Installation and Owner’s Manual 7, 10, 13 and 16kW Air-cooled, Automatic Standby Generators US C LISTED Models: 005240, 005280 (6 kW NG, 7 kW LP) 005241, 005281 (9 kW NG, 10 kW LP) 005242, 005282 (13 kW NG, 13 kW LP) 005243, 005244, (15 kW NG, 16 kW LP) 005283, 005284 Not intended for use as Primary Power in place of utility or in life-support applications. DANGER DEADLY EXHAUST FUMES.
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 during a utility power failure. This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation.
Table of Contents Air-cooled Generators Introduction ........................Inside Front Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance ............................ IFC How to Obtain Service..................................... IFC Authorized Dealer Locator Number ................... IFC Safety Rules ........................................................2 Standards Index ...................
IMPORTANT SAFETY INSTRUCTIONS Air-cooled Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators 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.
IMPORTANT SAFETY INSTRUCTIONS Air-cooled Generators ELECTRICAL HAZARDS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.
Section 1 — General Information Air-cooled Generators DANGER qualified electricians or contractors should Only 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 standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure that is intended for outdoor installation only.
Section 1 — General Information Air-cooled Generators 1.
Section 1 — General Information Air-cooled Generators 1.5 SPECIFICATIONS 1.5.1 GENERATOR Model Rated Max. Continuous Power Capacity (Watts*) Rated Voltage Rated Max.
Section 1 — General Information Air-cooled Generators 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 voltage is not connected to the unit or if it is below approximately 150-160 volts AC, then the system set light will flash rapidly.
Section 1 — General Information Air-cooled Generators 1.9 RECONFIGURING THE FUEL SYSTEM NOTE: Use an approved pipe sealant or joint compound on all threaded fittings to reduce the possibility of leakage. 1.9.1 7 KW, 410CC ENGINE To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.4): NOTE: The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 10 to 12 inches of water column (0.36 to 0.
Section 1 — General Information Air-cooled Generators Figure 1.5 - 10kW, GT-530 (Inlet Hose Slid Back) Figure 1.8 - 13/16kW, GT-990 (Airbox Cover Removed) Fuel Selection Lever - "Out" Position for Liquid Propane (Vapor) Fuel Fuel Selection Lever - "In" Position for Natural Gas Fuel Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) 1.10 LOCATION 1.10.1 GENERATOR Fuel Selection Lever - "Out" Position for Liquid Propane (Vapor) Fuel Figure 1.
Section 1 — General Information Air-cooled Generators • Install the generator as close as possible to the fuel supply, to reduce the length of piping. • Install the generator as close as possible to the transfer switch. REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION. • The genset must be installed on a level surface. The base frame must be level within two (2) inches all around. • The generator is typically placed on pea gravel or crushed stone.
Section 1 — General Information Air-cooled Generators Figure 1.10 – Battery Cable Connections not open or mutilate the battery. Released Do electrolyte has been known to be harmful to the skin and eyes, and to be toxic. electrolyte is a dilute sulfuric acid that is The harmful to the skin and eyes. It is electrically conductive and corrosive.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 2.1 BEFORE INITIAL START-UP Figure 2.1 – Remove Air Filter Cover NOTE: These units have been run and tested at the factory prior to being shipped and do not require any type of break-in. 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.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 2.3 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 breakers on the load center of the transfer box (T1 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).
Section 2 — Post Installation Start-up and Adjustments • 10, 13 & 16kW voltage should be greater than 240 volts and frequency should be greater than 60 Hz. 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.
Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 6. When the highest frequency is reached maximum power has been set. From this point turn the adjustment screw 1/4 turn counterclockwise. The regulator is now set. 7. Turn utility power to the main distribution panel back on. This can be done by switching the service main breaker to the on or closed position. Allow the generator to shut down. not make any unnecessary adjustments.
Section 3 — Operation Air-cooled Generators Figure 2.5 – Voltage Adjustment Potentiometer 3.1.3 “MANUAL” POSITION Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure. the switch set to AUTO, the engine may With crank and start at any time without warning. Such automatic starting normally occurs when utility power source voltage drops below a preset level or during the normal exercise cycle.
Section 3 — Operation Air-cooled Generators 3.3 SEQUENCE OF AUTOMATIC OPERATION The generator’s control panel houses a control logic circuit board. This board constantly monitors utility power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start.
Section 3 — Operation Air-cooled Generators 3.4.2 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.
3.6.2 HIGH TEMPERATURE SWITCH This switch’s contacts (Figure 3.3) close if the temperature should exceed approximately 144º C (293º 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.
4.1 FUSES Figure 4.2 — Oil Dipstick and Fill, 7kW The 15-amp fuse on the generator panel protects the DC control circuit against overload (Figure 4.1). This 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. 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.
Section 4 — Maintenance Air-cooled Generators 4.3 CHANGING THE ENGINE OIL Figure 4.5 – Oil Drain Hose and Filter 4.3.1 OIL CHANGE INTERVALS Low Oil Switch High Temp Switch See the "Service Schedule" section. 4.3.2 ENGINE OIL RECOMMENDATIONS All oil should meet minimum American Petroleum Institute (API) Service Class SJ, SL or better. Use no special additives. Select the oil's viscosity grade according to the expected operating temperature.
Figure 4.
4.6 BATTERY MAINTENANCE The battery should be inspected per the "Service Schedule" section. 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 battery hydrometer.
To adjust valve clearance (if necessary): 4.8 • Make sure the engine is at 60° to 80° F. • 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. • 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).
Section 4 — Maintenance Air-cooled Generators 4.10 CORROSION PROTECTION 4.11.2 RETURN TO SERVICE Periodically wash and wax the enclosure using automotive type products. Frequent washing is recommended in salt water/coastal areas. Spray engine linkages with a light oil such as WD-40. To return the unit to service after storage, proceed as follows: 4.11 OUT OF SERVICE PROCEDURE 4.11.
Section 4 — Maintenance Air-cooled Generators 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed.
Section 5 — Troubleshooting Air-cooled Generators 5.1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Tighten, clean or replace as necessary. 3. * 4. * 5. Charge or replace battery. 2. Loose, corroded or defective battery cables. 3. Defective starter contactor. (7 kW) 4. Defective starter motor. 5. Dead Battery. The engine cranks but will not start.
Section 6 — Notes Air-cooled Generators 28
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Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No.
Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431-D SHEET METAL PAINT/MATERIAL CODE LEGEND The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct color and material information must be included as a suffix at the end of the part number as shown below. Material Color Example: Desc. Part No.
Section 8 — Exploded Views and Parts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431-D ITEM PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators Control Panel – Drawing No. 0F9695-F ITEM PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators Transfer Switch Assembly – Drawing No. 0F9774-C ITEM PART NO. QTY. DESCRIPTION 1 2 3 0F8278 0D4800 0F5211 0D3092 0F8312 0C2237 1 1 1 1 1 1 3A 3B 3C 3D 077220 077220A 082574 084464 1 1 1 1 4 5 6 7 8 074908 024912 0A1658 063617 0E7889A 0E7889 6 1 1 1 1 1 0F9213 0A1495 0A1661 022473 081108 0D4684 0D4684A 0F8279 0F4790 022152 064526 0E6155 063378 0G0979 1 4 2 1 1 1 1 1 10.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 1 ITEM PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Engine – Drawing No. 0G3071-J - Part 2 ITEM PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 1 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 PART NO.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 2 ITEM PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 1 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 2 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 PART NO.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9422-C ITEM 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52 53 54 55 56 57 58 59 PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 10, 13, and 16kW, V-twin Generators – Drawing No. 0G4392-A ITEM PART NO. QTY.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 7 & 10kW, GN-410/GT-530 Regulator – Drawing No. 0F9425-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART NO.
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Section 8 — Exploded Views and Parts Lists Air-cooled Generators 13 & 16kW, GT-990 Regulator – Drawing No. 0F9426-A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 PART NO. 0F9285 0F5022 0C4647 0D4166 0F8096 022145 022129 0F4795 045771 0C6606 042907 026915A 0C5761 0C5968 0C6066 0C5759 0C5764 070728 0C6069 0F9189 045764 0C6731 0C6067 0C4706 0C6068 0C4643A 072683 049226 0D3308 051713 0F8979 051716 0E9533 0E9534 0E9535 QTY.
Section 10 – Warranty Air-cooled Generators NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.
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Section 10 – Warranty Air-cooled Generators GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN® "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below.