Guardian 005240 Installation And Owner's Manual
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Guardian 005240 Installation And Owner's Manual

7, 10, 13 and 16kw air-cooled, automatic standby generators
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Installation and
Owner's Manual
7, 10, 13 and 16kW Air-cooled,
Automatic Standby Generators
Models: 005240, 005280 (6 kW NG, 7 kW LP)
005241, 005281 (9 kW NG, 10 kW LP)
C
US
005242, 005282 (13 kW NG, 13 kW LP)
005243, 005244, (15 kW NG, 16 kW LP)
LISTED
005283, 005284
Not intended for use as Primary Power in place of utility or in
life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

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Summary of Contents for Guardian 005240

  • Page 1 Owner’s Manual 7, 10, 13 and 16kW Air-cooled, Automatic Standby Generators 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)

  • Page 2: Introduction

    The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recom- Thank you for purchasing this model of the Guardian mends that the operator read this Owner's Manual product line by Generac Power Systems Inc. This...

  • Page 3: Table Of Contents

    Table of Contents Air-cooled Generators Introduction ......Inside Front Cover Section 3 – Operation ........16 Read This Manual Thoroughly ......IFC Using the AUTO/OFF/MANUAL Switch ..16 Contents ............IFC Automatic Transfer Operation ..... 16 Operation and Maintenance ......IFC Sequence of Automatic Operation ....17 How to Obtain Service ........

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 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 Generators • Keep a fire extinguisher near the generator at all   ELECTRICAL HAZARDS times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for • All generators covered by this manual produce use on the standby electric system.

  • Page 6: Section 1 - General Information

    Section 1 — General Information Air-cooled 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  Only qualified electricians or contractors should of the conditions described in section "System Set attempt such installations, which must comply LED"...

  • Page 7: The Generator

    Section 1 — General Information Air-cooled Generators 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...

  • Page 8: Specifications

    Section 1 — General Information Air-cooled Generators 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...

  • Page 9: System Set Led

    Section 1 — General Information Air-cooled Generators SYSTEM SET LED Special considerations should be given when install- ing the unit where local conditions include flooding, The “System Set” LED is lit when all of the following tornados, hurricanes, earthquakes and unstable conditions are true: ground for the flexibility and strength of piping and 1.

  • Page 10: Reconfiguring The Fuel System

    Section 1 — General Information Air-cooled Generators RECONFIGURING THE NOTE: Use an approved pipe sealant or joint compound FUEL SYSTEM on all threaded fittings to reduce the possibility of leakage. 1.9.1 7 KW, 410CC ENGINE 9. Reverse procedure steps 1-6 to reinstall demand To reconfigure the fuel system from NG to LP , follow regulator.

  • Page 11: Location

    Section 1 — General Information Air-cooled Generators Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back) Figure 1.8 - 13/16kW, GT-990 (Airbox Cover Removed) Fuel Selection Lever - "Out" Position for Liquid Propane (Vapor) Fuel Fuel Selection Lever - "In" Position for Natural Gas Fuel...

  • Page 12: Battery Requirements

    Section 1 — General Information Air-cooled Generators • Install the generator as close as possible to the fuel • Install the transfer switch indoors on a firm, sturdy supporting structure. supply, to reduce the length of piping. • To prevent switch distortion, level the switch if •...

  • Page 13: The Battery

    Section 1 — General Information Air-cooled Generators Figure 1.10 – Battery Cable Connections  Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic.  The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes.

  • Page 14: Section 2 - Post Installation Start-Up And Adjustments

    Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators BEFORE INITIAL START-UP Figure 2.1 – Remove Air Filter Cover NOTE: These units have been run and tested at the fac- tory prior to being shipped and do not require any type of break-in.

  • Page 15: Electrical Checks

    Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators ELECTRICAL CHECKS 12. Set the generator’s main circuit breaker to its OFF (or OPEN) position. Let the engine run at no- Complete electrical checks as follows: load for a few minutes to stabilize internal engine 1.

  • Page 16: Checking Automatic Operation

    Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators ADJUSTING THE FUEL REGULATOR • 10, 13 & 16kW voltage should be greater than 240 volts and frequency should be greater than - 7KW (NATURAL GAS ONLY) 60 Hz. NOTE: 11.

  • Page 17: Engine Governor Adjustment

    Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 6. When the highest frequency is reached maximum 2. Hold the governor lever at its wide open throttle power has been set. From this point turn the position (clockwise), and rotate the governor adjustment screw 1/4 turn counterclockwise.

  • Page 18: Section 3 - Operation

    Section 3 — Operation Air-cooled Generators 3.1.3 “MANUAL” POSITION Figure 2.5 – Voltage Adjustment Potentiometer 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 19: Sequence Of Automatic Operation

    Section 3 — Operation Air-cooled Generators SEQUENCE OF AUTOMATIC • The timer will run for about one minute, and the generator will then shut down. OPERATION MANUAL TRANSFER OPERATION The generator’s control panel houses a control logic circuit board. This board constantly monitors util- 3.4.1 TRANSFER TO GENERATOR ity power source voltage.

