rtable Generator 004090 2, 004091 2, 004092 2, 004093 2, 004094 2, 004095 2, 004096 2, 004097 2, 004474 0, 004124 1, 004125 1, 004126 1, 004127 1, 004128 1, 004130 1, 004131 1, 004475 0 User Guide
®
POWER SYSTEMS, INC.  
Owner’s Manual  
Liquid-cooled, Prepackaged  
Standby Generators  
Model Numbers  
(Natural Gas)  
004090-2  
004092-2  
004094-2  
004096-2  
004091-2  
004093-2  
004095-2  
004097-2  
004474-0 (w/TS)  
(Liquid Propane Vapor)  
004124-1  
004126-1  
004128-1  
004131-1  
004125-1  
004127-1  
004130-1  
004475-0 (w/TS)  
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  
SHOULD ATTEMPT INSTALLATION!!  
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Table of Contents  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Automatic Operation..................................................................14  
INTRODUCTION ............................................................IFC  
Weekly Exercise Cycle..............................................................14  
Engine Heater ..........................................................................14  
Section 4  
SAFETY RULES ........................................................................2  
Section 1  
GENERAL INFORMATION ........................................................4  
Generator ....................................................................................4  
Automatic System Operation ......................................................4  
Generator AC Connection Systems ............................................4  
Main Circuit Breaker....................................................................5  
Generator Fuel System ..............................................................5  
Engine Protective Devices ..........................................................5  
Generator Specifications ............................................................6  
Unpacking....................................................................................7  
Lifting the Generator ..................................................................7  
Engine Specifications..................................................................7  
Fuel Consumption ......................................................................7  
Lifting the Generator ..................................................................7  
Torque Specifications ..................................................................8  
Engine Oil Recommendations ....................................................8  
Coolant Recommendations ........................................................8  
Before Installation........................................................................8  
Section 2  
MAINTENANCE........................................................................15  
Maintenance Performed by  
Authorized Service Facilities ....................................................15  
Overload Protection for Engine DC Electrical System..............15  
Checking Fluid Levels ..............................................................15  
Maintenance Owner/Operator Can Perform..............................16  
Miscellaneous Maintenance......................................................17  
Section 5  
TROUBLESHOOTING ..............................................................18  
Section 6  
SCHEDULED MAINTENANCE ................................................19  
Section 7  
WIRING DIAGRAMS AND SCHEMATICS..........................22-27  
Section 8  
EXPLODED VIEWS AND PARTS LISTS............................28-45  
Section 9  
STANDBY GENERATOR INSTALLATION ................................9  
Basic Standby Electric System..............................................................9  
Emergency Circuit Isolation Method....................................................10  
Total Circuit Isolation Method ..............................................................10  
Grounding the Generator ....................................................................10  
Generator AC Neutral Connections ....................................................10  
Transfer Switch Start Signal Connections ..........................................10  
Battery Installation ..............................................................................10  
Preparation Before Start-Up................................................................11  
Section 3  
INSTALLATION DRAWINGS ..............................................46-47  
Section 10  
WARRANTY .......................................................48- Back Cover  
Figure 1- Water Cooled Emergency Power System  
OPERATION ............................................................................12  
Using a Standard “GTS” Transfer Switch ..................................12  
Control Console Components ..................................................13  
Manual Transfer and Startup ....................................................13  
Retransfer and Shutdown..........................................................14  
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Important Safety Instructions  
Guardian Liquid-cooled 10 kW, 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.  
SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be  
followed during installation and maintenance of the generator and batteries.  
GENERAL HAZARDS  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
The engine exhaust from this product  
• For  
safety  
reasons,  
Generac  
recommends  
that this equipment be installed, serviced and  
repaired by a Generac Authorized Service Dealer or  
other competent, qualified electrician or installation  
technician who is familiar with applicable codes,  
standards and regulations. The operator also must  
comply with all such codes, standards and regula-  
tions.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
• Installation, operation, servicing and repair of this  
(and related) equipment must always comply with  
applicable codes, standards, laws and regulations.  
Adhere strictly to local, state and national electrical  
and building codes. Comply with regulations the  
Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the gener-  
ator is installed, operated and serviced in accordance  
with the manufacturer’s instructions and recommen-  
dations. Following installation, you must not do any-  
thing that might render the unit unsafe or in non-  
compliance with the aforementioned codes, stan-  
dards, laws and regulations.  
• The engine exhaust fumes contain carbon monoxide  
gas, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. For that reason, ade-  
quate ventilation must be provided. Exhaust gases  
must be piped safely away from any building or  
enclosure that houses the generator to an area where  
people, animals, etc., will not be harmed. This  
exhaust system must be installed properly, in strict  
compliance with applicable codes and standards.  
• Keep hands, feet, clothing, etc., away from drive belts,  
fans, and other moving or hot parts. Never remove  
any drive belt or fan guard while the unit is operating.  
• Adequate, unobstructed flow of cooling and ventilat-  
ing air is critical in any room or building housing the  
generator to prevent buildup of explosive gases and  
to ensure correct generator operation. Do not alter  
the installation or permit even partial blockage of  
ventilation provisions, as this can seriously affect safe  
operation of the generator.  
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. Many acci-  
dents are caused by failing to follow simple and funda-  
mental rules or precautions.  
Generac cannot possibly anticipate every possible cir-  
cumstance that might involve a hazard. The warnings in  
this  
manual,  
and  
on  
tags  
and  
decals  
affixed to the unit are, therefore, not all-inclusive. If you  
use a procedure, work method or operating technique  
that Generac does not specifically recommend, you  
must satisfy yourself that it is safe for you and others.  
You also must make sure the procedure, work method  
or operating technique that you choose does not render  
the generator unsafe.  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting its  
maintenance or being careless can cause  
possible injury or death. Permit only responsible and  
capable persons to install, operate or maintain this  
equipment.  
Potentially lethal voltages are generated by these  
machines. Ensure all steps are taken to render the  
machine safe before attempting to work on the  
generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running gen-  
erators.  
• Keep the area around the generator clean and unclut-  
tered. Remove any materials that could become haz-  
ardous.  
• When working on this equipment, remain alert at all  
times. Never work on the equipment when you are  
physically or mentally fatigued.  
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Important Safety Instructions  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
• Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer  
or replace all worn, damaged or defective parts using  
switch will crank and start automatically when nor-  
mal (utility) source voltage is removed or is below an  
acceptable preset level. To prevent such automatic  
start-up and possible injury to personnel, disable the  
generator’s automatic start circuit (battery cables,  
etc.) before working on or around the unit. Then,  
place a “Do Not Operate” tag on the generator control  
panel and on the transfer switch.  
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.  
Reconnect that cable last.  
• Never use the generator or any of its parts as a step.  
Stepping on the unit can stress and break parts, and  
may result in dangerous operating conditions from  
leaking exhaust gases, fuel leakage, oil leakage, etc.  
• In case of accident caused by electric shock, immedi-  
ately shut down the source of electrical power. If this  
is not possible, attempt to free the victim from the  
live conductor. AVOID DIRECT CONTACT WITH  
THE VICTIM. Use a nonconducting implement, such  
as a dry rope or board, to free the victim from the live  
conductor. If the victim is unconscious, apply first aid  
and get immediate medical help.  
• Never wear jewelry when working on this equipment.  
Jewelry can conduct electricity resulting in electric  
shock, or may get caught in moving components  
causing injury.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce dan-  
gerous electrical voltages and can cause fatal electrical  
shock. Utility power delivers extremely high and dan-  
gerous voltages to the transfer switch as well as the  
standby generator. Avoid contact with bare wires, ter-  
minals, connections, etc., on the generator as well as  
the transfer switch, if applicable. Ensure all appropri-  
ate covers, guards and barriers are in place before  
operating the generator. If you must work around an  
operating unit, stand on an insulated, dry surface to  
reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
• If people must stand on metal or concrete while  
installing, operating, servicing, adjusting or repairing  
this equipment, place insulative mats over a dry  
wooden platform. Work on the equipment only while  
standing on such insulative mats.  
FIRE HAZARDS  
• Keep a fire extinguisher near the generator at all  
times. Do NOT use any carbon tetra-chloride type  
extinguisher. Its fumes are toxic, and the liquid can  
deteriorate wiring insulation. Keep the extinguisher  
properly charged and be familiar with its use. If you  
have any question pertaining to fire extinguishers,  
consult your local fire department.  
EXPLOSION HAZARDS  
• The National Electrical Code (NEC), Article 250  
requires the frame and external electrically conduc-  
tive parts of the generator to be connected to an  
approved earth ground and/or grounding rods. This  
grounding will help prevent dangerous electrical  
shock that might be caused by a ground fault condi-  
tion in the generator set or by static electricity. Never  
disconnect the ground wire.  
• Wire gauge sizes of electrical wiring, cables and cord  
sets must be adequate to handle the maximum elec-  
trical current (ampacity) to which they will be sub-  
jected.  
• Before installing or servicing this (and related) equip-  
ment, make sure that all power voltage supplies are  
positively turned off at their source. Failure to do so  
will result in hazardous and possibly fatal electrical  
shock.  
• Connecting this unit to an electrical system normally  
supplied by an electric utility shall be by means of a  
transfer switch so as to isolate the generator electric  
system from the electric utility distribution system  
when the generator 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.  
• Properly ventilate any room or building housing the  
generator to prevent build-up of explosive gas.  
• Do not smoke around the generator. Wipe up any fuel  
or oil spills immediately. Ensure that no combustible  
materials are left in the generator compartment, or  
on or near the generator, as FIRE or EXPLOSION  
may result. 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. Comply with all laws regulating the storage  
and handling of fuels. Inspect the unit’s fuel system  
frequently and correct any leaks immediately. Fuel  
supply lines must be properly installed, purged and  
leak tested according to applicable fuel-gas codes  
before placing this equipment into service.  
• Diesel fuels are highly FLAMMABLE. Gaseous fluids  
such as natural gas and liquid propane (LP) gas are  
extremely EXPLOSIVE. Natural gas is lighter than air,  
and LP gas is heavier than air; install leak detectors  
accordingly.  
®
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Section 1 - General Information  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
GENERATOR  
AUTOMATIC SYSTEM OPERATION  
This equipment is an water-cooled, engine-driven gen- When this generator along with its transfer switch has  
erator set. The generator is designed to supply electrical been installed and interconnected, a circuit board in the  
power that operates critical electrical loads during util- generator panel constantly monitors utility power  
ity power failure. The unit has been factory-installed in source voltage. Should that voltage drop below a preset  
a weather resistant, all metal sound attenuated enclo- value, and remain at such a low state for a preset  
sure and is intended for outdoor installation only. Use amount of time, the generator cranks and starts. After  
this generator as a source of electrical power for the the generator starts, the transfer switch transfers load  
operation of 120 and/or 240 volts, single or 3-phase circuits so the generator can power them.  
loads, or 120 and/or 208 volts, 3-phase loads.  
When utility source voltage has been restored, the  
switch re-transfers back to the utility source voltage and  
the generator then shuts down.  
These models are available. They are rated as follows:  
Model 004090: Provides 10,000 watts (10 kW) of 1-phase power.  
GENERATOR AC  
Model 004091: Provides 10,000 watts (10 kW) of 3-phase power.  
CONNECTION SYSTEMS  
The generator was shipped from the factory with its sta-  
tor AC output leads connected in one of the “Delta” con-  
Model 004124: Provides 10,000 watts (10 kW) of 1-phase power.  
Model 004125: Provides 10,000 watts (10 kW) of 3-phase power.  
Model 004092: Provides 15,000 watts (15 kW) of 1 phase power.  
