Instruction/ maintenance manual of the product 04389-1, 04456-1, 04390-1 Generac
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PO WER SY STEMS, INC. ® GENERA C POWER SYSTEMS, INC. R R Installation and Owner’ s Man ual Air -cooled, Prepac kaged A utomatic Standb y Generator s 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) DEADL Y EXHAUST FUMES.
Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the Guardian product line by Generac P ower 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.
T able of Cont ents Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Generac ® Pow er Systems, Inc. 1 Introduction ........................Inside F ront Cover Read This Manual Thoroughly ........................IFC Contents ...................
2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained.
Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera- tion.
Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and r egulations.
Section 1 — General Information Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Generac ® Pow er Systems, Inc. 5 1.4 Y OU R GEN ER A T OR Control P anel Battery Compartment Fuel Regulator A.
6 Generac ® Pow er Systems, Inc. Section 1 — General Information Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1.5 SP E CI F ICA TIONS 1.5.
Generac ® Pow er Systems, Inc. 7 1 . 6 FUE L RE QUIRE MEN T S AN D R E C OM M EN D A TIONS W ith LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed above the liquid fuel in the storage tank.
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 .
Generac ® Pow er Systems, Inc. 9 Battery cables were factory connected at the genera- tor (Figure 1.5). Connect cables to battery posts as follows: 4. Connect the red battery cable (from starter con- tactor) to the battery post indicated by a positive, POS or (+).
10 Generac ® Pow er Systems, Inc. Be sure the utility power supply is turned off and the 5A and 15A fuses are r emoved from the generator control panel, or sparking may occur at the battery posts as you attach the cables and cause an explosion. 2.1 B EFOR E I N ITIAL S T ART -U P Before starting, complete the following: 1.
Generac ® Pow er Systems, Inc. 11 2.4 GEN ER A T OR TES TS UN DER L O AD T o 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. T urn OFF all loads connected to the transfer switch terminals T1 and T2.
12 Generac ® Pow er Systems, Inc. 3. T urn 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: 4. When full load has been achieved.
Generac ® Pow er Systems, Inc. 13 Section 3 — Operation Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 2.7 .2 1 2 KW AND 15 KW UN IT S 1. Loosen governor clamp bolt (See Figure 2.3). 2. Completely remove the idle spring . 3. W ith governor arm at wide open throttle position, rotate governor shaft fully clockwise.
14 Generac ® Pow er Systems, Inc. Section 3 — Operation Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 11. Drain the oil and remove the oil filter . Replace the oil filter according to Section 4.4, “Changing the Oil Filter” (P age 18).
Generac ® Pow er Systems, Inc. 15 D . Utility V oltage 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. Retransfer Time Delay • This timer runs for about 15 seconds.
16 Generac ® Pow er Systems, Inc. 1. V erify that the Auto/Off/Manual switch is set to A UTO . 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.
Generac ® Pow er Systems, Inc. 17 Figure 4.1 – Generator Control Panel 4.2 CH E CKI NG TH E ENGI N E OI L LEVEL F or oil capacities, see “Specifications,” Section 1.5 (P age 6). F or engine oil recommendations, see Section 4.3.1. T o check the engine oil level, proceed as follows (Figures 4.
18 Generac ® Pow er Systems, Inc. Figure 4.4 – Oil Drain Hose and Filter 4.4 CHANGI NG TH E OI L F I L TER Change the engine oil filter as follows: 1. W ith the oil drained, remove the old oil filter by turning it counterclockwise. 2. Apply a light coating of clean engine oil to the gas- ket of the new filter .
Generac ® Pow er Systems, Inc. 19 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 4.
20 Generac ® Pow er Systems, Inc. • Make sure the piston is at T op Dead Center (TDC) of its compression stroke (both valves closed). T o get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut.
Generac ® Pow er Systems, Inc. 21 4.1 2 OUT OF SERVICE P ROCEDU R E 4.1 2.1 REMOV AL F ROM SERVICE If you cannot exercise the generator every seven days, and it is to be out of service longer than 90 days, pre- pare the generator for storage as follows: 1.
22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 4.1 3 SERVICE S CH EDU LE A TTENTION: It is recommended that all service work be performed by your nearest Generac/Guar dian Authorized Dealer .
