®
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)
Not intended for use as Primary Power in place of utility or in
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life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
Table of Contents
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
3.2.2 “Off” Position....................................14
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
3.2.3 “Manual” Position ............................14
3.3 Automatic Transfer Operation ....................14
3.4 Sequence of Automatic Operation................14
3.5 Manual Transfer Operation ........................15
3.5.1 Transfer to Generator
Safety Rules ........................................................2
Power Source......................................15
Standards Index..................................................3
3.5.2 Transfer Back to Utility
Power Source......................................15
Section 1 – General Information ..................4
1.1 Unpacking/Inspection ....................................4
1.2 Protection Systems ........................................4
1.3 System Set LED ............................................4
1.4 Your Generator ..............................................5
1.5 Specifications ................................................6
1.5.1 Generator ..........................................6
1.5.2 Engine ................................................6
1.6 Fuel Requirements and Recommendations....7
1.7 Fuel Consumption ........................................7
1.8 Reconfiguring the Fuel System ......................7
1.8.1 7 kW, 410cc Engine ............................7
1.8.2 12 kW and 15 kW, 990cc Engine........7
1.9 Location ........................................................8
1.9.1 Generator ..........................................8
1.9.2 Transfer Switch..................................8
1.10 Battery Installation ........................................8
1.11 The Battery....................................................9
Section 2 – Post Installation Start-up
3.6 Setting the Exercise Timer ..........................15
3.7 Protection Systems ......................................16
3.7.1 Low Oil Pressure Switch ..................16
3.7.2 High Temperature Switch ................16
3.7.3 Overcrank ........................................16
3.7.4 Overspeed ........................................16
Section 4 – Maintenance ..............................16
4.1 Fuse ............................................................16
4.2 Checking the Engine Oil Level ....................17
4.3 Changing the Engine Oil ..............................17
4.3.1 Engine Oil Recommendations ..........17
4.3.2 Oil Change Procedure ......................17
4.4 Changing the Oil Filter ................................18
4.5 Changing the Engine Air Cleaner ................18
4.5.1 7 kW, 12 kW and 15 kW
Generators........................................18
4.6 Spark Plug(s) ..............................................18
4.7 Battery Maintenance....................................19
4.8 Adjusting GH-410/GT-990 Valve Clearance ..19
4.9 Cooling System............................................20
4.10 Attention After Submersion ........................20
4.11 Corrosion Protection ..................................20
4.12 Out of Service Procedure ............................21
4.12.1 Removal From Service......................21
4.12.2 Return to Service..............................21
4.13 Service Schedule ........................................22
and Adjustments ......................10
2.1 Before Initial Startup ..................................10
2.2 Check Transfer Switch Operation................10
2.3 Electrical Checks ........................................10
2.4 Generator Tests Under Load ......................11
2.5 Checking Automatic Operation....................11
2.6 Adjusting the Regulator (Natural Gas Only) ..11
2.7 Engine Governor Adjustment ......................12
2.7.1 7 kW Units ......................................12
2.7.2 12 kW and 15 kW Units ..................13
2.7.3 Additional Corrosion Protection ......13
2.8 Voltage Regulator Adjustment......................13
Section 5 – Troubleshooting ........................23
5.1 Troubleshooting Guide................................23
Section 6 – Electrical Data............................24
Section 7 – Exploded Views and
Parts Lists....................................32
Section 3 – Operation ....................................13
3.1 Break-in Procedure......................................13
3.2 Using the Auto/Off/Manual Switch ..............14
3.2.1 “Auto” Position..................................14
Section 8 – Mounting Dimensions..............53
Section 9 – Notes ............................................54
Section 10 – Warranty....................................56
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Generac Power Systems, Inc.
1
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.
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GENERAL HAZARDS
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• For safety reasons, Generac recommends
that the installation, initial start-up and
maintenance of this equipment is carried out by a
Generac/Guardian Authorized Dealer.
• The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust sys-
tem must be installed properly, in strict compli-
ance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompli-
ance with such codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical to correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seri-
ously affect safe operation of the generator. The
generator MUST be installed outdoors.
• When working on this equipment, remain alert at
all times. Never work on the equipment when you
are physically or mentally fatigued.
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WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
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
follow
simple
and
fundamental
rules
or precautions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals
affixed to the unit are, therefore, not all-inclusive. If
you use a procedure, work method or operating tech-
nique Generac does not specifically recommend, you
must satisfy yourself that it is safe for you and others.
You also must make sure the procedure, work
method or operating technique that you choose does
not render the generator unsafe.
• Inspect the generator regularly, and contact your
nearest Generac/Guardian Authorized Dealer for
parts needing repair or replacement.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental start up. Disconnect the cable from the bat-
tery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
DANGER
Despite the safe design of this generator,
!
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
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generators.
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Generac Power Systems, Inc.
