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. This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation.
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 ...
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. ...
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.
Section 1 — General Information Air-cooled Generators DANGER Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regu- lations. UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage. • This standby generator set is ready for installa- tion with a factory supplied and pre-mounted base pad and has a weather protective enclosure that is intended for outdoor installation only.
THE GENERATOR Figure 1.1 – 7kW, Single Cylinder GH-410 Engine Data Air Filter Dipstick Decal Cover Exhaust Enclosure Composite Base Oil Filter Figure 1.3 – 13kW and 16kW, V-twin GT-990 Engine Exhaust Enclosure Composite Base Section 1 — General Information Figure 1.2 –...
SYSTEM SET LED The “System Set” LED is lit when all of the following conditions are true: 1. The AUTO/OFF/MANUAL switch is set to the AUTO position. 2. The utility voltage being supplied to the unit is being sensed by the PCB. If the utility sense volt- age is not connected to the unit or if it is below approximately 150-160 volts AC, then the system set light will flash rapidly.
Section 1 — General Information Air-cooled Generators RECONFIGURING THE FUEL SYSTEM 1.9.1 7 KW, 410CC ENGINE To reconfigure the fuel system from NG to LP , follow these steps (Figure 1.4): NOTE: The primary regulator for the propane supply is NOT INCLUDED with the generator.
Section 1 — General Information Air-cooled Generators • Install the generator as close as possible to the fuel supply, to reduce the length of piping. • Install the generator as close as possible to the transfer switch. REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION.
Figure 1.10 – Battery Cable Connections NOTE: In areas where temperatures regularly fall below 10° F (-12° C) it is recommended that a pad type battery heater be installed to aid in cold climate starting (see Specifications). NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators BEFORE INITIAL START-UP 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. Before starting, complete the following: 1.
GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied, proceed as follows: 1. Set generator’s main circuit breaker to its OFF (or OPEN) position. 2. Turn OFF all breakers on the load center of the transfer box (T1 and T2). 3.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 1. Turn off utility power to the main distribution panel in the house. This can be done by switching the service main breaker to the off or open posi- tion. 2.
4. Connect a frequency meter across the generators AC output leads. 5. Turn the primary adjust screw to obtain a fre- quency reading of 61.5 Hertz. Turn the secondary adjust screw to obtain a frequency of 62.5 Hz. 6. When frequency is correct at no load, check the AC voltage reading.
Section 3 — Operation Air-cooled Generators 3.1.4 CHOKE OPERATION 1. 990 engines have an electric choke in the air box that is automatically controlled by the electronic control board. 2. 530 engines have an electric choke on the divider panel air inlet hose that is automatically con- trolled by the electronic control board.
4. Use the manual transfer handle inside the trans- fer switch to move the main contacts to their STANDBY position, i.e., loads connected to the standby power source (Figure 3.2). 5. To crank and start the engine, set the AUTO/OFF/ MANUAL switch to MANUAL.
Section 3 — Operation Air-cooled Generators Low speed exercise will be handled as follows: 1. The standard start sequence will be initiated. 2. The unit will run at 2,400 RPM. 3. If utility is lost during exercise, the controller will do the following: •...
3.6.5 RPM SENSOR FAILURE During cranking, if the board does not see a valid RPM signal within three (3) seconds, it will shut down and latch out on RPM sensor loss. During running, if the RPM signal is lost for one full second the board will shut down the engine, wait 15 seconds, then re-crank the engine.
Section 4 — Maintenance Air-cooled Generators Figure 4.3 — Oil Dipstick and Fill, 10kW Oil Dipstick Oil Fill Figure 4.4 — Oil Dipstick and Fill, 13kW and 16kW Oil Dipstick CHANGING THE ENGINE OIL 4.3.1 OIL CHANGE INTERVALS See the "Service Schedule" section. 4.3.2 ENGINE OIL RECOMMENDATIONS Use all season SAE 5W-30 synthetic oil or use SAE 30 oil of American Petroleum Institute (API) Service...
CHANGING THE ENGINE AIR CLEANER 4.4.1 7, 13, AND 16KW GENERATORS See Figures 1.1 and 1.2, for the location of the air cleaner. Use the following procedures (Figure 4.6, 7kW; Figure 4.8, 13/16kW): 1. Lift the roof and remove the door. 2.
Section 4 — Maintenance Air-cooled Generators 3. 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).
• Remove spark plug wires and position wires away from plugs. • Remove spark plugs. • Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut.
Section 4 — Maintenance Air-cooled Generators 4.10 CORROSION PROTECTION Periodically wash and wax the enclosure using auto- motive type products. Frequent washing is recom- mended in salt water/coastal areas. Spray engine linkages with a light oil such as WD-40. 4.11 OUT OF SERVICE PROCEDURE 4.11.1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days, and will be out of service longer than 90 days, pre-...
4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Authorized Dealer. SYSTEM/COMPONENT X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed. FUEL Fuel lines and connections* LUBRICATION Oil level Oil filter...
Section 5 — Troubleshooting Air-cooled Generators 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 1. Defective switch. is set to OFF , but the engine continues to run.
Section 9 — Exploded Views and Parts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431-B 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...
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.
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.
Section 10 – Warranty Air-cooled Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN ® "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.
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