Instruction/ maintenance manual of the product 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0, 004124-1, Generac
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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 (.
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.
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 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.
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.
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.
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.
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).
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.
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 .........
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.
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 .
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 .
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.
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).
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 .
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.
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”.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 MANIFOL.
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.
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.
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.
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.
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 A.
An important point after buying a device Generac 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, 00 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac 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, 00 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac 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, 00 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac 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, 00 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac 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, 00 will certainly help you make a decision on the purchase.
If you already are a holder of Generac 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, 00, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac 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, 00.
However, one of the most important roles played by the user manual is to help in solving problems with Generac 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, 00. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 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, 00 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
