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Anritsu MP1777A Universal Remote User Manual

1. ENGINE WIRING DIAGRAM KEY 3 BATTERY BA BRUSH ASSEMBLY C CHARGER 2 BCR BATTERY CHARGE RELAY UTILITY CB1 MAIN OUTPUT BREAKER 14 2 CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION 0 1 D DIODE DSW PCB MOUNTED DIP SWITCH TM FS FUEL SOLENOID F1 FUSE 15 224B F2 FUSE 5 AMP 13A 13A GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH 0 0 IC INLINE CONNECTOR 225B ICT INTERCONNECTION TERMINALS 0 IM IGNITION MODULE 224B LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SP SPARK PLUG 14 SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH 14 SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 14 IC olo l TB D 0 0 SP A 0 gt 6 0 0 IM 18 gt 5 14 85 gt 4 85 86 3 HTO IC 0 13 2 13 13 gt 1 C1 ds 18 IC LOP 56 56 56 351 0 13 56 85 56 4 2 4 Ji TS eo 23 SC P 194 CONTROL E 56 PRINTED CIRCUIT BOARD E 18 14 66 BLACK DSW S 1234 15 d gt 15 16 C 0 INDICATES 225 1 20 Vat
2. 22 225A 3 025 2 224A BATTERY 225B F2 225 gt 224 13A o 13 13A i i F1 224 1 7 7 9 9 f Por Y 1 16713 4 13A 77 13 2 0 i BATTERY CHARGE 66 14 19 WINDING ALIA JC d 66 2 2 22 0 amp 0 C2 4 uro 20 0 C2 11 0 pu tC 11 ENGINE RUN BA WINDING Cid 52 22 15 0 C1 3 ELECTRONIC 4 C2 10 C2 9 C2 3 VOLTAGE 4 4 REGULATOR 0 66A R 85 23 162 1 6 2 86 194 6 4 cB2 0 351 225 ji C2 7 224 E o id ids DPE WINDING STATOR 112131415 15A J2 23 239 1 4 DIAGRAM KEY 194 66 3 23 BA BRUSH ASSEMBLY 194 BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION 6 18 D DIODE 7 14 FS FUEL SOLENOID CONTROL 8 66A F1 FUSE 15 AMP PRINTED CIRCUIT 9 239 F2 FUSE 5 AMP BOARD 10 15A HTO HIGH OIL TEMPERATURE SWITCH 17 IM1 IGNITION MODULE CYLINDER 1 15 IM2 IGNITION MODULE CYLINDER 2 T LOW OIL PRESSURE SWITCH i m SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY 15 224 SP1 SP2 SPARK PLUGS 16 SW1 AUTO OFF MANUAL SWITCH 17 SW SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC ee Generac Power Systems Inc Generac Air cooled 7 kW 12 kW and 15 kW G
3. P 0 peo PB NMP n2 ASSEMBLY CRANKCASE HOUSING WITH SLEEVE SEAL 38 1 0 CRANKSHAFT SCREW TAPTITE M6 1 0 X 12 YC ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 G amp S RETAINER PISTON PIN 20 ROCKER COVER NO OIL FILL STUD M8 1 25 10MM X 30 G5 ZINC PISTON HC SET PISTON RING 90MM PIN PISTON ASSEMBLY CAMSHAFT amp GEAR SHAFT GOVERNOR ROLLER BEARING GOVERNOR PLATE ROLLER BEARING GOVERNOR ASSEMBLY GOVERNOR GEAR SPOOL GOVERNOR MACHINED GASKET CRANK CASE SEAL OIL PASSAGE ASSEMBLY CRANKSHAFT HORIZONTAL DIRECT DRIVE ASSEMBLY CONNECTING ROD SCREW SHC M6 1 0 X 50 G8 8 SCREEN OIL PICKUP ASSEMBLY OIL PUMP SLEEVE SEAMED DOWEL 10 DIA COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 GEROTOR OUTER CLAMP OIL TUBE ARM GOVERNOR E RING GOVERNOR ARM THRUST WASHER GOVERNOR BUSHING GOVERNOR LOWER ITEM PART NO QTY DESCRIPTION 0C3971C 0C5305 0C3027 0E9842 0C5731 0C3006 080318 093064 0C8808 0D2723B 0C2979 086515 0D2274 0D3867 078672 0C5371 072694 0D3998 0C3027 0D5313 0D6024 0C2976 086516 0C2229 083897 0D8067B 0D9853D 0C2978 043790 0D4010 0D4011 0D4012 0D4013 0D8675A 0D8675B 0D4015 0D4016 ASSEMBLY DIPSTICK WITH HANDLE TUBE DIPSTICK O RING OIL CLR 3 8 X 1 2 SEAL 42 1 0 CRANKSHAFT ASSEMBLY H
