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Generac 04389-1, 04456-1, 04390-1 Portable Generator User Manual

1. Cri 131n0 HIV 2 WAWANIN Looe 9 m 3GIS 1331 Letz 229 HOLIMS H3dJSNVH L vi 8 202 s ec 709 aaniaans 41 53 Generac Power Systems Inc NOTES Section 9 Notes Guardian Air cooled 7 kW 12 kW and 15 kW Generators 54 Generac Power Systems Inc Section 9 Notes NOTES Guardian Air cooled 7 kW 12 kW and 15 kW Generators Generac Power Systems Inc 55 Section 10 Warranty WARRANTY Guardian Air cooled 7 kW 12 kW and 15 kW Generators NOTE This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as t
2. 13 3 2 Using the Auto Off Manual Switch 14 3 2 1 Auto Position eree eet rs 14 Table of Contents TABLE OF CONTENTS 3 2 2 Off Position 14 3 2 3 Manual Position 14 3 3 Automatic Transfer Operation 14 3 4 Sequence of Automatic Operation 14 3 5 Manual Transfer Operation 15 3 5 1 Transfer to Generator Power SOUP CE ucinio snis 15 3 5 2 Transfer Back to Utility Power 15 3 6 Setting the Exercise Timer 15 3 7 Protection Systems 16 3 7 1 Low Oil Pressure Switch 16 3 7 2 High Temperature Switch 16 9 4 9 OVercr nk u ua ays rry 16 Df A OVerSpeed 16 Section 4 Maintenance 16 dd FUSE Qoo E 16 4 2 Checking the Engine Oil Level 17 4 3 Changing the Engine 17 4 3 1 Engine Oil Recommendations 17 4 3 2 Oil Change Procedure 17 4 4 Changing the Oil Filter 18 4 5 Changing the Engine Air Cleaner 18 4 5 1 7 kW 12 kW and 15 kW GEI6I lOILS pH iren 18 4 6 Spark PlUG S eerte tes 18 4 7 Battery Maintenance
3. 19 4 8 Adjusting GH 410 GT 990 Valve Clearance 19 4 9 Cooling System 20 4 10 Attention After Submersion 20 4 11 Corrosion Protection 20 4 12 Out of Service Procedure 21 4 12 1 Removal From Service 21 4 12 2 Return to 21 4 13 Service Schedule tries 22 Section 5 Troubleshooting 23 5 1 Troubleshooting Guide 23 Section 6 Electrical Data 24 Section 7 Exploded Views and Parts Lists 32 Section 8 Mounting Dimensions 53 Section 9 Notes 54 Section 10 Warranty 56 Generac Power Systems Inc 1 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Guardian Air cooled 7 kW 12 kW and 15 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A operation be copied and posted near the unit s installation site Safety should be stressed to A all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm A This p
4. ea Generac Power Systems Inc L E D ALARM INDICATORS CONTROL PANEL BOX Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 12 amp 15 kW Drawing No 0D8500 A ELECTRICAL DATA 225 224A 224 225A CLOSEST TO BEARING 224A BA 225A O TX BCR 2 18 o O 79 Ni N2 a8 AM sc 1 225 4 224B 2 66 gt 14 4 6 0 11 11 22 6 225 13A 22 22 4 4 r 0 6 r 6 44 224 162 c 162 55 C2 VOLTAGE REGULATOR 0 66 0 66A 4 N2 i 33 13 22 13 13 225 351 224 194 23 4 N2 Ni 13 351 44 23 56 18 11 13A 194 351 CUSTOMER I 15A CONNECTION 23 22 N2 9
5. When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down 3 5 MANUAL TRANSFER OPERATION 3 5 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generator s Auto Off Manual switch to OFF 2 Set the generator s main circuit breaker to its OFF or open position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A DIG A A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 4 Use the manual transfer handle inside the trans fer switch to move the main contacts to their Standby position i e loads connected to the standby power source Figure 3 2 Figure 3 2 Manual Transfer Switch Operation LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 5 To crank and start the engine set the Auto Off Manual switch to MANUAL 6 Let the engine stabilize and warm up for a few minutes 7 Setthe generator s main circuit breaker
6. 15 44 23 CB1 194 i 11 o 9 69 ot 15 239 240V 66A 15A V5 239 13 RED 17 C1 2 0 SC 14 56 14 C1 1 _ _ BATTERY sc 6 0 0 0 C1 6 0 BLACK CUSTOMER 18 IM v SUPPLIED C1 5 SP V VW Generac Bower Systems Inc 31 i urs Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators N Enclosure Drawing No 0D3416 K 32 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators Enclosure Drawing No 0D3416 K ITEM PART NO QTY DESCRIPTION 10 11 12 13 14 15 16 19 20 21 22 23 25 26 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 0 6140 001901 0 6735 0 7061 0 7062 0 7062 0 7063 0C7063A 0C7063B 007064 007065 0C7065A 0C8101A 0C8861 0C8101B 008862 008283 0C8284A 0C8284B 0C8284C 008285 0C8899A 0D1128 0D1128A 0D1605 0D1605A 0D1606 0D5264 0D1839 0D1840 0D2425 0D2588 0D2676 0D2677 0D2979B 0D2979B 0D2979C 0D2979D 0D2979E 0D3057A 0D3058A 0D3057B 0D3057C 0D3058C 0D3057D 0D3059A 0D3059B 0D3059C 0D7176 0D3059D 0D3059E 0C7781 0D3037 0D2537 0D2538 0D3037A 0A2115 E ci cx WO BO i c4 ld 2 ch ci oci L4 cio li B4 lx c l LX i c cA l4 l3 ck ASSEMBLY ENCLOSURE BASE 12KW 15KW ASSEMBLY
7. 4 0 0 L IM 18 5 14 0 85 4 85 86 3 HTO IC 0 132 SES 1 86 18 IC ES LOP 56 56 86 351 0 18 14 56 5 56 5 86 TN n 1 2 3 4 5 2 4 M 86 9 23 SC m 194 CONTROL 56 PRINTED CIRCUIT BOARD 18 14 66A BLACK RED DSW 2 289 1234 15 ON 17 15 15 2 0 ON INDICATES 225 1 20 Sense Transfomer ie 224 m 26 2 Remote Not Auto 2 12V 3 50 Hz Operation BATTERY 4 SPARE CUSTOMER SUPPLIED 28 Generac Power Systems Inc L E D ALARM INDICATORS Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators ae E ELECTRICAL Wiring Diagram 7 kW Drawing No 0D9013 A DATA 224A CLOSEST TO BEARING 225A
8. 1 5 Specifications 6 1 5 1 Generator e eogi niais 6 1 5 2 Engine ceteri et 6 1 6 Fuel Requirements and Recommendations 7 1 7 Fuel Consumption 7 1 8 Reconfiguring the Fuel System 7 1 8 1 7 kW 410cc Engine 7 1 8 2 12 kW and 15 kW 990cc Engine 7 1 9 Location neret tores ave sss 8 1 9 1 Generator irr eere perit 8 1 9 2 Transfer Switch 8 1 10 Battery Installation 8 1 11 The Batt ry eee orent 9 Section 2 Post Installation Start up and Adjustments 10 2 1 Before Initial Startup 10 2 2 Check Transfer Switch Operation 10 2 3 Electrical 10 2 4 Generator Tests Under Load 11 2 5 Checking Automatic Operation 11 2 6 Adjusting the Regulator Natural Gas Only 11 2 7 Engine Governor Adjustment 12 2 7 1 7 kW Units 12 2 7 2 12 kW and 15 kW Units 13 2 7 3 Additional Corrosion Protection 13 2 8 Voltage Regulator Adjustment 13 Section 3 Operation 13 3 1 Breakin
9. 10 32 x 9 16 025145 1 U BOLT 5 16 18 X 1 25 WITH SADDLE 004138 2 GASKET EXHAUST PORT 048031C 2 CLAMP HOSE BAND 030340 1 33 FT HOSE 1 4 ID SAE 30R7 Generac Power Systems Inc 47 QQ ums Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0D3539 B Part 1 48 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists CG urs Guardian Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0D3539 B Part 1 0 ITEM PART NO QTY DESCRIPTION 1 071978 1 ASSEMBLY CONNECTING ROD 2 071980 1 PIN PISTON D20 3 021533 1 SET PISTON RING 90MM 4 0C5848 1 PISTON HC 5 071983 2 RETAINER PISTON PIN 20 6 0D4287 1 ASSEMBLY CRANKSHAFT GH410 SMALL TAPER 7 0A7628 1 ARM GOVERNOR RC45 8 078658 1 PIN R GOVERNOR ARM 9 078659 2 WASHER GOVERNOR ARM THRUST 10 088261E 1 CRANKCASE SUBASSEMBLY WITH PLUGS GH410 11 072655 2 SEAL 35 CRANKSHAFT 12 0A7975 1 ASSEMBLY GOVERNOR GEAR 13 078645 1 C RING GOVERNOR GEAR RETAINER 14 0A7811 1 SPOOL GOVERNOR MACHINE 15 0A9877 1 ASSEMBLY CAMSHAFT amp GEAR 16 076701 1 GASKET CRANKCASE 17 021713B 1 GASKET HEAD 410 18 078691 1 COVER OIL PRESSURE RELIEF 19 045771 1 SPRING OIL RELIEF 360 20 045776 1 BALL DIA 11 32 PRESSURE RELIEF 21 076361 1 WASHER THRUST GOVERNOR GEAR 22 0A8898D 1 ASSEMBLY COVER GEAR TOP CHECK FILL 23 0D2274 2 RETAINER VALVE SPRING 24 004391 2 VALVE
10. ASSEMBLY GROUND WIRE ASSEMBLY IGNITION COIL WASHER LOCK M6 1 4 SCREW TAPTITE M6 1 0 X 25 BP STARTER SPARKPLUG WASHER LOCK M8 5 16 SCREW HHC M8 1 25 X 85 G8 8 KEY WOODRFF 4 X 19D NUT HEX LOCK M10 1 50 SPRING ANTI LASH ROD GOVERNOR CONTROL ASSEMBLY GOVERNOR LEVER SPRING GOVERNOR ASSEMBLY GOVERNOR ADJUSTER SCREW SHC M10 1 5 X 70 G10 9 SPRING GOVERNOR IDLE ASSEMBLY GOVERNOR ADJUSTER BRACKET SEAL GOVERNOR SHAFT Generac Power Systems Inc 43 QQ uere Section 7 Exploded Views and Parts Lists De Guardian Air cooled 7 kW 12 kW and 15 kW Generators 7 kW Generator Drawing No 0D3504 B 44 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists CG urs Guardian Air cooled 7 kW 12 kW and 15 kW Generators 7 kW Generator Drawing No 0D3504 B ITEM PART NO QTY DESCRIPTION 1 06934 1 ADAPTOR ENGINE 2 0C9935H 1 STATOR 3 0C9934H 1 ROTOR 4 0C6043A 1 CARRIER REAR BEARING 5 0C8096 1 FAN 8 CURVED BLADE 6 09593 1 MUFFLER 7 0D3220 1 TAIL PIPE MUFFLER 8 0C8860 1 PANEL MUFFLER BASE 9 031971 1 BEARING 6205 2NSE C3 10 03168 3 5 16 SPECIAL L WASH 11 056147 1 BOLT ROTOR HHCS 5 16 24 X 13 1 2 G5 12 0D1847 4 BOLT STATOR IHHC M8 1 25 x 305mm 13 0C7038C 1 BRACKET ALTERNATOR MOUNTING 14 0D1647 1 DUCT ALTERNATOR AIR 15 0D2558 1 GASKET ALTERNATOR AIR DUCT 16 0C7038B 1 BRACKET ENGINE MOUNTING 17 007758 4 RUBBER MOUNT 18 0388050AE0 1 CABLE 6 40 BLACK BATTERY 19 0C2417A 1 EARTH STRA
11. Amperes Minimum Group 26 26R 12 Volts and 550 Cold cranking Amperes Minimum Weight 452 Pounds 470 Pounds 487 Pounds Output Sound Level 23 ft 7m at full load Normal Operating Range 68 db A 70 5db A 71 5 db A 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature Load current values shown for 120 volts are maximum TOTAL values for two separate circuits The maximum current in each circuit must not exceed the value stated for 240 volts 15 000 watt with upgrade kit 04578 0 Kit includes power harnesses and 70 amp 2 pole circuit breaker 1 5 2 ENGINE Model 04389 1 Model 04456 1 Model 04390 1 Type of Engine GH 410 GT 990 GT 990 Number of Cylinders 1 2 2 Rated Horsepower 14 5 3 600 rpm 26 3 600 rpm 30 3 600 rpm Displacement 410cc 992cc 992cc Cylinder Block Aluminum w Cast Iron Sleeve Aluminum w Cast Iron Sleeve Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Ignition System Solid state w Magneto Solid state w Magneto Solid state w Magneto Re
12. C2 4 uro 0 0 I P lt 55 IW mm LOP 11 ENGINE RUN BA WINDING C144 swe 22 FIELD STATOR M 14 KO A OD C1 3 ELECTRONIC 4 C2 10 C2 9 VOLTAGE 4 4 REGULATOR 0 RUN 0 85 162 C2 11 86 6 4 cB2 7 l 351 225 2 2 7 224 6 EL 66A C2 8 2 WINDING STATOR 23 DIAGRAM KEY n 194 BA BRUSH ASSEMBLY 194 BCR BATTERY CHARGE RELAY a CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION ja SOLENOID CONTROL iom F1 FUSE 15 AMP PRINTED CIRCUIT F2 FUSE 5 AMP BOARD 5 HTO HIGH OIL TEMPERATURE SWITCH 17 HM HOUR RUN METER 15 IM IGNITION MODULE 0 LOP LOW OIL PRESSURE SWITCH 229 SC STARTER CONTACTER 224 SP SPARK PLUG SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 30 Generac Power Systems Inc Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic 7 kW Drawing No 0D9014 A ELECTRICAL DATA C2 6 22 TX C2 5 N2 56VA 224A 225 1VA 224 N1 194 69 lt amp CUSTOMER CONNECTIONS N2 N2 69 13 N1 N1 9 17 11 NEUTRAL 17 e i 22 15A 33 0 swi 194 120V POWER WINDING 120V 239 STATOR
