Generac 04077-2 User Manual

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POWER SYSTEMS. INC.

Owner’s Manual

GUARPIAIM"

by GEIMERAC* POWER SYSTEMS

Air-cooled, Prepackaged

Standby Generators

Models: 04077-2 (6 kW)

04109-2 (8 kW) 04079-2 (10 kW)

INTRODUCTION

Thank you for purchasing this model of the

Guardian product line by Generac Power Systems Inc. This model is a compact, high performance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate

critical loads during a utility power failure. This unit is factoiy installed in an all-weather, metal

enclosure that is intended exclusively for outdoor Instal lation. This generator will operate using either vapor

withdrawn liquid propane (LP) or natural gas (NG).

♦ READ THIS MANUAL THOROUGHLY

__ __ _ _

If you do not understand any portion of this manual, contact Generac or your nearest Generac/Guardian

Authorized Dealer for starting, operating and servic ing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARN ING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular opera tion that may be hazardous if performed incorrect ly or carelessly. Observe them carefully. Their defi nitions are as follows:

DANGER

After this heading, you can read instructions that,

if not strictly complied with, will result in personal injury or property damage.

WARNING

After this heading, you can read instructions that, if not strictly complied with, may result in personal injury or property damage.

------

ik CAUTION m

After this heading, you can read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

-----------

NOTE:

After this heading, you can read explanatory

statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates follows:

This symbol points out important safety informa

tion that, if not followed, could endanger personal safety and/or property of you and others.

This symbol points out potential explosion hazard.

The operator is responsible for proper and safe use

of the equipment. We strongly recommend that the operator read this Owner's Manual and thoroughly understand all instructions before using this equip ment. We also strongly recommend instructing other users to properly start and operate the unit.

This prepares them if they need to operate the

equipment in an emergency.

♦ CONTENTS

_________________________

This manual contains pertinent owner’s informa

tion, including warranty, electrical diagrams, exploded views and lists of repair parts, for three different Guardian models:

• 04077 - 6 kW, single-cylinder GN-410 Engine

• 04109 - 8 kW, V-twln GN-724 Engine

• 04079 - 10 kW, V-twtn GN-724 Engine

♦ OPERATION AND MAINTENANCE________

It is the operator's responsibility to perform all safe ty checks, to make sure that all maintenance for

safe operation is performed promptly, and to have the equipment checked periodically by a

Generac/Guardian Authorized Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as

such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your

Generac/Guardian Authorized Dealer for service

aids and accessories.

♦ HOW TO OBTAIN SERVICE

When your generator requires servicing or repairs,

simply contact a Generac/Guardian Authorized Dealer for assistance. Service technicians are facto ry-trained and are capable of handling all of your

service needs. When contacting a Generac/Guardian Authorized

Dealer or the factory about parts and service, always

supply the complete model number and serial num ber of your unit as given on its data decal, which is located on your generator. See Figure 1.1 or Figure

1.2 in section 1.6 (page 5) for decal location.

Model No.

AUTHORIZED

DEALER LOCATION

Serial No.

To locate the GENERAC/GUARDIAN AUTHORIZED

DEALER nearest you, please call this number:

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

hazard.

Gen e rac * Po w er Sy st em s , In c .

1-800-747-1530

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Table of Contents

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

TABLE

CONTENTS

Introduction...........................

Read This Manual Thoroughly

Inside Front Cover

....................

IFC

Contents ..........................................................IFC

Operation and Maintenance How to Obtain Service

Authorized Dealer Locator Number...............

Safety Rules ......................................................2

Section I - General inforniatiofi...............,..4

1.1 Unpacking/Inspection

1.2 Protection Systems

1.3 Additional Generator Features

..........................

..................................

......

................................

....................

IFC

1.4 Fuel Requirements and

Recommendations ...................................

1.5 Fuel Consumption ................................

1.6 Your Generator

1.7 Specifications

........................................

................................................

.....4

1.7.1 Generator..........................................6

1.7.2 Engine ............................................. 6

1.8 Reconfiguring the Fuel System

1.9 The Battery

Section 2 - Operation

.................................................

.....

................................ 8

2.1 Using the Auto/Off/Manual Switch

2.1.1 “Auto” Position

...............................

....................

............

2.1.2 “Off’Position.....................................8

2.1.3 “Manual” Position

2.2 Automatic Transfer Operation

2.3 Sequence of Automatic Operation

...........................

...................

...............

2.4 Manual Transfer Operation ........................9

2.4.1 Transfer to Generator

Power Source

...................................

2.4.2 Transfer Back to Utility

Power Source

2.5 Setting the Exercise Timer

2.6 Protection Systems

2.6.1 Low Oil Pressure Switch

2.6.2

2.6.3

High Temperature Switch Overcrank

...................................

...........................

.....................................

...............

.............

.......................................

10 10 10 10

2.6.3.1 Approximate Crank

Cycle Times ....................10

2.6.4

Overspeed

.......................................

Section 3 - Maintenance

3.1 Fuse

.............................................................

3.2 Checking the Engine Oil Level

3.3 Changing the Engine Oil

3.3.1 Engine Oil Recommendations

3.3.2 Oil Change Procedure

..............................

...................

...........................

........

...................

3.4 Changing the Oil Filter...............................12

3.5 Changing the Engine Air Cleaner

3.5.1 6 kW Generators

............................

3.5.2 8 kW and 10 kW Generators

4 4 4

3.7 Battery Maintenance ..................................13

3.8 Cooling System

3.9 Drive Belt

3.6 Spark Plug(s)

..............................................

.........................................

...................................................

3.10 Attention After Submersion ......................

3.11 Out of Service Procedure

...........................

3.11.1 Removal From Service....:

6 6

8 8

8 8 8

3.12 Service Schedule

Section 4 - Troubleshooting

.........................................

4.1 Troubleshooting Guide

Section 5 - Notes Section 6 - Electrical Data Section 7 - Exploded Views and

Parts Lists

Section 8 - Warranty

........................... ..............

......................................

....................................

3.11.2 Return to Service

...........................

.....

................................

.........................

.............

..........

........

....19

.......

12 12

13 14

.14

24 40

9 9

Generac* Power Systems, Inc.

SAFETY RULES

Important Safety Instructions

Guardian Air-cooled 6 kW, 8 kW and 10 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 Vk

to all operators and potential operators of this equipment.

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

WARNING:

I 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 Owners Manual and with the unit. The generator can operate safely, efficient ly and reliably only if it is properly installed, operat ed and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate eveiy possi ble circumstance that might involve a hazard. The

warnings 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

technique Generac does not specifically recom mend, you must satisfy yourself that it is safe for

you and others. You also must make sure the pro cedure, work method or operating technique that you clioosc does not render the generator unsafe.

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 generators.

^ GENERAL HAZARDS A

For .safety reasons, Generac recommends

that the installation, initial start-up and mainte nance of this equipment is carried out by a

Generac/Guardian Authorized Dealer.

The engine exhaust fumes contain carbon

monoxide, which can be DEADLY. This danger ous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and stan dards. Following installation, you must do noth

ing that might render the system unsafe or in

noncompliance wi.th 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 ven

tilating air is critical to correct generator opera

tion. Do not alter the installation or permit even

partial blockage of ventilation provisions, as this

can seriously affect safe operation of the genera

tor. 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.

Inspect the generator regularly, and contact your

nearest Generac/Guardian Authorized Dealer for parts needing repair or replacement.

Before perfoiming any maintenance on the gen

erator, disconnect its batteiy cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or H 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 conditions from leaking exhaust gases, fuel leak age, oil leakage, etc.

Generac* Power Systems, Inc.

Important Safety Instructions

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

SAFETY RULES

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 operation. Avoid contact with bare wires, ter

minals, connections, etc., while the unit is run

ning. Ensure all appropriate covers, guards and barriers are in place before operating the genera tor. If you must work around an operating unit, stand on an insulated, diy surface to reduce

shock hazard.

• 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 electri cal 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 (genera tor) 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 fuse.

• In case of accident caused by electric shock, immediately 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 noncon ducting implement, such as a rope or board, to free the victim from the live conductor. If the vic tim is unconscious, apply first aid and get imme diate 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.

FIRE HAZARDS

For frre 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 estab lished. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncom pliance with the aforementioned codes, stan dards, laws and regulations.

Keep a fire extinguisher near the generator at all

times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on tire standby electric system. Keep the

extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding 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 appli cable fuel-gas codes. Before placing the home standby 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.

Generac'^ Power Systems, Inc.

GENERAL

INFORMATION

Section 1 — General Information

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

DANGER

Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations.

1.1 UNPACKING/INSPEaiON

After unpacking, carefully inspect the contents for damage.

® 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.

® This UL listed, two-pole switch is rated at 100 AC

amperes at 250 volts maximum. This transfer switch is for indoor use only.

------

M. WARNING ik

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

701). Failure to isolate an electrical system 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.

----------

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 signa ture 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.

3. No alarms are present.

1.3 ADDITIONAL GENERATOR FEATURES

Your generator offers additional features that are

not factory preset:

1. Remote Start ~ This allows you to remotely start

your generator with the Auto/Off Manual switch set to AUTO.

2. Remote/Common Alarm - This allows for an alarm, Ught, hom, etc., to activate when any fault has occurred.

3. Remote Not Auto - The generator will not auto matically start during a utility failure.

These options may be set up by your nearest

Generac / Guardian Authorized Dealer.

