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Guardian 04389-3 Installation And Owner's Manual

Air-cooled, prepackaged automatic standby generators
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C
US
LISTED
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:
04389-3 (6 kW NG, 7 kW LP)
04456-3 (12 kW NG, 12 kW LP)
04390-3 (13 kW NG, 15 kW LP)
GENERAC
POWER SYSTEMS, INC.
R
R

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Summary of Contents for Guardian 04389-3

  • Page 1 Installation and Owner’s Manual Air-cooled, Prepackaged Automatic Standby Generators Models: 04389-3 (6 kW NG, 7 kW LP) 04456-3 (12 kW NG, 12 kW LP) LISTED 04390-3 (13 kW NG, 15 kW LP) GENERAC POWER SYSTEMS, INC.   Not intended for use as Primary Power in place of utility or in life-support applications.

  • Page 2: Introduction

    READ THIS MANUAL THOROUGHLY models: If any portion of this manual is not understood, contact • 04389-3 – 6 kW NG, 7 kW LP , single-cylinder GH- the nearest Authorized Dealer for starting, operating 410 Engine and servicing procedures.

  • Page 3: Table Of Contents

    Table of Contents Air-cooled 7 kW, 12 kW and 15 kW Generators Introduction ......Inside Front Cover Section 3 – Operation ........14 Read This Manual Thoroughly ......IFC Break-in Procedure ........14 Contents ............IFC Using the Auto/Off/Manual Switch ....14 Operation and Maintenance ......

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS 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 opera- tors and potential operators of this equipment.

  • Page 5: Standards Index

    IMPORTANT SAFETY INSTRUCTIONS 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 ELECTRICAL HAZARDS Fire Protection Association are appropriate for use on the standby electric system. Keep the extin- •...

  • Page 6: Section 1 - General Information

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators There are LED readouts on the control panel to notify DANGER personnel that one of these faults has occurred. There is also a “System Set” LED that is lit when all ...

  • Page 7: The Generator

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators THE GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Control Panel Data Dipstick Decal GFCI Outlet Exhaust Enclosure Fuel Regulator Fuel Inlet Battery Oil Filter Compartment Figure 1.2 –...

  • Page 8: Specifications

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators SPECIFICATIONS 1.5.1 GENERATOR Model 04389 Model 04456 Model 04390 Rated Max. Continuous Power 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP Capacity (Watts*) Rated Voltage 120/240 120/240 120/240...

  • Page 9: System Set Led

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators SYSTEM SET LED DANGER The “System Set” LED is lit when all of the following  Gaseous fuels such as natural gas and liquid conditions are true: propane (LP) gas are highly explosive.

  • Page 10: Location

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators 8. Refit the brass hose barb fitting to outlet port #1 13. To adjust the system to run on LP fuel, turn and the square headed steel pipe plug to outlet BOTH adjuster screws 1/2 TURN CLOCKWISE.

  • Page 11: Battery Installation

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators 1.10.2 TRANSFER SWITCH 4. Connect the red battery cable (from starter con- tactor) to the battery post indicated by a positive, POS or (+). 1.10.2.1 7 kW, 12 kW and 15 kW Units 5.

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

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW, 12 kW and 15 kW Generators • Spilled electrolyte is to be washed down with an 5. Check the engine crankcase oil level and, if neces- acid neutralizing agent. A common practice is to sary, fill to the dipstick FULL mark with the rec- use a solution of 1 pound (500 grams) bicarbonate ommended oil.

  • Page 13: Generator Tests Under Load

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW, 12 kW and 15 kW Generators 7. When certain that utility supply voltage is compat- ible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer ...

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

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW, 12 kW and 15 kW Generators 5. Turn ON the utility power supply to the transfer 5. The fuel regulator is fitted with one (7 kW), or two switch, using the means provided (such as a util- (12 &...

  • Page 15: Engine Governor Adjustment

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW, 12 kW and 15 kW Generators 2.7.2 12 KW AND 15 KW UNITS If this procedure or the equipment are not available, locate the nearest Dealer and they can perform the 1.

  • Page 16: Voltage Regulator Adjustment

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators BREAK-IN PROCEDURE 7. Restart the unit. 8. Slowly turn the idle adjust screw to adjust the Once the unit has been installed and all electrical no-load idle frequency to 63-63.5 Hz (with door checks have been made, it is strongly recommended open).

  • Page 17: Automatic Transfer Operation

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators 3.2.2 “OFF” POSITION 3.3.1 12 VDC ACCESSORY OUTLET This switch position shuts down the engine. This Your generator is equipped with a 12 VDC accessory position also prevents automatic operation. outlet in the Generator Control Panel.

