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Generac Power Systems 04389-3, 04456-3, 04390

1. 6 LO System oet LED uuu uuu 7 1 7 Fuel Requirements Recommendations 7 LS 7 1 9 Reconfiguring the Fuel System 7 2 u u uu sua ssssaasashsphsassasasqspssssaasaqqa 8 1 11 Battery Installation 9 Ti Ba gee eee ne AN 9 Section 2 Post Installation Start up and Adjustments 10 2 1 Before Initial Startup 10 2 2 Check Transfer Switch Operation 10 zi C Deo 10 2 4 Generator Tests Under Load 11 2 5 Checking Automatic Operation 11 2 6 Adjusting the Regulator Natural Gas Only 12 2 7 Engine Governor Adjustmentl 15 2 8 Voltage Regulator Adjustment 14 Table of Contents ru OF CONTENTS Section 3 Operation 14 3 1 Procedure 14 3 2 Using the Auto Off Manual Switch 14 3 9 Automatic Transfer Operation 15 3 4 Sequence of Automatic Operation 15 3 5 Manual Transfer Operation 16 0 0 Setting Exercise Timer 17 of Proleetion SySISGIIS u uu u sua s 17 Sectio
2. C2 6 92 TX C2 5 Bi 925A N2 N1 240VAC UTILITY Pe N2 N2 INPUT 224A 225 Ni 8 23 12Vdc 99 mere RELAY 19 COIL 224 1 0 12VDC ACCESSORY SOCKET CUSTOMER CONNECTIONS 15B WINDING 120V STATOR 15 7 4 CBI a 194 ke imn 13 a LL 7 Lu cB3 Tu 17 15 scr me 1 D N L L d AE 0 0 BLACK E 47 o ee EXTERNAL 15 CUSTOMER GFCI o SUPPLIED OUTEET 31 ELECTRICAL DATA lt Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram Single Cylinder Drawing No 0E9014 ENGINE WIRING BATTERY CHARGER UTILITY DIAGRAM KEY BA BRUSH ASSEMBLY 14 BCR BATTERY CHARGE RELAY CB1 OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION CB3 CIRCUIT BREAKER EXTERNAL OUTLET PUSH PULL D DIODE DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 7 5 AMP GRD CONTROL PANEL GROUND 225B HIGH OIL TEMPERATURE SWITCH 224 2248 2258 IC INLINE CONNECTOR 0 ICT INTERCONNECTION TERMINALS IM IGNITION MODULE LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SP SPARK PLUG 14 SW1 AUTO OFF MANUAL SWITCH SW SET EXERCISE SWITCH SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TR
3. BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 MAIN OUTPUT BREAKER 14 0 2 CIRCUIT BREAKER ALTERNATOR EXCITATION m CB3 CIRCUIT BREAKER EXTERNAL OUTLET PUSH PULL D DIODE 224B DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 7 5 0 0 18 13 GRD CONTROL PANEL GROUND 14 224B HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR 225B ICT INTERCONNECTION TERMINALS 0 IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY 0 0 SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW SET EXERCISE SWITCH SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 351 85 HTO 86 351 86 CONTROL PRINTED CIRCUIT BOARD 2 Remote Not Auto 3 50 Hz Operation 4 SPARE 12 L E D ALARM INDICATORS Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators agi ELECTRICAL Wiring Diagram V Twin Drawing No 0 9016 CONTROL PANEL BOX CLOSEST TO BEARING VOLTAGE REGULATOR 23 194 EXTERNAL OUTLET 66A 239 15 17 15 ok 1 LOAD 225 p 224 E 2 z 6 9
4. 240V GENERATOR m OUTPUT TO TRANSFER 5 SWITCH CONTACTOR 9 _ MANUAL CUSTOMER CONNECTION 12VDC ACCESSORY SOCKET 29 ELECTRICAL DATA 30 ELECTRONIC VOLTAGE REGULATOR BATTERY CHARGER DPE WINDING STATOR DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION CB3 CIRCUIT BREAKER EXTERNAL OUTLET PUSH PULL D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 7 5 AMP HTO HIGH OIL TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic V Twin Drawing No 0E9017 224B P 77 C2 1 ENGINE RUN WINDING STATOR C2 3 BATTERY CHARGE 66 WINDING ___ EE lt 62 2 0 HTO CONTROL PRINTED CIRCUIT BOARD LOP C1 3 22 225A 224A 225 224 13 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL Electrical Schematic V Twin Drawing No 0E9017 lt DATA 11
5. c UL Jus LISTED GUARDIA by Generac Power Systems Inc 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 04390 3 13 kW NG 15 kW LP ARARALR VVVVVV GUARD ANP by Generac Power Systems Inc N Not intended for use as Primary Power in place of utility or in N life support applications EG A DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY 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 instal lation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about
6. Inspect the generator regularly and contact the nearest Authorized Dealer for parts needing repair or replacement Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS 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 Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local ele
7. 35 BLK 1 BLK Li Lam 132 43 V3N8 1102412 gt Ad LIND 3BLV33N3D OL BEEN o LI X 1g I NIVW NUILIRSISISIG NIVW 29 072 MTA LHM MA m c ANd e 5 E 55 Ot ay es es gt 9 LL eL al 2 53 2 11012412 AOv2 9028 5155 IHM MTA LINONIO 1 5 e 14 9 LININID AO2I VGI WISE 8 021 1 Gi 5 5 ST 5 8 0 z 1 d LIRONIO 021 961 lt E TA IA S LIRONIO AOSI VGI LINIAIID AGre VOE I 1112412 0 2 906 36 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 8 Circuit Load Center Drawing No 0 7687 EOE RD i NCA LEGEND ATS AUTUMATIC TRANSFER SWITCH GISUTILIT CIL S REO Tr TER Ce GENERATUR CHIL amp RECTIFIER 500 FUSE LC CIRCUIT BREAKER CLUADSD N NEUTRAL TR TRANSFER RELAY IN TS TERMINAL STRIP 2 XB LIMIT SWITCHES lt lt Lu C3 IY Az DJ
8. BRACKET BOTTOM SUPPORT DUCT BASE AIR GASKET FRONT DIVIDER GASKET FRONT DIVIDER 7KW COVER FRONT EXHAUST ENCLOSURE COVER BACK EXHAUST ENCLOSURE CLOTH HARDWARE 266 7mm x 146mm CLOTH HARDWARE 266 7mm x 146mm 7KW CLOTH HARDWARE 543mm x 146mm CLOTH HARDWARE 266 7mm x 387 4mm CLOTH HARDWARE 7KW FOAM FRONT INTAKE BAFFLE FOAM FRONT INTAKE BAFFLE 7KW FOAM TOP INTAKE BAFFLE FOAM BACK INTAKE BAFFLE FOAM BACK INTAKE BAFFLE 7KW FOAM BACK ENCL STRIP FOAM EXHAUST SIDE ENCLOSURE END FOAM EXHAUST SIDE ENCLSURE FRONT FOAM EXHAUST FAN HOUSING WASHER SELF LOCKING WASHER SELF LOCKING 7KW FOAM FRONT EXHAUST ENCL COVER FOAM BACK EXHAUST ENCL COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE TYPE A WITH STUDS PIN HINGE TYPE B WITH STUDS PIN LATCH QUARTER TURN NON LOCKING WASHER NYLON 250 WASHER LOCK 6 1 4 RIVET POP 0 125 X 0 337 ITEM PART NO 47 047411 6 047411 4 48 043116 5 043116 6 49 0D3700 26 0D3700 24 50 0D4662 11 51 090388 36 24 52 092120 2 54 003167 1 55 0 3328 1 56 055414 1 57 092079 1 58 1658 2 59 0 2937 1 60 086729 1 61 0388040AJ0 1 62 022127 2 63 022129 6 022129 7 64 074908 8 65 0D2346 1 0D2345 1 66 023484F 1 67 022142 1 68 0A7836 2 69 0A8475 2 70 0912970069 1 71 0912970070 2 72 055450 2 73 0 5968 11 74 0D3701 1 75 0D3472 1 76 008742 1 77 068911 1 78 008442 1 008652 1 79 036937 2 80 022152 5 81 051713 2 82 022158 5 83 003031 1 84 026850
9. 1 2 7 KW UNITS Loosen the governor clamp bolt Figures 2 3 Hold the governor lever at its wide open throttle position and rotate the governor shaft clockwise as far as it will go Then tighten the governor lever clamp bolt to 70 inch pounds 8 N m Start the generator let it stabilize and warm up at no load Connect a frequency meter across the generators AC output leads 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 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the volt age regulator may require adjustment Figure 2 3 Engine Governor Adjustment Single Cylinder Engines SECONDARY ADJUST SCREW GOVERNOR SHAFT GOVERNOR PRIMARY CLAMP ADJUST BOLT SCREW C m N 2 7 2 12 KW AND 15 KW UNITS 1 Loosen governor clamp bolt See Figure 2 4 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 2 5 to adjust frequency to 58 Hz 5 Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6 Using a hand push the governor arm to the closed throttle position Make sure the idl
10. 13 Reconnect the battery cables as outlined in General Hazards page 2 and insert the 7 5A and 15A fuses into the generator control panel The generator is now ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 3 2 1 AUTO POSITION oelecting this switch position activates fully auto matic system operation It also allows personnel to start and exercise the engine every seven days with the setting of the exercise timer see Section 3 6 This position also is used for remote starting when it is set up PEE OPERATION Section 3 Operation Air cooled 7 kW 12 kW and 15 kW Generators 3 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation Figure 3 1 Generator Control Panel OUTLET FUSE a g Locate your nearest servicing dealer at www Guarcdiangenerators cen 7 5A CIRCUIT AUTO OFF MAN BREAKER SYSTEM SET 12 VDC LOW OIL SYSTEM FUSE HIGH TEMP OVER SPEED OVER CRANK 15 FLASHING GREEN LED NO UTILITY SENSE EXERCISE ACCESSORY 4 FLASHING RED LEDS TIME OUTLET 7 5A MAX EXERCISER NOT SET 3 2 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 amp With the switch set to AUTO the e
11. C 37 qp Li Y a del Leto a lt lt lt 2 ld gt SOLVASNSD OL EB 44 NIVW KE mH d NI VN NOTING LHM WALNAN NIVW UL 2VAOVC MTA IHM M 19 Wiring Diagram 12 Circuit Load Center Drawing 0E7687 WHT 11 Te L Jel x e ORG WHT gt a 5 3 9 5 MTA 2 LINONID 0 2 02 8 z ISTO LINONIO 0 2 902 Fil 9 1103313 021 02 2 8 1102812 021 902 S 5 14 OT 1109812 AO2I 902 5 I IHM 9NU 21 11012412 AO2I 9GI 519 7 9 i _ IHM DIA 11012412 AO2I 9GI 7 I M un 6 11012412 021 9 1 3 AND AND 11012412 AO2I 9GI DIA HIA G 11012412 AO2I 9GI LHM NAG IHM NNS 1102812 AOve VOE 1 1102812 0 2 06 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators M diae 4 ELECTRICAL Wiring Diagram 12 Circuit Load Center Drawing 0E7687 DATA KH ame e pLk 1 Nea LEGEND ATS AUTUMATIC TRANSFER SWITCH CHILE S eG ER Ce GENERATUR amp RECTIFIER Fl Fe 3A FUSE LC CIRCUITI BREAKER CLUADSD N NEUTRAL TR TRANSFER RELAY TS TERMINAL STRIP XB LIMII SWITCHES Y CI LJ lt
12. Figure 4 3 Oil Dipstick and Fill 12 kW and 15 kW Cil Dipstick Cil Fill Air cooled 7 kW 12 kW and 15 kW Generators 45 CHANGING THE ENGINE OIL 4 5 1 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 oynthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with break in oil See the Procedure Section 3 1 for the first required oil change Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 452 CHANGE PROCEDURE To change the oil proceed as follows 1 Run the engine until it is thoroughly warmed up then shut OFF the engine 2 Immediately after the engine shuts OFF pull the oil drain hose Figure 4 4 free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 for oil capaci ties Figure 4 4 Oil Drain Hose and Filter Low Oil Switch High Temp Switch MAINTENANCE 2 Section 4 Maintenance 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the
13. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 u Revision 02 01 05 Part No OF 33982 Revision D 10 05 05 Printec in U S A
14. earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing e Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses e Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE
15. generator temperatures 13 Set the generator s AUTO OFF MANUAL switch to OFF The engine should shut down NOTE It is important not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is cor rect but voltage is high or low the generator s voltage regulator requires adjustment 2 4 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 loads connected to the transfer switch terminals 1 T2 3 Set the generator s AUTO OFF MANUAL switch to OFF 4 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker POST INSTALLATION START UP ADJUSTMENTS amp Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 5 Manually set the transfer switch to the STANDBY position i e load terminals connected to the generator s 1 2 terminals The transfer switch operating lever should be down 6 Set the
16. 0 156 X 0 675 11 022473 1 WASHER FLAT 1 4 M6 12 0D3094 1 HARNESS GTS TO MAIN PANEL 13 004684 1 PLATE HARNESS ADAPTER 14 0E7900 1 SUBPLATE LOAD CENTER 15 0F4790 10 5 U CHANNEL 16 022152 6 WASHER LOCK 10 17 064526 2 SCREW HWHS 6 25 X 3 8 18 0 6155 1 ARM EXTENDER PIN 19 063378 4 HOLDER CABLE TIE 20 0A2110 4 SCREW SWAGE 1 4 20 X 1 2 ZINC 21 074138 2 LUG QUICK DISCONNECT NI S 10X45 DEG BRASS TIN 22 036933 6 SCREW 10 32 X 3 8 23 077033 6 LUG SLDLSS 1 0 14X9 16 AL CU 24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 028739 4 TIE WRAP UL 3 9 X 10 NAT L 26 0D4802 1 HARNESS GTS TO EXTERNAL CONNECTION BOX 27 0D3191 1 COVER RELAY amp TERM BLOCK 28 0D3088 1 WIRE HARNESS GTS LOAD CENTER NOT SHOWN FOR CLARITY 29 073591 2 FUSE HOLDER 30 073590A 2 FUSE 5A X BUSS 31 040213B 4 PCB SUPPORT SNAP IN 1 3 8 32 0 7888 1 CIRCUIT BREAKER 20A X 1P 33 0A7215 4 SCREW SW 1 4 20X5 8 WITH WASHER 34 0E7888B 5 CIRCUIT BREAKER 15 X 1P 35 0 7888 1 CIRCUIT BREAKER 30A X 2P 36 0D3320 1 COVER HARNESS ENTRY 37 0 6193 1 BRACKET ARM EXTENDER 47 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 CN VN NG 34 2 y Section 8 Exploded Views and Parts Lists Cp Air cooled 7 kW 12 kW and 15 kW Generators 12 kW and 15 kW 12 Circuit
17. 1 85 049813 1 86 0F0164A 1 87 0 0165 1 89 0 2874 1 90 043107 4 91 022145 10 92 045771 4 93 003906 2 94 0E4321 1 95 0E1330A 1 96 0 9692 1 97 042907 2 98 0 5241 1 99 0 5943 1 PARTS ib 00 DESCRIPTION SCREW HHC M6 1 0 X 16 08 8 SCREW 6 1 0 16 G8 8 7KW SCREW HHC M6 1 0 X 12 08 8 SCREW 6 1 0 12 G8 8 7KW NUT LOCKING FLANGE 6 1 0 NUT LOCKING FLANGE 6 1 0 7KW SCREW HHTT 8 1 2 X 20 BP SCREW TAPTITE M6 1 0 X 12 BP SCREW TAPTITE M6 1 0 X 12 BP 7KW NUT LOCK TRIC 6 X 1 0 Y ZNC GASKET BATTERY SUPPORT BRACKET PLUG PLASTIC 0 593 LUG SLDLSS 2 8X17 64 CU SCREW TAPTITE M6 1 0X25 BP L WASH SPECIAL BRACKET BATTERY HOLD DOWN 7KW CONTACTOR STARTER 7KW CABLE 46 RED BATTERY 38 5 NUT HEX 1 4 20 STEEL 7KW WASHER LOCK 5 16 WASHER LOCK 5 16 7KW SCREW TAPTITE 5 0 8 X 10 BP HARNESS ENGINE HARNESS ENGINE 7KW BUSHING SNAP SB 1000 12 SCREW HHC 5 16 18 X 3 4 G5 7KW RIVET 1 8 X 0 126 0 375 LSH POP L WASH SPECIAL 10 ASSEMBLY ROOF DOOR GROUND WIRE ASSEMBLY ROOF DOOR GROUND WIRE PLUG PLASTIC 1 375 GASKET EXTRUDED TRIM PLATE HOT GROMMET 2 75 X 1 16 EXTERNAL CONNECTION BOX POWER BLOCK HARNESS GENERATOR TO EXTERNAL CONNECTION BOX HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 7KW SCREW PPHM 10 32 X 1 WASHER LOCK 10 WASHER FLAT 5 NUT HEX 10 32 STEEL FUEL LINE 3 4 OUTDOOR NOT SHOWN WASHER SHAKPROOF EXT 1 4
18. 12 kW and 15 kW Generators INFORMATION 1 4 THE GENERATOR Figure 1 1 7 kW Single Cylinder GH 410 Engine eS 1 Control Oil Data Panel Dipstick Decal a eco GFCI m Outlet Exhaust Enclosure Regulator 00700 E Fuel E Fuel 0 k Inlet WIE 1 gt L 2 _ omposite Base Battery Oil Filter Compartment Figure 1 2 12 kW 15 kW V twin GT 990 760 Engine VA 1 Control 4 Data Panel Dipstick GFCI Outlet Exhaust Enclosure 5 Fuel 2 E Regulator 4 Fuel rk Inlet 4 4 4 7 ite B Oil Filter Battery Composite Base Compartment Section 1 General Information INFORMATION Air cooled 7 kW 12 kW and 15 kW Generators GENERAL 1 5 SPECIFICATIONS 1 5 1 GENERATOR Model 04389 Model 04456 Model 04390 Rated Max Continuous Power 13 000 NG 15 000 LP Capacity Watts Rated Voltage 1
19. 6 SEMS 123 0C3052 1 ASSY IGNITION COIL GV 990 CYLINDER 2 BARBED STR 1 4NPT X 3 8 124 022097 4 WASHER LOCK 6 1 4 CLAMP HOSE OETIKER 16 5mm 125 092079 4 SCREW TAPTITE M6 1 0 X 25 BP HOSE 3 8 1 0 X 6 LONG 126 0E4271 1 STARTER COOLER OIL 127 0D4529 2 SPARKPLUG PLASTITE 1 4 15 X 3 4 128 022129 2 WASHER LOCK 8 5 16 GASKET MANIFOLD PORT 129 061906 2 SCREW HHC 8 1 25 X 85 G8 8 MANIFOLD CYLINDER 2 130 082774 1 KEY WOODRFF 4 X 19D MANIFOLD CYLINDER 1 131 0 5343 1 NUT HEX LOCK M10 1 50 SLEEVE RUBBER 132 008468 1 SPRING ANTI LASH WASHER FLAT M8 SS 133 003048 1 ROD GOVERNOR CONTROL WASHER LOCK 8 SSTL 134 0D3754 1 ASSEMBLY GOVERNOR LEVER SCREW SHC 8 1 25 20 G12 9 135 0D3742 1 SPRING GOVERNOR PLATE BACKING WITH OIL COOLER 136 008482 1 ASSEMBLY GOVERNOR ADJUSTER GROUND WIRE CONNECTOR 137 0E0486 1 SCREW SHC M10 1 5 X 75 G10 9 FLYWHEEL ASSEMBLY 138 0D3743 1 SPRING GOVERNOR IDLE FAN NYLON 139 0D3705 1 ASSEMBLY GOVERNOR ADJUSTER PLATE FAN BRACKET WASHER SHAKEPROOF INT M8 SS 140 002993 1 SEAL GOVERNOR SHAFT SCREW HHC 8 1 25 12 G8 8 142 045771 1 NUT HEX 8 1 25 G8 WASHER 25mm 1 0 143 0D6147 7 SCREW HHFC M6 1 0 X 10mm NUT HEX M24 144 0E8152 1 O RING 0 49 I D X 0 07 THICK SNORKEL AIR INTAKE 145 0E7743 1 ASSY IGNITION COIL 270mm CYLINDER B HB PO NP HOUSING BLOWER NG COOLER 1 53 Section 8 Exploded Views and Parts Lists Air cooled 7
20. 8 0C8101 1 PANEL MUFFLER BASE 9 056482 1 BEARING 1 1811 2 8346 10 003168 3 5 16 SPECIAL LOCK WASHER 11 001838 1 BOLT HHCS 3 8 24 x 15 50 12 0D1846 4 BOLT HHCS 8 1 25 x 345mm 13 0 7038 1 BRACKET ALTERNATOR MOUNTING 14 0D1609 1 DUCT ALTERNATOR AIR 15 0D2559 1 GASKET ALTERNATOR AIR DUCT 16 0C7038A 1 BRACKET ENGINE MOUNTING 17 0 7758 4 RUBBER MOUNT 18 0388050AD0 1 CABLE 6 48 BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VYNL COAT 0 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 2 6 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406 0 X 1 6200 24 022237 5 WASHER LOCK 3 8 25 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 051731 4 SCREW HHC M8 1 25 X 50 G8 8 28 022145 12 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX M8 1 25 NYL INSERT 30 045756 2 SCREW TAPTITE M6 1 0X10 BP 31 022129 10 WASHER LOCK 8 5 16 32 022259 8 NUT HEX 5 16 18 STEEL 33 059637 2 SCREW TAPTITE 3 8 16 X 3 4 BP 34 0D4662 4 SCREW 5 16 18X3 4 HH THD ROLL 35 0 7065 FT HOSE RES 1 2 LP GAS 36 048031M 4 HOSE CLAMP 3 4 1 0 37 0 0462 4 NUT HEX W TOOTH WSHR 8 1 25 38 002824 1 SCREW TAP R 10 32 x 9 16 39 025145 1 U BOLT 5 16 18 X 1 25 WITH SADDLE 40 004138 2 GASKET EXHAUST PORT 41 040173 2 CLAMP HOSE 5 5 0 62 0 62 42 074995 1 44 FT HOSE 1 4 ID LPG 350PSI UL21 43 066849 2 SCREW HHTT M5 0 8 X 16 57 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators
21. GN410 Engine Drawing No 0F3981 A Part 1 58 Section 8 Exploded Views and Parts Lists Cp Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0F3981 A Part 1 O ITEM PART N TY DESCRIPTION 1 0E3221 1 ASSEMBLY CONNECTING ROD 2 0 1466 1 PIN PISTON 020 3 021533 1 SET PISTON RING 90MM 4 0E2985 1 PISTON HC 5 071983 2 RETAINER PISTON PIN 20 6 0E8440 1 ASSEMBLY CRANKSHAFT GH410 SMALL TAPER 7 0A7628 1 ARM GOVERNOR RC45 8 078658 1 PIN R GOVERNOR ARM 9 078659 2 WASHER GOVERNOR ARM THRUST 10 088261E 1 CRANKCASE SUBASSEMBLY WITH PLUGS GH410 11 0E3812 2 SEAL 35 1 0 CRANKSHAFT 12 0E6519 1 ASSEMBLY GOVERNOR GEAR 13 078645 1 C RING GOVERNOR GEAR RETAINER 14 0A7811 1 SPOOL GOVERNOR MACHINE 15 0A9877 1 ASSEMBLY CAMSHAFT amp GEAR 16 076701 1 GASKET CRANKCASE 17 021713 1 GASKET HEAD 410 18 078691 1 COVER OIL PRESSURE RELIEF 19 0A5771 1 SPRING OIL RELIEF 360 20 0A5776 1 BALL DIA 11 32 PRESSURE RELIEF 21 076361 1 WASHER THRUST GOVERNOR GEAR 22 0A8898D 1 ASSEMBLY COVER GEAR TOP CHECK FILL 23 0D2274 2 RETAINER VALVE SPRING 24 004391 2 VALVE SPRING LF 25 086025 1 SET GEROTOR 12 THK 26 0E3341 1 BALANCER 2 021714 1 ASSEMBLY CYLINDER HEAD SEATS amp GUIDES 28 086516 1 VALVE EXHAUST 29 086517 1 VALVE INTAKE 30 0D9853B 2 PUSH ROD 174 9 31 083897 2 32 077158 1 ASSEMBLY SCREEN OIL PICK UP 33 063150 1 GASKET ROCKER COVER 410 34 072694 2 STUD D20 PIVOT BALL 35 083907 2 ROC
22. Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING e Guardian generators that utilize non Guardian Generac replacement parts e Guardian generators utilizing non Guardian Generac automatic transfer switches Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Any Guardian generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist e Costs of normal maintenance adjustments installation and start up Steel enclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning
23. accessories such as a work light cell phone radio or any other automotive style accessory This outlet is capable of delivering a MAXIMUM of 7 5 Amps If the accessory to be used through this circuit demands too much power the fuse that protects this circuit will melt open and the circuit will not be functional wanNiNG amp This 12 VDC outlet draws power from the gen erator s starting battery and extended use of this outlet may drain the battery and the engine may not start This outlet should NOT be used for battery charging 5 5 2 120 VAC OUTLET Your generator is equipped with an external 15 amp 120 volt GFCI convenience outlet that is located in the right rear of the generator enclosure Figures 1 1 and 1 2 When the generator is running in the absence of utility power this outlet may be used to power items outside your home such as lights or power tools This outlet may also be used when utility power is present by running the generator in manual mode This oultlet does not provide power if the generator is not running This outlet is protected by a 15 amp circuit breaker located in the generator control panel Figure 3 1 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors util ity power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and sta
24. batteries When replacing the battery use the following type of battery Group 26 26R 12 volt DC negative ground battery with a rating of 350 cold cranking amps mini mum for 7 kW 525 cold cranking amps minimum for 12 and 15 KW at 17 8 C 0 F minimum When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service Schedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly connect ed and terminals are tight Observe battery polarity when connecting the battery to the generator set 21 BEFORE INITIAL START UP Before starting complete the following 1 Set the generator s main circuit breaker to its OFF or open position 2 Set the generator s AUTO OFF MANUAL switch to the OFF position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 4 Turn OFF all loads connected to the transfer switch terminals 1 and T2 10 Section 2 Post Installation Start up and Adjustments Air cooled 7 kW 12 kW and 15 kW Generators 5 Check the engine crankcase oil level and if neces sary fill to the dipstick FULL mark with the rec ommended oil Do not fill above the FULL mark 6 Check the fuel supply Gaseous fuel lines must have been properly pur