IMPORTANT SAFETY INSTRUCTIONS
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
• Keep a fire extinguisher near the generator at all
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for use
on the standby electric system. Keep the extin-
guisher properly charged and be familiar with its
use. If you have any question pertaining to fire
extinguishers, consult your local fire department.
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 opera-
tion. Avoid contact with bare wires, terminals, con-
nections, etc., while the unit is running. Ensure all
appropriate covers, guards and barriers are in
place before operating the generator. If you must
work around an operating unit, stand on an insu-
lated, dry surface to reduce shock hazard.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid
propane (LP) gas are extremely EXPLOSIVE.
Install the fuel supply system according to applica-
ble fuel-gas codes. Before placing the home stand-
by electric system into service, fuel system lines
must be properly purged and leak tested according
to applicable code. After installation, you must
inspect the fuel system periodically for leaks. No
leakage is permitted.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands
or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical system.
• After installing this home standby electrical sys-
tem, the generator may crank and start at any time
without warning. When this occurs, load circuits
are transferred to the STANDBY (generator) power
source. To prevent possible injury if such a start
and transfer occur, always set the generator’s
Auto/Off/Manual switch to its OFF position before
working on equipment and remove the 5A and 15A
fuses from the generator control panel.
STANDARDS INDEX
‹
In the absence of pertinent standards, codes, regula-
tions and laws, the published information listed
below may be used as installation guide for this
equipment.
• In case of accident caused by electric shock, imme-
diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply
first aid and get immediate medical help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS FOR HEALTH CARE FACILITIES, avail-
able same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available
from the Food and Energy Council, 909
University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRICAL SYS-
TEMS, available from the American Society of
Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
FIRE HAZARDS
• For fire safety, the generator must be installed and
maintained properly. Installation always must
comply with applicable codes, standards, laws and
regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regu-
lations.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
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Generac Power Systems, Inc.
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
1.2 PROTECTION SYSTEMS
DANGER
Unlike an automobile engine, the generator may have to
run for long periods of time with no operator present to
monitor engine conditions. For that reason, the engine is
equipped with the following systems that protect it
against potentially damaging conditions:
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.
1. Low Oil Pressure Sensor
2. High Temperature Sensor
There are LED readouts on the control panel to noti-
fy you that one of these faults has occurred. There is
also a “System Set” LED that is lit when all of the con-
ditions describe in Section 1.3 are true.
3. Overcrank
4. Overspeed
• This standby generator set has been factory sup-
plied with a weather protective enclosure that is
intended for outdoor installation only.
• This standby generator set is packaged with an
automatic transfer switch with built in load center.
The combination transfer switch and load center is
pre-wired with a 2 foot and 30 foot conduit. Circuit
breakers for emergency circuit connections are
included.
• This UL listed, 2-pole switch is rated at 100 AC
amperes at 250 volts maximum. This transfer
switch is for indoor use only.
1.3 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 volt-
age is not connected to the unit or if it is below
168 volts AC, then the system set light will flash
rapidly. This indicates that if the Auto/Off/Manual
switch is placed in the Auto position , the genera-
tor will start.
If this generator is used to power electrical load
circuits normally powered by a utility power
source, you are required by code to install a trans-
fer switch. The transfer switch must effectively iso-
late the electrical system from the utility distribu-
tion system when the generator is operating (NEC
700, 701 & 702). Failure to isolate an electrical sys-
tem by such means will result in damage to the
generator and also may result in injury or death to
utility power workers due to backfeed of electrical
energy.
3. The “Not In Auto” dip switch is set to the OFF
position on the control board.
4. No alarms are present, for example, low oil pres-
sure, high temperature, etc.
If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage on
the freight bill or affix his or her signature under the
consignor's memo of loss or damage.
If you note loss or damage after delivery, separate the
damaged materials and contact the carrier for claim
procedures.
“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later.
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Generac Power Systems, Inc.
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
Battery Compartment
Oil Filter
Figure 1.2 – 12 kW and 15 kW, V-twin GT-990 Engine
Data
Decal
Control
Panel
Oil Dipstick
Air Filter
Exhaust
Enclosure
Fuel Regulator
Battery Compartment
Oil Filter
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Generac Power Systems, Inc.
5
Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
1.5 SPECIFICATIONS
1.5.1 GENERATOR
‹
Model 04389-1
6,000 NG/7,000 LP
120/240
Model 04456-1
12,000 NG/12,000 LP 13,000 NG/15,000 LP†
Model 04390-1
Rated Max. Continuous Power Capacity (Watts*)
Rated Voltage
120/240
120/240
Rated Max. Continuous Load Current (Amps)
120 Volts**
50.0 NG/58.3 LP
100.0 NG/100.0 LP
108.3 NG/125.0 LP
240 Volts
25.0 NG/29.2 LP
50.0 NG/50.0 LP
54.2 NG/62.5 LP
Main Line Circuit Breaker
Phase
Number of Rotor Poles
Rated AC Frequency
Power Factor
30 Amp
50 Amp
60 Amp/70 Amp†
1
2
1
2
1
2
60 Hz
1
60 Hz
1
60 Hz
1
Recommended Air Filter
Battery Requirement
Generac Part # C8127 Generac Part # C8127 Generac Part # C8127
Group 26/26R
12 Volts and
Group 26/26R
12 Volts and
Group 26/26R
12 Volts and
350 Cold-cranking
Amperes Minimum
550 Cold-cranking
Amperes Minimum
550 Cold-cranking
Amperes Minimum
Weight
452 Pounds
68 db (A)
470 Pounds
70.5db (A)
-20°F (-28.8°C) to 104°F (40°C)
487 Pounds
71.5 db (A)
Output Sound Level @ 23 ft (7m) at full load
Normal Operating Range
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts.
