Guardian Technologies 04759-2, 04760-2 Introduction, Danger, ‹ Engine Emission Compliance Period

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INTRODUCTION

INTRODUCTION

Thank you for purchasing this Guardian model by Generac Power Systems Inc.. This model is a compact, high per- formance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation. This gen- erator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

This unit meets the 1998 and later California emissions regulations. To ensure that the engine continues to meet these regulations, refer to the following information and instructions in this owner’s manual.

‹ENGINE EMISSION COMPLIANCE PERIOD

For nonhandheld engines: The Emissions Compliance Period referred to on the Emissions Compliance label indi- cates the number of operating hours for which the engine has been shown to meet federal emission requirements.

For engines less than 225 cc displacement, Category C = 125 hours, B = 250 hours, and A = 500 hours.

For engines 225 cc or more, Category C = 250 hours, B = 500 hours, and A = 1000 hours.

‹READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Authorized Dealer for starting, operating and servic- ing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instruc- tions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

‹ENGINE EMISSION COMPLIANCE PERIOD‹READ THIS MANUAL THOROUGHLY DANGER

After this heading, read instructions that, if not strictly complied with, will result in serious person- al injury, including death, in addition to property damage.

After this heading, read instructions that, if not strictly complied with, may result in serious person- al injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essen- tial 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 others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

Thishazard.symbol points out potential electrical shock

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 equipment. We also strongly recommend instructing other users to properly start and operate the unit. This prepares 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 models:

04758-2 – 6 kW NG, 7 kW LP, single-cylinder GH-410 Engine

04759-2 – 12 kW NG, 12 kW LP, V-twin GT-990 Engine

04760-2 – 13 kW NG, 15 kW LP, V-twin GT-990 Engine

‹OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized Dealer. Normal maintenance 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 maintenance service.

Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expens- es at a minimum. See the Authorized Dealer for service aids and accessories.

‹HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact an Authorized Dealer for assistance. Service tech- nicians are factory-trained and are capable of handling all service needs.

When contacting an Authorized Dealer about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator.

Model No. ____________ Serial No.______________

AUTHORIZED DEALER LOCATION

To locate the nearest AUTHORIZED

DEALER , please call this number:

