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GENERA C POWER SYSTEMS, INC. R R Installation and Owner’ s Man ual 7, 10, 13 and 16kW Air -cooled, A utomatic Standby Generator s 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 D ANGER DEADL Y EXHAUST FUMES.
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 Air-cooled Generators 1 Introduction ........................ Inside F ront Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance .
2 Study these SAFETY RULES carefully before install- ing, 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.
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.
D ANGER Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and r egu- lations. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for damage.
Section 1 — General Information Air-cooled Generators 5 1.4 TH E GEN ER A T OR Air Filter Cover Control Pan el Fuel Regulator Battery Compartment Oil Filter Exhaust Enclosure Oil Dipstick Data Decal.
6 Section 1 — General Information Air-cooled Generators 1.5 SP E CI F ICA TIONS 1.5.1 GEN ERA T OR Model 05240 & 05280 05241 & 05281 05242 & 05282 05243 & 05244 05283 & 05284 Rated Max.
7 1.6 S Y S TEM SE T LED The “System Set ” LED is lit when all of the following conditions are true: 1. The AUTO/OFF/MANU AL switch is set to the A UTO position.
1.9 R E C ON F IGU R I NG TH E F U E L SYST E M 1.9.1 7 KW , 4 1 0CC ENGIN E T o reconfigure the fuel system from NG to LP , follow these steps (Figure 1.4): NOTE: The primary regulator for the propane supply is NOT INCL UDED with the generator . A fuel pres - sure of 10 to 12 inches of water column (0.
9 Figure 1.5 - 10kW , GT -530 (Inlet Hose Slid Back) Figure 1.6 - 10kW , GT -530 (Inlet Hose Slid Back) Figure 1.7 - 13/16kW , GT -990 (Airbox Cover Removed) Figure 1.
10 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 THA T LA WS OR CODES MA Y REGULA TE THE DIST ANCE AND LOCA TION . The genset must be installed on a level surface.
11 Figure 1.10 – Battery Cable Connections NOTE: In areas where temperatures regularly fall below 10° F (-12° C) it is recommended that a pad type battery heater be installed to aid in cold climate starting (see Specifications).
12 2.1 B EFOR E I N ITIAL S T ART -UP NOTE: These units have been run and tested at the fac- tory 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.
13 Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 2.4 GEN ER A T OR T ESTS U N 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.
14 1. T urn 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 F requency , with the roof open and door off, is set to 63-63.
15 4. Connect a frequency meter across the generators AC output leads. 5. T urn the primary adjust screw to obtain a fre - quency reading of 61.5 Hertz. T urn the secondary adjust screw to obtain a frequency of 62.5 Hz. 6. When frequency is correct at no load, check the AC voltage reading .
16 3.1.4 CHOKE OP ER A TION 1. 990 engines have an electric choke in the air box that is automatically controlled by the electronic control board. 2. 530 engines have an electric choke on the divider panel air inlet hose that is automatically con- trolled by the electronic control board.
17 Section 3 — Operation Air-cooled Generators 4. Use the manual transfer handle inside the trans- fer switch to move the main contacts to their ST ANDBY position, i.e., loads connected to the standby power source (Figure 3.2). 5. T o crank and start the engine, set the A UTO/OFF/ MANU AL switch to MANU AL.
18 Low speed exercise will be handled as follows: 1. The standard start sequence will be initiated. 2. The unit will run at 2,400 RPM. 3. If utility is lost during exercise, the controller will do the following: • W ait 10 seconds for utility to return.
19 3.6.5 R PM SENSOR F AIL UR E During cranking, if the board does not see a valid RPM signal within three (3) seconds, it will shut down and latch out on RPM sensor loss. During running, if the RPM signal is lost for one full second the board will shut down the engine, wait 15 seconds, then re - crank the engine.
20 Figure 4.3 — Oil Dipstick and Fill, 10kW Oil Dipstick Oil Fill Figure 4.4 — Oil Dipstick and Fill, 13kW and 16kW Oil Dipstick Oil Fill 4.3 CHANGI NG TH E ENGI N E OI L 4.3.1 OI L CHANGE INTERV AL S See the "Service Schedule" section. 4.
