Generac Power Systems 005053-0 Generac Power Systems Two Year Limited Warranty For Guardian

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GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®

Section 10 – Warranty

Guardian Liquid-cooled 25 kW Generator

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN®

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer. 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 Generac Guardian prepackaged emergency automatic standby genera- tors sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and main- tenance is required):

Engine - All Components Alternator - All Components Transfer System - All Components

Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be repaired promptly by the owner.

All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Guardian generators that utilize non-Guardian/Generac replacement parts.

Guardian generators utilizing non-Guardian/Generac automatic transfer switches.

Repairs performed by individuals other than Guardian/Generac authorized dealers.

Any Guardian generators used as rental or trailer mounted applications.

Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist.

Costs of normal maintenance, adjustments, installation and start-up.

Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised.

Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

Damage related to rodent and/or insect infestation.

Products that are modified or altered in a manner not authorized by Generac in writing.

Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace- ment of the defective part(s).

Failure due to misapplication.

Telephone, cellular phone, facsimile, internet access or other communication expenses.

Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

Rental equipment used while warranty repairs are being performed.

Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

Overnight freight costs for replacement part(s).

Overtime labor.

Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE 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 PART(S) 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.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC® POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Revision (10/01/04)

Part No. 0F1005

Revision C (12/15/04)

Printed in U.S.A.