25. counterclockwise Figure 4 1 Generator Control Panel 2 OUTLET FUSE EXTERNAL Locate your nearest servicing dealer www guardiangensrators coni CIRCUIT AUTO OFF MAN BREAKER SYSTEM SET 12 VDC LOW OIL SYSTEM FUSE HIGH TEMP OVER SPEED OVER CRANK 1 SET MS NEIN iS ERE EXERCISE ACCESSORY 4 FLASHING RED LEDS TIME OUTLET 7 5A MAX EXERCISER NOT SET 4 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figures 4 2 and 4 3 1 Start the generator by moving the AUTO OFF MANUAL switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth 18 3 Air cooled 7 kW 12 kW and 15 kW Generators Install the dipstick then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE FULL MARK caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine Install the dipstick Reset the AUTO OFF MANUAL switch to its origi nal position Figure 4 2 Dipstick and Fill 7 kW
26. generator s AUTO OFF MANUAL switch to MANUAL The engine should crank and start immediately 7 Let the engine stabilize and warm up for a few minutes 8 Set the generator s main circuit breaker to its ON or closed position Loads are now powered by the standby generator 9 Turn ON electrical loads connected to transfer switch 1 T2 Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 10 Connect an accurate AC voltmeter and a frequen cy meter across terminal lugs 1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 11 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 12 When testing under load is complete turn OFF electrical loads 13 Set the generator s main circuit breaker to its OFF or OPEN position 14 Let the engine run at no load for a few minutes 15 Set the AUTO OFF MANUAL switch to OFF The engine should shut down 2 5 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set generator s main circuit breaker to its OFF or OPEN position 2 Check that the AUTO OFF MANUAL switch is set to 3 Turn OFF the utility power supply to the transfer switch using means provided such as a utility main line c
27. lt A Z LOY L C 3g ELECTRICAL 1 N1A LEGEND ATS AUTOMATIC TRANSFER SWITCH C1 UTILITY COIL amp RECTIFIER C2 GENERATOR COIL amp RECTIFIER F1 F2 5A 600V FUSE LC CIRCUIT BREAKER LOADS TR TRANSFER RELAY TS TERMINAL STRIP XA XB LIMIT SWITCHES Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic 8 Circuit Load Center Drawing No 0E7815A 194 69 23 69 Q oPEN amp F2 1 9 E amp 0 ES NEUTRAL CONNECTION INSIDE SWITCH 6 o BLU oo VO 6 6 YLW 6 BRN m O BRNWHT o YLW WHT 6 0 LC 194 12Vdc TRANSER COIL 23 TS TO GENERATOR CONTROL PANEL 240 OUTPUT 1 BLACK TO GENERATOR RED OUTPUT CIRCUIT BREAKER NEUTRAL WHITE NEUTRAL WHITE 240VAC TO RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 15A 120V CIRCUIT 6 15A 120V CIRCUIT 5 20A 120V CIRCUIT 2 30A 240V CIRCUIT 1 VES CIRCUIT 30A 240V CIRCUIT 3 CONNECTION 15A 120V CIRCUIT 4 15A 120V CIRCUIT 7 15A 120V CIRCUIT 8 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators 5 4 ELECTRICAL Electrical Schematic 12 Circuit Load Center Drawing No 0E7815 DATA KH 194 194 12Vdc TRA
28. second can be accessed from the back of the unit enclosure by removing the plastic hole plug The screw can be turned with a long flat blade screwdriver Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators 13 To adjust the system to run on LP fuel turn BOTH adjuster screws 1 2 TURN CLOCKWISE The system should now be set for maximum power and best perfomance DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE SET PINS FROM THE REGULATOR HOUSING THIS WILL VOID THE WARRANTY 14 It may be necessary to make minor adjustments to the preset adjustment screw settings to achieve maximum power particularly at higher altitudes If experiencing problems with the unit producing maximum power follow the procedure in Section 2 6 Adjusting the Fuel Regulator Figure 1 4 Demand Regulator OUTLET PORTS FUEL HOSE BRASS HOSE FITTING IDLE CIRCUIT BRASS HOSE PORT 1 PRESSURE FITTING ADJUSTER SCREWS SMALL FUEL JET REGULATOR HOUSING PORT 1 10 LOCATION 1 10 1 GENERATOR Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet open ings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drifting consider using a windbreak to protect the unit Install the gen
29. 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 Use a large socket and socket wrench to rotate the nut and hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned MAINTENANCE 2 Section 4 Maintenance When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in lbs torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 4 10 Valve Clearance Adjustment Rocker Pivot Ball Arm Install new valve cover gasket Re attach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place Re attach the spark plug wire to the spark plug On GT 990 Repeat the process for the other cylin der 4 9 COOLING SYSTEM Air inlet and outlet openings in the generator com partme
30. the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved ad
31. 05315 32 005998 33 0D1667 34 002991 35 002988 36 002992 1 N N BRB OO Section 8 Exploded Views and Parts Lists PARTS Ce LISTS Air cooled 7 kW 12 kW and 15 kW Generators D GT 990 760 Engine Drawing No 0E8774 M Part 1 0 DESCRIPTION ITEM PART DESCRIPTION ASSEMBLY CRANKCASE HOUSING WITH 37 0C3971C 1 ASSEMBLY DIPSTICK WITH HANDLE SLEEVE 38 0C5305 1 TUBE DIPSTICK SEAL 38 1 0 CRANKSHAFT 39 003027 1 O RING OIL CLR 3 8 X 1 2 SCREW TAPTITE M6 1 0 X 12 YC 40 0E9842 1 SEAL 42 0 CRANKSHAFT ASSEMBLY BREATHER 41 065731 1 ASSEMBLY HOUSING COVER WITH GASKET BREATHER COVER SLEEVE SEPARATOR OIL BREATHER 42 0C3006 9 SCREW HHFC M10 1 5 X 55 ASSEMBLY HEAD 1 G amp S 43 080318 8 SCREW 6 1 0 25 RETAINER PISTON PIN 20 44 093064 1 ASSEMBLY OIL FILL CAP ROCKER COVER NO OIL FILL 45 0C8808 2 HOOK LIFTING STUD M8 1 25 10MM X 30 G5 ZINC 46 0D2723B 1 ROCKER COVER WITH OIL FILL PISTON HC 47 002979 2 GASKET VALVE COVER SET PISTON RING 90MM 48 086515 8 KEEPER VALVE SPRING PIN PISTON 49 0D2274 4 RETAINER VALVE SPRING ASSEMBLY CAMSHAFT amp GEAR 50 0D3867 4 SPRING VALVE SHAFT GOVERNOR 51 078672 2 SEAL VALVE STEM D7 ROLLER BEARING GOVERNOR PLATE 52 065371 4 WASHER VALVE SPRING ROLLER BEARING GOVERNOR 53 072694 4 STUD ROCKER ARM PIVOT ASSEMBLY GOVERNOR GEAR 54 0D3998 4 NUT HEX M8 1 0 G8 YEL CHR SPOOL GOVERNOR MACHINED 55 0C302
32. 1 4 48 049813 1 NUT HEX 6 1 0 49 031879 6 WASHER FLAT 4 031879 4 WASHER FLAT 4 7KW 50 023897 2 WASHER FLAT 10 51 0 9056 1 SOCKET 12VDC ACCESSORY 52 0 5840 1 CIRCUIT BREAKER 15A PUSH PULL MAIN RESET 53 036903 6 SCREW PPHM 6 32 X 5 8 54 0E7833 1 PLATE WEATHERPROOF 95 0 4261 1 OUTLET 15 GFCI DUPLEX 56 022985 4 WASHER FLAT 6 of 082625 4 NUT LOCK HEX 46 32 NYL INSERT 58 0E9171 1 GASKET WEATHERPROOF GFCI 59 0F4793 2 SCREW PPHM M3 0 5 x 10mm 45 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 0 7975 v A x NN yyy gt X 46 Section 8 Exploded Views and Parts Lists Cp Air cooled 7 kW 12 kW and 15 kW Generators 7 kW 8 Circuit Load Center Assembly Drawing 0 7975 O ITEM PART N TY DESCRIPTION 1 004801 1 BOX GTS LOAD CENTER 2 0D4800 1 COVER 8 POSITION GTS LOAD CENTER 3 002237 1 TRANSFER SWITCH HOME STANDBY 100A 2P 250V 3A 077220 1 COIL UTILITY 3B 077220A 1 COIL STANDBY 3C 082574 1 INSULATOR SIDEWALL NOT SHOWN 3D 084464 1 LIMIT SWITCH OPERATION NOT SHOWN 4 074908 8 SCREW TAPTITE M5 0 8 X 10 BP 5 024912 1 SCREW 1 4 20 X 5 8 BP 6 0A1658 1 WASHER SPECIAL 1 4 7 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 8 0 7889 1 8 CIRCUIT LOAD CENTER 125A 240V 9 041495 4 SCREW M4 0 7 X 10 10 0A1661 2 RIVET POP
33. 10 0C8283 11 0C8284A 12 0C8284B 13 0C8284C 14 0C8285 15 0C8899A 16 0D1128 0D1128A 17 0 4244 001605 18 001606 005264 19 001839 20 001840 21 002425 22 002588 002588 23 002676 24 002677 25 002979 002979 26 002979 27 0029790 0D2979E 28 0 4245 0D3058A 29 0 4245 30 0 4245 0D3058C 31 0D3057D 32 0D3059A 33 0D3059B 34 0D3059C 35 0D7176 36 0D3059D 37 003059 38 0C7781A 39 0D3037 40 0 0164 41 0 0165 42 003037 43 0 2115 44 022097 46 0 0710 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Enclosure Drawing No 0 0080 DESCRIPTION po c o cl cl c c cl KR l 5 18 ASSEMBLY ENCLOSURE BASE ASSEMBLY ENCLOSURE BASE 7KW SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE EXHAUST SIDE 7KW ENCLOSURE SIDE amp BACK ENCLOSURE SIDE amp BACK 7KW ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER PANEL ALTERNATOR DIVIDER 7KW PANEL MUFFLER BOX SIDE PANEL MUFFLER BOX SIDE 7KW COVER MUFFLER BOX COVER MUFFLER BOX 7KW GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 X48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER PANEL ENGINE DIVIDER 7KW BAFFLE INTAKE BAFFLE INTAKE 7KW HOUSING FAN BAFFLE EXHAUST 7KW BRACKET TOP SUPPORT
34. 13 4 PCB SUPPORT SNAP IN 1 3 8 32 0 7888 3 CIRCUIT BREAKER 20A 1P 33 0E7888 1 CIRCUIT BREAKER 20A 2P 34 0E7888B 5 CIRCUIT BREAKER 15 1 12 CIRCUIT LOAD CENTER 0E7888B 3 CIRCUIT BREAKER 15A 1P 10 CIRCUIT LOAD CENTER 35 0 7888 1 CIRCUIT BREAKER 30A 2 36 0D3320 1 COVER HARNESS ENTRY 37 0D3093 1 HARNESS GTS TO EXT CONN BOX 0D8597 1 HARNESS GTS TO EXT CONN BOX 8 5KW 38 075475 2 SCREW PPHM M4 0 7 X 10 39 0A7215 4 SCREW SW 1 4 20 X 5 8 WITH WASHER 40 0E6193 1 BRACKET ARM EXTENDER 49 PART Ce Qm Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators OG GT 990 760 Engine Drawing No 0E8774 M Part 1 64 1 60 62 63 o s 9 79 EA A as oN 24 aX l p Ss N Hh lt 9 16B 17 18 48 49 50 51 52 53 54 56 57 58 59 5 19 20 39 40 47 64 93 140 8 11 12 13 47 66 2 68 4 5 6 69 16A N LO lt lt 2 gt VS V7 5 I lt lt 7 sil lt 50 ITEM PART NO 1 005729 2 0E9843 3 090388 4 005372 5 003005 6 0E3372B 008067 8 071983 9 0C2981C 10 045761A 11 0 2985 12 021533 13 0 1466 14 004041 15 002983 16A 0 2985 16 0C2985B 17 0D4042 18 0A7811 19 0C2977 20 0C5943 21 0E4357E 22 0E3223 23 0D2157 24 0 6098 25 0D4123A 26 078699E 27 003011 28 063009 29 063010 30 093873 31 0
35. 20 240 Rated Max Continuous Load Current Amps 120 Volts 50 0 NG 58 3 LP 100 0 NG 100 0 LP 108 3 NG 125 0 LP 240 Volts 54 2 NG 62 5 LP Main Line Circuit Breaker 65 Amp Phase 1 Number of Rotor Poles 2 Rated AC Frequenc 60 Hz Power Factor 1 Recommended Air Filter Part 0C8127 Battery Requirement Group 26 26R Group 26 26R Group 26 26R 12 Volts and 12 Volts and 12 Volts and 350 Cold cranking 525 Cold cranking 25 Cold cranking Amperes Minimum Amperes Minimum peres Minimum Weight 487 Pounds 23 ft 7m at full load Normal Operating Range 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature Load current values shown for 120 volts are maximum TOTAL values for two separate circuits The maximum current in each circuit must not exceed the value stated for 240 volts 1 5 2 ENGINE Model 04389 Model 04456 Model 04390 Type of Engine GT 990 Number of Cylinders 2 Rated Horsepower 30 3 600 rpm Displacement 992cc Cylinder Block Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid state w Magneto Recommended Spark Plug RC12YC Spark Plug Gap 0 508 mm 0 020 inch Compression Ratio 9 5 1
36. 39 66A DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION CB3 CIRCUIT BREAKER EXTERNAL OUTLET PUSH PULL D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 7 5 AMP HTO HIGH OIL TEMPERATURE SWITCH HM HOUR RUN METER IM IGNITION MODULE LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SP SPARK PLUG SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC CONTROL PRINTED CIRCUIT BOARD Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL Electrical Schematic Single Cylinder Drawing No 0E9015 4 11 11 F 22 225 240 UTILITY INPUT 224A 12Vd _ C TRANSFER RELAY COIL 224 15 CUSTOMER 12VDC ACCESSORY CONNECTIONS SOCKET NEUTRAL POWER 120V WINDING 120V STATOR 15 0 5 1 23 11 au LL gt _ 239 h 240V N G G 15 1 3 lt RED L C1 2 14 14 iU U ea p T 1 0 15 1 6 0 0 BLACK _____ G CUSTOMER EXTERNAL lt 18 SUPPLIED 1 5 D
