Generac Power Systems Guardian 005240 Installation And Owner's Manual
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Generac Power Systems Guardian 005240 Installation And Owner's Manual

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Installation and
Owner's Manual
7, 10, 13 and 16kW Air-cooled, Automatic Standby Generators
C
US
LISTED
Not intended for use in critical life support
applications.
Only qualified electricians or contrac-
tors should attempt installation! Deadly
exhaust fumes. Outdoor installation only!
www.generac.com or 1-888-GENERAC
Models:
005240, 005280 (6 kW NG, 7 kW LP)
005241, 005281 (9 kW NG, 10 kW LP)
005242, 005282 (13 kW NG, 13 kW LP)
005243, 005244, (15 kW NG, 16 kW LP)
005283, 005284

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  • Page 1 Installation and Owner's Manual 7, 10, 13 and 16kW Air-cooled, Automatic Standby Generators LISTED Not intended for use in critical life support Models: 005240, 005280 (6 kW NG, 7 kW LP) applications. 005241, 005281 (9 kW NG, 10 kW LP) Only qualified electricians or contrac- 005242, 005282 (13 kW NG, 13 kW LP) tors should attempt installation! Deadly...

  • Page 2: Table Of Contents

    Table of Contents Introduction ............. 1 Operation .............. 15 Read This Manual Thoroughly ..........1 Using the AUTO/OFF/MANUAL Switch ......15 Contents ................1 Automatic Transfer Operation ........15 Operation and Maintenance ...........1 Sequence of Automatic Operation .........16 How to Obtain Service ............1 Authorized Dealer Locator Number ..........1 Manual Transfer Operation ..........16 Setting the Exercise Timer ..........17 Safety Rules ............

  • Page 3: Introduction

    Thank you for purchasing this model of the Guardian product line read this Owner’s Manual and thoroughly understand all instruc- by Generac Power Systems Inc. This model is a compact, high tions before using this equipment. The manufacturer also strongly...

  • Page 4: Safety Rules

    Safety Rules SAFETY RULES GENERAL HAZARDS For safety reasons, the manufacturer recommends that this • equipment be installed, serviced and repaired by a Service Save These Instructions – The manufacturer Dealer or other competent, qualified electrician or installation suggests that these rules for safe operation be copied and posted near the unit’s instal- technician who is familiar with applicable codes, standards lation site.

  • Page 5: Standards Index

    Safety Rules • The National Electrical Code (NEC) requires the frame and external STANDARDS INDEX electrically conductive parts of the generator to be connected to In the absence of pertinent standards, codes, regulations and laws, an approved earth ground. Local electrical codes also may require the published information listed below may be used as installation proper grounding of the generator electrical system.

  • Page 6: General Information

    General Information There are LED readouts on the control panel to notify personnel that one of these faults has occurred. There is also a System Only qualified electricians or contractors Set LED that is lit when all of the conditions described in section should attempt such installations, which must "System Set LED"...

  • Page 7: The Generator

    General Information THE GENERATOR Figure 1.1 – 7kW, Single Cylinder GH-410 Engine Figure 1.2 – 10kW, V-twin GT-530 Engine Control Control Panel Panel Data Data Air Filter Decal Dipstick Dipstick Decal Cover Exhaust Exhaust Enclosure Air Filter Enclosure Fuel Fuel Inlet Inlet (Back)

  • Page 8: Specifications

    General Information SPECIFICATIONS 1.5.1 GENERATOR Model 05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244 05283 & 05284 Rated Max. Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP Power Capacity (Watts*) Rated Voltage 120/240 120/240 120/240...

  • Page 9: System Set Led

    General Information SYSTEM SET LED Use an approved pipe sealant or joint compound on all threaded fitting. The “System Set” LED is lit when all of the following conditions are true: All installed gaseous fuel piping must be purged and leak tested prior to initial start-up in accordance with local codes, standards The AUTO/OFF/MANUAL switch is set to the AUTO position.