  • Page 20: Setting The Exercise Timer

    Section 3 — Operation Air-cooled Generators 3.4.2 TRANSFER BACK TO UTILITY POWER 3. Once the red LED's stop flashing, the generator will start and run for approximately 12 minutes SOURCE and then shut down. The exerciser is now set to When utility power has been restored, transfer back run at this time of day each week.
  • Page 21 Section 3 — Operation Air-cooled Generators 3.6.2 HIGH TEMPERATURE SWITCH 10kW, 13kW and 16kW Units: • 16 seconds ON This switch’s contacts (Figure 3.3) close if the tem- • 7 seconds OFF perature should exceed approximately 144º C (293º F), initiating an engine shutdown. The generator will •...

  • Page 22: Section 4 - Maintenance

    Section 4 — Maintenance Air-cooled Generators FUSES Figure 4.2 — Oil Dipstick and Fill, 7kW The 15-amp fuse on the generator panel protects the DC control circuit against overload (Figure 4.1). This Oil Dipstick and Fill fuse is wired in series with the battery output lead to the panel.

  • Page 23: Changing The Engine Oil

    Section 4 — Maintenance Air-cooled Generators CHANGING THE ENGINE OIL Figure 4.5 – Oil Drain Hose and Filter 4.3.1 OIL CHANGE INTERVALS Low Oil Switch High Temp Switch See the "Service Schedule" section. 4.3.2 ENGINE OIL RECOMMENDATIONS All oil should meet minimum American Petroleum Institute (API) Service Class SJ, SL or better.

  • Page 24: Spark Plug(S)

    Section 4 — Maintenance Air-cooled Generators Figure 4.6 — 7 kW, Engine Air Cleaner Location Figure 4.8 — 13 kW and 16 kW Engine Air Cleaner Screw Cleaner Cover Filter 3/4” Hole 4.4.2 10KW GENERATORS SPARK PLUG(S) See Figure 1.2 for the location of the air cleaner. Use Reset the spark plug(s) gap or replace the spark the following procedure (Figure 4.7): plug(s) as necessary.

  • Page 25: Battery Maintenance

    Section 4 — Maintenance Air-cooled Generators BATTERY MAINTENANCE  Lead-acid batteries present a risk of fire because The battery should be inspected per the "Service they generate hydrogen gas. The Schedule" section. The following procedure should be following procedures are to be followed: followed for inspection: •...

  • Page 26: Cooling System

    Section 4 — Maintenance Air-cooled Generators COOLING SYSTEM To adjust valve clearance (if necessary): Air inlet and outlet openings in the generator com- • Make sure the engine is at 60° to 80° F . partment must be open and unobstructed for con- •...

  • Page 27: Corrosion Protection

    Section 4 — Maintenance Air-cooled Generators 4.10 CORROSION PROTECTION 4.11.2 RETURN TO SERVICE Periodically wash and wax the enclosure using auto- To return the unit to service after storage, proceed motive type products. Frequent washing is recom- as follows: mended in salt water/coastal areas. Spray engine 1.

  • Page 28: Service Schedule

    Section 4 — Maintenance Air-cooled Generators 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...

  • Page 29: Section 5 - Troubleshooting

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

  • Page 30: Section 6 - Notes

    Section 6 — Notes Air-cooled Generators...

  • Page 31: Section 7 - Electrical Data

    Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9775 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK TO GENERATOR OUTPUT CIRCUIT BREAKER NEUTRAL (WHITE) NEUTRAL CONNECTION INSIDE SWITCH...
  • Page 32 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822-A...
  • Page 33 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822-A...
  • Page 34 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823-A...
  • Page 35 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823-A...
  • Page 36 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A...
  • Page 37 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A...
  • Page 38 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A...
  • Page 39 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A...
  • Page 40 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-A...
  • Page 41 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-A...