13. D 2 gt SP2 Generac Power Systems Inc 27 ELECTRICAL DATA SP Section 6 Electrical Data ENGINE WIRING Guardian Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 7 kW Drawing No 0D9013 A 3 2 1 BATTERY DIAGRAM KEY CHARGER UTILITY BA BRUSH ASSEMBLY 14 2 BCR BATTERY CHARGE RELAY 1 CB1 MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION 225A D DIODE DSW PCB MOUNTED DIP SWITCH FS E FS FUEL SOLENOID 13A F1 FUSE 15 AMP F2 FUSE 5 AMP 0 GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH 0 C INLINE CONNECTOR ICT INTERCONNECTION TERMINALS IM IGNITION MODULE LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SP SPARK PLUG 14 SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR 14 TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC IC ollo TN nem D 0 14 0 6 0
14. ENCLOSURE BASE 7KW SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE 12KW 15KW ENCLOSURE EXHAUST SIDE 7KW ENCLOSURE SIDE amp BACK 12KW 15KW ENCLOSURE SIDE amp BACK 7KW ENCLOSURE SIDE amp BACK 16KW ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER 12KW 15KW PANEL ALTERNATOR DIVIDER 7KW PANEL MUFFLER BOX SIDE 12KW 15KW PANEL MUFFLER BOX SIDE 7KW COVER MUFFLER BOX 12KW 15KW COVER MUFFLER BOX 7KW GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT 12KW 15KW PAD 24 X48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER 12KW 15KW PANEL ENGINE DIVIDER 7KW BAFFLE INTAKE 12KW 15KW BAFFLE INTAKE 7KW HOUSING FAN 12KW 15KW BAFFLE EXHAUST 7KW BRACKET TOP SUPPORT BRACKET BOTTOM SUPPORT DUCT BASE AIR 12KW 15KW GASKET FRONT DIVIDER COVER FRONT EXHAUST ENCLOSURE COVER BACK EXHAUST ENCLOSURE CLOTH HARDWARE 266 7mm x 146mm 12KW 15KW CLOTH HARDWARE 266 7mm x 146mm 7KW CLOTH HARDWARE 543mm x 146mm CLOTH HARDWARE 266 7mm x 387 4mm CLOTH HARDWARE 7KW FOAM FRONT INTAKE BAFFLE 12KW 15KW FOAM FRONT INTAKE BAFFLE 7KW FOAM TOP INTAKE BAFFLE 12KW 15KW FOAM BACK INTAKE BAFFLE 12KW 15KW FOAM BACK INTAKE BAFFLE 7KW FOAM BACK ENCL STRIP 12KW 15KW FOAM EXHAUST SIDE ENCLOSURE END FOAM EXHAUST SIDE ENCLOSURE FRONT FOAM EXHAUST FAN HOUSING 12KW 15KW WAS
15. Kit Contains 66 2 5 19 20 39 40 47 64 93 140 67 8 11 12 13 68 4 5 6 69 16 16B 17 18 70 7 48 49 50 51 52 53 54 55 56 58 59 60 71 48 49 50 51 52 53 54 55 56 58 59 60 62 72 27 28 29 73 3 32 33 34 35 36 40 72 4O Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators GT 990 Engine Drawing No 0D8674 C Part 1 ITEM PART NO QTY DESCRIPTION 0C5729 0C3008 090388 0C5372 0C3005 0C3003 0D8067A 071983 0C2981C 045761A 0C5848 021533 071980 0D4041 0C2983 0C2985A 0C2985B 0D4042 0A7811 002977 005943 0D4040E 0D4122E 0C2969 0D3961 0D2157 005313 0D4123 078699E 0C3011 0C3009 0C3010 093873 0C5315 0C5998 0D1667 0C2991 1 k sk sk s R R k NN no no no no n5 ASSEMBLY CRANKCASE HOUSING WITH SLEEVE SEAL 38 CRANKSHAFT SCREW TAPTITE M6 1 0 X 12 YC ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 G amp S RETAINER PISTON PIN 20 ROCKER COVER NO OIL FILL STUD M8 1 25 10MM X 30 G5 ZINC PISTON HC SET PISTON RING 90MM PIN PISTON D20 ASSEMBLY CAMSHAFT amp GEAR SHAFT GOVERNOR ROLLER BEARING GOVERNOR PLATE ROLLER BEARING GOVERNOR ASSEMBLY GOVERNOR GEAR SPOOL GOVERNOR MACHINED GAS
16. Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or dis connecting battery terminals warninc amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic MAINTENANCE 2 0 Section 4 Maintenance A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire N because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in ba
17. VALVE SEAL VALVE STEM D7 WASHER VALVE SPRING NUT JAM ROCKER ARM STUD ROCKER ARM M8 1 0 x 57mm PIVOT ROCKER ARM ROCKER ARM PLATE PUSH ROD GUIDE SCREW HHFC 8 1 25 X 65 VALVE EXHAUST VALVE INTAKE TAPPET SOLID ASSEMBLY HEAD 2 G amp S PUSHROD 144 6 GASKET HEAD BARBED ELBOW 90 3 8NPT X 3 8 KIT GASKET KIT PISTON amp RINGS KIT BREATHER ASSEMBLY KIT GOVERNOR ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OIL RELIEF Generac Power Systems Inc 41 QQ ums Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators 0 GT 990 760 Engine Drawing No 0D8674 C Part 2 42 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators GT 990 760 Engine Drawing No 0D8674 C Part 2 ITEM PART NO QTY DESCRIPTION 0C5136A 0C3024 0C3040 0C8127 0D8564A 0D8564B 0D2595 0D4417 0C3025 0D3083 067292 070185 075281 0C1085 043182 035461A 040173 0C9806 0C3026 0C9764 0C3043 0C7694 0C7693 0C3041 070008 070006 040976 0C3016A 085011 0C3725B 0C3031 0C3032 0A5992 051754 0C3033 N pop a pA RA oa AR RPO KNOB AIR CLEANER COVER AIRBOX NG LP PRE CLEANER ELEMENT AIR CLEANER ASSEMBLY MIXER AIRBOX 990 ASSEMBLY MIXER AIRBOX 760 SCREW SHOULDER 8MM
18. 18 13 n n 33 NI 194 eus 14 13 66 255 F2 F1 15A 17 mm O 17 13 EJ 15 17 2 0 225 swi S S 3 d 5 15 E z gt 2 224 ia Sie 3 5 3 S 3 m 8 15 U o 252555 22232 swe 240V GENERATOR 2 S b p AUTO OUTPUT TO TRANSFER SWITCH CONTACTOR 5 j 2 MANUAL Generac Power Systems Inc 25 Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic 12 amp 15 kW Drawing No 0D8501 A ELECTRICAL DATA 22 225A 224A BATTERY 225B F2 CHARGER 224B 13A S p 13 13 F1 7 7 9 9 Q ia 1 1673 4 13A 77 C2 1 zi BATTERY CHARGE 66 0 14 WINDING LACAN UA 66 C2 2 C2 4 uro 96 0 2 11 0 55 z LOP 11 ENGINE RUN BA WINDING C1 4 i Sw2 22 STATOR FIELD KPO OF 02 4 C1 3 ELECTRONIC C2 10 C2 9 VOLTAGE 4 4 REGULATOR 0 66A 0 6 85 162 C1 6 86 6 4 7 J 0 351 225 C2 7 224 028 AX HT 66A DPE WINDING STATOR DIAGRAM KEY 7 23 BA BRUSH ASSEMBLY 86 194 BCR BATTERY CHARGE RELAY 23 CB1 CIRCUIT BREAKER MAIN OUTPUT 194 CB2 CIRCUIT BREAKER ALT EXCITATION 56 D DIODE 18 FS FUEL SOLENOID 14 F1 FUSE 15 AM
19. CONTROL PANEL BOX OSEST IO 225 224 BA O 224A 0 225A TX CB2 E Trl N1 162 66 2 1 4 225A 10 224A lt s 66 2 8 14 4 6 7 11 6 11 11 22 5 66 s 22 22 4 4 4 0 0 N2 0 0 2 N1 6 t 1 44 162 162 55 C2 VOLTAGE REGULATOR 4 66A 0 0 66A 4 N2 33 13 22 225 0 351 224 0 194 23 2 N1 13 44 56 351 1 13A 194 351 CUSTOMER 15A CONNECTION 18 _ 33 22 7 14 e na 28 13 N1 194 F2 Fi n n CB1 0 13 i 239 U U UUU A s s 33 Swi 8 s 15 lt 3 ji 55 elle 110 sw2 8 15 9 2 2 dd AUTO 240V GENERATOR m 2 8 EE OUTPUT TO TRANSFER a 88 SWITCH CONTACTOR 2 ES MANUAL Generac Power Systems Inc 29 Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL DATA 7 Electrical Schematic 7 kW Drawing No 0D9014 A 22 225A BATTERY 225B F2 CHARGER 224B 13A 13 13A F1 7 7 9 9 MAS 1 3673 13A 77 C24 0 7 BATTERY CHARGE 66 14 15 WINDING AAJ 66 2 2 22 0 0
20. HHC M5 0 8 x 30mm Control Panel PARTS LISTS ITEM PART NO QTY DESCRIPTION 22 23 24 26 0D5240 051714 051714 0D8502 0D8441 0E0120 074908 049226 051716 0C3910 022507 099727 046689 063617 075475 043180 0D8439 0E0119 092036 045770 0C7171 0D2989 0D3700 0912970069 0A2311 0A1658 022473 038750 022097 049813 031879 031879 023897 O o SWITCH SPDT ON MOM ON NUT HEX M3 0 5 8 5KW 12KW 13KW NUT HEX M3 0 5 7KW NEUTRAL ISOLATOR HARNESS CONTROL PANEL WIRE NOT SHOWN 8 5KW 12KW 13KW HARNESS CONTROL PANEL WIRE NOT SHOWN 7KW SCREW TAPTITE M5 0 8 x 10 BP WASHER LOCK M5 NUT HEX M5 0 8 TRANSFORMER SCREW HHC 1 4 20 x 1 2 FUSE 5A X AGC5 TERMINAL STRIP RELAY PANEL 12VDC DPDT 10A 240VAC SCREW PPHM M4 0 7 x 10mm WASHER FLAT M4 COVER CONTROL PANEL COMPONENT 8 5KW 12KW 13KW COVER CONTROL PANEL COMPONENT 7KW SCREW PPHMS LW 6 32 x 1 4 SCREW HHC M5 0 8 x10mm COVER CONTROL PANEL 8 5KW 12KW 13KW COVER CONTROL PANEL 7KW NUT FLANGE M6 1 0 NYLOCK ASSEMBLY ROOF DOOR GROUND WIRE SCREW SWAGE 1 4 20 x 1 LOCKWASHER SPECIAL 1 4 WASHER FLAT 1 4 SCREW HHC M6 1 0 x 30mm WASHER LOCK M6 1 4 NUT HEX M6 1 0 WASHER FLAT 4 8 5KW 12KW 13KW WASHER FLAT 4 7KW WASHER FLAT 10 Generac Power Systems Inc 35 QQ ums Section 7 Exploded Views and Parts Lists Guardian Air c
21. M6 1 0 X 18 WASHER RUBBER 1 4 X 1 8 THICK SWITCH OIL PRESS ASSEMBLY OIL DRAIN HOSE NIPPLE 3 4 16 UNF FILTER OIL D 69 X 64 LONG SWITCH THERMAL 284F SCREW PPHM M3 0 5 X 8 WASHER LOCK M3 BARBED STR 1 4NPT X 3 8 WITH VIBRA SEAL CLAMP HOSE 5 5 62 62 HOSE 3 8 1 0 X 6 LONG COOLER OIL PLASTITE 1 4 15 X 3 4 GASKET MANIFOLD PORT MANIFOLD CYLINDER 2 MANIFOLD CYLINDER 1 SLEEVE RUBBER WASHER FLAT M8 SS WASHER LOCK M8 SSTL SCREW SHC M8 1 25 X 20 G12 9 PLATE BACKING GT990 WITH OIL COOL INSULATOR ASSEMBLY IGNITION FLYWHEEL ASSEMBLY FAN NYLON PLATE FAN WASHER SHAKEPROOF INT M8 SS SCREW 8 1 25 X 12 G8 8 WASHER 25mm PARTS ITEM PART QTY DESCRIPTION 108 109 110 0 3034 0 8549 0C3022A 0D1131 045756 0C9763 0C3036 0C8919 079246 0C3018 0C3019 0D1142A 0D1143 066849B 0C3053 0C3052 022097 092079 0C3017 0D4529 022129 061906 082774 052859 0C8468 0C3048 0D3754 0D3742 0C8482 0D2576 0D3743 0D3705 0C2993 N la La La La l la la 2a BBP HP allg NUT HEX M24 SNORKEL AIR INTAKE HOUSING BLOWER NG COOLER GUARD FAN SCREW TAPTITE M6 1X10 YELLOW CHROME NUT GROMMET 1 4 PLUG HOSE BREATHER BRACKET STARTER SCREW HHC M6 1 0 x 16 WITH LOCK WASHER WRAPPER UPPER CYLINDER 1 WRAPPER LOWER CYLINDER 1 WRAPPER LOWER CYLINDER 2 WRAPPER UPPER CYLINDER 2 SCREW TAPTITE M5 0 8 X 8 BP
22. SPRING LF 25 086025 1 SET GEROTOR 12 THK 26 007393 1 BALANCER 27 021714 1 ASSEMBLY CYLINDER HEAD SEATS amp GUIDES 28 086516 1 VALVE EXHAUST 29 086517 1 VALVE INTAKE 30 088396B 2 PUSH ROD 31 083897 2 TAPPET 32 077158 1 ASSEMBLY SCREEN OIL PICK UP 33 003150 1 GASKET ROCKER COVER 410 34 072694 2 STUD D20 PIVOT BALL 35 083907 2 ROCKER ARM 36 072696 2 NUT JAM ROCKER ARM 37 078694 1 PLATE PUSH ROD GUIDE 38 021742 4 SCREW HHFL M10 1 5 X 105 39 0D6094 1 ASSEMBLY ROCKER COVER BREATHER 40 076329 1 PLUG OIL FILL PLASTIC 41 086254 1 O RING 17 8 x 2 4 42 0D4788 1 PLUG STANDARD PIPE 3 8 STEEL SQUARE HEAD 43 074908 1 SCREW TAPTITE M5 0 8 X 10 BP 44 086515 4 KEEPER VALVE SPRING 45 078606 4 SCREW amp LOCKWASHER M6 1 X 12 46 0A1442 8 SCREW HHFC M8 1 25 X 42 47 078672 1 SEAL VALVE STEM D7 48 089673 2 WASHER VALVE SPRING 49 0B2104 1 WASHER LARGE SPRING 50 078699C 2 DOWEL SEAMED SLEEVE 51 0A7627 1 SHAFT GOVERNOR RC55 52 043790A 1 BARBED ELBOW 90 3 8NPT X 3 8 LOCKTITE 53 088590 1 DOWEL DIA 12 X 18L 54 078699B 1 DOWEL SLEEVE SEAMED 12 DIA Generac Power Systems Inc 49 QQ ums Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0D3539 B Part 2 50 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists CG urs Guardian Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0D3539 B Part 2 ITEM PART N
23. X 3 32 42 075281 1 SWITCH THERMAL 43 043182 2 WASHER LOCK M3 44 0C1085 2 SCREW PPHM M3 0 5 X 8 Generac Power Systems Inc 51 PARTS LISTS ITEM 0D5694 0 5765 0 4647 0C4680 0C6070 022985 022264 075475 0C5760A 0C6606 097934 004645 005761 005968 0C6066 0C5759 0C5764 0C5764A 18 070728 070728 19 0C6069 20 0C5762 a a a Lk E E PART NO QTY RR RO DESCRIPTION CASTING TWIN REGULATOR HOUSING SOLENOID TWIN REGULATOR GASKET SOLENOID PLUNGER LP REGULATOR ASSEMBLY SPRING SOLENOID PLUNGER WASHER FLAT 6 WASHER LOCK M4 SCREW PPHM M4 0 7 X 10 JET GN 410 ENGINE LP 7KW BARBED STRAIGHT 1 2NPT x 1 2 O RING CHECK VALVE ADJUSTER SCREW TWIN REGULATOR LEVER REGULATOR SUPPORT INLET SEAL SEAL INLET PIN PIVOT ARM SPRING REGULATOR SPRING REGULATOR 7KW SCREW PFHMS M3 0 5 x 5 SCREW PFHMS 0 5 x 5 7KW GASKET DIAPHRAGM COVER TWIN REGULATOR 5e Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators Gas Regulator Drawing No 0D8720 B PART NO QTY 045764 045764 0C6731 06067 004706 0C6068 0C4643A 026073 0A4032 0D3308 0D3308 004643 028414A 0D5698A 0C5760B 0C5760C 0C5760D 0C5760E 0D3973 16 FOR GT 760 ENGINE ONLY 36 37 DESCRIPTION SCREW TAPTITE M4X8 BP SCREW TAPTITE M
24. alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Guardian Air cooled 7 kW 12 kW and 15 kW Generators Keep a fire extinguisher near the generator at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extin guisher properly charged and be familiar with its use If you have any question pertaining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applica ble fuel gas codes Before placing the home stand by electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation you must inspect the fuel system periodically for leaks No leakage is permitted STANDARDS INDEX In the absence of pertinent standards codes regula tions and laws the published information listed below may be used as install
25. by placing washers between the switch enclosure and mounting sur face Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and corrosive vapors 1 10 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if nec essary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Set the generator s Auto Off Manual switch to OFF 2 Turn off utility power supply to the transfer switch 3 Remove the 5A and 15A fuses from the generator control panel warninc If the Auto Off Mlanual switch is not set to its OFF position the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off sparking can occur at the battery posts and cause an explosion Guardian Air cooled 7 kW 12 kW and 15 kW Generators Battery cables were factory connected at the genera tor Figure 1 5 Connect cables to battery posts as follows 4 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a nega tive NEG or NOTE Damage will result if battery connections are made in r
26. correspondingly high or low adjust the engine governor as follows 2 7 1 7 KW UNITS 1 Loosen the governor clamp bolt Figures 2 3 on page 13 2 Hold the governor lever at its wide open throttle position and rotate the governor shaft clockwise as far as it will go Then tighten the governor lever clamp bolt to 70 inch pounds 8 N m 3 Start the generator let it stabilize and warm up at no load 4 Connect a frequency meter across the generators AC output leads 5 Turn the speed adjust nut to obtain a frequency reading of 63 Hz 6 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the volt age regulator may require adjustment Figure 2 3 Engine Governor Adjustment Shaft Rotate Clockwise No Load Idle Governor Clamp Bolt Adjustment Screw Section 3 Operation OPERATION Guardian Air cooled 7 kW 12 kW and 15 kW Generators d 2 72 12 KW AND 15 KW UNITS 1 Loosen governor clamp bolt See Figure 2 3 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 2 4 to adjust frequency to 58 Hz 5 Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6 Using your hand push the governor a
27. 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 Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISS
28. kW adjustment screws While watching the frequency meter slowly turn the adjustment screws clockwise or counterclockwise one at a time until the highest frequency is read on the meter Only limited adjustment is available between the set pins 7 kW only Under no cir cumstances should any of the pins be removed Figures 2 1 and 2 2 Figure 2 1 Dual Fuel Regulators Adjustment Screw One Side Only Adjustment Screw Both sides 6 When the highest frequency is reached maximum power has been set From this point turn both adjustment screws 1 4 turn counterclockwise The regulator is now set Figure 2 2 Placement of Regulator MNA 12 Generac Power Systems Inc Guardian Air cooled 7 kW 12 kW and 15 kW Generators 7 Turn utility power to the main distribution panel back on This can be done by switching the serv ice main breaker to the on or closed position Allow the generator to shut down warninc amp A Do not make any unnecessary adjustments Factory settings are correct for most applica tions However when making adjustments be careful to avoid overspeeding the engine If this procedure or equipment are not available to you locate the Generac Guardian Dealer nearest you and they can perform the adjustments NOTE A service fee may be charged for this adjustment 27 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are
29. ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 5 2 1 AUTO POSITION Selecting this switch position activates fully automat ic system operation It also allows you to start and exercise the engine every seven days with the setting of the exercise timer see Section 3 6 Page 16 This position also is used for remote starting when it is set up 322 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 3 22 5 MANUAL POSITION Set the switch to Manual to crank and start the engine Transfer to standby power will not occur unless there is a utility failure Figure 3 1 Generator Control Panel FUSE Locate your nearest GENERAC dealer at www generac com b 5A GENER AC rower systems Inc SYSTEM SET LOW OIL FUSE HIGH TEMP e OVER SPEED OVER CRANK bw L 15A SET FLASHING GREEN LED EXERCISE OOO 4 FLASHING RED LEDS TIME bcd EXER CISER NOT SET AUTO OFF MAN A warninc amp A With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a pre set level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remo
30. such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 4 9 for vent locations Figure 4 9 Cooling Vent Locations AIR OUTLET 4 ttt t AIR INTAKE wanNING amp The exhaust from this product gets extremely 5 hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system cauroN amp A The maximum ambient temperature for your generator is 40 C 104 F 4 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it MUST NOT be started and operated Following any submersion in water have a Generac Guardian Authorized Dealer thoroughly clean and dry the gener ator 4 11 CORROSION PROTECTION Periodically wash and wax the enclosure using auto motive type products Frequent washing is recom mended in salt water coastal areas Spray engine linkages with a light oil such as WD 40 4 12 OUT OF SERVICE PROCEDURE 4 12 1 REMOVAL FROM SERVICE If you cannot exercise the generator every seven days and it is to be out of service longer than 90 days pre pare the generator for stora
31. the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE You must hold the rocker arm jam nut in place as you turn the pivot ball stud When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in lbs torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 4 10 Valve Clearance Adjustment Rocker Pivot Ball Arm Jam Nut Re attach the valve cover NOTE Start all four screws before tightening or you will not be able to get all the screws in place Make sure the valve cover gasket is in place Re attach the spark plug wire to the spark plug On GT 990 Repeat the process for the other cylinder 20 Generac Power Systems Inc Guardian Air cooled 7 kW 12 kW and 15 kW Generators 4 9 COOLING SYSTEM Air inlet and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes
32. the following addresses For Air cooled Product For Liquid cooled Product ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC GENERAC POWER SYSTEMS INC P O BOX 297 211 MURPHY DRIVE WHITEWATER WI 53190 EAGLE WI 53119 Part 1 56 Generac Power Systems Inc Section 10 Warranty Guardian Air cooled 7 kW 12 kW and 15 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertai
33. to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All trans portation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Generac Guardian generators utilizing non Generac Guardian automatic transfer switches Any Generac Guardian generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear
34. up and Adjustments Guardian Air cooled 7 kW 12 kW and 15 kW Generators DIG A The transfer switch is now electrically hot Contact with hot parts will result in extreme ly hazardous and possibly fatal electrical shock Proceed with caution 5 Use an accurate AC voltmeter to check utility power source voltage across transfer switch ter minals N1 and N2 Nominal line to line voltage should be 240 volts AC 6 Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 7 When certain that utility supply voltage is com patible with transfer switch and load circuit rat ings turn OFF the utility power supply to the transfer switch 8 On the generator panel set the Auto Off Manual switch to MANUAL The engine should crank and start 9 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator s main circuit breaker to its ON or closed position A Di A A Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock 10 Connect an accurate AC voltmeter and a frequen cy meter across transfer switch terminal lugs E1 and E2 Voltage should be 242 252 volts fre quency should read about 61 63 Hert
35. 156 X 160 164 20 022473 1 WASHER FLAT 1 4 ZINC 055450 1 PLUG HEYMAN DP1375 10KW 12KW 13KW 025034 1 PLUG STEEL 1 0625 STMPSN 3811 14KW 15KW 16KW 0D4684 1 HARNESS ADAPTER PLATE 0D3319 1 PANEL SUB BREAKER BASE 056326 1FT TRIM VINYL BLACK 1 8GP 022152 6 WASHER LOCK 10 087680 1 NUT WING M6 1 0 077441 1 HANDLE TRANSFER SWITCH HOME STANDBY 063378 4 HOLDER CABLE TIE 074138 2 LUG DIS QK NI S 10X45 DEG BR T 036933 6 SCREW PPHM 10 32 X 3 8 077033 6 LUG SLDLSS 1 0 14X9 16 AL CU 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 028739 4 TIE WRAP 3 9 X 10 NAT L UL 038150 2 WASHER FLAT 8 ZINC 0D3191 1 COVER RELAY amp TERM BLOCK 0D3088 1 WIRE HARNESS GTS LOAD CENTER NOT SHOWN FOR CLARITY 073591 2 FUSE HOLDER 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591 040213B 4 PCB SUPPORT SNAP IN 1 3 8 0C8037 3 CIRCT BRK 20 X 1 HOM120 0D3190 1 CIRCT BRK 20 X 2 HOM220 08036 5 CIRCT BRK 15 X 1 HOM115 08035 1 CIRCT BRK 30 X 2 HOM230 0D3320 1 COVER HARNESS ENTRY 0D3093 1 HARNESS GTS TO EXT CONN BOX 10KW 12KW 13KW 0D3926 1 HARNESS GTS TO EXT CONN BOX 14KW 15KW 16KW 022264 2 WASHER LOCK M4 0A7215 4 SCREW SW 1 4 20X5 8 N WA JS500 0A2110 4 SCREW SWAGE 1 4 20 X 1 2 ZINC 075475 2 SCREW M4 0 7 X 10 0D3094 1 HARNESS GTS TO MAIN PANEL Generac Power Systems Inc 39 PART ioe Section 7 Exploded Views and Parts Lists Le Guardian Air cooled 7 kW 12 kW and 15 kW Generators 0 GT 990 Engine Drawing No 0D8674 C Part 1
