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Generac Power Systems 04389-1, 04456-1, 04390-1 Installation And Owner's Manual

Air-cooled, prepackaged automatic standby generator
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POWER SYSTEMS, INC.
Not intended for use as Primary Power in place of utility or in
!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
Installation and
Owner's Manual
life-support applications.
DANGER
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)
GENERAC
R
POWER SYSTEMS, INC.
R
®
!

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Summary of Contents for Generac Power Systems 04389-1, 04456-1, 04390-1

  • Page 1 POWER SYSTEMS, INC. Not intended for use as Primary Power in place of utility or in DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!! Installation and Owner’s Manual Automatic Standby Generators GENERAC POWER SYSTEMS, INC. life-support applications. DANGER Air-cooled, Prepackaged Models: 04389-1 (6 kW NG, 7 kW LP)

  • Page 2: 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.

  • Page 3: Table Of Contents

    Section 6 – Electrical Data ...24 Section 7 – Exploded Views and Section 8 – Mounting Dimensions...53 Section 9 – Notes ...54 Section 10 – Warranty ...56 Table of Contents Power Source...15 Power Source...15 Generators...18 Parts Lists...32 Generac ® Power Systems, Inc.

  • Page 4: Safety Rules

    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.

  • Page 5: Standards Index

    NANCE OF FARM STANDBY ELECTRICAL SYS- TEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085. 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE, available same as Item 1. EXPLOSION HAZARDS Generac ® Power Systems, Inc.

  • Page 6: Section 1 - General Information

    “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 discovered later. Generac ® Power Systems, Inc. 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.

  • Page 7: Your Generator

    Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel Data Decal Battery Compartment Oil Filter Data Control Decal Panel Oil Dipstick Air Filter Oil Filter Air Filter Fuel Regulator Fuel Regulator Battery Compartment Generac ® Power Systems, Inc.

  • Page 8: Specifications

    12 Vdc 12 Vdc Approx. 1.5 Qts Approx. 1.7 Qts Generac Part # 70185 Generac Part # 70185 Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127 3,600 3,600 Model 04390-1 13,000 NG/15,000 LP† 120/240 108.3 NG/125.0 LP 54.2 NG/62.5 LP...

  • Page 9: Fuel Requirements And Recommendations

    NG FUEL SYSTEM NOTE: 1.8.2 12 KW AND 15 KW, 990CC ENGINES NOTE: outlet ports of the demand regulator. solenoid located on the top of the demand regu- lator. by rotating counterclockwise. Generac ® Power Systems, Inc. LP FUEL SYSTEM...

  • Page 10: Location

    If prevailing winds will cause blowing or drift- ing, you may need to consider using a windbreak to protect the unit. Generac ® Power Systems, Inc. • Install the generator on high ground where water levels will not rise and endanger it.

  • Page 11: The Battery

    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. DANGER Generac ® Power Systems, Inc.

  • Page 12: Section 2 - Post Installation Start-Up And Adjustments

    T1 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. DANGER The transfer switch is now electrically “hot.”...

  • Page 13: Generator Tests Under Load

    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. CHECKING AUTOMATIC OPERATION ADJUSTING THE REGULATOR (NATURAL GAS ONLY) Generac ® Power Systems, Inc. 11...

  • Page 14: Engine Governor Adjustment

    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. A service fee may be charged for this adjustment.

  • Page 15: Kw And 15 Kw Units

    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). NOTE: Generac ® Power Systems, Inc. 13...

  • Page 16: Using The Auto/Off/Manual Switch

    OFF and remove 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. AUTOMATIC TRANSFER...

  • Page 17: Manual Transfer Operation

    To select the desired day and time of day, you must perform the following sequence at that time. TRANSFER BACK TO UTILITY POWER SOURCE DANGER Generac ® Power Systems, Inc. 15...

  • Page 18: Protection Systems

    High Temperature Switches Low Oil Switch Drain Hose Oil Filter 16 Generac ® Power Systems, Inc. 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.

  • Page 19: Checking The Engine Oil Level

    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. 12 kW and 15 kW Oil Fill NOTE: Generac ® Power Systems, Inc. 17...

  • Page 20: Changing The Oil Filter

    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. Figure 4.6 — 7 kW, Engine Air Cleaner Location...

  • Page 21: Battery Maintenance

    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.

  • Page 22: Cooling System

    Stem 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.

  • Page 23: Out Of Service Procedure

    9. 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. If the battery was dead or disconnected, you must reset the exercise timer. NOTE: Generac ® Power Systems, Inc. 21...

  • Page 24: Service Schedule

    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 X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed.

  • Page 25: Section 5 - Troubleshooting

    There is no transfer to standby after utility source failure. Unit consumes large amounts of oil. *Contact your nearest Generac/Guardian Authorized Dealer for assistance. Section 5 — Troubleshooting Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators CAUSE 1. Fuse blown.