4. 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 A To Service Scledule 5529 522999 09 e 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 nnne 51 Section 10 Warranty 52 Generac Power Systems Inc M SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Generac Air cooled 7 kW 12 kW and 15 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe 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 otudy these SAFETY RULES carefully before instaling operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and
5. HTO HIGH OIL TEMPERATURE SWITCH 13A 13A IC INLINE CONNECTOR 0 0 ICT INTERCONNECTION TERMINALS IM1 IGNITION MODULE CYLINDER 1 225B IM2 IGNITION MODULE CYLINDER 2 0 224B LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY 14 SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH 0 0 SW SET EXERCISE SWITCH 14 SM STARTER MOTOR TB INSULATED TERMINAL BLOCK 14 TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC D ei 0 IM1 18 14 85 4 86 3 13 gt 2 13 13 D 1 16 13 13 IC 5 2 IC 16 IM2 SCR 351 85 HTO 351 86 112131415 2 56 U 1 A J1 86 194 CONTROL ea PRINTED CIRCUIT BOARD 18 66A BLACK DSW 15A 1234 15 INDICATES 225 20 Vac Sense Transformer
6. N SS OF SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC 6 1 0 X 16 G8 8 7KW SCREW HHC M6 1 0 X 12 G8 8 SCREW HHC M6 1 0 X 12 G8 8 7KW NUT LOCKING FLANGE M6 1 0 NUT LOCKING FLANGE M6 1 0 7KW SCREW HHTT 8 1 2 X 20 BP SCREW TAPTITE M6 1 0 X 12 BP SCREW TAPTITE M6 1 0 X 12 BP 7KW NUT LOCK TRIC M6 X 1 0 Y ZNC GASKET BATTERY SUPPORT BRACKET PLUG PLASTIC 0 593 LUG SLDLSS 2 8 17 64 CU SCREW TAPTITE M6 1 0X25 BP L WASH SPECIAL BRACKET BATTERY HOLD DOWN 7KW CONTACTOR STARTER 7KW CABLE 46 RED BATTERY 38 5 NUT HEX 1 4 20 STEEL 7KW WASHER LOCK 5 16 WASHER LOCK 5 16 7KW SCREW TAPTITE M5 0 8 X 10 BP HARNESS ENGINE HARNESS ENGINE 7KW BUSHING SNAP SB 1000 12 SCREW HHC 5 16 18 X 3 4 G5 7KW RIVET 1 8 X 0 126 0 375 LSH POP L WASH SPECIAL 10 ASSEMBLY ROOF DOOR GROUND WIRE ASSEMBLY ROOF DOOR GROUND WIRE PLUG PLASTIC 1 375 GASKET EXTRUDED TRIM PLATE HOT GROMMET 2 75 X 1 16 EXTERNAL CONNECTION BOX POWER BLOCK HARNESS GENERATOR TO EXTERNAL CONNECTION BOX HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 7KW SCREW PPHM 410 32 X 1 WASHER LOCK 10 WASHER FLAT M5 NUT HEX 10 32 STEEL FUEL LINE 3 4 OUTDOOR NOT SHOWN WASHER SHAKPROOF EXT 1 4 STEEL NUT HEX M6 1 0 G8 YELLOW CHROME HINGE TYPE A WITH STUDS SOCKET HINGE TYPE B WITH STUDS SOCKET SCREW HH
7. 225 224A CONTROL PANEL BOX 224 225A 224A 225A xx CLOSEST TO BEARING BCR CB2 BA L Jaial 422 46 7 9 13A 66 dx sl gt 162 0 225B 225B 7 10 224B 224B 0 2 66 6 11 14 2 55 0 4 6 7 lt 0 11 6 66 n 11 22 5 77 66 66 225 13A 0 11 4 HII 4 3 0 77 2 s 44 224 1 lt 162 55 VOLTAGE REGULATOR 0 66A 0 0 66A 33 4 N2 55 22 N1 13 13 225 13 351 224 194 23 4 N2 23 N1 s 351 44 13 11 13A 351 194 1n N2 22 13 23 194 NI 0 13 iid F2 F1 239 CB1 17 13 239 m w s id VL YU YU 0 swt i 225 po 224 1 gt E P 2 1 2 e rz Sw 240V GENERATOR 9 E AUTO OUTPUT TO TRANSFER 2 m 2 SWITCH CONTACTOR 5 z CUSTOMER MANUAL CONNECTION Power Systems Inc 25 Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL DATA Electrical Schematic 12 amp 15 kW Drawing No 0D8501 B 11
8. AHL Ad 1 11 LON 2v 611 SH3NHOO Yr S3 1OH ONILAN 7 NSNNNNS NNSNNSSS T3AVHO Wad 100761 9 MAIA 341 1331 6 21229 EM gt v v gt v gt v gt v A AAAAAA _ 167621 09 NEN Generac Power Systems Inc Section 9 Notes NOTES Generac Air cooled 7 kW 12 kW and 15 kW Generators Generac Power Systems Inc 51 Section 10 Warranty WARRANTY Generac Air cooled 7 kW 12 kW and 15 kW Generators NOTE This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your en
9. Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators PARTS 9 LISTS 7 kW Generator Drawing No 0D3504 D O PART NO QTY DESCRIPTION 0C6934 1 ADAPTOR ENGINE 0C9935H 1 STATOR 0C9934H 1 ROTOR 0C6043A 1 CARRIER REAR BEARING 0C8096 1 FAN 8 CURVED BLADE 0C9593 1 MUFFLER 0D3220 1 TAIL PIPE MUFFLER 0C8860 1 PANEL MUFFLER BASE 031971 1 BEARING 6205 2RS C3 0C3168 3 5 16 SPECIAL L WASH 056147 1 BOLT ROTOR 5 5 16 24 X 13 1 2 G5 0D1847 4 BOLT STATOR HHCS M8 1 25 x 305mm 0C7038C 1 BRACKET ALTERNATOR MOUNTING 0D1647 1 DUCT ALTERNATOR AIR 0D2558 1 GASKET ALTERNATOR AIR DUCT 0C7038B 1 BRACKET ENGINE MOUNTING 0C7758 4 RUBBER MOUNT 0388050AE0 1 CABLE 6 40 BLACK BATTERY 0C2417A 1 EARTH STRAP 3 8X 3 8 082121C 1 CLIP J VINYL COAT 625 ID 066386 1 ASSEMBLY BRUSH HOLDER 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 049451 1 WASHER FLAT 406 0 X 1 6200 022237 4 WASHER LOCK 3 8 022511 4 BOLT HHC 3 8 16 X 1 1 4 G5 022131 4 WASHER FLAT 3 8 ZINC 039287 4 SCREW HHC 8 1 25 X 45 G8 8 022145 12 WASHER FLAT 5 16 ZINC 049820 4 NUT LOCK HEX 8 1 25 NYL INSRT 090388 3 SCREW M6 1 0X12 022129 13 WASHER LOCK M8 5 16 022259 8 NUT HEX 5 16 18 STEEL 059637 2 SCREW TAPTITE 3 8 16 3 4 BP 048031K 3 BAND HOSE CLAMP 35 05 DIA 0C9592 1 BELLOWS 057822 2 CLAMP HOSE 8 53 1 00 040976 2 SCREW SHC 8 1 25 X 20 G12 9 0C2824 1 SCREW 10 32 X 9 16 025145 1 U BOLT 5 16 18 X 1 25 W SA
10. i e loads connected to the util ity power source Figure 3 2 6 Turn ON the utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 3 3 3 6 SETTING THE EXERCISE TIMER The generator is equipped with an exercise timer 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 day the following sequence is completed During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 3 1 allows for selection of the day and time for system exercise To select the desired day and time of day the follow ing sequence must be done at that time 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Hold down the set timer switch until the genera tor starts approximately 10 seconds and then release 3 The generator will start and run for approximately 12 minutes and then shut down on its own The exerciser will then be set to run at that time of 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 i
11. 1 9 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water colum 0 18 to 0 25 psi and for liquid propane 11 inches to 14 inches of water column 0 4 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water col umn for liquid propane for all load ranges 1 7 FUEL CONSUMPTION Nat Gas 1 2 Load Full Load 1 2 Load 66 119 082 30 04674 1 53 56 04675 15858 240 88 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour 1 8 RECONFIGURING THE FUEL SYSTEM 1 8 1 7 KW 410CC To reconfigure the fuel system from NG to LP follow these steps Figure 1 3 NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator A fuel pres sure of 11 to 14 inches of water column 0 4 to 0 5 psi to the fuel inlet of the generator MUST BE SUPPLIED 1 Turn off the main gas supply if connected 2 Open the roof and remove the door Section 1 General Information Generac Air cooled 7 kW 12 kW and 15 kW Generators GENERAL IN