36. 3 E 9 LISTS PARTS 0 34 Generac Power Systems Inc ITEM PART NO QTY 1 20 21 0A9947E 0A9947G 0A9947F 0A9947C 0A9947D 0A1801 083049 002174 075210A 0D3062 0D8615 032300 022676 033873 0D5045 023484E 075476 022264 051715 043182 043182 043181 0D8443 054502 053623 0D8438 0 0118 075235 1 _ Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators Drawing No 0D8503 E DESCRIPTION CIRCUIT BREAKER 30 X 2 240V SQD QOU230 7KW CIRCUIT BREAKER 40 X 2 240V SQD QOU240 8 5KW CIRCUIT BREAKER 50 X 2 240V SQD QOU250 12KW CIRCUIT BREAKER 60 X 2 240V SQD QOU260 13KW CIRCUIT BREAKER 70 X 2 240V SQD 000260 15KW ASSEMBLY BATTERY CHARGER ENGINE ASSEMBLY POTTED REGULATOR RELAY 12V 25A SPST 8 5KW 12KW 13KW BLOCK 1 POSITION HEX STAND OFF 466 32 x 3 8 ASSEMBLY HOME STANDBY CONTROLLER HOLDER FUSE FUSE 15AMP X AGC15 SWITCH ROCKER DIN RAIL SNAP BUSHING SB 687 8 SCREW PPHM M4 0 7 x 16mm WASHER LOCK M4 NUT HEX M4 0 7 WASHER LOCK M3 8 5KW 12KW 13KW WASHER LOCK M3 7KW SCREW PHM M3 0 5 x 10mm DECAL CONTROL PANEL NOT SHOWN CIRCUIT BREAKER 3 X 1 ETA 46 500 P 8 5KW 12KW 13KW CIRCUIT BREAKER 2 5 X 1 ETA 46 500 P 7KW CONTROL PANEL BOTTOM 8 5KW AA2KWI 13KW CONTROL PANEL BOTTOM 7KW SCREW
37. 4 YOUR GENERATOR Figure 1 1 7 kW Single Cylinder GH 410 Engine Control Panel Data Decal a N Exhaust MN d Enclosure L NET Filter Fuel Regulator Oil Filter Battery Compartment Figure 1 2 12 kW and 15 kW V twin GT 990 Engine N Data Control Decal Panel Cil Dipstick Air Filter Exhaust Enclosure Fuel Regulator Battery Compartment Oil Filter GENERAL INFORMATION Generac Power Systems Inc 5 1 5 SPECIFICATIONS 1 5 1 GENERATOR Section 1 General Information Guardian Air cooled 7 kW 12 kW and 15 kW Generators Model 04389 1 Model 04456 1 Model 04390 1 Rated Max Continuous Power Capacity Watts 6 000 NG 7 000 LP 12 000 NG 12 000 LP 13 000 NG 15 000 LP Rated Voltage 120 240 120 240 120 240 Rated Max Continuous Load Current Amps 120 Volts 50 0 NG 58 3 LP 100 0 NG 100 0 LP 108 3 NG 125 0 LP 240 Volts 25 0 NG 29 2 LP 50 0 NG 50 0 LP 54 2 NG 62 5 LP Main Line Circuit Breaker 30 Amp 50 Amp 60 Amp 70 Ampt Phase 1 1 1 Number of Rotor Poles 2 2 2 Rated AC Frequency 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 Recommended Air Filter Generac Part C8127 Generac Part C8127 Generac Part C8127 Battery Requirement Group 26 26R 12 Volts and 350 Cold cranking Amperes Minimum Group 26 26R 12 Volts and 550 Cold cranking
38. 4X8 BP 7KW RIVET POP 118 X 125 SUPPORT DIAPHRAGM DIAPHRAGM TWIN REGULATOR CAP DIAPHRAGM SUPPORT INLET TWIN REGULATOR 11 11 DIA PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD PIN LIMITED ADJUSTMENT WASHER FLAT M3 X 10mm O D WASHER FLAT M3 X 10mm O D 7KW INLET TWIN REGULATOR NO HOLE NOT SHOWN 7KW BARBED STRAIGHT 1 8 NPT X 1 4 JET IDLE PRIMER PHILLIPS HD JET GT760 CYL 1 NAT GAS JET GT760 CYL 2 NAT GAS JET GT 760 LP CYL 1 JET GT760 LP CYL 2 PLUG EXPANSION 16mm A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY PARTS LISTS 0 S3HONI SH3 L3IATTTIIA NI SNOISN3IWIG TV HV3H IS LHOIH Drawing No 0D3739 B AAAAAA AAAA4A r OSNIGNNOYS SS399Y ond 3AOW3H i S310H SS390V N Section 8 Mounting Dimensions Guardian Air cooled 7 kW 12 kW and 15 kW Generators H LINN aNnouv TV N3dO WrIWININ NWITTOO H31VM JO 34nss3ud Svo A3TINI TANS LAN v E em gzztt ew 0 98 uui zu Al dOOH JHL Ad L4 LON OG SH3NHOO SATOH NI14I1 00 ee 16101 Leet 067 pr
39. 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire N because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from your body before touching the battery by first touching a grounded metal surface A Be sure the Auto Off Manual switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Generac Power Systems Inc 9 POST INSTALLATION START UP ADJUSTMENTS Be sure the utility power supply is turned off and the 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as you attach the cables and cause an explosion 2 1 BEFORE INITIAL START UP Before starting complete the following 1 Set the generator s main circuit breaker to its OFF or open position 2 Setthe generator s Auto Off Manual switch to the OFF position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 4 Turn OFF al
40. 6 X 1 0 Y ZNC GASKET BATTERY SUPPORT BRACKET PLUG PLASTIC 0 593 HEYCO 1675 LUG SLDLSS 2 8X17 64 CU SCREW TAPTITE M6 1 0X25 BP LIWASH SPECIAL 1 4 BRACKET BATTERY HOLD DOWN 7KW CONTACTOR STARTER 7KW CABLE 6 RED BATTERY 38 5 NUT HEX 1 4 20 STEEL 7KW WASHER LOCK 5 16 12KW 15KW WASHER LOCK 5 16 7KW SCREW TAPTITE M5 0 8 X 10 BP HARNESS ENGINE 12KW 15KW HARNESS ENGINE 7KW BUSHING SNAP SB 1000 12 SCREW HHC 5 16 18 X 3 4 G5 7KW RIVET 1 8 X 0 126 0 375 LSH LIWASH SPECIAL 10 ASSEMBLY ROOF DOOR GROUND WIRE ASSEMBLY ROOF DOOR GROUND WIRE PLUG PLASTIC 1 375 12KW 15KW GASKET CLIP ON SELF GRIPPING PLATE HOT GROMMET 2 75 X 1 16 EXTERNAL CONNECTION BOX POWER BLOCK HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 12KW 15KW HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 7KW HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 16KW SCREW PPHM 10 32 X 1 WASHER LOCK 10 WASHER FLAT 10 ZINC NUT HEX 10 32 STEEL FUEL LINE 3 4 OUTDOOR NOT SHOWN WASHER SHAKPROOF EXT 1 4 STEEL NUT HEX 6 1 0 G8 YELLOW CHROME HINGE LIFT OFF TYPE A KNUCKLE HINGE LIFT OFF TYPE B KNUCKLE SCREW HHC M6 1 0 X 16 G8 8 SCREW SWAGE 1 4 20 X 1 SCREW HHC 8 1 25 X 25 WASHER FLAT 5 16 NUT HEX M8 1 25 SELF ALIGN SCREW M6 HH Generac Power Systems Inc 33 Guardian Air cooled 7 kW 12 kW and 15 kW Generators Section 7 Exploded Views and Parts Lists Control Panel Drawing No 0D850
41. E L RCISER NOT SET 42 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 Page 6 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figures 4 2 and 4 3 1 Start the generator by moving the Auto Off Manual switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth 3 Install the dipstick then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE FULL MARK caution Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 4 Install the dipstick 5 Reset the Auto Off Manual switch to its original position Figure 4 2 Oil Dipstick and Fill 7 kW Ef MAINTENANCE Section 4 Maintenance Figure 4 3 Oil Dipstick and Fill 12 kW and 15 kW Oil Dipstick 45 CHANGING THE ENGINE OIL 45 1 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 Synthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with break in oil
42. E DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR ICT INTERCONNECTION TERMINALS IM1 IGNITION MODULE CYLINDER 4H IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SP1 5 2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC ENGINE WIRING SP1 0 0 IM1 BATTERY CHARGER 225B 224B 13A TB 85 SP2 IC 86 IC IM2 85 86 BLACK RED 12V BATTERY CUSTOMER SUPPLIED SC 13 2 C1 SCR 86 tpe 851 86 1 2 3 4 5 J2 J1 CONTROL PRINTED CIRCUIT BOARD DSW 1234 muna Q ON INDICATES ON 1 20 Vac Sense Transformer 2 Remote Not Auto 3 50 Hz Operation 4 SPARE
43. GENERAG POWER SYSTEMS INC Installation and Owner s Manual GENERAC SWAS3IDDUZAINT Air cooled Prepackaged Automatic Standby Generators Models 04389 1 6 kW NG 7 kW LP 04456 1 12 kW NG 12 kW LP 04390 1 13 kW NG 15 kW LP d deo Jo O Not intended for use as Primary Power in place of utility or in life support applications DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model of the Guardian product line by Generac Power Systems Inc This model is a compact high performance air cooled engine driven generator designed to automatically supply electrical power to operate critical loads dur ing a utility power failure This unit is factory installed in an all weather metal enclo sure that is intended exclusively for outdoor installation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact Generac or your nearest Generac Guardian Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care lessly Observe t
44. HER SELF LOCKING 12KW 15KW WASHER SELF LOCKING 7KW FOAM FRONT EXHAUST ENCLOSURE COVER FOAM BACK EXHAUST ENCLOSURE COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE LIFT OFF TYPE A PIN HINGE LIFT OFF TYPE B PIN LATCH QUARTER TURN NON LOCKING WASHER NYLON 250 PARTS 00 ITEM PART NO QTY DESCRIPTION 44 45 46 47 48 49 50 51 79 80 81 82 83 84 85 87 88 89 90 91 92 93 022097 022473 036261 047411 043116 043116 0D3700 083512 090388 092120 0D3167 0A3328 055414 092079 0A1658 002937 086729 0388040AJ0 022127 022129 022129 074908 0D2346 0D2345 023484F 022142 0A7836 0A8475 0912970069 0912970070 055450 0D2023 0D3701 0D3472 008742 008911 0D3338 0D3419 0D3928 036937 022152 023897 022158 0D3031 026850 049813 0D2537A 0D2538A 047411 0A2311 043107 022145 045771 003906 9 4 14 12 5 6 18 11 34 Hw WASHER LOCK M6 1 4 WASHER FLAT ZINC RIVET POP 125 X 129 133 30 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M6 1 0 X 12 08 8 12KW 15KW SCREW HHC 6 1 0 X 12 G8 8 7KW NUT LOCKING FLANGE 6 1 0 SCREW TAPTITE M8 1 20 X 16 BP SCREW TAPTITE M6 1 0 X 12 BP 12KW 15KW SCREW TAPTITE M6 1 0 X 12 BP 7KW NUT LOCK TRIC
45. ION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Generac Power Systems Inc 57 Section 10 Warranty WARRANTY Guardian Air cooled 7 kW 12 kW and 15 kW Generators GENERAC POWER SYSTEMS STANDARD TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Dealer is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims
46. KET CRANK CASE SEAL OIL PASSAGE ASSEMBLY CRANKSHAFT HORIZONTAL DIRECT DRIVE GT 990 ASSEMBLY CRANKSHAFT HORIZONTAL DIRECT DRIVE GT 760 ASSEMBLY CONNECTING ROD GT 990 ASSEMBLY CONNECTING ROD GT 760 SCREW SHC 6 1 0 X 50 G8 8 SCREEN OIL PICKUP ASSEMBLY OIL PUMP SLEEVE SEAMED DOWEL 10 DIA COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 GEROTOR OUTER CLAMP OIL TUBE ARM GOVERNOR E RING GOVERNOR ARM PARTS ITEM PART NO QTY DESCRIPTION 35 0C2988 36 0C2992 37 0 3971 38 0C5305 39 0C3027 40 0C3007 41 005731 42 0C3006 43 0C8566 44 093064 45 0C8808 46 0D2723B 47 0C2979 48 086515 49 0D2274 50 0D3867 51 078672 52 0C5371 53 0D5326 54 0D6023 55 0D5354 56 0D5313 57 0D6024 58 0C2976 59 086516 60 002229 61 083897 62 0D8067B 63 088396D 64 0C2978 65 043790A LOCKTITE 66 0D4010 67 0D4011 68 0D4012 69 0D4013 70 0D8675A 71 0D8675B 72 0D4015 1 1 1 1 1 1 1 FS FMP i ak Qk s lt THRUST WASHER GOVERNOR BUSHING GOVERNOR LOWER ASSEMBLY DIPSTICK WITH HANDLE TUBE DIPSTICK O RING OIL CLR 3 8 X 1 2 SEAL 42 CRANKSHAFT ASSEMBLY HOUSING COVER WITH SLEEVE SCREW HHFC M10 1 5 X 55 SCREW HHFC M6 1 0 X 20 ASSEMBLY OIL FILL CAP HOOK LIFTING ROCKER COVER WITH OIL FILL GASKET VALVE COVER KEEPER VALVE SPRING RETAINER VALVE SPRING SPRING
47. LLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or conse quential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 531 90 Part No OD8S846 Revision B 08 26 02 Printed in U S A
