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 004126-1, Owner'S Manual Download Page 35 | Manualshive

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Generac

®

Power Systems, Inc. 33

ITEM

PART NO.

QTY.

DESCRIPTION

1

0A4355

1

MANIFOLD EXHAUST 1.5L

2

0C1636

1

NIPPLE TOE 1.5 NPT X 6.5 BL IRON

3

036434

4

BOLT U 5/16-18 X 2.09

036449

4

SADDLE 2 INCH

4

0C1330

1

PIPE EXHAUST

5

0C1318

1

FLEX PIPE EXHAUST

6

0C1068

1

SUPPORT MUFFLER 1.5L

7

0C1412

1

ELBOW EXHAUST 45 DEG

8

0A5728

1

MUFFLER 1.6/1.5L SAE

9

060366

2

STRAP MUFFLER 6" DIA

10

066889

4

SCREW HHC M8 X 1.25 X 20MM

11

022145

4

WASHER FLAT 5/16 ZINC

12

022129

4

WASHER LOCK M8-5/16

13

045771

4

NUT HEX M8-1.25 G8 YEL CHR

14

0A8974

1

CAP RAIN 2"

Section 7 - Exploded Views and Parts

Guardian Liquid-cooled 10 kW, 15 kW, 20 kW and 25 kW Generators

Exploded View – Muffler — Drawing No. 0C1408B

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Summary of Contents for 004090-2, 004091-2, 004092-2, 004093-2, 004094-2, 004095-2, 004096-2, 004097-2, 004474-0, 004124-1, 004125-1, 004126-1 004126-1,

Page 1: ...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 Vapor 004124 1 004125 1 004126 1 004127 1 004128 1 004130 1 004131 1 004475 0 w TS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION ...

Page 2: ... out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment We strongly recommend that the opera tor read this Owner s Manual and thoroughly under stand all instructions before using this equipment We also strongly recommend instructing other users to prope...

Page 3: ...ing the Generator 10 Generator AC Neutral Connections 10 Transfer Switch Start Signal Connections 10 Battery Installation 10 Preparation Before Start Up 11 Section 3 OPERATION 12 Using a Standard GTS Transfer Switch 12 Control Console Components 13 Manual Transfer and Startup 13 Retransfer and Shutdown 14 Automatic Operation 14 Weekly Exercise Cycle 14 Engine Heater 14 Section 3 MAINTENANCE 15 Mai...

Page 4: ...s installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation you must not do any thing that might render the unit unsafe or in non compliance with the aforementioned codes stan dards laws and regulations The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrat...

Page 5: ...erating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when nor mal utility source voltage is removed or is below an acceptable pr...

Page 6: ...G If this generator is used to power electrical load circuits normally powered by a utility power source you are required by code to install a transfer switch The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating NEC 701 Failure to isolate an electri cal system by such means results in damage to the generator and may a...

Page 7: ...than air and tends to settle in low areas ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running S...

Page 8: ...o start in that 90 second span DC FUSE This clearly labeled fuse is located on the front panel of the control system It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rat ing Generac normally uses an AGC fuse rate...

Page 9: ...r Using LP Gas 175 cubic ft 4 8 gal per hour Models 004094 004095 004126 004127 Using Natural Gas 359 cu ft per hour Using LP Gas 143 cubic ft 4 0 gal per hour Model 004092 004093 004128 Using Natural Gas 277 cu ft per hour Using LP Gas 110 cubic ft 3 1 gal per hour Models 004090 004091 004124 004125 Using Natural Gas 195 cu ft per hour Using LP Gas 77 cubic ft 2 2 gal per hour NOTE Fuel consumpti...

Page 10: ...nit will power You may have to group the critical essential loads together and wire them into a separate emer gency distribution panel This generator can be installed in conjunction with a standard Generac GTS type transfer switch if desired The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses a Control Module Assembly which contro...

Page 11: ... available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDA...

Page 12: ...e ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electri cal shock in the event of a ground fault condition in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug...

Page 13: ...by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries For recommended batteries see Specifications All batteries must be at 100 percent state of charge before they are installed on the generator When using maintenance free batteries it is not neces sary to check the specific gravity or electrolyte level Have these procedures performed ...

Page 14: ...o placing the unit into service and at recommended intervals Belt tension is correct when a force of approx imately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm Electrical System Make sure the generator is properly connected to an approved earth ground Make sure the generator battery is fully charged proper ly installed and interconnected and r...

Page 15: ...s 3 position switch as follows Set the switch to Auto for fully automatic operation See Automatic Operation Set switch to Manual position to crank and start the generator engine Set switch to Off position to shut down an operat ing engine With Off selected operation will not be possible DANGER With switch set to auto engine can crank and start suddenly without warning Such automatic start up norma...

Page 16: ...r of loads to genera tor output does not occur during the exercise To select day and time for exercising proceed as fol lows Set the Auto Off Manual switch to OFF Set generator main circuit breaker to OFF or OPEN Locate the rocker switch on the control panel identi fied with the words Set Exercise Time Figure 9 Push Set Exercise Time switch to ON position for 20 to 30 seconds and then release Swit...