1.4 FUEL REQUIREMENTS 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.

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 nat ural gas. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See section 1.8 (page 6) for instruc tions 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.

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.

1.2 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 3. Overcrank

2. High Temperature Sensor 4. Overspeed

There are LED readouts on the control panel to

notify you that one of these faults has occurred.

There is also a “System Set” LED that is lit when all

of the following conditions are true:

1. The Auto/Off/Manual switch is set to the AUTO

position.

2. The “Not In Auto” dip switch is set to the OFF

position on the control board.

4 G en er ac * P o we r Sy et em s , In c.

1.5 FUEL CONSUMPTION

Model #

04077 (6 kw) 04109 (8 kw) 79.7 04079 (10 kw) 100.8

*Natural gas is in cubic feet per hour.

**LP is in gallons per hour/cubic feet per hour.

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.

Nat. Gas (*)

1/2 Load Full Load

74.1 105.3 0.86/31.30

140.0 1.07/38.94 1.56/56.77

177.9 1.16/42.21

WARNING

1/2 Load Full Load

LP Vapor (**)

1.08/39.30

2.15/78.24

1.6 YOUR GENERATOR

Figure 1.1-6 kW, Single-cylinder GN-410 Engine

Section 1 — General Information

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

GENERAL

INFORMATION

Figure 1.2 - 8 kW/10 kW, V-twin GN-724 Engine

GENERAL

INFORMATION

1.7 SPECIFICATIONS

♦ 1.7.1 GENERATOR

Rated Maximum Continuous Power Capacity Rated Voltage

Section 1 — General Information

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Model 04077 (6 kW)

6,000 Watts*

120/240

Model 04109 (8 kW) Model 04079 (10 kW)

8,000 Watts*

120/240

10,000 Watts*

120/240

Rated Maximum Continuous Load Current

120 Volts

240 Volts Phase Number of Rotor Poles Rated AC Frequency Power Factor Recommended Air Filter Battery Requirement

50 Amperes 25 Amperes

1 2

60 Hz

Generac Part #73111

Group 26/26R

12 Volts and

350 Cold-cranking

Amperes Minimum

Weight

•Miudmuin waltiige iuid current are subject to and limited by such factoi-s as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximuin power decreases about 3.5 pereent for each 1,000 feet above sea level; and also will dettrease about 1 percent for each 12° C (10° F) above 15.5° C (60° F).

327 Pounds

66.7 Amperes

33.3 Amperes 1

60 Hz

Generac Part # 70941

Group 26/26R

12 Volts and

350 Cold-cranking

Amperes Minimum

357 Pounds

83.3 Amperes

41.6 Amperes 1 2

60 Hz

Generac Part # 70941

Group 26/26R

12 Volts and

350 Cold-cranking

Amperes Minimum

373 Pounds

♦ 1.7.2 ENGINE

Model 04077 (6 kW)

IVpe ol Engine

Number of Cylinders Rated Horsepower

14.5 @ 3,600 rpm Displacement Cylinder Block

Valve Arrangement

Ignition System

Aluminum w/Cast

Overhead Valves

Solid-state w/Magneto

Recommended Spark Plug

Spark Plug Gap

0.76 mm (0.030 inch)

Compression-Ratio

Starter

Oil Capacity Including Filter Recommended Oil Filter

1.8 RECONFIGURING THE

FUEL SYSTEM

Approx. 1.7 Qts

Generac Part #70185

To reconfigure the fuel system from NG to LP,

follow these steps:

1. Remove the carburetor fuel hose from the natu

ral gas port of the fuel load block and the brass fitting (Figure 1.3).

2. Remove the blanking plug from the LP port of

the load block (Figure 1.3).

GN-410

410CC

Iron Sleeve

RC12YC

8.6:1

12 Vdc

Model 04109 (8 kW)

Model 04079 (10 kW)

GN-724

25 @ 3,600 rpm

724CC

Aluminum w/Cast

Iron Sleeve

Overhead Valves

Solid-state w/Magneto

RC12YC

0.76 mm (0.030 inch)

8.6:1

12 Vdc

Approx. 2.0 Qts

Generac Part # 70185

Figure 1.3 - Natural Gas Setup'

Generac Part # 70185

GN-724

25 @ 3,600 rpm

724CC

Aluminum w/Cast

Iron Sleeve

Overhead Valves

RC12YC

8.6:1

12Vdc

Approx. 2.0 Qts

BRASS

Generac* Power Systems, Inc.

Section T — General Information

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

GENERAL

INFORMATION

3. Refit the fitting and hose to the LP port and the blanking plug to the natural gas port (Figure

1.4).

4. Reverse the procedure to convert back to natural gas.

NOTE:

The natural gas adjustment screw is preset dur ing installation and should not need any further adjustment.

Figure 1.4 - LP Gas Setup

BLANKING

1.9 THE BATTERY

Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized per sonnel away from batteries.

When replacing the battery, use the following type

of battery: Group 26/26R 12-volt battery with a rat ing of 350 cold-cranking amps at -17.8° C (0° F) minimum. When using a maintenance-free batteiy, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in the “Service Schedule."

A negative ground system is used. Batteiy connec

tions are shown on the wiring diagrams. Make sure the battery is correctly connected and terminals are tight. Observe battery polarity when connecting the

battery to the generator set.

NOTE:

Damage will result if the battery connections are made in reverse.

Your generator is equipped with a battery trick

le charger that is active when your unit is set up for automatic operation. The trickle charger is designed to help extend the life of your battery

by maintaining the battery when the unit is

not running.

DANGER

Do not dispose of the battery in a fire. The

battery is capable of exploding.

A battery presents a risk of electrical shock

and high short circuit current. The following precautions are to be observed when working

on batteries:

• 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 source prior to connecting or dis connecting battery terminals.

WARNING

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following procedures are to be observed;

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicar bonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire

because they generate hydrogen gas. The

following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from your body before

touching the battery by first touching a grounded metal surface.

Be sure the Auto/Off/Manual switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, or sparking may occur at the battery posts as

▲

you attach the cables and cause an explosion.

Generac* Power Systems, Inc.

OPERATION

Section 2 — Operation

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

2.1 USING THE AUTO/OFF/IVIANUAL

SWITCH (FIGURE 2.1)

♦ 2.1.1 "AUTO" POSITION

________________

Selecting this switch position activates fully auto

matic system operation. It also allows you to start and exercise the engine every 14 days with the set ting of the exercise timer (see section 2.5). This

position also is used for remote starting, when it is set up.

♦ 2.1.2 "OFF" POSITION

____________

This switch position shuts down the engine. This position also prevents automatic operation.

♦ 2.1.3 "MANUAL" POSITION

_____________

Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur

unless there is a utility failure.

Figure 2.1 - Generator Control Panel

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 drops below a pre set level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove the fuse before working on or around the generator or transfer switch. Then, place a "Do Not Operate" tag on the generator panel and on the transfer switch.

2.2 AUTOIVIATIC TRANSFER OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts

are set to their “Utility” position, i.e., loads con nected to the utility power source (Figure 2.2).

2. Be sure that normal utility power source voltage

is available to transfer switch terminal lugs N1 and N2.

3. Set the generator’s Auto/Off/Manual switch to

AUTO.

4. Set the generator’s main circuit breaker to its

ON (or closed) position.

With the preceding steps complete, the generator will start automatically when utility source voltage

drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to “Sequence of Automatic Operation.”

2.3 SEQUENCE OF

AUTOMATIC OPERATION

The generator’s control panel houses a control logic

circuit board. This board constantly monitors utili

ty power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start. After the engine

starts, the circuit board signals the transfer switch to activate and connect load circuits to the standby power supply (load terminal lugs T1/T2 connect to terminal lugs E1/E2).

Upon restoration of utility source voltage above a preset level, generator circuit board action signals the transfer switch to transfer loads back to that power supply. After retransfer, the engine is sig nalled to shut down.

The actual sequence of operation is controlled by sensors and timers on a control logic circuit board, as follows:

A. Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 60

percent of the nominal supply voltage, the sen

sor energizes a 15-second timer.

® Once the timer has expired, the engine will

crank and start.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a standby source.

C. Standby Voltage Sensor

« This sensor monitors generator AC output volt

age. When the voltage has reached 50 percent of the nominal rated voltage, transfer to stand

by can occur.

Generac* Power Systems, Inc.

Section 2 — Operation

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

OPERATION

pit

D. utility Voltage Pickup Sensor

• This sensor monitors utility power supply volt age. When that voltage is restored above 80 per cent of the nominal source voltage, a retransfer time delay starts timing.

E. Retransfer Time Delay

• This timer runs for about 15 seconds.

• At end of a 15-second delay, circuit board action de-energizes transfer relay in the trans fer switch.

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

• When the load is transferred back to utility power source, the engine cool-down timer starts timing.

• The timer will run for about one minute, and the generator will then shut down.

2.4 MANUAL TRANSFER OPERATION

♦ 2.4.1 TRANSFER TO GENERATOR

_______POWER SOURCE

________________

To start the generator and activate the transfer

switch manually, proceed as follows;

1. Set the generator’s Auto/Off/Manual switch

to OFF. Set the generator’s main circuit breaker to its

OFF (or open) position.

Turn OFF the utility power supply to the trans

fer switch using the means provided (such as a utility main line circuit breaker).

DANGER

Do not attempt to activate the transfer

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 extremely hazardous and possibly fatal electrical shock.