Generac ® Pow er Systems, Inc. 23 Section 5 — T roubleshooting Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 5.1 TROU B LE SHOO TI NG GUI DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. F use blown. 1. Replace 15A fuse in generator control panel.
24 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 1 2 & 15 kW – Drawing No. 0D85 00-A BATTERY CUS T O MER SU PPLIED 12V H T O B LA C K 86 LO P 85 IM2 L .E.
Generac ® Pow er Systems, Inc. 25 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 1 2 & 15 kW – Drawing No.
26 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 1 2 & 1 5 kW – Drawing No.
Generac ® Pow er Systems, Inc. 27 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 1 2 & 1 5 kW – Drawing No.
28 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 7 kW – Drawing No.
Generac ® Pow er Systems, Inc. 29 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 7 kW – Drawing No.
30 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 7 kW – Drawing No.
Generac ® Pow er Systems, Inc. 31 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 7 kW – Drawing No.
32 Generac ® Pow er Systems, Inc. A A 51 23 36 24 37 49 35 26 47 46 49 2 43 49 43 32 33 34 18 50 7 51 4 35 25 51 15 51 48 21 1 90 91 70 93 13 49 42 39 10 3 93 25 35 14 88 54 9 8 27 35 22 51 49 50 51 .
Generac ® Pow er Systems, Inc. 33 ITEM P ART NO .QTY . DESCRIPTION 1 0C6140 1 ASSEMBL Y , ENCLOSURE BASE (12KW / 15KW) 0D1901 1 ASSEMBL Y , ENCLOSURE BASE (7KW) 2 0C6735 2 SUPPORT , ROOF FOLDING 3 0C.
34 Generac ® Pow er Systems, Inc. 46 22 37 7 38 83 2 8, 9 27 44 47 0 13 19 14 15 35 17 49 14 15 5 3 4 16 23 36 39 38 45 48 2 28 29 17 16 4 6 7 23 27 42 12 45 44 20 40 11 1 43 35 14 30 29 28 3 41 24 4.
Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0A9947E 1 CIRCUIT BREAKER 30 X 2 240V SQD QOU230 (7KW) 0A9947G 1 CIRCUIT BREAKER 40 X 2 240V SQD QOU240 (8.
36 Generac ® Pow er Systems, Inc. 30 1 2 9 16 27 9 22 22 21 1 6 2 3 24 1 0 31 7 9 17 1 8 11 5 3 2 39 4 0 36 1 9 2 5 1 5 2 6 38 33 32 34 34 35 12 37 14 8 1 3 3B 3A Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW GT S Load Center Assembly – Drawing No.
Generac ® Pow er Systems, Inc. 37 ITEM P AR T NO . QTY . DESCRIPTION 1 0D4801 1 BO X GTS LOAD CENTER 2 0D4800 1 CO VER, 8 POSITION GTS LO AD CENTER 3 0C2237 1 TRANSFER SWITCH HOME ST ANDBY 100A2P250V.
38 Generac ® Pow er Systems, Inc. 30 1 16 27 9 22 22 21 16 2 3 24 1 0 31 7 9 17 1 8 6 11 5 3 2 39 4 0 36 1 9 2 5 1 5 2 6 38 41 33 32 34 34 35 42 37 12 14 8 1 3 3 B 3A Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW G TS Load Cent er Assembly – Drawing No.
Generac ® Pow er Systems, Inc. 39 ITEM P AR T NO . QTY . DESCRIPTION 1 0D3086 1 BO X GTS LOAD CENTER 2 0D3092 1 CO VER, 12 POSITION GTS LO AD CENTER 3 0C2237 1 TRANSFER SWITCH HOME ST ANDBY 100A2P250.
40 Generac ® Pow er Systems, Inc. 17 15 18 21 22 14 13 12 9 7 8 31 24 3 27 29 28 32 19 23 6 5 65 64 63 62 61 60 59 58 52 51 50 49 48 47 46 45 44 43 57 1 42 41 38 37 36 35 34 33 39 3 3 40 2 3 26 10 4 .
Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0C3008 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 8 SCREW , T APTITE M6-1.
42 Generac ® Pow er Systems, Inc. 112 112 111 108 107 106 105 104 103 102 100 109 99 92 95 96 91 89 90 89 88 86 85 83 84 82 81 130 99 118 114 126 94 93 117 79 78 76 77 75 74 122 125 123 125 119 120 1.
Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 74 0C5136A 2 KNOB, AIR CLEANER 75 0C3024 1 CO VER, AIRBO X NG/LP 76 0C3040 1 PRE-CLEANER, 77 0C8127 1 ELEMENT , AIR CLEANER 78 0D8564A 1 ASSEMBL Y , MIXER/AIRBO X 990 0D8564B 1 ASSEMBL Y , MIXER/AIRBO X 760 79 0D2595 4 SCREW SHOULDER (8MM) M6-1.
44 Generac ® Pow er Systems, Inc. 37 6 51 7 8 21 38 9 3 2 1 4 5 23 11 31 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 28 13 39 18 10 40 29 28 34 35 34 41 42 43 .
Generac ® Pow er Systems, Inc. 45 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator – Drawing No.
46 Generac ® Pow er Systems, Inc. 36 35 36 37 6 34 7 8 21 38 9 3 2 1 4 5 23 11 24 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 29 28 13 28 39 18 10 40 29 41 42 41 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator – Drawing No.
Generac ® Pow er Systems, Inc. 47 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator – Drawing No.
48 Generac ® Pow er Systems, Inc. 11 47 33 34 36 35 37 27 45 43 39 18 19 20 23 32 44 48 24 46 11 22 29 28 31 30 17 52 1 14 13 26 38 25 25 40 41 12 21 15 16 6 1 2 4 42 10 5 7 3 8 9 49 51 50 54 53 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine – Drawing No.
Generac ® Pow er Systems, Inc. 49 ITEM P AR T NO . QTY . DESCRIPTION 1 071978 1 ASSEMBL Y , CONNECTING ROD 2 071980 1 PIN, PIST ON D20 3 021533 1 SET , PIST ON RING 90MM 4 0C5848 1 PIST ON, HC 5 0719.
50 Generac ® Pow er Systems, Inc. 20 22 6 24 23 21 29 25 3 40 41 42 43 44 2 4 1 6 6 6 5 13 7 9 8 10 11 14 15 16 17 19 12 6 38 37 36 27 28 18 26 33 18 35 34 35 18 30 31 32 39 6 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine – Drawing No.
Generac ® Pow er Systems, Inc. 51 ITEM P AR T NO . QTY . DESCRIPTION 1 0C1069 5 SCREW , T APTITE M6-1.0X8 YELLO W CHROME 2 0D2922 1 HOUSING, BLO WER 3 0C8435 1 TUBE, DIPSTICK 4 0C9997 1 GU ARD , F AN.
ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA TOR HOUSING 2 0C5765 1 SOLENOID , TWIN REGULA TOR 3 0C4647 1 GASKET , SOLENOID 4 0C4680 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0C6070 1 SPRING-SOLENOID , PLUNGER 6 022985 4 W ASHER, FLA T #6 7 022264 4 W ASHER, LOCK M4 8 075475 4 SCREW PPHM M4-0.
Generac ® Pow er Systems, Inc. 53 Section 8 — Mounting Dimensions Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Drawing No. 0D3 7 3 9-B T M6PEM-T M6P M6PEM PE REAR VIEW L EFT S IDE VIEW T.
54 Generac ® Pow er Systems, Inc. Section 9 — Notes Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators.
Generac ® Pow er Systems, Inc. 55 Section 9 — Notes Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators.
56 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OUR W AR RANT Y R IGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine.
Generac ® Pow er Systems, Inc. 57 EM IS SION CONTROL S Y S TEM W AR R ANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines.
Part No. 0D8846 Re vision B (08/26/02) Printed in U.S.A. Section 1 0 – W arranty Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GEN ERAC PO WER SY STEMS S T AN D AR D "T WO YEAR" .
An important point after buying a device Generac 04389-1, 04456-1, 04390-1 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac 04389-1, 04456-1, 04390-1 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac 04389-1, 04456-1, 04390-1 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac 04389-1, 04456-1, 04390-1 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac 04389-1, 04456-1, 04390-1 will certainly help you make a decision on the purchase.
If you already are a holder of Generac 04389-1, 04456-1, 04390-1, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac 04389-1, 04456-1, 04390-1.
However, one of the most important roles played by the user manual is to help in solving problems with Generac 04389-1, 04456-1, 04390-1. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 04389-1, 04456-1, 04390-1 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
