Generac Power Systems Guardian 004188-1 Owner's Manual
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Generac Power Systems Guardian 004188-1 Owner's Manual

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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  • 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

    INTRODUCTION ...IFC SAFETY RULES...2 Section 1 GENERAL INFORMATION ...4 Generator ...4 Transfer Switch ...4 Automatic System Operation ...4 Generator AC Connection Systems ...4 Main Circuit Breaker ...5 Generator Fuel System ...5 Engine Protective Devices ...5 Unpacking...6 Lifting the Generator...6 Specifications ...6 Fuel Consumption...7 Torque Specifications ...7 Engine Oil Recommendations ...7...

  • Page 4: General Hazards

    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.

  • Page 5: Electrical Hazards

    • 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.

  • Page 6: Section 1 - General Information Guardian Liquid-Cooled 15 Kw, 20 Kw And 25 Kw Generators

    Section 1 - General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators GENERATOR This equipment is a liquid-cooled, engine-driven gener- ator set. The generator is designed to supply electrical power that operates critical electrical loads during util- ity power failure.

  • Page 7: Engine Protective Devices

    Model Rating Phase 004188 15,000 004189 15,000 004370 20,000 004371 20,000 004474 25,000 004475 25,000 Gaseous fuels such as natural and LP (propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted.

  • Page 8: Unpacking

    Section 1 — General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 1.6 - Low Coolant Level Sensor OVERSPEED SHUTDOWN The CMA circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator AC power windings, via sensing leads S15 and S16.

  • Page 9: Fuel Consumption

    ENGINE SPECIFICATIONS Make ...Mitsubishi Displacement ...92 inches Cylinder Arrangement ...4, in-line Valve Arrangement ...Overhead Cam Firing Order ...1-3-4-2 Number of Main Bearings ...5 Compression Ratio...9 to 1 No. of Teeth on Flywheel ...104 Ignition Timing at 1800 rpm ...35 degrees BTDC at 3600 rpm ...43 degrees BTDC Spark Plug Gap ...0.020-0.025 inch Recommended Spark Plugs...

  • Page 10: Section 2 - Installation Guardian Liquid-Cooled 15 Kw, 20 Kw And 25 Kw Generators

    Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distribution system when the generator is operating.

  • Page 11: Generator Mounting And Support

    GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least 6 inches thick and should extend beyond the enclosure to a distance of at least 3 inches on all sides.

  • Page 12: Generator Ac Neutral Connections

    Section 2 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators GENERATOR AC NEUTRAL CONNECTIONS Generac uses UNGROUNDED Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the genera- tor field.

  • Page 13: Preparation Before Start-Up

    PREPARATION BEFORE START-UP The instructions in this section assume that the stand- by generator has been properly installed, serviced, test- ed, adjusted and otherwise prepared for use by a com- petent, qualified installation contractor. Be sure to read the “Safety Rules” on pages 2 and 3, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

  • Page 14: Control Console Components

    Section 3 — Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators CONTROL CONSOLE COMPONENTS The components of a liquid-cooled generator control console (Figure 3.1) are as follows: Figure 3.1 - Liquid-Cooled Generator Panel AC VOLTMETER The voltmeter displays generator AC output voltage dur- ing operation.

  • Page 15: Manual Transfer And Startup

    NOTE: This fuse will not remove the + battery input power from the PCB when it opens. This means the exercise timer will not be reset. If this fuse does open, care- fully check the wiring to the start, fuel, field boost and transfer outputs before replacing the fuse.

  • Page 16: Section 4 - Maintenance Guardian Liquid-Cooled 15 Kw, 20 Kw And 25 Kw Generators

    Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators ENGINE HEATER The 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 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 Engine Oil Recommenations.) Figure 4.2 - Oil Dipstick and Oil Fill Cap BATTERY FLUID Check battery electrolyte fluid at least once weekly.

  • Page 18: Changing Engine Oil/Air Cleaner

    Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning.

  • Page 19: Miscellaneous Maintenance

    MISCELLANEOUS MAINTENANCE 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 resist- ance. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacu- um system or dry, low pressure air to remove any accu- mulations of dirt.