21 4.4 CHANGI NG TH E ENGI N E AI R CLEAN ER 4.4.1 7 , 1 3, AN D 1 6KW GEN ERA T ORS See Figures 1.1 and 1.2, for the location of the air cleaner . Use the following procedures (Figure 4.6, 7kW ; Figure 4.8, 13/16kW): 1. Lift the roof and remove the door .
22 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 inch) for 7 and 10kW ; and 1.02 mm (0.040 inch) for 13/16 kW by carefully bending the ground electrode (Figure 4.9). Figure 4.9 – Setting the Spark Plug Gap 4.
Remove spark plug wires and position wires away from plugs. Remove spark plugs. 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.
24 4.1 0 C OR ROSION PRO TECTION P eriodically wash and wax the enclosure using auto - motive type products. F requent washing is recom- mended in salt water/coastal areas. Spray engine linkages with a light oil such as WD -40. 4.1 1 OUT OF SERVICE P ROCEDU R E 4.
25 Section 4 — Maintenance Air-cooled Generators 4.1 2 SERVICE SCHEDU LE A TTENTION: It is recommended that all service work be performed by the nearest Authorized Dealer . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = W eekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Y early if Repair is Needed.
5.1 TROU B LE SHOO TI NG GU I DE Problem Cause Correction The engine will not crank. 1. F use blown. 1. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables.
27 27 Section 6 — Notes Air-cooled Generators.
28 Section 6 — Notes Air-cooled Generators.
29 Section 6 — Notes Air-cooled Generators.
30 Section 7 — Mounting Dimensions Air-cooled Generators Drawing No. 0F9424.
31 NEUTRAL CONNECTION INSIDE SWITCH XB NO C1 COM XA VR1 NC NC COM C2 VR2 NO TR 194 23 1 7 4 79 36 9 F2 CIRCUIT 10 BLACK (MAIN 1) 12Vdc TRANSER COIL RED (MAIN 2) NEUTRAL (WHITE) NEUTRAL (WHITE) 23 OPEN.
32 Section 8 — Electrical Data Air-cooled Generators Wiring Diagram – 1 0, 1 3 & 1 6kW , V- T win – Drawing No. 0F782 2 TX - TRANSFORMER, 16 V ac 56 V A & 16 V ac 1 V A (DUAL SEC.
33 Section 8 — Electrical Data Air-cooled Generators Wiring Diagram – 1 0, 1 3 & 1 6kW , V- T win – Drawing No. 0F782 2 0 4 CLOSEST TO BEARING OUTPUT TO TRANSFER 240V GENERA TOR SWITCH CONT .
34 Section 8 — Electrical Data Air-cooled Generators Electrical Schematic – 1 0, 1 3 & 16kW , V - Twin – Drawing No. 0F7 823 225B 224B 13 15 56 16 86 15A 224 15B PRINTED CIRCUIT 11 13 14 12 .
35 Section 8 — Electrical Data Air-cooled Generators Electrical Schematic – 1 0, 1 3 & 16kW , V - Twin – Drawing No. 0F7 823 WINDING 22 22 225A 56V A 225A 224A 224 225 225 14 224A 1V A 14 TX.
36 Section 8 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW , Single Cylinder – Drawing No. 0F7 820 CB - MAIN OUTPUT BREAKER BA - BRUSH ASSEMBL Y BCR - BA TTERY CHARGE RELA Y SC - .
37 Section 8 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW , Single Cylinder – Drawing No. 0F7 820 0 4 CLOSEST TO BEARING OUTPUT TO TRANSFER 240V GENERA TOR SWITCH CONT ACTOR 6 2 .
38 Section 8 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW , Single Cylinder – Drawing No. 0F7 821 225B 224B 13 86 15A 224 0 15B PRINTED CIRCUIT 11 13 14 12 CONTROL BOARD 5 .
39 Section 8 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW , Single Cylinder – Drawing No. 0F7 821 WINDING 22 22 225A 56V A 225A 224A 224 225 225 14 224A 1V A 14 TX 0 0 23 2.