1-800-333-1322

or locate us on the web at

www.generac.com

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Contents This manual should remain with the unit Models 04758-2 6 kW NG, 7 kW LP 04759-2 12 kW NG, 12 kW LP04760-2 13 kW NG, 15 kW LP  Not intended for use as Primary Power in place of utility ‹ HOW TO OBTAIN SERVICE ‹ CONTENTS‹ OPERATION AND MAINTENANCE INTRODUCTIONSection 4 - Maintenance Section 2 - Post Installation Start-upand Adjustments Section 5 - Troubleshooting WARNING   GENERAL HAZARDS IMPORTANT SAFETY INSTRUCTIONS This product contains or emits chemicals EXPLOSION HAZARDS   ELECTRICAL HAZARDS  FIRE HAZARDS  ‹ STANDARDS INDEX1.3 SYSTEM SET LED 1.1 UNPACKING/INSPECTION1.2 PROTECTION SYSTEMS DANGERFigure 1.2 - 12 kW/15 kW, V-twin GT-990/760 Engine 1.4 THE GENERATORFigure 1.1 - 7 kW, Single Cylinder GH-410 Engine ‹ 1.5.2 ENGINE 1.5 SPECIFICATIONS‹ 1.5.1 GENERATOR 1.7 FUEL CONSUMPTION 1.8 RECONFIGURING THE FUEL SYSTEM1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS DANGER‹ 1.9.1 GENERATOR 1.9 LOCATION‹ 1.8.2 12KW AND 15KW, 990CC ENGINES Figure 1.4 - Demand Regulator‹ 1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW, 12 kW and 15 kW Units 1.10 BATTERY INSTALLATION1.11 THE BATTERY Figure 1.5 - Battery Cable Connections2.3 ELECTRICAL CHECKS 2.2 CHECK TRANSFER SWITCH OPERATION2.1 BEFORE INITIAL START-UP Section 2 - Post Installation Start-up and Adjustments2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC OPERATIONFigure 2.1 - Dual Fuel Regulators 2.6 ADJUSTING THE REGULATOR NATURAL GAS ONLYFigure 2.2 - Placement of Regulator Figure 2.4 - V-twin Engine Governor Adjustment 2.7 ENGINE GOVERNOR ADJUSTMENTFigure 2.3 - Single Cylinder Engine Governor Adjustment Figure 2.5 - V-twin Full Load Speed Adjust ScrewFigure 2.6 - Voltage Adjustment Potentiometer 2.8 VOLTAGE REGULATOR ADJUSTMENT3.1 BREAK-IN PROCEDURE ‹ 3.2.1 “AUTO” POSITION3.5 MANUAL TRANSFER OPERATION 3.3 AUTOMATIC TRANSFER OPERATION3.4 SEQUENCE OF AUTOMATIC OPERATION ‹ 3.5.1 TRANSFER TO GENERATOR POWER SOURCE‹ 3.7.1 LOW OIL PRESSURE SWITCH 3.6 SETTING THE EXERCISE TIMER‹ 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE Figure 3.2 - Manual Transfer Switch Operation4.1 FUSE ‹ 3.7.2 HIGH TEMPERATURE SWITCHFigure 3.3 - Low Oil Pressure and High Temperature Switches 4.2 CHECKING THE ENGINE OIL LEVEL4.3 CHANGING THE ENGINE OIL 4.5 CHANGING THE ENGINE AIR CLEANER‹ 4.3.2 OIL CHANGE PROCEDURE 4.4 CHANGING THE OIL FILTERFigure 4.7 - 12 kW and 15 kW Engine Air Cleaner 4.7 BATTERY MAINTENANCEFigure 4.6 - 7 kW, Engine Air Cleaner Location Figure 4.8 - Setting the Spark Plug Gap4.9 COOLING SYSTEM 4.8 ADJUSTING VALVE CLEARANCEFigure 4.10 - Valve Clearance Adjustment ‹ 4.12.2 RETURN TO SERVICE 4.12 OUT OF SERVICE PROCEDURE‹ 4.12.1 REMOVAL FROM SERVICE 4.10 ATTENTION AFTER SUBMERSIONbe performed by the nearest Authorized Dealer 4.13 SERVICE SCHEDULEATTENTION It is recommended that all service work Cause 5.1 TROUBLESHOOTING GUIDEProblem CorrectionENGINE WIRING Section 6 - Electrical DataCONNECTION CONTROL PANEL BOXCUSTOMER Electrical Schematic - 12 & 15 kW - Drawing No. 0D8501-B Section 6 - Electrical Data ENGINE WIRING Section 6 - Electrical DataCUSTOMER 225A 224AElectrical Schematic - 7 kW - Drawing No. 0D9014-C Section 7 - Exploded Views and Parts Lists PRE PACKAGED UNITS ONLYFOAM, EXHAUST SIDE ENCLOSURE FRONT PART NO. QTY. DESCRIPTIONCLOTH, HARDWARE 266.7mm x 146mm 7KW FOAM, BACK EXHAUST ENCLOSURE COVERSection 7 - Exploded Views and Parts Lists PART NO. QTY DESCRIPTION69 16A, 16B, 17 Views and Parts Lists66 2, 5, 19, 20, 39, 40, 47, 64, 93 67 8, 11, 12 68 4, 5 72 27, 28 73 3, 32, 33, 34, 35, 36, 40ITEM PART NO. QTY. DESCRIPTION ASSEMBLY, CRANKCASE HOUSING WITHASSEMBLY, CRANKSHAFT HORIZONTAL ROLLER BEARING, GOVERNOR PLATESection 7 - Exploded Views and Parts Lists ASSY, IGNITION COIL GV-990 CYLINDER 7 kW Generator - Drawing No. 0D3504-E 1.8 FT 1.25 FT12 kW and 15 kW Generator - Drawing No. 0D3417-L 32 311.44 FT 2.6 FT3 FT Section 7 - Exploded Views and Parts Lists Section 7 - Exploded Views and Parts Lists DESCRIPTIONSection 7 - Exploded Views and Parts Lists Section 7 - Exploded Views and Parts Lists DESCRIPTIONSection 7 - Exploded Views and Parts Lists Section 7 - Exploded Views and Parts Lists Drawing No ALL DIMENSIONS IN MILLIMETERS INCHESSection 8 - Mounting Air-cooledSection 9 - Notes PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANWARRANTY SCHEDULE PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS