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

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Introduction

Table of Contents

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Introduction

Inside Front Cover

Read This Manual Thoroughly

IFC

Contents

IFC

Operation and Maintenance

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

IFC

How to Obtain Service

IFC

Authorized Dealer Locator Number

IFC

Safety Rules

2

Standards Index

3

Section 1 – General Information

4

1.1

Unpacking/Inspection

4

1.2

Protection Systems

4

1.3

System Set LED

4

1.4

The Generator

5

1.5

Specifications

6

 

1.5.1

Generator

6

 

1.5.2

Engine

6

1.6

Fuel Requirements and Recommendations....

7

1.7

Fuel Consumption

7

1.8

Reconfiguring the Fuel System

7

 

1.8.1

7 kW, 410CC

7

 

1.8.2 12 kW and 15 kW, 990cc Engines

8

1.9

Location

8

 

1.9.1

Generator

8

 

1.9.2

Transfer Switch

9

1.10

Battery Installation

9

1.11

The Battery

9

Section 2 – Post Installation Start-up

 

 

 

and Adjustments

10

2.1

Before Initial Start-up

10

2.2

Check Transfer Switch Operation

10

2.3

Electrical Checks

10

2.4

Generator Tests Under Load

11

2.5

Checking Automatic Operation

11

2.6Adjusting the Regulator (Natural Gas Only) ..12

2.7

Engine Governor Adjustment

13

 

2.7.1

7 kW Units

13

 

2.7.2 12 kW and 15 kW Units

13

 

2.7.3

Additional Corrosion Protection

14

2.8

Voltage Regulator Adjustment

14

Section 3 – Operation

14

3.1

Break-in Procedure

14

3.2

Using the Auto/Off/Manual Switch

14

 

3.2.1

“Auto” Position

14

 

3.2.2

“Off” Position

14

 

3.2.3

“Manual” Position

14

3.3

Automatic Transfer Operation

15

3.4

Sequence of Automatic Operation

15

3.5

Manual Transfer Operation

15

 

3.5.1

Transfer to Generator

 

 

 

Power Source

15

 

3.5.2 Transfer Back to Utility

 

 

 

Power Source

16

3.6

Setting the Exercise Timer

16

3.7

Protection Systems

16

 

3.7.1 Low Oil Pressure Switch

16

 

3.7.2

High Temperature Switch

16

 

3.7.3

Overcrank

17

 

3.7.4

Overspeed

17

Section 4 – Maintenance

17

4.1

Fuse

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17

4.2

Checking the Engine Oil Level

17

4.3

Changing the Engine Oil

18

 

4.3.1

Engine Oil Recommendations

18

 

4.3.2

Oil Change Procedure

18

4.4

Changing the Oil Filter

18

4.5

Changing the Engine Air Cleaner

18

 

4.5.1 7 kW, 12 kW and 15 kW

 

 

 

Generators

18

4.6

Spark Plug(s)

19

4.7

Battery Maintenance

19

4.8

Adjusting Valve Clearance

20

4.9

Cooling System

20

4.10

Attention After Submersion

21

4.11

Corrosion Protection

21

4.12

Out of Service Procedure

21

 

4.12.1 Removal From Service

21

 

4.12.2 Return to Service

21

4.13

Service Schedule

22

Section 5 – Troubleshooting

23

5.1

Troubleshooting Guide

23

Section 6 – Electrical Data

24

Section 7 – Exploded Views and

 

 

 

Parts Lists

32

Section 8 – Mounting Dimensions

50

Section 9 – Notes

51

Section 10 – Warranty

52

 

 

Generac® Power Systems, Inc.

