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Generac Power Systems Guardian 04389-1 Installation And Owner's Manual

Air-cooled, prepackaged automatic standby generators 6 kw ng, 7 kw lp/12 kw ng, 12 kw lp/13 kw ng, 15 kw lp
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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 Guardian 04389-1

  • Page 1 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) 04456-1 (12 kW NG, 12 kW LP) 04390-1 (13 kW NG, 15 kW LP)

  • Page 2: Introduction

    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 •...

  • Page 3: Table Of Contents

    Introduction ...Inside Front Cover Read This Manual Thoroughly ...IFC Contents ...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Dealer Locator Number ...IFC Safety Rules ...2 Standards Index ...3 Section 1 – General Information ...4 Unpacking/Inspection ...4 Protection Systems ...4 System Set LED ...4 Your Generator ...5 Specifications ...6...

  • Page 4: 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 operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.

  • Page 5: Standards Index

    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.

  • Page 6: Section 1 - General Information

    Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators DANGER Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage.

  • Page 7: Your Generator

    YOUR GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Exhaust Enclosure Figure 1.2 – 12 kW and 15 kW, V-twin GT-990 Engine Exhaust Enclosure Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel Data Decal Battery Compartment...

  • Page 8: Specifications

    Compression Ratio Starter Oil Capacity Including Filter Recommended Oil Filter Recommended Air Filter Operating RPM Generac ® Power Systems, Inc. Model 04389-1 Model 04456-1 6,000 NG/7,000 LP 12,000 NG/12,000 LP 120/240 120/240 50.0 NG/58.3 LP 100.0 NG/100.0 LP 25.0 NG/29.2 LP 50.0 NG/50.0 LP...

  • Page 9: Fuel Requirements And Recommendations

    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.

  • Page 10: Location

    Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 3. Remove the small hose clamp and hose from the fuel regulator. It may be necessary to pry the hose off of the brass fitting using a screw driver to gen- tly lift up the hose edge.

  • Page 11: Battery Installation

    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.

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

    Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators • 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.

  • Page 13: Generator Tests Under Load

    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 Hertz. 11. Connect the AC voltmeter test leads across termi- nal lug E1 and neutral;...

  • Page 14: Adjusting The Regulator (Natural Gas Only)

    Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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.

  • Page 15: Kw And 15 Kw Units

    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 Idle Spring Governor Shaft...

  • Page 16: Section 3 - Operation

    Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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.

  • Page 17: Sequence Of Automatic Operation

    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...

  • Page 18: Transfer Back To Utility Power Source

    Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored, transfer back to that source and shut down the generator. This can be accomplished as follows: 1.

  • Page 19: Overspeed

    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 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total 3.7.4 OVERSPEED...

  • Page 20: Changing The Engine Oil

    Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators CHANGING THE ENGINE OIL 4.3.1 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute (API) Service Class SG, SH or SJ. Use all season SAE 5W-30 Synthetic oil.

  • Page 21: Spark Plug(S)

    Figure 4.7 — 12 kW and 15 kW Engine Air Cleaner Screw SPARK PLUG(S) Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See Section 4.13 for mainte- nance requirements. 1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine.

  • Page 22: Adjusting Gh-410/Gt-990 Valve Clearance

    Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Lead-acid batteries present a risk of fire because they generate hydrogen gas. The following procedures are to be followed: • DO NOT SMOKE when near the battery; •...

  • Page 23: Attention After Submersion

    The exhaust from this product gets extremely 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. The maximum ambient temperature for the generator is 40°...

  • 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

    TROUBLESHOOTING GUIDE PROBLEM The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The Auto/Off/Manual switch is set to OFF , but the engine continues to run. There is no AC output from the generator.

  • Page 26: Section 6 - Electrical Data

    Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE DSW - PCB MOUNTED DIP SWITCH...
  • Page 27 224A 225A 225B 225B 224B 224B VOLTAGE REGULATOR Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B CONTROL PANEL BOX 224A 225A AUTO MANUAL Section 6 — Electrical Data CLOSEST TO BEARING 240V GENERATOR OUTPUT TO TRANSFER...
  • Page 28 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B C2-11 FIELD ELECTRONIC C2-10 VOLTAGE REGULATOR C2-8 (STATOR) DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB2 - CIRCUIT BREAKER, ALT.
  • Page 29 225A 56VA 224A C1-1 C1-5 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B C2-6 C2-5 POWER WINDING (STATOR) C2-1 Section 6 — Electrical Data 240VAC UTILITY INPUT 12Vdc TRANSFER RELAY...
  • Page 30 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No. 0D9013-C DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE DSW - PCB MOUNTED DIP SWITCH...
  • Page 31 224A 225A 224A 225B 225B 224B 224B VOLTAGE REGULATOR Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No. 0D9013-C CONTROL PANEL BOX 225A AUTO MANUAL CLOSEST TO BEARIN STATOR 240V GENERATOR OUTPUT TO TRANSFER...
  • Page 32 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D9014-B ELECTRONIC C2-10 VOLTAGE REGULATOR C2-8 DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB2 - CIRCUIT BREAKER, ALT.
  • Page 33 C2-6 225A 56VA 224A C1-1 C1-5 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D9014-B C2-5 POWER WINDING (STATOR) C1-2 C1-6 Section 6 — Electrical Data 240VAC UTILITY INPUT 12Vdc TRANSFER RELAY COIL...