37. 7 2 O RING 3 8 X 1 2 GASKET CRANK CASE 56 0D5313 4 ROCKER ARM SEAL OIL PASSAGE Br 006024 2 PLATE PUSH ROD GUIDE ASSEMBLY CRANKSHAFT HORIZONTAL 58 062976 12 SCREW 8 1 25 X 65 DIRECT DRIVE 59 086516 2 VALVE EXHAUST ASSEMBLY CONNECTING ROD 60 002229 2 VALVE INTAKE SCREW SHC 6 1 0 X 50 G8 8 61 083897 4 TAPPET SOLID SCREEN OIL PICKUP 62 0D8067B 1 ASSEMBLY HEAD 2 G amp S ASSEMBLY OIL PUMP 63 0D9853D 4 PUSHROD 147 SLEEVE SEAMED DOWEL 10 DIA 64 0C2978 2 GASKET HEAD COVER OIL RELIEF 65 043790 1 BARBED ELBOW 90 3 8NPT X 3 8 SPRING OIL RELIEF 66 0D4010 1 KIT GASKET BALL 1 2D OIL RELIEF 67 0D4011 1 KIT PISTON amp RINGS WASHER LOCK RIB M6 68 0D4012 1 KIT BREATHER ASSEMBLY GEROTOR OUTER 69 0D4013 1 KIT GOVERNOR ASSEMBLY CLAMP OIL TUBE 70 008675 1 KIT HEAD ASSEMBLY CYLINDER 1 ARM GOVERNOR 71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2 E RING GOVERNOR ARM 72 0D4015 1 KIT OIL RELIEF THRUST WASHER GOVERNOR 73 0D4016 1 KIT GEAR COVER n5 n BUSHING GOVERNOR LOWER 51 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 2 110 9 NS 9 j TESH N S Longs lt KG NO 7 A SEE a 9 SC N lt VOS 2 0 lt 7 7 2 2 52 ITE
38. ANSFORMER 16 Vac 56 amp 16 Vac 1 VA DUAL SEC 351 4 86 23 194 LL CONTROL 56 PRINTED CIRCUIT BOARD 18 14 g 66A DSW lt gt 239 1234 ON 17 1 nin as 15 L I 0 ON INDICATES T i 20 Vac Sense Transformer 224 2 Remote Not Auto 3 50 Hz Operation 4 SPARE L E D ALARM INDICATORS Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL Wiring Diagram Single Cylinder Drawing No 0 9014 lt DATA CONTROL PANEL BOX VOLTAGE REGULATOR 194 111111 23 EXTERNAL GFCI OUTLET LOAD 4 351 D gt gt 5 1 1 5 zl tb 8 5 SW2 240V GENERATOR 5 MANUAL OUTPUT TO TRANSFER 5 SWITCH CONTACTOR CUSTOMER 12VDC ACCESSORY SOCKET CO N N ECTI ON 33 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL DATA 7 Electrical Schematic Single Cylinder Drawing 0 9015 BATTERY 224A CHARGER 225 224 7 14 2 1 13 77 BATTERY CHARGE WINDING LOP ENGINE RUN WINDING STATOR ELECTRONIC 4 C2 10 C2 9 VOLTAGE 4 REGULATOR 0 Z N _ pm g PS gt e c e 6 23 162 is C2 11 194 CB2 1 5 0 2 7 194 224 1 d C2 8 OCA DPE WINDING STATOR 2
39. BUSHING SCREW PPHM M4 0 7 x 16mm NUT HEX LOCK M4 0 7 NYLON INSERT SCREW PPHM M3 0 5 x 8mm SCREW PPHM M3 0 5 x 8mm 7KW CIRCUIT BREAKER 3 X 1 ETA 46 500 P CIRCUIT BREAKER 2 5 X 1 ETA 46 500 P 7KW CONTROL PANEL BOTTOM CONTROL PANEL BOTTOM 7KW SCREW HHC M5 0 8 x 30mm SWITCH SPST ON ON N O NUT HEX LOCK M3 0 5 NYLON INSERT NUT HEX LOCK M3 0 5 NYLON INSERT 7KW NEUTRAL CONNECTOR HARNESS CONTROL PANEL NOT SHOWN HARNESS CONTROL PANEL WIRE NOT SHOWN 7KW PARTS Ce LISTS Control Panel Drawing No 0E9162 J 0 ITEM PART DESCRIPTION 074908 4 SCREW M5 0 8 x 10 28 049226 WASHER LOCK 5 29 082025 6 NUT HEX LOCK M5 0 8 NYLON INSERT 30 003910 1 TRANSFORMER 31 022507 2 SCREW HHC 1 4 20 x 1 2 32 0A9611 1 FUSE 7 55A X AGC5 33 046689 1 BLOCK TERMINAL STRIP 20A 4 X 6 X 1100V 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 35 075475 2 SCREW PPHM M4 0 7 x 10mm 36 043180 2 WASHER FLAT M4 37 0 8812 1 COVER CONTROL PANEL COMPONENT 0 8895 1 COVER CONTROL PANEL COMPONENT 7KW 38 092036 8 SCREW PPHMS LW 6 32 x 1 4 39 045770 2 SCREW HHC 5 0 8 x10mm 40 0E7866 1 COVER CONTROL PANEL 0E7867 1 COVER CONTROL PANEL 7KW 41 003700 8 NUT FLANGE 6 1 0 NYLOK 42 0912970069 1 ASSEMBLY ROOF DOOR GROUND WIRE 43 0E2874 1 SCREW 1 4 20 X 3 4 44 1658 2 WASHER LOCK SPECIAL 1 4 45 022473 3 WASHER FLAT 1 4 M6 46 038750 1 SCREW M6 1 0 x 30mm 47 022097 3 WASHER LOCK M6
40. Change Clean W Weekly R Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections x o o M LUBRICATION Oil level AND Y AND Y COOLING Enclosure louvers W BATTERY ensure dryness battery terminals Check charge state EVERY 6 M unsealed batteries only ENGINE AND MOUNTING Air cleaner x x R j Y Spark plug s Lx Fm Y GENERAL CONDITION Temperature COMPLETE TUNE UP TO BE COMPLETED BY AN Y AUTHORIZED DEALER 23 TROUBLESHOOTING 5 1 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 is set to OFF but the engine continues to run There is no AC output from the generator There is no transfer to standby after utility source failure Unit consumes large amounts of oil 24 Cause 1 Fuse blown 2 Loose corroded or defective battery cables 3 Defective starter contactor 7 kW 4 Defective starter motor 5 Dead Battery 1 Out of fuel 2 Defective fuel solenoid FS 3 Open 14 wire from engine control board 4 Defective spark plug s 5 Valve lash out of adjustment 1 Air cleaner plugged or damaged 2 Defective spark plug s 3 Fuel Regulator not set 4 Fuel Pressure incorrect 1 Defective switch 2 Auto Off Manual switch wired incorrectly 3 Defective control board 1 Main line circu
41. F 12 083512 1 SCREW TAPTITE M8 1 25 X 16 BP 13 0D1401A 1 BREATHER TUBE 14 091039 1 GASKET INTAKE ADAPTER 15 009619 1 ASSEMBLY PLASTIC CARB 16 049811 2 WASHER FLAT M6 17 022097 4 WASHER LOCK 6 1 4 18 040945 2 SCREW SHC M6 1 0 X 20 G12 9 19 086999 1 GASKET OIL FILTR ADAPTER 20 0D5667A 1 ADAPTER OIL FILTER 21 049821 2 SCREW SHC 8 1 25 X 30 012 9 22 099236 1 SWITCH OIL 8 0 PSI 23 070185B 1 OIL FILTER 24 082774 1 KEY WOODRFF 4 X 19D 25 091222E 1 FLYWHEEL WITH RING GEAR 32DEG 26 067198N 1 WASHER BELV 20 X 2 2 27 067890 1 NUT HEX FLYWHEEL 28 0E7585 1 SPARKPLUG 29 072734 1 ASSEMBLY GOVERNOR LEVER 12 HP 30 072735 1 ROD GOVERNOR CONTROL 31 063978 1 SPRING ANTI LASH 32 0 6040 1 ASSEMBLY WIRE 33 0D9760 1 ASSEMBLY IGNITION COIL 34 092079 2 SCREW TAPTITE M6 1 0 X 25 BP 35 0F3800 1 SPRING GOVERNOR 36 083502 1 BOLT GOVERNOR ADJUST M5 37 082025 1 NUT HEX LOCK M5 0 8 NYINS ZINC 38 0D3083 1 ASSEMBLY OIL DRAIN HOSE 39 0E7887C 1 ASSEMBLY CAP amp DIPSTICK 40 090072 1 O RING 9 16 X 3 4 X 3 32 41 075281 1 SWITCH THERMAL 42 022145 1 WASHER FLAT 5 16 M8 43 0 2094 2 SCREW 3 0 5 6 SEMS 44 0 4373 1 SPACER ENDFRAME 45 022717B 1 GOMMET 46 0 3865 1 SPRING SECONDARY 47 0 3855 1 BRACKET SECONDARY GOVERNOR SPRING 48 039253 1 SCREW 8 1 25 x 20 49 003751 1 SPRING IDLE RETURNING 50 0 3921 1 BARREL GOVERNOR ADJUSTMENT 51 008493 1 SCREW SHC M5 0 8 x 30 52 0D8758 1 ENGINE LIFT HOOK 61 i us Section 8 Exploded Vi
42. HER LOCK 8 5 16 32 022259 8 NUT HEX 5 16 18 STEEL 33 059637 2 SCREW TAPTITE 3 8 16X 3 4 BP 34 048031K 3 BAND HOSE CLAMP 35 05 DIA 35 0C9592 1 BELLOWS 36 048031M 2 HOSE CLAMP 3 4 37 040976 2 SCREW SHC 8 1 25 X 20 012 9 38 0C2824 1 SCREW 10 32 9 16 39 025145 1 U BOLT 5 16 18 X 1 25 W SADDLE 40 090239 1 GASKET EXHAUST 41 0 6989 1 STINGER ENGINE AIR 42 0D1214 1 BASE AIR CLEANER 43 068127 1 ELEMENT AIR CLEANER 44 003024 1 COVER AIR CLEANER NG LP 45 0D2273 1 TUBE 1 25 0 D x 20Ga x 12 125 LONG 46 055934N 1 CLAMP VINYL 1 31 X 281 2 47 0 7065 1 25 FT HOSE LP 1 2 1 0 48 0C5136A 2 KNOB AIR CLEANER 49 074906 4 SCREW 6 1 X 20 BP 50 022473 4 WASHER FLAT 1 4 ZINC 51 0D4662 6 SCREW M8 1 2 X 20 BP 52 0C8290 1 GASKET PANEL 53 066849 2 SCREW HHTT M5 0 8 X 16 55 56 PARTS qp is 00 Og 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 21 43 31 32 Section 8 Exploded Views and Parts Lists Cp Air cooled 7 kW 12 kW and 15 kW Generators 12 kW and 15 kW Generator Drawing No 0D3417 L O ITEM PART N TY DESCRIPTION 1 0 6934 1 ADAPTOR ENGINE 2 007930 1 STATOR 12KW 0D2359 STATOR 13KW 15KW 3 007944 1 ROTOR 12KW 0D2356 ROTOR 13KW 15KW 4 0C6043 1 CARRIER REAR BEARING 5 0D2336 1 12 CURVED BLADE 6 0D6634 1 MUFFLER 7 0D3220 1 TAIL PIPE MUFFLER
43. KER ARM 36 072696 2 NUT JAM ROCKER ARM 37 078694 1 PLATE PUSH ROD GUIDE 38 021742 4 SCREW HHFL M10 1 5 X 105 39 006094 1 ASSEMBLY ROCKER COVER BREATHER 40 076329 1 PLUG OIL FILL PLASTIC 41 0 0057 1 O RING 17 8 x 2 4 42 0D4788 1 PLUG STANDARD PIPE 3 8 STEEL SQUARE HEAD 43 074908 1 SCREW TAPTITE M5 0 8 X 10 BP 44 086515 4 KEEPER VALVE SPRING 45 078606 4 SCREW amp LOCKWASHER M6 1 X 12 46 0A1442 8 SCREW HHFC 8 1 25 X 42 47 078672 1 SEAL VALVE STEM D7 48 089673 2 WASHER VALVE SPRING 49 0B2104 1 WASHER LARGE SPRING 50 078699C 2 DOWEL SEAMED SLEEVE 51 0A7627 1 SHAFT GOVERNOR RC55 52 043790A 1 BARBED ELBOW 90 3 8NPT X 3 8 LOCKTITE 53 088590 1 DOWEL DIA 12 X 18L 54 078699B 1 DOWEL SLEEVE SEAMED 12 DIA 59 us Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 0 GN410 Engine Drawing 0F3981 A Part 2 39 Section 8 Exploded Views and Parts Lists Cp Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing 0F3981 A Part 2 O ITEM PART N TY DESCRIPTION 1 0C1069 5 SCREW TAPTITE M6 1 0X8 YELLOW CHROME 2 0D2922 1 HOUSING BLOWER 3 008435 1 TUBE DIPSTICK 4 0C9997 1 GUARD FAN 5 088434 1 WRAPPER BOTTOM 6 045756 11 SCREW TAPTITE M6 1X10 YELLOW CHROME 7 0 4176 1 WRAPPER 8 009004 1 ASSY STARTER 9 059985 2 SCREW SHC 8 1 25 45 G12 9 10 022129 3 WASHER LOCK M8 5 16 11 0 2458 1 BACKPLATE L F D
44. Load Center Assembly Drawing No 0E7973 F O ITEM PART N TY DESCRIPTION 1 003086 1 BOX GTS LOAD CENTER 2 0D3092 1 COVER 12 CIRCUIT GTS LOAD CENTER 0 5211 1 COVER 10 CIRCUIT GTS LOAD CENTER 3 002237 1 TRANSFER SWITCH HOME STANDBY 100A 2P 250V 3A 077220 1 COIL UTILITY 3B 077220A 1 COIL STANDBY 3C 082574 1 INSULATOR SIDEWALL NOT SHOWN 3D 084464 1 LIMIT SWITCH OPERATION NOT SHOWN 4 074908 6 SCREW HHTT M5 0 8 X 10 5 024912 1 SCREW 1 4 20 5 8 6 0A1658 1 LOCK WASHER SPECIAL 1 4 7 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 8 0E7889 1 12 CIRCUIT LOAD CENTER 125A 240V 9 041495 4 SCREW M4 0 7 X 10 10 0A1661 2 RIVET POP 156 X 675 11 022473 1 WASHER FLAT 1 4 M6 ZINC 12 055450 1 PLUG PLASTIC 1 375 025034 1 PLUG STEEL 1 0625 15KW 13 0D4684 1 HARNESS ADAPTER PLATE 14 0E7900 1 SUBPLATE LOAD CENTER 15 0 4790 10 5 U CHANNEL 16 022152 6 WASHER LOCK 10 17 064526 2 SCREW HWHS 6 25 X 3 8 18 0 6155 1 ARM EXTENDER PIN 19 063378 4 HOLDER CABLE TIE 20 0D3094 1 HARNESS GTS TO MAIN PANEL 21 074138 2 LUG QUICK DISCONNECT NI S 10X45 DEG BRASS TIN 22 036933 6 SCREW 10 32 3 8 23 077033 6 LUG SLDLSS 1 0 14X9 16 AL CU 24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 028739 4 TIE WRAP 3 9 X 10 26 0A2110 4 SCREW SWAGE 1 4 20 X 1 2 ZINC 27 003191 1 COVER RELAY amp TERMINAL BLOCK 28 0D3088 1 WIRE HARNESS GTS LOAD CENTER SHOWN FOR CLARITY 29 073591 2 FUSE HOLDER 30 073590A 2 FUSE 5A X BUSS 31 0402
45. M PART NO 74 0C5136A 75 003024 76 003040 77 068127 78 008564 0085648 79 002595 80 004417 81 003025 82 0D3083 83 007292 84 070185B 85 075281 86 0 2094 87 88 035461 89 0 6301 90 0 9806 91 003026 92 009764 93 003043 94 007694 95 0 7693 96 0C3041A 97 070008 98 070006 99 040976 100 0C3016A 101 0E4997 102 0C3725B 103 0 3031 104 0C3032 105 0A5992 106 051754 107 0C3033 108 0C3034 109 0C8549A 110 0C3022A BR BR Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators PARTS Ce LISTS GT 990 760 Engine Drawing No 0E8774 M Part 2 0 DESCRIPTION ITEM PART QTY DESCRIPTION KNOB AIR CLEANER 111 0D1131 1 GUARD COVER AIRBOX NG LP 112 045756 25 SCREW TAPTITE M6 1X10 YELLOW PRE CLEANER CHROME ELEMENT AIR CLEANER 113 0 9763 4 NUT GROMMET 1 4 PLUG ASSEMBLY MIXER AIRBOX 990 114 0C3036A 1 HOSE BREATHER ASSEMBLY MIXER AIRBOX 760 115 022145 1 WASHER FLAT 5 16 M8 ZINC SCREW SHOULDER 8MM M6 1 0 X 18 116 022129 1 WASHER LOCK 8 5 16 WASHER RUBBER 1 4 X 1 8 THICK 117 0C3018 1 WRAPPER UPPER CYLINDER 1 SWITCH OIL PRESS 118 0C3019 1 WRAPPER LOWER CYLINDER 1 ASSEMBLY OIL DRAIN HOSE 119 0D1142A 1 WRAPPER LOWER CYLINDER 2 NIPPLE 3 4 16 UNF 120 0D1143 1 WRAPPER UPPER CYLINDER 2 OIL FILTER 121 0E6043 2 SCREW TAPTITE M5 0 8 X 8 ZP SWITCH THERMAL 284F 122 0F1177 1 ASSEMBLY GROUND WIRE SCREW M3 0 5 X
