Generac Power Systems GUARDIAN 04079-2 Installation manual

POWER SYSTEMS, INC.
®
Post Installation Start-up
and Adjustment Manual
Air-cooled, Prepackaged
Standby Generators
Models:
04109-2 (8 kW)
04079-2 (10 kW)

Section1—PostInstallation Start-up and Adjustments
Guardian Air-cooled Generators
Section1–PostInstallation Start-up
and Adjustments ..........................................2
1.1 Before Initial Start-up ..............................2
1.2 Battery Installation ..................................2
1.3 Check Transfer Switch Operation..............3
1.4 Electrical Checks ......................................3
1.5 Generator Tests Under Load......................3
1.6 Checking Automatic Operation..................4
1.7 Setting the Exercise Timer ........................4
1.8 Adjusting the Load Block ..........................5
1.9 Engine Governor Adjustment ....................5
1.9.1 8 kW and 10 kW Units ..................5
1.9.2 Additional Corrosion Protection......5
1.10 Voltage Regulator Adjustment ..................6
1.11 Additional Generator Features ..................6
Section 2 – Notes ............................................7
1.1 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Set the generator's Auto/Off/Manual switch to the
OFF position.
2. Turn OFF the utility power supply to the transfer
switch using the means provided (such as the
utility main line circuit breaker).
3. Check the engine crankcase oil level and, if nec-
essary, fill to the dipstick FULL mark with the
recommended oil. Do not fill above the FULL
mark.
4. Check the fuel supply. Gaseous fuel lines must
have been properly purged and leak tested in
accordance with applicable fuel-gas codes. All
fuel shutoff valves in the fuel supply lines must be
open.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
1.2 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if nec-
essary and have the battery fully charged before
installing it.
Before installing and connecting the battery, complete
the following steps:
1. Set the generator's Auto/Off/Manual switch
to OFF.
2. Turn off utility power supply to the transfer
switch.
If the Auto/Off/Manual switch is not set to its
OFF position, the generator can crank and start
as soon as the battery cables are connected. If
the utility power supply is not turned off,
sparking can occur at the battery posts and
cause an explosion.
Battery cables were factory connected at the genera-
tor (Figure 1.1). Connect cables to battery posts as
follows:
1. Connect the red battery cable (from starter con-
tactor) to the battery post indicated by a positive,
POS or (+).
2. Connect the black battery cable (from frame
ground) to the battery post indicated by a nega-
tive, NEG or (—). NOTE:
Damage will result if battery connections are made
in reverse.
2 Generac®Power Systems, Inc.

Generac®Power Systems, Inc. 3
Section1—PostInstallation Start-up and Adjustments
Guardian Air-cooled Generators
Figure 1.1 – Battery Cable Connections
NOTE:
With the battery installed and utility power source
voltage available to the transfer switch, the battery
receives a trickle charge while the engine is not
running, to prevent self-discharge. The trickle
charge feature cannot be used to recharge a dis-
charged battery.
1.3 CHECK TRANSFER
SWITCH OPERATION
Refer to Section 2.5 (Page 9), of the owner’s manual
for manual operation procedures.
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
1.4 ELECTRICAL CHECKS
Complete electrical checks as follows:
1. Turn on the utility power supply to the transfer
switch using the means provided (such as a utili-
ty main line circuit breaker).
The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extreme-
ly hazardous and possibly fatal electrical shock.
Proceed with caution.
2. Use an accurate AC voltmeter to check utility
power source voltage across terminals N1 and
N2. Nominal line-to-line voltage should be 240
volts AC.
3. Check utility power source voltage across termi-
nals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-to-
neutral voltage should be 120 volts AC.
4. When certain that utility supply voltage is com-
patible with transfer switch and load circuit rat-
ings, turn OFF the utility power supply to the
transfer switch.
5. Set the generator's main circuit breaker to its
OFF (or open) position. Initial tests will be con-
ducted at no-load condition.
6. On the generator panel, set the Auto/Off/Manual
switch to MANUAL. The engine should crank and
start.
7. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set
the generator’s main circuit breaker to its ON (or
closed) position.
Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in
dangerous and possibly fatal electrical shock.
8. Connect an accurate AC voltmeter and an AC fre-
quency meter across transfer switch terminal
lugs E1 and E2. Voltage should be 242-252 volts;
frequency should read about 61-63 Hertz.
9. Connect the AC voltmeter test leads across termi-
nal lug E1 and neutral; then across E2 and neu-
tral. In both cases, voltage reading should be 121-
126 volts AC.
10. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at no-
load for a few minutes to stabilize internal engine
generator temperatures.
11. Set the generator's Auto/Off/Manual switch to
OFF. The engine should shut down.
NOTE:
It is important that you do not proceed until you
are certain that generator AC voltage and frequen-
cy are correct and within the stated limits.
Generally, if both AC frequency and voltage are
high or low, the engine governor requires adjust-
ment. If frequency is correct, but voltage is high or
low, the generator’s voltage regulator requires
adjustment.
1.5 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied,
proceed as follows:
1. Set generator’s main circuit breaker to its OFF
(or open) position.
2. Set the generator's Auto/Off/Manual switch
to OFF.
3. Turn OFF the utility power supply to the transfer
switch, using the means provided (such as a util-
ity main line circuit breaker).

