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Generac 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726-0 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y! This manual should remain with the unit. Not intended f or use in critical life support applications. ! ! Liquid-cooled, Prepac kaged Standb y Generators Model Numbers 004721-0, 004722-0, 004723-0, 004[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac P ower 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 writ- ten. However , the manufacturer reserves the[...]

  • Page 3

    T able of Contents Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION .................................. IFC SAFETY RULES ...................................... 2 Section 1 — GENERAL INFORMA TION ..................4 1.1 Generator ......................................................4 1.2 Tr[...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The genera- tor can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many acci- dents are caused by failing t[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 • Inspect the generator regularly , and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by[...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all metal enclosure and is intended for ou[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 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. Ask the fuel supplier for the Btu content of the fuel being used. F uel pressure for both natural gas and liquid propane set ups should be 11 inches to 14 inches of wa[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor 1.7 .4 O VERSPEED SH UTDOWN The Pre-pack circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator AC power windings, via sensing leads S15 and S16. Should AC frequency exceed about 72 Hz, cir- cuit board action will automatically shutdow[...]

  • Page 9

    1.1 0 SP ECIF ICA TIONS 1.1 0.1 GEN ERA T OR SP E CI F ICA TIONS 1.1 0.2 ENGI NE SP ECIF ICA TIONS Make ..............................................................................Mitsubishi Displacement ..............................................92 inches 3 (1.5 liters) Cylinder Arrangement ....................................................[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. NOTE: P ort 1 is for NG only and P ort 2 is for LP vapor only . No provision for simultaneous fuels has been made. Serious injury or damage may occur if not con- figured pr operly . Please consult an authorized Generac Service Dealer with any questions. 1.1 3 T ORQU E SP ECIF ICA TIONS Cylinder Head ...............[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 NOTE: F or more information about the installation of a standby system, order Engine - Generator Standby Electric P ower Systems Installer’s Guide and Reference Manual (part #046622) from a Generac Authorized Service Dealer . 2.1.1 N F P A ST A N DAR DS The following published standards booklets pertain- ing to s[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. NOTE: Generac recommends the use of a Generac P ower Systems “GTS” type transfer switch in conjunc- tion with this generator . 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator . If the generat[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 2.1 0 B A T TER Y I NST ALL A TION Standby generators installed with automatic transfer switches will crank and start automati- cally when NORMAL (UTILITY) source voltage is removed or is below an acceptable pr eset level. T o prevent such automatic start-up and possible injury to personnel, do not connect battery[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. 2.1 1.2 TR ANSFER SWIT CH If this generator is used to supply power to any elec- trical system normally powered by an electric utility , the National Electrical Code requires that a transfer switch be installed. The transfer switch prevents elec- trical backfeed between two different electrical sys- tems. (F or ad[...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 3.2.1 HO URME T E R Indicates time the engine -generator has operated, in hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for the gen- erator set. 3.2.2 AUT O/OF F/MANUAL SWIT CH Use this three -position switch as follows: • Set the switch to A UTO for fully automatic op[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 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 exer- cise every seven days thereafter , on[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 4.2 C OOLI NG SY STEM Air intake 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 . W ithout sufficient cooling and ventilating air flow , the engine/generator quickly ov[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 4.5.4 I NSPECT C OOLI NG SY S TEM • 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 CH E CK ENGI NE COOL ANT LEVEL See “Checking Fluid Levels” in Section 4.4. 4.5.6 P ERF[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 Figure 4.3 – Engine Air Cleaner See the “Scheduled Maintenance,” Section 4.7, for air cleaner maintenance. 4.5.1 2 SP AR K PL UGS Reset the spark plug gap or replace the spark plugs as necessary . See Section 4.7. 1. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine.[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. 4.6.3 BA TTER Y MAI NTENANCE 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 unseale[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Section 4 — Maintenance Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators 4.7 S CH EDU LED MAI NTENANCE The following is a recommended maintenance schedule for Generac Guardian small standby and residential gen- erator sets. The established intervals in the schedule are the maximum recommended when the[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Dat[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp. to be done Comp . to be done Comp . Required Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators 5.1 TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse b lown. 1. Replace fuse. 2. Loose or corroded or def ectiv e 2. Tighten, clean or replace batter y cables . batter y cables as[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 6 — Notes Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Section 6 — Notes Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 7 - Installation Diagram Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Drawing No. 0E1 53 3[...]

