Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726-0 ! Not intended for use in critical life support applications. ! ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.
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 are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.
Table of Contents Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators INTRODUCTION ..................................IFC SAFETY RULES ......................................2 Section 3 — OPERATION....................12 3.1 Using a Standard “GTS” Transfer Switch....12 3.2 Control Console Components......................12 Section 1 — GENERAL INFORMATION..................4 3.3 Manual Transfer and Startup ......................13 3.4 Automatic Operation ..................................13 1.
IMPORTANT SAFETY INSTRUCTIONS Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators ! SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. ! SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
IMPORTANT SAFETY INSTRUCTIONS Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators • Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.
Section 1 - General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 1.1 GENERATOR 1.3 AUTOMATIC SYSTEM OPERATION This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only.
Section 1 - General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 1.2 - Main Circuit Breaker Model Rating Phase 004721/004722 004723/004724 004725/004726 15,000 20,000 25,000 1 1 1 Actual Current C/B Rating* 62.5 70 83.3 90 104.2 125 * Amp Rating of CB structured under model. Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas and at least 2,520 Btus per cubic foot for LP gas.
Section 1 — General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators • LED 2 is YELLOW. This LED is on when the circuit board battery charger is on. This LED will cycle on and off with the battery charger, 4.85 hours on the 4.85 hours off. • LED 3 is GREEN. This LED will flash when the circuit board has load voltage available to it. This LED will function when voltage is available across T1 and T2. Figure 1.6 - Low Coolant Level Sensor 1.7.
Section 1 — General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators NOTE: 1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Single-Phase Model Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No. of Rotor Poles Driven Speed of Rotor Rotor Excitation System Type of Stator Rotor/Stator Insulation 004725 004723 004721 004726 004724 004722 25 20 15 120/240 2 4 3600 3600 1800 Direct excited brush type 4 Wire Class F 1.10.2 ENGINE SPECIFICATIONS Make..................
Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators NOTE: Port 1 is for NG only and Port 2 is for LP vapor only. No provision for simultaneous fuels has been made. DANGER ! Serious injury or damage may occur if not configured properly. Please consult an authorized Generac Service Dealer with any questions. 1.13 TORQUE SPECIFICATIONS Cylinder Head ............................................15 (+ 90° + 90°) ft.lb. Intake Manifold ............................................
Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators NOTE: For more information about the installation of a standby system, order Engine-Generator Standby Electric Power Systems Installer’s Guide and Reference Manual (part #046622) from a Generac Authorized Service Dealer. 2.1.
Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators NOTE: Generac recommends the use of a Generac Power Systems “GTS” type transfer switch in conjunction with this generator. 2.5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator.
Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 2.10 BATTERY INSTALLATION DANGER ! 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.
Section 3 — Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 2.11.2 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.
Section 3 - Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 3.2.1 NOTE: HOURMETER Indicates time the engine-generator has operated, in hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for the generator set. 3.2.2 AUTO/OFF/MANUAL SWITCH This fuse will not remove the positive (+) battery input power from the PCB when it opens. This means the exercise timer will not be reset.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators If the AUTO/OFF/MANUAL switch is switched 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 seven days thereafter, on day and time of day the switch was actuated.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 4.2 COOLING SYSTEM Figure 4.1 - Oil Dipstick and Oil Fill Cap Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow. OIL DIPSTICK Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 4.5.4 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. 4.5.5 CHECK ENGINE COOLANT LEVEL See “Checking Fluid Levels” in Section 4.4. 4.5.6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine-generator monthly.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 4.3 – Engine Air Cleaner Air Cleaner 4.6 MISCELLANEOUS MAINTENANCE 4.6.1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance. (Doors Removed for Clarity) See the “Scheduled Maintenance,” Section 4.7, for air cleaner maintenance. 4.5.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 4.6.3 BATTERY MAINTENANCE The battery should be inspected per the “Scheduled Maintenance,” Section 4.7. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. 3.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 4.7 SCHEDULED MAINTENANCE The following is a recommended maintenance schedule for Generac Guardian small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level. Correct as necessary. 5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary. 6.
Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Maintenance Tasks Level 1 Recommended to be done monthly/ 10 hrs. Level 2 Task Comp. (DateInitials) Required to be done 3 months/ Break-in 30 hrs. Level 3 Task Comp. (DateInitials) Required to be done Semiannually/ 50 hrs. Level 4 Task Comp. (DateInitials) Required to be done Annually/ 100 hrs. Task Comp. (DateInitials) 13.