48. NCY X Action Inspect Change Clean W Weekly R Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections X M LUBRICATION Oil level X M Oil X AFTER BREAK IN AND Y Oil filter X AFTER BREAK IN AND Y COOLING Enclosure louvers X X W BATTERY Remove corrosion X X M ensure dryness Clean and tighten X X M battery terminals Check charge state X R EVERY 6 M Electrolyte level x R EVERY 6 M unsealed batteries only ENGINE AND MOUNTING Air cleaner x R Y Spark plug s X R Y GENERAL CONDITION Vibration Noise Leakage X M Temperature COMPLETE TUNE UP TO BE COMPLETED BY A GENERAC Y GUARDIAN AUTHORIZED DEALER ee Generac Power Systems Inc Section 5 Troubleshooting TROUBLESHOOTING Guardian Air cooled 7 kW 12 kW and 15 kW Generators 5 1 TROUBLESHOOTING GUIDE CAUSE PROBLEM The engine will not crank 1 Fuse blown CORRECTION 1 Replace 15A fuse in generator control panel 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective starter contactor 7 KW 4 Defective starter motor 4 5 Dead Battery 5 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel solenoid FS 2 3 Open 14 wire from d 7 engine control board 4 Defective spark plug s 4 Clean re gap or replac
49. NESS GTS LOAD CENTER NOT SHOWN FOR CLARITY 073591 2 FUSE HOLDER 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591 040213B 4 PCB SUPPORT SNAP IN 1 3 8 08037 1 CIRCT BRK 20 X 1 HOM120 075475 2 SCREW PPHM M4 0 7 X 10 0C8036 5 CIRCT BRK 15 X 1 HOM115 0C8035 1 CIRCT BRK 30 X 2 HOM230 0D3320 1 COVER HARNESS ENTRY 0D4802 1 HARNESS GTS TO EXT CONN BOX 022264 2 WASHER LOCK M4 0A7215 4 SCREW SW 1 4 20X5 8 N WA JS500 0A2110 4 SCREW SWAGE 1 4 20 X 1 2 ZINC Generac Power Systems Inc 37 QQ ums Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators 0 12 kW and 15 kW GTS Load Center Assembly Drawing No 0D3996 D 38 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists CG urs Guardian Air cooled 7 kW 12 kW and 15 kW Generators 12 kW and 15 kW GTS Load Center Assembly Drawing No 0D3996 D PART NO QTY DESCRIPTION 0D3086 1 BOX GTS LOAD CENTER 0D3092 1 COVER 12 POSITION GTS LOAD CENTER 002237 1 TRANSFER SWITCH HOME STANDBY 100A2P250V 077220 1 COIL UTILITY 077220A 1 COIL STANDBY 082574 1 INSULATOR SIDEWALL NOT SHOWN 084464 1 LIMIT SWITCH OPERATION NOT SHOWN 074908 6 SCREW TAPTITE M5 0 8 X 10 BP 024912 1 SCREW TAPTITE 1 4 20 X 5 8 BP 0A1658 1 LOCK WASHER SPECIAL 1 4 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 0D3030 1 BASE MOUNTING 6 POLE 125A 240V 041495 4 SCREW TAPTITE M4 0 7X10 BP 0 1661 2 RIVET
50. O QTY DESCRIPTION 0C1069 SCREW TAPTITE 6 1 0 8 YELLOW CHROME 2 0D2922 1 HOUSING BLOWER 3 0C8435 1 TUBE DIPSTICK 4 009997 1 GUARD FAN 5 088434 1 WRAPPER BOTTOM 6 045756 11 SCREW TAPTITE M6 1X10 YELLOW CHROME 7 088433B 1 WRAPPER TOP 8 003794 1 BUMPER NEOPRENE 9 021544 1 STARTER ASSEMBLY EATON 10 040976 2 SCREW SHC M8 1 25 X 20 G12 9 11 022129 2 WASHER LOCK 8 5 16 12 0C2458A 1 BACKPLATE L F D F 13 083512 1 SCREW TAPTITE M8 1 2 X 16 YC 14 0D1401 1 BREATHER TUBE 15 091039 1 GASKET INTAKE ADAPTER 16 0C9619 1 ASSEMBLY PLASTIC CARB 17 049811 2 WASHER FLAT M6 18 022097 4 WASHER LOCK M6 1 4 19 040945 2 SCREW SHC M6 1 0 X 20 G12 9 20 086999 1 GASKET OIL FILTR ADAPTER 21 005667 1 ADAPTER OIL FILTER 22 049821 2 SCREW SHC M8 1 25 X 30 G12 9 23 099236 1 SWITCH OIL 8 0 PSI 24 070185 1 FILTER OIL DIA 69 X 64 LG 25 082774 1 KEY WOODRFF 4 X 19D 26 091222ESRV 1 FLYWHEEL WITH RING GEAR 32DEG 27 067198N 1 WASHER BELV 20 X 2 2 28 067890 1 NUT HEX FLYWHEEL 29 072347 1 SPARKPLUG 30 072734 1 ASSEMBLY GOVERNOR LEVER 12 HP 31 072735 1 ROD GOVERNOR CONTROL 32 03978 1 SPRING ANTI LASH 33 0C6040 1 ASSEMBLY WIRE 34 084542 1 ASSEMBLY IGNITION COIL GN LF 35 092079 2 SCREW TAPTITE M6 1 0 X 25 BP 36 0A8222 1 SPRING GOVERNOR 8 37 083502 1 BOLT GOVERNOR ADJUST M5 38 083503 1 NUT M5 0 8 METAL LOCK 39 0D3083 1 ASSEMBLY OIL DRAIN HOSE 40 008434 1 ASSEMBLY CAP amp DIPSTICK 41 090072 1 O RING 9 16 X 3 4
51. P 3 8X 3 8 20 082121C 1 CLIP J VINYL COAT 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406ID X 1 6200 24 022237 4 WASHER LOCK 3 8 25 022511 4 BOLT HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 039287 4 SCREW HHC 8 1 25 X 45 G8 8 28 022145 14 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX M8 1 25 NYL INSRT 30 090388 3 SCREW TAP M6 1 0X12 BP 31 022129 13 WASHER LOCK M8 5 16 32 022259 8 NUT HEX 5 16 18 STEEL 33 059637 2 SCREW TAPTITE 3 8 16X 3 4 BP 34 048031K 3 BAND HOSE CLAMP 35 05 DIA 35 09592 1 BELLOWS 36 057822 2 CLAMP HOSE 8 53 1 00 37 040976 2 SCREW SHC M8 1 25 X 20 G12 9 38 002824 3 SCREW TAPR 10 32 X 9 16 39 025145 1 U BOLT 5 16 18 X 1 25 W SADDLE 40 090239 1 GASKET EXHAUST 41 06989 1 STINGER ENGINE AIR IN 42 0D1214 1 BASE AIR CLEANER 43 008127 1 ELEMENT AIR CLEANER 44 003024 1 COVER AIR CLEANER NG LP 45 0D2273 1 TUBE 1 25 0 D x 20Ga x 12 125 LONG 46 055934N 1 CLAMP VINYL 1 31 X 281 Z 47 074994 1 25 FT HOSE 1 2ID LP GAS 48 0C5136A 2 KNOB AIR CLEANER 49 074906 4 SCREW TAPTITE M6 1 X 20 BP 50 022473 4 WASHER FLAT 1 4 ZINC 51 0D4662 6 SCREW HHTT M8 1 2 X 20 BP 52 068290 1 GASKET PANEL Generac Power Systems Inc 45 QQ ums Section 7 Exploded Views and Parts Lists Guardian Air cooled 7 kW 12 kW and 15 kW Generators 12 kW and 15 kW Generator Drawing No 0D3417 B 46 Generac Power Systems Inc ITEM Secti
52. P CONTROL 66A F2 FUSE 5 AMP PRINTED CIRCUIT 239 HTO HIGH OIL TEMPERATURE SWITCH BOARD 15A IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC ee Generac Power Systems Inc 225 Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic 12 amp 15 kW Drawing No 0D8501 A ELECTRICAL DATA C2 6 22 TX C2 5 225A N2 56VA 3 224A 225 1VA 3 224 1 194 59 2 amp CUSTOMER CONNECTIONS N2 N2 amp 13 N1 N1 amp 15 17 E P NEUTRAL 23 0 22 15A l 33 0 swi u 194 120V 15 POWER WINDING 120V 239 STATOR 15 44 23 bs 2d 194 14 19 239 0 240V 14 15A ja LLLI EN 239 13 RED 66A 17 mis 13 56 16 16 14 1 1 i 0 rs 0 0 0 I BLACK CUSTOMER IM1 SUPPLIED SP1 D 18 C1 5
53. Remove the brass hose fitting from the outlet port of the demand regulator 6 Remove the brass metering jet loosen counter clockwise from the housing port of the demand regulator located on the side of the regulator 7 Install new LP metering jet tighten clockwise in the outlet port of the demand regulator 8 Refit the brass hose fittings to the outlet port of the demand regulator 9 Reverse procedure steps 1 4 to reinstall demand regulator 10 Reverse the procedure to convert back to natural gas Figure 1 3 Demand Regulator FUEL HOSE on FUEL HOSE BRASS HOSE BRASS HOSE FITTING FITTING B FUEL JET HOUSING PORTS HOUSING PORTS LP FUEL SYSTEM NOTE The natural gas adjustment screw is preset during installation and should not need any further adjustment 1 8 2 12 KW AND 15 KW 990CC ENGINES To reconfigure the fuel system from NG to LP follow these steps NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator You must sup ply a fuel pressure of 11 to 14 inches of water col umn 0 6 psi to the fuel inlet of the generator 1 Turn off the main gas supply 2 Remove the three carburetor fuel hoses from the outlet ports of the demand regulator 3 Disconnect wire 0 and wire 14 from the gas solenoid located on the top of the demand regu lator 4 Remove the demand regulator from the enclosure by rot
54. See the Break in Procedure Section 3 1 Page 14 for the first required oil change A caution amp Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 4 3 2 OIL CHANGE PROCEDURE To change the oil proceed as follows 1 Run the engine until it is thoroughly warmed up then shut OFF the engine 2 Immediately after the engine shuts OFF pull the oil drain hose Figure 4 4 on page 18 free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 Page 6 for oil capacities Generac Power Systems Inc 17 MAINTENANCE 2 09 Section 4 Maintenance Figure 4 4 Oil Drain Hose and Filter Low Oil Switch High Temp Switch Oil Filter 44 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean engine oil to the gas ket of the new filter See Section 1 5 1 Page 6 for recommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter a
55. The engine should shut down 2 POST INSTALLATION START UP ADJUSTMENTS 2 5 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Check that the Auto Off Manual switch is set to OFF 3 Turn OFF the utility power supply to the transfer switch using means provided such as a utility main line circuit breaker 4 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 5 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker 6 Setthe Auto Off Manual switch to AUTO The sys tem is now ready for automatic operation 7 Turn OFF the utility power supply to the transfer switch With the Auto Off Manual switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by gen erator AC output turn ON the utility power supply to the transfer switch The following should occur After about six seconds the switch should transfer loads back to the utility power source e About one minute after retransfer the engine should shu
56. aintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc A ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera tion Avoid contact with bare wires terminals con nections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If you must work around an operating unit stand on an insu lated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical system After installing this home standby electrical sys tem th
57. all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 5 Manually set the transfer switch to the STANDBY position i e load terminals connected to the generator s E1 E2 terminals The transfer switch operating lever should be down 6 Set the generator s Auto Off Manual switch to MANUAL The engine should crank and start immediately 7 Let the engine stabilize and warm up for a few minutes 8 Set the generator s main circuit breaker to its ON or closed position Loads are now powered by the standby generator 9 Turn ON electrical loads connected to transfer switch 1 and T2 Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 10 Connect an accurate AC voltmeter and a frequen cy meter across terminal lugs E1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 11 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 12 When testing under load is complete turn OFF electrical loads 13 Set the generator s main circuit breaker to its OFF or open position 14 Let the engine run at no load for a few minutes 15 Set the Auto Off Manual switch to OFF
58. and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICA
59. ange switch contacts close and the engine shuts down The unit should not be restarted until oil is added The Auto Off Manual switch must then be turned to OFF and then back to AUTO 3 72 HIGH TEMPERATURE SWITCH This switch s contacts Figure 3 3 close if the tem perature should exceed approximately 140 C 2849 F initiating an engine shutdown Your generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level Figure 3 3 Low Oil Pressure and High Temperature Switches Low Oil Switch High Temp Switch E o e e lt Loose l Dun Pp Hose Oil Filter 16 Generac Power Systems Inc Guardian Air cooled 7 kW 12 kW and 15 kW Generators 3 7 3 OVERCRANK This feature prevents the generator from damaging itself when it continually attempts to start and anoth er problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED on the generator control panel will light indicating an over crank failure The Auto Off Manual switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the overcrank feature will continue to activate 3 7 3 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7