Figure 2.2 - Manual Transfer Switch Operation

IDAI CfilMECTEI TO imUTY PONEH SOURCE

LOU COMECTEl TO STMS8Y HmU SOMCI

switch

4. Use the manual transfer handle inside the transfer switch to move the main contacts to their "Standby” position, i.e., loads connected to the standby power source (Figure 2.2).

5. Turn ON the utility power supply to the trans fer switch using the means provided (such as a utility main line circuit breaker).

6. To crank and start the engine, set the Auto/Off/Manual switch to MANUAL.

7. Let the engine stabilize and warm up for a few minutes.

8. Set the generator’s main circuit breaker to its ON (or closed) position. The standby power source now powers the loads.

♦ 2A2 TRANSFER BACK TO UTILITY POWER SOURCE

When utility power has been restored, you will want to 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 noload to stabilize the internal temperatures.

3. Set the generator’s Auto/Off/Manual switch to its OFF (or open) position. The engine should shut down.

4. Chepk that utility power supply to the transfer

switch is turned OFF.

DANGER

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 extremely hazardous and possibly

fatal electrical shock.

Use the manual transfer handle inside the

5. transfer switch to move the main contacts back to their “Utility” position, i.e., loads connected to the utility power source (Figure 2.2).

Turn ON the utility power supply to the trans

fer switch using the means provided. Set the system to automatic operation as out

lined in “Automatic Transfer Operation,” section

2.2.

2.5 SETTING THE EXERCISE TIMER

Your generator is equipped with an exercise timer. Once it is set, the generator will start and exercise once every 14 days, on the day of the week and at the time of day you complete the following sequence. During this exercise period, the unit runs for approximately seven minutes and then shuts down. Transfer of loads to the generator out put does not occur during the exercise cycle.

Senerao® Power Syst:ems, Inc. S

OPERATION

(J)0:

Section 2 — Operation

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

A switch on the control panel (see Figure 3.1) allows you to select the day and time for system exercise. To select the desired day and time of day, proceed

as follows:

1. Verify that the Auto/Off/Manual switch is set

to AUTO.

2. Hold down the set timer switch until the gener

ator starts (approximately 10 seconds) and then release.

3. The generator will start and run for approxi

mately seven minutes and then shut down on its own. The exerciser will then be set to run at that time of day every week.

NOTE;

The exerciser will only work in the AUTO mode and will not work unless this procedure is performed. The exerciser will need to be reset every time the 12-volt battery is disconnected and then reconnected. The exerciser WILL NOT work if dip switch 2 (Remote Not Auto) is ON.

2.6 PROTECTION SYSTEMS

♦ 2.6.1 LOW OIL PRESSURE SWITCH

________

This switch (Figure 2.3) has normally closed contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, and the engine shuts down. The unit should not be restarted until oil is added, and the Auto/Off/Manual switch must be turned to OFF and then back to AUTO.

♦ 2.6.3 OVERCRANK

This feature prevents the generator from damaging

Itself when it continually attempts to start and another problem, such as no fuel supply, prevents it from starting. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LED will light indicating an overcrank failure.

The Auto/Off/Manual switch will need to be set to

OFF and then back to AUTO to reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank fea ture will continue to activate.

2.6.3.1 Approximate Crank Cycle Times

• 15 seconds ON

• 15 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total

• 2.6.4 OVERSPEED

___ _ ______________

This feature protects the generator from damage by

shutting it down if it happens to run faster than the preset kmlt. This protection also prevents the gener ator from supplying an output that could potentially damage appliances connected to the generator cir cuit. Contact your nearest Generac/Guardian

Authorized Dealer if this failure occurs.

♦ 2.6.2 HIGH TEMPERATURE SWITCH

_______

This switch’s (Figure 2.3) contacts close if the tem

perature should exceed approximately 140° C (284° F), initiating an engine shutdown. Your generator will automatically restart and the LED will reset once the temperature has returned to a safe oper ating level.

Figure 2.3 - Low Oil Pressure and

High Temperature Switches

HIGH

1 O Generac* Power Systems, Inc.

Section 3 — Maintenance

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

MAINTENANCE

3.1 FUSE

The generator panel’s 15-amp fuse (Figure 3.1) pro

tects the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel. If the fuse element has melted open, you can not crank or start the engine. You should replace the fuse using only an identical 15-amp replacement.

Figure 3.1 - Generator Control Panel

3.2 CHECKING THE ENGINE OIL LEVEL

For oil capacities, see “Specifications,” section 1.7. For engine oil recommendations, see section 3.3.1. To check the engine oil level, proceed as follows (Figure 3.2):

1. Start the generator by moving the Auto/ Off/Manual switch to the IVIANUAL position. Allow it to run for a short while and then shut it down by moving the switch to the OFF position.

Remove the dipstick and wipe it dry with a

clean cloth. Install and tighten the dipstick cap; then, remove it

again. The oil level should be at the dipstick “Full” mark. If necessary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL” MARK.

33 CHANGING THE ENGINE OIL

♦ 3.3.1 ENGINE OIL RECOMMENDATIONS

Use oil of American Petroleum Institute (API)

Service Class SG, SH or SJ. Select the viscosity based on the air temperature at the time of opera

tion. See the following chart:

Temperature

Above -7° C (20° F)

Below -7° C (20° F)

All Seasons

^Organic break-in oil is required before using synthetic oil.

Oil Grade (Recommended)

SAE 10W-30 or SAE 30

SAE 5W-20 or 5W-30

SAE 5W-30 Synthetic*

NOTE:

The unit is supplied with “break-in” oil. See the

“Service Schedule,” section 3.12, for the first required oil change.

---------

ik CAUTION Jk

Any attempt to crank or start the engine before

it has been properly serviced with the recom mended oil may result in an engine failure.

♦ 3.3.2 OIL CHANGE PROCEDURE

-----------------------

__________

To change the oil, proceed as follows:

Run the engine until it is thoroughly warmed

up then shut OFF the engine. Immediately after the engine shuts OFF, pull

the oil drain hose (Figure 3.3) free of its retain ing clip. Remove the cap from the hose and drain the oil into a suitable container.

Figure 3.3 - Oil Drain Hose

------

Jk CAUTION

Never operate the engine

below the "Add" mark on the dipstick. Doing

this could damage the engine.

with

A-

the oil level

4. Install and tighten the dipstick.

5. Reset the Auto/ Off/Manual switch to its origi nal position.

Figure 3.2 - Oil Dipstick and Fill

After the oil has drained, replace the cap onto

the end of the oil drain hose. Retain the hose in the clip. Refill with the proper recommended oil (see sec

tion 3.3.1). See section 1.7.2 (page 6) for oil capacities.

Oenerac® Power Systems, Inc. 1 i

MAINTENANCE

Section 3 — Maintenance

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

3.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by

turning it counterclockwise.

2. Apply a light coating of clean engine oil to the gasket of the new filter. See section 1.7.2 (page

6) for recommended filter.

3. Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter. Then, tighten the filter an additional 3/4 to one turn (Figure 3.4).

4. Refill with the proper recommended oil (see sec tion 3.3.1). See section 1.7.2 (page 6) for oil capacities.

5. Start the engine and check for leaks.

Figure 3.4 - Engine Oil Filter

See the “Service Schedule,” section 3.12 (page 15) for air cleaner maintenance. See section 1.7.1 for air filter replacement part number.

Figure 3.5 - 6 kW Engine Air Cleaner

♦ 3.5.2 8 KWAND 10 KW GENERATORS

_____

To replace the engine air cleaner, simply loosen the hose clamp. This air cleaner should NOT be cleaned and reused. See section 1.7.1 for air filter replace ment part number.

3.5 CHANGING THE ENGINE

AIR CLEANER

3.5.1 6 KW GENERATORS

See Figure 1.1 (page 5) for the location of your air cleaner. Clean and reoil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. Service the foam precleaner more frequently if you operate the generator in extremely dusty or dirty conditions. Use the follow ing procedure (Figure 3.5):

Turn the two screws counterclockwise to loosen.

Remove the cover, foam precleaner and paper filter. Remove the foam precleaner from the cover.

Wash the foam precleaner in liquid detergent and water.

Wrap the foam precleaner in a clean cloth and gently squeeze it dry.

Saturate the foam precleaner in clean engine oil. Gently squeeze it in a clean cloth to remove excess oil and to distribute oil (DO NOT TWIST).

Install the foam precleaner into the cover, fol

7. lowed by the paper filter.

Install the cover, foam precleaner and paper filter.

Tighten the two screws to retain the filter in place.

1 S Generac* Power Systems, Inc.

3.6 SPARK PLUG(S)

Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See section 3.12 for mainte nance requirements.

1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine. Clean by scraping or washing using a wire

brush and commercial solvent. Do not blast the

spark plug(s) to clean.

2. Remove the spark plug(s) and check the condi

tion. Replace the spark plug(s) if worn or if reuse is questionable. See section 3.12 (page 15) for rec ommended Inspection.

Section 3 — Maintenance

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

MAINTENANCE

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 inch) by carefully bending the ground electrode (Figure 3.7).

Figure 3.7 - Setting the Spark Plug Gap

SET PLUG GAP AT 0.76 mm

(0.030 inch)

3.7 BATTERY MAINTENANCE

The batteiy should be inspected per the “Service

Schedule,” section 3.12 (page 15). 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 batter ies and, if necessary, fill with DISTILLED

WATER ONLY. DO NOT USE TAP WATER IN

BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type battery hydrometer.

