Generac Power Systems 04758-2, 04759-2, 04760-2 owner manual General Hazards, Danger

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Despite the safe design of this generator,

IMPORTANT SAFETY INSTRUCTIONS

Guardian Air-cooled 7 kW, 12 kW and 15 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 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 defects or other reproductive harm.

!

WARNING:

!

 

 

 

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 Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precau- tions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warn- ings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating tech- nique Generac does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique cho- sen does not render the generator unsafe.

Parts of the generator are rotating and/or hot!during operation. Exercise care near running generators. 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 !

For safety reasons, Generac recommends that the installation, initial start-up and maintenance of this equipment is carried out by a Generac Authorized Dealer.

The engine exhaust fumes contain carbon monox- ide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust sys- tem must be installed properly, in strict compli- ance with applicable codes and standards. Following installation, do nothing that might ren- der the system unsafe or in noncompliance with 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 venti- lating air is critical to correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seri- ously affect safe operation of the generator. The generator MUST be installed outdoors.

When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

Inspect the generator regularly, and contact the nearest Generac Authorized Dealer for parts need- ing repair or replacement.

Before performing any maintenance on the genera- tor, disconnect its battery cables to prevent acci- dental start up. Disconnect the cable from the bat- tery post indicated by a NEGATIVE, NEG or (–) 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 con- ditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

2 Generac® Power Systems, Inc.

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Contents Models 04758-2 6 kW NG, 7 kW LP 04759-2 12 kW NG, 12 kW LP 04760-2 13 kW NG, 15 kW LPThis manual should remain with the unit Installation and Owner’s Manual‹ CONTENTS ‹ OPERATION AND MAINTENANCE‹ HOW TO OBTAIN SERVICE INTRODUCTIONIntroduction GENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot during operation. Exercise care near running generatorsELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹ STANDARDS INDEX1.1 UNPACKING/INSPECTION 1.2 PROTECTION SYSTEMS1.3 SYSTEM SET LED DANGERFigure 1.1 - 7 kW, Single Cylinder GH-410 Engine 1.4 THE GENERATORFigure 1.2 - 12 kW/15 kW, V-twin GT-990/760 Engine ‹ 1.5.1 GENERATOR 1.5 SPECIFICATIONS‹ 1.5.2 ENGINE 1.8 RECONFIGURING THE FUEL SYSTEM 1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS1.7 FUEL CONSUMPTION DANGER1.9 LOCATION 1.8.2 12KW AND 15KW, 990CC ENGINES1.9.1 GENERATOR Figure 1.4 - Demand Regulator1.10 BATTERY INSTALLATION 1.11 THE BATTERY1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW, 12 kW and 15 kW Units Figure 1.5 - Battery Cable Connections2.1 BEFORE INITIAL START-UP 2.2 CHECK TRANSFER SWITCH OPERATION2.3 ELECTRICAL CHECKS 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC OPERATIONFigure 2.2 - Placement of Regulator 2.6 ADJUSTING THE REGULATOR NATURAL GAS ONLYFigure 2.1 - Dual Fuel Regulators 2.7 ENGINE GOVERNOR ADJUSTMENT Figure 2.4 - V-twin Engine Governor AdjustmentFigure 2.3 - Single Cylinder Engine Governor Adjustment Figure 2.5 - V-twin Full Load Speed Adjust Screw2.8 VOLTAGE REGULATOR ADJUSTMENT 3.1 BREAK-IN PROCEDURE3.2 USING THE AUTO/OFF/MANUAL SWITCH FIGURE Figure 2.6 - Voltage Adjustment Potentiometer3.3 AUTOMATIC TRANSFER OPERATION 3.5 MANUAL TRANSFER OPERATION3.4 SEQUENCE OF AUTOMATIC OPERATION ‹ 3.5.1 TRANSFER TO GENERATOR POWER SOURCE‹ 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE ‹ 3.7.1 LOW OIL PRESSURE SWITCH‹ 3.7.2 HIGH TEMPERATURE SWITCH Figure 3.2 - Manual Transfer Switch OperationFigure 3.3 - Low Oil Pressure and High Temperature Switches 4.2 CHECKING THE ENGINE OIL LEVEL4.1 FUSE ‹ 3.7.3 OVERCRANK4.5 CHANGING THE ENGINE AIR CLEANER ‹ 4.3.2 OIL CHANGE PROCEDURE4.3 CHANGING THE ENGINE OIL 4.4 CHANGING THE OIL FILTER4.7 BATTERY MAINTENANCE Figure 4.6 - 7 kW, Engine Air Cleaner LocationFigure 4.7 - 12 kW and 15 kW Engine Air Cleaner Figure 4.8 - Setting the Spark Plug GapFigure 4.10 - Valve Clearance Adjustment 4.8 ADJUSTING VALVE CLEARANCE4.9 COOLING SYSTEM 4.12 OUT OF SERVICE PROCEDURE ‹ 4.12.2 RETURN TO SERVICE‹ 4.12.1 REMOVAL FROM SERVICE 4.10 ATTENTION AFTER SUBMERSION4.13 SERVICE SCHEDULE 5.1 TROUBLESHOOTING GUIDE PROBLEMCAUSE CORRECTIONENGINE WIRING 24 Generac Power Systems, IncSection 6 - Electrical Data CUSTOMER CONTROL PANEL BOXCONNECTION 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 DataGenerac Power Systems, Inc 225A 30 Generac Power Systems, Inc224A 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 27, 28 36 Generac Power Systems, Inc35, 36, 40 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 3 FT 2.6 FT1.33 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 50 Generac Power Systems, Inc ALL DIMENSIONS IN MILLIMETERS INCHESSection 8 - Mounting Guardian Air-cooled 7 kW, 12 Drawing No. 0D3739-BSection 9 - Notes YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGEPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENTEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGGENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORSWARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING