Generac 004189-1 manual

PO WER SY STEMS, INC. ® Owner ’ s Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers (Natural Gas) 004188-1 004370-2 004474-1 (Liquid Propane V apor) 004189-1 004371-2 004475-1 ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!![...]

Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the standby gen- erator set product line by Generac P ower Systems. Every effort was expended to make sure that the infor- mation and instructions in this manual were both accu- rate and current at the time the manual was written. However , the manufacturer reserve[...]

T able of Contents Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION .................................... IFC SAFETY RULES .......................................... 2 Section 1 GENERAL INFORMA TION ......................4 Generator .............................................................[...]

2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The genera- tor can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many acci- dents are caused by failing t[...]

Generac ® Pow er Systems, Inc. 3 • Inspect the generator regularly , and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by[...]

4 Generac ® Pow er Systems, Inc. GEN ER A T OR This equipment is a liquid- cooled, engine - driven gener- ator set. The generator is designed to supply electrical power that operates critical electrical loads during util- ity power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor [...]

Generac ® Pow er Systems, Inc. 5 Gaseous fuels such as natural and LP (propane) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explo- sion. No leakage of fuel is permitted. Natural gas, which is lighter than air , tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas. ENG[...]

6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor OVERSPEED SH UTDO WN The CMA circuit board on liquid cooled units receives AC frequency (rpm) signals directly from the stator A C power windings, via sensing leads S15 and S16. Should AC frequency exceed about 72 Hz, circuit board action will automatically shutdown the engine [...]

ENGI NE SP ECIF ICA TIONS Make ..................................................................................Mitsubishi Displacement ....................................................92 inches 3 (1.5 liters) Cylinder Arrangement ..........................................................4, in-line V alve Arr angement ..........................[...]

8 Generac ® Pow er Systems, Inc. If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set. Only qualified, competent installation contractors or electricians thoroughly familiar with applicable code[...]

Generac ® Pow er Systems, Inc. 9 GEN ER A T OR MOU NTI NG AN D SU P PORT Retain the generator compartment to a concrete slab with 1/4-inch masonry type anchor bolts. Be sure the bolts are long enough to retain the compartment. The slab should be at least 6 inches thick and should extend beyond the enclosure to a distance of at least 3 inches on al[...]

10 Generac ® Pow er Systems, Inc. GEN ER A T OR AC NEUTR AL CONN ECTIONS Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the genera- tor field. The actual [...]

Generac ® Pow er Systems, Inc. 11 P R EP AR A TION B EFOR E ST ART -U P The instructions in this section assume that the stand- by generator has been properly installed, serviced, test- ed, adjusted and otherwise prepared for use by a com- petent, qualified installation contractor . Be sure to read the “Safety Rules” on P ages 2 and 3, as well[...]

12 Generac ® Pow er Systems, Inc. C ONTROL C ONS OLE COMPON ENTS The components of a liquid- cooled generator control console (Figure 3.1) are as follows: Figure 3.1 - Liquid-Cooled Generator Panel AC VO L T M ET E R The voltmeter displays generator AC output voltage dur- ing operation. V oltage is regulated by a solid state volt- age regulator an[...]

Generac ® Pow er Systems, Inc. 13 NOTE: This fuse will not remove the + battery input power from the PCB when it opens. This means the exercise timer will not be reset. If this fuse does open, care- fully check the wiring to the start, fuel, field boost and transfer outputs before replacing the fuse. M E TER R EADING SELECT OR SWIT CH: Switch perm[...]

14 Generac ® Pow er Systems, Inc. ENGI N E H EA TER Y our Generac standby generator comes equipped with a block heater (Figure 4.1), similar to the block heaters used in automotive applications. The block heater is wired to a grounded plug . Figure 4.1 - Engine Block Heater Refer to applicable wiring diagram(s) and electrical schematic(s) at back [...]

Generac ® Pow er Systems, Inc. 15 • If oil level is below the dipstick ADD mark, remove oil fill cap. Add the recommended oil to bring oil level up to the FULL mark. DO NOT FILL ABOVE THE “FULL ” MARK. See page 6 for recommended oils. Figure 4.2 - Oil Dipstick and Oil Fill Cap B A TTE R Y FL UID Check battery electrolyte fluid at least once [...]

16 Generac ® Pow er Systems, Inc. CHANGI NG ENGIN E OI L Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning . This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retainin[...]

