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Generac Power Systems 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726-0 Owner's Manual

Liquid-cooled, prepackaged standby generators
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Owner's Manual
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
!
!
Not intended for use in critical life support applications.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION!!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.

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Related Manuals for Generac Power Systems 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726-0

Summary of Contents for Generac Power Systems 004721-0, 004722-0, 004723-0, 004724-0, 004725-0, 004725-1, 004725-2, 004725-3, 004726-0

  • Page 1 Owner’s Manual 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 Not intended for use in critical life support applications. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac Power 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.

  • 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 ...4 Generator Fuel System ...4 Engine Protective Devices ...5 Unpacking ...6 Lifting the Generator ...6 1.10 Specifications ...7 1.11 Fuel Consumption ...7 1.12 Reconfiguring the Fuel System ...7...

  • Page 4: Safety Rules

    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

    Section 1 - General Information Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators GENERATOR 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 outdoor installation only.

  • Page 7: Engine Protective Devices

    Model Rating 004721/004722 15,000 004723/004724 20,000 004725/004726 25,000 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.

  • Page 8: Unpacking

    M1 M1 M1 M1 M1 M1 CR37 CR41 2002 GENERAC POWER SYSTEMS, ASSY #076009A 1.7.5 PCB OPERATION LED’S • LED 1 is RED. The LED is on when utility sensing is NOT available to the circuit board. This LED will function only when the Auto/Off/Manual switch is set in the Auto position.

  • Page 9: Specifications

    1.10 SPECIFICATIONS 1.10.1 GENERATOR SPECIFICATIONS Model 004725 004723 004721 004726 004724 004722 Rated Max. Cont. AC Power Output (kW) Rated voltage (volts) No. of Rotor Poles Driven Speed of Rotor 3600 Rotor Excitation System Direct excited brush type Type of Stator Rotor/Stator Insulation 1.10.2 ENGINE SPECIFICATIONS Make...Mitsubishi...

  • Page 10: Torque Specifications

    Using any high silicate anti-freeze boosters or additives will also cause overheating. Generac Power Systems also recommends that any soluble oil inhibitor is NOT used for this equipment. Generac ®...

  • Page 11: Generator Location

    2.1.1 NFPA STANDARDS The following published standards booklets pertain- ing to standby electric systems are available form the National Fire Protection Association Batterymarch Park, Quincy, MA 02269: • NFPA STATIONARY ENGINES AND GAS TURBINES. • NFPA No. 76A, ESSENTIAL ELECTRICAL SYS- TEMS FOR HEALTH CARE FACILITIES.

  • Page 12: Emergency Circuit Isolation Method

    Figure 2.2 – Generator Grounding Lug (typical) GENERATOR AC NEUTRAL CONNECTIONS Generac Power Systems uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the exces- sive current opens the load circuit breaker or col- lapses the generator field.

  • Page 13: Battery Installation

    2.10 BATTERY INSTALLATION DANGER 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 preset level. To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until the NORMAL source voltage at the transfer switch is correct and the system is ready to be put into operation.

  • Page 14: Section 3 - Operation

    Section 3 — Operation Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Before starting the generator for the first time, the installer must complete the following procedures. For follow-up maintenance information and/or service intervals, please refer to Section 4, “Maintenance.” 2.11.2 TRANSFER SWITCH If this generator is used to supply power to any elec- trical system normally powered by an electric utility,...

  • Page 15: Control Console Components

    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 FUSE FAULT 15-A INDICATOR HOUR METER AUTO MANUAL 3.2.1 HOURMETER 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.

  • Page 16: Engine Heater

    Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators • Set the AUTO/OFF/MANUAL 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”...

  • Page 17: Cooling System

    E. EVERY 500 OPERATING HOURS 1.Service air cleaner. 2.Check starter. 3.Check engine DC alternator. F. EVERY 800 OPERATING HOURS 1.Retorque cylinder head. (See Torque Specs, Section 1.13.) 2.Retorque intake and exhaust manifold. (See Torque Specs, Section 1.13.) 3.Check engine compression. 4.Check valve clearance.

  • Page 18: Maintenance Owner/Operator Can Perform

    Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators MAINTENANCE OWNER/ OPERATOR CAN PERFORM 4.5.1 CHECK ENGINE OIL LEVEL Refer to “Checking Fluid Levels” in Section 4.4. 4.5.2 CHECK BATTERY • Check battery fluid level each week as outlined under “Check Fluid Levels”.

  • Page 19: Miscellaneous Maintenance

    After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD” MARK. 7. Start engine and check for oil leaks. 4.5.11 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 059402), simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.3).
  • Page 20 Section 4 — Maintenance Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 4.6.2 BATTERY 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: •...

  • Page 21: Scheduled Maintenance

    SCHEDULED MAINTENANCE 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 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 Section 4 — 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 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 5 - Troubleshooting

    Section 5 — Troubleshooting Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators TROUBLESHOOTING POINTS PROBLEM Engine won’t crank. Engine cranks but won't start Engine starts hard, runs rough. Engine starts then shuts down. AUTO/OFF/MANUAL Switch at OFF, engine continues to run No AC output from generator.

  • Page 25: Section 6 - Notes

    Section 6 — Notes Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Generac ® Power Systems, Inc. 23...
  • Page 26 Section 6 — Notes Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators 24 Generac ® Power Systems, Inc.

  • Page 27: Section 7 - Installation Diagram

    Section 7 - Installation Diagram Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Drawing No. 0E1533-A Generac ® Power Systems, Inc. 25...