60. ating counterclockwise Generac Power Systems Inc 7 5 Remove the small brass hose fitting from the idle circuit port of the regulator housing Remove the small jet 005698 located in the side of the regulator housing and install it into the small threaded hole in the idle circuit port on the regulator 7 Refit the brass hose fitting to the idle circuit port of the regulator Use pipe thread sealant to reseal the threads on the hose fitting 8 Identify both adjustment screws NOTE One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit 9 Reverse procedure steps 1 4 to re install the demand regulator 10 To adjust the system to run on LP fuel simply turn the adjuster screw that is accessed from inside the front of the unit 1 4 turn clockwise This will now set the system for maximum power and best performance on LP fuel 11 The fuel system will now allow the engine to run on LP fuel It may be necessary to make minor adjustments to the preset screw settings to achieve maximum power If you experience prob lems with the unit producing maximum power follow the procedure in Section 2 6 Adjusting the Regulator Figure 1 4 Demand Regulator FUEL HOSE BRASS HOSE FITTING IDLE CIRCUIT PORT SMALL BRASS HOSE FUEL JET 1 REGULATOR HOUSING PORT ADJUSTER SCREWS 1 9 LOCATION 1 9 1 GENERATOR Install
61. ation guide for this equipment 1 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76 ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES avail able same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRICAL SYS TEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Generac Power Systems Inc 3 DIG A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage This standby generator set has been factory sup plied with a weather protective enclosu
62. be 11 inches to 14 inches of water column 0 6 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure 11 14 to the gen erator Low gas pressure can cause hard starting and could affect engine durability 1 7 FUEL CONSUMPTION Nat Gas LP Vapor 1 2 Load Full Load 1 2 Load Full Load 74 105 0 91 33 1 21 44 1 114 185 1 34 48 9 2 17 79 0 148 5 240 1 73 63 2 2 80 102 3 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour A DIG A Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion 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 1 8 RECONFIGURING THE FUEL SYSTEM 1 8 1 7 KW 410CC ENGINE To reconfigure the fuel system from NG to LP follow these steps l Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port of the demand regulator Figure 1 3 Section 1 General Information Guardian Air cooled 7 kW 12 kW and 15 kW Generators GENERAL INFORMATION 3 Disconnect wire 0 and wire 14 from the gas solenoid located on the top of the demand regu lator 4 Remove the demand regulator by rotating coun terclockwise 5
63. brush and commercial solvent Do not blast the spark plug s to clean 2 Remove the spark plug s and check the condi tion Replace the spark plug s if worn or if reuse is questionable See Section 4 13 Page 22 for recommended inspection Guardian Air cooled 7 kW 12 kW and 15 kW Generators 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 inch for 7 kW and 0 50 mm 0 020 inch for 12 15 kW by carefully bending the ground electrode Figure 4 8 Figure 4 8 Setting the Spark Plug Gap SET PLUG GAP AT 0 76 mm 0 50 mm 0 030 inch 0 020 inch 47 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 13 Page 22 The following pro cedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A DIG A Do not dispose of the battery in a fire The battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove the 5A and 15A fuses from the generator control panel
64. ce voltage above a pre set level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 70 per cent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to the standby source C Standby Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur Section 3 Operation OPERATION Guardian Air cooled 7 kW 12 kW and 15 kW Generators T D Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored above 70 per cent of the nominal source voltage a retransfer time delay starts timing E Retransfer Time Delay This timer runs for about 15 seconds At end of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs Engine Cool down Timer
65. commended Spark Plug RC12YC RC12YC RC12YC Spark Plug Gap 0 76 mm 0 030 inch 0 76 mm 0 020 inch 0 76 mm 0 020 inch Compression Ratio 8 6 1 9 5 1 9 5 1 Starter 12 Vdc 12 Vdc 12Vdc Oil Capacity Including Filter Approx 1 5 Qts Approx 1 7 Qts Approx 1 7 Qts Recommended Oil Filter Generac Part 70185 Generac Part 70185 Generac Part 70185 Recommended Air Filter Generac Part 0C8127 Generac Part 0C8127 Generac Part 0C8127 Operating RPM 3 600 3 600 3 600 6 Generac Power Systems Inc 1 6 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section 1 8 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask your fuel supplier for the Btu content of your fuel Fuel pressure for both natural gas and liquid propane set ups should
66. contact a Generac Guardian Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting a Generac Guardian Authorized Dealer or the factory about parts and service always supply the complete model number and serial number of your unit as given on its data decal which is locat ed on your generator See Figure 1 1 or Figure 1 2 in Section 1 6 Page 5 for decal location Model No Serial No AUTHORIZED DEALER LOCATION To locate the GENERAC GUARDIAN AUTHORIZED DEALER nearest you please call this number 1 800 333 1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER Guardian Air cooled 7 kW 12 kW and 15 kW Generators Introduction Inside Front Cover Read This Manual Thoroughly IFC CCODIGEUS IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC Safety Rules 2 Standards MAE iis aee dece ern ee et ein 3 Section 1 General Information 4 1 1 Unpacking Inspection 4 1 2 Protection Systems 4 1 3 System Set LED 4 1 4 Your Generator uu rtp anie 5
67. e Section 4 3 1 Page 17 If necessary drain and refill with the proper oil Check the state of the battery Fill all cells of unsealed batteries to the proper level with dis tilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery See Specifications Section 1 5 Page 6 for type and size Clean and wipe the entire generator Remove the 5A and 15A fuses from the generator control panel Reconnect the battery Observe bat tery polarity Damage may occur if the battery is connected incorrectly Open the fuel shutoff valve Insert the 5A and 15A fuses into the generator contro panel Start the unit by moving the Auto Off Manual switch to MANUAL Allow the unit to warm up thoroughly Stop the unit by setting the Auto Off Manual switch to OFF Turn on the utility power to the transfer switch 10 Set the Auto Off Manual switch to AUTO 11 Your generator is now ready for service NOTE If the battery was dead or disconnected you must reset the exercise timer Generac Power Systems Inc 21 MAINTENANCE 2 0 Section 4 Maintenance Guardian Air cooled 7 kW 12 kW and 15 kW Generators 4 13 SERVICE SCHEDULE ATTENTION It is recommended that all service work be performed by your nearest Generac Guardian Authorized Dealer SYSTEM COMPONENT PROCEDURE FREQUE
68. e generator may crank and start at any time without warning When this occurs load circuits are transferred to the STANDBY generator power source To prevent possible injury if such a start and transfer occur always set the generator s Auto Off Manual switch to its OFF position before working on equipment and remove the 5A and 15A fuses from the generator control panel In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might
69. e plug s 5 Valve lash out of adjustment 5 Reset valve lash The engine starts hard l Air cleaner plugged 1 Check replace air cleaner and runs rough or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s 3 Fuel Regulator not set 3 Set Fuel Regulator 4 Fuel Pressure incorrect 4 Confirm fuel pressure to regulator is 11 14 water column 0 6 psi The Auto Off Manual switch l Defective switch pot is set to OFE but the engine 2 Auto Off Manual switch 2 continues to run wired incorrectly 3 Defective control board 3 There is no AC output fron 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON or closed 2 Generator internal failure 2 There is no transfer to l Defective transfer switch coil L standby after utility 2 Defective transfer relay 2 source failure 3 Transfer relay circuit open 4 Defective control logic board 4 Unit consumes large l Break in procedure p t amounts of oil not followed see Section 2 1 Contact your nearest Generac Guardian Authorized Dealer for assistance Generac Power Systems Inc 23 Section 6 Electrical Data Guardian Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 12 amp 15 kW Drawing No 0D8500 A ELECTRICAL DATA DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY MAIN OUTPUT BREAKER 2 CIRCUIT BREAKER ALTERNATOR EXCITATION D DIOD
70. everse Figure 1 5 Battery Cable Connections BLACK LEAD FROM FRAME RED LEAD FROM STARTER CONTACTOR Z m T BATTERY BLACK NOTE Your generator is equipped with a battery trickle charger that is active when your unit is set up for automatic operation With the battery installed and utility power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charger is designed to help extend the life of your battery by maintaining the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 11 THE BATTERY Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries When replacing the battery use the following type of battery Group 26 26R 12 volt DC negative ground battery with a rating of 350 cold cranking amps min imum for 7 kW 550 cold cranking amps minimum for 12 and 15 kW at 17 8 C 0 F minimum When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service Schedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly con
71. ge as follows 1 2 3 Start the engine and let it warm up Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down Once the unit has shut down it will signal a low oil fault Set the Auto Off Manual switch to OFF and turn off the utility power to the transfer switch Remove the 5A and 15A fuses from the generator control panel Disconnect the battery cables as outlined in General Hazards page 2 While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations Section 4 3 1 Page 17 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor Clean and wipe the entire generator Guardian Air cooled 7 kW 12 kW and 15 kW Generators MAINTENANCE Section 4 Maintenance 4 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 2 8 9 Verify that utility power is turned off and that the Auto Off Manual switch is set to OFF Check the tag on the engine for oil viscosity and classification Verify that the correct recommend ed oil is used in the engine se