Page 17: ... the circuit is overloaded CAUTION If a circuit breaker opens or a fuse element melts you should find the cause of the overload before resetting the circuit breaker or replacing the fuse CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level Figure 11 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dips...

Page 18: ...GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the gover nor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are s...

Page 19: ...en not in use Refer to specific instructions and warnings that accompany your battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated...

Page 20: ...eeded 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low Coolant Level Switch 7 Replace Switch Auto Off Manual Switch at OFF 1 Defective Auto Off Manual switch 1 Re...

Page 21: ...Generac Power Systems Inc 19 Section 5 Notes Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators ...

Page 22: ...20 Generac Power Systems Inc Section 6 Electrical Data Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Wiring Diagram Control Panel 1 Phase Drawing No 0A2803C FUSE ...

Page 23: ...Generac Power Systems Inc 21 Section 6 Electrical Data Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Electrical Schematic Control Panel 1 Phase Drawing No 0A2802A ...

Page 24: ...22 Generac Power Systems Inc Section 6 Electrical Data Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Wiring Diagram Control Panel 3 Phase Drawing No 0A2804C ...

Page 25: ...Generac Power Systems Inc 23 Section 6 Electrical Data Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Electrical Schematic Control Panel 3 Phase Drawing No 0A2805B ...

Page 26: ...24 Generac Power Systems Inc Section 6 Electrical Data Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Wiring Diagram Control Panel 3 Phase Drawing No 0A7176A ...

Page 27: ...Generac Power Systems Inc 25 Section 6 Electrical Data Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Electrical Schematic Control Panel 3 Phase Drawing No 0A7182A ...

Page 28: ...26 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Enclosure Drawing No 0C1404A ...

Page 29: ...ITEM PART NO QTY DESCRIPTION 24 22129 12 LOCKWASHER 5 16 M8 25 22127 4 NUT 1 2 20 26 22145 12 FLAT WASHER 5 16 M8 27 89961 24ft FOAM STRIP 3 4 x 1 4 28 22473 20 FLAT WASHER 1 4 M6 29 82570 1 PLUG BUTTON 4 30 39253 12 HHCS M8 1 25 x 20 31 42568 14 HHCS M6 1 0 x 20LG 35 49813 4 NUT HEX M6 1 0 37 37337 4 HEX NUT JAM 3 8 24 38 A6807 1 LATCH CAM REWORK 39 57042 2 LATCH AND CAM 40 67577 4 SPEED NUT 1 4 ...

Page 30: ...28 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Control Panel Drawing No 0C8847B ...

Page 31: ... 34 043116 4 SCREW HHC M6 1 0 X 12 G8 8 ITEM PART NO QTY DESCRIPTION 35 056739 1 RELAY SOLENOID 12VDC PNL MNT 36 072252 2 GROMMET 1 37 X 06 X 1 00 37 063212 1 GROMMET 1 75 X 12 X 1 50 38 058318 2 TRANSFRM 150A TO 5A 5VA 39 033121 2 SCREW HHM 10 32 X 1 2 40 049226 4 WASHER LOCK M5 41 023897 10 WASHER FLAT 10 ZINC 42 075595 1 ASSM CMA BOX 43 049811 8 WASHER FLAT M6 44 072355 2 HHCS M6 1X12 A C HD 45...

Page 32: ...30 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Radiator Drawing No 0C1406B ...

Page 33: ... LOWER RADIATOR 20 0A6258 1 HOSE UPPER RADIATOR 21 029032 1 HOSE 9 32 ID 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 5 NUT HEX 1 4 20 STEEL 25 022145 12 WASHER FLAT 5 16 ZINC 26 022129 12 WASHER LOCK M8 5 16 27 045771 12 NUT HEX M8 1 25 G8 YEL CHR 28 042907 12 SCREW HHC M8 1 25 X 16 G8 8 29 076749 1 TANK COOLANT RECOVERY 30 080712 1 BRACKET COOLANT R...

Page 34: ... 5 16 8 045771 12 NUT HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 2 SCREW HHC M8 1 25 X 60 G8 8 12 057821 2 SCREW HHC M8 1 25 X 40 G8 8 13 021991 1 EARTH STRAP 14 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 15 0A2308 1 PLUG BUTTON 2 DIA 32 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Radiator Dra...

Page 35: ...XHAUST 6 0C1068 1 SUPPORT MUFFLER 1 5L 7 0C1412 1 ELBOW EXHAUST 45 DEG 8 0A5728 1 MUFFLER 1 6 1 5L SAE 9 060366 2 STRAP MUFFLER 6 DIA 10 066889 4 SCREW HHC M8 X 1 25 X 20MM 11 022145 4 WASHER FLAT 5 16 ZINC 12 022129 4 WASHER LOCK M8 5 16 13 045771 4 NUT HEX M8 1 25 G8 YEL CHR 14 0A8974 1 CAP RAIN 2 Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Ex...

Page 36: ...20 057903 1 CIRCT BRK 25 X 2 240V ITE 057472 1 CIRCT BRK 30 X 2 240V ITE 077906 1 CIRCT BRK 35X2 W 39782 BRACKET 043240 1 CIRCT BRK 40X2 240V ITEM PART NO QTY DESCRIPTION 057905 1 CIRCT BRK 45X2 240V 039765 1 CIRCT BRK 50X2 240V 39782 BRKT 048373 1 CIRCT BRK 70X2 240V 063452 1 CIRCT BRK 80X2 240V 039766 1 CIRCT BRK 90X2 240V 048374 1 CIRCT BRK 100X2 240V 0A2077 1 CIRCT BRK 125X2 120 240V 9 056967 ...

Page 37: ...HER LOCK M4 10 051787 2 SCREW HHC M4 0 7 X 16 G8 8 11 079847 1 BOX CMA 12 0A8504 1 DECAL CMA LABEL 0A8504A 1 DECAL CMA LABEL 13 022661V 083 TUBING SHRINK 19 ID RED ITEM PART NO QTY DESCRIPTION 14 038057 2 GROMMET 7 8 X 1 16 X 3 4 15 058443 2 SCREW CRIMPTITE 1 4 20 X 5 8 16 081224 1 DECAL MFG NAMEPLATE 17 079682 1 HARNESS CMA WIRE 18 086093 2 DECAL CMA WARNING 19 083736 1 DECAL CSA GTS 20 051715 2 ...

Page 38: ...64256 2 SCREW HHM 6 32 X 3 8 SELF TAP 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0A7041 1 ASSEMBLY CARBURATOR LINKAGE 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 LIQUID NEOPRENE 14 029333A 1 TIE WRAP 7 BLACK 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 36 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 k...

Page 39: ...CK M10 7 052213 1 SCREW HHC M10 1 25 X 20 G8 8 8 059567 2 BOLT BATTERY HOLD DOWN 9 078121 1 BAR BATTERY HOLDDOWN 10 022145 2 WASHER FLAT M8 5 16 ZINC 11 022129 2 WASHER LOCK 5 16 12 022259 2 NUT HEX 5 16 18 STEEL 13 050331A 1 BATTERY POST COVER RED 14 050331 1 BATTERY POSTCOVER BLACK 15 075763 3 BOOT BATTERY CABLE Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 k...

Page 40: ...38 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Generator Drawing No 0A9348B ...

Page 41: ... 8 12 0A5601 1 COVER REAR BEARING CARRIER ITEM PART NO QTY DESCRIPTION 13 075554B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 097146 1 FAN RING GEAR ASSEM 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A5061 1 SPACER FLEX PLATE 19 0A4989 1 PLATE FLEX 20 052213 1 SCREW HHC M10 1 25 X 20 G8 8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10 1 5 X 35 G8 8 23 046526 ...

Page 42: ...40 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Natural Gas Fuel System Drawing No 0A9349E ...

Page 43: ...59403 1 CARBURETOR CA55 EM 20 059401 1 GASKET CARBURETOR 21 034154 4 SCREW PHM 10 24 X 1 2 CAD 22 022152 4 WASHER LOCK 10 23 023897 4 WASHER FLAT 10 ZINC 24 062522 1 STUD THR 1 4 20X3 F THR G2 ZNC 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050280 1 DECAL FUEL INLET LPG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 052219 1 BARBED STR 1 8NPT X 5 16 30 048031C 3 CLAMP HOSE BAND...

Page 44: ...42 Generac Power Systems Inc Section 7 Exploded Views and Parts Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Exploded View Engine Compartment Drawing No 0A7642J ...

Page 45: ...NTAKE 38 057522 1 SENSOR COOLANT LEVEL 39 0A6751 1 SW TMP 245DEG 3 8NPT ITEM PART NO QTY DESCRIPTION 40 034339 1 BARBED EL 90 3 8NPT X 5 8 41 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 42 061012 1 PLUG STD PIPE 1 8 SCKT HD 43 039253 6 SCREW HHC M8 1 25 X 20 G8 8 44 0A5110 1 PIPE WATER INLET 45 0A7006 1 O RING 1 1 16X1 5 16X1 8 46 025507 2 WASHER SHAKEPROOF EXT 7 16 STL 47 022500B 2 SPACER 41X 75X 25 S...

Page 46: ...44 Generac Power Systems Inc Section 8 Installation Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Installation Drawing Drawing No 0C1450 ...

Page 47: ...Generac Power Systems Inc 45 Section 8 Installation Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators Installation Drawing Drawing No 0C1450 ...

Page 48: ...46 Generac Power Systems Inc Section 9 Notes Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators ...

Page 49: ...Generac Power Systems Inc 47 Section 9 Notes Guardian Liquid cooled 10 kW 15 kW 20 kW and 25 kW Generators ...

Page 50: ...y any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem occurs The ...

Page 51: ...n 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Servi...

Page 52: ... SHALL NOT APPLY TO THE FOLLOWING 1 Costs of normal maintenance adjustments installation and start up 2 Units sold rated or used for Prime Power applications as Prime Power has been defined by Generac Contact a dis tributor for Prime Power definition and warranty 3 Failures due to a normal wear and tear or b accident misuse abuse negligence or improper installation 4 Products that are modified or ...

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