DANGER

Do not dispose of the battery in a fire. The

battery is capable of exploding. A battery presents a risk of electrical shock

and high short circuit current. The following precautions are to be observed when working on batteries:

• 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 source prior to connecting or dis

connecting battery terminals.

WARNING

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicar bonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire

because they generate hydrogen gas. The

following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from your body before touching the battery by first touching a grounded metal surface.

Be sure the Auto/Off/Manual switch is set to

the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off,

or sparking may occur at the battery posts as

you attach the cables and cause an explosion.

3.8 COOLING SYSTEM

Air inlet and outlet openings in the generator com partment must be open and unobstructed for con tinued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to quickly shut down. (See Figure 3.8, page

14, for vent locations.)

Generac* Power Systems, Inc. 1 3

MAINTENANCE

Section 3 — Maintenance

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Figure 3.8 - Cooling Vent Locations

/ f

mntfiKE

maouGH

THEROOF

AJRffTAKE

THROUGH THE ROOF

AJRINT<V<E

■ THROUGH THE ROOF

I I

-A WARNING A~

The exhaust from this product gets extremely

hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

---------

Ik CAUTION ià

The maximum ambient temperature for your

generator is 48.9° C (120° F).

-------------------------

3.9 DRIVE BELT

The engine drives the generator rotor by means of a

pulley and drive belt arrangement. The drive train, drive belt and pulleys are warranted for the life of the generator. Drive belt tension was properly adjusted before the unit was shipped from the factory. If you suspect that drive belt tension is incorrect, contact a Generac/Guardian Authorized Dealer.

3.10 ATTENTION AFTER SUBIVIERSION

If the generator has been submerged in water, it MUST NOT be started and operated. Following any submersion in water, have a Generac/ Guardian Authorized Dealer thoroughly clean and dry the generator.

3.11 OUT OF SERVICE PROCEDURE

♦ 3.11.1 REMOVAL FROM SERVICE

If you cannot exercise the generator every 14 days, and it is to be out of service longer than 90 days, prepare 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

line and allow the unit to shut down.

1 4 G en er ac ’ P ow e r S ys te m s, Inc .

______ __

3. Once the unit has shut down, it will signal a low

oil fault.

4. Set the Auto/Off/Manual switch to OFF and

turn off the utility power to the transfer switch.

5. While the engine is still warm from running, drain the oil completely. Refill the crankcase

with oil. See "Engine Oil Recommendations,”

section 3.3.1 (page 11).

6. Attach a tag to the engine indicating the viscos ity and classification of the oil in the crankcase.

7. Remove the spark plug(s) and spray fogging agent into the spark plug(s) threaded openings. Reinstall and tighten the spark plug(s).

8. Remove the battery and store it in a cool, diy

room on a wooden board. Never store the bat tery on any concrete or earthen floor.

9. Clean and wipe the entire generator.

♦ 5.11.2 RETURN TO SERVICE________________________

To return the unit to service after storage, proceed

as follows:

1. Verify that utility power is turned off and that

the Auto/Off/Manual switch is set to OFF.

2. Check the tag on the engine for oil viscosity and

classification. Verify that the correct recom mended oil is used in the engine (see section

3.3.1, page 11). If necessary, drain and refill with the proper oil.

3. Check the state of the battery. Fill all cells of

unsealed batteries to the proper level with dis tilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the bat tery. See “Specifications,” section 1.7 (page 6), for type and size.

4. Clean and wipe the entire generator.

5. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.

6. Open the fuel shutoff valve.

7. Start the unit by moving the Auto/Off/Manual switch to MANUAL. Allow the unit to warm up thoroughly.

8. Stop the unit and set the Auto/Off/Manual switch to AUTO.

9. Turn on the utility power to the transfer switch.

10. Your generator is now ready for service.

NOTE:

If the battery was dead or disconnected, you must reset the exercise timer.

3.12 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by your nearest Generac/Guardian Authorized Dealer.

Section 3 — Maintenance

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

MAINTENANCE

3=^

SYSTEM/COMPONENT X = Action

R = Replace as Necessary * = Notify Dealer

if Repair is Needed.

FUEL

Fuel lines and connections*

LUBRICATION

Oil level

Oil Oil filter Oil line leakage*

COOLING

Enclosure louvers

EXHAUST LINE

Exhaust outlet

Spark arrestor*

BATTERY

Remove corrosion,

ensure dryness

Clean and tighten

battery terminals Check charge state Electrolyte level

(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner

6 kW foam precleaner

Spark plug(s)

GENERAL CONDITION

Vibration, Noise, Leakage, Temperature*

COMPLETE TUNE-UP*

PROCEDURE

Inspect Change Clean

X X

R R

X X

TO BE COMPLETED BY A GENERAC/

GUARDIAN AUTHORIZED DEALER

FREQUENCY

W = Weekly

M = Monthly

Y = Yearly

H = Hours

M M •

FIRST 9 H,

EVERY 100 H AND Y

FIRST 9 H,

EVERY 200 H AND Y

100 H

W W

M M

EVERY 6 M EVERY 6 M

100 H AND Y

EVERY 25 H OR

EVERY 3 M

100 H AND Y

Generac” Power Systems, Inc. i S

TROUBLESHOOTING

4.1 TROUBLESHOOTING GUIDE

Section 4 — Troubleshooting

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

PROBLEM CAUSE

The engine will not crank. 1. Fuse blown

2. Loose, corroded or defective battery cables

3. Defective starter contactor

4. Defective starter motor

5. Dead Battery

The engine cranks but 1. Out of fuel

will not start.

2. Defective fuel solenoid (FS)

3. Open #14 wire from engine control board

4. Defective spark plug(s)

The engine starts hard

and runs rough.

1. Air cleaner plugged or damaged

2. Defective spark plug(s)

The engine starts, but shuts

down when the Start/Stop switch is released.

1. Engine oil level low

2. Defective low oil pressure switch

3. Defective high temperature switch

4. Defective control board

CORRECTION

1. Replace fuse.

2. Tighten, clean or replace as necessary.

4. Charge or replace battery.

1. Replenish fuel.

3. Clean, re-gap or replace plug(s).

4. Check, clean or replace air cleaner.

1. Clean, re-gap or replace plug(s).

2. Check oil and add oil as needed.

The Auto/Off/Manual switch

is set to OFF, but the engine continues to run.

1. Defective switch

2. Auto/Off/Manual switch wired incorrectly

3. Defective control board

There is no AC output from

1. Main line circuit breaker open

the generator.

2. Generator internal failure 2.

There is no transfer to 1. Defective transfer switch coil

standby after utility 2. Defective transfer relay source failure.

3. Transfer relay circuit open 3.

4. Defective control logic board 4.

♦ Contact your nearest Generac/Guardian Authorized Dealer for assistance.

1 6 Generac* Power Systems, Inc.

1. Reset circuit breaker to ON (or closed).

Section 5 — Notes

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

NOTES

Generac* Power Systems, Inc. 1 ~7

NOTES

Section 5 — Notes

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

1 B Generac* Power Systems, Inc.

c LD

i=l LD

Section 6 — Electrical Data

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Transfer Switch Schematic and Wiring Diagrams - Drawing No. C2381 -

(X)

ELECTRICAL

DATA

—I

C=)

LJ I

u ex

H- _I < (/0

a -I a: □ z <H- 0.

Generac* Power Systems, Inc. 1 9

Section 6 — Electrical Data

ELECTRICAL

DATA

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators Wiring Diagram - Drawing No. C2136-E

ENGINE WIRING

DIAGRAM KEY

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RECTIFIER CBl - MAIN OUTPUT BREAKER СВа - CIRCUIT BREAKER, ALTERNATOR EXCITATION

D - DIODE

DSV - PCB MOUNTED DIP SWITCH FS - FUEL SOLENOID Г1 - FUSE 15 AMP GRD - CONTROL PANEL GROUND НТО - HIGH OIL TEMPERATURE SWITCH HM - HOUR RUN METER

IC - INLINE CONNECTOR

ICT - INTERCONNECTION TERMINALS

IMI - IGNITION MODULE, CYLINDER Й1 IM2 - IGNITION MODULE, CYLINDER «2 LDP - LOW OIL PRESSURE SWITCH RAR - REMOTE ALARM RELAY R1 - 6KW = I OHM, 25W RESISTOR

8KW = 0-5 OHM, 25W RESISTOR

lOKW = 2x1 OHM, 25W RESISTOR IN SERIES SPI, SP2 - SPARK PLUGS SVI - AUTO / OFF / MANUAL SWITCH SV2 - SET EXERCISE SWITCH SM - STARTER MOTOR SS ~ STARTER SOLENOID ТВ - INSULATED TERMINAL BLOCK TXl - 56 VA TRANSFORMER - 240 / 16 Vac TX2 - 6 VA TRANSFORMER - 240 / 16 Vac

SO Generac* Power Systems, Inc.