72. he carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny 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 contacting a Generac Authorized Warranty Serv
73. hem carefully Their definitions are as follows DIG A After this heading you can read instructions that if not strictly complied with will result in serious personal injury including death in addition to property damage waRNING amp After this heading you can read instructions that if not strictly complied with may result in serious personal injury or property damage caution After this heading you can read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading you can read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows A This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of you and others This symbol points out potential explosion hazard This symbol points out potential fire hazard Generac Power Systems Inc A 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 operator read
74. ice Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe impor tant rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty serv ice evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at one of
75. ity power supply to the transfer switch using the means provided such as a utili ty main line circuit breaker 3 The unit will start and the transfer switch will transfer to standby 4 Using the transfer switch s built in emergency load center turn on circuits to load the generator to approximately 25 rated load and run the unit for one hour Run the unit for one hour at 50 rated load Run the unit for one hour at 75 rated load Run the unit for one hour at 100 rated load Turn ON the utility power supply to the transfer switch which will allow the transfer switch to transfer back to utility power The unit will con tinue to run for one minute and then shut down 9 Allow the unit to cool 10 Set the generator s Auto Off Manual switch to OFF Remove the 5A and 15A fuses from the gen erator control panel Disconnect the battery cables as outlined in General Hazards page 2 Generac Power Systems Inc 13 OPERATION Section 3 Operation Guardian Air cooled 7 kW 12 kW and 15 kW Generators 11 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Page 18 Replace the oil with synthet ic oil as recommended in Section 4 3 Changing the Engine Oil Page 17 12 Reconnect the battery cables as outlined in General Hazards page 2 and insert the 5A and 15A fuses into the generator control panel The generator is now
76. l loads connected to the transfer switch terminals T1 and T2 5 Check the engine crankcase oil level and if neces sary fill to the dipstick FULL mark with the rec ommended oil Do not fill above the FULL mark 6 Check the fuel supply Gaseous fuel lines must have been properly purged and leak tested in accor dance with applicable fuel gas codes All fuel shut off valves in the fuel supply lines must be open caution Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 22 CHECK TRANSFER SWITCH OPERATION Refer to Section 3 5 Page 15 of the owner s manual for manual operation procedures A DX A A Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 2 5 ELECTRICAL CHECKS Complete electrical checks as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Set the generator s Auto Off Manual switch to the OFF position 3 Turn OFF all loads connected to the transfer switch terminals 1 and T2 4 Turn on the utility power supply to the transfer switch using the means provided such as a utili ty main line circuit breaker 10 Generac Power Systems Inc Section 2 Post Installation Start
77. n additional 3 4 to one turn Figure 4 4 4 Refil with the proper recommended oil see Section 4 3 1 Page 17 See Section 1 5 2 Page 6 for oil capacities 5 Start the engine and check for leaks 4 5 CHANGING THE ENGINE AIR CLEANER 451 7KW 12 KW AND 15 KW GENERATORS See Figures 1 1 and 1 2 Page 5 for the location of your air cleaner Use the following procedure Figure 4 6 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box 5 Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule Section 4 13 Page 22 for air cleaner maintenance See Section 1 5 1 Page 6 for air filter replacement part number 18 Generac Power Systems Inc Guardian Air cooled 7 kW 12 kW and 15 kW Generators Figure 4 6 7 kW Engine Air Cleaner Location Fuel Air Cleaner Regulator Figure 4 7 12 kW 15 kW Engine Air Cleaner 4 6 SPARK PLUG S Reset the spark plug s gap or replace the spark plug s as necessary See Section 4 13 Page 22 for maintenance requirements 1 Clean the area around the base of the spark plug s to keep dirt and debris out of the engine Clean by scraping or washing using a wire
78. nect ed and terminals are tight Observe battery polarity when connecting the battery to the generator set Section 1 General Information GENERAL INFORMATION DIG A Do not dispose of the battery in a fire The battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove the 5A and 15A fuses from the generator control panel Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or dis connecting battery terminals warninc Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound
79. ns to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 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
80. on 7 Exploded Views and Parts Lists CG urs Guardian Air cooled 7 kW 12 kW and 15 kW Generators 12 kW and 15 kW Generator Drawing No 0D3417 B 0 PART NO QTY DESCRIPTION 0C6934 1 ADAPTOR ENGINE 0C7930 1 STATOR 12KW 0D2359 STATOR 15KW 007944 1 ROTOR 12KW 0D2356 ROTOR 15KW 0C6043 1 CARRIER REAR BEARING 0D2336 1 FAN 12 CURVED BLADE 006042 1 MUFFLER 0D3220 1 TAIL PIPE MUFFLER 068101 1 PANEL MUFFLER BASE 056482 1 BEARING 1 1811 2 8346 0C3168 3 5 16 SPECIAL LOCK WASHER 0D1838 1 BOLT HHCS 3 8 24 x 15 50 0D1846 4 BOLT HHCS M8 1 25 x 345mm 007038 1 BRACKET ALTERNATOR MOUNTING 0D1609 1 DUCT ALTERNATOR AIR 0D2559 1 GASKET ALTERNATOR AIR DUCT 0C7038A 1 BRACKET ENGINE MOUNTING 007758 4 RUBBER MOUNT 0388050AD0 1 CABLE 6 48 BLACK BATTERY 0C2417A 1 EARTH STRAP 3 8X 3 8 082121C 1 CLIP J VYNL COAT 0 625 ID 066386 1 ASSEMBLY BRUSH HOLDER 029451 2 6 FT TAPE ELEC UL FOAM 1 8 X 1 2 049451 1 WASHER FLAT 406ID X 1 6200 022237 5 WASHER LOCK 3 8 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 022131 4 WASHER FLAT 3 8 ZINC 039288 4 SCREW HHC 8 1 25 x 55 98 8 022145 14 WASHER FLAT 5 16 ZINC 049820 4 NUT LOCK HEX M8 1 25 NYL INSERT 045756 2 SCREW TAPTITE M6 1 0X10 BP 022129 10 WASHER LOCK M8 5 16 022259 8 NUT HEX 5 16 18 STEEL 059637 2 SCREW TAPTITE 3 8 16 X 3 4 BP 083512 4 SCREW TAPTITE M8 1 25 X 16 BP 074994 2 83 FT HOSE RES 1 2 LP GAS 057822 4 CLAMP HOSE 8 53 1 00 052858 4 NUT LOCK M8 0C2824 3 SCREW TAP R
81. ooled 7 kW 12 kW and 15 kW Generators 0 7 kW GTS Load Center Assembly Drawing No 0D3997 E 36 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists CG urs Guardian Air cooled 7 kW 12 kW and 15 kW Generators 7 kW GTS Load Center Assembly Drawing No 0D3997 E PART NO QTY DESCRIPTION 0D4801 1 BOX GTS LOAD CENTER 0D4800 1 COVER 8 POSITION GTS LOAD CENTER 002237 1 TRANSFER SWITCH HOME STANDBY 100A2P250V 077220 1 COIL UTILITY 077220A 1 COIL STANDBY 082574 1 INSULATOR SIDEWALL NOT SHOWN 084464 1 LIMIT SWITCH OPERATION NOT SHOWN 074908 6 SCREW TAPTITE M5 0 8 X 10 BP 024912 1 SCREW TAPTITE 1 4 20 X 5 8 BP 0A1658 1 LOCK WASHER SPECIAL 1 4 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 0D3030A 1 BASE MOUNTING 6 POLE 125A 240V 041495 4 SCREW TAPTITE M4 0 7X10 BP 0A1661 2 RIVET POP 156 X 160 164 20 022478 1 WASHER FLAT 1 4 ZINC 0D3094 1 HARNESS GTS TO MAIN PANEL 0D4684A 1 HARNESS ADAPTER PLATE 0D3319 1 PANEL SUB BREAKER BASE 056326 1 FT TRIM VINYL BLACK 1 8GP 022152 6 WASHER LOCK 10 087680 1 NUT WING M6 1 0 077441 1 HANDLE TRANSFER SWITCH HOME STANDBY 063378 4 HOLDER CABLE TIE 074138 2 LUG DIS QK NI S 10X45 DEG BR T 036933 6 SCREW PPHM 10 32 X 3 8 077033 6 LUG SLDLSS 1 0 14X9 16 AL CU 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 028739 4 TIE WRAP 3 9 X 10 NAT L UL 038150 2 WASHER FLAT 8 ZINC 0D3191 1 COVER RELAY amp TERM BLOCK 0D3088 1 WIRE HAR
82. ot during operation Exercise care near running generators e Generac Power Systems Inc GENERAL HAZARDS For safety reasons Generac recommends that the installation initial start up and maintenance of this equipment is carried out by a Generac Guardian Authorized Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator The generator MUST be installed outdoors When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Inspect the generator regularly and contact your nearest Generac Guardian Authorized Dealer for parts needing repair or replacement Before performing any m
83. re that is intended for outdoor installation only This standby generator set is packaged with an automatic transfer switch with built in load center The combination transfer switch and load center is pre wired with a 2 foot and 30 foot conduit Circuit breakers for emergency circuit connections are included This UL listed 2 pole switch is rated at 100 AC amperes at 250 volts maximum This transfer switch is for indoor use only warninc amp A 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 trans fer switch The transfer switch must effectively iso late the electrical system from the utility distribu tion system when the generator is operating NEC 700 701 amp 702 Failure to isolate an electrical sys tem by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage If you note loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is disco
84. rm to the closed throttle position Make sure the idle spring does not stretch at all 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz with door open 9 The governor is now set Figure 2 4 Full Load Speed Adjust Screw Full Load Speed Adjust Screw 2 73 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corrosion inhibiting spray such as WD 40 or a comparable product 2 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62 63 Hertz slowly turn the slotted potentiometer Figure 2 5 until line volt age reads 247 252 volts NOTE You must remove the access panel on top of the control panel to adjust the voltage regulator Figure 2 5 Voltage Adjustment Potentiometer l j 9 NOTE The voltage regulator is housed above the genera tor s control panel The regulator maintains a volt age in direct proportion to frequency at a 2 to 1 ratio For example at 62 Hertz line to neutral voltage will be 124 volts 3 1 BREAK IN PROCEDURE Once the unit has been installed and all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Set the generators Auto Off Manual switch to AUTO 2 Turn OFF the util