  • 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-Q PRE PACKAGED UNITS ONLY 32 Generac ® Power Systems, Inc.
  • Page 35 ITEM PART NO.QTY. DESCRIPTION 0C6140 ASSEMBLY, ENCLOSURE BASE (12KW/15KW) 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 0C6735 SUPPORT, ROOF FOLDING 0C7061 ENCLOSURE, FRONT 0C7062 ENCLOSURE, EXHAUST SIDE (12KW / 15KW) 0C7062A ENCLOSURE, EXHAUST SIDE (7KW) 0C7063 ENCLOSURE, SIDE & BACK (12KW / 15KW) 0C7063A ENCLOSURE, SIDE &...
  • 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-F 34 Generac ® Power Systems, Inc.
  • Page 37 ITEM PART NO. QTY. DESCRIPTION 0A9947E CIRCUIT BREAKER 30 X 2 240V SQD QOU230 (7KW) 0A9947G CIRCUIT BREAKER 40 X 2 240V SQD QOU240 (8.5KW) 0A9947F CIRCUIT BREAKER 50 X 2 240V SQD QOU250 (12KW) 0A9947C CIRCUIT BREAKER 60 X 2 240V SQD QOU260 (13KW) 0A9947D CIRCUIT BREAKER 70 X 2 240V SQD...
  • 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 ITEM PART NO. 0D4801 0D4800 0C2237 077220 077220A 082574 084464 074908 024912 0A1658 063617 0D3030A 0A1495 0A1661 022473 0D3094 0D4684A 0D3319 056326 022152 087680 077441 063378 074138 036933 077033 048850 028739 038150 0D3191 0D3088 073591 073590A 040213B 0C8037 075475 0C8036 0C8035 0D3320 0D4802...
  • 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 12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D ITEM PART NO. 0D3086 0D3092 0C2237 077220 077220A 082574 084464 074908 024912 0A1658 063617 0D3030 0A1495 0A1661 022473 055450 025034 0D4684 0D3319 056326 022152 087680 077441 063378 074138 036933 077033...
  • 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-E Part 1 40 Generac ® Power Systems, Inc.
  • Page 43 ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE 0C3008 SEAL, 38 I.D. CRANKSHAFT 090388 SCREW, TAPTITE M6-1.0 X 12 YC 0C5372 ASSEMBLY, BREATHER 0C3005 GASKET, BREATHER COVER 0E1684 SEPARATOR, OIL BREATHER 0D8067A ASSEMBLY, HEAD #1 G&S 071983 RETAINER, PISTON PIN 20 0C2981C ROCKER, COVER NO OIL FILL...
  • 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-E Part 2 42 Generac ® Power Systems, Inc. 11 116...
  • Page 45 ITEM PART NO. QTY. DESCRIPTION 0C5136A KNOB, AIR CLEANER 0C3024 COVER, AIRBOX NG/LP 0C3040 PRE-CLEANER, 0C8127 ELEMENT, AIR CLEANER 0D8564A ASSEMBLY, MIXER/AIRBOX 990 0D8564B ASSEMBLY, MIXER/AIRBOX 760 0D2595 SCREW SHOULDER (8MM) M6-1.0 X 18 0D4417 WASHER,RUBBER 1/4" X 1/8" THICK 0C3025 SWITCH, OIL PRESS 0D3083...
  • 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-C 44 Generac ® Power Systems, Inc.
  • Page 47 ITEM PART NO. 0C6934 0C9935H 0C9934H 0C6043A 0C8096 0C9593 0D3220 0C8860 031971 0C3168 056147 0D1847 0C7038C 0D1647 0D2558 0C7038B 0C7758 0388050AE0 0C2417A 082121C 066386 029451 049451 022237 022511 022131 039287 022145 049820 090388 022129 022259 059637 048031K 0C9592 057822 040976 0C2824 025145 090239...
  • 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-D 46 Generac ® Power Systems, Inc.
  • Page 49 ITEM PART NO. 0C6934 0C7930 0D2359 0C7944 0D2356 0C6043 0D2336 0D6634 0D3220 0C8101 056482 0C3168 0D1838 0D1846 0C7038 0D1609 0D2559 0C7038A 0C7758 0388050AD0 0C2417A 082121C 066386 029451 049451 022237 022511 022131 039288 022145 049820 045756 022129 022259 059637 083512 074994 057822 052858 0C2824...
  • 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-D Part 1 48 Generac ® Power Systems, Inc.
  • Page 51 ITEM PART NO. 071978 071980 021533 0C5848 071983 0D4287 0A7628 078658 078659 088261E 072655 0A7975 078645 0A7811 0A9877 076701 021713B 078691 0A5771 0A5776 076361 0A8898D 0D2274 0C4391 086025 0C7393 021714 086516 086517 088396B 083897 077158 0C3150 072694 083907 072696 078694 021742 0C3972 076329...
  • 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-D Part 2 50 Generac ® Power Systems, Inc.
  • Page 53 ITEM PART NO. 0C1069 0D2922 0C8435 0C9997 088434 045756 088433B 0D9004A 059985 022129 0C2458A 083512 0D1401 091039 0C9619 049811 022097 040945 086999 0D5667A 049821 099236 070185 082774 091222E 067198N 067890 072347 072734 072735 0C3978 0C6040 084542 092079 0A8222 083502 083503 0D3083 0C8434 090072...
  • Page 54 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-B ITEM PART NO. QTY. DESCRIPTION 0D5694 CASTING, TWIN REGULATOR HOUSING 0C5765 SOLENOID, TWIN REGULATOR 0C4647 GASKET , SOLENOID 0C4680 PLUNGER, LP REGULATOR ASSEMBLY 0C6070...

  • 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

    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.

  • Page 59: 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.
  • Page 60 GUARDIAN “EMERGENCY AUTOMATIC STANDBY GENERATORS” For a period of two years from the date of original sale, 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.

This manual is also suitable for:

Guardian 04390-1Guardian 04456-1

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