Generac ® Pow er Systems, Inc. 17 M IS CELL AN E OUS MAI NTENANCE CLEAN ING TH E GEN ER A T OR Keep your generator as clean and as dry as possible. Dirt and moisture that accumulates on internal genera- tor windings have an adverse effect on insulation resist- ance. P eriodically clean generator exterior surfaces. A soft brush may be used to loose[...]

18 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators P ROB LEM CAUSE C OR R E CTION Engine won’t crank. 1. 30 amp fuse b lown. 1. Replace fuse. 2. Loose or corroded or def ective 2. Tighten, clean or replace battery cables. battery cables as necessar y . 3. Def ective star te[...]

Generac ® Pow er Systems, Inc. 19 Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators F ollowing is a recommended maintenance schedule for Generac Guardian small standby and residential genera- tor sets. The established intervals in the schedule are the maximum recommended when the unit is used in an aver[...]

20 Generac ® Pow er Systems, Inc. Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be [...]

Generac ® Pow er Systems, Inc. 21 Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be [...]

22 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — Control P anel (1 -Phase) —Drawing No. 0A2803-D[...]

Generac ® Pow er Systems, Inc. 23 Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — Control P anel (1 -Phase) —Drawing No. 0A2803-D[...]

24 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — Control Panel (1 -Phase) — Drawing No. 0A2802-B[...]

Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7 1 7 6-A Generac ® Pow er Systems, Inc. 25 (A C OUTLET)[...]

26 Generac ® Pow er Systems, Inc. Section 7 - Electrical Data Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — 1.5L Gas Engine — Drawing No. 0A71 82-A FED CIRCUIT (AC OUTLET)[...]

Generac ® Pow er Systems, Inc. 27 ITEM P ART NO . QTY . DESCRIPTION 1 97575 2 BRACE, SIDE 2 A3769 2 DOOR, ENCLOSURE 3 A3768 1 DOOR, ENCLOSURE 4 A5314 1 T OP , ENCLOSURE 5 67042 2 LA TCH 6 22264 6 LOCK W ASHER, #8 7 67035 6 SCREW , P AN HEAD MACH.-#8-32 x 5/16" 8 82570 2 PLUG-4" 9 A7215 10 SW AGE F ASTENER-W/NYLON W ASHER ITEM P ART NO . [...]

28 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Enclosure (2 5kW) — Drawing No. 0C1 404-B[...]

Generac ® Pow er Systems, Inc. 29 ITEM P ART NO . QTY . DESCRIPTION 1 0A2110 32 SCREW SW AGE 1/4-20 X 1/2 Z/YC 2 0A2115 32 W ASHER NYLON .250 3 0A3133A 4 HINGE SLIP MALE LH 0A3133B 4 HINGE SLIP FEMALE LH 0A3133C 2 HINGE SLIP MALE RH 0A3133D 2 HINGE SLIP FEMALE RH 4 0A3359 24 SCREW BHSC M6-1.0 X 16 SS 5 0A3360 24 SHAKEPROOF INT M6 SS 6 0C1245 1 P A[...]

30 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Control P anel (1 5 and 20 kW) — Drawing No. 0A28 7 2-F[...]

Generac ® Pow er Systems, Inc. 31 ITEM P ART NO .QTY . DESCRIPTION 1 098062 1 SUPPORT , CONTR OL P ANEL, L.H. 2 075589 1 BRACKET , V OL T AGE REGULA TOR 3 0A1775 1 CONTROL, P ANEL-BACK 4 098063 1 SUPPORT , CONTR OL P ANEL R.H. 5 0A2106 1 SILKSCREEN, "P" P ANEL 6 057073 1 BLOCK, JUNCTION 7 022985 ** W ASHER, FLA T #6 8 070080 2 INSULA T O[...]

32 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Control P anel (25kW) — Drawing No. 0C884 7 -C[...]

ITEM P ART NO .QTY . DESCRIPTION 1 0C5077 1 SUPPOR T , CONTROL P ANEL L.H. 2 075589 1 BRACKET , V OL T AGE REGULA TOR 3 0A1775 1 CONTRLP ANEL-BACK 4 0C5078 1 SUPPOR T CONTROL P ANEL R.H. 5 0C4224A 1 SILKSCREEN, P ANEL (SAE) 6 057073 1 BLOCK JUNCTION 3/8-16 7 022985 4 W ASHER FLA T #6 ZINC 8 081988 1 DECAL EXERCISE INFO 9 070043 1 V OL TMETER AC 0-3[...]

