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Generac 04758-1, 04759-1, 04760-1, 04758-1,04759-1,04760-1 4.13 SERVICE SCHEDULE

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Section 4 — Maintenance

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

4.13 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by the nearest Generac Authorized Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly

R = Replace as Necessary M = Monthly

* = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* XM

LUBRICATION

Oil level XM

Oil X AFTER BREAK-IN,

AND Y

Oil filter X AFTER BREAK-IN,

AND Y

COOLING

Enclosure louvers XXW

BATTERY

Remove corrosion, XXM

ensure dryness

Clean and tighten XXM

battery terminals

Check charge state X R EVERY 6 M

Electrolyte level X R EVERY 6 M

(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner XR Y

Spark plug(s) XR Y

GENERAL CONDITION

Vibration, Noise, Leakage, XM

Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY A GENERAC Y

AUTHORIZED DEALER

Contents

Main Installation and Owners Manual Air-cooled Automatic Standby Generators !! DANGER INTRODUCTION ENGINE EMISSION COMPLIANCE PERIOD READ THIS MANUAL THOROUGHLY CONTENTS OPERATION AND MAINTENANCE Introduction ........................Inside Front Cover Safety Rules ........................................................2 Section 1 General Information ..................4 Section 2 Post Installation Start-up and Adjustments ......................10 Section 3 Operation....................................13 WARNING: !! WARNING: ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS STANDARDS INDEX 1.1 UNPACKING/INSPECTION 1.2 PROTECTION SYSTEMS DANGER 1.3 SYSTEM SET LED 1.4 THE GENERATOR Figure 1.1 7 kW, Single Cylinder GH-410 Engine Figure 1.2 12 kW/15 kW, V-twin GT-990 Engine Section 1 General Information 1.5 SPECIFICATIONS 1.5.1 GENERATOR 1.5.2 ENGINE 1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS 1.7 FUEL CONSUMPTION DANGER 1.8 RECONFIGURING TH E FUEL SYSTEM 1.8.1 7 KW, 410CC 1.9 LOCATION 1.9.1 GENERATOR 1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW, 12 kW and 15 kW Units 1.10 BATTERY INSTALLATION Figure 1.5 Battery Cable Connections 1.11 THE BATTERY 2.1 BEFORE INITIAL START-UP 2.2 CHECK TRANSFER SWITCH 2.3 ELECTRICAL CHECKS DANGER 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC 2.6 ADJUSTING THE REGULATOR (NATURAL GAS ONLY) Figure 2.1 Dual Fuel Regulators Figure 2.2 Placement of Regulator 2.7 ENGINE GOVERNOR ADJUSTMENT 2.7.1 7 KW UNITS 2.8 VOLTAGE REGULATOR ADJUSTMENT Figure 2.5 Voltage Adjustment Potentiometer 3.1 BREAK-IN PROCEDURE 3.2 USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1) 3.2.1 AUTO POSITION 3.2.2 OFF POSITION 3.2.3 MANUAL POSITION Figure 3.1 Generator Control Panel 3.5 MANUAL TRANSFER OPERATION 3.5.1 TRANSFER TO GENERATOR POWER SOURCE Figure 3.2 Manual Transfer Switch Operation 3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE 3.6 SETTING THE EXERCISE TIMER 3.7 PROTECTION SYSTEMS 3.7.1 LOW OIL PRESSURE SWITCH 3.7.2 HIGH TEMPERATURE SWITCH Figure 3.3 Low Oil Pressure and High Temperature Switches 4.1 FUSE Figure 4.1 Generator Control Panel 4.2 CHECKING THE ENGINE OIL LEVEL Figure 4.2 Oil Dipstick and Fill, 7 kW Figure 4.3 Oil Dipstick and Fill, 12 kW and 15 kW 4.4 CHANGING THE OIL FILTER 4.5 CHANGING THE ENGINE AIR CLEANER 4.5.1 7 KW, 12 KW AND 15 KW GENERATORS Figure 4.6 7 kW, Engine Air Cleaner Location Figure 4.7 12 kW and 15 kW Engine Air Cleaner 4.6 SPARK PLUG(S) Figure 4.8 Setting the Spark Plug Gap 4.7 BATTERY MAINTENANCE 4.8 ADJUSTING VALVE CLEARANCE Figure 4.10 - Valve Clearance Adjustment 4.9 COOLING SYSTEM Figure 4.9 Cooling Vent Locations 4.10 ATTENTION AFTER SUBMERSION 4.11 CORROSION PROTECTION 4.12 OUT OF SERVICE PROCEDURE 4.12.1 REMOVAL FROM SERVICE 4.12.2 RETUR N TO SERVICE 4.13 SERVICE SCHEDULE 5.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Wiring Diagram 12 & 15 kW Drawing No. 0D8500-B S G D P Wiring Diagram 12 & 15 kW Drawing No. 0D8500-B C 8 5 2 Page Electrical Schematic 12 & 15 kW Drawing No. 0D8501-B TX N2 N1 SP D + - Wiring Diagram 7 kW Drawing No. 0D9013-C 0 4 C N1 94 Page Electrical Schematic 7 kW Drawing No. 0D9014-C N2 N1 TX Page Enclosure Drawing No. 0D3416-R Page Page Page Page Page Page 7 kW Generator Drawing No. 0D3504-C Page Page Page Page Page GN410 Engine Drawing No. 0D3539-F Part 2 Page FOR GT 760 ENGINE ONLY Page Section 8 Mounting Dimensions Drawing No. 0D3739-B [ S O Page CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURERS EMISSION CONTROL SYSTEM WARRANTY COVERAGE: PURCHASERS/OWNERS WARRANTY RESPONSIBILITIES: 1-800-333-1322 EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING: WARRANTY SCHEDULE THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: GENERACPOWER SYSTEMS, INC. P.O. BOX 297 WHITEWATER, WI 53190