46. NSER COIL 23 69 23 E1 TS TO 69 OPEN 69 GENERATOR N1A Fo CONTROL PANEL N2 amp F1 240VAC OUTPUT X 90 N1A E1 1 69 BLACK E1 EE RED OUTPUT CIRCUIT BREAKER 2 NEUTER NEUTRAL WHITE CONNECTION B NEUTRAL WHITE 240VAC TO RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 o 6 BLU WHT 20A 120V CIRCUIT 10 o ORG _15A 120V CIRCUIT 9 20A 120V CIRCUIT 6 6 o VIO _15A 120V CIRCUIT 5 O YEL 20A 40V CIRCUIT 2 lt TH 6 30A 240V CIRCUIT 1 CIRCUIT O BRNWHT 30A 240V CIRCUIT 3 1 o YELWHT 20A 240V CIRCUIT 4 _15A 120V CIRCUIT 7 LEGEND O PNK 20A 120V CIRCUIT 8 ATS AUTOMATIC TRANSFER SWITCH C1 UTILITY COIL amp RECTIFIER 5 6 VIONWHT 15A 120V CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 5A 600V FUSE TR TRANSFER RELAY TS TERMINAL STRIP LC XA XB LIMIT SWITCHES 41 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Enclosure Drawing No 0 0080 LISTS PARTS der G PRE PACKAGED UNITS ONLY A E ITEM PART NO 1 066140 001901 2 066735 OF0063 4 0C7062 0C7062A 5 0 8811 0 8811 6 0 9873 7 0 7065 0C7065A 8 0C8101A 0C8861 9 0C8101B 0C8862
47. P follow these steps NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator A fuel pres sure of 10 to 12 inches of water column 0 36 to 0 43 psi to the fuel inlet of the generator MUST BE SUPPLIED 1 Turn off the gas supply if connected 2 Open the roof and remove the door 3 Remove the battery if installed 4 Remove the engine air in baffle located on the left hand side of the battery compartment Two M6 screws are located on top of the baffle and two M6 screws are located on the inside of the baffle towards the back 5 Remove the small hose clamp and hose from the fuel regulator It may be necessary to pry the hose off of the brass fitting using a screwdriver to gen tly lift up the hose edge 6 Remove the small brass hose fitting from the regulator casting 7 Place the small fuel jet thread side first into the threaded hole originally occupied by the brass hose fitting Figure 1 4 8 Using a short No 2 Phillips screw driver thread the small fuel jet into the regulator casting Do not over tighten 9 Apply thread sealant to the threads of the hose fitting and replace it into the regulator body 10 Re attach the small hose and hose clamp and tighten as necessary 11 Replace the engine air in baffle using the four M6 screws 12 Identify both brass adjustment screws on the regulator NOTE One adjustment screw can be accessed from the front of the unit and the
48. POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 5 To crank and start the engine set the AUTO OFF MANUAL switch to MANUAL 6 Let the engine stabilize and warm up for a few minutes 7 Set the generator s main circuit breaker to its or closed position The standby power source now powers the loads 3 5 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Let the engine run for a minute or two at no load to stabilize the internal temperatures 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 A AN Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock OPERATION Section 3 Operation Air cooled 7 kW 12 kW and 15 kW Generators 5 Use the manual transfer handle inside the trans fer switch to move the main contacts back to their UTILITY position i e loads connected to the util ity power source Figure 3 2 6 Turn ON th
49. Retransfer Time Delay This timer runs for about 15 seconds At end of 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts tim ing The timer will run for about one minute and the generator will then shut down 5 5 MANUAL TRANSFER OPERATION 3 5 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Setthe generator s AUTO OFF MANUAL switch to OFF 2 Set the generator s main circuit breaker to its OFF or open position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A AN Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal elec trical shock 16 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 Figure 3 2 Manual Transfer Switch Operation LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY
50. STEEL NUT HEX M6 1 0 G8 YELLOW CHROME HINGE TYPE A WITH STUDS SOCKET HINGE TYPE B WITH STUDS SOCKET SCREW HHTR 1 4 20 X 3 4 SCREW HHC M8 1 25 X 25 WASHER FLAT 5 16 NUT HEX M8 1 25 SELF ALIGN SCREW M6 HH PANEL EXHAUST ALIGNMENT GROMMET 38 1 CROSS SLIT WITH HOLE BRACKET REGULATOR MOUNTING SCREW HHC M8 1 25 X 16mm PLATE COVER GASKET COVER 43 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Control Panel Drawing No 0E9162 J eeu ITEM PART NO 1 0 7886 0 7886 0 7886 2 0A1801 3 083049 4 002174 5 075210A 6 0D3062 008615 008615 8 032300 9 022676 10 0 4494 11 0 7890 12 023484 13 075476 15 0E6480 17 001085 001085 19 054502 053623 20 0E7870 0E7871 21 075235 22 0D5240 23 0D9784 0D9784 24 0D8502 26 0 8956 0 8957 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators DESCRIPTION 4 KR BR CIRCUIT BREAKER 30A X 2P 240V 7KW CIRCUIT BREAKER 50A X 2P 240V 12KW CIRCUIT BREAKER 65A X 2P 240V 13 45KW ASSEMBLY BATTERY CHARGER ENGINE ASSEMBLY POTTED REGULATOR RELAY 12V 25A SPST BLOCK 1 POSITION HEX STAND OFF 46 32 x 3 8 ASSEMBLY HOME STANDBY CONTROLLER ASSEMBLY HOME STANDBY CONTROLLER 7KW HOLDER FUSE FUSE 15AMP X AGC15 SWITCH ROCKER DPDT ON OFF ON CIRCUIT BREAKER MOUNTING BRACKET SNAP
51. Starter 12Vdc Oil Capacity Including Filter Approx 1 7 Qts Recommended Oil Filter Part 070185B Recommended Air Filter Part 0C8127 Operating RPM 3 600 1 6 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 168 volts AC then the system set light will flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto position the generator will start 3 The Not In Auto dip switch is set to the OFF position on the control board 4 No alarms are present for example low oil pres sure high temperature etc 1 7 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section 1 9 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu c
52. USED ON 7KW HOME STANDBY 21 045764 16 SCREW TAPTITE M4X8 BP LISTS OG PARTS Imensions Section 9 Mounting D Air cooled 7 kW 12 kW and 15 kW Generators Drawing No 0D3739 C S3HONI SH313NITIIN SNOISNAWIG 11 lt 3015 ONIGNNOYS 55300 SAOWSY S310H 55300 318 2 NAI TIOO 21 01 HOdV 3NvdOUd AINON NWN100 H31VM 4 9 SVD AUNSSAYd 1915 LIINI 1905 LAN 47 6 9 66 11 1617141 064 166112706 ED N3dO WANININ 096 6 LINN aNnouv 191100 168712621 2b 614 J JHL A8 151 LON Od SH3NHOO r SATOH 9 WAWANIN 1 GIS 1431 19 229 80 91 9 22 09 qariadns 3l HOLIMS H34SNVH1 11 81 202 0 63 Section 10 Warranty 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 Generac are pleased to explai
53. a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tions are as follows After this heading read instructions that if not strictly complied with will result in serious person al injury including death in addition to property damage warnings amp After this heading read instructions that if not strictly complied with may result in serious person al injury or property damage After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the haz ards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others This symbol points out potential explosion haz This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the
54. all opera tors and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Manual with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique uti lized does not render the generator unsafe A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equi
55. ctrical codes also may require proper grounding of the generator electrical system After installing this home standby electrical sys tem the generator may crank and start at any time without warning When this occurs load cir cuits are transferred to the STANDBY generator power source To prevent possible injury if such a start and transfer occur always set the generator s Auto Off Manual switch to its OFF position before working on equipment and remove the 7 5A and 15A fuses from the generator control panel In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the g
56. d on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine 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 part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal com a Spark plug ponents b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 65 Section 10 Warranty WARRANTY Air cooled 7 kW 12 kW and 15 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a pe
57. e spring does not stretch at all Figure 2 4 Engine Governor Adjustment V twin Engines Idle Spring ap ent WA lt J m 1 7 Cu NN lt S SLE No Load Idle Governor Clamp Bolt Adjustment Screw Figure 2 5 Full Load Speed Adjust Screw V twin Engines Full Load Speed Adjust Screw 13 OPERATION Section 3 Operation 1r Air cooled 7 kW 12 kW and 15 kW Generators 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz with door open 9 The governor is now set 2 7 3 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corrosion inhibiting spray such as WD 40 or a comparable product 2 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62 63 Hertz slowly turn the slotted potentiometer Figure 2 6 until line volt age reads 247 252 volts Figure 2 6 Voltage Adjustment Potentiometer DJ NOTE The access panel on top of the control panel must be removed to adjust the voltage regulator NOTE The voltage regulator is housed above the gen erators control panel The regulator maintains a voltage in direct proportion to frequency at a 2 to 1 ratio For example at 62 Hertz line to neutral voltage will be 124 volts 14 3 1 BREAK IN PROCEDURE Once the unit has been installed a
58. e the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 555 1522 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 The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a lo
59. e utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 3 3 3 6 SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day the following sequence is completed During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 3 1 per mits selection of the day and time for the system to exercise At the chosen time perform the following sequence to select the desired day and time of day the system will exercise 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Hold down the Set Exercise Time switch until the generator starts approximately 10 seconds and then release 3 The generator will start and run for approximate ly 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is per formed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected caution amp The exerciser WILL NOT work if di
