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Generac Power Systems 04389-0 Installation And Owner's Manual

Air-cooled, prepackaged automatic standby generators
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POWER SYSTEMS, INC.
Not intended for use as Primary Power in place of utility or in life-
!
support applications.
Owner's Manual
DANGER
DEADLY EXHAUST FUMES.
OUTDOOR INSTALLATION ONLY!!
Installation and
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
04389-0 (6 kW NG, 7 kW LP)
04456-0 (10 kW NG, 12 kW LP)
04390-0 (13 kW NG, 15 kW LP)
GENERAC
POWER SYSTEMS, INC.
R
R
®
!

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Summary of Contents for Generac Power Systems 04389-0

  • Page 1 Installation and Owner’s Manual Air-cooled, Prepackaged Automatic Standby Generators Models: 04389-0 (6 kW NG, 7 kW LP) 04456-0 (10 kW NG, 12 kW LP) 04390-0 (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 Guardian models: • 04389-0 – 6 kW NG, 7 kW LP , single-cylinder GH- If you do not understand any portion of this manual, 410 Engine contact Generac or your nearest Generac/Guardian •...

  • Page 3: Table Of Contents

    Voltage Regulator Adjustment ......13 Section 8 – Notes ..........53 Section 3 – Operation ........13 Section 9 – Mounting Dimensions....55 Break-in Procedure........13 Section 10 – Warranty ........56 Using the Auto/Off/Manual Switch ....13 3.2.1 “Auto” Position ........13 Generac Power Systems, Inc. ®...

  • Page 4: Safety Rules

    • When working on this equipment, remain alert at nique Generac does not specifically recommend, you all times. Never work on the equipment when you must satisfy yourself that it is safe for you and others.

  • Page 5: Standards Index

    Agricultural Engineers, 2950 Niles Road, St. and render the unit in noncompliance with the Joseph, MI 49085. aforementioned codes, standards, laws and regu- 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE lations. LIQUIDS CODE, available same as Item 1. Generac Power Systems, Inc. ®...

  • Page 6: Section 1 - General Information

    –Type 14 AWG wire is recommended. procedures. –These options should be wired to the unit by a qualified electrician or Generac/Guardian Authorized Dealer. “Concealed damage” is understood to mean damage 2. Remote/Common Alarm – This allows for an to the contents of a package that is not in evidence at alarm, light, horn, etc., to activate when any fault...

  • Page 7: Your Generator

    Exhaust Enclosure Air Filter Fuel Regulator Battery Compartment Oil Filter Figure 1.3 – 12 kW/15 kW, V-twin GT-760/GT-990 Engine Data Control Decal Panel Oil Dipstick Air Filter Exhaust Enclosure Fuel Regulator Battery Compartment Oil Filter Generac Power Systems, Inc. ®...

  • Page 8: Specifications

    Approx. 1.7 Qts Recommended Oil Filter Generac Part # 70185 Generac Part # 70185 Generac Part # 70185 Recommended Air Filter Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127 Operating RPM 3,600 3,600 3,600 Generac Power Systems, Inc.

  • Page 9: Fuel Requirements And Recommendations

    1. Turn the main gas supply off. front of the unit and the second can be accessed 2. Remove the carburetor fuel hose(s) from the outlet from the back of the unit. port(s) of the demand regulator (Figure 1.4). Generac Power Systems, Inc. ®...

  • Page 10: Location

    • To prevent switch distortion, level the switch if nec- essary. This can be done by placing washers between the switch enclosure and mounting sur- face. • Never install the switch where water or any corro- sive substance might drip onto the enclosure. Generac Power Systems, Inc. ®...

  • Page 11: The Battery

    “Add” mark on the dipstick. Doing The electrolyte is a dilute sulfuric acid that is this could damage the engine. harmful to the skin and eyes. It is electrically conductive and corrosive. Generac Power Systems, Inc. ®...

  • Page 12: Check Transfer Switch Operation

    7. Set the generator’s main circuit breaker to its ON with live transfer switch parts will result in (or closed) position. Loads are now powered by dangerous and possibly fatal electrical shock. the standby generator. 10 Generac Power Systems, Inc. ®...

  • Page 13: Checking Automatic Operation

    • After about six seconds, the switch should transfer loads back to the utility power source. • About one minute after retransfer, the engine should shut down. 6. When the highest frequency is reached maximum power has been set. Generac Power Systems, Inc. 11 ®...

  • Page 14: Engine Governor Adjustment

    58 Hz. If this procedure or equipment are not available to 5. Remove load, stop engine, loosen the idle adjust you, locate the Generac Guardian Dealer nearest you screw and reconnect the idle spring. and they can perform the adjustments.

  • Page 15: Additional Corrosion Protection

    3. The unit will start, and the transfer switch will transfer to standby. 4. Using the transfer switch’s built-in emergency load center, turn on circuits to load the generator to approximately 25% load and run the unit for one hour. Generac Power Systems, Inc. 13 ®...