Model 004093: Provides 15,000 watts (15 kW) of 3 phase power.  
Model 004126: Provides 15,000 watts (15 kW) of 1 phase power.  
Model 004127: Provides 15,000 watts (15 kW) of 3 phase power.  
Model 004094: Provides 20,000 watts (20 kW) of 1-phase power.  
Model 004095: Provides 20,000 watts (20 kW) of 3-phase power.  
Model 004128: Provides 20,000 watts (20 kW) of 1-phase power.  
Model 004096: Provides 25,000 watts (25 kW) of 1 phase power.  
Model 004097: Provides 25,000 watts (25 kW) of 3 phase power.  
Model 004130: Provides 25,000 watts (25 kW) of 1 phase power.  
Model 004131: Provides 25,000 watts (25 kW) of 3 phase power.  
Model 004474: Provides 25,000 watts (25 kW) of 1 phase power.  
Model 004475: Provides 25,000 watts (25 kW) of 1 phase power.  
figurations, as shown in Figure 2. This type of connec-  
tion system will supply a 120 and/or 240 volts, 1 or  
3-phase output as shown in the illustration.  
Figure 2 - Generator AC Connection System  
WARNING: If this generator is used to power  
electrical load circuits normally powered by a  
utility power source, you are required by code to  
install a transfer switch. The transfer switch must  
effectively isolate the electric system from the  
utility distribution system when the generator is  
operating (NEC 701). Failure to isolate an electri-  
cal system by such means results in damage to  
the generator and may also result in injury or  
even death to utility power workers due to back-  
feed of electrical energy.  
If, however, load voltage requires 120/208 volts, 3-phase  
output, generator will require reconnecting of the sta-  
tor’s output leads. This task should only be performed  
by a qualified Generac service technician. Refer to the  
installation manual (Part No. 079699) for details.  
®
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Section 1 - General Information  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Figure 3 represents a single-phase, 3-wire generator AC  
WARNING: 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. Natural gas, which is lighter  
than air, tends to collect in high areas. LP gas is heavier  
than air and tends to settle in low areas.  
connection system. The stator assembly in this system  
consists of a pair of stationary windings, with two leads  
brought out of each winding. Each single winding can  
supply 120 volts AC, 60 Hertz. When the two windings  
are connected in series, a 240 volts, 60 Hertz AC output  
results. Typically the two “hot” leads in the circuit are  
Wires No. 11 and 44. The “Neutral” leads are the junc-  
tion of Wires 22 and 33.  
ENGINE PROTECTIVE DEVICES  
The engine has several safety switches which cause the  
engine to automatically shut down under the following  
conditions: low oil pressure, high coolant temperature,  
engine overspeed, low coolant level or overcrank.  
Figure 3 - Generator AC Connection System  
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 4).  
Figure 4 - Low Oil Pressure Switch  
MAIN CIRCUIT BREAKER  
The generator’s main circuit breaker is included with the unit as  
shipped from the factory. The breaker for each unit is described in  
Figure 5 below.  
GENERATOR FUEL SYSTEM  
Your unit has been factory tested and adjusted using a  
natural gas fuel system. If propane (LP) gas is pre-  
ferred, contact an authorized service dealer.  
Figure 5 - Main Circuit Breaker  
Model  
Rating  
Phase  
Actual Current C/B Rating*  
% over rating Circuit Breaker  
004090-2  
004091-2  
004124-1  
004125-1  
004092-2  
004093-2  
004126-1  
004127-1  
004094-2  
004095-2  
004128-1  
004096-2  
004097-2  
004130-1  
004131-1  
004474-0  
004475-0  
10,000  
10,000  
10,000  
10,000  
15,000  
15,000  
15,000  
15,000  
20,000  
20,000  
20,000  
25,000  
25,000  
25,000  
25,000  
25,000  
25,000  
1
3
1
3
1
3
1
3
1
3
1
1
3
1
3
1
1
41.7  
30.1  
41.7  
30.1  
62.5  
45.2  
62.5  
45.2  
83.3  
60.2  
83.3  
104.2  
75.3  
104.2  
75.3  
104.2  
104.2  
50  
40  
50  
40  
70  
60  
70  
60  
90  
70  
90  
125  
90  
125  
90  
125  
125  
120%  
133%  
120%  
133%  
112%  
133%  
112%  
133%  
108%  
116%  
108%  
120%  
120%  
120%  
120%  
120%  
120%  
50A BQ2  
40A BQ3  
50A BQ2  
40A BQ3  
70A BQ2  
60A BQ3  
70A BQ2  
60A BQ3  
90A BQ2  
70A BQ3  
90A BQ2  
125A BQ2  
90A BQ3  
125A BQ2  
90A BQ3  
125A BQ2  
125A BQ2  
* Amp Rating of C/B structured under model.  
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Section 1 — General Information  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Figure 7 - Low Coolant Level Sensor  
HIGH COOLANT TEMPERATURE SWITCH:  
Normally open (N.O.) thermostatic switch has sensing  
tip which is immersed in captive coolant. Should  
coolant temperature exceed about 230°F (110°C), the  
switch contacts close, which causes the engine to shut  
down automatically (Figure 6).  
Figure 6- High Coolant Temperature Switch  
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. Should  
AC frequency exceed about 72 Hz, circuit board action  
will automatically shutdown the engine (Figure 8).  
*Rated power of generator is subject to and limited by  
such factors as ambient temperature, altitude, engine  
condition, and other factors. Engine power will decrease  
about 3.5% for each 1000 feet above sea level and will  
decrease an additional 1% for each 10°F above 60°F.  
Maximum output power of the generator is limited by  
LOW COOLANT LEVEL SWITCH:  
maximum engine power.  
Should engine coolant level drop below the level of the  
high coolant temperature switch, it is possible for the  
engine to overheat without automatic shutdown. To  
prevent such overheating without automatic shut down,  
the engine has a low coolant level sensor. If the engine  
coolant drops too low, the engine automatically shuts  
down (Figure 7).  
† Models 004474 & 004475 has same specifications  
as models 004096 & 004130 below.  
SPECIFICATIONS  
GENERATOR SPECIFICATIONS  
3-Phase  
1-Phase  
Model  
004097  
004131  
004095  
004093  
004127  
004091  
004125  
004096† 004094 004092 004090  
004130† 004126 004128 004124  
*Rated Max. Cont.  
AC Power Output (kW)  
Rated Voltage (volts)  
Rated Max. Cont.  
Current @ 240 V, 1Ø  
Current @ 240 V, 3Ø  
No. of Rotor Poles  
Driven Speed of Rotor  
Rotor Excitation System  
Type of Stator  
25  
20  
15  
10  
25  
20  
15  
120/240  
10  
120/240  
N/A  
75.3  
N/A  
60.2  
N/A  
45.2  
N/A  
30.1  
104.2  
N/A  
83.3  
N/A  
62.5  
N/A  
41.7  
N/A  
2
4
2
4
3600  
3600  
1800  
1800  
3600  
3600  
1800  
1800  
Direct excited brush type system  
12 wire reconnectable  
Class F  
Rotor/Stator Insulation  
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Section 1 — General Information  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Figure 8 - Control Module Assembly Circuit Board  
SPECIFICATIONS  
ENGINE SPECIFICATIONS  
Make................................................................................Mitsubishi  
Displacement ................................................92 inches3 (1.5 liters)  
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  
OVERCRANK SHUTDOWN:  
After 90 seconds of crank-rest cycles, this function ends  
cranking if the engine fails to start in that 90-second  
span.  
Champion ......................................................................RN11YC4  
Oil Pressure......................................................................30-50 psi  
Crankcase Oil Capacity..........................4.0 U.S. quarts (3.8 liters)  
Recommended Engine Oil..........................................SAE 15W-40  
Type of Cooling System ....................Pressurized, closed recovery  
Cooling Fan ................................................................Pusher Type  
Cooling System Capacity ........................2 U.S. gallons (7.6 liters)  
DC FUSE  
This clearly labeled fuse is located on the front panel of  
the control system. It protects the panel wiring and  
components from damaging overload. Always remove  
this fuse before commencing work on the generator.  
The unit will not start or crank if the fuse is blown.  
Replace the fuse with one of the same size, type, and rat-  
ing. Generac normally uses an AGC fuse rated at 30  
amps.  
Recommended Coolant..............................Use a 50-50 mixture of  
ethylene glycol base.  
FUEL CONSUMPTION  
UNPACKING  
Models 004096, 004097, 004130, 004131, 004474, 004475  
Using Natural Gas ....................................441 cu. ft. per hour  
Using LP Gas ........................175 cubic ft.(4.8 gal.) per hour  
Models 004094, 004095, 004128  
UNPACKING PRECAUTIONS:  
Handle shipping cartons and crates with care. Use care  
to avoid damage from dropping, bumping, collision, etc.  
Store and unpack cartons with the proper side up, as  
noted on the shipping carton.  
Using Natural Gas ....................................359 cu. ft. per hour  
Using LP Gas ........................143 cubic ft. (4.0 gal.) per hour  
Model 004092, 004093, 004126, 004127  
INSPECTION:  
Using Natural Gas ....................................277 cu. ft. per hour  
Using LP Gas ........................110 cubic ft.(3.1 gal.) per hour  
Models 004090, 004091, 004124, 004125  
After unpacking, carefully inspect the generator for any  
damage that may have occurred during shipment. If  
loss or damage is noted at the time of delivery, have the  
person(s) making delivery note all damage on the freight  
bill or affix his signature under the consignor’s memo of  
loss or damage.  
Using Natural Gas ....................................195 cu. ft. per hour  
Using LP Gas ..........................77 cubic ft. (2.2 gal.) per hour  
NOTE:  
LIFTING THE GENERATOR  
Fuel consumption is given at rated maximum con-  
tinuous power output when using natural gas rated  
at 1000 Btu per cubic foot; or LP gas rated 2520  
Btu per cubic foot. Actual fuel consumption  
obtained may vary depending on such variables as  
applied load, ambient temperature, engine condi-  
WARNING: When lifting or hoisting equipment is used,  
be careful not to touch overhead power lines. The  
generators weight of more than 900 pounds requires  
proper tools, equipment, and qualified personnel to be  
used in all phases of handling and unpacking.  
tions and other environmental factors.  
®
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Section 1 — General Information  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
TORQUE SPECIFICATIONS  
Cylinder Head......................................15 (+ 90° + 90°) ft.lb.  
Intake Manifold ..........................................................13 ft.lb.  
Exhaust Manifold ......................................................13 ft.lb.  
Do not use any chromate base rust inhibitor with eth-  
ylene glycol base anti-freeze or chromiumhydroxide  
(“green slime”) forms and will cause overheating.  
Engines that have been operated with a chromate base  
rust inhibitor must be chemically cleaned before  
adding ethylene glycol base anti-freeze. Using any  
high silicate anti-freeze boosters or additives will also  
cause overheating. We also recommend that you DO  
NOT use any soluable oil inhibitor for this equipment.  
ENGINE OIL RECOMMENDATIONS  
The unit has been filled with 15W-40 engine oil at the  
factory. Use a high-quality detergent oil classified “For  
Service CC, SD, SE, SF.” Detergent oils keep the engine  
cleaner and reduce carbon deposits. Use oil having the  
following SAE viscosity rating, based on the ambient  
temperature range anticipated before the next oil  
change:  
BEFORE INSTALLATION  
Before installing this equipment, check the ratings of  
both the generator and the transfer switch. Read  
“Emergency Isolation Method” and “Total Circuit  
Isolation Method” in the installation manual (Part No.  