  • Page 20: Section 5 - Troubleshooting Guardian Liquid-Cooled 15 Kw, 20 Kw And 25 Kw Generators

    Section 5 — Troubleshooting Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators TROUBLESHOOTING POINTS PROBLEM CAUSE Engine won’t crank. 1. 30 amp fuse blown. 2. Loose or corroded or defective 3. Defective starter contactor. 4. Defective starter motor. 5.

  • Page 21: Service Maintenance Interval Information

    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: Maintenance Tasks

    Section 6 — Scheduled Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Maintenance Level 1 Tasks Recom- mended 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.

  • Page 23: Section 6 - Scheduled Maintenance

    Maintenance Level 1 Tasks Recom- mended to be done monthly/ 10 hrs. 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions.

  • Page 24: 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

    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

    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-B BLACK WHITE GREEN ® 26 Generac Power Systems, Inc. DC-A ACTUATOR CONNECTOR 12V BATTERY BLACK LEGEND CC - CONTROL CONTACTOR DCA - DC ALTERNATOR...

  • Page 29: Section 8 - Exploded Views And Parts

    Exploded View – Enclosure (15 and 20 kW) — Drawing No. 0A7188-D ITEM PART NO. QTY. DESCRIPTION 97575 BRACE, SIDE A3769 DOOR, ENCLOSURE A3768 DOOR, ENCLOSURE A5314 TOP, ENCLOSURE 67042 LATCH 22264 LOCK WASHER, #8 67035 SCREW, PAN HEAD MACH.-#8-32 x 5/16"...
  • 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-D 28 Generac ® Power Systems, Inc.
  • Page 31 ITEM PART NO. QTY. 0A2110 0A2115 0A3133A 0A3133B 0A3133C 0A3133D 0A3359 0A3360 0C1245 0C1245A 0A3449 0A4822 0A4823 0A4824 0A4825 0A4826 0C1193 0A4831 0A4832 0C1067 0C1067A 0C1068 0C8817 0C1244 0A9955 022097 022129 022127 022145 089961 24 FT. 022473 082570 039253 042568 0D3397 0D3785 037337...
  • 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 Exploded View – Control Panel (15 and 20 kW) — Drawing No. 0A2872-F ITEM PART NO.QTY. DESCRIPTION 098062 SUPPORT, CONTROL PANEL, L.H. 075589 BRACKET, VOLTAGE REGULATOR 0A1775 CONTROL, PANEL-BACK 098063 SUPPORT, CONTROL PANEL R.H. 0A2106 SILKSCREEN, "P" PANEL 057073 BLOCK, JUNCTION 022985 WASHER, FLAT #6 070080...
  • 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-D VIEW ON "B" 32 Generac ® Power Systems, Inc. "C" "B" VIEW ON "C" INSIDE PANEL FACE VIEW ON "A"...
  • Page 35 ITEM PART NO.QTY. DESCRIPTION 0C5077 SUPPORT CONTROL PANEL LH 075589 BRACKET VOLTAGE REGULATOR 0A1775 CONTROL PANEL-BACK 0C5078 SUPPORT CONTROL PANEL RH 0C4224A SILKSCREEN PANEL (SAE) 057073 BLOCK JUNCTION 3/8-16 022985 WASHER FLAT #6 ZINC 081988 DECAL EXERCISE INFO 070043 VOLTMETER AC 0-300 070055 AMMETER AC 0-100 070042...
  • Page 36 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Radiator (15 & 20 kW) — Drawing No. 0A7206-D 34 Generac ® Power Systems, Inc.
  • Page 37 ITEM PART NO. QTY. 0A6272 0A5734 0A6237 0A6238 084918 050967 057823 099502 083709 052250 042568 022097 049813 022473 084427 050967 075443 056892 0A6284 0A6258 029032 031669 060035 022127 022145 022129 045771 042907 076749 080712 0A7215 0A7275 0A2111 065852 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View –...
  • 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-C 36 Generac ® Power Systems, Inc.
  • Page 39 ITEM PART NO. QTY. 0A5734 0A6237 0A6238 084918 050967 12" 057823 099502 083709 042568 022097 049813 022473 084427 050967 18" 075443 056892 0A6284 0A6258 029032 022127 022145 022129 045771 042907 076749 080712 0A7215 030486 0A2111 065852 0C1067A 0C1067 0C1480 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View –...
  • Page 40 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Mounting Base (15 & 20 kW) — Drawing No. 0A7187-A ITEM PART NO. QTY. C2632 70936 70936C 39253 22145 22129 45771 71956 51730...
