Generac 04389-1, 04456-1, 04390-1 Introduction, Authorized Dealer Location, Danger, ‹Contents

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INTRODUCTION

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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).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 them carefully. Their definitions are as follows:

‹READ THIS MANUAL THOROUGHLY DANGER DANGER

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.

After this heading, you can read instructions that, if not strictly complied with, may result in serious personal injury or property damage.

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:

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.

safety and/or property of you and others. This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. We strongly recommend that the operator read 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 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.

Generac® Power Systems, Inc.

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Contents POWER SYSTEMS POWER SYSTEMS, INCDEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY DANGERDANGER INTRODUCTIONAUTHORIZED DEALER LOCATION ‹CONTENTSIntroduction Parts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator EXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS ‹STANDARDS INDEX1.3SYSTEM SET LED 1.1UNPACKING/INSPECTION1.2PROTECTION SYSTEMS Figure 1.2 - 12 kW and 15 kW, V-twin GT-990Engine 1.4YOUR GENERATORFigure 1.1 - 7 kW, Single Cylinder GH-410Engine ‹1.5.2 ENGINE 1.5 SPECIFICATIONS‹ 1.5.1 GENERATOR 1.7FUEL CONSUMPTION 1.8RECONFIGURING THE FUEL SYSTEM1.6FUEL REQUIREMENTS AND RECOMMENDATIONS DANGER1.9.2 TRANSFER SWITCH 1.10 BATTERY INSTALLATION1.9LOCATION 1.9.1 GENERATORWear rubber gloves and boots 1.11 THE BATTERYFigure 1.5 - Battery Cable Connections Do not open or mutilate the battery. Released2.3ELECTRICAL CHECKS 2.2CHECK TRANSFER SWITCH OPERATION2.1BEFORE INITIAL START-UP Never operate the engine with the oil level2.5CHECKING AUTOMATIC OPERATION 2.6ADJUSTING THE REGULATOR NATURAL GAS ONLY2.4GENERATOR TESTS UNDER LOAD Figure 2.3 - Engine Governor Adjustment 2.7ENGINE GOVERNOR ADJUSTMENTFigure 2.2 - Placement of Regulator Do not make any unnecessary adjustmentsFigure 2.4 - Full Load Speed Adjust Screw 2.8VOLTAGE REGULATOR ADJUSTMENT3.1BREAK-INPROCEDURE Figure 2.5 - Voltage Adjustment PotentiometerWith the switch set to AUTO, the engine may 3.3AUTOMATIC TRANSFER OPERATION3.2USING THE AUTO/OFF/MANUAL SWITCH FIGURE 3.4SEQUENCE OF AUTOMATIC OPERATION‹3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE 3.6SETTING THE EXERCISE TIMER3.5MANUAL TRANSFER OPERATION Figure 3.2 - Manual Transfer Switch Operation‹3.7.1 LOW OIL PRESSURE SWITCH 3.7PROTECTION SYSTEMS4.1FUSE ‹3.7.2 HIGH TEMPERATURE SWITCH‹ 4.3.2 OIL CHANGE PROCEDURE 4.2CHECKING THE ENGINE OIL LEVEL4.3CHANGING THE ENGINE OIL ‹4.3.1 ENGINE OIL RECOMMENDATIONS4.6SPARK PLUGS 4.5CHANGING THE ENGINE AIR CLEANER4.4CHANGING THE OIL FILTER Figure 4.6 - 7 kW, Engine Air Cleaner LocationFigure 4.8 - Setting the Spark Plug Gap 4.7BATTERY MAINTENANCE4.8ADJUSTING GH-410/GT-990VALVE CLEARANCE 4.11 CORROSION PROTECTION 4.9COOLING SYSTEM4.10 ATTENTION AFTER SUBMERSION Figure 4.10 - Valve Clearance Adjustment‹4.12.2 RETURN TO SERVICE 4.12 OUT OF SERVICE PROCEDURE‹4.12.1 REMOVAL FROM SERVICE 4.13 SERVICE SCHEDULE CAUSE 5.1TROUBLESHOOTING GUIDEPROBLEM CORRECTION24 Generac Power Systems, Inc Section 6 - Electrical DataCONNECTION CONTROL PANEL BOXCUSTOMER 26 Generac Power Systems, Inc C2-6 Wiring Diagram - 7 kW - Drawing No. 0D9013-A 28 Generac Power Systems, IncCUSTOMER CONNECTION CLOSEST TO BEA 4 0 STATOR30 Generac Power Systems, Inc C2-6 Section 7 - Exploded Views and Parts Lists 32 Generac Power Systems, IncPART NO.QTY. DESCRIPTION Control Panel - Drawing No. 0D8503-E DESCRIPTION Section 7 - Exploded Views and Parts Lists 0D4801 37 17 24 0D3086 Kit Contains DESCRIPTION 42 Generac Power Systems, Inc DESCRIPTION 44 Generac Power Systems, Inc 7 kW Generator - Drawing No. 0D3504-B 46 Generac Power Systems, Inc 12 kW and 15 kW Generator - Drawing No. 0D3417-B 48 Generac Power Systems, Inc GN410 Engine - Drawing No. 0D3539-BPart 50 Generac Power Systems, Inc 0C1069 PART NO. QTY Guardian Air Section 8 - Mounting DimensionsTRANSFER SWITCH NTAKE54 Generac Power Systems, Inc Generac Power Systems, Inc PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS Section 10 - WarrantyEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGP.O. BOX WHITEWATER, WI WARRANTY SCHEDULEGENERAC POWER SYSTEMS, INC