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Generac 04390-0, 04456-0, 04390-0 manual

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Table of contents for the manual

  • Page 1

    [...]

  • Page 2

    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. This unit is fa[...]

  • Page 3

    T able of Contents 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 ..........................................................IFC Operation and Maintenance ............................IFC[...]

  • Page 4

    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. Many accidents are caused by failing to fo[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA ZAR 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. A void contact with bare wires, te[...]

  • Page 6

    Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and r egulations. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been factory sup- plied with a weather protective enclosure that is i[...]

  • Page 7

    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[...]

  • Page 8

    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 1.5.1 GEN ERA T OR Model 04389 Model 04456 Model 04390 Rated Max. Continuous P ower Capacity (W atts*) 6,000 NG/7,000 LP 10,000 NG/12,000 LP 13,000 NG/15,000 LP† Rated V oltage 120/240 120/240 120/240[...]

  • Page 9

    Generac ® Pow er Systems, Inc. 7 1 . 6 FUE L RE QUIRE ME N T S AN D REC OMM EN D A TIONS 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 Resource[...]

  • Page 10

    3. The unit has been factory set to run on NG fuel. T o reset the system to run on LP fuel, turn the two adjustment screws 1/2 turn clockwise. Use a large screwdriver to make this adjustment. Be sure to replace the plastic plug in the back of the enclosure once the adjustment has been made. 4. The fuel system will now allow the engine to run on LP [...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 NOTE: Y our generator is equipped with a battery trickle charger that is active when your unit is set up for automatic operation. W ith the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running , to prevent self- di[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. 2.2 CH E CK TRANSF ER SWIT CH OP ER A TION Refer to Section 3.5 (P age 14), of the owner’s manual for manual operation procedures. 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 suppl[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 8. T urn ON electrical loads. Apply an electrical load equal to the full rated wattage/amperage capacity of the installed generator . 9. Connect an accurate AC frequency meter across terminal lugs E1 and E2. V oltage should be greater than 230 volts; frequency should be greater than 58 Hertz. 10. Let the generator[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Figure 2.2 — Placement of Regulator 7. T urn utility power to the main distribution panel back on. This can be done by switching the serv- ice main breaker to the on or closed position. Allow the generator to shut down. Do not make any unnecessary adjustments. Factory settings are corr ect for most applica- tion[...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 Section 3 — Operation Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 2.7 .3 ADDITIONAL COR ROSION P RO TECTION P eriodically spray all engine linkage parts and brack- ets with corrosion inhibiting spray such as WD -40 or a comparable product. 2.8 V OL T A GE R E GUL A T OR ADJ US TM ENT W ith the freque[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. Section 3 — Operation Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators With the switch set to AUTO, the engine may crank and start at any time without warning. Such automatic starting normally occurs when utility power source voltage dr ops below a pre- set level or during the normal exercise cycle. T o p[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 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 extr emely hazardous and possibly fatal electrical shock. 4. Use the manual transfer handle inside the trans- fer swit[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 3.7 P RO TECTION S Y S TEMS 3.7 .1 LO W OIL P R E S SU RE SWIT CH This switch (Figure 3.3) has normally closed contacts that are held open by engine oil pressure during crank- ing and operating . Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not b[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine. 4. Install the dipstick. 5. Reset the Auto/Off/Manual switch to its original position. Figure 4.2 — Oil Dipstick and Fill, 7 kW Figure 4.3 — Oil Dipstick and Fill, 12 kW and 15 kW 4.3 CHANG[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. 4.5 CHANGI NG THE ENGI N E AI R CLEANER 4.5.1 7 KW , 1 2 KW AN D 1 5 KW GEN ERA T ORS See Figures 1.2 and 1.3, (P age 5), for the location of your air cleaner . Use the following procedure (Figure 4.6): 1. T urn the two screws counterclockwise to loosen. 2. Remove the cover and air filter . 3. W ipe away dust or d[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 • Remove watches, rings or other metal objects; • 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 sour ce prior to connecting or dis- connecting battery terminals. Do not open or mutilate the battery . Re[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Figure 4.10 - V alve Clearance Adjustment • Install new valve cover gasket. • Re -attach the valve cover . NOTE: Start all four screws before tightening or you will not be able 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 . ?[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 4.1 2 OUT OF SERVICE P ROCEDUR E 4.1 2.1 R EMO V 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. Start the engine and let it warm up. 2. Close the fuel shutoff valve in the fuel supply lin[...]

  • Page 24

    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 . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = W eekly R = Rep[...]

  • Page 25

    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 GU I DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective s[...]

  • Page 26

    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 – 12 & 15 k W – Drawing No. 0C783 0-B[...]

