® POWER SYSTEMS, INC. Installation and Owner’s Manual Air-cooled, Prepackaged Automatic Standby Generators Models: 04389-1 (6 kW NG, 7 kW LP) 04456-1 (12 kW NG, 12 kW LP) 04390-1 (13 kW NG, 15 kW LP) GENERAC R POWER SYSTEMS, INC. R ! 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 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Introduction ........................Inside Front Cover 3.2.2 “Off” Position ....................................14 Read This Manual Thoroughly ........................IFC Contents ..........................................................IFC Operation and Maintenance ............................IFC How to Obtain Service ....................................IFC Authorized Dealer Locator Number ....................IFC 3.2.
IMPORTANT SAFETY INSTRUCTIONS Guardian Air-cooled 7 kW, 12 kW and 15 kW 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: ! GENERAL HAZARDS ! ! 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 Guardian Air-cooled 7 kW, 12 kW and 15 kW 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 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators DANGER 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 standby generator set has been factory supplied with a weather protective enclosure that is intended for outdoor installation only.
Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1.4 YOUR GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Control Panel Data Decal Exhaust Enclosure Air Filter Fuel Regulator Oil Filter Battery Compartment Figure 1.2 – 12 kW and 15 kW, V-twin GT-990 Engine Oil Dipstick Data Decal Air Filter Control Panel Exhaust Enclosure Fuel Regulator Battery Compartment Oil Filter Generac® Power Systems, Inc.
Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1.5 SPECIFICATIONS 1.5.1 GENERATOR Rated Max. Continuous Power Capacity (Watts*) Rated Voltage Rated Max.
Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 1.6 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.
Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 5. Remove the small brass hose fitting from the idle circuit port of the regulator housing. 6. Remove the small jet (0D5698A) located in the side of the regulator housing and install it into the small threaded hole in the idle circuit port on the regulator. 7. Refit the brass hose fitting to the idle circuit port of the regulator. Use pipe thread sealant to reseal the threads on the hose fitting. 8.
Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Battery cables were factory connected at the generator (Figure 1.5). Connect cables to battery posts as follows: 4. Connect the red battery cable (from starter contactor) 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 negative, NEG or (—). NOTE: Damage will result if battery connections are made in reverse. Figure 1.
Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Be sure the utility power supply is turned off and the 5A and 15A fuses are removed from the generator control panel, or sparking may occur at the battery posts as you attach the cables and cause an explosion. 2.1 BEFORE INITIAL START-UP Before starting, complete the following: 1. Set the generator’s main circuit breaker to its OFF (or open) position. 2.
Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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 T1 and T2. 3. Set the generator's Auto/Off/Manual switch to OFF. 4.
Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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: Unit 7 kW 12 kW 15 kW 120 Volts 50.0 amps 100.0 amps 108.3 amps 240 25.0 50.0 54.1 Volts amps amps amps 4. When full load has been achieved.
Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators ◆ 2.7.2 12 KW AND 15 KW UNITS Figure 2.5 – Voltage Adjustment Potentiometer 1. Loosen governor clamp bolt (See Figure 2.3). 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 2.4) to adjust frequency to 58 Hz. 5.
Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 11. Drain the oil and remove the oil filter. Replace the oil filter according to Section 4.4, “Changing the Oil Filter” (Page 18). Replace the oil with synthetic oil as recommended in Section 4.3, “Changing the Engine Oil” (Page 17). 12. Reconnect the battery cables as outlined in “General Hazards” (page 2) and insert the 5A and 15A fuses into the generator control panel. The generator is now ready for service. 3.
Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators D.Utility Voltage Pickup Sensor • This sensor monitors utility power supply voltage. When that voltage is restored above 70 percent of the nominal source voltage, a retransfer time delay starts timing. E.Retransfer Time Delay • This timer runs for about 15 seconds. • At end of a 15-second delay, circuit board action de-energizes transfer relay in the transfer switch. • Retransfer to utility power source then occurs. F.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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 approximately 12 minutes and then shut down on its own. The exerciser will then be set to run at that time of day every week.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Figure 4.3 — Oil Dipstick and Fill, 12 kW and 15 kW Figure 4.1 – Generator Control Panel FUSE R Locat e y our near est Oil Dipstick d e a le r a t : R POWER SYSTEMS, INC. 5A AUTO OFF SYSTEM SET MAN. LOW OIL HIGH TEMP. FUSE OVER SPEED OVER CRANK 15A 4.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Figure 4.4 – Oil Drain Hose and Filter Low Oil Switch Figure 4.6 — 7 kW, Engine Air Cleaner Location High Temp Switch Air Cleaner Fuel Regulator Loos en Oil Drain Hose Oil Filter 4.4 Figure 4.7 — 12 kW and 15 kW Engine Air Cleaner CHANGING THE OIL FILTER Change the engine oil filter as follows: 1. With the oil drained, remove the old oil filter by turning it counterclockwise. 2.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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 / 0.50 mm (0.030 inch / 0.020 inch) • • • • 4.7 The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators • Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. 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.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 4.12 OUT OF SERVICE PROCEDURE 4.12.2 RETURN TO SERVICE 4.12.1 REMOVAL FROM SERVICE To return the unit to service after storage, proceed as follows: If you cannot exercise the generator every seven days, and it is to be out of service longer than 90 days, prepare the generator for storage as follows: 1. Start the engine and let it warm up. 2.
Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 4.13 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by your nearest Generac/Guardian Authorized Dealer. SYSTEM/COMPONENT X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed.
Section 5 — Troubleshooting Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 5.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE The engine will not crank. 1. Fuse blown. 2. 3. 4. 5. 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. CORRECTION 1. Replace 15A fuse in generator control panel. Loose, corroded or defective 2.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No.
Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0D3416-K ITEM PART NO.QTY.
Section 7 — Exploded Views and Parts Lists 29 28 36 31 30 39 35 3 17 13 17 4 19 45 44 47 27 0 38 37 7 22 46 14 15 2 48 29 28 35 6 38 7 16 23 27 8 32 8,9 34 Generac® Power Systems, Inc. 5 15 14 34 23 16 12 3 40 20 49 43 13 45 44 42 1 41 11 14 47 45 24 45 31 47 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0D8503-E ITEM PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW GTS Load Center Assembly – Drawing No. 0D3997-E 31 37 7 9 17 11 5 2 18 3A 29 36 24 10 22 16 30 9 27 15 13 1 3 19 25 3B 22 40 12 16 21 23 26 14 38 33 32 8 34 35 34 36 Generac® Power Systems, Inc.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW GTS Load Center Assembly – Drawing No. 0D3997-E ITEM 1 2 3 3A 3B 3C 3D 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 PART NO.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D 12 31 37 7 9 17 6 11 5 2 18 3A 22 16 30 9 36 24 10 27 15 13 1 3 19 25 3B 22 40 42 16 21 23 26 14 38 41 8 33 35 32 34 34 38 Generac® Power Systems, Inc.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D ITEM 1 2 3 3A 3B 3C 3D 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No. 0D8674-C Part 1 ITEM PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0D8674-C Part 2 74 138 75 122 124 76 139 125 135 136 123 77 137 120 125 79 124 133 78 132 131 119 80 134 115 116 127 114 117 121 81 130 82 118 97 98 126 99 96 95 83 128 129 100 102 84 86 85 88 89 109 103 93 87 105 104 94 97 98 99 112 90 110 106 101 89 91 92 107 112 108 112 113 111 42 Generac® Power Systems, Inc.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0D8674-C Part 2 ITEM PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-B 36 45 30 47 49 50 48 46 44 34 42 41 6 43 34 51 35 40 34 7 29 1 37 31 18 2 39 28 3 26 21 8 4 38 24 25 9 22 32 30 20 12 32 31 28 23 11 52 17 38 31 17 10 10 14 5 19 28 10 15 16 27 19 32 33 31 13 28 31 32 44 Generac® Power Systems, Inc.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-B ITEM PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-B 36 35 36 6 34 40 41 42 41 29 7 1 37 28 2 39 3 29 26 21 8 4 38 24 22 32 30 20 12 32 31 28 23 11 17 10 17 38 31 19 10 14 5 18 25 9 28 10 15 16 27 19 32 33 24 13 28 31 32 46 Generac® Power Systems, Inc.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-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 38 39 40 41 42 PART NO. QTY.
Section 7 — Exploded Views and Parts Lists 42 10 17 50 31 25 28 27 37 24 35 36 23 44 33 45 43 39 19 18 20 34 46 11 32 22 48 47 26 41 38 29 30 25 12 51 40 21 13 14 15 53 49 1 6 54 16 52 1 2 5 4 3 7 11 8 9 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0D3539-B Part 1 48 Generac® Power Systems, Inc.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0D3539-B Part 1 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.
Section 7 — Exploded Views and Parts Lists 27 24 5 23 50 Generac® Power Systems, Inc. 6 13 7 20 6 6 21 42 43 44 22 41 3 40 39 6 29 15 18 19 17 16 14 8 9 30 32 25 31 6 11 10 12 28 33 26 1 36 35 18 18 35 34 2 37 38 4 6 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0D3539-B Part 2 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 PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-B 10 8 7 34 33 2 6 36 21 5 10 20 37 32 4 37 3 25 24 23 10 1 22 35 FOR GT 760 ENGINE ONLY 19 16 26 29 18 15 14 12 11 28 17 19 13 27 31 32 12 23 22 26 15 14 11 25 29 18 20 16 17 28 24 13 9 21 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NO. QTY.
716 [28 743 [29 M6PEM M6P M6PEM-T PE T LEFT SIDE VIEW 622 [24.5"] 604 [23.5"] 76.2mm [3.00"] PEA GRAVEL MINUMUM 704 [27.7"] 207 [8.14"] TRANSFER SWITCH (IF SUPPLIED) 308 [12"] FRONT VIEW 1232 [48.5"] 1193 [47"] "DO NOT LIFT BY THE ROOF" LIFTING HOLES 4-CORNERS Ø30.2mm [Ø1.19"] 149 [5.9"] RIGHT SIDE VIEW 490.7 [ AIR 260 [10.2"] **ALL DIMENSIONS IN: MILLIMETERS [INCHES] REAR VIEW ROUNDING LUG CABLE ACCESS HOLES.
Section 9 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 54 Generac® Power Systems, Inc.
Section 9 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Generac® Power Systems, Inc.
Section 10 – Warranty Guardian 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 explain the Emission Control System Warranty on your new engine.
Section 10 – Warranty Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Section 10 – Warranty Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GENERAC POWER SYSTEMS STANDARD "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN® "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years Generac Power Systems, Inc.