Generac Power Systems Guardian 004721-0 Owner'S Manual Download Page 27 | Manualshive

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Generac

®

Power Systems, Inc.

25

Section 7 - Installation Diagram

Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators

Drawing No. 0E1533

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Summary of Contents for Guardian 004721-0

Page 1: ... DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit Not intended for use in critical life support applications 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 ...

Page 2: ...plosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing other users to properly st...

Page 3: ...ency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 12 3 3 Manual Transfer and Startup 13 3 4 Autom...

Page 4: ... the gener ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentra...

Page 5: ...tor is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when nor mal utility source voltage is removed or is below an acce...

Page 6: ...osure and the mounting surface Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors Failure to utilize a Generac Guardian transfer switch with this generator will void the warranty 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with i...

Page 7: ...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 oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 7 2 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has sensing tip wh...

Page 8: ... fuse is blown Replace the fuse with one of the same size type and rating Generac normally uses an AGC fuse rated at 15 amps part number 022676 1 8 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 8 2 INSPECTION After unp...

Page 9: ...l gas and liquid propane set ups should be 11 inches to 14 inches of water column 0 6 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure 11 14 to the gen erator Low gas pressure can cause hard starting and could affect engine durability 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconf...

Page 10: ...uit Isolation Method in the installation manual Part No 079699 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power The critical essential loads may need to be grouped together and wired into a sepa rate emergency distribution panel This generator can be installed in conjunction with a standard Generac GTS type transfer switch if ...

Page 11: ...sider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good r...

Page 12: ...de requires the frame and external electrically conductive parts of this equip ment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations Do not connect the ground wire to an...

Page 13: ...nd 500 grams bicarbon ate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The fol lowing procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause ...

Page 14: ...e generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged prop erly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 USING A STANDARD GTS TRANSFER SWITCH When required the pre pack...

Page 15: ...eld boost and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outputs NOTE 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 If this fuse does open carefully check the wiring to the start fuel field boost and transfer outputs before replacing the fuse 3 2 6 SET EXE...

Page 16: ...20V 15A Utility fed cir cuit for the block heater 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A EVERY THREE MONTHS 1 Check battery state of charge and condition 2 Inspect and test fuel system 3 Check transfer switch 4 Inspect exhaust system 5 Check engine ignition system 6 Check fan belts B ONCE EVERY SIX MONTHS 1 Test Engine Safety Devices low oil pressure low coolant level high co...

Page 17: ...FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recom mended oils Figure 4 1 Oil Dipstick and Oil Fill Cap 4 4 2 BATTERY FLUID Check battery electrolyte fluid at least once weekly Fluid should cover separators in all battery cells If fluid level is ...

Page 18: ... supplied only at the proper gov erned speed Some connected electrical load devices may be damaged by incorrect fre quency and or voltage Only qualified service technicians should adjust the governed speed 4 5 10 CHANGING ENGINE OIL Refer to maintenance performed by authorized serv ice facilities for engine oil and filter change frequen cies Drain the oil while the engine is still warm from run ni...

Page 19: ...once a year to help pre vent corrosion Once each year have the generator cleaned and inspected by an Authorized Service Dealer That deal er will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively...

Page 20: ...uric 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 the fluid is spilled 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 dischar...

Page 21: ...ative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready ...

Page 22: ...thermal protection level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessar...

Page 23: ...for at least 1 hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil f...

Page 24: ... Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defecti...

Page 25: ...Generac Power Systems Inc 23 Section 6 Notes Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ...

Page 26: ...24 Generac Power Systems Inc Section 6 Notes Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators ...

Page 27: ...Generac Power Systems Inc 25 Section 7 Installation Diagram Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Drawing No 0E1533 ...

Page 28: ...TO 00 OUTPUT CONNECTION 120 240V 1 PHASE E1 E2 CLOSEST TO BEARING BRUSH HOLDER MOUNTING SCREW 23 178 183 183 183 FO SW 23 194 T2 15C 15 225A 94 BLUE BLUE RED BLACK BLACK BROWN YELLOW TO GOVERNOR 178 85 56 0 1 85 85 225 BLUE RED BLACK BLACK 15C 0 162 4 S16 ACTUATOR S15 S15 S16 S16 S16 229 229 229 T2 T1 85 85 56 56 14 178 178 15E 239 239 15C 15 15 S15 S16 4 4 4 4 15A 15E 225A 225A 4 4 4 4 4 183 183 ...

Page 29: ...OLLER TO ELECTRONIC LOS WLS BLACK GREEN WHITE GRD BATTERY 12 V 1 12 56 GRD 13 0 BLACK SM CC RED ACTUATOR CONNECTOR ACTUATOR GOVERNOR DC VR DC A DIS FS 85 85 85 13 14 13 49 0 48 49 48 85 85 85 56 0 13 14 14 14 RED 14 14 0 0 0 0 0 16 0 6 5 4 3 8 11 12 10 9 1 2 3 4 5 0 0 WLS WATER LEVEL SENSOR SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH LOS LOW OIL PRESSURE SWITCH FS FUEL SOLENOID DCA DC ALTERNATOR...