12. 15 KW UNITS 1 Loosen governor clamp bolt See Figure 2 4 Figure 2 4 V twin Engine Governor Adjustment Idle Spring Governor Shaft 9 159 A m CG S No Load ldle Adjustment Screw Governor Clamp Bolt 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 2 5 to adjust frequency to 58 Hz o Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6 Using a hand push the governor arm to the closed throttle position Make sure the idle spring does not stretch at all POST INSTALLATION START UP ADJUSTMENTS 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz 9 The governor is now set Figure 2 5 V twin Full Load Speed Adjust Screw Full Load Speed Adjust Screw 2 1 3 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corrosion inhibiting spray such as WD 40 or a comparable product 2 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62 63 5 Hertz slowly turn the slotted potentiometer Figure 2 6 until line voltage reads 244 252 volts NOTE Remove the access panel on top of the control panel to adjust th
13. 15 kW V twin GT 990 760 Engine Control Oi Panel Dipstick Outlet Exhaust Enclosure Fuel Regulator Fuel Inlet u Battery Composite Base Cil Filter Compartment Generac Power Systems Inc 5 GENERAL Section 1 General Information INFORMATION Generac Air cooled 7 kW 12 kW and 15 kW Generators 1 5 SPECIFICATIONS 1 5 1 GENERATOR Rated Max Continuous Power Capacity Watts Rated Voltage Rated Max Continuous Load Current Amps 120 Volts 240 Volts Main Line Circuit Breaker Phase Number of Rotor Poles Rated AC Frequency Power Factor Recommended Air Filter Battery Requirement at 17 8 C 0 F Weight Output Sound Level 23 ft 7m at full load Normal Operating Range Model 04673 Model 04674 Model 04675 6 000 NG 7 000 LP 12 000 NG 12 000 LP 13 000 NG 15 000 LP 120 240 120 240 120 240 50 0 NG 58 3 LP 100 NG 100 0 LP 108 3 NG 125 0 LP 25 0 NG 29 2 LP 50 NG 50 0 LP 54 2 NG 62 5 LP 30 Amp 60 Amp 70 Amp 1 2 60 Hz 1 Generac Part C8127 Group 26 26R Group 26 26R Group 26 26R 12 Volts and 12 Volts and 12 Volts and 350 Cold cranking 525 Cold cranking 525 Cold cranking Amperes Minimum Amperes Minimum Amperes Minimum 487 Pounds 68 db A 70 5db A 71 5 db A 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power a
14. CONTENTS 2 22 ON POSION ctr deber tnter inte 14 3 2 3 Manual Position 14 3 9 Automatic Transfer Operation 14 3 4 Sequence of Automatic Operation 14 3 5 Manual Transfer Operation 15 3 5 1 Transfer to Generator Power Source 15 3 5 2 Transfer Back to Utility POWER SOUTCE 15 3 6 Setting the Exercise Timer 16 3 7 JEOLGCHOLD SyS emsSs 16 3 7 1 Low Oil Pressure Switch 16 3 7 2 High Temperature Switch 16 Deb CVE 16 IA OVORSDOCUQ 17 Section 4 Maintenance 17 ol TILL OO 17 4 2 Checking the Engine Oil Level 17 4 3 Changing the Engine Oil 17 4 3 1 Engine Oil Recommendations 17 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 JENEL ALON S E T 18 ZI 19 4 7 Battery Maintenance 19 4 8 Adjusting Valve Clearance 20 4 9 Cooling System 20 4 10 Attention After Submersion