40 Section 8 — Electrical Data Air-cooled Generators Wiring Diagram – 8, 1 0, 1 2 and 1 6 Circuit Load Center – Drawing No. 0F90 7 0-A.
41 Section 8 — Electrical Data Air-cooled Generators Wiring Diagram – 8, 1 0, 1 2 and 1 6 Circuit Load Center – Drawing No. 0F90 7 0-A.
42 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431 -B SHEET MET AL P AINT/MA TERIAL CODE LEGEND The follo wing exploded vie ws contain part numbers of various sheet metal components. Only the base par t number is listed.
43 ITEM P ART NO . QTY . DESCRIPTION 1 0F9653 1 P AD , 24 X 48” WITH MOUNTING HOLES 2 045771 4 NUT HEX M8-1.25 3 022129 4 W ASHER LOCK 5/16 022129 5 WASHER LOCK 5/16 (7KW) 4 022145 8 W ASHER FLA T 5/16 5 043107 4 SCREW HHC M8-1.25 X 25 6 090388 15 SCREW T APTITE M6-1.
44 32 44 19 29 3 17 27 29 8,9 37 22 10 27 15 43 44 20 6 13 17 35 21 5 34 15 25 23 36 30 12 26 7 32 28 2 39 17 23 4 25 18 13 17 14 16 40 15 33 24 31 44 38 32 44 43 1 41 31 11 42 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators Control Panel – Drawing No.
45 ITEM P ART NO . QTY . DESCRIPTION 1 0E7886A 1 CIRCUIT BREAKER 30A X 2P 240V (7KW) 0E7886D 1 CIRCUIT BREAKER 45A X 2P 240V (10KW) 0E7886K 1 CIRCUIT BREAKER 55A X 2P 240V (13KW) 0E7886J 1 CIRCUIT BRE.
46 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators T ransfer Switch Assembly – Drawing No. 0F9 77 4-A.
47 ITEM P ART NO . QTY . DESCRIPTION 1 0F8278 1 BOX LOAD CENTER 2 0D4800 1 CO VER, 8 CIRCUIT LOAD CENTER 0F5211 1 CO VER, 10 CIRCUIT LOAD CENTER 0D3092 1 CO VER, 12 CIRCUIT LOAD CENTER 0F8312 1 COVER,.
48 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 3 & 1 6kW, G T -990 Eng ine – Drawing No. 0F9430-C - Part 1.
49 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0E9843 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 3 SCREW , T APTITE M6-1.
50 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 3 & 1 6kW, G T -990 Eng ine – Drawing No. 0F9430-C - Part 2.
51 ITEM P ART NO . QTY . DESCRIPTION 64 022145 1 W ASHER FLA T M8 – 5/16 65 0C5136A 2 KNOB, AIR CLEANER 66 0C3024 1 CO VER, AIRBOX NG/LP 67 0C3040 1 PRE-CLEANER, 68 0C8127 1 ELEMENT , AIR CLEANER 69 0F9255 1 ASSEMBL Y , MIXER/AIRBO X 990 70 0E9582 4 SCREW SHLDR(8MM) M6-1.
52 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0kW , GT -53 0 Eng ine – Drawing No. 0F9429-C - Part 1.
53 ITEM P ART NO . QTY . DESCRIPTION 1 0E9428B 1 CRANKCASE 2 0E3812 2 SEAL D 35 X 48.2 3 0C8566 2 SCREW HHFC M6 – 1.0 X 20 4 0E9367A 1 ASSY , BREA THER 5 0E9366 1 GASKET BREA THER ASSY 6 0E9304 1 CY.
54 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0kW , GT -53 0 Eng ine – Drawing No. 0F9429-C - Part 2.
55 ITEM P ART NO . QTY . DESCRIPTION 58 022097 3 W ASHER LOCK M6-1/4 59 0E9561 1 INT AKE AD APTER 60 0E9472 1 GASKET , AIRBO X T O CARB/MIXER 61 0E9471 1 GASKET , MANIFOLD TO CARB/MIXER 62 078643B 4 BOL T , CARB MOUNT M6 – 1.0 X 85 63 0D9784 1 NUT HEX LOCK M3 – 0.