Page 30: ...2 N1 N2 23 194 11 22 33 44 CB1 0 S16 S15 E1 00 E2 CUSTOMER CONNECTION 120 240V 1 PHASE TRANSFER SWITCH CONNECTION TS3 EC AR ALTERNATOR ROTOR AS ALTERNATOR STATOR CB1 2 CIRCUIT BREAKERS DPE EXCITATION WINDING F FUSE 15 AMPS GCU GOVERNOR CONTROL UNIT PCB CIRCUIT BOARD CONTROLLER TS1 2 3 TERMINAL BOARDS VR VOLTAGE REGULATOR LEGEND AS F SA SUPRESSION ASSEMBLY TR1 TRANSFORMER UTILITY SENSING 183 178 18...

Page 31: ...OTOR LOS LOW OIL SWITCH ISC IGNITION SYSTEM CONTACT GRD GROUND EH ENGINE HEATER DCA DC ALTERNATOR CC CONTROL CONTACTOR 12V BATTERY FED CIRCUIT TO 120V 15A UTILITY 0 BLACK GREEN WHITE EH 0 CC 16 RED SM TO CONTROL PANEL TERMINAL STRIP 14 56 85 DC A 14 56 14 CC FS 0 0 85 WTS LOS WLS GRD BLACK 0 LEGEND 13 49 49 13 CONTROL UNIT TO CONTROL PANEL GOVERNOR GOVERNOR ACTUATOR ACTUATOR CONNECTOR 49 49 14 14 ...

Page 32: ...ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 6 7 9 10 10 5 4 INTAKE MANIFOLD REF 6 ...

Page 33: ...EARTH STRAP 13 0D9335 2 PANEL SUPPORT 14 0D9336 2 PANEL BRACKET 15 0C2454 16 SCREW TH FRM M6 1 X 16 N WA Z JS 16 047411 1 SCREW HHC M6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK M6 1 4 18 022473 1 WASHER FLAT 1 4 M6 ZINC 19 055414 1 LUG SLDLSS 2 8 X 17 64 CU 20 049813 5 NUT HEX M6 X 1 0 G8 YEL CHR 21 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 22 0A1694 2 1 1 2 BUTTON PLUG 8 13 15 15 9 17 10 20 14 4 22 3 10...

Page 34: ... ACCESS COVER CABLE NUTS ITEM 26 USE LOCTITE ON 11 25 24 7 10 4 9 24 15 10 19 8 5 10 NOTE 11 19 26 6 10 4 26 18 10 15 Y 26 14 13 17 26 11 17 15 1 21 24 3 23 22 11 2 11 29 Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW and 20 kW Generators Standard Compartment Drawing No 0E0771 D ...

Page 35: ...022152 3 WASHER LOCK 10 15 0912970064 3 ASSEMBLY BASE DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT 10 STL 17 0912970063 3 GRD WIRE ASS Y 99HSB 18 022264 6 WASHER LOCK 8 M4 19 067035 6 SCREW PPHM 8 32 X 5 16 20 022127 1 NUT HEX 1 4 20 STEEL 21 0C2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1 4 ZINC 23 022097 1 WASHER LOCK M6 1 4 24 0D2023 3 GASKET CLIP ON SELF GRIPPING 25 0C2164 1 LA...

Page 36: ... 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 10 32 Y Y 10 14 15 18 17 19 15 17 34 29 31 21 11 10 3 22 24 23 46 28 30 27 2 NUT 037337 USE LOCTITE ON 17 NOTE STATES FOAM IS ON FAR SIDE STATES FOAM IS ON NEAR SIDE 11 47 20 Section 9 Exploded Views and Parts Guardian Liquid cooled 25 kW Generators Acoustic Compartment Drawing No 0E0772 E ...

Page 37: ...WASHER LOCK M6 1 4 24 022127 9 NUT HEX 1 4 20 STEEL 25 0D8663 2 BAFFLE CNTRL PNL 1 5L ACOUSTIC 26 0D8665 2 BAFFLE DOOR 1 5L ACOUSTIC UNIT 27 0E0072D 1 ACSTC INSLTN 1 5L DUCT RH PNL 28 0E0072B 1 ACSTC INSLTN 1 5L DUCT LH PNL 29 0E0072Q 2 ACSTC INSLTN 1 5L RAD SUPPORT 30 0E0072C 1 ACSTC INSLTN 1 5L DUCT FNT PNL 31 0E0072A 1 ACSTC INSLTN 1 5L ROOF PANEL 32 0E0072M 2 ACSTC INSLTN 1 5L SIDE DR PNL 33 0...

Page 38: ...oled 15 kW 20 kW and 25 kW Generators Control Panel Drawing No 0E0778 G A 22 28 51 26 29 TO A 26 25 10 27 33 9 31 53 52 55 54 58 8 6 7 5 31 50 34 49 12 28 42 3 40 39 38 41 11 2 30 57 17 16 18 28 28 A 21 56 14 38 13 40 24 23 39 41 1 40 28 35 20 44 46 45 47 39 15 36 32 32 37 48 41 4 43 ...

Page 39: ...T 1 4 M6 ZINC 28 0C2212 10 SCREW PHTT M4 0 7 X 16 ZYC 29 023762 2 WASHER SHAKEPROOF EXT 10 STL ITEM PART NO QTY DESCRIPTION 30 0C2267 14 SCREW HHTT M5 0 8 X 12 BP 31 023897 15 WASHER FLAT 10 ZINC 32 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0E2514 1 STRAIGHT WIRE CONNECTOR 1 1 2 36 0A1354A 1 REGULATOR DC ALT 37 074908 4 SCREW HHTT M5 ...

Page 40: ... 17 18 20 26 21 20 25 22 24 57 33 11 14 9 24 72 10 11 10 14 1 24 35 34 36 44 45 14 71 12 46 11 10 49 47 70 11 10 6 69 56 55 67 59 52 58 64 63 65 62 60 7 Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Engine Drawing No 0E1228 E 38 Generac Power Systems Inc ...

Page 41: ...EL 90 3 8 NPT X 5 8 41 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD ITEM PART NO QTY DESCRIPTION 42 061012 1 PLUG STD PIPE 1 8 SCKT HD 43 039253 4 SCREW HHC M8 1 25 X 20 G8 8 44 0A5110 1 PIPE WATER INLET 45 0A7006 1 O RING 1 1 16 X 1 5 16 X 1 8 46 025507 2 WASHER SHAKEPROOF EXT 7 16 STL 47 022500B 2 SPACER 41 X 75 X 25 ST ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1 8 50 042574 1 A...

Page 42: ...IDWAY UP ENGINE BLOCK 14 TUBE ON BLOCK TO THERMOSTAT 31 10 23 26 8 20 WATER INLET 8 19 8 8 6 ADAPTER 12 24 7 16 7 7 15 13 TO ENGINE BYPASS 33 34 11 12 Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Radiator Drawing No 0E0769 G 40 Generac Power Systems Inc ...

Page 43: ...8 18 056892 4 SCREW CRIMPTITE 10 24 X 3 8 19 0A6284 1 HOSE LOWER RADIATR 20 0A6258 1 HOSE UPPER RADIATR 21 029032 1 HOSE 9 32 ID 36 LG 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 4 NUT HEX 1 4 20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE 38 87 28 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS 29 076749 1 TANK COOLANT RECOVERY 30 0E0726 1 BRACK...

Page 44: ...OUT 2 41 40 11 14 9 C 12 14 16 17 8 43 15 D 4 5 27 42 23 2 7 6 40 21 39 36 38 28 30 34 24 25 6 6 41 26 37 35 22 13 NATURAL GAS OUT 1 PORT 41 3 11 D Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Fuel System Drawing No 0E0774 D ...

Page 45: ...522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0D8492Q 1 DECAL EMISSION CTRL 1 5 NG 2004 10 15KW NATURAL GAS 0D8492R 1 DECAL EMISSION CTRL 1 5 LP 2004 10 15KW LP VAPOR UNITS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0E0590 1 VEN...

Page 46: ...12 5 9 15 14 17 To Blower Housing 32 23 24 35 1 21 28 7 22 33 10 29 16 30 18 2 6 19 20 31 21 4 To Engine Crankshaft 26 Section 9 Exploded Views and Parts Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators Alternator Drawing No 0A9348 F ...

Page 47: ...SH 11 075476 4 SCREW PPHM M4 0 7 X 16 12 0A5601 1 COVER REAR BEARING CARRIER 13 075554B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 097146 1 FAN RING GEAR ASSEM 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A5061 1 SPACER FLEX PLATE 19 0A4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12 1 75 X 40 G8 8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10 1 5 X 35 G8 8 23 0...

Page 48: ...3 3 BOOT BATTERY CABLE 9 0D8668 1 BRACKET BATTERY HOLD DOWN 1 5 13 050331A 1 BATTERY POST COVER RED 14 050331 1 BATTERY POSTCOVER BLACK 15 0C2454 2 SCREW TH FRM M6 1X16 N WA Z JS 16 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 15 SOLENOID 8 13 1 2 STARTER 14 8 TO ENGINE BLOCK 5 6 7 9 16 3 4 46 Generac Power Systems Inc Section 9 Exploded Views and Parts Guardi...

Page 49: ...TOR 1 5L MITSU 7 0E0170 1 BLANKET EXHAUST 1 5L MITSU 8 0D9437 1 MUFFLER 1 5L ACOUSTIC STANDARD 9 060366 2 STRAP MUFFLER 6 DIA 10 039253 4 SCREW HHC M8 1 25 X 20 G8 8 11 022145 4 WASHER FLAT 5 16 ZINC 12 022129 4 WASHER LOCK M8 5 16 13 045771 4 NUT HEX M8 1 25 G8 YEL CHR 14 0A8974 1 CAP RAIN 2 15 027837 2 SCREW RHM 1 4 20 X 2 1 4 3 9 14 5 4 2 10 8 15 3 9 6 13 12 3 7 Section 9 Exploded Views and Par...

Page 50: ...y any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem occurs The ...

Page 51: ...tion 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Se...

Page 52: ... Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft van...

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