15. ITEM PART NO QTY DESCRIPTION 1 0C6140 0D1901 0C6735 0 0063 0C7062 0C7062A 0 8811 0 8811 0 9873 067065 0 7065 0C8101A 0C8861 0C8101B 0C8862 0C8283 0C8284A 0C8284B 0C8284C 0C8285 0C8899A 0D1128 0D1128A 0 4244 001605 001606 005264 001839 001840 002425 002588 002588 002676 002677 002979 002979 0D2979C 0D2979D 0D2979E 0 4245 003058 0 4245 0 4245 003058 0030570 0D3059A 0D3059B 0D3059C 0D7176 0D3059D 003059 0C7781A 0D3037 070164 0 0165 0D3037A 0A2115 022097 0 0710 ASSEMBLY ENCLOSURE BASE ASSEMBLY ENCLOSURE BASE 7KW SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE EXHAUST SIDE 7KW ENCLOSURE SIDE amp BACK ENCLOSURE SIDE amp BACK 7KW ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER PANEL ALTERNATOR DIVIDER 7KW PANEL MUFFLER BOX SIDE PANEL MUFFLER BOX SIDE 7KW COVER MUFFLER BOX COVER MUFFLER BOX 7KW GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 X48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER PANEL ENGINE DIVIDER 7KW BAFFLE INTAKE BAFFLE INTAKE 7KW HOUSING FAN BAFFLE EXHAUST 7KW BRACKET TOP SUPPORT BRACKET BOTTOM SUPPORT DUCT BASE AIR
16. SM 224 12V BATTERY Remote Not Auto 50 Hz Operation SPARE 17 16 15 14 13 12 11 9 8 7 e 5 4 3 2 oo N CUSTOMER SUPPLIED sc L E D ALARM INDICATORS 24 Generac Power Systems Inc Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL Wiring Diagram 12 amp 15 kW Drawing No 0D8500 B lt DATA
17. Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first sched
18. 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 2 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set the generator s main circuit breaker to it s OFF or open position 2 Check that the AUTO OFF MANUAL switch is set to OFF 3 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 4 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker o Set the AUTO OFF MANUAL switch to AUTO Then set the generator s main circuit breaker to its ON or closed position The system is now ready for automatic operation 6 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 After starting the transfer switch should connect load circuits to the standby side Let the system go
19. 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 ELECTRICAL HAZARDS generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera tion Avoid contact with bare wires terminals con nections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical system After installing this home standby electrical sys tem the generator may crank and start at any time without warning When this occurs load circuits are transferred to the STANDBY generator power source To prevent possible injury if such a sta
20. 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
21. the life of the battery by maintaining the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 11 THE BATTERY Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries When replacing the battery use the following type of battery Group 26 26R 12 volt battery with a rating of 350 cold cranking amps minimum for 7 kW 525 cold cranking amps minimum for 12 and 15 kW at 17 8 C 0 F minimum When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service ochedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly connected and terminals are tight Observe battery polarity when connecting the battery to the generator set Do not dispose of the battery a fire The battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries e Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and e