079699).  
Temperature  
Above 80° F (27° C)  
32° to 80° F (-1° to 27° C)  
Below 32° F (0° C)  
Oil Grade (Recommended)  
SAE 30W or 15W-40  
SAE 20W-20 or 15W-40  
SAE 10W or 15W-40  
CAUTION: Any attempt to crank or start the  
engine before it has been properly serviced with  
the recommended oil may result in an engine  
failure.  
The generator’s rated wattage/amperage capacity must  
be adequate to handle all electrical loads that the unit  
will power. You may have to group the critical (essential)  
loads together and wire them into a separate “emer-  
gency” distribution panel.  
COOLANT RECOMMENDATIONS  
This generator can be installed in conjunction with a  
standard Generac “GTS” type transfer switch, if  
desired.  
Use a mixture of half low silicate, ethylene glycol base  
anti-freeze and half soft water. Cooling system capacity  
is about 8 U.S. quarts (8.5 liters). Use only soft water  
and only low silicate anti-freeze. If desired, add a high  
quality rust inhibitor to the recommended coolant mix-  
ture. When adding coolant, always add the recom-  
mended 50-50 mixture.  
The standard transfer switch has no sensing or con-  
trolling circuit boards. Instead, the generator control  
console houses a “Control Module Assembly”, which  
controls all phases of operation, including engine start  
up and load transfer.  
®
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Section 2 — Installation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
STANDBY GENERATOR INSTALLATION  
Connecting this generator to an electrical system normally supplied by an electric utility shall be by  
means of a transfer switch (such as the Generac “GTS” type transfer switch), so as to isolate the electric  
system from the utility distribution system when the generator is operating. Failure to isolate the  
electric system by these means will result in damage to the generator and may also result in injury  
or death to utility workers due to backfeed of electrical energy.  
• Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85 John  
Street, New York, N.Y. 10038.  
If an open bottom is used, the engine-generator is  
• AGRICULTURAL WIRING HANDBOOK, obtainable  
to be installed over non-combustible materials  
from the Food and Energy Council, 909 University  
and should be located such that combustible  
Avenue, Columbia, MO, 65201.  
materials are not capable of accumulating under  
• ASAE EP-364.2, INSTALLATION AND MAINTE-  
NANCE OF FARM STANDBY ELECTRIC POWER,  
available from the American Society of Agricultural  
Engineers, 2950 Niles Road, St. Joseph, MI 49085.  
• A52.1, AMERICAN NATIONAL STANDARD FOR  
CHIMNEYS, FIREPLACES AND VENTING SYS-  
TEMS, available from the American National  
Standard Institute, 1430 Broadway, New York, N.Y.  
10018.  
the generator set.  
Only qualified, competent installation contractors or  
electricians thoroughly familiar with applicable codes,  
standards and regulations should install this standby  
electric power system. The installation must comply  
strictly with all codes, standards and regulations per-  
taining to the installation.  
BASIC STANDBY ELECTRIC SYSTEM  
Figure 2.1 shows a schematic diagram of a basic stand-  
by electric system. Both the UTILITY power supply and  
the STANDBY (generator) output are connected to an  
approved transfer switch. The transfer switch is  
required by electrical code and serves the following  
functions:  
After the system has been installed, you must not do  
anything that might render the installation in noncom-  
pliance with such codes, standards and regulations.  
NOTE:  
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.  
• Permits the LOAD circuits to be connected to only one  
power supply at a time.  
• Prevents electrical backfeed between the generator  
NFPA STANDARDS  
N
and the UTILITY power circuits.  
The following published standards booklets pertaining  
to standby electric systems are available form the  
National Fire Protection Association (NFPA),  
Batterymarch Park, Quincy, MA 02269:  
Notice that both the STANDBY and the UTILITY power  
supplies to the transfer switch are protected against  
overload by a main line circuit breaker.  
NOTE:  
• NFPA No. 37, STATIONARY COMBUSTION ENGINES  
AND GAS TURBINES.  
Generac recommends the use of a Generac power  
systems “GTS” type transfer switch in conjunction  
with this generator.  
• NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS  
FOR HEALTH CARE FACILITIES.  
Figure 2.1 – Basic Standby Electric System  
• NFPA No. 220, STANDARD TYPES OF BUILDING  
CONSTRUCTION  
• NFPA No. 68, GUIDE FOR EXPLOSION VENTING  
• NFPA No. 70, NATIONAL ELECTRICAL CODE.  
• NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE.  
• NFPA No. 10, INSTALLATION, MAINTENANCE AND  
USE OF PORTABLE FIRE EXTINGUISHERS.  
OTHER PUBLISHED STANDARDS  
N
In addition to NFPA standards, the following informa-  
tion pertaining to the installation and use of standby  
electric systems is available:  
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Section 2 — Installation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Figure 2.2 – Generator Grounding Lug (typical)  
EMERGENCY CIRCUIT  
ISOLATION METHOD  
This prevents overloading the generator by keeping elec-  
trical loads below the wattage/amperage capacity of the  
generator. If the generator is powering only critical  
loads, within the wattage/amperage capacity, during util-  
ity power outages, you might consider using the emer-  
gency circuit isolation method.  
Critical electrical loads are grouped together and wired  
into a separate “Emergency Distribution Panel.” Load  
circuits powered by that panel are within the  
wattage/amperage capacity of the generator set. When  
this method is used, it is difficult to overload the gener-  
ator. The transfer switch must meet the following  
requirements:  
GENERATOR AC  
• It must have an ampere rating equal to the total  
amperage rating of the emergency distribution panel  
circuit.  
NEUTRAL CONNECTIONS  
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 generator field. The actu-  
al result depends on the electrical characteristics of the  
particular installed generator.  
• Have it installed between the building’s main distribu-  
tion panel and the emergency distribution panel.  
TOTAL CIRCUIT ISOLATION METHOD  
When a generator capable of powering all electrical  
loads in the circuit is to be installed, you may use the  
“Total Circuit Isolation Method.” It is possible for the  
generator to be overloaded when this isolation method  
is employed. The following apply to the transfer switch  
in this type of system.  
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.  
• Ampere rating of the transfer switch must equal the  
ampere rating of the normal incoming utility service.  
• The transfer switch is installed between the utility  
service entrance and the building distribution panel.  
Connect the two-wire start signal from the automatic  
transfer switch to the automatic start connection, which is  
located in the right hand corner inside the control panel.  
Match wires 178 and 183 in the transfer switch to 178  
and 183 on the terminal strip in the control panel. The  
GROUNDING THE GENERATOR  
The National Electrical Code requires the frame and  
external electrically conductive parts of this equipment  
to be properly connected to an approved earth ground  
and/or grounding rods. For that purpose, a GROUND conductors for the two-wire start circuit must be in their  
LUG (Figure 2.2) is provided on the generator mounting  
base. Consult a qualified electrician for grounding  
requirements in your area. Grounding procedures must  
meet local regulations.  
own conduit.  
BATTERY INSTALLATION  
Standby generators installed with automatic trans-  
fer switches will crank and start automatically  
when normal (utility) source voltage is removed or  
is below an acceptable preset level. To prevent  
such automatic start-up and possible injury to per-  
sonnel, do not connect battery cables until you are  
certain that normal source voltage at the transfer  
switch is correct and you are ready to place the  
system into operation.  
Do not connect the ground wire to any pipe that  
carries a flammable or explosive substance – FIRE  
or an EXPLOSION may result.  
Proper grounding helps protect personnel against electri-  
cal shock in the event of a ground fault condition in the  
generator or in connected electrical devices. In addition,  
grounding helps dissipate static electricity that often  
builds up in ungrounded devices.  
Storage batteries give off explosive hydrogen gas.  
This gas can form an explosive mixture around  
the battery for several hours after charging. The  
slightest spark can ignite the gas and cause  
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Section 2 — Installation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Servicing of batteries is to be performed or supervised  
an explosion. Such an explosion can shatter the bat-  
tery and cause blindness or other injury. Any area that  
houses a storage battery must be properly ventilated.  
Do not allow smoking, open flame, sparks or any spark  
producing tools or equipment near the battery.  
by personnel knowledgeable of batteries and the  
required precautions. Keep unauthorized personnel  
away from batteries.  
For recommended batteries, see “Specifications.” All  
batteries must be at 100 percent state-of-charge before  
they are installed on the generator.  
Battery electrolyte fluid is an extremely caustic  
sulfuric 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 you spill the fluid, flush the affected  
area immediately with clear water.  
When using maintenance-free batteries, it is not neces-  
sary to check the specific gravity or electrolyte level.  
Have these procedures performed at the intervals spec-  
ified in Section 4, “Maintenance.” A negative ground sys-  
tem is used. Battery connections are shown on the  
wiring diagrams. Make sure all batteries are correctly  
connected and terminals are tight. Observe battery  
polarity when connecting batteries to the generator set.  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
Note:  
Do not open or mutilate the battery. Released  
electrolyte can be toxic and harmful to the skin  
and eyes.  
Damage will result if the battery connections are  
made in reverse.  
The battery represents a risk of high short circuit  
current. When working on the battery, always  
remove watches, rings or other metal objects, and  
only use tools that have insulated handles.  
PREPARATION BEFORE START-UP  
The instructions in this section assume that the standby  
generator has been properly installed, serviced, tested,  
adjusted and otherwise prepared for use by a competent,  
qualified installation contractor. Be sure to read the  
“Safety Rules” on Pages 2 and 3, as well as all other safe-  
ty information in this manual, before attempting to  
operate this (and related) equipment.  
VENTED BATTERIES  
N
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically con-  
ductive and corrosive. The following procedures  
are to be observed:  
PRIOR TO INITIAL START-UP  
• Wear full eye protection and protective clothing,  
• Where electrolyte contacts the skin, wash it off  
immediately with water,  
• Where electrolyte contacts the eyes, flush thoroughly  
and immediately with water and seek medical atten-  
tion, and  
Prior to initially starting the generator, it must be  
properly prepared for use. Any attempt to crank  
or start the engine before it has been properly  
serviced with the recommended types and quanti-  
ties of engine fluids (oil, coolant, fuel, etc.) may  
result in an engine failure.  
• Spilled electrolyte is to be washed down with an acid-  
neutralizing agent. A common practice is to use a  
solution of one pound (500 grams) bicarbonate 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.  
Before starting the generator for the first time, the  
installer must complete the following procedures. For  
follow-up maintenance information and/or service inter-  
vals, please refer to Section 4, “Maintenance.”  
Transfer Switch  
If this generator is used to supply power to any electri-  
cal system normally powered by an electric utility, the  
National Electrical Code requires that a transfer switch  
be installed. The transfer switch prevents electrical  
backfeed between two different electrical systems.  
(For additional information, see the applicable transfer  
switch manual for this unit.) The transfer switch, as  
well as the generator and other standby components,  
must be properly located and mounted in strict compli-  
ance with applicable codes, standards and regulations.  
Lead acid batteries present a risk of fire because  
they generate hydrogen gas. The following proce-  
dure are to be followed:  
• DO NOT SMOKE when near batteries,  
• DO NOT cause flame or spark in battery area, and  
• Discharge static electricity from body before touching  
batteries by first touching a grounded metal surface.  
®
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Section 3 — Installation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
• When utility source voltage drops below a pre-set  
Fuel System  
level, transfer switch action closes the circuit. The  
engine then cranks and starts as controlled by the  
pre-packaged generator’s Control Module circuit  
board.  
Make sure the fuel supply system to the generator (a)  
delivers the correct fuel at the correct pressure and (b)  
is properly purged and leak tested according to code.  
