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Guardian Technologies 004725-2 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 a natural gas set up should be five inches to 14 inches of water column (0.18 to 0[...]

  • 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 2.1.1 N F P A ST A N DAR DS The following published standards booklets pertain- ing to standby electric systems are available form the National Fire P rotection Association (NFP A), Batterymarch P ark, Quincy , MA 02269: • NFP A No. 37, ST A TIONARY COMBUSTION ENGINES AND GAS TURBINES. • NFP A No. 76A, ESSENTIA[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. 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 generator is powering only crit- ical loads, within the wattage/amperage capacity , dur- ing utility power outages, consider using the eme[...]

  • 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. Before starting the generator for the first time, the installer must complete the following procedures. F or follow-up maintenance information and/or service intervals, please refer to Section 4, “Maintenance.” 2.1 1.2 TR ANSFER SWIT CH If this generator is used to supply power to any elec- trical system norma[...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 3.2 C ONTROL CONS OLE C OM PON ENTS The components of a liquid- cooled generator control console (Figure 3.1) are as follows: Figure 3.1 - Liquid-Cooled Generator Panel 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 mai[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. • Set the A UTO/OFF/MANU AL switch to OFF . • Set generator main circuit breaker to OFF or OPEN . • Locate the rocker switch on the control panel iden- tified with the words “Set Exercise Time” (F igure 3.2). • Push “Set Exercise T ime” switch to ON position for 20 to 30 seconds and then release. S[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 E. EVER Y 500 OPER A TI NG HOU RS 1. Service air cleaner . 2. Check starter . 3. Check engine DC alternator . F . EVER Y 800 OPER A TING HOU RS 1.Retorque cylinder head. (See T orque Specs, Section 1.13.) 2. Retorque intake and exhaust manifold. (See T orque Specs, Section 1.13.) 3. Check engine compression. 4. Ch[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 4.5 MAI NTENANCE O WN ER/ OP ER A T OR CAN P ER FOR M 4.5.1 CH E CK ENGI NE OI L LEVEL Refer to “Checking Fluid Levels” in Section 4.4. 4.5.2 CH E CK BA TTER Y • Check battery fluid level each week as outlined under “Check Fluid Levels”. • Check battery cables for condition, tightness, cor- rosion or d[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERA TE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK. 7. Start engine and check for oil leaks. 4.5.1 1 CHANGI NG THE ENGI N E AI R CLEAN ER T o replace the engine air cleaner , (part number 059402), simply remove the air cleane[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. 4.6.2 BA TTER Y All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery . If such information is not available, observe the following precautions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start t[...]

  • 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-A[...]

  • 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-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-C[...]

  • 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. N U T S ITEM #2 6. US E L OC TITE ON PANEL F O R A CC E SS CO VER C ABL E WELD S T U D U NDER R OOF 17 GROUND WIRE . FA S TENER T O S E CU R E US E D OO R LAT CH N O TE : 11 2 5 24 7 4 9 24 2 2 5 8 5 11 1 0 5 N O TE : 2 6 6 1 0 4 1 8 1 9 1 8 1 0 1 5 " Y" 1 6 2 6 14 1 3 17 2 6 11 1 1 17 1 5 1 21 31 30 24 [...]

  • 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. T YPI C AL O F FR O NT D UC T & R OOF P ANEL. S E CU RE A S S H O WN. F O R A CC E SS CO VER C ABLE WELD STUD UNDER ROOF US E D OO R LAT C H NO TE: 24 36 4 3 38 42 7 9 8 4 19 39 33 6 22 11 12 5 34 3 11 5 40 25 42 1 1 26 4 35 3 10 11 "Y" 10 "Y " 13 14 15 1 7 18 1 15 17 3 4 29 3 1 21 50 49 11[...]

  • 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

    W ATERP U MP HARDWARE 72 3 7 6 13 9 10 11 2 8 7 12 24 30 1 15 16 5 4 43 24 1 38 40 3 42 41 30 24 24 23 11 10 1 11 19 1 7 11 26 18 20 17 21 22 0 28 20 21 25 23 24 46 5 7 33 11 1 4 9 24 10 11 10 14 TO 24 44 35 3 4 36 45 14 71 46 10 11 12 48 47 70 24 43 74 5 1 55 66 69 73 56 59 5 2 5 4 58 65 6 4 63 2 6 2 60 7 3 2 Section 9 - Exploded Views and P arts [...]

  • Page 41

    ITEM P ART NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 022473 6 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 051520N 1 TUBING 5/8 ID X 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 - .551 10 0[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. 4 3 L.P. VAP OR P O R T " OU T 2 " 9 1 3 4 0 41 11 10 " D" 1 5 4 5 21 24 2 5 30 28 33 2 0 1 9 14 " C" 12 17 1 6 31 32 6 6 39 2 6 38 1 41 4 0 37 34 36 35 22 " C" 1 3 8 1 8 27 2 42 6 7 23 ( NATURAL GAS ) " OU T 1 " 11 P O R T 2 9 " D" Section 9 - Exploded V[...]

  • 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 23 24 35 1 21 28 7 22 1 29 16 30 18 6 19 20 3 1 21 4 T o En g ine C rankshaft 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-G[...]

  • 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 REF BA TT 12VDC 75-AH 26 (NO T INCLUDED) 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[...]

  • 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 M (03/22/05) Printed in U.S.A. Section 1 0 – W arranty Guardian Liquid-cooled 1 5 kW , 20 kW and 2 5 kW Generators GENERA C PO WER SYSTEMS "TWO YEAR" LIMITED W ARRANTY FOR GU ARDIAN ® "PREP A CKA GED EMERGENCY A UT OMA TIC ST ANDBY GENERA T ORS" F or a period of two years from the date of original sal[...]