  • Page 41 ITEM PART NO. QTY. 0A9955 070936 070936C 039253 022145 022129 045771 071956 051730 057821 021991 027482 0A2308 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Mounting Base (25 kW) — Drawing No. 0C1405-A DESCRIPTION BASE MOUNTING DAMPENER VIBRATION...
  • Page 42 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Muffler (15 & 20 kW) — Drawing No. 0A7618-B ITEM PART NO. QTY. 020689 060366 059933 080761 059939 075546A 036434 022259 022129 036449...
  • Page 43 ITEM PART NO. QTY. 0A4355 0C1636 036434 036449 0C1330 0C1318 0C1068 0C1412 0A5728 060366 066889 022145 022129 045771 0A8974 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Muffler (25 kW) — Drawing No. 0C1408-B DESCRIPTION MANIFOLD EXHAUST 1.5L NIPPLE TOE 1.5 NPT X 6.5 BL IRON...
  • Page 44 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Circuit Breaker — Drawing No. 0D8294 ITEM PART NO. QTY. 0A2106 0A2952 039782 048373 039766 0A2077 023965 022264 42 Generac ®...
  • Page 45 ITEM PART NO. QTY. DESCRIPTION 074100 ASSY HOME STDBY LOGIC (MODELS 921, 863, 865) 076009A PP LOGIC ASM 50/60HZ (MODEL 9428) 072566 NUT SPACER .250 PCB 080882 SCREW PPH TAPPING #6X5/8 SS 074978 DECAL TERMINAL STRIP 047822 BLOCK TERM 20A 7 X 6 X 1100V 075476 SCREW PPHM M4-0.7 X 16 083264...
  • Page 46 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View – Battery — Drawing No. 098922-E ITEM PART NO. QTY. 077483 038804D 038805B 0742600131 022131 046526 052213 059567 078121 022145 022129 022259 050331A 050331...
  • Page 47 CARB. ARM (REF.) ITEM PART NO. QTY. 098290 098941A 098958A 098942A 098225 043146 022097 064526 098783 037398 0A7041 0A7106 074031 029333A 022507 022473 Section 8 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Exploded View –...
  • 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-F 46 Generac ® Power Systems, Inc.
  • Page 49 ITEM PART NO. QTY. 098671 098681 098675 098936 0A5336A 0A1659 071912 049226 051713 022129 098672 098673 098674 098682 098683 098684 098676 098677 098678 097620 098937 097621 0A5382 075591 075476 0A5601 075554B 0A9375 022152 097146 042558 0A5061 0A4989 053557 051769 049541 046526 045772 26 *...
  • 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. 0C1667-F 48 Generac ® Power Systems, Inc.
  • Page 51 ITEM PART NO. QTY. --------- 075580 026915 039253 022145 022129 045771 0A2666 046747 0C3714 0A5547 0C1475 0A9911 0A7989 0A6593 059402 037561 059403 059401 076011 022152 023897 062522 022127 022259 050279 028717 052219 048031C 029032 029032 032552 0A4682 042907 055934D 0A7040 0D8492J 0D8492K * SHOWN IN OTHER VIEW...
  • 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 ITEM PART NO. QTY. DESCRIPTION 0A4531 ENGINE-1.5L 035685 CLAMP HOSE #28 1.32 - 2.25 075546A PIPE-FLEX EXHAUST 0A45310258 GASKET-EXHAUST MANIFOLD 0A4355 MANIFOLD-EXHAUST 0A6699 SHIELD HEAT EXHAUST 022097 WASHER LOCK M6-1/4 022507 SCREW HHC 1/4-20 X 1/2 G5 052212 SCREW HHC M10-1.25 X 25 G8.8 046526 WASHER-LOCK-M10 022131...

  • Page 54: Section 9 - Installation Guardian Liquid-Cooled 15 Kw, 20 Kw And 25 Kw Generators Installation Drawing 15 & 20 Kw - Drawing No. 0A7214-C

    Section 9 — Installation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Installation Drawing 15 & 20 kW – Drawing No. 0A7214-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. 0A7214-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

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.

  • Page 59: 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 con- tinue for 24 consecutive months thereafter.

  • Page 60: Warranty Schedule

    "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective.

This manual is also suitable for:

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

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