60. enerator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regula tions SAFETY RULES 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 Fire Protection Association are appropriate for use on the standby electric system Keep the extin guisher properly charged and be familiar with its use Consult the local fire department with any questions pertaining to fire extinguishers EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids such as natural gas and liquid pro pane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applicable fuel gas codes Before placing the home standby electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation inspect the fuel system periodically for leaks No leakage is permit ted STANDARDS INDEX In the abse
61. ents 1 Clean the area around the base of the spark plug s to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug s to clean 2 Remove the spark plug s and check the condi tion Replace the spark plug s if worn or if reuse is questionable See Section 4 13 for recommend ed inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 inch for 7 kW and 0 50 mm 0 020 inch for 12 15 kW by carefully bending the ground electrode Figure 4 8 Figure 4 8 Setting the Spark Plug Gap SET PLUG GAP AT 0 76 mm 030 inch 7kW 0 508 mm 020 inch 12 amp 15kW C Z 9 5 Air cooled 7 kW 12 kW and 15 kW Generators 4 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 13 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A A Do not dispose of the battery in a fire The battery is capable of exploding A battery presents a risk
62. equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for three different models e 04389 3 6 kW NG 7 kW LP single cylinder GH 410 Engine 04456 3 12 kW NG 12 kW LP V twin GT 990 Engine 04390 3 13 kW NG 15 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator r
63. equires servicing or repairs contact an Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Dealer about parts and service always supply the complete model num ber and serial number of the unit as given on its data decal which is located on the generator See Figure 1 1 or Figure 1 2 in Section 1 6 for decal location Model No Serial No AUTHORIZED DEALER LOCATION locate the nearest GUARDIAN AUTHORIZED DEALER please call this number 1 800 333 1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER or visit www guardiangenerators com Air cooled 7 kW 12 kW and 15 kW Generators Introduction Inside Front Cover Read This Manual Thoroughly IFC COMETS e IFC Operation and Maintenance IFC How to Obtain 5 IFC Authorized Dealer Locator Number IFC Safety Rules c 2 sS a lards Index DIE Ibo UP OMA SS ODE 3 Section 1 General Information 4 11 Unpacking Inspection 4 1 2 Prolteelion Dy SUING uuu 4 1 3 NEC Requirement for Arc Fault Circuit Interruption Breaker for Bedrooms 4 LA TH Coole ere creme 5 15 Specifications
64. erator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow three feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds 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 HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE The genset must be installed on a level surface The base frame must be level within two 2 inches all around 1 10 2 TRANSFER SWITCH 1 10 2 1 7 kW 12 kW and 15 kW Units The transfer switch shipped with this generator is enclosed in a NEMA 1 enclosure This type of enclo sure is intended for indoor use only Follow these rules Install the transfer switch indoors a firm sturdy supporting structure To prevent switch distortion level the switch necessary 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 Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors wARNING amp If the AUTO OFF MANUAL switch is not set to its OFF position
65. ews and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 0 Gas Regulator Drawing 0D8720 H ITEM PART DESCRIPTION ITEM PART QTY DESCRIPTION 1 0D5694 1 CASTING TWIN REGULATOR HOUSING 22 0 6731 2 RIVET POP 118 X 125 2 0 5022 1 SOLENOID COIL 12VDC 23 0C6067 2 SUPPORT DIAPHRAGM 3 004647 1 GASKET SOLENOID 24 004706 2 DIAPHRAGM TWIN REGULATOR 4 004166 1 PLUNGER LP REGULATOR ASSEMBLY 25 0 6068 2 CAP DIAPHRAGM SUPPORT 5 0 6070 1 SPRING SOLENOID PLUNGER 26 0C4643A 2 INLET TWIN REGULATOR 11 11 DIA 8 0 4795 4 SCREW SEMS 4 0 7 X 10 27 026073 1 PLUG STANDARD PIPE 1 8 STEEL 9 0C5760J 1 JET GN 410 ENGINE LP 7KW SQUARE HEAD 10 0 6606 2 BARBED STRAIGHT 1 2 x 1 2 026073 2 PLUG STANDARD PIPE 1 8 STEEL 11 097934 O RING CHECK VALVE SQUARE HEAD 7KW 12 004645 27 ADJUSTER SCREW TWIN REGULATOR 28 0A4032 2 PIN LIMITED ADJUSTMENT 13 0C5761 2 LEVER REGULATOR 29 0D3308 4 WASHER FLAT X 10mm O D 14 0C5968 2 SUPPORT INLET SEAL 30 024310 1 PLUG STANDARD PIPE 1 2 STEEL 15 0 6066 2 SEAL INLET SQUARE HEAD 7KW 16 0C5759 2 PIN PIVOT ARM 31 028414A 1 BARBED STRAIGHT 1 8 NPT X 1 4 17 0C5764 2 SPRING REGULATOR 32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD V TWIN 0C5764A 2 SPRING REGULATOR 7KW ONLY 18 070728 4 SCREW PFHMS 0 5 x 5 37 0D3973 1 PLUG EXPANSION 16mm 19 0C6069 2 GASKET DIAPHRAGM 20 0C5762 2 COVER TWIN REGULATOR A QUANTITY OF 1 1 TO BE
66. fault is detected 2 Dwelling Unit Bedrooms All branch circuits that supply 125 volt single phase 15 and 20 ampere outlets installed in dwelling unit bedrooms shall be protected by an arc fault circuit interrupter listed to provide protection of the entire branch circuit Section 210 12 requires that AFCI protection be provided on branch circuits that supply outlets receptacle lighting etc in dwelling bedrooms The requirement is limited to 15 and 20 ampere 125 volt circuits There is no prohibition against provid ing AFCI protection on other circuits or in locations other than bedrooms Because circuits are often shared between a bedroom and other areas such as closets and hallways providing AFCI protection on the complete circuit would comply with 210 12 If during the installation of the home standby system the decision is made to provide back up power to a bedroom branch circuit then the circuit breaker in the transfer switch should be replaced with an Arc Fault Circuit Interrupter It is most important that breakers only be switched like for like For instance if replacing a 15A breaker it MUST be replaced with a 15A AFCI breaker Likewise a 20A breaker MUST be replaced with a 20A AFCI These AFCI breakers are available at the nearest Home Depot or hardware store Siemens Item Description Q115AF 15A Single Pole AFCI Q120AF 20A Single Pole AFCI Section 1 General Information GENERAL Air cooled 7 kW
67. ge to the contents of a package that is not in evidence at the time of delivery but is discovered later 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 3 4 Overspeed 1 Low Oil Pressure Sensor 2 High Temperature Sensor 4 Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators There are LED readouts on the control panel to notify personnel that one of these faults has occurred There is also a System Set LED that is lit when all of the conditions describe in Section 1 3 are true 1 5 NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION BREAKER FOR BEDROOMS In 2001 the National Electric Code NEC intro duced a requirement for new construction This new requirement indicates the need for Arc Fault Circuit Interrupters to be used to protect the complete branch circuit that feeds a dwelling bedroom The actual NEC requirement is indicated below 1 5 1 SECTION 210 12 ARC FAULT CIRCUIT INTERRUPTER PROTECTION 1 Definition An arc fault circuit interrupter is device intended to provide protection from the effects of arc faults by recognizing characteristics unique to arcing and by functioning to de ener gize the circuit when an arc
68. ged and leak tested in accordance with applicable fuel gas codes All fuel shutoff valves in the fuel supply lines must be open caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 2 22 CHECK TRANSFER SWITCH OPERATION Refer to Section 3 5 of the owner s manual for man ual operation procedures A Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 2 5 ELECTRICAL CHECKS Complete electrical checks as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Set the generator s Auto Off Manual switch to the OFF position 3 Turn OFF all loads connected to the transfer switch terminals 1 and T2 4 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker DX A The transfer switch is now electrically hot Contact with hot parts will result in extremely hazardous and possibly fatal electrical shock Proceed with caution 5 Use an accurate AC voltmeter to check utility power source voltage across transfer switch ter minals 1 N2 Nominal line to line voltage should be 240 volt
69. he primary regulator for the propane supply is NOT INCLUDED with the generator A fuel pres sure of 10 to 12 inches of water column 0 36 to 0 43 psi to the fuel inlet of the generator MUST BE SUPPLIED 1 Turn off the main gas supply if connected 2 Open the roof and remove the door 3 Remove the battery if installed 4 Disconnect wire 0 and wire 14 from the gas solenoid on top of the demand regulator 5 Remove the carburetor fuel hose from the outlet port of the demand regulator 6 Remove the demand regulator by removing the fastener that retains the regulator mounting bracket 7 Remove the square headed steel pipe plug from outlet port 1 and the brass hose barb fitting from outlet port 72 Figure 1 3 Demand Regulator HOSE amp PLUG SWITCHED SIDES FUEL HOSE ind PIPE FUEL HOSE BRASS HOSE BRASS HOSE FITTING FITTING OUTLET PORT ADJUSTMENT SCREW FUEL JET NG FUEL SYSTEM LP FUEL SYSTEM 8 Refit the brass hose barb fitting to outlet port 1 and the square headed steel pipe plug to outlet port 2 9 Reverse procedure steps 1 5 to reinstall demand regulator 10 Take the plastic plug supplied in the poly bag with the generator and press it into the 3 4 hole on the bottom of the air cleaner base Figure 4 6 11 Reverse the procedure to convert back to natural gas 1 9 2 12KW AND 15KW V TWIN ENGINES To reconfigure the fuel system from NG to L
70. ircuit breaker 4 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 11 POST INSTALLATION START UP ADJUSTMENTS 5 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker 6 Set the AUTO OFF MANUAL switch to AUTO The system is now ready for automatic operation 7 Turn OFF the utility power supply to the transfer switch With the AUTO OFF MANUAL switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power supply to the transfer switch The following should occur After about 13 seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down 2 6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Although the generator has been factory set to pro vide maximum power it may be necessary in some areas to adjust this setting Because natural gas has different BTU or power content across the country the engine may not perform as designed If experiencing engine problems at high or full load conditions follow these ste