No fuel leakage is permitted. See “Specifications” (Page  
7) for more information.  
• After the engine starts and when the generator AC  
output voltage and frequency have reached a pre-set  
value, transfer switch circuits signal the transfer  
switch main contacts to actuate to the “Standby”  
power source side. Generator AC output then powers  
load circuits.  
• When the utility power source voltage is restored  
above a pre-set level, transfer switch solid state cir-  
cuits signal the switch main contacts to move back to  
their utility power source side.  
Generator Set Lubrication  
Check the engine crankcase oil level before operating  
and add oil to the proper level – the dipstick “FULL”  
mark. Never operate the engine with the oil level below  
the dipstick “ADD” mark. See “Specifications” (Page 7)  
and “Engine Oil Recommendations” (Page 8).  
NOTE:  
• Following re-transfer back to the utility power source  
side, transfer switch circuit board action opens the  
circuit. Engine then shuts down.  
This engine is shipped from the manufacturer with  
15W-40 oil. This oil should be changed after 30  
hours of operation.  
NOTE:  
Engine Coolant  
If your generator is installed in conjunction with a  
standard GTS type transfer switch, refer to the  
applicable transfer switch manual for exact oper-  
ating parameters and timing sequences.  
Have the engine cooling system properly filled with the  
recommended coolant mixture. Check the system for  
leaks and other problems. See “Specifications” (Page 7)  
and “Coolant” (Page 8).  
CONTROL CONSOLE COMPONENTS  
The components of a water-cooled generator control  
console (Figure 8) are as follows:  
Belt Tension  
Check the engine fan belt tension and condition prior to  
placing the unit into service and at recommended  
intervals. Belt tension is correct when a force of approx-  
imately 22 pounds (10 kg), applied midway between  
pulleys, deflects the belt about 3/8- to 5/8-inch  
(10 to 16 mm).  
Figure 8 - Water-Cooled Generator Panel  
Electrical System  
Make sure the generator is properly connected to an  
approved earth ground and/or ground rod.  
Make sure the generator battery is fully charged, proper-  
ly 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.  
USING A STANDARD “GTS” TRANSFER  
SWITCH  
AC VOLTMETER:  
When required, the pre-packaged standby generator  
can be installed with a standard Generac “GTS” type  
automatic transfer switch.  
The voltmeter displays generator AC output voltage dur-  
ing operation. Voltage is regulated by a solid state volt-  
age regulator and is proportional to AC frequency. Refer  
to your unit’s DATA PLATE for rated AC voltage.  
When you use a standard GTS type transfer switch, it  
controls automatic operation and automatic transfer as  
follows:  
• Solid state circuits in the transfer switch monitor util-  
ity power source voltage.  
®
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Section 3 - Operation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
AC AMMETER:  
FAULT INDICATOR LAMP:  
Indicated current draw of connected electrical loads Lamp goes ON when one or more of the following  
during operation. DO NOT EXCEED YOUR UNIT’S engine faults occurs and when engine shuts down.  
RATED MAXIMUM CONTINUOUS CURRENT. Refer to  
• Low oil pressure  
• High coolant temperature  
• Low coolant level  
• Overcrank  
• Overspeed  
the unit DATA PLATE.  
AC FREQUENCY METER:  
30 AMP FUSE:  
Indicates generator AC output frequency in “Hertz”  
(cycles per second). Frequency is proportional to engine  
speed. Units with a 4-pole rotor supplies 60 Hertz at  
1800 rpm. Units with a 2-pole rotor supplies 60 Hz at  
3600 rpm. Frequency reading with no electrical loads  
connected (no-load condition) should be between 59-61  
Hertz.  
Fuse protects the control console’s DC control circuit  
against electrical overload. If the fuse has melted open  
because of an overload, engine cranking and startup  
cannot occur. Should you need to replace the fuse, use  
only an identical 30-amp replacement fuse. (Type AGC)  
7.5 AMP INLINE FUSE:  
DC VOLTMETER:  
A 7.5 Amp inline fuse has been added to the wire har-  
ness of all units starting in the second half of 2001. This  
inline fuse is connected in the 15A line that runs  
between the Auto/Off/Manual switch and position 10 of  
the 76009A PCB. This fuse protects the start, fuel, field  
boost, and transfer outputs from the PCB and will open  
if there is excessive current draw on any one of these  
outputs.  
The generator is equipped with a belt-driven DC  
alternator, which maintains battery state of charge when  
the engine operates. The Control Module Assembly also  
incorporates a trickle charge circuit which maintains  
battery state of charge during non-operating periods.  
Battery voltage should read about 12.5 to 14.5 volts DC.  
A
low battery voltage indicates the battery is  
discharging.  
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, carefully check the wiring to the start, fuel,  
field boost and transfer outputs before replacing  
the fuse.  
HOURMETER:  
Indicates time the engine-generator has operated, in  
hours and tenths of hours. Use the hourmeter along  
with the periodic maintenance schedule for your gener-  
ator set.  
AUTO/OFF/MANUAL SWITCH:  
Use this 3-position switch as follows:  
METER READING SELECTOR SWITCH:  
Switch permits you to select either line-to-line or  
line-to-neutral voltage and amperage readings on the  
console AC voltmeter and AC ammeter.  
• Set the switch to “Auto” for fully automatic operation.  
See “Automatic Operation”.  
• Set switch to “Manual” position to crank and start the  
generator engine.  
SET EXERCISE TIME SWITCH:  
Switch allows you to program the generator to start and  
exercise automatically. “See Weekly Exercise Cycle.”  
• Set switch to “Off” position to shut down an operat-  
ing engine. With “Off” selected, operation will not be  
possible.  
DANGER! With switch set to "auto", engine can  
crank and start suddenly without warning. Such  
automatic start up normally occurs when utility  
source voltage drops below a pre-set level. To  
prevent possible injury that might be caused by  
such sudden starts, set AUTO/OFF/MANUAL  
switch to "off" before working on or around the  
unit. Then, place a "do not operate" tag on con-  
trol console.  
MANUAL TRANSFER AND START UP  
To transfer electrical loads to the “Standby” (generator)  
power source side and start the engine manually, refer  
to the Owner’s Manual of your particular transfer  
switch.  
®
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Section 3 — Operation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
• Set the generator main circuit breaker to its ON or  
RETRANSFER AND SHUTDOWN  
CLOSED position.  
When utility power source voltage has been restored,  
electrical loads may be transferred back to that source  
and the generator can be shut down as follows:  
• Generator is now programmed to start and exercise  
every 7 days thereafter, on day and time of day the  
switch was actuated.  
• Place a sign on the generator control panel and the  
transfer switch, indicating the day and time the  
generator will be exercising.  
• Verify that utility power supply voltage to the transfer  
switch has been positively turned “Off,” using what-  
ever means provided (such as utility main line circuit  
breaker).  
NOTE:  
• Set the generator’s main circuit breaker to its “Off” or  
If battery terminals are disconnected or control  
panel fuse is removed, the exercise timer needs to  
be reset for correct automatic exercise operation.  
“Open” position.  
• Let the generator engine run at no-load for a few min-  
utes, to stabilize internal unit temperatures.  
• On the generator console, set the Auto-Off-Manual  
switch to “Off”. Wait for engine to come to a com-  
plete stop.  
Figure 9 - “Set Exercise” Switch  
• For transfer to utility position, refer to the Owner’s  
Manual of your particular transfer switch.  
• Turn on the utility power supply to the transfer  
switch, using whatever means provided (such as a  
utility main line circuit breaker). The utility power  
source now powers the loads.  
AUTOMATIC OPERATION  
To set the system for fully automatic operation, proceed  
as follows:  
• Check that load circuits are connected to the ENGINE HEATER  
utility power supply.  
Your Generac standby generator comes equipped with a  
block heater (Figure 10), similar to the block heaters  
used in automotive applications.  
• Set the Auto/Off/Manual switch to its “Auto” position.  
• Set the generator main circuit breaker to its “On” or  
“Closed” position.  
Figure 10 - Engine Block Heater  
WEEKLY EXERCISE CYCLE  
The generator will start and exercise once every 7 days.  
During this weekly exercise, the unit runs for about 20  
minutes and shuts down. Transfer of loads to genera-  
tor output does not occur during the exercise.  
To select day and time for exercising, proceed as  
follows:  
• 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 identi-  
fied with the words “Set Exercise Time” (Figure 9).  
• Push “Set Exercise Time” switch to ON position for  
20 to 30 seconds and then release. Switch will spring  
back into its original position when released.  
• Wait 30 seconds before setting the Auto/Off/Manual  
switch to “AUTO” position.  
Refer to applicable wiring diagram(s) and electrical schematic(s) at  
back of manual for wiring connections. Customer supplies a 120V  
15A Utility fed circuit for the block heater.  
CAUTION: If you switch the Auto/Off/Manual  
switch too soon, the engine may start. If engine  
does start, it will shut down automatically in  
about two (2) minutes.  
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Section 4 — Maintenance  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
MAINTENANCE PERFORMED BY  
AUTHORIZED SERVICE FACILITIES  
CHECKING FLUID LEVELS  
CHECK ENGINE OIL  
A. EVERY THREE MONTHS  
Check engine crankcase oil level (Figure 11) at least  
every 20 hours of operation, or prior to use.  
1.Check battery state of charge and condition.  
2.Inspect and test fuel system.  
3.Check transfer switch.  
• Remove oil dipstick and wipe dry with a clean,  
lint-free cloth.  
• Install oil dipstick, then remove again.  
4.Inspect exhaust system.  
• Oil should be between 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 page 6 for recommended oils.  
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 coolant temperature).  
Figure 11 - Oil Dipstick and Oil Fill Cap  
c
C. ONCE ANNUALLY  
1.Test engine governor; adjust or repair, if needed.  
2.Clean, inspect generator.  
3.Flush cooling system.  
OIL FILL CAP  
OIL DIPSTICK  
D. FIRST 100 OPERATING HOURS  
1.Change engine oil and oil filter. (After initial change,  
service engine oil and filter at 150 operating hours  
or 6 months, whichever comes first.)  
2.Retorque cylinder head. (See Torque Specs, page 7.)  
3.Retorque intake and exhaust manifold. (See Torque  
Specs, page 7.)  
ap  
E. EVERY 500 OPERATING HOURS  
1.Service air cleaner.  
2.Check starter.  
BATTERY FLUID  
Check battery electrolyte fluid at least once weekly.  
Fluid should cover separators in all battery cells. If  
fluid level is low, add distilled water to cover tops of sep-  
arators. DO NOT USE TAP WATER IN BATTERY.  
3.Check engine DC alternator.  
F. EVERY 800 OPERATING HOURS  
1.Retorque cylinder head. (See Torque Specs, page 7.)  
2.Retorque intake and exhaust manifold. (See Torque  
Specs, page 7.)  
ENGINE COOLANT  
Check coolant level in coolant recovery bottle. See  
Specifications, page 8  
3.Check engine compression.  
4.Check valve clearance.  
• Add recommended coolant mixture as necessary.  
• Periodically remove radiator pressure cap to make  
sure the coolant recovery system is functioning  
properly. Coolant should be at bottom of radiator  
filler neck. 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 Facility. Inspect cooling system and  
coolant recovery system for leaks.  
OVERLOAD PROTECTION FOR ENGINE DC  
ELECTRICAL SYSTEM  
Engine cranking, start up and running are controlled by  
a solid state Engine Controller circuit board. Battery  
voltage is delivered to that circuit board via a 30 amp  
fuse. These overcurrent protection devices will open if  
the circuit is overloaded.  
