Generac Power Systems 04758-2, 04759-2, 04760-2 owner manual Introduction, Danger, ‹ Contents

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INTRODUCTION

INTRODUCTION

Thank you for purchasing this Guardian model by Generac Power Systems Inc.. This model is a compact, high per- formance, air-cooled, engine-driven generator designed to automatically supply electrical power to operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation. This genera- tor will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).

This unit meets the 1998 and later California emissions reg- ulations. To ensure that the engine continues to meet these regulations, refer to the following information and instruc- tions in this owner’s manual.

‹ENGINE EMISSION COMPLIANCE PERIOD

For nonhandheld engines: The Emissions Compliance Period referred to on the Emissions Compliance label indi- cates the number of operating hours for which the engine has been shown to meet federal emission requirements.

For engines less than 225 cc displacement, Category C = 125 hours, B = 250 hours, and A = 500 hours.

For engines 225 cc or more, Category C = 250 hours, B = 500 hours, and A = 1000 hours.

‹READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest Generac Authorized Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAU- TION and NOTE blocks are used to alert personnel to spe- cial instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

‹ENGINE EMISSION COMPLIANCE PERIOD‹READ THIS MANUAL THOROUGHLY DANGER

After this heading, read instructions that, if not strictly complied with, will result in serious person- al injury, including death, in addition to property damage.

After this heading, read instructions that, if not strictly complied with, may result in serious person- al injury or property damage.

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

NOTE:

After this heading, read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the spe- cial 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 others.

This symbol points out potential explosion hazard.

 DANGER This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator is responsible for proper and safe use of the equipment. We strongly recommend that the opera- tor read this Owner's Manual and thoroughly understand all instructions before using this equipment. 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 information, including warranty, electrical diagrams, exploded views and lists of repair parts, for three different Guardian mod- els:

04758-2 – 6 kW NG, 7 kW LP, single-cylinder GH-410 Engine

04759-2 – 12 kW NG, 12 kW LP, V-twin GT-990 Engine

04760-2 – 13 kW NG, 15 kW LP, V-twin GT-990 Engine

‹OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is per- formed promptly, and to have the equipment checked peri- odically by a Generac Authorized Dealer. Normal mainte- nance service and replacement of parts are the responsibili- ty 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 the generator ensures a minimum number of problems and keep operating expens- es at a minimum. See the Generac Authorized Dealer for service aids and accessories.

‹HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact a Generac Authorized Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

When contacting a Generac Authorized Dealer or the factory about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator. See Figure 1.1 or Figure 1.2 in Section 1.4 for decal location.