22. the overcrank feature will continue to activate Generac Air cooled 7 kW 12 kW and 15 kW Generators 3 7 3 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 3 74 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gener ator from supplying an output that could potentially damage appliances connected to the generator cir cuit Contact the nearest Generac Authorized Dealer if this failure occurs 4 1 FUSE The generator panel s 15 amp fuse Figure 4 1 protects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open the engine cannot crank or start Replace the fuse using only an identical 15 amp replacement The generator panel s 5 amp fuse protects the battery charge circuit against overload If the fuse element has melted open battery charging will not be possible Replace the fuse using only an identical 5 amp replace ment To remove fuse push cap down and rotate coun terclockwise Figure 4 1 Generator Control Panel FUSE Locate your nearest GENERAC dealer at www generac com AC power systems INC SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK 15A SET F
23. thor oughly understand all instructions before using this equipment Generac also strongly recommends 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 models e 04673 2 6 kW NG 7 kW LP single cylinder GH 410 Engine 04674 2 12 kW NG 12 kW LP V twin GT 990 Engine 04675 3 13 kW NG 15 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Dealer Normal maintenance service and replacement of parts are the responsibility 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 expenses 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 as
24. 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 15 seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down Generac Power Systems Inc 11 POST C 5 Section 2 Post Installation Start up and Adjustments oM Generac Air cooled 7 kW 12 kW and 15 kW Generators START UP ADJUSTMENTS 2 6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Although the generator has been factory set to pro vide maximum power it may be necessary in some areas to adjust this setting Because natural gas has different BTU or power content across the country the engine may not perform as designed If experiencing engine problems at high or full load conditions follow these steps It will require a fre quency meter to perform this procedure 1 Turn off utility power to the main distribution panel in the house This can be done by switching the service main breaker to the off or open posi tion 2 Allow the generator to start before loading the generator Confirm the no load frequency with the roof open and door off is set at 63 63 5 Hz Transfer load to emergency circuits 3 Turn on appliances lights pumps etc that are on the emergency circuits in an attempt to fully load the gener
25. 0E8774 K Part 2 ITEM PART NO QTY DESCRIPTION 0C5136A 0C3024 0C3040 0C8127 0D8564A 0D8564B 0D2595 0D4417 003025 0D3083 007292 070185B 075281 0 2094 035461 0C7649 0C9806 0C3026 0C9764 0C3043 0C7694 0C7693 0C3041A 070008 070006 040976 0C3016A 0E4997 0C3725B 063031 003032 0A5992 051754 0C3033 0C3034 0C8549A 0C3022A 2 1 1 1 1 1 4 4 1 1 1 1 1 2 2 4 2 1 4 2 1 1 2 4 4 4 1 1 1 1 1 2 2 1 1 1 1 KNOB AIR CLEANER COVER AIRBOX NG LP PRE CLEANER ELEMENT AIR CLEANER ASSEMBLY MIXER AIRBOX 990 ASSEMBLY MIXER AIRBOX 760 SCREW SHOULDER 8MM M6 1 0 X 18 WASHER RUBBER 1 4 X 1 8 THICK SWITCH OIL PRESS ASSEMBLY OIL DRAIN HOSE NIPPLE 3 4 16 UNF OIL FILTER SWITCH THERMAL 284F SCREW M3 0 5 X 6 SEMS BARBED STR 1 4NPT X 3 8 CLAMP HOSE 38 87 HOSE 3 8 1 D X 6 LONG COOLER OIL PLASTITE 1 4 15 X 3 4 GASKET MANIFOLD PORT MANIFOLD CYLINDER 2 MANIFOLD CYLINDER 1 SLEEVE RUBBER WASHER FLAT M8 SS WASHER LOCK M8 SSTL SCREW SHC 8 1 25 X 20 G12 9 PLATE BACKING WITH OIL COOLER GROUND WIRE CONNECTOR FLYWHEEL ASSEMBLY FAN NYLON PLATE FAN WASHER SHAKEPROOF INT M8 SS SCREW HHC 8 1 25 X 12 G8 8 WASHER 25mm 1 0 NUT HEX M24 SNORKEL AIR INTAKE HOUSING BLOWER NG COOLER PARTS ib ues 00 ITEM PART NO QTY DESCRIPTION 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 13
