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Generac Power Systems 005240, 005280, 005241, 005281, 005242, 005282, 005243, 005244, 005283, 005284 manual

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Table of contents for the manual

  • Page 1

    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. OUTDOOR INST ALLA TION ONL Y! Not intended f or use as [...]

  • Page 2

    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 factory installed in an all-weath[...]

  • Page 3

    T able of Cont ents Air-cooled Generators 1 Introduction ........................ Inside F ront Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance ............................ IFC How to Obtain Service ..................................... [...]

  • Page 4

    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. Many accidents are caused by failing to follow simple and fundamental ru[...]

  • Page 5

    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. A void contact with bare wires, terminals, connections, etc.,[...]

  • Page 6

    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. This standby generator set is ready for installa- tion with a factory supplied and pre -mo[...]

  • Page 7

    Section 1 — General Information Air-cooled Generators 5 1.4 TH E GEN ER A T OR[...]

  • Page 8

    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. Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP P ower Capacity (W atts*) Rated V oltage 120/240 120/2[...]

  • Page 9

    7 1.6 S YS TEM SET 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. 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 approximately 150-160 volts A[...]

  • Page 10

    1.9 R E CONF 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 (0.36 to 0.43 psi) to the fuel inlet of the generat[...]

  • Page 11

    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 1.8 - 13/16kW , GT -990 (Airbox Cover Removed) 1.1 0 L OCA TION 1.1 0.1 GEN ER A T OR Install the generator set, in its protective enclosure, outdoors , where adequate cooling and venti[...]

  • Page 12

    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. The base frame must be level within two (2) inches all arou[...]

  • Page 13

    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). NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic o[...]

  • Page 14

    12 2.1 B EFOR E IN ITIAL ST ART -U P 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. 2. Set the generator's A UTO/OFF/MANU AL switch to the OFF positi[...]

  • Page 15

    13 Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 2.3 ELE CTR ICAL CH E CK S Complete electrical checks as follows: 1. Set the generator's main circuit breaker to its OFF (or OPEN) position. 2. Set the generator's A UTO/OFF/MANU AL switch to the OFF position. 3. T urn OFF all breakers on the load center of [...]

  • Page 16

    14 • 10, 13 & 16kW voltage should be greater than 240 volts and frequency should be greater than 60 Hz. 11. Let the generator run at full rated load for 20-30 minutes. Listen for unusual noises, vibration or other indications of abnormal operation. Check for oil leaks, evidence of overheating, etc. 12. When testing under load is complete, tur[...]

  • Page 17

    15 6. When the highest frequency is reached maximum power has been set. F rom this point turn the adjustment screw 1/4 turn counterclockwise. The regulator is now set. 7. T urn utility power to the main distribution panel back on. This can be done by switching the ser - vice main breaker to the on or closed position. Allow the generator to shut dow[...]

  • Page 18

    16 Figure 2.5 – V oltage Adjustment Potentiometer Tu r n t o adjust voltage . 3.1 USI NG TH E AUT O/OF F/MAN UAL SWIT CH (F IGU R E 3.1) 3.1.1 “ AUT O” POSITION Selecting this switch position activates fully automatic system operation. It also allows the unit to automati- cally start and exercise the engine every seven days with the setting o[...]

  • Page 19

    17 Section 3 — Operation Air-cooled Generators 3.3 SE QU ENCE OF AUT OMA TIC OP ER A TION The generator’s control panel houses a control logic circuit board. This board constantly monitors util- ity power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start. After the engi[...]

  • Page 20

    18 3.4.2 TR ANSF ER B ACK T O UTI LIT Y POWER SOURCE When utility power has been restored, transfer back to that source and shut down the generator . This can be accomplished as follows: 1. Set the generator’s main circuit breaker to its OFF (or OPEN) position. 2. Let the engine run for a minute or two at no -load to stabilize the internal temper[...]

  • Page 21

    19 3.6.2 H IGH TEMP ER A TU R E SWIT CH This switch ’s contacts (Figure 3.3) close if the tem- perature should exceed approximately 144º C (293º F), initiating an engine shutdown. The generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level. Figure 3.3[...]

  • Page 22

    20 4.1 F USE S The 15-amp fuse on the generator panel protects the DC control circuit against overload (Figure 4.1). This fuse is wired in series with the battery output lead to the panel. If this fuse element has melted open, the engine will not be able to crank or start. Replace this fuse using only an identical 15-amp replacement fuse. T o repla[...]