  • Page 27

    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 – 12 & 15 k W – Drawing No. 0C783 0-B[...]

  • Page 28

    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 – 12 & 15 k W – Drawing No. 0C783 6-B[...]

  • Page 29

    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 – 12 & 15 k W – Drawing No. 0C783 6-B[...]

  • Page 30

    TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) ENGINE WIRING IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TB - INSULATED TERMINAL BLOCK RAR - REMOTE ALARM RELAY BCR - BATTERY CHARGE RELAY BA - BRUSH ASSEMBLY CB1 - MAIN OUTPUT BREAKER CB[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29[...]

  • Page 32

    IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) RAR - REMOTE ALARM RELAY CB1 - CIRCUIT BREAKER, MAIN OUTPUT FS - FUEL SOLENOID F1 - FUSE 15 AMP HTO - HIGH OIL TEMPERATURE SWITCH HM - HOUR RUN [...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 2 15 34 J2 2 1 3 2 1 8 14 16 17 15 11 13 12 10 9 J1 7 5 6 3 4 2 1 229 224A 239 15A 0 15 18 240V IM 0 15 194 13 17 17 15B 15 23 15 239 SW1 194 178 15A 229 N1 N2 183 22 11 23 11 22 229 RAR 15B 11 SP 44 POWER WINDING 120V 120V 33 NEUTRAL N2 N1 23 CUSTOMER CONNECTIONS 211 178 183 194 210 0 17 0 SC FS HM 56 14 BATTERY [...]

  • Page 34

    32 Generac ® Pow er Systems, Inc.[...]

  • Page 35

    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 0C7061 1 ENCLOSURE, FRONT 4 0C7062 1 ENCLOSURE, EXHA UST SIDE (12KW / 15KW) 0C7062A 1 ENCLOSURE, EXHA UST SIDE (7KW) 5 0C7063 1 ENCLOSURE, SIDE & B[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. 21 23 17 22 17 37 38 8,32 8,9 27 4 16 24 10 13 19 14 15 35 11 25 17 31 14 15 5 34 16 23 36 39 38 16 31 23 2 28 29 21 17 16 4 6 7 31 23 27 42 12 45 44 20 40 33 1 43 15 35 14 30 29 28 3 28 29 41[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0A9947E 1 CIRCUIT BREAKER 30 X 2 240V SQD QOU230 (7KW) 0A9947F 1 CIRCUIT BREAKER 50 X 2 240V SQD QOU245 (12KW) 0A9947C 1 CIRCUIT BREAKER 60 X 2 240V SQD QOU260 (13KW) 2 0A18010SR V 1 ASSEMBL Y , BA TTER Y CHARGER ENGINE 3 0830490SR V 1 ASSEMBL Y , POTTED REGULA TOR W/FIN 4 0C217[...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. 30 1 29 23 16 27 9 22 22 21 16 23 24 10 31 7 9 17 18 4 6 11 5 3 2 39 40 4 36 19 25 15 26 38 33 32 34 34 35 12 37 14 8 13[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0D4801 1 BO X GTS LO AD CENTER 2 0D4800 1 CO VER, 8 POSITION GTS LO AD CENTER 3 0C2237 1 TRANSFER SWITCH HOME ST ANDBY 100A2P250V 4 074908 6 SCREW T APTITE M5-0.8 X 10 BP 5 024912 1 SCREW T APTITE 1/4-20 X 5/8 BP 6 0A1658 1 LOCK W ASHER, SPECIAL-1/4" 7 063617 1 RELA Y P ANE[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. 30 1 29 23 16 27 9 22 22 21 16 23 24 10 31 7 9 17 18 4 6 11 5 3 2 39 40 4 36 19 25 15 26 38 41 33 32 34 34 35 42 37 12 14 8 13[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 1 0D3086 1 BO X GTS LO AD CENTER 2 0D3092 1 CO VER, 12 POSITION GTS LO AD CENTER 3 0C2237 1 TRANSFER SWITCH HOME ST ANDBY 100A2P250V 4 074908 6 SCREW T APTITE M5-0.8 X 10 BP 5 024912 1 SCREW T APTITE 1/4-20 X 5/8 BP 6 0A1658 1 LOCK W ASHER, SPECIAL-1/4" 7 063617 1 RELA Y P AN[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. 17 16 15 18 21 22 14 13 12 9 7 8 31 24 3 27 29 28 32 19 23 6 5 64 63 62 61 60 59 58 57 52 51 50 49 48 47 46 45 44 43 53 54 55 56 1 42 41 38 37 36 35 34 33 39 3 3 40 2 3 26 10 4 34 25 11 30 20 65 2, 5, 19, 20, 39, 40, 47, 63, 92, 141 8, 11, 12, 13 66 4, 5, 6 67 16, 17, 18 68 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, [...]