  • Page 28

    NB S ET EXER C I S E S WIT CH TERMINAL S TRIP 7 P OS. V O LTA G E RE GU LAT OR VR T S3 - - S W 2 - FL - SU PRE SS I O N A SS EMBL Y NE U TRAL BL OCK FA U LT LI G H T H OU R METE R F US E 1 5 AMP S FIELD BREAKER LED G EN D F T S1 FL T S2 S W 2 F1 C B 2 P CB C B 1 T S1 A S ALTERNAT O R S TAT OR - C APA C IT OR TR1 C A P GCU A S 1 2 4 X 1 1 4 1 11 44 [...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Section 8 - Electrical Data Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Wiring Diagram — 1.5L Engine — Drawing No. 0E0343-A 4 3 2 1 5 6 9 8 1 0 11 12 CO NNE C TI ON PANEL CO NTR OL LE G EN D EH U TILITY FE D C IR CU I T T O 12 0 V / 1 5A GO VERN OR CO NTR O LLE R T O ELE C TR O NI C L OS WL S B[...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. Section 8 - Electrical Data Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Wiring Diagram — 1.5L Guardian — Drawing No. 0E1 525 FL 3 4 1 5 6 1 13 2 5 7 D 11 9 B A 17 16 10 12 E 4 3 15 14 GCU S W1 S W2 A LTERNATE TR1 2 2 5 N2 N1A ( BLUE ) ( RED ) A A B ( BLACK ) ( BLACK ) + - 14 S A VR S H O WN IN [...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 Section 8 - Electrical Data Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Electrical Schematic — 1.5L — Drawing No. 0A7 1 82-B WT S - WATER TEMPERAT U RE S WIT C H WL S - WATER LEVEL S WIT CH F S - F U EL SO LEN O I D S M - S TARTER M O T OR L OS - L O W O IL S WIT CH I SC - I G NITI O N S Y S TE[...]

  • Page 32

    ITEM P ART NO . QTY . DESCRIPTION 1 098290 1 ASM MO T OR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECT OR 3 098958A REF CONNECT OR INTERF ACE ASSEMBL Y 4 098942A 1 CO VER CONNECT OR HOUSING 5 098225 2 SCREW FHM #2 X 5/8 SELF T AP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 W ASHER LOCK M6-1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM 9 098783 1 LEVE[...]

  • Page 33

    ITEM P ART NO . QTY . DESCRIPTION 1 0D8656 1 BASE MOUNTING 1.5L STNRD & A CSTC 2 027482 2 W ASHER SHAKEPR OOF EXT 5/16 STL 3 070936 2 D AMPENER VIBRA TION 4 070936C 2 VIB. ISO. 70-75 DURO 5 039253 8 SCREW HHC M8-1.25 X 20 G8.8 6 022145 12 W ASHER FLA T 5/16 ZINC 7 022129 16 W ASHER LOCK M8-5/16 8 045771 4 NUT HEX M8-1.25 G8 YEL CHR 9 071956 4 W[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. 17 G R OU ND WIRE. F A S TENER T O S E CU RE NO TE: W ELD S T U D U NDER R OO F E L F O R A CC E SS CO VER C ABLE NU T S ITEM #2 6 . US E L OC TITE O N 11 25 24 7 10 4 9 24 15 10 19 8 5 10 NO TE: 11 19 26 6 10 4 26 18 1 0 15 " Y" 26 14 13 1 7 26 11 17 15 1 21 24 3 23 22 11 2 11 29 Section 9 - Exploded Vi[...]

