIESEL-SDUND / PRE-PACKAGE

INSTALLATION

DIMENSIONS IN: MILLIMETERS I INCH]

NOTE: AL^ CONNECTION MUST BE FLEXIBLE,

WEIGHT DATA

UNIT: approximately 540 ka [1190 Uo, I

UNIT WX DIESEL: 685 ka [1510 lb.]

Generac® Power Svstams. fnc. 33

Section 3 - Warranty

Guardian Liquid-cooled 8 kW Generators

FEDERAL AND CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT

(for non-road Diesel engines rated under 19 kW)

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The U.S. Emaronmental Protection Agency (EPA), the California Air Resources Board (GARB), Generac Power Systems,

Inc. (GENERIC) and the engine manufacturer for this equipment, Ishikawajima Shibaura Machinery Co., Ltd. (ISM), are pleased to explain the federal and California emission control system warranty on your engine.

In California, new' 2000 and later small non-road engines must be designed, built and equipped to meet the state’s strin

gent anti-smog standards. In other states, new 2000 and later non-road diesel engines rated under 19 kW must be

designed, built and equipped to conform to applicable EPA regulations. ISM must wa.rrant the emission control system on your engine for that period of time listed below provided there has

been no abuse, neglect or improper maintenance of your small non-road diesel engine. Your California and EPA emission control system may include parts such as the fuel injection system and other emis

sion-related assemblies.

MTiere a warrantable condition exists, GENERkC will repair your engine at no cost to you, including diagnosis, parts and labor, on behalf of ISM. Mthough ISM is ultimately responsible for this w'arranty, GENERAC has agreed to cany^ out ISM's warranty repair responsibilities, and GENERIC should be your primary contact for emission-related warranty service.

MANUFACTURER'S WARRANTY COVERAGE

Far. 2000 and later small non-road diesel engines first sold in California, and 2000 and later non-road diesel engines rated under 19 kW first sold in all other states, the applicable warranty' period is two (2) years or 1,500 hours, whichevrer comes first.

If any emission-related part on your engine is defective, the part wall be repaired or replaced by a Generac Authorized Warranty Service FacillW on behalf of ISM.

PARTS COVERED

This emission control system warranty applies to the following engine emission control parts.

• Fuel Injection Pump • Fuel Injectors Intake Manifold Air Cleaner Element

• Exhaust Manifold

• Miscellaneous Hoses, Bolts and Connectors

OWNER'S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance listed in your O w ner 's

Man ua l. GENERAC and ISM recommend that you retain the original purchase documentation and all receipts covering

maintenance on your engine, but GENERAC and ISM cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the engine owner, you should be aware, however, that GENERAC and ISM may deny you warranty coverage if your

engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for contacting 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 Warranq/ Service Facility nearest you. call our toll-free number:

1-800-333-1322

If you have any questions regarding your warranty rights and responsibilities, you should contact GENERAC at the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

211 MURPHY DRIVE

EAGLE, Wl 53119

Page 1

¿40 Generac® Power Systems, Inc.

Section 8 - Warranty

Guardian Liquid-cooled 8 kW Generators

OBLIGATIONS ÄND RIGHTS OF THE MANUFACTURER ÄND OWNER

The new model year, class of diesel engine, and emission application determination for your engine are identified on the

emission control information label affixed to the right-hand side of your engine's timing gear case. The rvarran ty period begins on the date the new equipment is sold to the first retail purchaser.

Any emission control system parts scheduled for regular inspection that are proven defeciive during nonnal use will be

repaii-ed or replaced during the warrano,' period. Any warranted pan: that is scheduled for replacement and tliat fails prior

to replacement will be repaired or replaced under warranty, and the repaired or replaced part will be covered under xvarranty for the remainder of the period prior to the first scheduled replacement. The wananb/ repairs and service will be performed by any Generac Authorized Warranty Service Facilirt, with no charge for parts or labor (including diagnosis).

As the engine omier. you are responsible to perform all the required maintenance listed in your Owner's Ma nu al . GENERiàC will not deny an emission warranty claim solely because you have no record of maintenance; however, a claim may be denied if your fadlure to perform maintenance resulted in the failure of a warranted part. R.eceipts covering reg ular maintenance should be retained in the event of questions, and these receipts should be passed on to each subse quent owner of the engine.