L. E. D - ALARM INDICATORS

Section 6 — Electrical Data

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Wiring Diagram - Drawing No. C2136-E

ELECTRICAL

DATA

Generac® Power Systems, Inc. ai

rWfTìi^

ELECTRICAL

DATA

Section 6 — Electrical Data

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators Electrical Schematic - Drawing No. C2666-D

BCR - BAHERY CHARGE RECTIFIER CB2 - CIRCUIT BREAKER. ALTERNATOR EXCITATION

FS - FUEL SOLENOID FI - FUSE 15 AMP НТО - HIGH OIL TEMPERATURE SWITCH HM - HOUR RUN METER IMI - IGNITION MODULE, CYLINDER #1

IM2 - IGNITION MODULE, CYLINDER §2

LOP - LOW OIL PRESSURE SWITCH RAR - REMOTE ALARM RELAY

R1 - 6KW = 1 OHM. 25W RESISTOR

8KW = 0.5 OHM, 25W RESISTOR

SC - STARTER CONTACTER SPI, SP2 - SPARK PLUGS SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX1 - 56 VA TRANSFORMER - 240 / 16 Vac TX2 - 6 VA TRANSFORMER - 240 / 16 Voc

SS Generac* Power Systems, Inc.

10KW -2x1 OHM. 25W RESISTOR IN SERIES

Section 6 — Electrical Data

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Electrical Schematic - Drawing No. C2666-D

ELECTRICAL

DATA

Generac® Power Systems, Inc. S3

PARTS

USTS

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW Generator GN-410 Engine - Drawing No. A7894-C

'll

-14

-54 42

aa Generac* Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW Generator

GN-4I0 Engine - Drawing No. A7894-C

^PARTS

LISTS

ТЕМ

PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

21533 1 PISTON RING SET

30 72655 2

3 71978 1 CONNECTING ROD WITH CAP 31

AND BOLT 32

71980 1 PISTON PIN 33

5 71983 2 PISTON PIN RETAINER

76361 1 THRUST WASHER A5776 A7308 78645

CAMSHAFT SEAL

1 PRESSURE RELIEF BALL

1 GOVERNOR SPOOL

1 GOVERNOR RETAINER 6 21713B 1 CYLINDER HEAD GASKET (C-RING) 7 A1442

21742

8 9 96699 1

10 76701 1 CRANKCASE GASKET 38 11 45756

12 80308 2 BREATHER GASKET 13 80309 1 14

80338 1 26925 1 PIPE PLUG-3/8" 49 84430 1

83897

72694

72696 2 JAM NUT (ROCKER ARM)

78672 1 SEAL, VALVE STEM 53

78694

83907

21 22 21714

86514

23 24

86515 4

25 86516 1

86517

26 27 89673 2 WASHER, VALVE SPRING

91308 2 VALVE SPRING

A9877

FLANGED HEX HD. CAP-

78691 1 COVER, OIL PRESSURE

SCREW M8-1.25x42

4 MIO 1.5 X 105MM HHFL 36 74908 1

PISTON 37

2 M6 I.Ox 10TAPTITE (THD.

FORMING)

A8930 1

A5771 B2104

89280D

40 42

78658 1 GOVERNOR ARM "R" PIN

1 1 SPRING WASHER 1 OIL SUMP ASSEMBLY

BREATHER COVER 43 78659 2 OIL BREATHER SEPARATOR 48 C3396C 1

TAPPET, SOLID

86002

2 PIVOT BALL STUD 51 86026 1

88396B

PUSH ROD GUIDE PLATE 54 90747

90416A

2 1 1

2 ROCKER ARM 55 C3150 1

CYLINDER HEAD WA/ALVE

SEATS AND GUIDES

57 92362

58 79246 4

2 VALVE SPRING RETAINER

VALVE SPRING KEEPER 59 83921 1 EXHAUST VALVE 60 77158 1 INTAKE VALVE ASSEMBLY

63 76329 1

CAMSHAFT ASSEMBLY 65

64 86254

93064

RELIEF M5-0.8 X 10MMTAPTITE GOVERNOR GEAR ASSEMBLY OIL PRESSURE SPRING

THRUST WASHER CRANKCASE SUB ASSEMBLY BALANCER OUTER GEROTOR INNER GEROTOR PUSH ROD CRANKSHAFT ASSEMBLY BREATHER VALVE ASSEMBLY ROCKER COVER GASKET ROCKER COVER W/FILL M6-1.0 X 16MM HEX HEAD. SCREW AND LOCK WASHER BEARING TUBE SHAFT

OIL SCREEN PICKUP OIL FILL PLUG

"0" RING 17.8 I.D.x 2.4 THICK OIL FILL CAP ASSEMBLY

Generac* Power Systems, Inc. SS

PARTS

LISTS

Section 7 — Exploded Views and Parts Lists

Guardian 8 kW and 10 kW Generators GN-724 Engine - Drawing No. C2474-

S6 Generac* Power Systems, Inc.

'«iiCM

CM LO

(3H I3

™Q0

_________

A®

Section 7 — Exploded Views and Parts Lists

Guardian 8 kW and 10 kW Generators

GN-724 Engine - Drawing No. C2474-

^PARTS

LISTS

PART NO. QTY.DESCRIPTION ITEM

TEM

Cl 198

1 100-C1198

2 101-C1198 1 BUSHING/SEAL KIT

GN-724 ENGINE 309

1 CYLINDER ASSEMBLY 310 150-C1198

311 151-Cl 198

(MAGNETO SIDE) 333 3 102-C1198 1 4

103-C1198 104-C1198 1 CYLINDER HEAD

OIL SEAL 334 154-C1198

1 ENGINE SUMP

337

(CYLINDER #1) 358

105-C1198

1 CYLINDER HEAD

404 156-C1198

(CYLINDER #2) 7 106-C1198 1

107-C1198 1 BREATHER ASSEMBLY 513 75261

8 9 108-C1198 1

10 109-C1198

CYLINDER HEAD GASKET 510 157-C1198

BREATHER GASKET 552 158-C1198

1 SCREW (BREATHER

552A 159-C1198

ASSEMBLY) 579 160-C1198

12 110-C1198 1 CRANKCASE GASKET 615

112-C1198 1

15A

113-C1198 114-C1198 1 CRANKSHAFT

16 20 115-C1198 1 22 116-C1198 1 23 117-C1198 25 119-C1198

OIL DRAIN PLUG

1 OIL DRAIN PLUG

616 162-C1198

691 165-C1198

OIL SEAL

697 166-C1198 SCREW (ENGINE SUMP) 718 167-C1198 FLYWHEEL

1 1 PISTON ASSEMBLY

741

742 169-C1198 (STANDARD) 750

120-C1198

1 PISTON ASSEMBLY 783

(.010 OVERSIZE) 797 173-C1198

121-C1198 122-C1198 1

26 123-C1198

124-C1198 1

125-C1198 1 RING SET (.020 OVERSIZE)

126-C1198 1

127-C1198 1

28 128-C1198 1

129-C1198 1

1 PISTON ASSEMBLY 798

(.020 OVERSIZE)

801 175-C1198 PISTON ASSEMBLY 802 176-C1198 (.030 OVERSIZE)

851

1 RING SET (STANDARD) 868

RING SET (.010 OVERSIZE) 914

934 RING SET (.030 OVERSIZE) 943 PISTON PIN LOCK PISTON PIN (STANDARD) 965 179-C1198 CONNECTING ROD

1005

(STANDARD) 1006 181-C1198

130-C1198

33 131-Cl 198 1

1 SCREW (CONNECTING ROD)

EXHAUST VALVE

1017 182-C1198

1022 183-C1198 34 132-C1198 1 INTAKE VALVE 1023 35 133-C1198 36 133-C1198 40 134-C1198 1 42 193-C1198 1 VALVE KEEPER ASSEMBLY 45 124-85110 46 136-C1198

146 138-C1198 192

139-C1198

1 VALVE SPRING (INTAKE) 1

VALVE SPRING (EXHAUST) VALVE RETAINER

VALVE TAPPET 1 CAMSHAFT 1

TIMING KEY 1035 1

ROCKER ARM ADJUSTOR 1051

1024 185-C1198 1026

1026A187-C1198 1029 188-C1198 1033

219 144-C1198 1 GOVERNOR GEAR 1090 220 145-C1198 250 146-C1198 252

147-C1198 1

1 WASHER (GOVERNOR GEAR) 1 BREATHER RETAINER

OIL COLLECTOR

1100

PART NO.