1

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Contents Installation and Owner’s Manual Models 04758-2 6 kW NG, 7 kW LP 04759-2 12 kW NG, 12 kW LP04760-2 13 kW NG, 15 kW LP This manual should remain with the unitINTRODUCTION ‹ CONTENTS‹ OPERATION AND MAINTENANCE ‹ HOW TO OBTAIN SERVICEIntroduction during operation. Exercise care near running generators GENERAL HAZARDSDespite the safe design of this generator Parts of the generator are rotating and/or hot‹ STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDSDANGER 1.1 UNPACKING/INSPECTION1.2 PROTECTION SYSTEMS 1.3 SYSTEM SET LED1.4 THE GENERATOR Figure 1.1 - 7 kW, Single Cylinder GH-410 EngineFigure 1.2 - 12 kW/15 kW, V-twin GT-990/760 Engine 1.5 SPECIFICATIONS ‹ 1.5.1 GENERATOR‹ 1.5.2 ENGINE DANGER 1.8 RECONFIGURING THE FUEL SYSTEM1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS 1.7 FUEL CONSUMPTIONFigure 1.4 - Demand Regulator 1.9 LOCATION1.8.2 12KW AND 15KW, 990CC ENGINES 1.9.1 GENERATORFigure 1.5 - Battery Cable Connections 1.10 BATTERY INSTALLATION1.11 THE BATTERY 1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW, 12 kW and 15 kW Units2.2 CHECK TRANSFER SWITCH OPERATION 2.1 BEFORE INITIAL START-UP2.3 ELECTRICAL CHECKS 2.5 CHECKING AUTOMATIC OPERATION 2.4 GENERATOR TESTS UNDER LOAD2.6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Figure 2.2 - Placement of RegulatorFigure 2.1 - Dual Fuel Regulators Figure 2.5 - V-twin Full Load Speed Adjust Screw 2.7 ENGINE GOVERNOR ADJUSTMENTFigure 2.4 - V-twin Engine Governor Adjustment Figure 2.3 - Single Cylinder Engine Governor AdjustmentFigure 2.6 - Voltage Adjustment Potentiometer 2.8 VOLTAGE REGULATOR ADJUSTMENT3.1 BREAK-IN PROCEDURE 3.2 USING THE AUTO/OFF/MANUAL SWITCH FIGURE‹ 3.5.1 TRANSFER TO GENERATOR POWER SOURCE 3.3 AUTOMATIC TRANSFER OPERATION3.5 MANUAL TRANSFER OPERATION 3.4 SEQUENCE OF AUTOMATIC OPERATIONFigure 3.2 - Manual Transfer Switch Operation ‹ 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE‹ 3.7.1 LOW OIL PRESSURE SWITCH ‹ 3.7.2 HIGH TEMPERATURE SWITCH‹ 3.7.3 OVERCRANK Figure 3.3 - Low Oil Pressure and High Temperature Switches4.2 CHECKING THE ENGINE OIL LEVEL 4.1 FUSE4.4 CHANGING THE OIL FILTER 4.5 CHANGING THE ENGINE AIR CLEANER‹ 4.3.2 OIL CHANGE PROCEDURE 4.3 CHANGING THE ENGINE OILFigure 4.8 - Setting the Spark Plug Gap 4.7 BATTERY MAINTENANCEFigure 4.6 - 7 kW, Engine Air Cleaner Location Figure 4.7 - 12 kW and 15 kW Engine Air Cleaner4.8 ADJUSTING VALVE CLEARANCE Figure 4.10 - Valve Clearance Adjustment4.9 COOLING SYSTEM 4.10 ATTENTION AFTER SUBMERSION 4.12 OUT OF SERVICE PROCEDURE‹ 4.12.2 RETURN TO SERVICE ‹ 4.12.1 REMOVAL FROM SERVICE4.13 SERVICE SCHEDULE CORRECTION 5.1 TROUBLESHOOTING GUIDEPROBLEM CAUSE24 Generac Power Systems, Inc ENGINE WIRINGSection 6 - Electrical Data CONTROL PANEL BOX CUSTOMERCONNECTION 26 Generac Power Systems, Inc Electrical Schematic - 12 & 15 kW - Drawing No. 0D8501-BSection 6 - Electrical Data Section 6 - Electrical Data 28 Generac Power Systems, IncCUSTOMER 30 Generac Power Systems, Inc 225A224A Electrical Schematic - 7 kW - Drawing No. 0D9014-C 32 Generac Power Systems, Inc Section 7 - Exploded Views and Parts ListsPART NO. QTY. DESCRIPTION 34 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 36 Generac Power Systems, Inc 27, 2835, 36, 40 DESCRIPTION PART NO. QTY38 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 14 20 40 Generac Power Systems, Inc1.25 FT 1.8 FT42 Generac Power Systems, Inc 2.6 FT 3 FT1.33 FT 44 Generac Power Systems, Inc DESCRIPTION 46 Generac Power Systems, Inc DESCRIPTION 48 Generac Power Systems, Inc DESCRIPTION Guardian Air-cooled 7 kW, 12 Drawing No. 0D3739-B 50 Generac Power Systems, IncALL DIMENSIONS IN MILLIMETERS INCHES Section 8 - MountingSection 9 - Notes CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYTHIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIANPREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS WARRANTY SCHEDULE