26. 3B 078691 0 5771 0 5776 076361 0A8898D 0D2274 0C4391 086025 0E3341 021714 086516 086517 0D9853B 083897 077158 0C3150 072694 083907 072696 078694 021742 0D6094 076329 0 0057 004788 074908 086515 078606 0 1442 078672 089673 082104 0786996 0 7627 043790 088590 078699 QTY Po BR S BR PO PO Po P PD P SK HS Pp Po SH po Generac Air cooled 7 kW 12 kW and 15 kW Generators PARTS Section 7 Exploded Views and Parts Lists 9 GN410 Engine Drawing 0E9180 B Part 1 DESCRIPTION ASSEMBLY CONNECTING ROD PIN PISTON D20 SET PISTON RING 90MM PISTON HC RETAINER PISTON PIN 20 ASSEMBLY CRANKSHAFT GH410 SMALL TAPER ARM GOVERNOR RC45 PIN GOVERNOR ARM WASHER GOVERNOR ARM THRUST CRANKCASE SUBASSEMBLY WITH PLUGS GH410 SEAL 35 1 0 CRANKSHAFT ASSEMBLY GOVERNOR GEAR C RING GOVERNOR GEAR RETAINER SPOOL GOVERNOR MACHINE ASSEMBLY CAMSHAFT amp GEAR GASKET CRANKCASE GASKET HEAD 410 COVER OIL PRESSURE RELIEF SPRING OIL RELIEF 360 BALL DIA 11 32 PRESSURE RELIEF WASHER THRUST GOVERNOR GEAR ASSEMBLY COVER GEAR TOP CHECK FILL RETAINER VALVE SPRING VALVE SPRING LF SET GEROTOR 12 THK BALANCER ASSEMBLY CYLINDER HEAD SEATS amp GUIDES VALVE EXHAUST VALVE INTAKE PUSH ROD 174 9 TAPPET ASSEMBLY SCREEN OIL PICK
27. 4795 0C5760J 0C6606 097934 0C4645 0C5761 0C5968 0C6066 0C5759 0C5764 0C5764A 070728 0C6069 0C5762 045764 0C6731 0C6067 0C4706 0C6068 0C4643A 026073 026073 0 4032 003308 024310 028414 005698 003973 mo m m n rS DO IO P Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators Gas Regulator Drawing No 0D8720 G DESCRIPTION CASTING TWIN REGULATOR HOUSING SOLENOID COIL 12VDC GASKET SOLENOID PLUNGER LP REGULATOR ASSEMBLY SPRING SOLENOID PLUNGER SCREW PPHM SEMS M4 0 7 X 10 JET GN 410 ENGINE LP 7KW BARBED STRAIGHT 1 2NPT x 1 2 O RING CHECK VALVE ADJUSTER SCREW TWIN REGULATOR LEVER REGULATOR SUPPORT INLET SEAL SEAL INLET PIN PIVOT ARM SPRING REGULATOR SPRING REGULATOR 7KW SCREW PFHMS M3 0 5 x 5 GASKET DIAPHRAGM COVER TWIN REGULATOR SCREW TAPTITE M4X8 BP RIVET POP 118 X 125 SUPPORT DIAPHRAGM DIAPHRAGM TWIN REGULATOR CAP DIAPHRAGM SUPPORT INLET TWIN REGULATOR 11 11 DIA PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD 7KW PIN LIMITED ADJUSTMENT WASHER FLAT M3 X 10mm O D PLUG STANDARD PIPE 1 2 STEEL SQUARE HEAD 7KW BARBED STRAIGHT 1 8 NPT X 1 4 JET IDLE PRIMER PHILLIPS HD V TWIN ONLY PLUG EXPANSION 16mm A QUANTITY OF 1 1 TO BE USED ON 7KW HOME STANDBY PARTS qea 00 Generac Power