  • Page 16: Automatic Transfer Operation

    3. Turn OFF the utility power supply to the transfer supply. After retransfer, the engine is signalled to shut switch using the means provided (such as a down. utility main line circuit breaker). 14 Generac Power Systems, Inc. ®...

  • Page 17: Transfer Back To Utility Power Source

    3. Set the generator’s Auto/Off/Manual switch to its OFF (or open) position. The engine should shut down. 4. Check that utility power supply to the transfer switch is turned OFF . Generac Power Systems, Inc. 15 ®...

  • Page 18: Protection Systems

    “Full” mark only. DO NOT FILL ABOVE THE “FULL ” MARK. • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total 16 Generac Power Systems, Inc. ®...

  • Page 19: Changing The Engine Oil

    5. Start the engine and check for leaks. NOTE: The unit is supplied with “break-in” oil. See the “Break-in Procedure,” Section 3.1 (Page 12), for the first required oil change. Generac Power Systems, Inc. 17 ®...

  • Page 20: Changing The Engine Air Cleaner

    Do not dispose of the battery in a fire. The battery is capable of exploding. A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries: 18 Generac Power Systems, Inc. ®...

  • Page 21: Adjusting Valve Clearance

    Important: If you feel uncomfortable about doing this battery; and procedure or you don't have the proper tools, please • Disconnect charging source prior to connecting or dis- contact your Generac Authorized dealer for service connecting battery terminals. assistance. This is a very important step to insure longest life for your engine.

  • Page 22: Cooling System

    (See Figure 4.9 for vent locations.) Periodically wash and wax the enclosure using automo- tive type products. Frequent washing is recommended in salt water/coastal areas. Spray engine linkages with a light oil such as WD-40. 20 Generac Power Systems, Inc. ®...

  • Page 23: Out Of Service Procedure

    9. Turn on the utility power to the transfer switch. 9. Clean and wipe the entire generator. 10. Your generator is now ready for service. NOTE: If the battery was dead or disconnected, you must reset the exercise timer. Generac Power Systems, Inc. 21 ®...

  • 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 PROCEDURE FREQUENCY X = Action Inspect...

  • Page 25: Section 5 - Troubleshooting

    3. Transfer relay circuit open 3. * 4. Defective control logic board 4. * Unit consumes large 1. Break-in procedure 1. * amounts of oil. not followed (see Section 2.1) *Contact your nearest Generac/Guardian Authorized Dealer for assistance. Generac Power Systems, Inc. 23 ®...

  • 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. 0C7830-B 24 Generac ® Power Systems, Inc.
  • Page 27 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0C7830-B Generac ® Power Systems, Inc. 25...
  • Page 28 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0C7836-B 26 Generac ® Power Systems, Inc.
  • Page 29 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0C7836-B Generac ® Power Systems, Inc. 27...
  • Page 30 TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) CONTROL PRINTED CIRCUIT BOARD BLACK 1 2 3 ON - INDICATES 1 - 20 Vac Sense Transformer 2 - Remote Not Auto 3 - 50 Hz Operation BATTERY 4 - SPARE CUSTOMER SUPPLIED 28 Generac ® Power Systems, Inc.
  • Page 31 Wiring Diagram – 7 kW – Drawing No. 0D5700-B 224A CLOSEST TO BEARING CONTROL PANEL BOX 225A 224A 225A STATOR 225A 224A VOLTAGE REGULATOR CUSTOMER CONNECTION AUTO 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR MANUAL Generac ® Power Systems, Inc. 29...
  • Page 32 SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) 30 Generac ® Power Systems, Inc.
  • Page 33 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D5701-A C2-6 C2-5 56VA 224A CUSTOMER CONNECTIONS NEUTRAL 120V 120V POWER WINDING (STATOR) 240V C1-2 C1-1 BATTERY C1-6 BLACK CUSTOMER SUPPLIED C1-5 Generac ® Power Systems, Inc. 31...

