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Generac Power Systems 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, manual

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Table of contents for the manual

  • Page 1

    PO WER SY STEMS, INC. ® Owner’ s Man ual Liquid-cooled, Prepac kaged Standb y Generators Model Numbers (Natural Gas) 004090-2 004091-2 004092-2 004093-2 004094-2 004095-2 004096-2 004097-2 004474-0 (w/TS) (Liquid Propane V apor) 004124-1 004125-1 004126-1 004127-1 004128-1 004130-1 004131-1 004475-0 (w/TS) ONL Y QUALIFIED ELECTRICIANS OR CONTRAC[...]

  • Page 2

    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[...]

  • Page 3

    T able of Cont ents Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION ............................................................ SAFETY RULES ........................................................................2 Section 1 GENERAL INFORMA TION ....................................[...]

  • Page 4

    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[...]

  • Page 5

    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[...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. GEN ER A T OR This equipment is an water - cooled, engine - driven gen- erator 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 sound attenuated enclo- sure and is i[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 Figure 3 represents a single-phase, 3-wire generator AC 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 [...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. L OW C OOL ANT LEVEL SWIT CH: 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. T o prevent such overheating without automatic shut down, the engine has a low coolant level sensor . If the engine coolant dro[...]

  • Page 9

    I NSPECTION: 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. LI FTI NG TH E GEN ERA T OR W ARNING: [...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. B EFORE I NST ALL A TION Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Isolation Method” and “T otal Circuit Isolation Method” in the installation manual (P art No. 079699). The generator’s rated wattage/amperage capacity must be adequat[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 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[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. EM ERGENCY CIRCU IT IS OL A TION 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 [...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 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 . Battery electrolyte fluid is an extr emely causti[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Fuel Syst em 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” (P age 7) for more information. If the unit has been idle for a long period of ti[...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 C ONTROL CONS OLE COMPON ENT S The components of a water - cooled generator control console (Figure 8) are as follows: Figure 8 - Water -Cooled Generator Panel AC V OL TM E TER: The voltmeter displays generator AC output voltage dur- ing operation. V oltage is regulated by a solid state volt- age regulator and is [...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. R E TR ANSF ER AN D SHUTDOWN 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: • V erify that utility power supply voltage to the transfer switch has been positively turned “Off,” using what- ever means [...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 MAI NTENANCE PER FOR M ED B Y AUTHOR IZED SERVICE F ACILITI E S A. EVER Y TH R EE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. B. ONCE EVER Y SIX MONTHS 1. T est Engi[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. MAI NTENANCE O WN ER/OP ER A T OR CAN P ER FOR M CH E CK ENGI NE OI L LEVEL Refer to “Checking Fluid Levels” on page 15. CH E CK BA TTER Y • Check battery fluid level each week as outlined under “Check Fluid Levels”. • Check battery cables for condition, tightness, corro- sion or damage. Clean, tighten[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 CAUTION: After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERA TE ENGINE WITH OIL BELOW THE DIP- STICK “ADD” MARK. 7. Start engine and check for oil leaks. COOLANT CHANGE Every year , have Authorized Service F acility drain, flush and refill the cooling system. See SPECIFICA T[...]

  • Page 20

    Section 4 — T roubleshooting Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators P ROB LEM CAUSE C OR R ECTION Engine won’t crank. 1. 30 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cables as necessary . 3. Defectiv e star ter contactor . 3. Replace contactor . 4. Defe[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Section 5 - Notes Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 6 - Electrical Data Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Wiring Diagram — Control P anel (1 -Phase) —Drawing No. 0A2803C FUSE[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 6 - Electrical Data Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Electrical Schematic — Control Panel (1 -Phase) — Drawing No. 0A2802A[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 6 - Electrical Data Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Wiring Diagram — Control P anel (3-Phase) — Drawing No. 0A2804C[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 6 - Electrical Data Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A2 805B[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Section 6 - Electrical Data Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Wiring Diagram — Control P anel (3-Phase) — Drawing No. 0A7 1 7 6A[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 6 - Electrical Data Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A7 1 82A[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Exploded View – Enclosure — Drawing No. 0C1 404A[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 ITEM P ART NO . QTY . DESCRIPTION 1 A2110 32 1/4"-20-1/2" F ASTENER 2 A2115 32 1/4" NYLON W ASHER 3 A3133A 4 SLIP HINGE, MALE L.H. A3133B 4 SLIP HINGE, FEMALE L.H. A3133C 2 SLIP HINGE, MALE R.H. A3133D 2 SLIP HINGE, FEMALE R.H. 4 A3359 24 BHSCS M6 x 16 S.S . 5 A3360 24 SHAKEPROOF , INT M6 S.S. 6 C12[...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Exploded View – Control P anel — Drawing No. 0C884 7B[...]