34 Generac ® Pow er Systems, Inc. To w a t e r inl e t t ube (Midway up engine block ) To en g ine bypas s "A" To base o f w a t e r inl et tube (On block) 24 12 30 31 2 9 4 12 1 3 12 14 11 7 5 7 6 7 1 6 7 8 3 8 2 6 2 5 27 22 11 17 8 1 9 32 1 2 3 8 2 0 8 adapte r To th e rmo s t at 9 21 9 " A" 2 1 0 1 0 24 14 12 1 7 14 12 1 8 4[...]

Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0A6272 1 SUPPORT RADIA T OR 2 0A5734 1 RADIA TOR 1.5L 3 0A6237 1 VENTURI 1.5L MODINE 4 0A6238 1 GUARD F AN 1.5L MODINE 5 084918 1 HEA TER ENGINE 0500W 120V 6 050967 12" HOSE 5/8 ID RIA 250F 7 057823 4 CLAMP HOSE #10 .56 - 1.06 8 099502 4 CLAMP HOSE #24 B1.06 - 2.00 9 083709[...]

36 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Radiator (2 5 kW) — Drawing No. 0C1 406-B[...]

Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 2 0A5734 1 RADIA TOR 1.5L 3 0A6237 1 VENTURI 1.5L 4 0A6238 1 GUARD F AN 5 084918 1 HEA TER 500W 1020 6 050967 12" HOSE RES 5/8 RIA 250F 7 057823 4 CLAMP HOSE #10 .56 - 1.06 8 099502 4 CLAMP HOSE #24 1.06 - 2.00 9 083709 2 CLAMP WIRE HOSE .573 - .551 11 042568 6 SCREW HHC M6-1[...]

ITEM P ART NO . QTY . DESCRIPTION 1 C2632 1 BASE, MOUNTING 3 70936 2 ISOLA T OR-VIBRA TION 4 70936C 2 ISOLA T OR, VIBRA TION 5 39253 8 CAPSCREW , HEX HEAD-M8-1.25 x 20MM 6 22145 12 FLA T W ASHER-M8 7 22129 12 LOCK W ASHER-M8 8 45771 12 NUT , HEX-M8-1.25 9 71956 4 W ASHER, VIBRA TION ISOLA TOR 10 51730 2 CAPSCREW , HEX HEAD-M8-1.25 x 60MM 12 57821 2[...]

Generac ® Pow er Systems, Inc. 39 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Mounting Base (2 5 kW) — Drawing No. 0C1 405-A ITEM P ART NO . QTY . DESCRIPTION 1 0A9955 1 BASE MOUNTING 3 070936 2 D AMPENER VIBRA TION 4 070936C 2 DAMPENER VIBRA TION 5 039253 8 SCREW HHC M8-1.25[...]

ITEM P ART NO . QTY . DESCRIPTION 1 020689 1 MUFFLER W/RAIN SHLD 2 060366 1 MUFFLR STRAP 6IN DIA 3 059933 1 ELBO W 90 DEG 2 NPT 4 080761 1 NIPPLE TOE 2 NPT X 4.5 BLK IR ON 5 059939 1 RAIN CAP 2.37 I.D . 6 075546A 1 PIPE FLEX EXHAUST 7 036434 1 BOL T U 5/16-18 X 2.09 8 022259 2 NUT HEX 5/16-18 STEEL 9 022129 6 W ASHER LOCK M8-5/16 10 036449 1 SADDLE[...]

Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHAUST 1.5L 2 0C1636 1 NIPPLE TOE 1.5 NPT X 6.5 BL IR ON 3 036434 4 BOL T U 5/16-18 X 2.09 036449 4 SADDLE 2 INCH 4 0C1330 1 PIPE EXHA UST 5 0C1318 1 FLEX PIPE EXHA UST 6 0C1068 1 SUPPOR T MUFFLER 1.5L 7 0C1412 1 ELBO W EXHA UST 45 DEG 8 0A5728 1 MUFFLER 1.6/1[...]

ITEM P ART NO . QTY . DESCRIPTION 1 0A2106 1 SILKSCREEN "P" P ANEL 2 0A2952 1 COVER BQ CIRCUIT BREAKER 3 039782 1 BRA CKET MOUNTING CIRCUIT BREAKER 4 048373 1 CIRCUIT BREAKER 70 X 2 240V 39782 BRKT 039766 1 CIRCUIT BREAKER 90 X 2 240V 39782 BRKT 0A2077 1 CIRCUIT BREAKER 125 X 2 120/240V 39783 BRKT 5 023965 2 SCREW RHM #8-32 X 3/8 6 022264[...]

Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 074100 1 ASSY HOME STDBY LOGIC (MODELS 921, 863, 865) 076009A 1 PP LOGIC ASM 50/60HZ (MODEL 9428) 2 072566 4 NUT SP A CER .250 PCB 3 080882 4 SCREW PPH T APPING #6X5/8 SS 4 074978 1 DECAL TERMINAL STRIP 5 047822 1 BLOCK TERM 20A 7 X 6 X 1100V 6 075476 2 SCREW PPHM M4-0.7 X 16 7 [...]

44 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Batt ery — Drawing No. 098922-E ITEM P ART NO . QTY . DESCRIPTION 1 077483 1 BA TT 12VDC 75-AH 26/26R 2 038804D 1 CABLE BA TT RED #4 X 20.00 3 038805B 1 CABLE BA TT BLK #4 X 23.00 4 0742600131 1 ASS[...]

Generac ® Pow er Systems, Inc. 45 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Governor Assembly — Drawing No. 0A7 21 6-A ITEM P ART NO . QTY . DESCRIPTION 1 098290 1 ASM MO TOR STEPPER 2 098941A 1 HOUSING GOVERNOR CONNECT OR 3 098958A 1 CONNECTOR INTERF ACE ASSEMBL Y 4 098942[...]

46 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A93 48-C[...]

Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 098671 1 ASSY RO TOR 10KW 098681 1 ASSY RO T OR 15KW 098675 1 ASSY RO T OR 20KW 098936 1 ASSY RO T OR 25KW 2 0A5336A 1 HOUSING BLO WER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 5 022152 4 LOCK W ASHER-#10 6 051713 4 W ASHER FLA T M5 7 022129 4 W ASHER LOCK M8[...]

48 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Gaseous F uel System — Drawing No. 0A93 49-E[...]

Generac ® Pow er Systems, Inc. 49 ITEM P ART NO . QTY . DESCRIPTION 1 0C2632 1 WELDMENT MOUNTING BASE 2 075580 2 FLANGE FUEL INLET 3 026915 3 NIPPLE CLOSE 3/4 X 1.375 4 039253 4 SCREW HHC-M8-1.25 X 20 5 022145 5 W ASHER FLA T 5/16 ZINC 6 022129 7 W ASHER LOCK M8-5/16 7 045771 4 NUT HEX M8-1.25 G8 YEL CHR 8 0A2666 2 SOLENOID GAS FUEL 9 046747 1 BUS[...]

50 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642-J[...]

Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 035685 1 CLAMP HOSE #28 1.32 - 2.25 3 075546A 1 PIPE-FLEX EXHAUST 4 0A45310258 1 GASKET -EXHA UST MANIFOLD 5 0A4355 1 MANIFOLD-EXHA UST 6 0A6699 1 SHIELD HEA T EXHA UST 7 022097 8 WASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5 9 052212 4 SCREW HHC[...]

52 Generac ® Pow er Systems, Inc. Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 1 5 & 20 kW – Drawing No. A7 21 4-C[...]

Generac ® Pow er Systems, Inc. 53 Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 1 5 & 20 kW – Drawing No. A7 21 4-C Air Intake Air Intake Air Outlet[...]

54 Generac ® Pow er Systems, Inc. Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 25 kW – Drawing No. 0C1 450[...]

Generac ® Pow er Systems, Inc. 55 Section 9 — Installation Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing 25 kW – Drawing No. 0C1 450 Air Intake Air Intake Air Intake[...]

56 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEMENT Y OU R W AR R ANT Y R IGHT S AN D OBLIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and [...]

Generac ® Pow er Systems, Inc. 57 EM IS SION CONTROL S YS TEM W AR R ANTY Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered[...]

Part No. 0D6444 Revision 0 (11/14/01) Printed in U.S.A. Section 1 0 – Warranty Guardian Liquid-cooled 1 5 kW, 2 0 kW and 25 kW Generators GEN ERAC PO WER SY STEMS "TWO YEAR" S T AN D AR D W AR R ANT Y FOR GUARDIAN ® "P REP ACKAGED EMERGENCY AUT OMA TIC S T ANDBY GENER A T ORS" F or a period of two years or 2000 hours of opera[...]