It is recomtmended that replacement parts used for maintenance or repairs be CTENERibC authorized and approved parts to maintain the qualibv originally designed into your emission certified engine. However, any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided vrtthout charge to the owner. Such use will not reduce the warranty obligations of GENERIC. Add-on or modified parts may not be used for mainte nance or warranty repairs. Such use will be grounds for disallowing a warranty claim, and GENERIC will not be liable to warrant failures of warranted parts caused by the use of an add-on or modified part.

LIMITATIONS

This warranty shall not cover atny of the following:

la) Systems and parts that were not first installed on the new equipment or engine as original equipmænt by GENERAC. (b) Conditions resulting from tampering, misuse, abuse, improper adjustment, engine alteration, use of add-on or mod

ified parts, use of replacement parts that are not the same in performance and durability as GENERFC-approved replacement parts, accident, failure to use the recommended fuel or oil, use of unapproved fuel or oil additives, or fail

ure to perform required maintenance, (c) Replacement parts used for required or scheduled maintenance. id) Consequential damages such as loss of time, inconvenience, or loss of use of this engine or equipment. (e) Damages or repair costs caused by the owner's unreasonable delay in making the engine available for inspection

and repair. (f) Diagnosis or inspection fees that do not result in eligible warranty service being; performed. (g) Equipment with an altered or disconnected hourmeter where the hours cannot be determined, fh) Equipment normally operated outside the United States. (i) Accident-caused damage, acts of nature, or other events beyond GENERTC’S control.

(j) Warranty repairs undertaken or attempted by the owner or any other person who is not affiliated with a Generac

Authorized Warranty Service Facility.

OBTAINING WARRANTY SERVICE

To obtain service under this warranty, promptly contact your nearest Generac Authorized Service Dealer or a Generac Authorized Warranty Ser.lce Facility-. If available, prortde the GENERIC representative with the original purchase receipt (showing the initial date of purchase) and all available maintenance records.

Page 2

Generac^' Power Systems, Inc. ■4'!

—I

Section 8 - Warranty

Guardian Liquid-cooled 8 kW Generators

GENERAC POWER SYSTEIVIS' STANDARD ONE-YEAR LIMITED WARRANTY

FOR STANDBY POWER SYSTEIVIS

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES.

For a period of 1 (one) year or 1,500 (one thousand five hundred) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warrant}' Sendee Facility, is found to be defective under normal use and service, in accordance witli the warranty schedule set forth below. Any eqrnpment that the purchaser/owner claims to be defective must be examined by the nearest Generac Authorized Warramy 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

Generac generators used in “Standby” applications, as Generac has defined Standby, provided said generators have been

initially installed and Inspected on-site by a Generac Authorized Service Dealer or branch thereof.

WARRANTY SCHEDULE

YEAR ONE - 100% (one hundred 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 maximum, round trio, and applies only to permanently wired and

mounted units.

All warranty expense allowances are subject to the conditions defined in Generac’s W ar ra nty Poli cie s, Pr oc ed ure s and Fla t

Rat e M a nu al.

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:

• Costs of normal maintenance, adjustments, installation and start-up.

• Units sold, rated or used for "Prime Power” applications as Generac has defined Prime Power. Contact a Generac Authorized Service Dealer for Prime Power definition and warranty.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or Improper installation.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust,

fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any Incidental, consequential or indirect damages caused by defects In materials or workmanship, or any delay in repair or replacement of the defective part(s).

• Failure due to misapplication,

• Telephone, telegraph, teletype or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific imlt warranty period.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFIC.ULLY. GENERAC MAIÍES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow' limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERkC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED .ABOVE, IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR C O NS EQ U EN T IA L DAMAGES. ELTIN 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 warranb/ gives you specific legal rights. You also may have other rights that vary from state to state.

Part Mo. casi

Revision A (as/as/oa] Printed in LJ.S.A.

Generac Power Systems 04137-0 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SUARDIAry

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