71. it breaker open 2 Generator internal failure 1 Defective transfer switch coil 2 Defective transfer relay 3 Transfer relay circuit open 4 Defective control logic board 1 Break in procedure Section 5 Troubleshooting Air cooled 7 kW 12 kW and 15 kW Generators TROUBLESHOOTING GUIDE not followed see Section 3 1 Correction 1 Replace 15A fuse in generator control panel 2 Tighten clean or replace as necessary BD 7 4 5 Charge or replace battery 1 Replenish fuel 2 3 4 Clean re gap or replace plug s 5 Reset valve lash 1 Check replace air cleaner 2 Clean re gap or replace plug s 3 Set Fuel Regulator 4 Confirm fuel pressure to regulator is 10 12 water column 0 36 0 43 psi for LP and 5 7 water colum 0 18 0 25 psi for natural gas 1 2 3 1 Reset circuit breaker to ON or closed L 5 4 L Contact the nearest Authorized Dealer for assistance Section 6 Notes Air cooled 7 kW 12 kW and 15 kW Generators NOTES 25 NOTES 26 Section 6 Notes Air cooled 7 kW 12 kW and 15 kW Generators Section 6 Notes Air cooled 7 kW 12 kW and 15 kW Generators NOTES 27 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL lt Wirtng Diagram V Twin Drawing 0 9016 ENGINE WIRING BATTERY DIAGRAM KEY CHARGER
72. kW 12 kW and 15 kW Generators 7 kW Generator Drawing No 0D3504 E 47 45 30 eo gt O gt NC N dw aK aN E e y y 4 Z Z orhD KELSO 51 52 We 52 21 54 Section 8 Exploded Views and Parts Lists Cp Air cooled 7 kW 12 kW and 15 kW Generators 7 kW Generator Drawing 0D3504 E O ITEM PART N TY DESCRIPTION 1 0 6934 1 ADAPTOR ENGINE 2 0C9935H 1 STATOR 3 0C9934H 1 4 0C6043A 1 CARRIER REAR BEARING 5 0C8096 1 FAN 8 CURVED BLADE 6 0C9593 1 MUFFLER 7 0D3220 1 TAIL PIPE MUFFLER 8 0C8860 1 PANEL MUFFLER BASE 9 031971 1 BEARING 6205 2RS C3 10 003168 3 5 16 SPECIAL L WASH 11 056147 1 BOLT ROTOR 5 5 16 24 13 1 2 G5 12 0D1847 4 BOLT STATOR HHCS M8 1 25 x 305mm 13 0C7038C 1 BRACKET ALTERNATOR MOUNTING 14 0D1647 1 DUCT ALTERNATOR AIR 15 0D2558 1 GASKET ALTERNATOR AIR DUCT 16 0C7038B 1 BRACKET ENGINE MOUNTING 17 067758 4 RUBBER MOUNT 18 0388050AE0 1 CABLE 6 40 BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VINYL COAT 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406ID X 1 6200 24 022237 4 WASHER LOCK 3 8 25 022511 4 BOLT HHC 3 8 16 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 039287 4 SCREW HHC 8 1 25 45 G8 8 28 022145 12 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX 8 1 25 NYL INSRT 30 090388 3 SCREW TAP M6 1 0X12 BP 31 022129 13 WAS
73. l be out of service longer than 90 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 Once the unit has shut down it will signal a low oil fault 4 Set the generator s main circuit breaker to its OFF or open position 5 Set the AUTO OFF MANUAL switch to OFF and turn off the utility power to the transfer switch Remove the 7 5A and 15A fuses from the genera tor control panel Disconnect the battery cables as outlined in General Hazards page 2 6 While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations Section 4 3 1 ee 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 agent into the spark plug s threaded openings Reinstall and tighten the spark plug s 9 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 10 Clean and wipe the entire generator 4 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Verify that utility power is turned off and that the AUTO OFF MANUAL switch is set to OFF 2 Check the tag on the engine for oil visc
74. n 4 18 I n 18 4 2 Checking the Engine Oil Level 18 4 3 Changing the Engine Oil 19 44 Changing the Oil Filter 19 4 5 Changing the Engine Air Cleaner 19 AO Spark 20 4 7 Battery Maintenance 20 4 8 Adjusting GH 410 GT 990 760 21 49 Cooling System 21 4 10 Attention After Submersion 22 4 11 Corrosion Protection 22 4 12 Out of Service Procedure 22 4 13 Service Schedule cont k es P S ESQ EUIS 23 Section 5 Troubleshooting 24 5 1 Troubleshooting Guide 24 Section 6 Notes 25 Section 7 Electrical Data 28 Section 8 Exploded Views and Parts Lists 42 Section 9 Mounting Dimensions 63 Section 10 Warranty 64 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 N be copied and posted near the unit s installation site Safety should be stressed to
75. n 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 Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifica tion or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied 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 ensur
76. nce of pertinent standards codes regu lations and laws the published information listed below may be used as installation guide for this equipment E NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76 ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK avail able from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCEOFFARM STANDBYELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 DX A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage This sta
77. nd all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Set the generator s AUTO OFF MANUAL switch to AUTO 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker 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 rated load and run the unit for one hour Run the unit for one hour at 50 rated load Run the unit for one hour at 75 rated load Run the unit for one hour at 100 rated load Turn ON the utility power supply to the transfer switch which will allow the transfer switch to transfer back to utility power The unit will con tinue to run for one minute and then shut down Allow the unit to cool 10 Set the generator s main circuit breaker to its OFF or OPEN position 11 Set the generator s AUTO OFF MANUAL switch to OFF Remove the 7 5A and 15 fuses from the generator control panel Disconnect the battery cables as outlined in General Hazards 12 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Replace the oil with synthetic oil as recommended in Section 4 3 Changing the Engine Oil
78. ndby generator set has been factory sup plied with a weather protective enclosure that is intended for outdoor installation only This UL listed standby generator set is packaged with an automatic transfer switch with built in load center The combination transfer switch and load center is pre wired with a two foot and 30 foot conduit Circuit breakers for emergency circuit connections are included This UL listed 2 pole switch is rated at 100 AC amperes at 250 volts maximum This transfer switch is for indoor use only amp AN If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electrical system from the utility dis tribution system when the generator is operat ing NEC 700 701 amp 702 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix their signature under the consignor s memo of loss or damage If a loss or damage is noted after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean dama
79. nger warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at one of the following addresses For Air cooled Product For Liquid cooled Product ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC GENERAC POWER SYSTEMS INC P O BOX 297 211 MURPHY DRIVE WHITEWATER WI 53190 EAGLE WI 53119 Part 1 ea Section 10 Warranty Air cooled 7 kW 12 kW and 15 kW Generators 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 equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equi
80. ngine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a pre set level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuses before working on or around the generator or transfer switch Then place a DO NOT OPERATE tag on the genera tor panel and on the transfer switch 3 5 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their UTILITY position i e loads con nected to the utility power source Figure 3 2 2 Be sure that normal UTILITY power source volt age is available to transfer switch terminal lugs and N2 3 Set the generator s AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Section 3 4 Sequence of Automatic Operation 3 3 1 12 VDC ACCESSORY OUTLET Your generator is equipped with a 12 VDC accessory outlet in the Generator Control Panel Figure 3 1 With the generator running or in standby mode this outlet may be used to temporarily power low power
81. nt must be open and unobstructed for con tinued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 4 9 for vent loca tions Figure 4 9 Cooling Vent Locations AIR lt 4 t AIR INTAKE 4 d e MAINTENANCE Section 4 Maintenance WARNING A The exhaust from this product gets extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system caution amp The maximum ambient temperature for the gen erator is 40 C 104 F 4 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it must not be started and operated Following any submer sion in water have an Authorized Dealer thoroughly clean and dry the generator 4 11 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 12 OUT OF SERVICE PROCEDURE 4 12 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and wil
82. of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries Remove the 7 5A and 15A fuses from the genera tor control panel e Remove watches rings or other metal objects e Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or disconnecting battery terminals wanNiNG 4 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 It is electrically conductive and corrosive The following procedures are to be observed e Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Air cooled 7 kW 12 kW and 15 kW Generators Lead acid ba
83. oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean engine oil to the gasket of the new filter See Section 1 5 1 for rec ommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 4 4 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 for oil capaci ties 5 Start the engine and check for leaks 4 5 CHANGING THE ENGINE AIR CLEANER 4 5 1 7 KW 12 KW AND 15 KW GENERATORS See Figures 1 1 and 1 2 for the location of the air cleaner Use the following procedure Figure 4 6 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box 5 Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule Section 4 13 for air cleaner maintenance See Section 1 5 1 for air filter replacement part number Figure 4 6 7 kW Engine Air Cleaner Location Fuel Air Cleaner Regulator 19 MAINTENANCE Section 4 Maintenance Figure 4 7 12 kW and 15 kW Engine Air Cleaner 4 6 SPARK PLUG S Reset the spark plug s gap or replace the spark plug s as necessary See Section 4 13 for mainte nance requirem
84. ontent of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water colum 0 18 to 0 25 psi and for liquid propane 10 inches to 12 inches of water column 0 36 to 0 43 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges 1 8 FUEL CONSUMPTION Nat Gas 1 2 Load Full Load 1 2 Load Full Load 0 82 30 66 1 53 56 04390 1 58 58 2 40 88 Natural gas is cubic feet hour LP is in gallons per hour cubic feet per hour Values given are approximate Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators GENERAL INFORMATION 1091 A Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 9 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 3 NOTE T