CAUTION! If a circuit breaker opens or a fuse  
element melts, you should find the cause of the  
overload before resetting the circuit breaker or  
replacing the fuse.  
®
Generac Power Systems, Inc. 15  
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Section 4 — Maintenance  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
DANGER: Do not attempt to adjust the gover-  
MAINTENANCE OWNER/OPERATOR CAN  
PERFORM  
nor. Only qualified service facilities should  
adjust the governor. Excessively high operating  
speeds are dangerous and increase the risk of  
personal injury. Low speeds impose a heavy  
load on the engine when adequate engine  
power is not available and may shorten engine  
life. Correct rated frequency and voltage are  
supplied only at the proper governed speed.  
Some connected electrical load devices may be  
damaged by incorrect frequency and/or voltage.  
Only qualified service technicians should adjust  
the governed speed.  
CHECK ENGINE OIL LEVEL  
Refer to “Checking Fluid Levels” on page 15.  
CHECK BATTERY  
• Check battery fluid level each week as outlined under  
“Check Fluid Levels”.  
• Check battery cables for condition, tightness, corro-  
sion or damage.  
necessary.  
Clean, tighten or replace as  
CHANGING ENGINE OIL  
Refer to maintenance performed by authorized service  
facilities for engine oil and filter change frequencies.  
EXERCISE SYSTEM  
Start the generator engine at least once every seven days  
and let it run at least 20 minutes. See page 14, “Weekly  
Exercise Cycle”.  
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:  
INSPECT COOLING SYSTEM  
• Inspect engine cooling system at least once each  
month.  
1.Remove OIL DRAIN HOSE from its retaining clip.  
2.Loosen and remove OIL DRAIN HOSE CAP. Drain  
oil completely into suitable container.  
• Check hoses for damage, deterioration, leaks, etc.  
3.When all oil has drained, install and tighten OIL  
DRAIN HOSE CAP, and re-install into its retaining  
clip.  
4.Turn OIL FILTER (Figure 12) counterclockwise and  
remove. Dispose of old filter.  
Correct any discrepancies found.  
• Check hose clamps for tightness.  
CHECK ENGINE COOLANT LEVEL  
See “Checking Fluid Levels” on page 15.  
Figure 12 - Oil Filter  
PERFORM VISUAL INSPECTION  
Complete a thorough visual inspection of the entire  
engine-generator monthly. Look for obvious damage,  
loose, missing or corroded nuts, bolts and other fasten-  
ers. Look for fuel, oil or coolant leaks.  
INSPECT EXHAUST SYSTEM  
Inspect the exhaust system at least once every three  
months. Check all exhaust system pipes, mufflers,  
clamps, etc. for condition, tightness, leaks, security,  
damage.  
OIL FILTER  
CHECK FAN BELT  
• Inspect fan belts every three months. Replace any  
damaged, deteriorated, worn or otherwise defective  
belt.  
• Check fan belt tension. Thumb pressure, exerted  
midway between pulleys, should deflect about 3/8 to  
3/4 inch. Adjust belt tension as required.  
5.Apply light coating of new engine oil to seal of new  
oil filter. Install FILTER and tighten by hand only.  
DO NOT OVERTIGHTEN.  
INSPECT ENGINE GOVERNOR  
Visually inspect electronic governor.  
®
16 Generac Power Systems, Inc.  
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Section 4 — Maintenance  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
6.Remove OIL FILL CAP (Figure 11, page 15). Add • DO NOT use jumper cables and a booster battery to  
recommended oil (see SPECIFICATIONS). DO NOT  
FILL ABOVE THE DIPSTICK “FULL” MARK.  
Crankcase oil capacity is 4.0 U.S. quarts (3.8 liters)  
crank or start the generator engine.  
• DO NOT recharge a weak battery while it is installed  
in the generator. Remove battery from generator and  
recharge in a well-ventilated area, away from fuel  
vapors, sparks, heat or flames.  
• Battery electrolyte fluid is an extremely caustic  
sulfuric solution that can cause severe burns. DO  
NOT permit fluid to contact eyes, skin, clothing,  
painted surfaces, wiring insulation, etc. If you spill  
any battery fluid, flush the affected area with clear  
water immediately.  
CAUTION: After refilling the crankcase with oil,  
always check oil level on dipstick. NEVER  
OPERATE ENGINE WITH OIL BELOW THE DIP-  
STICK “ADD” MARK.  
7.Start engine and check for oil leaks.  
COOLANT CHANGE  
Every year, have Authorized Service Facility drain, flush  
and refill the cooling system. See SPECIFICATIONS  
(page 8) for cooling system recommendations.  
• Always wear safety glasses, rubber apron and gloves  
when handling a battery.  
• Batteries give off explosive hydrogen gas while  
charging. The gas can form an explosive mixture  
around the battery for several hours after charging.  
Any spark, heat or flames can ignite the gas and  
cause an explosion which can shatter the battery,  
causing blindness or other serious injury.  
MISCELLANEOUS MAINTENANCE  
CLEANING THE GENERATOR  
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.  
BATTERY REPLACEMENT  
Generac uses these different types of vented batteries on  
units ranging up to 400 kW. When replacing batteries,  
use the same number and the type of battery that  
follows:  
Periodically clean generator exterior surfaces. A soft  
brush may be used to loosen caked on dirt. You can use  
a vacuum system or dry, low pressure air to remove any  
accumulations of dirt. The generator is housed inside  
an all-weather enclosure, clean the enclosure with a  
soft, damp cloth or sponge and water.  
Generac P/N  
BCI Group No.  
CCA  
700 @ 0 deg. F  
058665  
27F  
Note:  
Once each year have the generator cleaned and inspect-  
ed by an Authorized Service Facility. That facility 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.  
The BCI number should be located directly  
on the battery.  
Finally, have the insulation resistance of stator and  
rotor windings checked. If insulation resistances are  
excessively low, the generator may require drying.  
BATTERY  
All lead-acid storage batteries discharge when not in  
use. Refer to specific instructions and warnings that  
accompany your battery. If such information is not  
available, observe the following precautions when  
handling a battery:  
®
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Section 5 — Troubleshooting  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
PERIODIC REPLACEMENT PARTS  
Part Name  
Generac’s Part Number  
Oil Filter  
# 0A45310244  
# 046627  
Radiator Cap  
Air Cleaner  
Spark Plug  
# 059402  
# 0A45310275  
TROUBLESHOOTING POINTS  
PROBLEM  
CAUSE  
CORRECTION  
Engine won’t crank.  
1. 30 amp fuse blown.  
2. Loose or corroded or defective  
1. Replace fuse.  
2. Tighten, clean or replace  
battery cables as necessary.  
3. Defective starter contactor.  
4. Defective starter motor.  
5. Dead or Defective Battery.  
3. Replace contactor.  
4. Replace starter motor.  
5. Remove, change or replace battery.  
Engine cranks but won't start  
1. Out of fuel.  
2. Fuel solenoid (FS) is defective  
1. Replenish fuel.  
2. Replace solenoid.  
3. Reconnect wire.  
3. Open Wire #14 from Engine Control  
circuit board  
4. Spark plugs defective.  
4. Clean, regap or replace plugs.  
1. Clean or replace as needed.  
Engine starts hard, runs rough.  
Engine starts then shuts down.  
1. Flame arrestor (air cleaner) plugged or  
damaged.  
2. Plugged fuel line.  
3. Defective spark plugs.  
2. Unclog fuel line.  
3. Clean, regap or replace plugs.  
1. Engine oil level is low.  
2. Engine is overheated.  
3. Defective Low Oil Pressure Switch  
4. Defective Coolant Temperature Switch  
5. Defective Control Module circuit board.  
6. Coolant Level is Low.  
1. Check oil and add oil as needed.  
2. Check cooling system for leaks.  
3. Replace switch.  
4. Replace switch.  
5. Replace board.  
6. Repair leak - Add coolant.  
7. Replace Switch.  
7. Defective Low Coolant Level Switch  
Auto/Off/Manual Switch at OFF,  
engine continues to run  
1. Defective Auto/Off/Manual switch  
1. Replace switch.  
2. Reconnect/close wire.  
2. Open/disconnected wire #15A between  
Auto/Off/Manual switch and Control  
Module circuit board.  
3. Defective Control Module circuit board  
3. Replace board.  
No AC output from generator.  
1. Check main line circuit breaker.  
2. Check circuit breaker & fuses.  
3. Transfer switch set to NORMAL position  
4. Generator internal failure.  
1. Reset to ON or CLOSED.  
2. Reset and replace, if necessary.  
3. Set to GENERATOR position.  
4. Contact an Authorized Generac  
facility.  
5. Thermal circuit breaker open.  
5. Auto-reset - Wait 5 min. and  
attempt restart.  
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Section 6 — Scheduled Maintenance  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Following is a recommended maintenance schedule for Generac small standby and residential generator sets from  
8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. 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. Use the unit hour  
meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next  
required maintenance interval.  
Service Maintenance Interval Information:  
The various service maintenance intervals are designated by interval numbers as follows:  
1 An early inspection of the generator set to insure it is ready to operate when required and to identify any poten-  
tial problem areas.  
Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 man-  
hours per unit to complete.  
This inspection may be performed by the end user providing the following safety steps are taken to prevent  
the engine from starting automatically without warning:  
To prevent injury, perform the following steps in the order indicated before starting any maintenance:  
•
Disable the generator set from starting and/or connecting to the load by setting the control panel  
Auto-Off-Manual switch to the “OFF” position.  
Remove the control panel fuse.  
Turn off the battery charger.  
Remove the negative battery cable.  
•
•
•
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition  
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 to operate and carry the load when  
required, and to identify any potential problem areas.  
Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of  
the unit and requires approximately 2.5 man-hours per unit to complete.  
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge  
to accomplish and should be performed only by an authorized Generac Service Dealer.  
3 An operational inspection of the generator set to insure it is ready to operate and carry the load when required,  
and to identify any potential problem areas.  
Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5  
man-hours per unit to complete.  
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge  
to accomplish and should be performed only by an authorized Generac Service Dealer.  
4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and  
to identify any potential problem areas.  
Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0  
man-hours per unit to complete.  
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge  
to accomplish and should be performed only by an authorized Generac Service Dealer.  
®
Generac Power Systems, Inc. 19  
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Section 6 — Scheduled Maintenance  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Maintenance  
Tasks  
Level 1  
Recom-  
mended  
Level 2  
Required  
Level 3  
Required  
Level 4  
Task  
Task  
Task  
Task  
Comp.  
Comp. to be done Comp. to be done Comp.  
Required  
to be done (Date-  
3 months/  
Break-in  
30 hrs.  
(Date-  
Initials)  
Semi-  
annually/ Initials)  
50 hrs.  
(Date-  
to be done (Date-  
Annually/ Initials)  
100 hrs.  
monthly/  
10 hrs.  
Initials)  
1. Disable the unit from  
operating per the first page  
warning.  
2. Check the engine oil level.  
Adjust as necessary.  
3. Check the engine coolant  
level. Adjust as necessary.  
4. Check the engine coolant  
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 diesel fuel  
supply level for diesel  
engine driven units. Fill  
as necessary.  
7. Drain water and sediment  
from the diesel fuel tank on  
diesel engine driven units.  
8. Drain water from the fuel  
line water separator on  
diesel engine driven units  
if the unit is equipped with  
one.  
9. Check the air inlets and  
outlets for debris. Clean as  
necessary.  
10. Check the battery  
electrolyte level if  
accessible. Adjust as  
necessary.  
11. Check the battery posts,  
cables, and charger for  
loose connections,  
corrosion, and proper  
operation. Correct as  
necessary.  
