Instruction/ maintenance manual of the product 004475-1 Generac
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PO WER SY STEMS, INC. ® Owner ’ s Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers (Natural Gas) 004188-1 004370-2 004474-1 (Liquid Propane V apor) 004189-1 004371-2 004475-1 ONL .
Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the standby gen- erator set product line by Generac P ower 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.
T able of Contents Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION .................................... IFC SAFETY RULES .......................................... 2 Section 1 GENERAL INFORMA TION .
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.
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.
4 Generac ® Pow er Systems, Inc. GEN ER A T OR 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.
Generac ® Pow er Systems, Inc. 5 Gaseous fuels such as natural and LP (propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explo- sion. No leakage of fuel is permitted. Natural gas, which is lighter than air , tends to collect in high areas.
6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor OVERSPEED SH UTDO WN The CMA circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator A C power windings, via sensing leads S15 and S16.
ENGI NE SP ECIF ICA TIONS Make ..................................................................................Mitsubishi Displacement ....................................................92 inches 3 (1.5 liters) Cylinder Arrangement ................
8 Generac ® Pow er Systems, Inc. If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set.
Generac ® Pow er Systems, Inc. 9 GEN ER A T OR MOU NTI NG AN D SU P PORT Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts.
10 Generac ® Pow er Systems, Inc. GEN ER A T OR AC NEUTR AL CONN ECTIONS Generac 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 excessive current opens the load circuit breaker or collapses the genera- tor field.
Generac ® Pow er Systems, Inc. 11 P R EP AR A TION B EFOR E ST ART -U P 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 .
12 Generac ® Pow er Systems, Inc. C ONTROL C ONS OLE COMPON ENTS The components of a liquid- cooled generator control console (Figure 3.1) are as follows: Figure 3.1 - Liquid-Cooled Generator Panel AC VO L T M ET E R The voltmeter displays generator AC output voltage dur- ing operation.
Generac ® Pow er Systems, Inc. 13 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.
14 Generac ® Pow er Systems, Inc. ENGI N E H EA TER Y our 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 . Figure 4.
Generac ® Pow er Systems, Inc. 15 • 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 page 6 for recommended oils. Figure 4.
16 Generac ® Pow er Systems, Inc. CHANGI NG ENGIN E OI L 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 . This means warm up the engine, shut it down and drain immediately as follows: 1.
Generac ® Pow er Systems, Inc. 17 M IS CELL AN E OUS MAI NTENANCE CLEAN ING TH E GEN ER A T OR Keep your generator as clean and as dry as possible. Dirt and moisture that accumulates on internal genera- tor windings have an adverse effect on insulation resist- ance.
18 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators P ROB LEM CAUSE C OR R E CTION Engine won’t crank. 1. 30 amp fuse b lown. 1. Replace fuse. 2. Loose or corroded or def ective 2.
Generac ® Pow er Systems, Inc. 19 Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators F ollowing is a recommended maintenance schedule for Generac Guardian small standby and residential genera- tor sets.
20 Generac ® Pow er Systems, Inc. Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 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 .
Generac ® Pow er Systems, Inc. 21 Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 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 .
22 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — Control P anel (1 -Phase) —Drawing No.
Generac ® Pow er Systems, Inc. 23 Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — Control P anel (1 -Phase) —Drawing No.
24 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — Control Panel (1 -Phase) — Drawing No.
Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7 1 7 6-A Generac ® Pow er Systems, Inc.
26 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — 1.5L Gas Engine — Drawing No.
Generac ® Pow er Systems, Inc. 27 ITEM P ART NO . QTY . DESCRIPTION 1 97575 2 BRACE, SIDE 2 A3769 2 DOOR, ENCLOSURE 3 A3768 1 DOOR, ENCLOSURE 4 A5314 1 T OP , ENCLOSURE 5 67042 2 LA TCH 6 22264 6 LOCK W ASHER, #8 7 67035 6 SCREW , P AN HEAD MACH.-#8-32 x 5/16" 8 82570 2 PLUG-4" 9 A7215 10 SW AGE F ASTENER-W/NYLON W ASHER ITEM P ART NO .
28 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Enclosure (2 5kW) — Drawing No.
Generac ® Pow er Systems, Inc. 29 ITEM P ART NO . QTY . DESCRIPTION 1 0A2110 32 SCREW SW AGE 1/4-20 X 1/2 Z/YC 2 0A2115 32 W ASHER NYLON .250 3 0A3133A 4 HINGE SLIP MALE LH 0A3133B 4 HINGE SLIP FEMALE LH 0A3133C 2 HINGE SLIP MALE RH 0A3133D 2 HINGE SLIP FEMALE RH 4 0A3359 24 SCREW BHSC M6-1.
30 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Control P anel (1 5 and 20 kW) — Drawing No.
Generac ® Pow er Systems, Inc. 31 ITEM P ART NO .QTY . DESCRIPTION 1 098062 1 SUPPORT , CONTR OL P ANEL, L.H. 2 075589 1 BRACKET , V OL T AGE REGULA TOR 3 0A1775 1 CONTROL, P ANEL-BACK 4 098063 1 SUPPORT , CONTR OL P ANEL R.
32 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Control P anel (25kW) — Drawing No.
ITEM P ART NO .QTY . DESCRIPTION 1 0C5077 1 SUPPOR T , CONTROL P ANEL L.H. 2 075589 1 BRACKET , V OL T AGE REGULA TOR 3 0A1775 1 CONTRLP ANEL-BACK 4 0C5078 1 SUPPOR T CONTROL P ANEL R.
34 Generac ® Pow er Systems, Inc. To w a t e r inl e t t ube (Midway up engine block ) To en g ine bypas s "A" To base o f w a t e r inl et tube (On block) 24 12 30 31 2 9 4 12 1 3 12 14 11.
Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0A6272 1 SUPPORT RADIA T OR 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 050967 12" HOSE 5/8 ID RIA 250F 7 057823 4 CLAMP HOSE #10 .
36 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Radiator (2 5 kW) — Drawing No.
Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 2 0A5734 1 RADIA TOR 1.5L 3 0A6237 1 VENTURI 1.5L 4 0A6238 1 GUARD F AN 5 084918 1 HEA TER 500W 1020 6 050967 12" HOSE RES 5/8 RIA 250F 7 057823 4 CLAMP HOSE #10 .56 - 1.06 8 099502 4 CLAMP HOSE #24 1.
ITEM P ART NO . QTY . DESCRIPTION 1 C2632 1 BASE, MOUNTING 3 70936 2 ISOLA T OR-VIBRA TION 4 70936C 2 ISOLA T OR, VIBRA TION 5 39253 8 CAPSCREW , HEX HEAD-M8-1.25 x 20MM 6 22145 12 FLA T W ASHER-M8 7 22129 12 LOCK W ASHER-M8 8 45771 12 NUT , HEX-M8-1.
Generac ® Pow er Systems, Inc. 39 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Mounting Base (2 5 kW) — Drawing No. 0C1 405-A ITEM P ART NO . QTY . DESCRIPTION 1 0A9955 1 BASE MOUNTING 3 070936 2 D AMPENER VIBRA TION 4 070936C 2 DAMPENER VIBRA TION 5 039253 8 SCREW HHC M8-1.
ITEM P ART NO . QTY . DESCRIPTION 1 020689 1 MUFFLER W/RAIN SHLD 2 060366 1 MUFFLR STRAP 6IN DIA 3 059933 1 ELBO W 90 DEG 2 NPT 4 080761 1 NIPPLE TOE 2 NPT X 4.5 BLK IR ON 5 059939 1 RAIN CAP 2.37 I.D . 6 075546A 1 PIPE FLEX EXHAUST 7 036434 1 BOL T U 5/16-18 X 2.
Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHAUST 1.5L 2 0C1636 1 NIPPLE TOE 1.5 NPT X 6.5 BL IR ON 3 036434 4 BOL T U 5/16-18 X 2.09 036449 4 SADDLE 2 INCH 4 0C1330 1 PIPE EXHA UST 5 0C1318 1 FLEX PIPE EXHA UST 6 0C1068 1 SUPPOR T MUFFLER 1.
ITEM P ART NO . QTY . DESCRIPTION 1 0A2106 1 SILKSCREEN "P" P ANEL 2 0A2952 1 COVER BQ CIRCUIT BREAKER 3 039782 1 BRA CKET MOUNTING CIRCUIT BREAKER 4 048373 1 CIRCUIT BREAKER 70 X 2 240V 397.
Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 074100 1 ASSY HOME STDBY LOGIC (MODELS 921, 863, 865) 076009A 1 PP LOGIC ASM 50/60HZ (MODEL 9428) 2 072566 4 NUT SP A CER .250 PCB 3 080882 4 SCREW PPH T APPING #6X5/8 SS 4 074978 1 DECAL TERMINAL STRIP 5 047822 1 BLOCK TERM 20A 7 X 6 X 1100V 6 075476 2 SCREW PPHM M4-0.
44 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Batt ery — Drawing No. 098922-E ITEM P ART NO . QTY . DESCRIPTION 1 077483 1 BA TT 12VDC 75-AH 26/26R 2 038804D 1 CABLE BA TT RED #4 X 20.
Generac ® Pow er Systems, Inc. 45 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Governor Assembly — Drawing No.
46 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Generator — Drawing No.
Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 098671 1 ASSY RO TOR 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 BLO WER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.
48 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Gaseous F uel System — Drawing No.
Generac ® Pow er Systems, Inc. 49 ITEM P ART NO . QTY . DESCRIPTION 1 0C2632 1 WELDMENT MOUNTING BASE 2 075580 2 FLANGE FUEL INLET 3 026915 3 NIPPLE CLOSE 3/4 X 1.375 4 039253 4 SCREW HHC-M8-1.25 X 20 5 022145 5 W ASHER FLA T 5/16 ZINC 6 022129 7 W ASHER LOCK M8-5/16 7 045771 4 NUT HEX M8-1.
50 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No.
Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 035685 1 CLAMP HOSE #28 1.32 - 2.25 3 075546A 1 PIPE-FLEX EXHAUST 4 0A45310258 1 GASKET -EXHA UST MANIFOLD.
52 Generac ® Pow er Systems, Inc. Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 1 5 & 20 kW – Drawing No.
Generac ® Pow er Systems, Inc. 53 Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 1 5 & 20 kW – Drawing No.
54 Generac ® Pow er Systems, Inc. Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 25 kW – Drawing No.
Generac ® Pow er Systems, Inc. 55 Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 25 kW – Drawing No.
56 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEMENT Y OU R W AR R ANT Y R IGHT S AN D OBLIGA 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.
Generac ® Pow er Systems, Inc. 57 EM IS SION CONTROL S YS TEM 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.
Part No. 0D6444 Revision 0 (11/14/01) Printed in U.S.A. Section 1 0 – Warranty Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators GEN ERAC PO WER SY STEMS "TWO YEAR" S T AN D AR D .
An important point after buying a device Generac 004475-1 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac 004475-1 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac 004475-1 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac 004475-1 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac 004475-1 will certainly help you make a decision on the purchase.
If you already are a holder of Generac 004475-1, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac 004475-1.
However, one of the most important roles played by the user manual is to help in solving problems with Generac 004475-1. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 004475-1 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