56 32 23 34 35 36 45 39 33 20 19 18 43 44 46 11 49 29 37 27 28 30 31 17 52 47 48 24 38 26 22 40 41 25 25 50 15 53 14 21 12 51 13 54 16 1 6 1 2 11 10 42 5 7 9 8 3 4 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 7kW , GN-4 10 Engine – Drawing No.
57 ITEM P ART NO . QTY . DESCRIPTION 1 0E3221 1 ASSEMBL Y , CONNECTING ROD 2 0E1466 1 PIN, PISTON D20 3 021533 1 SET , PIST ON RING 90MM 4 0E2985 1 PIST ON, HC 5 071983 2 RET AINER, PIST ON PIN 20 6 0.
58 19 20 41 7 12 6 6 6 21 43 23 15 16 14 18 17 31 30 27 2 45 38 22 6 5 40 3 39 28 13 11 47 44 29 8 6 24 10 51 9 50 46 49 18 25 32 34 26 18 1 35 34 33 48 52 10 42 4 6 36 37 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 7kW , GN-4 10 Engine – Drawing No.
59 ITEM P ART NO . QTY . DESCRIPTION 1 0C1069 5 SCREW , T APTITE M6-1.0X8 YELLOW CHROME 2 0D2922 1 HOUSING, BLOWER 3 0F8426 1 TUBE, DIPSTICK 4 0C9997 1 GUARD , F AN 5 088434 1 WRAPPER, BOTT OM 6 045756 11 SCREW , T APTITE M6-1X10 YELLOW CHROME 7 0C4176A 1 WRAPPER, T OP 8 0D9004A 1 ASSY , ST AR TER 9 059985 2 SCREW , SHC M8-1.
60 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 7kW , GN-4 10 Engine – Drawing No. 0F9422-B.
61 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 7kW , GN-4 10 Engine – Drawing No. 0F9422-B ITEM P ART NO . QTY . DESCRIPTION 1 0F8186 1 ADAPT OR, ENGINE 2 0F5540H 1 ST A TOR.
62 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0, 1 3, and 16kW , V -twin Generators – Drawing No. 0F9423-C.
63 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0, 1 3, and 16kW , V -twin Generators – Drawing No. 0F9423-C ITEM P ART NO .
64 7KW 17 20 10 25 21 24 19 23 22 35 7 26 36 33 29 32 18 14 15 16 13 34 27 37 5 36 10 37 6 4 3 2 8 10 17 1 26 15 14 13 16 31 22 19 9 30 21 25 20 24 29 18 23 11 12 28 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 7 & 1 0kW , GN-41 0/GT -530 Regulator – Drawing No.
65 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA TOR HOUSING (7KW) 0F9285 1 CASTING, TWIN REGULA TOR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 1 GASKET , SOLENOID 4 0D4166 1.
66 16 13 34 5 11 6 7 17 26 14 15 3 9 7 35 4 6 33 3 2 12 27 32 30 28 8 1 31 8 10 27 18 19 22 23 29 21 25 24 20 Section 9 — Exploded Views and P ar ts Lists Air-cooled Generators 1 3 & 1 6kW, G T -990 Regulator – Drawing No.
67 ITEM P ART NO . QTY . DESCRIPTION 1 0F9285 1 CASTING, TWIN REGULA T OR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 2 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0F8096 1 BRKT REGULA T OR MOUNTING 990 6 022145 4 W ASHER FLA T 5/16-M8 7 022129 4 W ASHER LOCK 5/16-M8 8 0F4795 8 SCREW PPHM SEMS M4-0.
68 CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEMENT Y OUR W ARR ANT 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.
69 EM IS SION CONTROL S YS 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. 0F9421 Revision C (05/22/06) Printed in U.S.A. Section 1 0 – Warranty Air-cooled Generators GENERA C PO WER SYSTEMS "TW O YEAR" LIMITED W ARRANTY FOR GU ARDIAN ® "PREP A CKA GED EMERGENCY A UT OMA TIC ST ANDBY GENERA T ORS" F or a period of two years from the date of original sale, Generac P ower S ystems , Inc.
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