12. Check the unit wiring for  
loose connections,  
corrosion, and damage.  
Correct as necessary.  
13. Check the engine  
accessory drive belts for  
wear, weather cracking,  
and damage. Replace as  
necessary.  
®
20 Generac Power Systems, Inc.  
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Section 6 — Scheduled Maintenance  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Maintenance  
Tasks  
Level 1  
Recom-  
mended  
Level 2  
Required  
Level 3  
Required  
Level 4  
Task  
Task  
Task  
Task  
Comp.  
Comp. to be done Comp. to be done Comp.  
Required  
to be done (Date-  
3 months/  
Break-in  
30 hrs.  
(Date-  
Initials)  
Semi-  
annually/ Initials)  
50 hrs.  
(Date-  
to be done (Date-  
Annually/ Initials)  
100 hrs.  
monthly/  
10 hrs.  
Initials)  
14. Visually inspect the unit  
looking for leaks, wear or  
damage, loose connections  
or components, and  
corrosion. Correct as  
necessary.  
15. Test the engine and  
transfer switch safety  
devices. Correct and/or  
adjust as necessary.  
16. 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. Correct as  
necessary.  
17. 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.  
18. Change the engine oil.  
19. Replace the engine oil  
filter(s).  
20. Replace the engine air  
filter(s).  
21. Replace the engine fuel  
filter(s) on diesel engine  
driven units and re-prime  
the fuel system.  
22. Check the engine spark  
plugs on gas engine driven  
units. Clean and re-gap or  
replace as necessary.  
23. Perform a 5 minute no-load  
operational run of the unit  
looking for any post service  
problems.  
24. Return the unit to standby  
setup for operation when  
required.  
®
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Section 7 - Electrical Data  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Wiring Diagram — Control Panel (1-Phase) —Drawing No. 0A2803-D  
®
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Section 7 - Electrical Data  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Electrical Schematic — Control Panel (1-Phase) — Drawing No. 0A2802-B  
®
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Section 7 - Electrical Data  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Wiring Diagram — Control Panel (3-Phase) — Drawing No. 0A2804-D  
®
24 Generac Power Systems, Inc.  
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Section 7 - Electrical Data  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A2805-C  
®
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Section 7 - Electrical Data  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7176-A  
®
26 Generac Power Systems, Inc.  
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Section 7 - Electrical Data  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Electrical Schematic — 1.5L Gas Engine — Drawing No. 0A7182-A  
®
Generac Power Systems, Inc. 27  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Enclosure — Drawing No. 0C1404-B  
®
28 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Enclosure — Drawing No. 0C1404-A  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
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  
32  
32  
4
4
2
SCREW SWAGE 1/4-20 X 1/2 Z/YC  
WASHER NYLON .250  
HINGE SLIP MALE LH  
HINGE SLIP FEMALE LH  
HINGE SLIP MALE RH  
HINGE SLIP FEMALE RH  
SCREW BHSC M6-1.0 X 16 SS  
SHAKEPROOF INT M6 SS  
PANEL TOP SIDE LH  
PANELTOP SIDE RH  
27  
28  
29  
089961  
022473  
082570  
24ft.  
20  
1
FOAM STRIP 3/4 X 1/4  
WASHER FLAT 1/4 ZINC  
PLUG PLASTIC 4 PLUG BTTN  
#425  
SCREW HHC M8-1.25 X 20 G8.8  
SCREW HHC M6-1.0 X 20 G8.8  
DECAL CAUTION HOT SURFACES  
BRACE REAR DOOR  
NUT HEX JAM 3/8-24 SS  
LATCH REWORK 48.5MM  
LATCH AND CAM  
30  
31  
32  
36  
37  
38  
39  
40  
42  
43*  
44*  
45*  
46*  
47*  
48*  
49*  
039253  
042568  
12  
14  
2
1
4
1
2
4
4
1
2
1
1
1
1
2
2
4
5
6
24  
24  
1
1
2
1
2
1
1
1
1
1
2
1
1
1
1
0D3397  
0D3785  
037337  
0A6807  
057042  
7
8
9
DOOR SIDE  
PANEL FRONT  
067577  
022413  
NUT SPEED 1/4-20  
PANEL SIDE BOTTOM  
PANEL REAR  
CORNER POST REAR LH  
CORNER POST REAR RH  
TOP ENCLOSURE 1.5 SAE  
DOOR REAR  
SCREW HHC 1/4-20 X 1 G5  
INSULATION PANEL TOP  
PANEL SIDE DOOR  
INSULATION PANEL FRONT R.H.  
INSULATION PANEL FRONT L.H.  
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  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
23  
24  
25  
26  
0C1053B  
0C1053A  
0C1053E  
0C1053F  
0C1053G  
0C1053H  
0C1053D  
DUCT  
SUPPORT RADIATOR LH  
SUPPORT RADIATOR RH  
SUPPORT MUFFLER 1.5L  
TOP CONTROL PANEL SAE  
DUCT FRONT 1.5L SAE  
BASE MOUNTING  
WASHER LOCK M6-1/4  
WASHER LOCK M8-5/16  
NUT HEX 1/4-20 STEEL  
WASHER FLAT 5/16 ZINC  
50*  
51*  
52*  
53*  
54  
0C1053J  
0C1053K  
0C1053L  
0C1053M  
078115  
1
1
1
1
14  
2
1
1
16  
12  
4
55  
030486  
12  
* NOTE: THESE PARTS ARE INCLUDED IN KIT 0C1053Z.  
®
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1Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Control Panel — Drawing No. 0C8847-C  
®
30 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Control Panel — Drawing No. 0C8847-C  
ITEM  
PART NO. QTY.  
DESCRIPTION  
ITEM  
PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0C5077  
075589  
0A1775  
0C5078  
0C4224A  
057073  
022985  
081988  
070043  
070055  
070042  
070081  
076037  
022152  
022158  
061945  
032300  
022668  
076020  
083048  
0A2077  
075476  
022264  
0A3968  
039782  
0C2323  
076039  
051756  
048476  
022237  
022097  
022473  
082573  
043116  
056739  
072252  
1
1
1
1
1
1
4
1
1
1
1
1
1
10  
10  
1
1
1
1
1
1
14  
14  
1
1
2
2
3
1
1
8
8
1
4
SUPPORT, CONTROL PANEL L.H.  
BRACKET, VOLTAGE REGULATOR  
CONTRLPANEL-BACK  
SUPPORT CONTROL PANEL R.H.  
SILKSCREEN, PANEL (SAE)  
BLOCK JUNCTION 3/8-16  
WASHER FLAT #6 ZINC  
DECAL EXERCISE INFO  
VOLTMETER AC 0-300  
AMMETER AC 0-100  
FREQUENCY METER 55-65HZ  
HOURMETER  
VOLTMETER DC 8-18V  
WASHER, LOCK #10  
NUT, HEX #10-32 STEEL  
SWITCH 6A AMP/V SELECTOR  
HOLDER, FUSE  
FUSE 30A X AGC30 HLDR22669 HKP  
SWITCH DPDT 15/10 SP ON-OFF-ON  
ASY POTTED REG WOFIN  
CIRCT BRK 125X2 120/240V  
SCREW, PPHM-M4-0.7 x 16MM  
WASHER, LOCK-M4  
CAPACITOR, FILTER ASSY.  
BRACKET CIRCT BRK MOUNTING  
SCREW TAPTITE PH 6-32X5/8 ZYC  
SCREW PPHM M5-0.8 X 40  
SCREW HHC M10-1.5 X 20 G8.8  
CIRCT BRK 4.5X1 AUT30KW CNT45K  
WASHER LOCK 3/8  
WASHER LOCK M6-1/4  
WASHER FLAT 1/4 ZINC  
SWITCH DPST 5 125V SPD RCKR  
SCREW HHC M6-1.0 X 12 G8.8  
RELAY SOLENOID 12VDC PNL MNT  
GROMMET 1.37 X .06 X 1.00  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
48  
49  
50  
51  
52  
53  
54*  
55  
56  
57  
58  
59*  
60*  
61  
62  
63  
64  
65  
66  
67  
68**  
69**  
063212  
058318  
033121  
049226  
023897  
075595  
049811  
072355  
055440  
022241  
022155  
098647  
057335  
021480  
048766  
058589  
070882  
0A7215  
076040  
049813  
061979  
0A2833  
0A6821  
064009  
064009  
0A1354A  
0C2212  
0C3826  
0C4427  
0C8817  
0D5324  
0A9611  
1
2
2
4
10  
1
8
2
1
1
2
1
1
1
1
1
1
10  
2
8
1
1
1
1
1
1
6
2
8
1
1
GROMMET 1.75 X .12 X 1.50  
TRANSFRM 150A TO 5A 5VA  
SCREW HHM 10-32 X 1/2  
WASHER LOCK M5  
WASHER FLAT #10 ZINC  
ASSM.,CMA BOX  
WASHER FLAT M6  
HHCS M6-1X12-A/C-.HD  
SCREW HHC M5-0.8 X 25 G8.8  
NUT HEX 3/8-16 STEEL  
WASHER LOCK #6  
ASSY L.C. ELECT GOV  
BLOCK TERM 20A 20 X 6 X 1100V  
DECAL TERMINAL STRIP  
BLOCK TERM 20A 2 X 6 X 1100V  
DECAL WARN ENG START  
ASSY SUPPRESSION  
SCREW SW 1/4-20X5/8 N WA JS500  
SCREW PPHM M5-0.8 X 16  
NUT HEX M6-1.0 G8 YEL CHR  
BUS BAR  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
HARNESS PNL "PP" 1P  
HARNESS WIRING (1.5L)  
LIGHT 12VDC .02A LED RED PILOT  
DECAL, TRANS. SWITCH CONN.  
REGULATOR - DC ALT  
SCREW TAPTITE PH M4-0.7X16 ZYC  
HINGE, CONTROL PANEL  
M6X1.0X12 T.H.M.S SS  
TOP, CONTROL PANEL (SAE)  
FUSE & HOLDER LITTLE 7.5A  
FUSE 7.5AXBK/AGC7.5NX  
REF  
* NOT SHOWN ON THIS ASSEMBLY  
** PART OF CONTROL PANEL WIRE HARNESS  
1
2
®
Generac Power Systems, Inc. 31  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Radiator — Drawing No. 0C1406-B  
®
32 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Radiator — Drawing No. 0C1406-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
0A4822  
0A5734  
0A6237  
0A6238  
084918  
050967  
057823  
099502  
083709  
042568  
022097  
049813  
022473  
084427  
050967  
075443  
056892  
0A6284  
0A6258  
029032  
031669  
060035  
022127  
022145  
022129  
045771  
042907  
076749  
080712  
0A7215  
030486  
0A2111  
065852  
0C1067A  
0C1067  
0C1480  
1
1
1
1
1
12"  
4
4
2
6
15  
2
11  
1
18"  
6
4
1
1
1
4
PANEL FRONT  
RADIATOR 1.5L  
VENTURI 1.5L  
GUARD FAN  
HEATER 500W 1020  
HOSE RES 5/8 RIA 250F  
CLAMP HOSE #10 .56 - 1.06  
CLAMP HOSE #24 1.06 - 2.00  
CLAMP WIRE HOSE .573 - .551  
SCREW HHC M6-1.0 X 20 G8.8  
WASHER LOCK M6-1/4  
NUT HEX M6 -1.0 G8 YEL CHR  
WASHER FLAT M6-1/4 ZINC  
BRACKET HEATER  
HOSE RES 5/8 RIA 250F  
CRMPTIT 1/4-20 X 5/8  
CRMPTIT 10-24 X 3/8  
HOSE LOWER RADIATOR  
HOSE UPPER RADIATOR  
HOSE 9/32 ID  
BOLT CARR 1/4-20 X 1-3/4 JS500  
SPACER .41 X .75 X .87 ST/ZNC  
NUT HEX 1/4-20 STEEL  
WASHER FLAT 5/16 ZINC  
WASHER LOCK M8-5/16  
NUT HEX M8-1.25 G8 YEL CHR  
SCREW HHC M8-1.25 X 16 G8.8  
TANK COOLANT RECOVERY  
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  
9
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
4
5
12  
12  
12  
12  
1
1
1
2
2
2
1
1
1
®
Generac Power Systems, Inc. 33  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Radiator — Drawing No. 0C1405-A  
ITEM  
PART NO. QTY.  