  • Page 28: Section 8 - Electrical Data

    Section 8 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel —Drawing No. 0E0345 26 Generac ® Power Systems, Inc. BLACK...
  • Page 29 Section 8 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L Engine — Drawing No. 0E0343-B Generac ® Power Systems, Inc. 27...
  • Page 30 Section 8 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L Guardian — Drawing No. 0E1525 BLACK BLACK BLUE BLUE ® 28 Generac Power Systems, Inc.
  • Page 31 Section 8 - Electrical Data Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Electrical Schematic — 1.5L — Drawing No. 0A7182-C Generac ® Power Systems, Inc. 29...

  • Page 32: Parts Lists

    Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Governor Assembly — Drawing No. 0E1331-B TO "A" CARBURETOR ARM (REF.) ITEM PART NO. QTY. 098290 098941A 098958A 098942A 098225 043146 022097 084543A 098783 037398 0E1326...
  • Page 33 ITEM PART NO. QTY. 0D8656 027482 070936 070936C 039253 022145 022129 045771 071956 051730 021991 0D9335 0D9336 0C2454 047411 022097 022473 055414 049813 026850 0A1694 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Mounting Base —...
  • Page 34 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW and 20 kW Generators Standard Compartment — Drawing No. 0E0771-F 32 Generac ® Power Systems, Inc. "Y" WELD STUD UNDER ROOF PANEL FOR ACCESS COVER CABLE NOTE: USE DOOR LATCH FASTENER TO SECURE GROUND WIRE.
  • Page 35 ITEM PART NO. QTY. 0D8666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 051716 022152 0912970064 023762 0912970063 022264 067035 022127 0C2634A 022473 022097 0D2023 0F3390 037337 0D2023 0D8664A 0D8664B 30 * 0F1563 31 * 0C2634 * I/N'S 30 & 31 PART OF I/N 21. Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW and 20 kW Generators Standard Compartment —...
  • Page 36 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 25 kW Generators Acoustic Compartment — Drawing No. 0E0772-H 34 Generac ® Power Systems, Inc.
  • Page 37 ITEM PART NO. QTY. 0D8666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 051716 022152 0912970064 023762 0912970063 022264 067035 078115 0C2634A 022473 022097 022127 0D8663 0D8665 0E0072D 0E0072B 0E0072Q 0E0072C 0E0072A 0E0072M 0E0072P 0E0072L 0E0072N 0E0072G 0E0072J 0E0072F 0E0072E...
  • Page 38 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Control Panel — Drawing No. 0E0778-G 36 Generac ® Power Systems, Inc.
  • Page 39 ITEM PART NO. QTY. DESCRIPTION 0D9322 PANEL BACK & BOTTOM GUARDIAN 0D9332 PANEL LH SIDE GUARDIAN & SPRN 0D9325A PANEL FRONT CONTROL GUARDIAN W/ SILKSC 0D9330 PANEL RH SIDE C-PANEL SML BRK 0C1457 HOURMETER 064009 LIGHT 12VDC .02A LED RED PILOT 032300 HOLDER FUSE 022676...
  • Page 40 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Engine — Drawing No. 0E1228-H 38 Generac ® Power Systems, Inc.
  • Page 41 ITEM PART NO. QTY. DESCRIPTION 0A4531 ENGINE-1.5L 022473 WASHER FLAT 1/4 ZINC 0A45310258 GASKET-EXHAUST MANIFOLD 0A4355 MANIFOLD-EXHAUST 0E2632 HEAT SHIELD EXH 1.5L 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 42 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Radiator — Drawing No. 0E0769-J 40 Generac ® Power Systems, Inc.
  • Page 43 ITEM PART NO. QTY. 0D8657 0A5734 0A6237 0A6238 084918 051520N 048031C 099502 083709 052250 047411 022097 049813 022473 084427 051520Z 17 * 058443 056892 0A6284 0A6258 029032 031669 060035 022127 046627 0C7649 0C2454 076749 0E0726 035461 0A7275 0A2111 065852 047290A * FAN GUARD KIT 0E3596 (NOT USED WITH LEVEL ONE GUARDING) Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators...
  • Page 44 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Fuel System — Drawing No. 0E0774-F "C" "D" PORT "OUT 2" L.P. VAPOR 42 Generac ® Power Systems, Inc. "C" PORT "OUT 1" (NATURAL GAS) "D"...
  • Page 45 ITEM PART NO. QTY. --------- 075580 0E1006 039253 022145 022129 045771 0A7040 032552 029032 0E1056 029032 0A5547 048031C 0D1509 16 ** 0E0591 059402 037561 0E1028 059401 21 ** 091526 22 ** 049226 026307 062522 022127 022259 050279 0A6125 0D8492T 30 ** 0E1104 31 ** 0E0668...
  • Page 46 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Alternator — Drawing No. 0A9348-G 44 Generac ® Power Systems, Inc.
  • Page 47 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 0A5601A 075554B 0A9375 022152 097146 042558 0A5061 0A4989 053557 051769 049541 046526 045772 26 *...
  • Page 48 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Battery — Drawing No. 0E0770-B ITEM PART NO. QTY. 077483 038804D 038805B 0742600131 022131 046526 052213 075763 0D8668 050331A 050331 0C2454 025507 027482 46 Generac ®...
  • Page 49 ITEM PART NO. QTY. 0A4355 0E2844 036434 036449 0E0109 0C1318 0D8657 0E0170 0D9437 060366 039253 022145 022129 045771 0A8974 027837 Section 9 - Exploded Views and Parts Guardian Liquid-cooled 15 kW, 20 kW and 25 kW Generators Muffler — Drawing No. 0E0773-A DESCRIPTION MANIFOLD EXHAUST 1.5L NIPPLE TOE 1.5NPTX5.5 BLK IRON...

  • Page 50: 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 51: 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 52 "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.

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