149-C1198

153-C1198

72347

155-C1198

161-Cl 198

168-C1198 170-C1198

171-Cl 198 174-C1198

75272 1

193-C1198 109-C1198 177-C1198 178-C1198

180-C1198

184-C1198

186-C1198

189-C1198 190-C1198 191-C1198 192-C1198

230-85110

QTY.DESCRIPTION

1 MOTOR STARTER 1

BOLT (STARTER MOTOR)

1 BRUSH SET

MAGNETO ARMATURE

SCREW (MAGNETO ARMATURE)

SPARK PLUG 1 ENGINE GASKET SET 1 WASHER (GOVERNOR

CRANK) 1 DRIVE-STARTER

CLUTCH-DRIVE 1

BUSHING-GOVERNOR CRANK 1 BUSHING-GOVERNOR CRANK

NUT (STARTER CABLE) 1

RETAINER-GOVERNOR

SHAFT

CRANK-GOVERNOR 1

GOVERNOR SHAFT SEAL

1 SCREW (DRIVE CAP)

1 PIN-LOCATING 1 GEAR-TIMING

1 E-RING RETAINER

1 SCREW (OIL PUMP COVER)

GEAR-PINION

1 NUT (BRUSH RETAINER)

SCREW (ROCKER ARM)

1 1 CAP-DRIVE 1 CAP-END

SPARK PLUG TERMINAL

1 VALVE SEAL

1 SCREW (ROCKER COVER)

1 SCREW (FAN RETAINER)

1 0-RING SEAL (OIL PUMP

COVER) 1 OIL PUMP COVER 1 FAN-FLYWHEEL 1 RETAINER-FAN 1 OIL PUMP SCREEN 1 GASKET-ROCKER COVER 1

COVER-ROCKER

(CYLINDER #2) 1 PUMP-OIL 1 ROD-PUSH (STEEL)

ROD-PUSH (ALUMINUM)

1 1 ROCKER ARM 1 VALVE OVERHAUL KIT 1

SHAFT-PUMP 1

RING-RETAINING

RETAINER-BRUSH

1 1 ROCKER ARM PIVOT

Generac* Power Systems, Inc. S7

PARTS

LISTS

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW Generator GN-410 Engine Accessories - Drawing No. C2910-

Oi 10

CM CM

58 Generac’ Power Systems, Inc.

Section 7 — Expioded Views and Parts Lists

Guardian Air-cooled 6 kW Generator

GN-410 Engine Accessories - Drawing No. C2910-

^PARTS

LISTS

TEM

PART NO. QTY. DESCRIPTION ITEM

A6532

91039

51753 4 72347 5 89228

A7336B 1

6 7

90970

A6564

56893

A6778

96290

73111 13 81646 14

A6563

15 C3633

16 Cl 228

49813 18 83512 19 20753

20 92164

QTY.

DESCRIPTION

LEVER, GOVERNOR ARM

1 BOLT, HEX HD. WASHER/LOCK

WASHER-M6-1.0X30 LG 1 NUT, GOVERNOR LEVER 1

SPRING, GOVERNOR 1 BELLCRANK, GOV. RODS 2 WASHER, FELT-BELLCRANK 1 BOLT, SHOULDER M6-1.0 x

15 LG 1

ROD, LINKAGE GOV. LEVER-

MANIFOLD, INTAKE

GASKET, INTAKE ADAPTOR 22 83532

HHCS-M6-1.0X40 LG

SPARK PLUG GASKET, CARB./MANIFOLD

CARBURETOR 25 91633 1 GASKET, AIR CLEANER 1

BASE, AIR CLEANER 27 91161

2 CRIMPTITE-#10-24 X 1/2" LG

1 SPRING, ANTILASH.

PART NO.

21 91916

86681

23 24 74962C

92586

A6913

2 STUD, CARB. MOUNT M6-1.0 x BELLCRANK

90 LG

A6785 1 FILTER, AIR 1 PRE-CLEANER, AIR FILTER 1 COVER, CLEANER

2 SCREW ASSEMBLY, AIR 32

CLEANER

A6581

30 31 22473

22097

A7029

1 DECAL, AIR CLEANER

2 M6-1.0-NUT 34 A6780 2

TAPTITE-M8-1.25X 15 LG

HHCS-M6-1.0 X 60 LG 35

22145

ROD, LINKAGE BELLCRANKCARB.

BREATHER TUBE, HOSE 2 M6-FLAT WASHER 4

M6-LOCK WASHER 1

NYLON WASHER .31" x .26" x

.13" 1

SPRING, ANTILASH BELL-

CRANK TO CARB. 1 M8-FLAT WASHER

1 GOV. SPRING -ADJUSTMENT

BRACKET

Generac* Power Systems, Inc. S9

PARTS

USTS

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW Generator GN-410 Sheet Metal - Drawing No. C2480-

30 Generac® Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW Generator

GN-4I0 Sheet Metal - Drawing No. C2480-

^PARTS

LISTS

TEM

PART NO. QTY.

A4323 45756

DESCRIPTION

1 SCROLL, FLYWHEEL 28 38593

SCREW, TAPTITE M6-1.0 x 3/8"

10 LG

3 29289 2.5 FT. FOAM TAPE

ITEM PART NO. QTY. DESCRIPTION

22473

A6357A

4 SRV-91222-F 1 FLYWHEEL, MAGNETIZED

67198-N 1

WASHER, BELLVILLE M20 6 67890 1 NUT, M20 X 1.5 7

A4456

1 3/8" SPECIAL LOCK

WASHER 33

SCREW, CRIMPTITE #10-24 34 11 -74260

8 56893

X .5" LG

9 A6358 1 COVER,TOP FLYWHEEL

10 91646 1

DEFLECTOR, EXHAUST 36 PORT

90954B 1 WRAPPER, STARTER SIDE

A6489A

A6359A 1 WRAPPER, CARB. SIDE

90892

91159 1 BUSHING, RUBBER

37 91160

11 92572 1 ASSEMBLY, IGNITION COIL 38 91161

92079 22717A 1

13 14 73132 1

23897

15 16 89685 1 17 22129

22127

2 SCREW, TAPTITE M6-1.0 x

25 LG

GROMMET, RUBBER BOOT, SPARK PLUG

#10 FLAT WASHER

GROMMET RUBBER

LOCKWASHER-M8

HEX NUT-1/4"-20

39 49821 2 BOLT, SOCKET HD. 40 86999 41 60108 1 42 75281 1

19 57821 2 CAPSCR., HEX HD.-M8-1.25

x40 LG

59637 4 SCREW, TAPTITE 3/8"-16 x

.75" LG

21544

22 40976 2

MOTOR, STARTER-12VOLT 45

SOCKET HD. CAPSCR., M8- 46

43 70728 44 43182 2

70185 1 C3304 1

1.25 X 20 LG 82774

23 A9841 1 24

A8875 25 A7299 1 26 A9539 1

EXHAUST MANIFOLD

1 ASSEMBLY, DIPSTICK & CAP

OIL DRAIN/DIPSTICKTUBE 49 OIL DRAIN HOSE 50 ASSEMBLY 51

31580 1 PIPE NIPPLE, 3/8" X 8.5" LG.

47 48 C1951

90239 1 C2866 1 CLAMP-1.25" A9816

40976

BRASS STREET ELBOW,

1 FLAT WASHER, 1/4"-M6

1 WRAPPER, ENGINE SPARK

PLUG

WRAPPER, REAR GEAR CASE

ASSEMBLY, WIRE-STARTER

(#16)

SUPPORT OIL FILTER

1 WASHER, RUBBER

1 BOLT, SHOULDER-M6-1.0 x

15 LG.

CAPSCR.-M8-1.25x30 LG

1 GASKET, OIL FILTER SUP-

PORT ADAPTER SWITCH, OIL PRESSURE-10 PSI SWITCH, OIL TEMPERATURE SCREW, PHILIPS PAN HD.

MACH.-M3-.5 X 5 LG LOCK WASHER-M3 FILTER, OIL ENGINE, LONG BLOCKGN410VSRV KEY, WOODRUFF 4x 19 DIA.

GASKET GASKET

EXHAUST FLEX

M8- 1.25 X 20 SOCKET HEAD

Generac® Power Systems, Inc. 31

PARTS

LISTS

Section 7 — Exploded Views and Parts Lists

Guardian 8 kW and TO kW Generators GN-724 Engine Accessories and Sheet Metal - Drawing No. C2371-

32 Generac* Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian 8 kW and 10 kW Generators

GN-724 Engine Accessories and Sheet Metal - Drawing No. C2371-

..PARTS

LISTS

TEM

PART NO.

Cl 350A 1

C1351A

3 Cl 354A

C1353A

Cl 355

C1355A

QTY. DESCRIPTION ITEM PART NO.

WRAPPER, VALLEY 41 56893 WRAPPER, CYLINDER #1

STARTER, WRAPPER 43 Cl 349 1

WRAPPER, CRANKCASE

1 1 10KW COVER, ENGINE 45 Cl 676 1 GOVERNOR LEVER

8KW COVER, ENGINE 46 C1679 1 GOVERNOR LINKAGE

6 Cl 352A 1 WRAPPER, CYLINDER

#2-BACK 48 Cl 859 1 SPRING, IDLE

Cl 468A

WRAPPER, CYLINDER 49

#2-FRONT

66480 1

Cl 460

Cl 285

Cl 625

C2784 1 TUBE, INTAKE 55

35685

70941 1

Cl 626

C2689

GASKET, AIR CLEANER

1 CARBURETOR

MANIFOLD INTAKE

GASKET, INTAKE 54 65852

CLAMP, #28 56 Cl 863 1 BAFFLE

FILTER, AIR

GASKET CARBURETOR

M6-1.0 X 16 SOCKET HEAD SCREW 60

39287 2 M8-1.25 X 45 HEX HEAD BOLT 61 91159 2

A9736 1 A9736A

22287 2

C2421 1

C2425

C2424 1 CAP, SPRING 23 C2422 24

C2423 25

74908 26

22413 4

Cl 702 1 BREATHER HOSE

FRAME, 10KW FRAME, 8KW

Y4-20 X 3/4" HEX HEAD BOLT ROD, SPEED CONTROL 65 38593 1 BRACKET, SPEED CONTROL

1 1 SPRING, SPEED CONTROL 68

NUT, SPEED CONTROL

4 M5-0.8 X 10 TAPTITE

1/4-20 X 1" HEX HEAD BOLT

28 A9027 1 OIL ADAPTOR

A9028

Cl 557 1 0-RING, 13/16" I.D.