4 Generac®Power Systems, Inc.
Section1—PostInstallation Start-up and Adjustments
Guardian Air-cooled Generators
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
4. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's E1/E2 terminals. The transfer switch
operating lever should be down.
5. Set the generator's Auto/Off/Manual switch to
MANUAL. The engine should crank and start
immediately.
6. Let the engine stabilize and warm up for a few
minutes.
7. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.
8. Turn ON electrical loads. Apply an electrical load
equal to the full rated wattage/amperage capacity
of the installed generator.
9. Connect an accurate AC frequency meter across
terminal lugs E1 and E2. Voltage should be
greater than 230 volts; frequency should be
greater than 58 Hertz.
10. Let the generator run at full rated load for 20-30
minutes. Listen for unusual noises, vibration or
other indications of abnormal operation. Check
for oil leaks, evidence of overheating, etc.
11. When testing under load is complete, turn OFF
electrical loads.
12. Set the generator's main circuit breakers to their
OFF (or open) positions.
13. Let the engine run at no-load for a few minutes.
14. Set the Auto/Off/Manual switch to OFF. The
engine should shut down.
1.6 CHECKING AUTOMATIC
OPERATION
To check the system for proper automatic operation,
proceed as follows:
1. Check that the Auto/Off/Manual switch is set to
OFF.
2. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the util-
ity power source side.
3. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a util-
ity main line circuit breaker).
4. Set the Auto/Off/Manual switch to AUTO. The sys-
tem is now ready for automatic operation.
5. Turn OFF the utility power supply to the transfer
switch.
With the Auto/Off/Manual switch at AUTO, the engine
should crank and start when the utility source power
is turned OFF. After starting, the transfer switch
should connect load circuits to the standby side. Let
the system go through its entire automatic sequence
of operation.
With the generator running and loads powered by
generator AC output, turn ON the utility power sup-
ply to the transfer switch. The following should
occur:
• After about six seconds, the switch should transfer
loads back to the utility power source.
• About one minute after retransfer, the engine
should shut down.
1.7 SETTING THE EXERCISE TIMER
Your generator is equipped with an exercise timer
(Figure 1.2). Once it is set, the generator will start
and exercise once every seven days, on the day of the
week and at the time of the day that you complete the
following sequence. For example, if you want the gen-
erator to exercise on sundays at 6:00 PM, you will
need to complete the sequence at that exact time.
1. Verify or place the “Auto/Off/Manual” switch in the
AUTO position.
2. Hold down the “Set Exercise Timer” switch until
the generator starts (approximately 10 seconds)
and then release.
Figure 1.2 — Setting the Exercise Timer
3. The generator will start and run for approximate-
ly 12 minutes and then shut down automatically.
The exerciser is now set to run at the same time
and day every week.
NOTE:
The exerciser will only work in the AUTO mode
and will not work unless this procedure is per-
formed. 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.
Set Exercise Timer Auto/Off/Manual Switch