  • Page 26: Section 6 - Electrical Data

    SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TB - INSULATED TERMINAL BLOCK TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) 24 Generac ® Power Systems, Inc. DIAGRAM KEY ENGINE WIRING...
  • Page 27 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-A CONTROL PANEL BOX 225A AUTO MANUAL CLOSEST TO BEARING STATOR CUSTOMER CONNECTION OUTPUT TO TRANSFER SWITCH CONTACTOR Generac ® Power Systems, Inc. 25...
  • Page 28 SP1, SP2 - SPARK PLUGS SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) 26 Generac ® Power Systems, Inc. BATTERY 225B...
  • Page 29 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-A C2-6 C2-5 C1-1 C1-5 Section 6 — Electrical Data POWER WINDING (STATOR) C2-1 BLACK Generac ® Power Systems, Inc. 27 CUSTOMER CONNECTIONS NEUTRAL 120V 120V 240V BATTERY CUSTOMER...
  • Page 30 SM - STARTER MOTOR TB - INSULATED TERMINAL BLOCK TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) BLACK BATTERY CUSTOMER SUPPLIED 28 Generac ® Power Systems, Inc. L.E.D - ALARM INDICATORS 225A 224A CONTROL...
  • Page 31 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No. 0D9013-A CONTROL PANEL BOX 225A AUTO MANUAL Section 6 — Electrical Data CLOSEST TO BEA CUSTOMER CONNECTION 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR Generac ® Power Systems, Inc. 29 STATOR...
  • Page 32 SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) 30 Generac ® Power Systems, Inc. BATTERY 225B...
  • Page 33 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D9014-A C2-6 C2-5 C1-2 C1-6 120V POWER WINDING (STATOR) 240V BATTERY BLACK CUSTOMER SUPPLIED Generac ® Power Systems, Inc. 31 CUSTOMER CONNECTIONS 120V...

  • Page 34: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0D3416-K 44 85 79 80 32 Generac ® Power Systems, Inc.
  • Page 35 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 M8-1.25 X 25 WASHER FLAT 5/16 NUT HEX M8-1.25 SELF-ALIGN SCREW M6 HH Generac ® Power Systems, Inc. 33...
  • Page 36 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0D8503-E 34 Generac ® Power Systems, Inc.
  • Page 37 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...
  • Page 38 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW GTS Load Center Assembly – Drawing No. 0D3997-E 36 Generac ® Power Systems, Inc.
  • Page 39 CIRCT BRK 15 X 1 HOM115 CIRCT BRK 30 X 2 HOM230 COVER - HARNESS ENTRY HARNESS, GTS TO EXT CONN BOX WASHER LOCK M4 SCREW SW 1/4-20X5/8 N WA JS500 SCREW SWAGE 1/4-20 X 1/2 ZINC Generac ® Power Systems, Inc. 37...
  • Page 40 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D 38 Generac ® Power Systems, Inc.
  • Page 41 HARNESS, GTS TO EXT CONN BOX (14KW / 15KW / 16KW) WASHER LOCK M4 SCREW SW 1/4-20X5/8 N WA JS500 SCREW SWAGE 1/4-20 X 1/2 ZINC SCREW PPHM M4-0.7 X 10 HARNESS,GTS TO MAIN PANEL Generac ® Power Systems, Inc. 39...
  • Page 42 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 29 28 40 Generac ® Power Systems, Inc. Kit Contains: 66 2, 5, 19, 20, 39, 40, 47, 64, 93, 140...
  • Page 43 PUSHROD, 144.6 GASKET, HEAD BARBED ELBOW 90 3/8NPT X 3/8 KIT GASKET KIT PISTON & 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...
  • Page 44 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 86 85 42 Generac ® Power Systems, Inc. 115 116...
  • Page 45 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...
  • Page 46 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-B 44 Generac ® Power Systems, Inc.
  • Page 47 TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG CLAMP VINYL 1.31 X .281 Z 1.25 FT HOSE 1\2ID LP GAS KNOB, AIR CLEANER SCREW TAPTITE M6-1 X 20 BP WASHER FLAT 1/4 ZINC SCREW HHTT M8-1.2 X 20 BP GASKET, PANEL Generac ® Power Systems, Inc. 45...
  • Page 48 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.
  • Page 49 CLAMP HOSE #8 .53 - 1.00 NUT LOCK M8 SCREW TAP-R #10-32 x 9/16 U-BOLT 5/16"-18 X 1.25" WITH SADDLE GASKET, EXHAUST PORT CLAMP HOSE BAND ¼" 1.33 FT HOSE 1/4 ID SAE 30R7 Generac ® Power Systems, Inc. 47...
  • Page 50 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.
  • Page 51 SCREW, HHFC M8-1.25 X 42 SEAL, VALVE STEM D7 WASHER, VALVE SPRING WASHER, LARGE SPRING DOWEL, SEAMED SLEEVE SHAFT, GOVERNOR RC55 BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE DOWEL DIA 12 X 18L DOWEL, SLEEVE SEAMED 12 DIA. Generac ® Power Systems, Inc. 49...
  • Page 52 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.
  • Page 53 SPRING, GOVERNOR 8# BOLT, GOVERNOR ADJUST M5 NUT, M5-0.8 METAL LOCK ASSEMBLY, OIL DRAIN HOSE ASSEMBLY, CAP & DIPSTICK O-RING 9/16 X 3/4 X 3/32 SWITCH, THERMAL WASHER LOCK M3 SCREW PPHM M3-0.5 X 8 Generac ® Power Systems, Inc. 51...
  • Page 54 0C5764A SPRING, REGULATOR (7KW) 070728 SCREW, PFHMS M3-0.5 x 5 070728 SCREW, PFHMS M3-0.5 x 5 (7KW) 0C6069 GASKET, DIAPHRAGM 0C5762 COVER, TWIN REGULATOR 52 Generac ® Power Systems, Inc. ITEM PART NO. QTY. 045764 045764 0C6731 0C6067 0C4706 0C6068...

  • Page 55: Section 8 - Mounting Dimensions

    Section 8 — Mounting Dimensions Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Drawing No. 0D3739-B Generac ® Power Systems, Inc. 53...

  • Page 56: Section 9 - Notes

    Section 9 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 54 Generac ® Power Systems, Inc.
  • Page 57 Section 9 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Generac ® Power Systems, Inc. 55...

  • Page 58: Section 10 - Warranty

    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.

  • Page 59: Emission Control System Warranty

    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”...
  • Page 60 "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.

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