  • Page 35

    ITEM P ART NO . QTY . DESCRIPTION 1 0D8666 1 ROOF A CSTC&STND CMPR TMNT 1.5L 2 0D8664C 1 DUCT CENTER 1.5L 3 0D8657 1 SUPPOR T RADIA TOR 1.5L MITSU 4 0D8660 2 BRA CE SIDE 1.5L MITSU 5 0A7568 2 DOORWELDMENT 1.5EPS 6 0D8659 1 CORNER POST REAR RH SIDE 1.5L 7 0D8662 1 DOOR REAR COMP ARTMENT 1.5L 8 0D8661 1 BRA CE REAR 1.5L MITSU 9 0D8658 1 CORNER PO[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. PANEL FOR ACCESS COVER CABLE W ELD S T U D U NDER R OO F P ANEL. S E CU RE A S S H O WN. T YPI C AL O F FR O NT D UC T & R OOF US E D OO R LAT C H NO TE: 24 43 38 42 7 45 36 9 10 8 10 4 19 39 18 6 22 23 1 11 5 40 25 42 1 11 11 26 4 35 1 0 3 2 "Y" " Y" 10 14 15 18 17 19 15 17 3 4 29 3 1 21 1[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0D8666 1 ROOF A CSTC & STND CMPR TMNT 1.5L 2 0D8664C 1 DUCT CENTER 1.5L 3 0D8657 1 SUPPOR T RADIA TOR 1.5L MITSU 4 0D8660 2 BRA CE SIDE 1.5L MITSU 5 0A7568 2 DOOR WELDMENT 1.5 EPS 6 0D8659 1 CORNER POST REAR RH SIDE 1.5L 7 0D8662 1 DOOR REAR COMP ARTMENT 1.5L 8 0D8661 1 BRA [...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. Section 9 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Control Panel — Drawing No. 0E0 77 8-G A 22 28 5 1 26 29 T O 'A' 26 25 10 27 33 9 3 1 53 5 2 55 5 4 58 8 6 7 5 3 1 50 3 4 49 12 28 42 3 40 39 38 41 11 2 30 5 7 17 16 18 28 28 'A ' 2 1 56 14 38 13[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0D9322 1 P ANEL BACK & BO TT OM GU ARDIAN 2 0D9332 1 P ANEL LH SIDE GUARDIAN & SPRN 3 0D9325A 1 P ANEL FRONT CONTR OL GU ARDIAN W/ SILKSC 4 0D9330 1 P ANEL RH SIDE C-P ANEL SML BRK 5 0C1457 1 HOURMETER 6 064009 1 LIGHT 12VDC .02A LED RED PILOT 7 032300 1 HOLDER FUSE 8 02[...]

  • Page 40

    6 1 WATERPUMP HARDWARE 13 9 10 11 2 8 7 12 24 10 14 15 16 6 32 5 4 1 24 39 41 30 17 11 10 14 11 19 17 18 20 26 21 20 25 22 24 5 7 33 1 1 14 9 24 72 10 11 10 14 1 24 35 3 4 36 44 45 14 71 12 46 11 10 49 47 70 11 10 6 69 56 55 6 7 59 5 2 58 6 4 63 65 6 2 60 7 Section 9 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Gener[...]

  • Page 41

    ITEM P ART NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 022473 2 W ASHER FLA T 1/4 ZINC 4 0A45310258 1 GASKET -EXHA UST MANIFOLD 5 0A4355 1 MANIFOLD-EXHA UST 6 0E2632 1 HEA T SHIELD EXH 1.5L 7 022097 8 W ASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5 9 052212 2 SCREW HHC M10-1.25 X 25 G8.8 10 046526 4 W ASHER-LOCK-M10 11 022131 20 W ASHE[...]

  • Page 42

    14 11 17 28 ( BOTTOM ONLY ) "A " 28 22 9 30 3 2 29 10 2 21 1 3 2 3 35 18 14 12 33 17 34 4 TO WATER INLE T ( MIDWAY UP ENGINE BLOCK ) 14 TUBE (ON BLOCK) TO THERM OS TAT 3 1 10 23 26 8 20 WATER INLET 8 19 8 8 6 ADAPTER 12 24 7 16 7 7 15 13 TO EN G INE BYPA SS 33 3 4 11 12 Section 9 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW ,[...]

  • Page 43

    ITEM P ART NO . QTY . DESCRIPTION 1 0D8657 1 SUPPOR T RADIA TOR 1.5L MITSU 2 0A5734 1 RADIA TOR 1.5L 3 0A6237 1 VENTURI 1.5L MODINE 4 * 0A6238 1 GUARD F AN 1.5L MODINE 5 084918 1 HEA TER ENGINE 0500W 120V 6 050967 1 HOSE 5/8 ID RIA 250F 12" 7 048031C 4 CLAMP HOSE BAND 1/4 8 099502 4 CLAMP HOSE #24 B1.06 - 2.00 9 083709 1 CLAMP WIRE HOSE .573 -[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. 2 9 33 32 31 1 8 2 0 1 0 1 9 L.P. VAP OR P O R T " OU T 2 " 41 4 0 11 14 9 " C" 12 14 1 6 17 8 4 3 1 5 " D" 4 5 27 42 2 3 2 7 6 4 0 21 39 36 38 2 8 30 34 24 2 5 6 6 41 26 37 35 22 1 3 ( NATURAL GAS ) " OU T 1 " P O R T 41 3 11 " D" Section 9 - Exploded Views and P [...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E1006 1 ASSY REGULA TOR 1.5L N.G.OR LPV 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 6 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 0A7040 1 BRACKET -RAD HO[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. 8 36 13 3 12 5 9 15 14 17 T o Blow e r H ousin g 3 2 2 3 24 35 1 21 28 7 22 33 10 29 16 30 18 2 6 19 20 3 1 2 1 4 T o En g ine C rankshaf t 26 Section 9 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators Alternator — Drawing No. 0A93 48-F[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 098671 1 ASSY RO T OR 10KW 098681 1 ASSY RO T OR 15KW 098675 1 ASSY RO T OR 20KW 098936 1 ASSY RO T OR 25KW 2 0A5336A 1 HOUSING BLOWER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 SS 5 049226 4 W ASHER LOCK M5 6 051713 4 W ASHER FLA T M5 7 022129 4 W ASHER LOCK [...]

  • Page 48

    ITEM P ART NO . QTY . DESCRIPTION 1 077483 1 BA TT 12VDC 75-AH 26 2 038804D 1 CABLE BA TT RED #4 X 20.00 3 038805B 1 CABLE BA TT BLK #4 X 23.00 4 0742600131 1 ASSY ,WIRE#16 RED 1.6 5 022131 1 W ASHER FLA T 3/8 ZINC 6 046526 1 W ASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 075763 3 BOO T , BA TTER Y CABLE 9 0D8668 1 BRA CKET , BA TTERY H[...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHA UST 1.5L 2 0E2844 1 NIPPLE T OE 1.5NPTX5.5 BLK IRON 3 036434 3 BOL T U 5/16-18 X 2.09 036449 3 SADDLE 2 INCH 4 0E0109 1 PIPE,EXHA UST 1.5L STNDRD&ACSTC 5 0C1318 1 FLEX PIPE EXHA UST 6 0D8657 1 SUPPOR T , RADIA TOR 1.5L MITSU 7 0E0170 1 BLANKET , EXHAUS[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OU R W ARR ANT Y RIGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and g[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 EM IS SION CONTROL S Y STEM W AR R ANTY Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered[...]

  • Page 52

    Part No. 0E1151 Revision J (06/28/04) Printed in U.S.A. Section 1 0 – W arranty Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators GEN ERAC PO WER SY S TEMS S T AN D ARD "T WO YEAR" LIM ITED W ARR ANT Y FOR GU AR DIAN ® "P R EP A CK A GED EM ERGENCY AUT OMA TIC ST ANDBY GENER A T ORS" F or a period of two years Gener[...]