DESCRIPTION  
1
3
4
5
6
7
8
9
10  
12  
13  
14  
15  
0A9955  
070936  
070936C  
039253  
022145  
022129  
045771  
071956  
051730  
057821  
021991  
027482  
0A2308  
1
2
2
BASE MOUNTING  
DAMPENER VIBRATION  
DAMPENER VIBRATION  
SCREW HHC M8-1.25 X 20 G8.8  
WASHER FLAT 5/16 ZINC  
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  
8
12  
12  
12  
4
2
2
1
2
1
WASHER SHAKEPROOF EXT 5/16 STL  
PLUG BUTTON 2" DIA  
®
34 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Muffler — Drawing No. 0C1408-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
0A4355  
0C1636  
036434  
036449  
0C1330  
0C1318  
0C1068  
0C1412  
0A5728  
060366  
066889  
022145  
022129  
045771  
0A8974  
1
1
4
4
1
1
1
1
1
2
4
4
4
4
1
MANIFOLD EXHAUST 1.5L  
NIPPLE TOE 1.5 NPT X 6.5 BL IRON  
BOLT U 5/16-18 X 2.09  
SADDLE 2 INCH  
PIPE EXHAUST  
FLEX PIPE EXHAUST  
SUPPORT MUFFLER 1.5L  
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"  
4
5
6
7
8
9
10  
11  
12  
13  
14  
®
Generac Power Systems, Inc. 35  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Circuit Breaker — Drawing No. 0A3371-B  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
0A2103  
0A2104  
0A2105  
0A2106  
0A2052  
033130  
022264  
039783  
080522  
047585  
057906  
056783  
049942  
040533  
049135  
062812  
053691  
040532  
039782  
076640  
057903  
057472  
077906  
043240  
1
1
1
1
1
-
SILKSCREEN "A" PANEL  
SILKSCREEN "B" PANEL  
SILKSCREEN "C" PANEL  
SILKSCREEN "P" PANEL  
COVER BQ CIRCUIT BREAKER  
SCREW HHM #8-32 X 1/4  
WASHER LOCK M4  
BRACKET MOUNTING CIRCT BRK  
CIRCT BRK 20 X 3 INACTIVE  
CIRCT BRK 30 X 3 240V MT PL  
CIRCT BRK 35 X 3 240V  
CIRCT BRK 40X3 240V  
CIRCT BRK 50X3 W/MOUNT PL ITE  
CIRCT BRK 60X3 240V  
CIRCT BRK 70 X 3 240V  
CIR BKR 80-A 3P BQ3  
CIRCT BRK 90 X 3 ITE BQ3-B090  
CIRCT BRK 100X3 240V 39783 BR  
BRACKET MOUNTING CIRCT BRK  
CIRCT BRK 20 X 2 ITE BQ2-B020  
CIRCT BRK 25 X 2 240V ITE  
CIRCT BRK 30 X 2 240V ITE  
CIRCT BRK 35X2 W/39782 BRACKET  
CIRCT BRK 40X2 240V  
057905  
039765  
048373  
063452  
039766  
048374  
0A2077  
056967  
053640  
038150  
022471  
0A2670  
0A2820  
0A2821  
0A2822  
0A2828  
1
1
1
1
1
1
1
3
4
4
4
1
1
1
1
1
CIRCT BRK 45X2 240V  
CIRCT BRK 50X2 240V 39782 BRKT  
CIRCT BRK 70X2 240V  
CIRCT BRK 80X2 240V  
CIRCT BRK 90X2 240V  
CIRCT BRK 100X2 240V  
CIRCT BRK 125X2 120/240V  
PLUG PLASTIC .375  
SCREW RHM #8-32 X 3-1/4  
WASHER FLAT #8 ZINC  
NUT HEX #8-32 STEEL  
COVER,CIR.BRKR. 480V  
MCB 16A 3P 480V B-TR  
MCB 25A 3P 480V B-TR  
MCB 32A 3P 480V B-TR  
MCB 40A 3P 480V B-TR  
2*  
3
4
5
6
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
9
10  
11  
12  
13**  
14  
7
8
* USE WITH ITEM 14 ONLY  
** USE WITH ITEM 8 ONLY  
®
36 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – CMA Assembly — Drawing No. 081086-D  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
074100  
1
1
ASSY HOME STDBY LOGIC  
(MODELS 921, 863, 865)  
PP LOGIC ASM 50/60HZ  
(MODEL 9428)  
NUT SPACER .250 PCB  
SCREW PPH TAPPING #6X5/8 SS  
DECAL TERMINAL STRIP  
BLOCK TERM 20A 7 X 6 X 1100V  
SCREW PPHM M4-0.7 X 16  
TRANSFORMER ASM CMA 240/12V  
WASHER FLAT #6 ZINC  
WASHER LOCK M4  
SCREW HHC M4-0.7 X 16 G8.8  
BOX CMA  
DECAL, CMA LABEL  
DECAL, CMA LABEL  
TUBING SHRINK 19"ID RED  
14  
15  
16  
17*  
18  
19  
20  
21  
038057  
058443  
081224  
079682  
086093  
083736  
051715  
077401  
2
2
1
1
2
1
2
1
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  
076009A  
2
3
4
5
6
7
8
9
072566  
080882  
074978  
047822  
075476  
083264  
022985  
022264  
051787  
079847  
0A8504  
0A8504A  
022661V  
4
4
1
1
2
1
4
4
2
1
1
1
.083'  
NUT HEX M4-0.7 G8 YEL CHR  
COVER SILKSCREEN CMA  
* NOT SHOWN  
10  
11  
12  
13*  
®
Generac Power Systems, Inc. 37  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Battery — Drawing No. 098922-E  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
077483  
038804D  
038805B  
0742600131  
022131  
046526  
052213  
059567  
078121  
022145  
022129  
022259  
050331A  
050331  
075763  
1
1
1
1
1
1
1
2
1
2
2
2
1
1
3
BATT 12VDC 75-AH 26  
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  
BOLT BATTERY HOLD DOWN  
BAR BATTERY HOLDDOWN  
WASHER FLAT M8-5/16 ZINC  
WASHER LOCK 5/16  
NUT HEX 5/16-18 STEEL  
BATTERY POST COVER (RED+)  
BATTERY POSTCOVER (BLACK-)  
BOOT, BATTERY CABLE  
®
38 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Governor Assembly — Drawing No. 0A7216-A  
ITEM  
PART NO.QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
098290  
098941A  
098958A  
098942A  
098225  
043146  
022097  
064526  
098783  
037398  
0A7041  
0A7106  
074031  
029333A  
022507  
022473  
1
1
1
1
2
3
5
2
1
2
1
1
-
ASM MOTOR STEPPER  
HOUSING GOVERNOR CONNECTOR  
CONNECTOR INTERFACE ASSEMBLY  
COVER CONNECTOR HOUSING  
SCREW FHM #2 X 5/8 SELF TAP  
SCREW HHC M6-1.0 X 10 G8.8  
WASHER LOCK M6-1/4  
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  
1
2
2
TIE WRAP 7" BLACK  
SCREW HHC 1/4-20 X 1/2 G5  
WASHER FLAT 1/4 ZINC  
®
Generac Power Systems, Inc. 39  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Generator — Drawing No. 0A9348-B  
®
40 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Generator — Drawing No. 0A9348-B  
ITEM  
PART NO. QTY.  
DESCRIPTION  
ITEM  
PART NO. QTY.  
DESCRIPTION  
1
098671  
098681  
098675  
098936  
0A5336A  
0A1659  
071912  
022152  
051713  
022129  
098672  
098673  
098674  
098682  
098683  
098684  
098676  
098677  
098678  
097620  
098937  
097621  
0A5382  
075591  
052813  
0A5601  
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
ASSY ROTOR 10KW  
ASSY ROTOR 15KW  
ASSY ROTOR 20KW  
ASSY ROTOR 25KW  
HOUSING BLOWER  
SCREEN AIR OUTLET  
SCREW PPHM M5-0.8 X 8  
LOCK WASHER-#10  
WASHER FLAT M5  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25**  
26*  
27  
075554B  
0A9375  
022152  
097146  
042558  
0A5061  
0A4989  
052213  
051769  
049541  
046526  
045772  
082130B  
087599  
077043E  
4
4
4
1
1
1
1
1
6
4
4
4
1
1
1
BOLT,STATOR X 16"LG  
SCREW RHM #10-24 X 2  
WASHER LOCK #10  
FAN & RING GEAR ASSEM.  
KEY SQ 3/8 X 1 STEEL  
SPACER-FLEX PLATE  
PLATE, FLEX  
SCREW HHC M10-1.25 X 20 G8.8  
WASHER LOCK M12  
SCREW HHC M10-1.5 X 35 G8.8  
WASHER LOCK M10  
NUT HEX M10-1.5 G8 YEL CHR  
ASSY MPU SPEED SENSOR 48"  
PLUG PLASTIC 3/8 CAPLUG #2  
FLEX CONDUIT 1" BLCK  
(NOT SHOWN)  
WASHER FLAT 3/8 ZINC  
SPACER ROTOR SHAFT  
SCREW HHC M12-1.25 X 25 G8.8  
WASHER FLAT M12  
2
3
4
5
6
7
8
WASHER LOCK M8-5/16  
ASSY STATOR 10KW A  
ASSY STATOR 10KW D  
ASSY STATOR 10KW GJK  
ASSY STATOR 15KW 1PH A  
ASSY STATOR 15KW 3PH D  
ASSY STATOR 15KW 1PH GJK  
ASSY STATOR 20KW 1PH A  
ASSY STATOR 20KW 1PH A  
ASSY STATOR 20KW 1PH GJK  
ASSY STATOR 25KW 1PH A  
ASSY STATOR 25KW 1PH D  
ASSY STATOR 25KW 1PH D  
BEARING CARRIER REAR  
HOLDER, BRUSH ASSEM.  