  • Page 42: Section 8 - Exploded Views And Parts Lists

    Section 8 — Exploded Views and Parts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431-D SHEET METAL PAINT/MATERIAL CODE LEGEND The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct color and material information must be included as a suffi...
  • Page 43 Section 8 — Exploded Views and Parts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431-D ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F9653 PAD, 24 X 48” WITH MOUNTING HOLES 0F5438 HARNESS, ENGINE (7KW) 045771 NUT HEX M8-1.25 0F5434 HARNESS ENG V-T HSB 022129...
  • Page 44 Section 8 — Exploded Views and Parts Lists Air-cooled Generators Control Panel – Drawing No. 0F9695-F...
  • Page 45 Section 8 — Exploded Views and Parts Lists Air-cooled Generators Control Panel – Drawing No. 0F9695-F ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7886A CIRCUIT BREAKER 30A X 2P 240V (7KW) 0D8502 NEUTRAL BLOCK 0E7886D CIRCUIT BREAKER 45A X 2P 240V 031879 WASHER FLAT #4 (10KW)
  • Page 46 Section 8 — Exploded Views and Parts Lists Air-cooled Generators Transfer Switch Assembly – Drawing No. 0F9774-C...
  • Page 47 Section 8 — Exploded Views and Parts Lists Air-cooled Generators Transfer Switch Assembly – Drawing No. 0F9774-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F8278 BOX LOAD CENTER 074138 LUG QUICK DISCONNECT NI-S 10X45 0D4800 COVER, 8 CIRCUIT LOAD CENTER DEG BRASS / TIN 0F5211 COVER, 10 CIRCUIT LOAD CENTER...
  • Page 48 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 1...
  • Page 49 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 1 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSY, CRANKCASE WITH SLEEVE 043790A BARBED ELBOW 90 3/8NPT X 3/8 VS 0E9843A SEAL, 38 I.D.
  • Page 50 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 2...
  • Page 51 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 022145 WASHER FLAT M8 – 5/16 0D1143 WRAPPER, UPPER CYLINDER 2 0C5136A KNOB, AIR CLEANER 0E9323...
  • Page 52 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 1...
  • Page 53 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 1 ITEM PART NO. QTY. DESCRIPTION 0E9428B CRANKCASE 0E3812 SEAL D 35 X 48.2 0C8566 SCREW HHFC M6 – 1.0 X 20 0E9367A ASSY, BREATHER 0E9366...
  • Page 54 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 2...
  • Page 55 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 022097 WASHER LOCK M6-1/4 094090 THERMAL SWITCH 0E9561 INTAKE ADAPTER 0F2094 SCREW PPHM M3-0.5 X 6 SEMS 0E9472...
  • Page 56 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 1...
  • Page 57 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 1 ITEM PART NO. QTY. DESCRIPTION 0E3221 ASSEMBLY, CONNECTING ROD 0E1466 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0E2985 PISTON, HC 071983 RETAINER, PISTON PIN 20 0E8440...
  • Page 58 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 2...
  • Page 59 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 2 ITEM PART NO. QTY. DESCRIPTION 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0F8426 TUBE, DIPSTICK 0C9997 GUARD, FAN 088434 WRAPPER, BOTTOM 045756...
  • Page 60 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9422-C...
  • Page 61 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9422-C ITEM PART NO. QTY. DESCRIPTION 0F8186 ADAPTOR, ENGINE 0F5540H STATOR 0C9934H ROTOR 0F7774A CARRIER, REAR BEARING 0C8096 FAN, 8” CURVED BLADE 0F6591 MUFFLER 0F8078 TAIL PIPE, MUFFLER 056482...
  • Page 62 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10, 13, and 16kW, V-twin Generators – Drawing No. 0G4392-A...
  • Page 63 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10, 13, and 16kW, V-twin Generators – Drawing No. 0G4392-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 040976 SCREW SHC M8-1.25 X 20mm 022129 WASHER LOCK M8-5/16 0F6694 STATOR (16KW) 022259...
  • Page 64 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7 & 10kW, GN-410/GT-530 Regulator – Drawing No. 0F9425-B...
  • Page 65 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7 & 10kW, GN-410/GT-530 Regulator – Drawing No. 0F9425-B ITEM PART NO. QTY. DESCRIPTION 0D5694 CASTING, TWIN REGULATOR HOUSING (7KW) 0F9285 CASTING, TWIN REGULATOR HOUSING 0F5022 SOLENOID COIL, 12VDC 0C4647 GASKET , SOLENOID 0D4166 PLUNGER, LP REGULATOR ASSEMBLY...
  • Page 66 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Regulator – Drawing No. 0F9426-A...
  • Page 67 Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Regulator – Drawing No. 0F9426-A ITEM PART NO. QTY. DESCRIPTION 0F9285 CASTING, TWIN REGULATOR HOUSING 0F5022 SOLENOID COIL, 12VDC 0C4647 GASKET , SOLENOID 0D4166 PLUNGER, LP REGULATOR ASSEMBLY 0F8096 BRKT REGULATOR MOUNTING 990 022145...

  • Page 68: Section 9 - Mounting Dimensions

    Section 9 — Mounting Dimensions Air-cooled Generators Drawing No. 0F9424-D...
  • Page 69 Section 9 — Mounting Dimensions Air-cooled Generators Drawing No. 0F9424-D...

  • Page 70: Section 10 - Warranty

    Section 10 – Warranty Air-cooled 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. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed, built and equipped to meet the state’s stringent anti-smog standards.
  • Page 71 Section 10 – Warranty Air-cooled 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 72 "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.

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