31 Cl 547

Cl 546 1 0-RING, 2-3/8" HEAD SCREW

74948

Cl 623 1

1 OIL ADAPTOR BOLT 73 A9820 1 EXHAUST MANIFOLD 1 0-RING, 7/8" 75

4 FITTING, 5/16" COMPRESSION 76 Cl 950 2

OIL TUBE, RETURN 77

35 Cl 622 1 OIL TUBE, OUT 78 36 37 38 39 40

A6898 70185 60108

11-74260 1

22507

1 OIL FILTER SUPPORT 1 OIL FILTER 1 OIL PRESSURE SWITCH

STARTER CABLE 82 C2418 1/4-20 X i/z" HEX HEAD BOLT 83 C2419 1 WASHER, FLYWHEEL

QTY. DESCRIPTION

10-24 X 1/2 "CRIMPTITE

A2311 2

1/4-20 X 1" TAPTITE

SCROLL, FLYWHEEL

44 Cl 677

47 Cl 680

22097 22717B

22717A

51 52 22127 53 C2420 1

GOVERNOR BRACKET

SPRING, ANTI-LASH

1/4" LOCK WASHER

GROMMET

2 1/4-20 HEX NUT

KEY

1 CLIP

C2441 1 WIRE DIODE ASSEMBLY

36261 2 POP RIVET, 1/8" X .23 S.S.

58 22129

5/16" LOCK WASHER

59 C2693 1 CARRIAGE BOLT V4-20 x 1-3/8"

49811 1 M6 FLAT WASHER

RUBBER BUSHING

62 74962A

C2145

64 74902

1 SPRING, GOVERNOR

GASKET, SET ENGINE COVER

2 SHIELD WRAPPER

90 DEG.ST. ELBOW 3/8" 66 67

Cl 983 A7299 1 A8875 43790A

3/8" X 11-1/4" PIPE

DIPSTICK TUBE DIPSTICK & CAP

1 1 90 DEG. HOSE FITTING

3/8" X 3/8"

C2078

70 71

75246 4 3/8-16 X 1-1/4" TAPTITE

A4456 1 3/8" SPECIAL LOCK WASHER

74 Cl 624

OIL DRAIN HOSE

2 EXHAUST GASKET

75789 4 5/16-18 X %" SOCKET

GASKET, EXHAUST

23897 23762 73132

C2866

A9816

84 C2824

#10 FLAT WASHER

6 1 STAR WASHER #10 2 BOOT, SPARK PLUG 1 CLAMP

EXHAUST FLEX

NUT, FLYWHEEL

1 1 TAP-R 10-32 X 9/16"

Generac® Power Systems, Inc. 33

PARTS

LISTS

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators Control Panel Assembly - Drawing No. C2373-

34 Oenerac“ Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Control Panel Assembly - Drawing No. C2373-

,PARTS

LISTS

ТЕМ

PART NO. QTY.

A9909 1 CONTROL PANEL

A1801

83048

C2174

7521OA 1 TERMINAL BLOCK 33 A2053

40213

Cl 537

65795 1

32300

22676 1

33873 1

75234

A2769

23484F

75476 2

16 22264 17

51715

80077 1 M4-0.7 X 20 PHILLIPS

43182

43181 6

86729 1 STARTER CONTACTOR

Cl 227 23 54502 1 24

A1495 2 25

75235 4 M5-0.8 X 30 HEX HD. 26

22985

DESCRIPTION

1 ASSEMBLY, ENGINE BATTERY 28

CHARGER

ASSEMBLY VOLTAGE

REGULATOR 31

RELAY 12V. 25A SPST

ITEM PART NO. QTY. DESCRIPTION

27 29

30 32

92113 51714 Cl 457 A2110 2 SWAGEFORM, X4"-20 99076 1 74908 3

1 SWITCH SPDT (MOM)

M3-0.5 HEX NUT

1 HOURMETER

TRANSFORMER, 16V 56VA M5-0.8 X 10 TAPTITE

1 M6-1.0x65HEXHEAD

4 PCB SUPPORT, SNAP-IN

ASSEMBLY, PCB

CONTROLLER RECTIFIER, BATTERY 37 CHARGER

1 HOLDER, FUSE 39 51716

34 35

22473 1 M6 FLAT WASHER 22097

36 49813

22471

49226 4 M5 LOCK WASHER

M6 LOCK WASHER

M6-1.0 HEX NUT #8-32 HEX NUT

2 4

M5-0.8 HEX NUT FUSE, 15 AMP. 40 36261 2 POP RIVET 1/8 X .23 SWITCH, DPDT-ROCKER

RESISTER, 1 OHM 25W 42

1 1 LUG, GROUND 8-TABS

SNAP BUSHING

M4-0.7 X 16 PHILLIPS 43 PAN HEAD 44 M4 LOCK WASHER

M4-0.7 HEX NUT

PAN HEAD М3 LOCK WASHER 49 75475

M3-0.5 X 10 PAN HEAD 50 DECAL, CONTROL PANEL

(NOT SHOWN) CIRCUIT BREAKER AUTO RESET 54 M4-0.7 X 10 TAPTITE 55

M4/#6 FLAT WASHER

41 A9896 1 BOX COVER

A9947B

A9947A

1 45A CIRCUIT BREAKER (10KW)

35A CIRCUIT BREAKER (8KW)

A9947 1 25A CIRCUIT BREAKER (6KW)

45 46 47 48

A9992A A9992D A9992B A9992C 1 INSULATING PLATE A9872 A9895 1

TERMINAL BLOCK

1 NUMBER STRIP

2 END BRACKETS

1 DIN RAIL

CONNECTION BOX

4 M4 X 0.7 X 10 PMMS

M4 FLAT WASHER TRANSFORMER, 16V 6VA

2 #6 LOCK WASHER

#6-32 X V4" PHILLIPS PAN

51 52

38150 6 C2657 1

22155

Cl 381 2

HEAD, SELF TAPPING

22127 2 '/4-20 HEX NUT

Cl 226 1

56 31879

HARNESS (NOT SHOWN)

2 #4 FLAT WASHER

Generac® Power Systems, Inc. 35

^PARTS

LISTS

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Alternator - Drawing No. C2374-

PART NO. QTY. DESCRIPTION

C2079 1

6/8KW LOWER BEARING CARRIER

A9226 1

10KW LOWER BEARING

CARRIER 2 31971 3 A5649H 1

73163H 1

A9064 1

73159 1

5 C1854H 1

C1855H 1 Cl 856

6 72379B 1

BEARING

6KW ROTOR ASSEMBLY

8KW ROTOR ASSEMBLY

10KW ROTOR ASSEMBLY 14

BEARING

6KW STATOR ASSEMBLY

8KW STATOR ASSEMBLY

10KW STATOR ASSEMBLY

6/8KW UPPER BEARING CARRIER

A9227

10KW UPPER BEARING

CARRIER

77006 4 A6529

8 73146 4

A9918

36 Generac" Power Systems, Inc.

8/10 KW STATOR BOLT

6 KW STATOR BOLT 6/8KW NYLON SLIDES

10KW NYLON SLIDES

ITEM PART NO. QTY. DESCRIPTION

9 Cl 878 2 6/8KW SLIDE SUPPORT

A9202 75242

10KW SLIDE SUPPORT

2 4

ALTERNATOR MOUNTING SPRING

12 52858 13 75215 2

75237

29459

SPRING CENTERING WASHER

10 FLANGED LOCKING NUT

SPRING CENTERING WASHER

2 BELT TENSIONING SPRING

15 C2375 2 M8 X 90 HEX HD. SET SCREW

(6/8KW)

51730 2 M8 x60 HEX HD. SET SCREW

(10KW)

45771

4 M8 NUT 17 27756 4 NYLON WASHER 18 66849 2 M5 X 15MM SCREW 19 20

66386 C2094 Cl 696 1 22145 2 M8 FLAT WASHER

BRUSH HOLDER ASSEMBLY

1 1 6/8KW ALTERNATOR COVER

10KW ALTERNATOR COVER

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Transfer Switch - Drawing No. C2696-

..PARTS

LISTS

TEM

PART NO. QTY.

C2259

DESCRIPTION ITEM

1 TRANSFER SWITCH

ENCLOSURE 18 77441 1

74975 1 C2237 1 TRANSFER SWITCH 21 74138 4

74908 4 M5-0.8 X 10TAPTITE

ENCLOSURE COVER 19

5 24912 1 '/4-20 X 5/8" TAPTITE 6 A1658 7

63617 1 RELAY-1 OAMP. 12 VOLTS DC

27628

24940 A1661

10 11

62684 1 LUG, GROUND

42568 4 M6- 1.0 X 20 HEX HEAD BOLT 28 C2260 1

WASHER '/4 SHAKEPROOF

1 HEX NUT-3/8"-16 POSITION 4 8-32 X '/2" TAPTITE 25 2 POP RIVET, .156 D X .5 26 22473 4

PART NO.

64113 1 22131 1

36932

23 77033 24

48850 77052

C2261 1 COVER

QTY.

DESCRIPTION

WING NUT, M6-1.0

MANUAL TRANSFER HANDLE FLATWASHER-3/8" MALE DISCONNECT ADAPTOR SCREW, PAN HEAD

NO. 10-32 X '/4" SOLDERLESS LUG

1 TERMINAL BLOCK-5

MALE DISCONNECT ADAPTOR

FLAT WASHER-M6

TRANSFER WIRE HARNESS 13 22097 4 LOCK WASHER M6 (NOT SHOWN FOR CLARITY) 14

57073

66849 2 M5-.8 X 16 TAPTITE 31

16 22152

NEUTRAL LUG-JUNCTION 29 73591 2 BLOCK 30

6 LOCK WASHER NO. 10

73590A

40213B

FUSE HOLDER FUSE, 5A 600 VOLT

STAND-OFF

Generac* Power Systems, Inc. 37

^PARTS

LISTS

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators Mounting Base Assembly - Drawing No. C2372-

TEM

PART NO.

