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withdrawn liquid propane (LP) or natural gas (NG).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

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