Generac®Power Systems, Inc. 5
1.8 ADJUSTING THE LOAD BLOCK
When the natural gas system is being used, the load
block is fitted with an adjustment screw that has
been calibrated to provide maximum power.
However, because of variations in the Btu content of
natural gas across the country, it may be necessary to
readjust the load block.
• Connect a frequency meter to the output of the gen-
erator.
• Start the unit and apply full load according to the
following chart:
• Allow the unit to stabilize; then, turn the adjust-
ment screw slowly clockwise or counterclockwise
and watch the frequency.
• When the highest frequency is reached, turn the
adjustment screw counterclockwise 1/4 turn.
• The fuel system is now set.
• For LP gas operations, the hose and blanking plug
must be reconfigured as shown in Figure 1.4, (Page
7) of the owner’s manual. The unit is set to provide
maximum power using LP gas.
Do not make any unnecessary adjustments.
Factory settings are correct for most applica-
tions. However, when making adjustments, be
careful to avoid overspeeding the engine.
1.9 ENGINE GOVERNOR ADJUSTMENT
If both AC frequency and voltage are correspondingly
high or low, adjust the engine governor as follows:
1.9.1 8 KW AND 10 KW UNITS
1. Loosen the governor clamp bolt (Figure 1.3).
2. Push the spring end of the governor lever clock-
wise to the wide open throttle position of
the lever.
• Hold the governor lever at wide open throttle and,
with a screwdriver, rotate the governor shaft fully
clockwise.
• Before tightening, verify that the governor lever is
pushed all the way onto the governor shaft.
• While holding the governor shaft fully clockwise
and the governor lever at wide open throttle,
tighten the governor clamp bolt to 130 inch-
pounds (8 N-m).
3. Start the engine; let it stabilize and warm up at
no-load.
4. Turn the speed adjust nut to obtain a frequency
reading of 62 Hertz.
5. When frequency is correct at no-load, check the
AC voltage reading. If voltage is incorrect, the volt-
age regulator may require adjustment.
Figure 1.3–8kWand10kW
Engine Governor Adjustment
NOTE:
If the engine continues to run fast, use a pair of
pliers to bend the bend tab clockwise to release
tension on the lower governor spring.
1.9.2 ADDITIONAL CORROSION PROTECTION
Periodically spray all engine linkage parts and brack-
ets with corrosion inhibiting spray such as WD-40 or
a comparable product.
◆
Side View
Back View
Front View
Carburetor
Spring
Carburetor
Spring
Governor Lever
Spring Speed Adjust Nut
Bend Tab
Governor Spring
Governor
Shaft
Governor
C amp Bo t
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Section1—PostInstallation Start-up and Adjustments
Guardian Air-cooled Generators
Unit 120 Volts 240 Volts
8 kW 66.7 amps 33.3 amps
10 kW 83.3 amps 41.6 amps

6 Generac®Power Systems, Inc.
1.10 VOLTAGE REGULATOR
ADJUSTMENT
With the frequency between 61-62 Hertz, slowly turn
the slotted potentiometer (Figure 1.4) until line volt-
age reads 244-252 volts.
NOTE:
You must remove the roof to adjust the voltage
regulator.
Figure 1.4 – Voltage Adjustment Potentiometer
NOTE:
The voltage regulator is housed in the generator's
control panel. The regulator maintains
a voltage in direct proportion to frequency at a 2-
to-1 ratio. For example, at 62 Hertz, line-to-neu-
tral voltage will be 124 volts.
1.11 ADDITIONAL GENERATOR
FEATURES
1.11.1 8 KW AND 10 KW UNITS
The 8 kW and 10 kW air-cooled Guardians offer addi-
tional features that are not factory preset:
1. Remote Start – This allows for remote starting of
the generator by means of the #183 (common)
and #178 (normally open) lines with the
Auto/Off/Manual switch set to AUTO. Closure of
the circuit starts the unit; opening of the circuit
stops the unit. See Figure 1.5.
NOTE:
This function will work only with the unit in the
AUTO mode.
Figure 1.5 – Remote Start/Alarm Options
–Type 14 AWG wire is recommended.
–These options should be wired to the unit by a qualified electrician or
Generac/Guardian Authorized Dealer.
2. Remote/Common Alarm – This allows for an
alarm, light, horn, etc., to activate when any fault
has occurred. Lines #210 (common) and #211
(normally open) provide a “closure” on common
fault, which can be used for 120 volts, 10 amps
maximum. See Figure 1.5.
3. Remote Not Auto – The generator will not auto-
matically start during a utility failure.
◆
Section1—PostInstallation Start-up and Adjustments
Guardian Air-cooled Generators

Generac®Power Systems, Inc. 7
Section2—Notes
Guardian Air-cooled Generators

Part No. D1962
GENERAC®POWER SYSTEMS, INC.
757 NORTH NEWCOMB ROAD
WHITEWATER, WI 53190
PH: [phone] •FAX: [phone]
Revision 0 (11/08/00) Printed in U.S.A.