85. osity and classification Verify that the correct recommend ed oil is used in the engine see Section 4 3 1 If necessary drain and refill with the proper oil 3 Check the state of the battery Fill all cells of unsealed batteries to the proper level with dis tilled water DO NOT USE WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery oee Specifications Section 1 5 for type and size 4 Clean and wipe the entire generator o Remove the 7 5A and 15 fuses from the genera tor control panel Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 6 Open the fuel shutoff valve 7 Insert the 7 5A and 15A fuses into the generator control panel Start the unit by moving the AUTO OFF MANUAL switch to MANUAL Allow the unit to warm up thoroughly 8 Stop the unit by setting the AUTO OFF MANUAL switch to OFF 9 Turn on the utility power to the transfer switch 10 Set the AUTO OFF MANUAL switch to AUTO 11 The generator is now ready for service NOTE If the battery was dead or disconnected the exer cise timer must be reset Section 4 Maintenance Air cooled 7 kW 12 kW and 15 kW Generators MAINTENANCE 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
86. p switch 2 on the controller printed circuit board Remote Not Auto is ON 5 7 PROTECTION SYSTEMS 5 71 LOW OIL PRESSURE SWITCH This switch Figure 3 3 has normally closed con tacts that are held open by engine oil pressure dur ing cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added The AUTO OFF MANUAL switch must then be turned to OFF and then back to AUTO 5 72 HIGH TEMPERATURE SWITCH This switch s contacts Figure 3 3 close if the tem perature should exceed approximately 1409 C 2849 F initiating an engine shutdown The generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level Figure 3 3 Low Oil Pressure and High Temperature Switches Low Oil Switch High Temp Switch qo 5 7 5 This feature prevents the generator from damaging itself when it continually attempts to start and anoth er problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED on the generator control panel will light indicating an overcrank failure The AUTO OFF MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repai
87. pment AN Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and main tenance of this equipment is carried out by an Authorized Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator The generator MUST be installed outdoors When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued
88. pped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for
89. ps It will require a fre quency meter to perform this procedure 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 Allow the generator to start Before loading the generator confirm that the No Load Frequency with the roof open and door off is set to 63 63 5 Hz Transfer load to emergency circuits 3 Turn on appliances lights pumps etc that are on the emergency circuits in an attempt to fully load the generator Be cautious not to overload the generator Use the following chart as a guide 120 Volts 240 Volts 50 0 amps 100 0 amps 108 3 amps 54 1 amps 4 When 3 4 load has been achieved Connect a fre quency meter to the output lugs of the generator s main line circuit breaker 12 Section 2 Post Installation Start up and Adjustments Air cooled 7 kW 12 kW and 15 kW Generators The fuel regulator is fitted with one 7 kW or two 12 amp 15 kW adjustment screws While watch ing the frequency meter slowly turn the adjust ment screws clockwise or counterclockwise one at a time until the highest frequency is read on the meter Only limited adjustment is available because of the set pin Under no circumstances should any of the pins be removed Figures 2 1 and 2 2 Figure 2 1 Dual Fuel Regulators V twin 410 Adjustment Adjustment Set Screw x One Side Pin Bo
90. red the overcrank feature will continue to activate 3 7 3 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 17 MAINTENANCE Section 4 Maintenance 3 7 4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gen erator from supplying an output that could poten tially damage appliances connected to the generator circuit Contact the nearest Authorized Dealer if this failure occurs 4 1 FUSES The generator panel s 15 amp fuse Figure 4 1 pro tects the DC control circuit and the battery charge circuit against overload This fuse is wired in series with the battery output lead to the panel If this fuse element has melted open the engine will not be able to crank or start The generator will also lose all bat tery charge capabilities Replace this fuse using only an identical 15 amp replacement fuse To replace the fuse push the fuse holder cap down and rotate it counterclockwise The generator panels 7 5 amp fuse protects the 12 VDC accessory socket If the fuse element has melted open the 12 VDC socket will not be able to provide power to any accessories Replace this fuse using only an identical 7 5 amp replacement fuse To replace the fuse push the fuse holder cap down and rotate it
91. riod 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 Any equipment that the purchaser owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and main tenance is required Engine All Components Alternator All Components Transfer System All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks scrapes dents or scratches to the painted enclosure should be repaired promptly by the owner All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies
92. rt After the engine starts the circuit board signals the transfer switch to acti vate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs 1 2 Upon restoration of utility source voltage above a preset level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage 15 OPERATION Section 3 Operation lx Air cooled 7 kW 12 kW and 15 kW Generators If utility source voltage drops below about 60 percent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to the standby source C Standby Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored above 70 per cent of the nominal source voltage a retransfer time delay starts timing E
93. s AC 6 Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 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 switch 8 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 9 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator s main circuit breaker to its ON or CLOSED position A Dita A AN Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dan gerous and possibly fatal electrical shock 10 Connect an accurate AC voltmeter and a fre quency meter across transfer switch terminal lugs 1 and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz 11 Connect the AC voltmeter test leads across ter minal lug El and neutral then across E2 and neutral In both cases voltage reading should be 121 126 volts AC 12 Set the generator s main circuit breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine
94. th Sides 2 Only Set Pin Both Sides 6 When the highest frequency is reached maximum power has been set From this point turn both adjustment screws 1 4 turn counterclockwise The regulator is now set Figure 2 2 Placement of Regulator 55 Do 55059090006 ANN LAE m RRR Cus NM XX SS 5 MN MN NN ROY RY VN WY N 4 RRNA uh XX ROT Y Adjustment Screw 7 Turn utility power to the main distribution panel back on This can be done by switching the ser vice main breaker to the on or closed position Allow the generator to shut down wanNiNG Do not make any unnecessary adjustments Factory settings are correct for most applica tions However when making adjustments be careful to avoid overspeeding the engine gt Section 2 Post Installation Start up and Adjustments POST INSTALLATION Air cooled 7 kW 12 kW and 15 kW Generators STARTUP ADJUSTMENTS If this procedure or the equipment are not available locate the nearest Dealer and they can perform the adjustments NOTE A service fee may be charged for this adjustment 2 7 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low adjust the engine governor as follows 2 71
95. the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off spark ing can occur at the battery posts and cause an explosion 1 11 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Set the generator s AUTO OFF MANUAL switch to OFF 2 Turn off utility power supply to the transfer switch 3 Remove the 7 5A and 15A fuses from the genera tor control panel Battery cables were factory connected at the genera tor Figure 1 5 Connect cables to battery posts as follows Figure 1 5 Battery Cable Connections BLACK LEAD oa FROM FRAME RED LEAD FROM STARTER CONTACTOR ee i BATTERY Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators GENERAL INFORMATION 4 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a nega tive NEG or NOTE Damage will result if battery connections are made in reverse NOTE The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation With the battery installed and utilit
96. tteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off and the 7 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 8 ADJUSTING GH 410 GT 990 760 VALVE CLEARANCE After the first 6 months of operation adjust the valve clearance in the engine Important If feeling uncomfortable about doing this procedure or the proper tools are not available please contact the Authorized Dealer for service assistance This is a very important step to insure longest life for the engine To adjust valve clearance Make sure the engine is at room temperature Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Make sure the piston is at Top Dead Center TDC of its compression
97. y power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charger is designed to help extend the life of the battery by maintain ing the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 12 THE BATTERY DIT A 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 pre cautions are to be observed when working on batteries Remove the 7 5A and 15A fuses from the genera tor control panel Remove watches rings or other metal objects e Use tools with insulated handles e Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or disconnecting battery terminals amp 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 It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water e Where electrol
98. yte contacts the eyes flush thoroughly and immediately with water and seek medical attention and POST INSTALLATION START UP ADJUSTMENTS Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off and the 7 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as the cables are attached and cause an explosion Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from

Generac Power Systems 04389-3, 04456-3, 04390

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