  • Page 23

    21 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. 4.3.2 ENGI NE OI L R EC OMM EN D A TIONS All oil should meet minimum American P etroleum Institute (API) Service Class SJ , SL or better . Use no special additives. Select the oil's viscosity grade according to the expected operating[...]

  • Page 24

    22 Figure 4.6 — 7 kW , Engine Air Cleaner Location[...]

  • Page 25

    4.6 B A T TER Y MAINTENANCE The battery should be inspected per the "Service Schedule" section. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary . 2. Check the battery fluid level of unsealed batteries and, if necessary , fill wit[...]

  • Page 26

    24 T o adjust valve clearance (if necessary): Make sure the engine is at 60° to 80° F . Make sure that the spark plug wire is removed from the spark plug and out of the way . Remove the four screws attaching the valve cover with a #2 or #3 Phillips screwdriver . Loosen the rocker jam nut. Use an 10mm allen wrench to turn the pivot ball stud while[...]

  • Page 27

    25 Section 4 — Maintenance Air-cooled Generators 25 4.1 0 C OR ROSION PRO TE CTION 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 4.1 1.1 R EMOV AL F ROM SERVICE If t[...]

  • Page 28

    26 Section 4 — Maintenance Air-cooled Generators 26 4.1 2 SERVICE SCHEDU LE A TTENTION: It is recommended that all service work be performed by the nearest 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. FUEL F uel lin[...]

  • Page 29

    *Contact the nearest Authorized Dealer for assistance. 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. as necessary . 3. Defective starter [...]

  • Page 30

    28 Section 6 — Notes Air-cooled Generators[...]

  • Page 31

    29[...]

  • Page 32

    30 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 1 0, 1 3 & 1 6kW , V - Twin – Drawing No. 0F7 822-A[...]

  • Page 33

    31 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 1 0, 1 3 & 1 6kW , V - Twin – Drawing No. 0F7 822-A[...]

  • Page 34

    32 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 1 0, 1 3 & 1 6kW , V- T win – Drawing No. 0F782 3-A[...]

  • Page 35

    33 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 1 0, 1 3 & 1 6kW , V- T win – Drawing No. 0F782 3-A[...]

  • Page 36

    34 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW , Single Cylinder – Drawing No. 0F7 820-A[...]

  • Page 37

    35 Section 7 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW , Single Cylinder – Drawing No. 0F7 820-A[...]

  • Page 38

    36 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW , Single Cylinder – Drawing No. 0F7 821 -A[...]

  • Page 39

    37 Section 7 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW , Single Cylinder – Drawing No. 0F7 821 -A[...]

  • Page 40

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  • Page 41

    39[...]

  • Page 42

    40 Section 8 — Exploded Views and P ar ts Lists Air-cooled Generators Enclosure – Drawing No. 0F9431 -D SHEET MET AL P AINT/MA TERIAL CODE LEGEND The follo wing exploded vie ws contain par t numbers of various sheet metal components. Only the base par t number is listed. When ordering sheet metal, the correct color and material information must[...]

  • Page 43

    41 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 M6-1.0 X 12 7 0D3700 24 NUT , LOCKING FLANGE M6-1.0 0D3700* 14 NUT , LOCKING FLANGE M[...]

  • Page 44

    42[...]

  • Page 45

    43 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 BREAKER 65A X 2P 240V (16KW) 0E7886L 1 CIRCUIT BREAKER 80A X 2P 240V (18KW) 2 0A1801 1 ASSEMBL Y , BA TTER Y CHARGER ENGINE 3 0F9719 1 ASSEMBL Y , POTTED[...]

  • Page 46

    44[...]

  • Page 47

    45 ITEM P ART NO . QTY . DESCRIPTION 1 0F8278 1 BOX LOAD CENTER 2 0D4800 1 COVER, 8 CIRCUIT LO AD CENTER 0F5211 1 COVER, 10 CIRCUIT LO AD CENTER 0D3092 1 CO VER, 12 CIRCUIT LOAD CENTER 0F8312 1 COVER, 16 CIRCUIT LO AD CENTER 3 0C2237 1 TRANSFER SWITCH HOME ST ANDBY 100A 2P 250V 3A 077220 1 COIL UTILITY 3B 077220A 1 COIL ST ANDBY 3C 082574 1 INSULA [...]

  • Page 48

    46[...]