Model No. ____________ Serial No. ______________

AUTHORIZED DEALER LOCATION

To locate the GENERAC AUTHORIZED

DEALER nearest you, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

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Contents This manual should remain with the unit Models 04758-2 6 kW NG, 7 kW LP 04759-2 12 kW NG, 12 kW LP04760-2 13 kW NG, 15 kW LP Installation and Owner’s Manual‹ HOW TO OBTAIN SERVICE ‹ CONTENTS‹ OPERATION AND MAINTENANCE INTRODUCTIONIntroduction Parts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator during operation. Exercise care near running generatorsEXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS ‹ STANDARDS INDEX1.3 SYSTEM SET LED 1.1 UNPACKING/INSPECTION1.2 PROTECTION SYSTEMS DANGERFigure 1.2 - 12 kW/15 kW, V-twin GT-990/760 Engine 1.4 THE GENERATORFigure 1.1 - 7 kW, Single Cylinder GH-410 Engine ‹ 1.5.2 ENGINE 1.5 SPECIFICATIONS‹ 1.5.1 GENERATOR 1.7 FUEL CONSUMPTION 1.8 RECONFIGURING THE FUEL SYSTEM1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS DANGER1.9.1 GENERATOR 1.9 LOCATION1.8.2 12KW AND 15KW, 990CC ENGINES Figure 1.4 - Demand Regulator1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW, 12 kW and 15 kW Units 1.10 BATTERY INSTALLATION1.11 THE BATTERY Figure 1.5 - Battery Cable Connections2.3 ELECTRICAL CHECKS 2.2 CHECK TRANSFER SWITCH OPERATION2.1 BEFORE INITIAL START-UP 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC OPERATIONFigure 2.1 - Dual Fuel Regulators 2.6 ADJUSTING THE REGULATOR NATURAL GAS ONLYFigure 2.2 - Placement of Regulator Figure 2.3 - Single Cylinder Engine Governor Adjustment 2.7 ENGINE GOVERNOR ADJUSTMENTFigure 2.4 - V-twin Engine Governor Adjustment Figure 2.5 - V-twin Full Load Speed Adjust Screw3.2 USING THE AUTO/OFF/MANUAL SWITCH FIGURE 2.8 VOLTAGE REGULATOR ADJUSTMENT3.1 BREAK-IN PROCEDURE Figure 2.6 - Voltage Adjustment Potentiometer3.4 SEQUENCE OF AUTOMATIC OPERATION 3.3 AUTOMATIC TRANSFER OPERATION3.5 MANUAL TRANSFER OPERATION ‹ 3.5.1 TRANSFER TO GENERATOR POWER SOURCE‹ 3.7.2 HIGH TEMPERATURE SWITCH ‹ 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE‹ 3.7.1 LOW OIL PRESSURE SWITCH Figure 3.2 - Manual Transfer Switch Operation4.1 FUSE Figure 3.3 - Low Oil Pressure and High Temperature Switches4.2 CHECKING THE ENGINE OIL LEVEL ‹ 3.7.3 OVERCRANK4.3 CHANGING THE ENGINE OIL 4.5 CHANGING THE ENGINE AIR CLEANER‹ 4.3.2 OIL CHANGE PROCEDURE 4.4 CHANGING THE OIL FILTERFigure 4.7 - 12 kW and 15 kW Engine Air Cleaner 4.7 BATTERY MAINTENANCEFigure 4.6 - 7 kW, Engine Air Cleaner Location Figure 4.8 - Setting the Spark Plug Gap4.9 COOLING SYSTEM 4.8 ADJUSTING VALVE CLEARANCEFigure 4.10 - Valve Clearance Adjustment ‹ 4.12.1 REMOVAL FROM SERVICE 4.12 OUT OF SERVICE PROCEDURE‹ 4.12.2 RETURN TO SERVICE 4.10 ATTENTION AFTER SUBMERSION4.13 SERVICE SCHEDULE CAUSE 5.1 TROUBLESHOOTING GUIDEPROBLEM CORRECTIONSection 6 - Electrical Data 24 Generac Power Systems, IncENGINE WIRING CONNECTION CONTROL PANEL BOXCUSTOMER Electrical Schematic - 12 & 15 kW - Drawing No. 0D8501-B 26 Generac Power Systems, IncGenerac Power Systems, Inc 28 Generac Power Systems, Inc Section 6 - Electrical DataCONTROL PANEL BOX 224A 30 Generac Power Systems, Inc225A Electrical Schematic - 7 kW - Drawing No. 0D9014-C Section 7 - Exploded Views and Parts Lists 32 Generac Power Systems, IncPART NO. QTY. DESCRIPTION 34 Generac Power Systems, Inc PART NO. QTY. DESCRIPTION 35, 36, 40 36 Generac Power Systems, Inc27, 28 PART NO. QTY DESCRIPTION38 Generac Power Systems, Inc DESCRIPTION 40 Generac Power Systems, Inc 14 201.8 FT 1.25 FT42 Generac Power Systems, Inc 1.33 FT 2.6 FT3 FT 44 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 46 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 48 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists Section 8 - Mounting 50 Generac Power Systems, IncALL DIMENSIONS IN MILLIMETERS INCHES Guardian Air-cooled 7 kW, 12 Drawing No. 0D3739-BSection 9 - Notes PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGWARRANTY SCHEDULE GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANPREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING