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Generac Power Systems Guardian 004188-1 Owner's Manual

Liquid-cooled, prepackaged standby generators
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®
POWER SYSTEMS, INC.
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
(Natural Gas)
004188-1
004370-2
004474-1
(Liquid Propane Vapor)
004189-1
004371-2
004475-1
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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Summary of Contents for Generac Power Systems Guardian 004188-1

  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers (Natural Gas) 004188-1 004370-2 004474-1 (Liquid Propane Vapor) 004189-1 004371-2 004475-1 ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing this model of the standby gen- erator set product line by Generac Power Systems. Every effort was expended to make sure that the infor- mation and instructions in this manual were both accu- rate and current at the time the manual was written.

  • Page 3: Table Of Contents

    Section 5 TROUBLESHOOTING ...18 Section 6 SCHEDULED MAINTENANCE ...19 Section 7 WIRING DIAGRAMS AND SCHEMATICS ...22 Section 8 EXPLODED VIEWS AND PARTS LISTS ...27 Section 9 INSTALLATION DRAWINGS ...52 Section 10 WARRANTY ...56 Table of Contents Generac Power Systems, Inc. ®...

  • Page 4: Safety Rules

    Generac Power Systems, Inc. ® • For safety reasons, Generac recommends that this equipment be installed, serviced and repaired by a Generac Authorized Service Dealer or other compe- tent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations.

  • Page 5: Electrical Hazards

    Keep the area surrounding the generator clean and free from debris. • Generac generator sets may operate using one of sev- eral types of fuels. All fuel types are potentially FLAM- MABLE and/or EXPLOSIVE and should be handled with care.

  • Page 6: Section 1 - General Information

    • Protect the switch at all times against excessive mois- ture, dust, dirt, lint, construction grit and corrosive vapors. Generac Power Systems, Inc. ® AUTOMATIC SYSTEM OPERATION When this generator, along with its transfer switch, has...

  • Page 7: Main Circuit Breaker

    (Figure 1.6). % over rating Circuit Breaker 112% 112% 108% 108% 120% 120% Figure 1.4 - Low Oil Pressure Switch Generac Power Systems, Inc. ® 70A BQ2 70A BQ2 90A BQ2 90A BQ2 125A BQ2 125A BQ2...

  • Page 8: Unpacking

    The unit will not start or crank if the fuse is blown. Replace the fuse with one of the same size, type, and rating. Generac normally uses an AGC fuse rated at 30 amps. UNPACKING UNPACKING PRECAUTIONS Handle shipping cartons and crates with care.

  • Page 9: Fuel Consumption

    “emer- gency” distribution panel. This generator can be installed in conjunction with a standard Generac “GTS” type transfer switch, if desired. The standard transfer switch has no sensing or con- trolling circuit boards. Instead, the generator control console houses a “Control Module Assembly”, which...

  • Page 10: Standby Generator Installation

    For more information about the installation of a stand- by system, you can order Engine-Generator Standby Electric Power Systems Installer’s Guide and Reference Manual (part #046622) from your Generac Authorized Service Dealer. NFPA STANDARDS The following published standards booklets pertaining...

  • Page 11: Generator Mounting And Support

    NOTE: Generac recommends the use of a Generac power systems “GTS” type transfer switch in conjunction with this generator. Figure 2.1 – Basic Standby Electric System...

  • Page 12: Generator Ac Neutral Connections

    TRANSFER SWITCH START SIGNAL CONNECTIONS If your generator is to be installed with an automatic transfer switch, such as a Generac GTS-type switch, it will be necessary to connect the two-wire start control system. Connect the two-wire start signal from the automatic...

  • Page 13: Preparation Before Start-Up

    USING A STANDARD “GTS” TRANSFER SWITCH When required, the pre-packaged standby generator can be installed with a standard Generac “GTS” type automatic transfer switch. When you use a standard GTS type transfer switch, it controls automatic operation and automatic transfer as follows: •...

  • Page 14: Control Console Components

    Battery voltage should read about 12.5 to 14.5 volts DC. A low battery voltage indicates the battery is discharging. 12 Generac Power Systems, Inc. ® HOURMETER Indicates time the engine-generator has operated, in hours and tenths of hours.