  • Page 10: Reconfiguring The Fuel System

    General Information RECONFIGURING THE Reverse procedure steps 1-6 to reinstall demand regulator. 10. Take the plastic plug supplied in the poly-bag with the genera- FUEL SYSTEM tor and press it into the 3/4” hole on the bottom of the air cleaner base (Figure 4.6).

  • Page 11: Location

    General Information 1.10 LOCATION Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) 1.10.1 GENERATOR The engine exhaust fumes contain carbon Fuel Selection monoxide, which can be DEADLY. This dan- Lever - "Out" gerous gas, if breathed in sufficient concen- Position for trations, can cause unconsciousness or even Liquid Propane...

  • Page 12: Battery Requirements

    General Information 1.12 BATTERY INSTALLATION • Install the unit where services will not be affected or obstructed, including concealed, underground or covered services such as Fill the battery with the proper electrolyte fluid if necessary and electrical, fuel, phone, air conditioning or irrigation. have the battery fully charged before installing it.

  • Page 13: The Battery

    Post Installation Start-up and Adjustments  1.13 THE BATTERY  Be sure the utility power supply is turned off and the 15A fuse is removed from the gener- ator control panel, or sparking may occur at the battery posts as the cables are attached ...

  • Page 14: Check Transfer Switch Operation

    Post Installation Start-up and Adjustments CHECK TRANSFER SWITCH 10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. 7kW voltage OPERATION should be 242-252 volts at a frequency of 61-63 Hertz. 10, 13, and 16kW voltage should be 247-249 volts at a frequency Refer to the "Manual Transfer Operation"...

  • Page 15: Checking Automatic Operation

    Post Installation Start-up and Adjustments ADJUSTING THE FUEL 10. Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2. REGULATOR - 7KW (NATURAL • 7kW voltage should be greater than 230 volts and frequency should be greater than 58 Hz. GAS ONLY) •...

  • Page 16: Engine Governor Adjustment

    Post Installation Start-up and Adjustments Start the generator; let it stabilize and warm up at no-load. Connect a frequency meter across the generators AC output Do not make any unnecessary adjustments. leads. Factory settings are correct for most appli- Turn the primary adjust screw to obtain a frequency reading cations.

  • Page 17: Operation

    Operation Figure 2.5 – Voltage Adjustment Potentiometer 3.1.3 “MANUAL” POSITION Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure. With the switch set to AUTO, the engine may crank and start at any time without warning.

  • Page 18: Sequence Of Automatic Operation

    Operation SEQUENCE OF AUTOMATIC MANUAL TRANSFER OPERATION OPERATION The generator’s control panel houses a control logic circuit board. 3.4.1 TRANSFER TO GENERATOR This board constantly monitors utility power source voltage. POWER SOURCE Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start.

  • Page 19: Setting The Exercise Timer

    Operation 3.4.2 TRANSFER BACK TO UTILITY POWER SOURCE NOTE: The exerciser will only work in the AUTO mode and will not work When utility power has been restored, transfer back to that source unless this procedure is performed. The exerciser will need to and shut down the generator.

  • Page 20: Maintenance

    Maintenance Figure 3.3 – Low Oil Pressure and If the unit fails to start, the overcrank alarm LED will be illumi- nated. High Temperature Switches 3.6.4 OVERSPEED Low Oil Switch High Temp Switch This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit.

  • Page 21: Checking The Engine Oil Level

    Maintenance CHECKING THE ENGINE Figure 4.4 — Oil Dipstick and Fill, 13kW and 16kW OIL LEVEL For oil capacities, see the Specifications section. For engine oil Oil Dipstick recommendations, see the Engine Oil Recommendations section. To check the engine oil level, proceed as follows (Figures 4.2, 4.3 and 4.4): Move the AUTO/OFF/ MANUAL switch to the OFF position.

  • Page 22: Changing The Engine Air Cleaner

    Maintenance CHANGING THE ENGINE 4.3.3 OIL & OIL FILTER CHANGE PROCEDURE To change the oil, proceed as follows: AIR CLEANER Start the engine by moving the AUTO/OFF/MANUAL switch to 4.4.1 7, 13, AND 16KW GENERATORS MANUAL and run until it is thoroughly warmed up. Then shut OFF the engine by moving the switch to the OFF position.

  • Page 23: Spark Plug(S)

    Maintenance Figure 4.7 — 10kW Engine Air Cleaner Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 inch) for 7 and 10kW; and 1.02 mm (0.040 inch) for 13/16 kW by carefully bending the ground electrode (Figure 4.9).

  • Page 24: Adjusting Gh-410/Gt-530/990 Valve Clearance

    Maintenance • Wear full eye protection and protective clothing; • Make sure the piston is at Top Dead Center (TDC) of its com- • Where electrolyte contacts the skin, wash it off pression stroke (both valves closed). To get the piston at TDC, immediately with water;...

  • Page 25: Cooling System

    Maintenance COOLING SYSTEM 4.10 CORROSION PROTECTION Air inlet and outlet openings in the generator compartment must Periodically wash and wax the enclosure using automotive type be open and unobstructed for continued proper operation. This products. Frequent washing is recommended in salt water/coastal includes such obstructions as high grass, weeds, brush, leaves areas.
  • Page 26 Maintenance 4.11.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: Verify that utility power is turned off and that the AUTO/OFF/ MANUAL switch is set to OFF. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see the Engine Oil Recommendations section).

  • Page 27: Service Schedule

    Maintenance 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly if Repair is Needed.

  • Page 28: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. Fuse blown. Correct short circuit condition, replace 15A fuse in generator control panel. Loose, corroded or defective Tighten, clean or replace battery cables. as necessary. Defective starter contactor. (7 kW) Defective starter motor.

  • Page 29: Notes

    Notes...
  • Page 30 Notes...
  • Page 31 Notes...

  • Page 32: Mounting Dimensions

    Mounting Dimensions Drawing No. 0F9424-D...
  • Page 33 Mounting Dimensions Drawing No. 0F9424-D...

  • Page 34: Warranty

    IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System 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.