Cl 753 1

A9628 1 ASSEMBLY, ENCLOSURE

QTY. DESCRIPTION

ALTERNATOR PULLEY 21

BASE 3 C1112 1 4

75224D

38353

A9593

A9827

8 Cl 441

V-BELT

ENGINE PULLEY

RUBBER MOUNT

EXHAUST DUCT ASSEMBLY

BLOWER HOUSING

GASKET SET, BLOWER HOUSING

22473 5

10 22097 2

22287 2

12 C2824 7

13 26307 1 14

C2206

M6 FLAT WASHER

M6 LOCK WASHER

74-20 X W HEX HEAD

TAP-R 10-32 X 9/16" 90DEG. STREET ELBOW-3/4"

BARBED HOSE FITTING

15 74994 2 FT. 72" I.D. HOSE 16 57822 2 17

63463

C1616 C1616B 1

19 75211 1

C2131

Generac* Power Systems, Inc.

HOSE CLAMP #8

BARBED HOSE FITTING

8/10 KW LOAD BLOCK 6 KW LOAD BLOCK GAS REGULATOR 37

GASKET SET, AIR DUCT

ITEM PART NO.

C1751

QTY. DESCRIPTION

ALTERNATOR FAN MODEL04077, 04109 (7”)

Cl 752

ALTERNATOR FAN MODEL04079 (8”)

22131 5 3/8" FLAT WASHER 23 22237 24 23152 4 25 22241

3/8" LOCK WASHER 3/8"-16 X %" HEX HEAD BOLT

3/8-16 NUT 26 22145 3 5/16 FLAT WASHER 27 28 29

22129

3 5/16 LOCK WASHER 55173 3 M8-1.25 X 20 HEX HEAD 79246 3 M6-1.0 X 16 HEX HEAD WITH

LOCK WASHER

30 49451

1 7GA. X .41" X 1.62" FLAT

WASHER

22237

3/8" LOCK WASHER

42633 1 3/8"-24 X 1" HEX HEAD

33 73118 1 3/8"-24x 2-1/4" HEX HEAD 34 C2417 35 36

A4456 1 A1658 2 74" LOCK WASHER-SPECIAL

1 GROUND STRAP

3/8" LOCK WASHER-SPECIAL

49813 1 M6-1.0 NUT 38 AB38805 1 39 A2311 1

CABLE, BLACK-BATTERY 74"-20 X 1" FASTENER

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

Enclosure - Drawing No. C2370-

..PARTS

LISTS

ITEM

13 14 15 16

17 18 22097 19

20 21

PART NO.

A9962 1 PLATE, INTAKE 22 79246

A9892 1 ENCLOSURE, ROOF

C1199

A9677 1 RAIL, TOP SUPPORT 25 22129 5

A9633

A9651

A9897

A9629

A9631

A9632 1 COVER, EXHAUST BOX

78115 15

A9816 Cl 023 A2110 5 26915 A2666 22473 26

49813 C2866 57822

QTY.

DESCRIPTION ITEM

1 PANEL, ENCLOSURE-ALT

SIDE

1 ENCLOSURE, DOOR

MUFFLER

1 SUPPORT, BRACKET

MUFFLER

1 SIDE AND BACK ENCLOSURE

BOX, MUFFLER

SELF LOCKING DOME WASHER

1 FLEX-EXHAUST PIPE 32

DOOR LATCH 33

74-20 X 1/2" SWAGE FASTENER 34 C2206 1 BARBED FITTING

%" NPT CLOSE NIPPLE 35 FUEL SOLENOID

M6 FLAT WASHER M6 LOCK WASHER

M6 -1.0 NUT 39

EXHAUST CLAMP-1.25" 40

CLAMP #8

PART NO.QTY.DESCRIPTION

M6- 1,0 X 16 HEX HD, & LOCK

WASHER

29745 2

23 24

22145 22241 2 3/8"- 16 HEX NUT

26 27 C2310 1

A2393

28 29 A9961

30 A9963

A9964

56893 5 22259

C2506A 2 MESH, DOOR PANEL C2506B

37 C2506C 1

38 22131

22237 2 3/8" LOCK WASHER C2502

Generac* Power Systems, Inc. 39

3/8"-16 X 1" HEX HEAD M8 FLAT WASHER

M8 LOCK WASHER GASKET, SET-MUFFLER BOX

M6 1.0 X 16 FLAT SOCKET HD.

CAPSCR.

1 BATTERY TRAY

1 BATTERY TRAY SUPPORT

ANGLED BATTERY TRAY

SUPPORT CRIMPTITE-10-24 X Ya 5/16"- 18 HEX NUT

MESH, EXHAUST BOX

MESH, EXHAUST OUTLET

3/8" FLAT WASHER

BARRIER FOAM

Section 8 - Warranty

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

CALIFORNIA ElVIlSSION CONTROL WARRANTY STATEiVIENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment

engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neg

lect, unapproved modification or improper maintenance of your engine. Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac

will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY CO¥ERAGE:

Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related component or system on your engine is found to be defective in mate rials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your fac tory supplied Owner's Manual For warranty purposes, Generac recommends that you retain all receipts covering main tenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty cover age or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper mainte nance or unapproved modifications, or the use of counterfeit and/or ‘grey market’ parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a

problem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service

Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,’’ which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there Is any con flict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except In circum stances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of the sale to the original purchaser/owner.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 8

WAUKESHA, Wl 53187

Part 1

40 Generac* Power Systems, Inc.

Section 8 - Warranty

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:

(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin

on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine

or equipment and to each subsequent purchaser/owner that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its

authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a

warranted emissions-related part to fall to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the

Owner’s Manual shall be warranted for the ECS Warranty Period. If any such part falls during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner's

Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s

Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be war ranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emis sions-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no

charge to the owner at a Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held

responsible for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately

caused by a failure under warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts suffi

cient to meet the expected demand for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any

ECS Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or ‘grey market’ parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or ‘grey market’ part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System; 3) Ignition System including;

1.2) LPG/Natural Gas carburetion assembly and its Internal a) Spark plug components.

a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped) e) LP liquid vaporizer (if so equipped)

b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) Including: a) Muffler gasket b) Exhaust manifold

5) Crankcase Breather Assembly Including: a) Breather connection tube

2) Air Induction System including: a) Intake pipe/manifold b) Air cleaner

■ •Generac engine types covered by this warranty statement include the following:

1) Prepackaged Standby Generator

2) Auxiliary Power Unit (APU) Generator

3) Standby Generator

Part 2

Generac* Power Systems, Inc. 41

Section 8 - Warranty

^^RRAHTil

GENERAC POWER SYSTEfViS' TWO - YEAR" STANDARD WARRANTY FOR GUARDIAN

Guardian Air-cooled 6 kW, 8 kW and 10 kW Generators

"AIR COOLED, PREPACKAGED STANDBY GENERATORS "

For a period of two years or 2,000 hours of operation from the date of original sale, whichever occurs first Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac

Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the fac

tory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Guardian air cooled, prepackaged standby generators sold and rated for use in "Standby" applications, as Generac has defined Standby.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) coverage on mileage*, part(s) and labor as listed (proof of purchase and maintenance is required):

• Engine - All components

• Alternator - All Components

• Transfer System - All Components

*Travel allowance is limited to 300 miles or 7.5 hours maximum round trip and applies only to per manently wired and mounted units.

All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies,

Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Costs of normal maintenance, adjustments, installation and start-up. Failures caused by any contaminated fuels or oils. Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As

with all mechanical devices, the GH- and GV-Series engines need periodic part(s) service and replacement to perform

well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine. Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust,

fire, freezing, lightning, earthquake, windstorm, hall, volcanic eruption, water or flood, tornado or hurricane. Products that are modified or altered in a manner not authorized by Generac in writing. Any incidental, consequential or Indirect damages caused by defects in materials or workmanship, or any delay in repair

or replacement of the defective part(s). Failure due to misapplication. Telephone, telegraph, Teletype or other communication expenses. Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific

unit warranty period. Rental equipment used while warranty repairs are being performed. Overnight freight costs for replacement part(s). Overtime labor. Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICU LAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above lim itation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE, IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exelusion or limitation of incidental or consequential damages, so the above limitation may not apply to you Purchaser/owner agrees to make no claims against Generac based on negligence.

This warranty gives you specific legal rights. You also may have other rights that vary from state to state.

GEIMERAC* POWER SYSTEMS, IIMC.

Part No.

C9035

RO. BOX B • WAUKESHA, Wl 531

PH: (41 4] 544-4S1 1 ■ FAX: [41 4] 544-5BB3

Revision O (07/ai/DO)

Printed in U.S.A.

Generac 04077-2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ELECTRICAL HAZARDS

FIRE HAZARDS

EXPLOSION HAZARDS

1.1 UNPACKING/INSPEaiON

1.5 FUEL CONSUMPTION

1.7 SPECIFICATIONS

3.4 CHANGING THE OIL FILTER

3.6 SPARK PLUG(S)