Section 5 — Troubleshooting Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 5.1 TROUBLESHOOTING POINTS PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor. 4. Replace starter motor. 5. Remove, change or replace battery.
Section 6 — Notes Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Generac® Power Systems, Inc.
Section 6 — Notes Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 24 Generac® Power Systems, Inc.
Section 7 - Installation Diagram Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Drawing No. 0E1533 Generac® Power Systems, Inc.
(BLACK) (BLACK) (BLUE) (RED) BLUE 178 225A 239 178 225 BLUE 0 225A 15A 178 239 183 4 TR1 YELLOW 8 F1 15C 15C BLUE 14 15 14 15 0 183 162 CB2 162 BLACK BLACK 15C 2 0 4 0 4 15E 6 14 AS - FO SW 23 194 0 S16 14 S16 94 23 85 TS2 CAP 0 0 0 13 14 13 4 229 14 229 S16 S15 SUPRESSION ASSEMBLY FUSE 15 AMPS 56 56 BLUE 85 85 85 TERMINAL STRIP 7 POS.
Section 8 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L Engine — Drawing No.
EC 28 Generac® Power Systems, Inc.
Section 8 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Electrical Schematic — 1.5L — Drawing No.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Governor Assembly — Drawing No. 0E1331-B 5 4 3 ITEM (13) NEOPRENE COATING 2 1 14 6 7 10 WIRE HARNESS 15 12 9 7 16 "A" 17 TO "A" 10 7 CARBURETOR ARM (REF.) 6 INTAKE MANIFOLD (REF.) 11 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NO. 098290 098941A 098958A 098942A 098225 043146 022097 084543A 098783 037398 0E1326 0A7106 074031 029333A 022507 022473 064526 0E1694 QTY.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Mounting Base — Drawing No. 0E0768-B 8 7 6 14 5 13 7 6 4 9 15 6 10 15 20 5 7 6 11 17 18 16 2 3 9 10 22 1 15 20 22 ITEM 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 PART NO. 0D8656 027482 070936 070936C 039253 022145 022129 045771 071956 051730 021991 0D9335 0D9336 0C2454 047411 022097 022473 055414 049813 026850 0A1694 QTY.
9 32 Generac® Power Systems, Inc. 11 25 24 10 10 4 15 7 24 19 8 5 6 26 13 14 10 4 18 26 17 26 19 "Y" 26 10 15 17 11 11 15 1 21 10 24 3 FASTENER TO SECURE GROUND WIRE. NOTE: 17 11 NOTE: USE LOCTITE ON NUTS ITEM #26. 22 23 2 29 11 WELD STUD UNDER ROOF EL FOR ACCESS COVER CABLE Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW and 20 kW Generators Standard Compartment — Drawing No.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW and 20 kW Generators Standard Compartment — Drawing No. 0E0771-D ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PART NO. 0D8666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 051716 022152 0912970064 023762 0912970063 022264 067035 022127 0C2634A 022473 022097 0D2023 0C2164 037337 0D2023 0D8664A 0D8664B QTY.
34 Generac® Power Systems, Inc. 36 9 43 10 38 8 10 4 45 39 7 18 42 19 6 1 22 23 11 24 35 10 14 4 10 "Y" "Y" 15 26 18 32 19 17 11 11 17 5 15 34 1 21 29 31 10 42 24 22 23 3 40 11 28 25 46 30 2 20 STATES FOAM IS ON FAR SIDE STATES FOAM IS ON NEAR SIDE 11 NOTE: USE DOOR LATCH 17 NOTE: USE LOCTITE ON NUT #037337. TYPICAL OF FRONT DUCT & ROOF PANEL. SECURE AS SHOWN.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generators Acoustic Compartment — Drawing No. 0E0772-E ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 PART NO.
Section 9 - Exploded Views and Parts 39 32 27 25 26 33 6 10 7 8 58 31 5 55 54 9 53 52 3 TO 'A' 50 34 42 38 39 49 40 41 12 28 11 2 30 31 36 Generac® Power Systems, Inc. 57 17 28 18 28 26 16 51 13 29 38 A 23 39 24 'A' 40 41 21 28 14 56 22 35 20 1 28 43 15 45 46 44 47 32 37 36 40 41 48 4 Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Control Panel — Drawing No.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Control Panel — Drawing No. 0E0778-G ITEM PART NO. QTY.