  • Page 31

    ITEM P ART NO . QTY . DESCRIPTION 1 0C5077 1 SUPPORT , CONTROL P ANEL L.H. 2 075589 1 BRACKET , VOL T AGE REGULA T OR 3 0A1775 1 CONTRLP ANEL-BA CK 4 0C5078 1 SUPPORT CONTR OL 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 VOL TMETER AC 0-3[...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Exploded View – Radiator — Drawing No. 0C1 406B[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 ITEM P ART NO . Q TY . DESCRIPTION 1 0A4822 1 P ANEL FR ONT 2 0A5734 1 RADIA T OR 1.5L 3 0A6237 1 VENTURI 1.5L 4 0A6238 1 GU ARD 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 - .55[...]

  • Page 34

    ITEM P AR T NO . QTY . DESCRIPTION 1 0A9955 1 BASE MOUNTING 3 070936 2 D AMPENER VIBRA TION 4 070936C 2 D AMPENER VIBRA TION 5 039253 8 SCREW HHC M8-1.25 X 20 G8.8 6 022145 12 W ASHER FLA T 5/16 ZINC 7 022129 12 W ASHER LOCK M8-5/16 8 045771 12 NUT HEX M8-1.25 G8 YEL CHR 9 071956 4 W ASHER FLA T M8 10 051730 2 SCREW HHC M8-1.25 X 60 G8.8 12 057821 [...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 ITEM P AR T NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHA UST 1.5L 2 0C1636 1 NIPPLE T OE 1.5 NPT X 6.5 BL IRON 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 SUPPORT MUFFLER 1.5L 7 0C1412 1 ELBOW EXHA UST 45 DEG 8 0A5728 1 MUFFLER 1.6/1[...]

  • Page 36

    ITEM P ART NO . QTY . DESCRIPTION 1 0A2103 1 SILKSCREEN "A" P ANEL 0A2104 1 SILKSCREEN "B" P ANEL 0A2105 1 SILKSCREEN "C" P ANEL 0A2106 1 SILKSCREEN "P" P ANEL 2* 0A2052 1 CO VER BQ CIRCUIT BREAKER 3 033130 - SCREW HHM #8-32 X 1/4 4 022264 - W ASHER LOCK M4 5 039783 1 BRA CKET MOUNTING CIRCT BRK 6 080522 1 CI[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 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 ACER .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 0[...]

  • Page 38

    ITEM P ART NO .QTY . DESCRIPTION 1 098290 1 ASM MOT OR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECT OR 3 098958A 1 CONNECT OR INTERF A CE ASSEMBL Y 4 098942A 1 CO VER CONNECT OR HOUSING 5 098225 2 SCREW FHM #2 X 5/8 SELF T AP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 W ASHER LOCK M6-1/4 8 064256 2 SCREW HHM #6-32 X 3/8 SELF T AP 9 098783 1 [...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 I TEM P AR T NO . QTY . DESCRIPTION 1 077483 1 BA TT 12VDC 75-AH 26 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 ASSY ,WIRE#16 RED 1.6 5 022131 1 W ASHER FLA T 3/8 ZINC 6 046526 1 W ASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 059567 2 BOL T BA TTER Y HOL[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Exploded View – Generator — Drawing No. 0A93 48B[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 ITEM P AR T NO . QTY . DESCRIPTION 1 098671 1 ASSY RO T OR 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 BLOWER 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 M[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Exploded View – Natural Gas F uel System — Drawing No. 0A93 49E[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 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[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Exploded View – Engine Compartment — Drawing No. 0A7642J[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P AR T NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 035685 1 CLAMP HOSE #28 1.32 - 2.25 3 075546A 1 PIPE-FLEX EXHA UST 4 0A45310258 1 GASKET -EXHA UST MANIFOLD 5 0A4355 1 MANIFOLD-EXHA UST 6 0A6699 1 SHIELD HEA T EXHA UST 7 022097 8 W ASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5 9 052212 4 SCREW [...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. Section 8 — Installation Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1 450[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 Section 8 — Installation Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1 450[...]

  • Page 48

    46 Generac ® Pow er Systems, Inc. Section 9 — Notes Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators[...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 Section 9 — Notes Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. CALI FORN IA EM IS SION C ONTROL W AR RANT Y ST A TEMENT Y OUR W AR RANT Y R IGHTS AND OB LIGA 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 gard[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 EM IS SION CONTROL S YS TEM W AR R ANT Y 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 Period shall begin on the date the new engine or equipment is purchased by/delivered[...]

  • Page 52

    Part No. C8840 Revision 0 (04/25/01) Printed in U.S.A. Section 9 – W arranty Guardian Liquid-cooled 1 0 kW , 1 5 kW , 20 kW and 25 kW Generators GEN ERAC’S S T AN D AR D ON E- YEAR LIM ITED W ARR ANT Y FOR ST ANDBY PO WER SY STEMS F or a period of one year or 1,500 hours of operation from the date of original sale, whichever occurs first, Gener[...]