  • Page 35: Emission Control System Warranty

    Warranty 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 equip- ment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
  • Page 36 "AIR-COOLED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of three years from successful activation of the unit (one (1) year or one thousand hours, whichever occurs first, for units in international markets), Generac Power Systems, Inc. (Generac) warrants that its standby 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(s) which, upon examination, inspection and testing by Generac or an Authorized/Certified Generac Service Dealer, is found to be defective.
  • Page 48 0F8186 ADAPTOR, ENGINE 0F5540H STATOR 0C9934H ROTOR 0F7774A CARRIER, REAR BEARING 0C8096 FAN, 8” CURVED BLADE 0F6591 MUFFLER 0F8078 TAIL PIPE, MUFFLER 056482 BEARING 0C3168 5/16 SPECIAL L/WASH 056147 BOLT ROTOR HHCS 5/16”-24 X 13-1/2” G5 0D1847 BOLT STATOR IHHCS M8-1.25 x 305mm 0C7038C BRACKET, ALTERNATOR MOUNTING 0F9445...
  • Page 51 0D5694 CASTING, TWIN REGULATOR HOUSING (7KW) 0F9285 CASTING, TWIN REGULATOR HOUSING 0F5022 SOLENOID COIL, 12VDC 0C4647 GASKET , SOLENOID 0D4166 PLUNGER, LP REGULATOR ASSEMBLY 0F8822 REGULATOR BRACKET 022145 WASHER FLAT 5/16-M8 022129 WASHER LOCK 5/16-M8 0F4795 SCREW PPHM SEMS M4-0.7 X 10 0C5760P FUEL JET GASEOUS REGULATOR (7KW) 0C6606...
  • Page 53 0F9285 CASTING, TWIN REGULATOR HOUSING 0F5022 SOLENOID COIL, 12VDC 0C4647 GASKET , SOLENOID 0D4166 PLUNGER, LP REGULATOR ASSEMBLY 0F8096 BRKT REGULATOR MOUNTING 990 022145 WASHER FLAT 5/16-M8 022129 WASHER LOCK 5/16-M8 0F4795 SCREW PPHM SEMS M4-0.7 X 10 045771 NUT HEX M8-1.25 0C6606 BARBED STRAIGHT ½...
  • Page 55 0E3221 ASSEMBLY, CONNECTING ROD 0E1466 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0E2985 PISTON, HC 071983 RETAINER, PISTON PIN 20 0E8440 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER 0A7628 ARM, GOVERNOR RC45 078658 PIN, “R” GOVERNOR ARM 078659 WASHER, GOVERNOR ARM THRUST 088261E CRANKCASE, SUBASSEMBLY WITH PLUGS GH410 0E3812...
  • Page 57 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0F8426 TUBE, DIPSTICK 0C9997 GUARD, FAN 088434 WRAPPER, BOTTOM 045756 SCREW, TAPTITE M6-1X10 YELLOW CHROME 0C4176A WRAPPER, TOP 0D9004A ASSY, STARTER 059985 SCREW, SHC M8-1.25 X 45 G12.9 022129 WASHER, LOCK M8-5/16 0C2458A BACKPLATE, L/F D/F 083512...
  • Page 59 0E9428B CRANKCASE 0C3592 KEEPER, VALVE SPRING 0E3812 SEAL D 35 X 48.2 0C3733 VALVE RETAINER 0J9667 SCREW HHFC M6 – 1.0 X 20 W/PATCH 0C4390 SPRING VALVE 0E9367A ASSY, BREATHER 088156 SEAL, VALVE STEM 0E9366 GASKET BREATHER ASSY 084186 WASHER, VALVE SPRING 0E9304 CYLINDER HEAD 1 0E9368...
  • Page 61 022097 WASHER LOCK M6-1/4 0F2094 SCREW PPHM M3-0.5 X 6 SEMS 0E9561 INTAKE ADAPTER 0G4403 ASSY OIL DRAIN HOSE 0E9472 GASKET, AIRBOX TO CARB/MIXER 0D9235 OIL PRESSURE SWITCH HOBBS 5PSI 0E9471 GASKET, MANIFOLD TO CARB/MIXER 082774 KEY, WOODRUFF 4 X 19D 078643B BOLT, CARB MOUNT M6 –...