6 38 Generac® Power Systems, Inc. 8 7 2 9 10 5 11 12 24 4 13 14 39 10 15 1 24 32 41 16 30 72 14 1 10 9 24 35 34 33 11 45 10 44 11 14 19 10 24 36 17 11 20 10 11 14 12 47 17 26 46 18 11 49 71 14 10 21 20 70 11 57 22 6 24 25 69 67 56 55 59 58 63 65 64 52 61 7 WATERPUMP HARDWARE 62 60 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Engine — Drawing No.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Engine — Drawing No. 0E1228-E ITEM PART NO. QTY.
28 22 40 Generac® Power Systems, Inc. 32 28 "A" 30 29 (BOTTOM ONLY) 1 10 2 21 9 32 31 23 26 35 10 8 8 8 8 3 14 12 12 24 18 TO THERMOSTAT ADAPTER 14 WATER INLET TUBE (ON BLOCK) 19 20 7 33 34 TO WATER INLET (MIDWAY UP ENGINE BLOCK) 7 16 7 TO ENGINE BYPASS 4 15 17 6 13 17 14 11 34 33 12 11 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Radiator — Drawing No.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Radiator — Drawing No. 0E0769-G ITEM 1 2 3 4* 5 6 7 8 9 10 11 12 13 14 15 16 17 * 18 19 20 21 22 23 24 26 27 28 29 30 31 32 33 34 35 PART NO. 0D8657 0A5734 0A6237 0A6238 084918 050967 048031C 099502 083709 052250 047411 022097 049813 022473 084427 050967 075443 056892 0A6284 0A6258 029032 031669 060035 022127 046627 0C7649 0C2454 076749 0E0726 035461 0A7275 0A2111 065852 047290A QTY.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Fuel System — Drawing No. 0E0774-D 18 13 21 24 25 8 22 17 16 29 "C" 14 30 12 34 31 36 37 35 32 33 38 39 19 40 41 26 20 6 28 PORT "OUT 1" (NATURAL GAS) 41 3 6 11 43 9 14 10 42 "D" 23 40 41 6 PORT "OUT 2" 2 11 15 4 L.P. VAPOR 42 Generac® Power Systems, Inc.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Fuel System — Drawing No. 0E0774-D ITEM PART NO.
Section 9 - Exploded Views and Parts 14 15 2 18 9 To Blower Housing 8 36 32 24 1 23 35 17 7 13 16 29 28 33 22 10 30 21 3 31 12 21 20 19 6 5 4 26 To Engine Crankshaft Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Alternator — Drawing No. 0A9348-F 44 Generac® Power Systems, Inc.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Alternator — Drawing No. 0A9348-F ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 * 27 28 29 30 31 32 33 35 36 PART NO.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Battery — Drawing No. 0E0770-A 2 STARTER SOLENOID 8 13 4 14 8 3 1 TO ENGINE BLOCK 16 6 5 7 9 15 ITEM 1 2 3 4 5 6 7 8 9 13 14 15 16 17 PART NO. 077483 038804D 038805B 0742600131 022131 046526 052213 075763 0D8668 050331A 050331 0C2454 025507 027482 QTY. 1 1 1 1 1 1 1 3 1 1 1 2 1 2 DESCRIPTION BATT 12VDC 75-AH 26 CABLE BATT RED #4 X 20.00 CABLE BATT BLK #4 X 23.00 ASSY,WIRE#16 RED 1.
Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Muffler — Drawing No. 0E0773-A 10 9 14 8 15 6 12 13 9 3 7 3 5 4 3 2 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART NO. 0A4355 0E2844 036434 036449 0E0109 0C1318 0D8657 0E0170 0D9437 060366 039253 022145 022129 045771 0A8974 027837 QTY. 1 1 3 3 1 1 1 1 1 2 4 4 4 4 1 2 DESCRIPTION MANIFOLD EXHAUST 1.5L NIPPLE TOE 1.5NPTX5.5 BLK IRON BOLT U 5/16-18 X 2.09 SADDLE 2 INCH PIPE,EXHAUST 1.
Section 10 – Warranty Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards.
Section 10 – Warranty Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Section 10 – Warranty Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators GENERAC POWER SYSTEMS STANDARD "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN® "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years Generac Power Systems, Inc.