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Contents SHOULD ATTEMPT INSTALLATION Owner’s ManualLiquid-cooled, Prepackaged Standby Generators This manual should remain with the unitAUTHORIZED SERVICE DEALER LOCATION ‹ OPERATION AND MAINTENANCE‹ HOW TO OBTAIN SERVICE INTRODUCTIONTable of Contents Guardian Liquid-cooled 25 kW GeneratorGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot during operation. Exercise care near running gen- eratorsELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.2 TRANSFER SWITCH 1.1 GENERATOR1.3 AUTOMATIC SYSTEM OPERATION 1.4 GENERATOR AC CONNECTION SYSTEMS‹ 1.7.1 LOW OIL PRESSURE SWITCH ‹ 1.7.2 HIGH COOLANT TEMPERATURE SWITCH‹ 1.7.3 LOW COOLANT LEVEL SWITCH Figure 1.4 - Low Oil Pressure Switch1.10 SPECIFICATIONS ‹ 1.7.6 LOW BATTERY‹ 1.8.1 UNPACKING PRECAUTIONS 1.8 UNPACKING1.12 RECONFIGURING THE FUEL SYSTEM FOR LP VAPOR Figure 1.8 - Reconfigure the Fuel System1.11 FUEL CONSUMPTION ‹ 1.10.2 GENERATOR1.15 BEFORE INSTALLATION 2.1 STANDBY GENERATOR INSTALLATION1.13 ENGINE OIL RECOMMENDATIONS 1.14 COOLANT RECOMMENDATIONS2.3 GENERATOR MOUNTING AND SUPPORT 2.4 BASIC STANDBY ELECTRIC SYSTEM2.2 GENERATOR LOCATION ‹ 2.1.2 OTHER PUBLISHED STANDARDS2.9 USING AN ENGINEERED “GTS” TRANSFER SWITCH 2.5 EMERGENCY CIRCUIT ISOLATION METHOD2.6 TOTAL CIRCUIT ISOLATION METHOD 2.7 GROUNDING THE GENERATOR2.10 BATTERY INSTALLATION Pos2 OFF - Standard Prepackaged ATS Application‹ 2.10.1 VENTED BATTERIES Standby generators installed with automatic3.1 ENGINEERED GTS TRANSFER SWITCH ‹ 2.11.2 TRANSFER SWITCH2.11 PREPARATION BEFORE START-UP ‹ 2.11.1 PRIOR TO INITIAL START-UP‹ 3.2.2 FAULT INDICATOR LEDS ‹ 3.2.1 AUTO/OFF/MANUAL SWITCH‹ 3.2.5 SET EXERCISE TIME SWITCH 3.2 CONTROL CONSOLE COMPONENTS‹ 3.2.6 SYSTEM READY LED 3.4 ENGINE GOVERNOR ADJUSTMENTS3.3 MANUAL TRANSFER AND START-UP Figure 3.2 - Engine Governor Adjustment Figure 3.3 - “Set Exercise Time” Switch3.6 AUTOMATIC OPERATION 3.7 WEEKLY EXERCISE CYCLE3.8 CONTROL BOARD DIP SWITCH SETTINGS 4.1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIESA. EVERY THREE MONTHS B. ONCE EVERY SIX MONTHS4.2 EXHAUST MANIFOLD PROCEDURE 4.3 INTAKE MANIFOLD PROCEDURE4.4 CYLINDER HEAD PROCEDURE Figure 4.1 - Intake Manifold Installation4.7 CHECKING FLUID LEVELS 4.8 MAINTENANCE OWNER/ OPERATOR CAN PERFORM4.6 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM ‹ 4.8.11 CHANGING THE ENGINE AIR CLEANER Figure 4.4 - Setting the Spark Plug Gap‹ 4.8.8 CHECK FAN BELT ‹ 4.8.9 INSPECT ENGINE GOVERNOR4.9 MISCELLANEOUS MAINTENANCE ‹ 4.9.1 CLEANING THE GENERATOR‹ 4.9.2 BATTERY ‹ 4.9.3 BATTERY MAINTENANCE4.10 SCHEDULED MAINTENANCE Service Maintenance Interval InformationTurn off the battery charger turn OFF utility supply to ATS Remove the negative battery cableTasks MaintenanceLevel Maintenance TROUBLESHOOTING POINTS PROBLEMCAUSE CORRECTIONGenerac Power Systems, Inc Section 7 - Electrical Data Wiring Diagram - 2.5L Engine 15kW & 20kW units -Drawing No. 0F141126 Generac Power Systems, Inc Generac Power Systems, Inc 28 Generac Power Systems, Inc Generac Power Systems, Inc Wiring Diagram - 2.5L Engine 25kW unit -Drawing No. 0E9982-B 30 Generac Power Systems, IncGenerac Power Systems, Inc Electrical Schematic - 2.5L 25kW unit - Drawing No. 0E9983-B 32 Generac Power Systems, IncGenerac Power Systems, Inc HARNESS WIRE 34 Generac Power Systems, IncMOUNT BLOCK ENGINEDESCRIPTION PANEL FOR ACCESS GROUND WIRECOVER CABLE FASTENER TO SECUREEnclosure - Drawing No. 0E9720-D 38 Generac Power Systems, Inc HINGE CONTINUOUS 1.5L CTRL PNL 40 Generac Power Systems, Inc Section 8 - Exploded Views and Parts 42 Generac Power Systems, Inc Guardian Liquid-cooled 25 kW Generator Engine - Drawing No. 0E9918-ESTEPPER MOTOR UNITS ONLY TO RADIATORSOURCE GENERAC-BOSCH GOV GASKET, 2.5L FORD EXHAUST MANSERPENTINE BELT - 41 3/8 LENGTH BRKT,D.C. ALTERNATORMACHINED0E1028A I/N TO ENGINECOVER 44 Generac Power Systems, IncDESCRIPTION LOCKTIGHT LEADS46 Generac Power Systems, Inc Alternator - Drawing No. 0E8660-CROTOR REPLACEMENT PARTS ROTOR 390 30KW 1P DIRECT HSB 3.0L FORD & 2.5L FORDSTR 390 35AD1 HSB 382MM LONG3.0L FORD & 2.5L FORD CONDUIT FLEX 1-1/4 30 LG - 3.0L FORD & 3.9L CHRYSLER48 Generac Power Systems, Inc SCREW HHC M8-1.25 X 60 G8.8 FTSECURE WIRE HARNESS ITEM 13 NEOPRENECOATING WITH TIE WRAP AS SHOWN50 Generac Power Systems, Inc 1024SUPPORT,RADIATOR 2.5L FORD HOSE, UPPER RADIATOR 174MMSection 9 - Installation Diagram Installation Diagram - Drawing No. 0F1020-AYOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGEPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGGENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN WARRANTY SCHEDULETHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS, INC P.O. BOX 297 WHITEWATER, WI