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Generac 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0 manual

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Table of contents for the manual

  • Page 1

    PO WER SY STEMS, INC. ® Owner ’ s Manual Liquid-cooled, Prepackaged Standby 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 CONTRACTO[...]

  • 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 Contents Guardian Liquid-cooled 1 0 kW, 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 .................................[...]

  • 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. H IGH C OOL ANT TEMP ER A TUR E SWIT CH: 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 T empera[...]

  • Page 9

    Figur e8-C o n t r o l Module Assembly Circuit Board OVERCRAN K SHUTDOWN: After 90 seconds of crank -rest cycles, this function ends cranking if the engine fails to start in that 90- second span. DC F USE This clearly labeled fuse is located on the front panel of the control system. It protects the panel wiring and components from damaging overload[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. T ORQU E SP E CI F ICA TIONS Cylinder Head ......................................15 (+ 90° + 90°) ft.lb. Intake Manifold ..........................................................13 ft.lb. Exhaust Manifold ......................................................13 ft.lb. ENGI N E OI L R E C OM M EN D A TIONS The un[...]

  • 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 CI RCU IT IS OL A TION M ETHOD 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 th[...]

  • 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. Generator Set Lubrication Check the engine crankc[...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 AC AMM E TER: Indicated current draw of connected electrical loads during operation. DO NOT EX CEED YOUR UNIT’S RA TED MAXIMUM CONTINUOUS CURRENT . Refer to the unit DA T A PLA TE. AC FR E QU ENCY METER: Indicates generator AC output frequency in “Hertz” (cycles per second). F requency is proportional to eng[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. R E TR ANSF ER AN D SH UTDO WN 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 mean[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE F A CI LITI 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 E[...]

  • 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 T TER Y • Check battery fluid level each week as outlined under “Check Fluid Levels”. • Check battery cables for condition, tightness, corro- sion or damage. Clean, tighte[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 6. Remove OIL FILL CAP (Figure 11, page 15). Add recommended oil (see SPECIFICA TIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL ” MARK. Crankcase oil capacity is 4.0 U .S. quarts (3.8 liters) CAUTION: After refilling the crankcase with oil, always check oil level on dipstick. NEVER OPERA TE ENGINE WITH OIL BELOW [...]

  • Page 20

    Sectio n5—T roubleshooting Guardian Liquid-cooled 1 0 kW, 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 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. Defect[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators F ollowing 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[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 0 kW, 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[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 6 — Scheduled Maintenance Guardian Liquid-cooled 1 0 kW, 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[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. S e c t i o n7-E l e c t r i c a l Data Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — Control P anel (1 -Phase) —Drawing No. 0A2803-D[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 S e c t i o n7-E l e c t r i c a lD a t a Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — Control Panel (1 -Phase) — Drawing No. 0A2802-B[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Sectio n7-E l ectrical Data Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — Control P anel (3-Phase) — Drawing No. 0A2804-D[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 S e c t i o n7-E l e c t r i c a lD a t a Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — Control Panel (3-Phase) — Drawing No. 0A2 805-C[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. S e c t i o n7-E l e c t r i c a l Data Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Wiring Diagram — 1.5L Gas Engine — Drawing No. 0A7 1 7 6-A[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 S e c t i o n7-E l e c t r i c a lD a t a Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Electrical Schematic — 1.5L Gas Engine — Drawing No. 0A71 82-A[...]

  • Page 30

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

  • Page 31

    Generac ® Pow er Systems, Inc. 29 ITEM P AR T 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 [...]

  • Page 32

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

  • Page 33

    ITEM P AR T NO . QTY . DESCRIPTION 1 0C5077 1 SUPPOR T , CONTROL P ANEL L.H. 2 075589 1 BRACKET , V OL T AGE REGULA T OR 3 0A1775 1 CONTRLP ANEL-BA CK 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 A [...]

  • Page 34

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

  • Page 35

    Generac ® Pow er Systems, Inc. 33 ITEM P ART NO. QTY . DESCRIPTION 1 0A4822 1 P ANEL FRONT 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 1 1[...]

  • Page 36

    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 37

    Generac ® Pow er Systems, Inc. 35 ITEM P AR T NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHA UST 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[...]

  • Page 38

    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 - WASHER LOCK M4 5 039783 1 BRA CKET MOUNTING CIRCT BRK 6 080522 1 CIRC[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 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 20 A7X6X 1100V 6 075476 2 SCREW PPHM M4-0.7 X 16 7 0832[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Batt ery — Drawing No. 098922-E 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[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW, 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 T OR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECT OR 3 098958A 1 CONNECTOR INTERF A CE ASSEMBL Y[...]

  • Page 42

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

  • Page 43

    Generac ® Pow er Systems, Inc. 41 ITEM P ART 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 M8[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. Section 8 - Exploded Views and P arts Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Exploded View – Natural Gas F uel System — Drawing No. 0A9349-E[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P AR T 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 BU[...]

  • Page 46

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

  • Page 47

    Generac ® Pow er Systems, Inc. 45 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 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 H[...]

  • Page 48

    46 Generac ® Pow er Systems, Inc. Sectio n9—I nstallation Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1 450[...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 Sectio n9—I nstallation Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators Installation Drawing – Drawing No. 0C1 450[...]

  • Page 50

    48 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 [...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 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[...]

  • Page 52

    Part No. C8840 Revision 1 (07/6/01) Printed in U.S.A. Section 1 0 – Warranty Guardian Liquid-cooled 1 0 kW, 1 5 kW, 2 0 kW and 25 kW Generators GEN ERAC’S S T AND AR D ONE- YEAR LI M ITED W AR R ANTY 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, Generac[...]