  • Page 49

    47 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSY , CRANKCASE WITH SLEEVE 2 0E9843A 1 SEAL, 38 I.D . CRANKSHAFT GREEN 3 0G0919 5 SCREW , HHFCS M6-1.0 X 12 G8.8 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER COVER 6 0E3372B 1 SEP ARA T OR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 G&S 8 071983 4 RET AINER, PIST ON PIN 20 9[...]

  • Page 50

    48[...]

  • Page 51

    49 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, AIRBO X 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) M6-1.0 X 21 71 0D4417 4 W ASHER,RUBBER 1/4" X 1/8" THICK 72 0E7585A 2[...]

  • Page 52

    50[...]

  • Page 53

    51 Section 8 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0kW , GT -53 0 Eng ine – Drawing No. 0F9429-N - P ar t 1 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 CYLINDER HEAD 1 7 0E93[...]

  • Page 54

    52[...]

  • Page 55

    53 Section 8 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0kW , GT -53 0 Eng ine – Drawing No. 0F9429-N - P ar t 2 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 TO CARB/MIXER 61 0E9471 1 GASKET , MANIFOLD TO CARB/MIXER 62 078643B 4 BOL T , CARB MOUNT M6 [...]

  • Page 56

    54[...]

  • Page 57

    55 ITEM P ART NO . QTY . DESCRIPTION 1 0E3221 1 ASSEMBL Y , CONNECTING ROD 2 0E1466 1 PIN, PIST ON 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 0E8440 1 ASSEMBL Y , CRANKSHAFT GH410 SMALL T APER 7 0A7628 1 ARM, GO VERNOR RC45 8 078658 1 PIN, “R” GO VERNOR ARM 9 078659 2 WASHER, GO VERNOR A[...]

  • Page 58

    56[...]

  • Page 59

    57 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 GU ARD , F AN 5 088434 1 WRAPPER, BO TTOM 6 045756 11 SCREW , T APTITE M6-1X10 YELLO W CHROME 7 0C4176A 1 WRAPPER, T OP 8 0D9004A 1 ASSY , ST ARTER 9 059985 2 SCREW , SHC M8-1.25 X 45 G12.9 10 02212[...]

  • Page 60

    58[...]

  • Page 61

    59 Section 8 — Exploded Views and P ar ts Lists Air-cooled Generators 7kW , GN-4 1 0 Engine – Drawing No. 0F9422-C ITEM P ART NO . QTY . DESCRIPTION 1 0F8186 1 ADAPT OR, ENGINE 2 0F5540H 1 ST A TOR 3 0C9934H 1 ROT OR 4 0F7774A 1 CARRIER, REAR BEARING 5 0C8096 1 F AN, 8” CUR VED BLADE 6 0F6591 1 MUFFLER 7 0F8078 1 T AIL PIPE, MUFFLER 9 056482 [...]

  • Page 62

    60[...]

  • Page 63

    61 Section 8 — Exploded Views and P ar ts Lists Air-cooled Generators 1 0, 1 3, and 1 6kW , V-twin Generators – Drawing No. 0G43 92-A ITEM P ART NO . QTY . DESCRIPTION 1 040976 4 SCREW SHC M8-1.25 X 20mm 2 0F6694 1 ST A TOR (16KW) 0F5538 1 ST A TOR (13KW) 0F7548 1 ST A TOR (10KW) 3 0F9795 1 RO T OR (16KW) 0F5539 1 RO T OR (13KW) 0F7549 1 RO T O[...]

  • Page 64

    62[...]

  • Page 65

    63 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA T OR HOUSING (7KW) 0F9285 1 CASTING, TWIN REGULA T OR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 1 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0F8822 1 REGULA T OR BRACKET 6 022145 2 WASHER FLA T 5/16-M8 7 022129 2 WASHER LOCK 5/16-M8 8 0F4795 4 SCREW PP[...]

  • Page 66

    64[...]

  • Page 67

    65 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 WASHER FLA T 5/16-M8 7 022129 4 WASHER LOCK 5/16-M8 8 0F4795 8 SCREW PPHM SEMS M4-0.7 X 10 9 045771 2 NUT HEX [...]

  • Page 68

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  • Page 70

    68 CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEMENT 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. * In California, new utility , and lawn and garden equipment engines must be de[...]

  • Page 71

    69[...]

  • Page 72

    Part No. 0F9421 Revision L (08/14/07) Printed in U.S.A. Section 1 0 – Warranty Air-cooled Generators GENERA C PO WER SYSTEMS "TWO 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. (Gene[...]