  • Page 18: Manual Transfer Operation

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators • If utility source voltage drops below about 60 4. Use the manual transfer handle inside the trans- percent of the nominal supply voltage, the sensor fer switch to move the main contacts to their energizes a 15-second timer.

  • Page 19: Setting The Exercise Timer

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators 3.7.2 HIGH TEMPERATURE SWITCH 5. Use the manual transfer handle inside the trans- fer switch to move the main contacts back to their This switch’s contacts (Figure 3.3) close if the tem- UTILITY position, i.e., loads connected to the util- perature should exceed approximately 140º...

  • Page 20: Section 4 - Maintenance

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators 3.7.4 OVERSPEED 3. Install the dipstick; then, remove it again. The oil level should be at the dipstick “Full” mark. If nec- This feature protects the generator from damage by essary, add oil to the “Full”...

  • Page 21: Changing The Engine Oil

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators CHANGING THE ENGINE OIL CHANGING THE OIL FILTER Change the engine oil filter as follows: 4.3.1 ENGINE OIL RECOMMENDATIONS 1. With the oil drained, remove the old oil filter by Use oil of American Petroleum Institute (API) Service turning it counterclockwise.

  • Page 22: Spark Plug(S)

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators BATTERY MAINTENANCE Figure 4.7 — 12 kW and 15 kW Engine Air Cleaner The battery should be inspected per the “Service Schedule,” Section 4.13. The following procedure should be followed for inspection: Screw 1.

  • Page 23: Adjusting

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators When valve clearance is correct, hold the pivot ball  Lead-acid batteries present a risk of fire because stud in place with the allen wrench and tighten the they generate hydrogen gas.

  • Page 24: Attention After Submersion

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators 7. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase. 8. Remove the spark plug(s) and spray fogging  The exhaust from this product gets extremely agent into the spark plug(s) threaded openings.

  • Page 25: Service Schedule

    Section 4 — Maintenance 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 the nearest Authorized Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly...

  • Page 26: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Air-cooled 7 kW, 12 kW and 15 kW Generators TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables.

  • Page 27: Section 6 - Notes

    Section 6 — Notes Air-cooled 7 kW, 12 kW and 15 kW Generators...
  • Page 28 Section 6 — Notes Air-cooled 7 kW, 12 kW and 15 kW Generators...
  • Page 29 Section 6 — Notes Air-cooled 7 kW, 12 kW and 15 kW Generators...

  • Page 30: Section 7 - Electrical Data

    Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – V-Twin – Drawing No. 0E9016 ENGINE WIRING BATTERY DIAGRAM KEY CHARGER BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION 225B CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL...
  • Page 31 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – V-Twin – Drawing No. 0E9016 CONTROL PANEL BOX 224A 225A 224A 225A CLOSEST TO BEARING STATOR 224B 224B 225B 225B VOLTAGE REGULATOR EXTERNAL GFCI OUTLET LOAD...
  • Page 32 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – V-Twin – Drawing No. 0E9017 225A 225A 224A 224A BATTERY 225B CHARGER 224B C2-1 BATTERY CHARGE WINDING C2-2 C2-4 C2-11 ENGINE RUN WINDING C1-4 (STATOR) FIELD...
  • Page 33 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – V-Twin – Drawing No. 0E9017 C2-6 C2-5 225A 240VAC UTILITY 56VA INPUT 224A 12Vdc TRANSFER RELAY COIL 12VDC ACCESSORY SOCKET CUSTOMER CONNECTIONS 120V POWER 120V WINDING...
  • Page 34 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – Single Cylinder – Drawing No. 0E9014 ENGINE WIRING BATTERY DIAGRAM KEY CHARGER (UTILITY) BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION 225B CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL...
  • Page 35 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – Single Cylinder – Drawing No. 0E9014 CONTROL PANEL BOX 224A 225A CLOSEST TO BEA 224A 225A STATOR 224B 225B 225B 224B VOLTAGE REGULATOR EXTERNAL GFCI LOAD...
  • Page 36 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – Single Cylinder – Drawing No. 0E9015 225A 225A 224A 224A BATTERY 225B CHARGER 224B 225A 224A C2-1 BATTERY CHARGE WINDING C2-2 C2-4 ENGINE RUN WINDING C1-4 (STATOR)
  • Page 37 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – Single Cylinder – Drawing No. 0E9015 C2-6 C2-5 225A 240VAC UTILITY 56VA INPUT 224A 12Vdc TRANSFER RELAY COIL CUSTOMER CONNECTIONS 12VDC ACCESSORY SOCKET NEUTRAL 120V POWER...
  • Page 38 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 8 Circuit Load Center – Drawing No. 0E7687A...
  • Page 39 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 8 Circuit Load Center – Drawing No. 0E7687A...
  • Page 40 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 Circuit Load Center – Drawing No. 0E7687$...
  • Page 41 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 Circuit Load Center – Drawing No. 0E7687$...
  • Page 42 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 8 Circuit Load Center – Drawing No. 0E7815A 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK TO GENERATOR OUTPUT CIRCUIT BREAKER NEUTRAL (WHITE) NEUTRAL...
  • Page 43 Section 7 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 Circuit Load Center – Drawing No. 0E7815$ 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK TO GENERATOR OUTPUT CIRCUIT BREAKER NEUTRAL (WHITE) NEUTRAL...