  • Page 15: Manual Transfer And Startup

    If battery terminals are disconnected or control panel fuse is removed, the exercise timer needs to be reset for correct automatic exercise operation. Section 3 - Operation NOTE: Figure 3.2 - “Set Exercise” Switch Generac Power Systems, Inc. 13 ®...

  • Page 16: Engine Heater

    Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators ENGINE HEATER Your Generac standby generator comes equipped with a block heater (Figure 4.1), similar to the block heaters used in automotive applications. The block heater is wired to a grounded plug.

  • Page 17: Maintenance Owner/Operator Can Perform

    If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary. To have pressure cap tested, contact an authorized Generac Service Dealer. Inspect cooling system and coolant recovery system for leaks. MAINTENANCE OWNER/OPERATOR CAN...

  • Page 18: Changing Engine Oil/Air Cleaner

    To replace the engine air cleaner, (part number 59402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reat- taching the cover (Figure 4.4). 16 Generac Power Systems, Inc. ® Figure 4.4 – Engine Air Cleaner See the “Service Schedule,”...

  • Page 19: Miscellaneous Maintenance

    When replacing batteries, use the same number and the type of battery that follows: BCI Group No. The BCI number should be located directly on the battery. 26/26R 525 @ 0 deg. F Note: Generac Power Systems, Inc. 17 ®...

  • Page 20: Section 5 - Troubleshooting

    1. Replace switch. 2. Reconnect/close wire. 3. Replace board. 1. Reset to ON or CLOSED. 2. Reset and replace, if necessary. 3. Set to GENERATOR position. 4. Contact an Authorized Generac facility. 5. Auto-reset - Wait 5 min. and attempt restart.

  • Page 21: Section 6 - Scheduled Maintenance

    Following is a recommended maintenance schedule for Generac Guardian small standby and residential genera- tor 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.
  • Page 22 Correct as necessary. 12. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary. 20 Generac Power Systems, Inc. ® Level 2 Task Required Task Comp. to be done Comp.
  • Page 23 3 months/ (Date- Initials) Break-in Initials) 30 hrs. Level 3 Level 4 Required Task to be done Comp. Required Semi- (Date- to be done annually/ Initials) Annually/ 50 hrs. 100 hrs. Generac Power Systems, Inc. 21 ® Task Comp. (Date- Initials)

  • Page 24: Wiring Diagrams And Schematics

    Section 7 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803-D 22 Generac ® Power Systems, Inc.
  • Page 25 Section 7 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803-D Generac ® Power Systems, Inc. 23...
  • Page 26 Section 7 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Electrical Schematic — Control Panel (1-Phase) — Drawing No. 0A2802-B 24 Generac Power Systems, Inc. ®...
  • Page 27 Section 7 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7176-A Generac Power Systems, Inc. 25 ®...
  • Page 28 Section 7 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Electrical Schematic — 1.5L Gas Engine — Drawing No. 0A7182-A OUTLET) CIRCUIT 26 Generac ® Power Systems, Inc.

  • Page 29: Exploded Views And

    PART NO. QTY. DESCRIPTION 32990 C2164 29107 A1694 91297-063 91297-064 49813 70005 49811 BUMPER LATCH GROMMET 3/16"-7/8" BUTTON-PLUG 1-1/2" GROUND WIRE ASSEMBLY GROUND WIRE ASSEMBLY HEX NUT M6 x 1.0 LOCK WASHER M6 FLAT WASHER M6 Generac Power Systems, Inc. 27 ®...
  • Page 30 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Enclosure (25kW) — Drawing No. 0C1404-B 28 Generac Power Systems, Inc. ®...
  • Page 31 INSULATION DUCT FRONT INSULATION PANEL FRONT TOP INSULATION PANEL DUCT SIDE TOP INSULATION PANEL, REAR INSULATION DUCT L.H. SIDE INSULATION DUCT R.H. SIDE INSULATION DOOR REAR WASHER SELF LOC/DOME GROMMET 7/16 X 1/16 X 1/4 Generac Power Systems, Inc. 29 ®...
  • Page 32 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel (15 and 20 kW) — Drawing No. 0A2872-F 30 Generac Power Systems, Inc. ®...
  • Page 33 PILOT LIGHT RED 14-V. DECAL-EXERCISE INFO CAPLUG, BPF-1/4" SCREW, PPHM 6-32 x 5/8 LG WASHER, LOCK #6 STEPPER MOTOR KIT PPHMS, M5-0.8 x 16MM WASHER, LOCK M5 FUSE & HOLDER LITTLE 7.5A FUSE 7.5AXBK/AGC7.5NX Generac Power Systems, Inc. 31 ®...
  • Page 34 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Control Panel (25kW) — Drawing No. 0C8847-C 32 Generac Power Systems, Inc. ®...
  • Page 35 DECAL, TRANS. SWITCH CONN. 0A1354A REGULATOR - DC ALT 0C2212 SCREW TAPTITE PH M4-0.7X16 ZYC 0C3826 HINGE, CONTROL PANEL 0C4427 M6X1.0X12 T.H.M.S SS 0C8817 TOP, CONTROL PANEL (SAE) 0D5324 FUSE & HOLDER LITTLE 7.5A 0A9611 FUSE 7.5AXBK/AGC7.5NX Generac Power Systems, Inc. 33 ®...
  • Page 36 (Bottom only) "A" To thermostat adapter To water inlet tube (Midway up engine block) To base of water inlet tube (On block) "A" To engine bypass...
  • Page 37 SCREW HHC M8-1.25 X 16 G8.8 TANK COOLANT RECOVERY BRACKET COOLANT RECOVERY TANK SCREW SWAGE 1/4-20 X 5/8 N WA JS500 FOAM 1.5 X 1 ADHESIVE BACKING SCREW SWAGE 10-32 X 5/16 Z/YC SPRING CLIP HOLDER .37-.62 Generac Power Systems, Inc. 35 ®...
  • Page 38 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator (25 kW) — Drawing No. 0C1406-B 36 Generac Power Systems, Inc. ®...
  • Page 39 BRACKET COOLANT RECOVERY TANK SCREW SW 1/4-20X5/8 N WA JS500 GROMMET 7/16 X 1/16 X 1/4 SCREW SWAGE 10-32 X 5/16 Z/YC NUT SPRINGCLIP .37 - .62 SUPPORT RADIATOR RH SUPPORT RADIATOR LH BRACKET COOLANT BOTTLE Generac Power Systems, Inc. 37 ®...
  • Page 40 70936 70936C 39253 22145 22129 45771 71956 51730 57821 21991 27482 A2308 38 Generac Power Systems, Inc. ® DESCRIPTION BASE, MOUNTING ISOLATOR-VIBRATION ISOLATOR, VIBRATION CAPSCREW, HEX HEAD-M8-1.25 x 20MM FLAT WASHER-M8 LOCK WASHER-M8 NUT, HEX-M8-1.25 WASHER, VIBRATION ISOLATOR CAPSCREW, HEX HEAD-M8-1.25 x 60MM CAPSCREW, HEX HEAD-M8-1.25 x 40MM...
  • Page 41 WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR WASHER FLAT M8 SCREW HHC M8-1.25 X 60 G8.8 SCREW HHC M8-1.25 X 40 G8.8 EARTH STRAP WASHER SHAKEPROOF EXT 5/16 STL PLUG BUTTON 2" DIA Generac Power Systems, Inc. 39 ®...
  • Page 42 036434 022259 022129 036449 076032 039253 045771 0C3683 0A7215 40 Generac Power Systems, Inc. ® DESCRIPTION MUFFLER W/RAIN SHLD MUFFLR STRAP 6IN DIA ELBOW 90 DEG 2 NPT NIPPLE TOE 2 NPT X 4.5 BLK IRON RAIN CAP 2.37 I.D.
  • Page 43 ELBOW EXHAUST 45 DEG MUFFLER 1.6/1.5L SAE STRAP MUFFLER 6" DIA SCREW HHC M8 X 1.25 X 20MM WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR CAP RAIN 2" Generac Power Systems, Inc. 41 ®...
  • Page 44 0A2106 0A2952 039782 048373 039766 0A2077 023965 022264 42 Generac Power Systems, Inc. ® DESCRIPTION SILKSCREEN "P" PANEL COVER BQ CIRCUIT BREAKER BRACKET MOUNTING CIRCUIT BREAKER CIRCUIT BREAKER 70 X 2 240V 39782 BRKT CIRCUIT BREAKER 90 X 2 240V 39782 BRKT...
  • Page 45 TUBING SHRINK 19"ID RED GROMMET 7/8 X 1/16 X 3/4 SCREW CRIMPTITE 1/4-20 X 5/8 DECAL MFG NAMEPLATE HARNESS CMA WIRE DECAL CMA WARNING DECAL CSA GTS NUT HEX M4-0.7 G8 YEL CHR COVER SILKSCREEN CMA Generac Power Systems, Inc. 43 ®...
  • Page 46 052213 059567 078121 022145 022129 022259 050331A 050331 075763 44 Generac Power Systems, Inc. ® DESCRIPTION BATT 12VDC 75-AH 26/26R CABLE BATT RED #4 X 20.00 CABLE BATT BLK #4 X 23.00 ASSY,WIRE#16 RED 1.6 WASHER FLAT 3/8 ZINC WASHER LOCK M10 SCREW HHC M10-1.25 X 20 G8.8...
  • Page 47 SCREW HHM #6-32 X 3/8 SELF TAP LEVER STEPPER MOTOR NUT LOCK HEX #10-32 NYL INS ASSEMBLY CARBURATOR LINKAGE BRACKET STEPPER MOTOR LIQUID NEOPRENE TIE WRAP 7" BLACK SCREW HHC 1/4-20 X 1/2 G5 WASHER FLAT 1/4 ZINC Generac Power Systems, Inc. 45 ®...
  • Page 48 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A9348-C 46 Generac Power Systems, Inc. ®...
  • Page 49 FLEX CONDUIT 1" BLACK (NOT SHOWN) WASHER FLAT 3/8 ZINC SPACER ROTOR SHAFT SCREW HHC M12-1.25 X 25 G8.8 WASHER FLAT M12 DECAL-WARNING WASHER SHAKEPROOF INT #8 WASHER FLAT .34 ID X .75 OD Generac Power Systems, Inc. 47 ®...
  • Page 50 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Gaseous Fuel System — Drawing No. 0A9349-E 48 Generac Power Systems, Inc. ®...
  • Page 51 HOSE 9/32 ID HOSE 9/32 ID BARBED EL 90 5/16 X 1/8NPT MANIFOLD INTAKE 1.5 SCREW HHC M8-1.25 X 16 G8.8 CLAMP VINYL 1.06 X .406 Z BRACKET-RADIATOR HOSE TORX PLUS BHS M8 X 30 Generac Power Systems, Inc. 49 ®...
  • Page 52 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642-J 50 Generac Power Systems, Inc. ®...
  • Page 53 V-BELT 3/8 X 32-1/8 1.5L V-BELT 3/8 X 28.9 1.5L SPACER PULLEY FILTER OIL ADAPTER DRAIN OIL GROUND WIRE (STARTER) CLAMP HOSE - OIL DRAIN HOSE ASM.-OIL DRAIN CAP HEX 1/4NPT BRASS NAMEPLATE ENGINE WASHER FLAT 1/4 ZINC Generac Power Systems, Inc. 51 ®...

  • Page 54: Installation Drawings

    Section 9 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Installation Drawing 15 & 20 kW – Drawing No. A7214-C 52 Generac Power Systems, Inc. ®...
  • Page 55 Section 9 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Installation Drawing 15 & 20 kW – Drawing No. A7214-C Generac Power Systems, Inc. 53 ®...
  • Page 56 Section 9 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Installation Drawing 25 kW – Drawing No. 0C1450 54 Generac Power Systems, Inc. ®...
  • Page 57 Section 9 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Installation Drawing 25 kW – Drawing No. 0C1450 Air Intake Air Intake Air Intake Generac Power Systems, Inc. 55 ®...

  • Page 58: Section 10 - Warranty

    Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

  • Page 59: Emission Control System Warranty

    Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market”...
  • Page 60 "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years or 2000 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 Warranty Service Dealer, is found to be defective under normal use and service, in accor- dance with the warranty schedule set forth below.

This manual is also suitable for:

Guardian 004189-1Guardian 004370-2Guardian 004371-2Guardian 004474-1Guardian 004475-1

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