  • Page 43

    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 M6-1.0 X 12 BP 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER COVER 6 0C3003 3 SEP ARA TOR, OIL BREA THER 7 0C2231 1 ASSEMBL Y , HEAD #1 G&S 8 [...]

  • Page 44

    42 Generac ® Pow er Systems, Inc.[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 73 0C5136A 2 KNOB, AIR CLEANER 74 0C3024 1 CO VER, AIRBO X NG/LP 75 0C3040 1 PRE-CLEANER, 76 0C8127 1 ELEMENT , AIR CLEANER 77 0C7720 1 MIXER / AIRBO X, ASSEMBL Y 78 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18 79 0D4417 4 W ASHER,R UBBER 1/4" X 1/8" THICK 80 0C3025 1 SWITC[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc.[...]

  • Page 47

    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. 0D35 04-B ITEM P ART NO . QTY . DESCRIPTION 1 0C6934 1 AD APT OR, ENGINE 2 0C9935H 1 ST A T OR 3 0C9934H 1 RO T OR 4 0C6043A 1 CARRIER, REAR BEARING 5 0C8096 1 F AN, 8" CUR VED [...]

  • Page 48

    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 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. 0D3 4 1 7-[...]

  • Page 49

    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. 0D3 4 1 7-A ITEM P ART NO . QTY . DESCRIPTION 1 0C6934 1 AD APT OR, ENGINE 2 0C7930 1 ST A T OR 12KW 0D2359 ST A TOR 15KW 3 0C7944 1 RO T OR 12KW 0D2356 R O T OR 15KW 4 [...]

  • Page 50

    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[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 ITEM P ART 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 071983 2 RET AINER, PIST ON PIN 20 6 0D4287 1 ASSEMBL Y , CRANKSHAFT GH410 SMALL T APER 7 0A7628 1 ARM, GOVERNOR RC45 8 078658 1 PIN, "R" GO VERN[...]

  • Page 52

    50 Generac ® Pow er Systems, Inc.[...]

  • Page 53

    Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 0C1069 5 SCREW , T APTITE M6-1.0X8 YELLO W CHROME 2 0D2922 1 HOUSING, BLOWER 3 0C8435 1 TUBE, DIPSTICK 4 0C9997 1 GUARD , F AN 5 088434 1 WRAPPER, BO TT OM 6 045756 11 SCREW , T APTITE M6-1X10 YELLO W CHROME 7 088433B 1 WRAPPER, TOP 8 0C3794 1 BUMPER, NEOPRENE 9 021544 1 ST ARTE[...]

  • Page 54

    ITEM P ART NO . QTY . DESCRIPTION 1 0C5322 1 CASTING, TWIN REGULA TOR HOUSING 2 0C5765 1 SOLENOID , TWIN REGULA T OR 3 0C4647 1 GASKET , SOLENOID 4 0C4680 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0C6070 1 SPRING-SOLENOID , PLUNGER 6 022985 4 WASHER, FLA T #6 7 022264 4 WASHER, LOCK M4 8 075475 4 SCREW PPHM M4-0.7 X 10 9 0C5760D 2 JET , GN 990 ENGINE L[...]

  • Page 55

    Generac ® Pow er Systems, Inc. 53 Section 8 — Notes Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators[...]

  • Page 56

    54 Generac ® Pow er Systems, Inc. Section 8 — Notes Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators[...]

  • Page 57

    Generac ® Pow er Systems, Inc. 55 Section 9 — Mounting Dimensions Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Drawing No. 0D3 7 3 9-A TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM CBHOM-F CBHOM-F 120/240v 120/240v TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F C[...]

  • Page 58

    56 Generac ® Pow er Systems, Inc. CALI FORN IA EM IS SION C ONTROL W AR R ANTY ST A TEM ENT Y OU R W AR R ANT Y RIGHTS 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. * In California, new utility , and lawn and ga[...]

  • Page 59

    Generac ® Pow er Systems, Inc. 57 EM IS SION C ONTROL SY S TEM W ARR ANTY 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. The ECS W arranty Period shall begin on the date the new engine or equipment is purchased by/delivered [...]

  • Page 60

    GEN ERAC PO WER S YS TEMS "TWO YEAR" S T AN D ARD W ARR ANT Y FOR GUARDIAN ® "P REP ACKAGED EMERGENCY AUT OMA TIC ST AN DB Y GEN ERA T ORS" F or a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, Generac P ower Systems, Inc. (Generac) will, at its option, repair or replace a[...]