  • Page 44: Section 8 - Exploded Views And Parts Lists

    Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0F0080-C PRE PACKAGED UNITS ONLY...
  • Page 45 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0F0080-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C6140 ASSEMBLY, ENCLOSURE BASE 047411 SCREW HHC M6-1.0 X 16 G8.8 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 047411...
  • Page 46 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E9162-J...
  • Page 47 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E9162-J ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7886A CIRCUIT BREAKER 30A X 2P 240V (7KW) 074908 SCREW TAPTITE, M5-0.8 x 10 BP 0E7886E...
  • Page 48 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW, 8 Circuit Load Center Assembly – Drawing No. 0E7975-B...
  • Page 49 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW, 8 Circuit Load Center Assembly – Drawing No. 0E7975-B ITEM PART NO. QTY. DESCRIPTION 0D4801 BOX GTS LOAD CENTER 0D4800 COVER, 8 POSITION GTS LOAD CENTER 0C2237 TRANSFER SWITCH HOME STANDBY 100A 2P 250V 077220...
  • Page 50 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW, 12 Circuit Load Center Assembly – Drawing No. 0E7973-F...
  • Page 51 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW, 12 Circuit Load Center Assembly – Drawing No. 0E7973-F ITEM PART NO. QTY. DESCRIPTION 0D3086 BOX GTS LOAD CENTER 0D3092 COVER, 12 CIRCUIT GTS LOAD CENTER 0F5211...
  • Page 52 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-M Part 1...
  • Page 53 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-M Part 1 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH 0C3971C ASSEMBLY, DIPSTICK WITH HANDLE SLEEVE...
  • Page 54 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-M Part 2 123, 145 97 98...
  • Page 55 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-M Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5136A KNOB, AIR CLEANER 0D1131 GUARD, FAN 0C3024 COVER, AIRBOX NG/LP...
  • Page 56 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-E...
  • Page 57 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-E ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0C9935H STATOR 0C9934H ROTOR 0C6043A CARRIER, REAR BEARING 0C8096 FAN, 8"...
  • Page 58 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-L...
  • Page 59 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-L ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0C7930 STATOR 12KW 0D2359 STATOR 13KW / 15KW 0C7944 ROTOR 12KW 0D2356...
  • Page 60 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 1...
  • Page 61 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 1 ITEM PART NO. QTY. DESCRIPTION 0E3221 ASSEMBLY, CONNECTING ROD 0E1466 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0E2985 PISTON, HC 071983...
  • Page 62 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 2...
  • Page 63 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 2 ITEM PART NO. QTY. DESCRIPTION 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0C8435 TUBE, DIPSTICK 0C9997 GUARD, FAN...
  • Page 64 Section 8 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-H 29 18 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D5694 CASTING, TWIN REGULATOR HOUSING 0C6731 RIVET, POP .118 X .125 0F5022...

  • Page 65: Section 9 - Mounting Dimensions

    Section 9 — Mounting Dimensions Air-cooled 7 kW, 12 kW and 15 kW Generators Drawing No. 0D3739-C TYPE HOM CBHOM-F TYPE HOM CBHOM-F TYPE HOM CBHOM-F TYPE HOM CBHOM-F TYPE HOM CBHOM-F TYPE HOM CBHOM-F 120/240v 120/240v 120/240v 120/240v 120/240v 120/240v...

  • Page 66: Section 10 - Warranty

    Section 10 – Warranty 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.
  • Page 67 Section 10 – Warranty Air-cooled 7 kW, 12 kW and 15 kW Generators 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 continue for 24 consecutive months thereafter.
  • Page 68 "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective.

This manual is also suitable for:

04456-304390-3Plus 04389-3Plus 04456-3Plus 04390-3

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