† 15,000 watt with upgrade kit 04578-0. Kit includes power harnesses and 70 amp 2-pole circuit breaker.
1.5.2 ENGINE
‹
Model 04389-1
GH-410
Model 04456-1
GT-990
Model 04390-1
GT-990
Type of Engine
Number of Cylinders
Rated Horsepower
Displacement
1
2
2
14.5 @ 3,600 rpm
410cc
26 @ 3,600 rpm
992cc
30 @ 3,600 rpm
992cc
Cylinder Block
Aluminum w/Cast
Iron Sleeve
Aluminum w/Cast
Iron Sleeve
Aluminum w/Cast
Iron Sleeve
Valve Arrangement
Ignition System
Recommended Spark Plug
Spark Plug Gap
Compression Ratio
Starter
Overhead Valves
Solid-state w/Magneto
RC12YC
0.76 mm (0.030 inch)
8.6:1
Overhead Valves
Solid-state w/Magneto
RC12YC
0.76 mm (0.020 inch)
9.5:1
Overhead Valves
Solid-state w/Magneto
RC12YC
0.76 mm (0.020 inch)
9.5:1
12 Vdc
12 Vdc
12Vdc
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
Approx. 1.5 Qts
Approx. 1.7 Qts
Approx. 1.7 Qts
Generac Part # 70185 Generac Part # 70185 Generac Part # 70185
Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127
3,600
3,600
3,600
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Generac Power Systems, Inc.
Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
3. Disconnect wire #0 and wire #14 from the gas
1.6 FUEL REQUIREMENTS
solenoid located on the top of the demand regu-
lator.
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.
4. Remove the demand regulator by rotating coun-
terclockwise.
5. Remove the brass hose fitting from the outlet port
of the demand regulator.
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. The unit will run on natural gas or LP
gas, but it has been factory set to run on natural gas.
Should the primary fuel need to be changed to LP
gas, the fuel system needs to be reconfigured. See
Section 1.8 for instructions on reconfiguration of the
fuel system.
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at
least 2,520 Btus per cubic foot for LP gas. Ask your
fuel supplier for the Btu content of your fuel.
6. Remove the brass metering jet (loosen counter-
clockwise) from the housing port of the demand
regulator located on the side of the regulator.
7. Install new LP metering jet (tighten clockwise) in
the outlet port of the demand regulator.
8. Refit the brass hose fittings to the outlet port of
the demand regulator.
9. Reverse procedure steps 1-4 to reinstall demand
regulator.
10. Reverse the procedure to convert back to natural
gas.
Figure 1.3 – Demand Regulator
Fuel pressure for both natural gas and liquid
propane set ups should be 11 inches to 14 inches
of water column (0.6 psi) at all load ranges.
FUEL HOSE
FUEL HOSE
BRASS HOSE
FITTING
BRASS HOSE
FITTING
NOTE:
FUEL JET
HOUSING
PORTS
HOUSING
PORTS
A seperate gas line and regulator may be needed
to assure proper gas pressure (11-14”) to the gen-
erator. Low gas pressure can cause hard starting
and could affect engine durability.
1.7 FUEL CONSUMPTION
Model #
Nat. Gas (*)
LP Vapor (**)
1/2 Load Full Load 1/2 Load
Full Load
1.21/44.1
2.17/79.0
2.80/102.3
04389
04456
04390
74
105
185
240
0.91/33
1.34/48.9
1.73/63.2
NG FUEL SYSTEM
LP FUEL SYSTEM
114
NOTE:
148.5
*Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
The natural gas adjustment screw is preset during
installation and should not need any further
adjustment.
DANGER
Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause
an explosion. No leakage of fuel is permitted.
Natural gas, which is lighter than air, tends to
collect in high areas. LP gas is heavier than air
and tends to settle in low areas.
1.8.2 12 KW AND 15 KW, 990CC ENGINES
◆
To reconfigure the fuel system from NG to LP,
follow these steps:
NOTE:
The primary regulator for the propane supply is
NOT INCLUDED with the generator. You must sup-
ply a fuel pressure of 11 to 14 inches of water col-
umn (0.6 psi) to the fuel inlet of the generator.
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