  • 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-K 44 85 79 80 32 Generac Power Systems, Inc. ®...
  • Page 35 WASHER FLAT 5/16 0D2537 HINGE, LIFT OFF, TYPE A PIN 045771 NUT HEX M8-1.25 0D2538 HINGE, LIFT OFF, TYPE B PIN 0C3906 SELF-ALIGN SCREW M6 HH 0D3037A LATCH, QUARTER TURN NON-LOCKING 0A2115 WASHER NYLON .250" Generac Power Systems, Inc. 33 ®...
  • Page 36 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0D3418-D 8,32 34 Generac Power Systems, Inc. ®...
  • Page 37 CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P 0A2311 SCREW SWAGE 1/4-20 X 1 Z/YC (7KW) 0A1658 L/WASH SPECIAL 1/4" 0C6002A CONTROL, PANEL BOTTOM (12KW / 15KW) 022473 WASHER FLAT 1/4 ZINC 0D2985 CONTROL, PANEL BOTTOM (7KW) Generac Power Systems, Inc. 35 ®...
  • 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-C 36 Generac Power Systems, Inc. ®...
  • Page 39 CIRCT BRK 30 X 2 HOM230 0D3320 COVER - HARNESS ENTRY 0D4802 HARNESS, GTS TO EXT CONN BOX 022264 WASHER LOCK M4 0A7215 SCREW SW 1/4-20X5/8 N WA JS500 0A2110 SCREW SWAGE 1/4-20 X 1/2 ZINC Generac Power Systems, Inc. 37 ®...
  • 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-B 38 Generac Power Systems, Inc. ®...
  • Page 41 HARNESS, GTS LD CTR TO EXT CONN BOX (14KW / 15KW / 16KW) 022264 WASHER LOCK M4 0A7215 SCREW SW 1/4-20X5/8 N WA JS500 0A2110 SCREW SWAGE 1/4-20 X 1/2 ZINC 075475 SCREW PPHM M4-0.7 X 10 0D3094 HARNESS,GTS TO MAIN PANEL Generac Power Systems, Inc. 39 ®...
  • Page 42 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 61 7, 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59 27, 28, 29 3, 32, 33, 34, 35, 36, 40, 71 29 28 55 56 40 Generac Power Systems, Inc. ®...
  • Page 43 KIT HEAD ASSEMBLY CYLINDER 1 0C5315 GEROTOR, OUTER 0D4014A KIT HEAD ASSEMBLY CYLINDER 2 0C5998 CLAMP, OIL TUBE 0D4015 KIT OIL RELIEF 0D1667 ARM, GOVERNOR 0D4016 KIT GEAR COVER 0C2991 E-RING, GOVERNOR ARM 0C2988 THRUST WASHER, GOVERNOR Generac Power Systems, Inc. 41 ®...
  • 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. 0D3415-A Part 2 85 84 42 Generac Power Systems, Inc. ®...
  • Page 45 0D3743 SPRING, GOVERNOR IDLE 0C3032 PLATE, FAN 0D3705 ASSEMBLY, GOVERNOR ADJUSTER 0A5992 WASHER SHAKEPROOF INT M8 SS BRACKET 051754 SCREW HHC M8-1.25 X 12 G8.8 0C2993 SEAL, GOVERNOR SHAFT (NOT SHOWN) 0C3033 WASHER, M5 Generac Power Systems, Inc. 43 ®...
  • 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-B 44 Generac Power Systems, Inc. ®...
  • Page 47 CLAMP VINYL 1.31 X .281 Z 074994 1.25 FT HOSE 1\2ID LP GAS 0C5136A KNOB, AIR CLEANER 074906 SCREW TAPTITE M6-1 X 20 BP 022473 WASHER FLAT 1/4 ZINC 0D4662 SCREW HHTT M8-1.2 X 20 BP 0C8290 GASKET, PANEL Generac Power Systems, Inc. 45 ®...
  • 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-A 46 Generac Power Systems, Inc. ®...
  • Page 49 2.83 FT HOSE RES 1/2 LP GAS 057822 CLAMP HOSE #8 .53 - 1.00 052858 NUT LOCK M8 0C2824 SCREW TAP-R #10-32 x 9/16 025145 U-BOLT 5/16"-18 X 1.25" WITH SADDLE 0C4138 GASKET, EXHAUST PORT Generac Power Systems, Inc. 47 ®...
  • 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-B Part 1 48 Generac Power Systems, Inc. ®...
  • Page 51 BARBED ELBOW 90 3/8NPT X 3/8 0C4391 VALVE SPRING LF LOCKTITE 086025 SET,GEROTOR 12 THK 088590 DOWEL DIA 12 X 18L 0C7393 BALANCER 078699B DOWEL, SLEEVE SEAMED 12 DIA. 021714 ASSEMBLY,CYLINDER HEAD SEATS & GUIDES Generac Power Systems, Inc. 49 ®...
  • 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-B Part 2 50 Generac Power Systems, Inc. ®...
  • Page 53 SWITCH, THERMAL 040945 SCREW, SHC M6-1.0 X 20 G12.9 043182 WASHER LOCK M3 086999 GASKET,OIL FILTR ADAPTER 0C1085 SCREW PPHM M3-0.5 X 8 0D5667A ADAPTER, OIL FILTER 049821 SCREW, SHC M8-1.25 X 30 G12.9 Generac Power Systems, Inc. 51 ®...
  • Page 54 SPRING, REGULATOR (7KW) NOT SHOWN (7KW) 070728 SCREW, PFIHM M3-0.5 x 5 (12KW / 15KW) * A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY 070728 SCREW, PFIHM M3-0.5 x 5 (7KW) 52 Generac Power Systems, Inc. ®...

  • Page 55: Section 8 - Notes

    Section 8 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Generac Power Systems, Inc. 53 ®...
  • Page 56 Section 8 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 54 Generac Power Systems, Inc. ®...

  • Page 57: Section 9 - Mounting Dimensions

    120/240v 120/240v TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F Generac Power Systems, Inc. 55 ®...

  • Page 58: Section 10 - Warranty

    Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

  • Page 59: Emission Control System Warranty

    Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market”...

  • Page 60: Generac Power Systems, Inc

    "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, 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 accor- dance with the warranty schedule set forth below.

This manual is also suitable for:

04456-004390-0

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