85. roduct contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a procedure work method or operating tech nique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that you choose does not render the generator unsafe DIG A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator 4 Parts of the generator are rotating and or h
86. seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 3 7 4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gener ator from supplying an output that could potentially damage appliances connected to the generator cir cuit Contact your nearest Generac Guardian Authorized Dealer if this failure occurs 4 1 FUSE The generator panel s 15 amp fuse Figure 4 1 protects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open you cannot crank or start the engine You should replace the fuse using only an identical 15 amp replacement The generator panel s 5 amp fuse protects the battery charge circuit against overload If the fuse element has melted open you will not have battery charging capa bility You should replace the fuse using only an identi cal 5 amp replacement To remove fuse push cap down and rotate counterclockwise Guardian Air cooled 7 kW 12 kW and 15 kW Generators Figure 4 1 Generator Control Panel AUTO OFF MAN Locate your nearest GENEHAC dealer at VV gjjenerac com GENER power systems inc SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK SET FLASHING GREEN LED EXERCISE FLASHING RED LEDS TIME OO EX
87. t down 2 6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Although the generator has been factory set to pro vide maximum power it may be necessary in some areas to adjust this setting Because natural gas has different BTU or power content across the country the engine may not perform as designed If you experience engine problems at high or full load conditions follow these steps It will require a fre quency meter to perform this procedure 1 Turn off utility power to the main distribution panel in the house This can be done by switching the service main breaker to the off or open posi tion 2 Allow the generator to start Before loading the generator confirm that the No Load Frequency with the roof open and door off is set to 63 63 5 Hz Transfer load to emergency circuits Generac Power Systems Inc 11 2 POST Section 2 Post Installation Start up and Adjustments INSTALLATION START UP ADJUSTMENTS 3 Turn on appliances lights pumps etc that are on the emergency circuits in an attempt to fully load the generator Be cautious not to overload the generator Use the following chart as a guide 120 Volts 50 0 amps 100 0 amps 108 3 amps 240 Volts 25 0 amps 50 0 amps 54 1 amps 4 When full load has been achieved Connect a fre quency meter to the output lugs of the generator s main line circuit breaker 5 The fuelregulator is fitted with one 7 kW or two 12 amp 15
88. the day of the week and at the time of day you complete the following sequence During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 3 1 Page 14 allows you to select the day and time for system exer cise To select the desired day and time of day you must perform the following sequence at that time Generac Power Systems Inc 15 MAINTENANCE 2 0 1 Verify that Auto Off Manual switch is set to AUTO 2 Hold down the Set Exercise Time switch until the generator starts approximately 10 seconds and then release 3 The generator will start and run for approximately 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week Section 4 Maintenance NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is performed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected The exerciser WILL NOT work if dip switch 2 on the controller printed circuit board Remote Not Auto is ON 3 7 PROTECTION SYSTEMS 3 7 1 LOW OIL PRESSURE SWITCH This switch Figure 3 3 has normally closed contacts that are held open by engine oil pressure during crank ing and operating Should oil pressure drop below the 8 psi r
89. the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing you may need to consider using a windbreak to protect the unit 8 Generac Power Systems Inc Section 1 General Information Guardian Air cooled 7 kW 12 kW and 15 kW Generators Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow 5 feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds Install the generator as close as possible to the fuel supply to reduce the length of piping Install the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DIS TANCE 1 9 22 TRANSFER SWITCH 1 9 2 1 7 kW 12 kW and 15 kW Units The transfer switch shipped with this generator is enclosed in a NEMA 1 enclosure This type of enclo sure is intended for indoor use only Follow these rules Install the transfer switch indoors on a firm stur dy supporting structure To prevent switch distortion level the switch if nec essary This can be done
90. this Owner s Manual and thoroughly understand all instructions before using this equip ment We also strongly recommend instructing other users to properly start and operate the unit This pre pares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for three different Guardian models 04389 1 6 kW NG 7 kW LP single cylinder GH 410 Engine 04456 1 12 kW NG 12 kW LP V twin GT 990 Engine 04390 1 13 kW NG 15 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Guardian Authorized Dealer Normal main tenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for mainte nance service Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum See your Generac Guardian Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When your generator requires servicing or repairs simply
91. to its ON or closed position The standby power source now powers the loads 552 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored you will want to transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Letthe engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generator s Auto Off Manual switch to its OFF or open position The engine should shut down 4 Check that utility power supply to the transfer switch is turned OFF DIG A A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 5 Use the manual transfer handle inside the trans fer switch to move the main contacts back to their Utility position i e loads connected to the util ity power source Figure 3 2 6 Turn ON the utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 3 3 Page 14 3 6 SETTING THE EXERCISE TIMER Your generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on
92. ttery area and Discharge static electricity from your body before touching the battery by first touching a grounded metal surface A Be sure the Auto Off Manual switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off and the 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as you attach the cables and cause an explosion 4 8 ADJUSTING GH 410 GT 990 VALVE CLEARANCE After the first 50 hours of operation you should adjust the valve clearance in the engine Important If you feel uncomfortable about doing this procedure or you don t have the proper tools please contact your Generac Authorized dealer for service assistance This is a very important step to insure longest life for your engine To adjust valve clearance Make sure the engine is at room temperature Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Generac Power Systems Inc 19 MAINTENANCE Section 4 Maintenance Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen at the front of
93. ve the fuses before working on or around the generator or transfer switch Then place a Do Not Operate tag on the gen erator panel and on the transfer switch 14 Generac Power Systems Inc 3 3 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source Figure 3 2 Page 15 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generators Auto Off Manual switch to AUTO 4 Setthe generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Section 3 4 Sequence of Automatic Operation 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors utility power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power sup ply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility sour
94. vered later 4 Generac Power Systems Inc Section 1 General Information Guardian Air cooled 7 kW 12 kW and 15 kW Generators 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator present to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 1 Low Oil Pressure Sensor 3 Overcrank 2 High Temperature Sensor 4 Overspeed There are LED readouts on the control panel to noti fy you that one of these faults has occurred There is also a System Set LED that is lit when all of the con ditions describe in Section 1 3 are true 1 5 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true 1 The Auto Off Manual switch is set to the AUTO position 2 The utility voltage being supplied to the unit is being sensed by the PCB If the utility sense volt age is not connected to the unit or if it is below 168 volts AC then the system set light will flash rapidly This indicates that if the Auto Off Manual switch is placed in the Auto position the genera tor will start 3 The Not In Auto dip switch is set to the OFF position on the control board 4 No alarms are present for example low oil pres sure high temperature etc Section 1 General Information Guardian Air cooled 7 kW 12 kW and 15 kW Generators 1
95. z 11 Connect the AC voltmeter test leads across termi nal lug E1 and neutral then across E2 and neu tral In both cases voltage reading should be 121 126 volts AC 12 Set the generator s main circuit breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 13 Set generator s Auto Off Manual switch to OFF The engine should shut down NOTE It is important that you do not proceed until you are certain that generator AC voltage and frequen cy are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjust ment If frequency is correct but voltage is high or low the generator s voltage regulator requires adjustment Section 2 Post Installation Start up and Adjustments Guardian Air cooled 7 kW 12 kW and 15 kW Generators 2 4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows l Set generator s main circuit breaker to its OFF or open position 2 Turn OFFall loads connected to the transfer switch terminals T1 and T2 3 Set the generator s Auto Off Manual switch to OFF 4 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker wanNING A Do not attempt manual transfer switch opera tion until

Generac 04389-1, 04456-1, 04390-1 Portable Generator User Manual

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