  • Page 63 0E9428B CRANKCASE 0C3592 KEEPER, VALVE SPRING 0E3812 SEAL D 35 X 48.2 0C3733 VALVE RETAINER 0C8566 SCREW HHFC M6 – 1.0 X 20 0C4390 SPRING VALVE 0E9367A ASSY, BREATHER 088156 SEAL, VALVE STEM 0E9366 GASKET BREATHER ASSY 084186 WASHER, VALVE SPRING 0E9304 CYLINDER HEAD 1 0E9368...
  • Page 65 022097 WASHER LOCK M6-1/4 0F2094 SCREW PPHM M3-0.5 X 6 SEMS 0E9561 INTAKE ADAPTER 0G4403 ASSY OIL DRAIN HOSE 0E9472 GASKET, AIRBOX TO CARB/MIXER 0D9235 OIL PRESSURE SWITCH HOBBS 5PSI 0E9471 GASKET, MANIFOLD TO CARB/MIXER 082774 KEY, WOODRUFF 4 X 19D 078643B BOLT, CARB MOUNT M6 –...
  • Page 67 0F9653 PAD, 24 X 48” WITH MOUNTING HOLES 0F8263 PANEL, ENGINE DIVIDER (7KW) 045771 NUT HEX M8-1.25 0F7886 PANEL, ENGINE DIVIDER (10KW) 022129 WASHER LOCK 5/16 0F7885 PANEL, ENGINE DIVIDER 022129 WASHER LOCK 5/16 (7KW) 023484H BUSHING SNAP SB-1500-18 022145 WASHER FLAT 5/16 0D3058A FOAM, FRONT INTAKE BAFFLE (7KW)
  • Page 69 0E7886A CIRCUIT BREAKER 30A X 2P 240V (7KW) 0E7886D CIRCUIT BREAKER 45A X 2P 240V (10KW) 0D9784 NUT HEX LOCK M3-0.5 NYLON INSERT 0E7886E CIRCUIT BREAKER 50A X 2P 240V (12KW) 0D9784 NUT HEX LOCK M3-0.5 NYLON INSERT (7KW) 0E7886K CIRCUIT BREAKER 55A X 2P 240V (13KW) 0D8502 NEUTRAL BLOCK...
  • Page 71 0F8278 BOX LOAD CENTER 0D4800 COVER, 8 CIRCUIT LOAD CENTER 0F5211 COVER, 10 CIRCUIT LOAD CENTER 0D3092 COVER, 12 CIRCUIT LOAD CENTER 0F8312 COVER, 16 CIRCUIT LOAD CENTER 0C2237 TRANSFER SWITCH HOME STANDBY 100A 2P 250V 077220 COIL UTILITY 077220A COIL STANDBY 082574 INSULATOR-SIDEWALL (NOT SHOWN)
  • Page 74 0G7908A ASSY, CRANKCASE WITH SLEEVE 0F8054 GEARCOVER / ADAPTOR GTH-990 0E9843A SEAL, 38 I.D. CRANKSHAFT GREEN 0C3006 SCREW, HHFC M10-1.5 X 55 0G0919 SCREW, HHFCS M6-1.0 X 12 G8.8 080318 SCREW HHFC M6-1.0 X 25 0G9100 ASSEMBLY, BREATHER DUAL BREATHER 093064 ASSEMBLY, OIL FILL CAP 0C3005...
  • Page 76 022145 WASHER FLAT M8 – 5/16 0E9568 ASSY, THROTTLE SHAFT 0C5136A KNOB, AIR CLEANER (13,14,16,17Kw) 0E9565 THROTTLE VALVE 0C5136D KNOB,AIR CLEANER (20Kw) 074027 SCREW PPHM M3 – 0.5 X 5 0C3024 COVER, AIRBOX NG/LP (13,14,16,17Kw) 0C3044 COVER, DUST, MIX/AIRBOX 0G5895 COVER, AIRBOX NG/LP (20Kw) 0C4756 SPRING, IDLE ADJUST...
  • Page 78 0G7908A ASSY, CRANKCASE WITH SLEEVE 0F8054 GEARCOVER / ADAPTOR GTH-990 0E9843A SEAL, 38 I.D. CRANKSHAFT GREEN 0C3006 SCREW, HHFC M10-1.5 X 55 0G0919 SCREW, HHFCS M6-1.0 X 12 G8.8 080318 SCREW HHFC M6-1.0 X 25 0G9100 ASSEMBLY, BREATHER DUAL BREATHER 093064 ASSEMBLY, OIL FILL CAP 0C3005...
  • Page 80 022145 WASHER FLAT M8 – 5/16 0E9568 ASSY, THROTTLE SHAFT 0C5136A KNOB, AIR CLEANER (13,14,16,17Kw) 0E9565 THROTTLE VALVE 0C5136D KNOB,AIR CLEANER (20Kw) 074027 SCREW PPHM M3 – 0.5 X 5 0C3024 COVER, AIRBOX NG/LP (13,14,16,17Kw) 0C3044 COVER, DUST, MIX/AIRBOX 0G5895 COVER, AIRBOX NG/LP (20Kw) 0C4756 SPRING, IDLE ADJUST...
  • Page 82 040976 SCREW SHC M8-1.25 X 20mm 022129 WASHER LOCK M8-5/16 0F6694 STATOR (16KW) 022259 NUT LOCK HEX 5/16-18 0F5538 STATOR (13KW) 059637 SCREW TAPTITE 3/8-16 X ¾ 0F7548 STATOR (10KW) 0E9591 SPRING-CHOKE RETURN (10KW) 0F9795 ROTOR (16KW) 0F7065 3 FT HOSE RES ½...

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