SCREW HHC M4-0.7 X 20 G8.8  
COVER, REAR BEARING CARRIER  
28  
29  
30  
31  
32  
33  
35  
022131  
072578  
0A7043  
049808  
058589  
023365  
0A8830  
4
1
5
5
1
4
4
DECAL-WARNING  
WASHER SHAKEPROOF INT #8  
WASHER FLAT .34ID X .75OD  
9
10  
11  
12  
* USED ON PRE-PACKAGED UNITS ONLY  
** USED ON "C" OPTION PANEL UNITS ONLY  
®
Generac Power Systems, Inc. 41  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Natural Gas Fuel System — Drawing No. 0A9349-E  
®
42 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Natural Gas Fuel System — Drawing No. 0A9349-E  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0C2632  
075580  
026915  
039253  
022145  
022129  
045771  
0A2666  
046747  
0C3714  
0A5547  
0C1475  
0A9911  
0A7989  
0A6593  
059402  
037561  
059403  
059401  
034154  
022152  
023897  
062522  
022127  
022259  
050280  
0A6125  
052219  
048031C  
029032  
029032  
032552  
0A4682  
042907  
055934D  
0A7040  
0C3153  
1
2
3
4
5
7
4
2
1
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
2
1
2
1
3
WELDMENT MOUNTING BASE  
FLANGE FUEL INLET  
NIPPLE CLOSE 3/4 X 1.375  
SCREW HHC-M8-1.25 X 20  
WASHER FLAT 5/16 ZINC  
WASHER LOCK M8-5/16  
NUT HEX M8-1.25 G8 YEL CHR  
SOLENOID GAS FUEL  
BUSHING REDUCER 3/4 TO 3/8  
ASSY HOSE NG/LPV.31"  
COVER AIR CLEANER  
REGULATOR NATURAL GAS EM  
REGULATOR L.P. GAS EM  
NIPPLE PIPE 3/8 NPT X 4 BLK IRON  
ADAPTOR CARBURETOR  
FILTER ELEMENT  
NUT WING 1/4-20 NYLK  
CARBURETOR, CA55 EM  
GASKET CARBURETOR  
SCREW PHM 10-24 X 1/2 CAD  
WASHER LOCK #10  
WASHER FLAT #10 ZINC  
STUD THR 1/4-20X3 F THR G2 ZNC  
NUT HEX 1/4-20 STEEL  
NUT HEX 5/16-18 STEEL  
DECAL FUEL INLET LPG  
STUD 5/16-18 X 1.25 F THR  
BARBED STR 1/8NPT X 5/16  
CLAMP HOSE BAND 1/4  
HOSE 9/32 ID  
11  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
6-1/2"  
11"  
1
1
1
1
1
1
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. 43  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Engine Compartment — Drawing No. 0A7642-J  
®
44 Generac Power Systems, Inc.  
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Section 8 - Exploded Views and Parts  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Exploded View – Engine Compartment — Drawing No. 0A7642-J  
ITEM  
PART NO.  
QTY. DESCRIPTION  
ITEM  
PART NO.  
QTY. DESCRIPTION  
BARBED EL 90 3/8NPT X 5/8  
1
2
3
4
5
6
7
8
9
0A4531  
035685  
075546A  
0A45310258  
0A4355  
0A6699  
022097  
022507  
052212  
046526  
022131  
0C2499  
055993  
045772  
023586  
020692  
0A7005  
052243  
0A4772  
070901  
051735  
056768  
022145  
022129  
022259  
052213  
047411  
052830  
045771  
058306  
030795  
0A2711A  
048665  
075885  
0A45310257  
0A4682  
057522  
0A6751  
1
1
1
1
1
1
8
2
4
ENGINE-1.5L  
CLAMP HOSE #28 1.32 - 2.25  
PIPE-FLEX EXHAUST  
GASKET-EXHAUST MANIFOLD  
MANIFOLD-EXHAUST  
SHIELD HEAT EXHAUST  
WASHER LOCK M6-1/4  
SCREW HHC 1/4-20 X 1/2 G5  
SCREW HHC M10-1.25 X 25 G8.8  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
034339  
026925  
061012  
039253  
0A5110  
0A7006  
025507  
022500B  
0A8584  
036277  
042574  
026073A  
0A6701  
039414  
0A5568  
051769  
0A4804  
0A4800  
0A5839  
0A1354B  
0A4839  
055816  
049811  
075614  
0A2628  
0A5275  
0A5586  
0A4814  
0A45310244  
0C1852  
0912970066  
070928  
069860C  
069811  
0A5317  
022473  
1
1
1
6
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
PLUG STD PIPE 3/8 STEEL SQ HD  
PLUG STD PIPE 1/8 SCKT HD  
SCREW HHC M8-1.25 X 20 G8.8  
PIPE WATER-INLET  
O-RING 1-1/16X1-5/16X1/8  
WASHER SHAKEPROOF EXT 7/16 STL  
SPACER .41X.75X.25 ST/ZNC  
SWITCH OIL PRESSURE  
ELBOW 90D STREET 1/8  
ADAPTOR 1/8NPTF TO 1/8-28  
PLUG STD PIPE 1/4 STEEL SQ HD  
SCREW HHC M10-1.5 X 110 G8.8  
SCREW HHC M8-1.25 X 35 G8.8  
SCREW HHC M12-1.25 X 55 G8.8  
WASHER LOCK M12  
PULLEY-CRANKSHAFT (1800 RPM)  
PULLEY-CRANKSHAFT (3600 RPM)  
BRACKET - ALT SUPPRT  
DC ALTERNATOR-12V  
ARM ADJUST ALTERNATOR  
SCREW HHC M6-1.0 X 70 G8.8  
WASHER FLAT M6  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
14 WASHER-LOCK-M10  
16 WASHER FLAT 3/8 ZINC  
2
1
4
2
1
2
1
1
2
3
2
2
STAMPING ENG FOOT  
SPACER .41 X .75 X .12 STL/ZNC  
NUT HEX M10-1.5 G8 YEL CHR  
SCREW SHC 5/16-18 X 2 G8.8 NZ  
STARTER-12V  
SPACER .56 X 1 X .37 ST/ZNC  
SCREW HHC M10-1.5 X 60 G8.8  
ENGINE PLATE  
57  
58  
59  
60  
61  
62  
63  
64  
SLEEVE DOWEL BLHSG  
SCREW HHC M10-1.5 X 70 G8.8  
SCREW HHC M10-1.5 X 90 G8.8  
WASHER FLAT 5/16 ZINC  
23 WASHER LOCK M8-5/16  
FAN ENG PUSHER 6/380  
PULLEY - FAN 95 DIA  
V-BELT 3/8 X 32-1/8 1.5L  
V-BELT 3/8 X 28.9 1.5L  
SPACER PULLEY  
FILTER OIL  
2
1
2
2
NUT HEX 5/16-18 STEEL  
SCREW HHC M10-1.25 X 20 G8.8  
SCREW HHC M6-1.0 X 16 G8.8  
SCREW HHC M10-1.25 X 45 G8.8  
65  
66  
67  
68  
69  
70  
71  
72  
73  
10 NUT HEX M8-1.25 G8 YEL CHR  
5
2
1
1
1
1
1
1
1
SCREW SHC M8-1.25 X 25 G12.9  
SCREW HHC 5/16-18 X 1 G5  
ADAPTER-THERMOSTAT  
GASKET THERMOSTAT  
THERMOSTAT 195 DEG  
GASKET INLET MANIFOLD  
MANIFOLD-INTAKE  
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  
SENSOR COOLANT LEVEL  
SW-TMP 245DEG 3/8NPT  
®
Generac Power Systems, Inc. 45  
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Section 9 — Installation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Installation Drawing – Drawing No. 0C1450  
®
46 Generac Power Systems, Inc.  
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Section 9 — Installation  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
Installation Drawing – Drawing No. 0C1450  
®
Generac Power Systems, Inc. 47  
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Section 10 – Warranty  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission  
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be  
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control  
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi-  
cation or improper maintenance of your engine.  
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will  
repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.  
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:  
Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur-  
ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or  
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.  
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:  
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory  
supplied 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.  
As the engine purchaser/owner, you should, however, be aware that Generac may deny 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 warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.  
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.  
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:  
1-800-333-1322  
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System  
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. Both the ECS Warranty and the Generac Warranty describe impor-  
tant rights and obligations with respect to your new engine.  
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty serv-  
ice, evidence must be presented showing the date of the sale to the original purchaser/owner.  
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol-  
lowing address:  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 8  
WAUKESHA, WI 53187  
Part 1  
®
48 Generac Power Systems, Inc.  
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Section 10 – Warranty  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
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.  
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or  
equipment and to each subsequent purchaser/owner that each of its engines is ...  
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its  
authority, and  
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war-  
ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man-  
ufacturer’s application for certification.  
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:  
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s  
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall  
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the  
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual  
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or  
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS  
Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s  
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part  
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection  
(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 Service Facility.  
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsi-  
ble for diagnostic costs if the repair is deemed warrantable.  
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused  
by a failure under warranty of any emission-related part covered by the ECS Warranty.  
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient  
to meet the expected demand for such emission-related parts.  
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS  
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac  
ECS Warranty obligations.  
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac  
engine. 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” part.  
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:  
1) Fuel Metering System:  
3) Ignition System including:  
a) Spark plug  
b) Ignition module  
1.2) LPG/Natural Gas carburetion assembly and its internal  
components.  
a) Fuel controller (if so equipped)  
4) Catalytic Muffler Assembly (if so equipped) including:  
a) Muffler gasket  
b) Exhaust manifold  
b) Mixer and its gaskets (if so equipped)  
c) Carburetor and its gaskets (if so equipped)  
d) Primary gas regulator (if so equipped)  
e) LP liquid vaporizer (if so equipped)  
5) Crankcase Breather Assembly including:  
a) Breather connection tube  
2) Air Induction System including:  
a) Intake pipe/manifold  
b) Air cleaner  
*Generac engine types covered by this warranty statement include the following:  
1) Prepackaged Standby Generator  
2) Auxiliary Power Unit (APU) Generator  
3) Standby Generator  
Part 2  
®
Generac Power Systems, Inc. 49  
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Section 10 – Warranty  
Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators  
GENERAC’S STANDARD ONE-YEAR LIMITED WARRANTY FOR STANDBY POWER SYSTEMS  
For a period of one year or 1,500 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 by Generac or a  
Generac/Guardian Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance  
with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned  
to  
and  
examined  
by  
the  
nearest  
Generac/Guardian  
Authorized  
Warranty  
Service  
Facility.  
All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the  
purchaser/owner. This warranty applies only to generators used in “Standby” applications, as Standby has been defined by  
Generac, provided said generators have been initially installed and inspected on-site by a Generac/Guardian Authorized  
Service Dealer or branch thereof.  
WARRANTY SCHEDULE  
YEAR ONE – 100 percent coverage on mileage*, labor and parts listed:  
• Engine – All components  
• Alternator – All components  
• Transfer System – All components  
*Travel allowance is limited to 300 miles or 7.5 hours, whichever occurs first, and applies only to permanently wired and  
mounted units.  
All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat  
Rate Manual.  
Units that have been resold are not covered under the Generac warranty, as this warranty is not transferable.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
1. Costs of normal maintenance, adjustments, installation and start-up.  
2. Units sold, rated or used for “Prime Power” applications as Prime Power has been defined by Generac. Contact a dis-  
tributor for Prime Power definition and warranty.  
3. Failures due to (a) normal wear and tear, or (b) accident, misuse, abuse, negligence or improper installation.  
4. Products that are modified or altered in a manner not authorized by Generac in writing.  
5. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair  
or replacement of the defective parts.  
6. Failure due to misapplication.  
7. Telephone, telegraph, teletype or other communication expenses.  
8. Living or travel expenses of persons performing service, except as specifically included within the terms of a specific unit  
warranty.  
9. Rental equipment used while warranty repairs are being performed.  
10. Overtime labor.  
11. Starting batteries, fuses, light bulbs and engine fluids.  
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. SPECIFICALLY, GENERAC MAKES  
NO OTHER WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not  
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.  
GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PARTS AS STATED ABOVE. IN NO EVENT  
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE  
A DIRECT RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or  
consequential damages, so the above limitation may not apply to you. Purchaser/owner agrees to make no claims against  
Generac based on negligence.  
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.  
®
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 8  
WAUKESHA, WI 53187  
Part No. C8840  
Revision 1 (07/6/01)  
Printed in U.S.A.  
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