28. 5 136 137 138 139 140 142 143 144 145 001131 045756 0 9763 0C3036A 022145 022129 0C3018 0C3019 0D1142A 0D1143 0E6043 0F1177 0 1338 022097 092079 0 4271 004529 022129 061906 082774 0 5343 0C8468 0C3048 0D3754 0D3742 0C8482 0 0486 003743 003705 0C2993 045771 006147 0E8152 OF 1338A 1 25 GUARD FAN SCREW TAPTITE M6 1X10 YELLOW CHROME NUT GROMMET 1 4 PLUG HOSE BREATHER WASHER FLAT 5 16 8 ZINC WASHER LOCK M8 5 16 WRAPPER UPPER CYLINDER 1 WRAPPER LOWER CYLINDER 1 WRAPPER LOWER CYLINDER 2 WRAPPER UPPER CYLINDER 2 SCREW TAPTITE M5 0 8 X 8 ZP ASSEMBLY GROUND WIRE ASSY IGN COIL W DIODE NO ADV WASHER LOCK M6 1 4 SCREW TAPTITE M6 1 0 X 25 BP STARTER SPARKPLUG WASHER LOCK M8 5 16 SCREW HHC 8 1 25 X 85 G8 8 KEY WOODRFF 4 X 19D NUT HEX LOCK M10 1 50 SPRING ANTI LASH ROD GOVERNOR CONTROL ASSEMBLY GOVERNOR LEVER SPRING GOVERNOR ASSEMBLY GOVERNOR ADJUSTER SCREW SHC M10 1 5 X 75 G10 9 SPRING GOVERNOR IDLE ASSEMBLY GOVERNOR ADJUSTER BRACKET SEAL GOVERNOR SHAFT NUT HEX M8 1 25 G8 SCREW HHFC M6 1 0 X 10mm O RING 0 49 1 0 0 07 THICK ASSY IGN COIL W DIODE NO ADV Generac Power Systems Inc 39 Section 7 Exploded Views and Parts Lists PARTS Ce LISTS gt Generac Air cooled 7 kW 12 kW and 15 kW Generators KO 7 kW Generator Drawing No 0D3504 D 47 45 30 Generac Power Systems Inc ITEM CONDO WP
29. ATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery See Specifications Section 1 5 for type and size o Clean and wipe the entire generator 6 Remove the 5A fuse from the generator control panel 7 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incor rectly Replace the 5A fuse in the generator control panel 8 Open the fuel shutoff valve 9 Start the unit by moving the AUTO OFF MANUAL switch to MANUAL Allow the unit to warm up thor oughly 10 Stop the unit and set the AUTO OFF MANUAL switch to AUTO Set the generator s main circuit breaker to its ON or closed position 11 Turn on the utility power to the transfer switch 12 The generator is now ready for service NOTE If the battery was dead or disconnected the exercise timer must be reset Generac Power Systems Inc 21 Section 4 Maintenance MAINTENANCE Generac 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 Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections M LUBRICATION Oil level M _ o Oil X AFTER BREAK IN AND Y Oil filter X AFTER BREAK IN A
30. Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug s to clean 2 Remove the spark plug s and check the condi tion Replace the spark plug s if worn or if reuse is questionable See Section 4 13 for recom mended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 inch for 7 kW and 0 50 mm 0 020 inch for 12 15 kW by carefully bending the ground electrode Figure 4 8 Figure 4 8 Setting the Spark Plug Gap SET PLUG GAP AT 0 76 mm 0 50 mm 0 030 inch 0 020 inch 2 2 to ae M 7 4 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 13 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A Do not dispose of the battery a fire The battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries MAINTENANCE 5 Section 4 Maintenance e Remove watches r
31. DDLE 090239 1 GASKET EXHAUST 0C6989 1 STINGER ENGINE AIR IN 0D1214 1 BASE AIR CLEANER 0C8127 1 ELEMENT AIR CLEANER 0C3024 1 COVER AIR CLEANER 002273 1 TUBE 1 25 0 D x 20Ga x 12 125 LONG 055934N 1 CLAMP VINYL 1 31 X 281 Z 074994 1 25 FT HOSE 1 2ID PETROLEUM 0C5136A 2 KNOB AIR CLEANER 074906 4 SCREW TAPTITE M6 1 X 20 BP 022473 4 WASHER FLAT 1 4 ZINC 0D4662 6 SCREW HHTT M8 1 2 X 20 BP 0C8290 1 GASKET PANEL 066849 2 SCREW HHTT M5 0 8 X 16 Generac Power Systems Inc 41 us Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators KO 12 kW and 15 kW Generator Drawing No 0D3417 J en Rs k N NN CN AM _ e m k 7 OL iS 32 31 28 17 34 42 Generac Power Systems Inc ITEM Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators PARTS 9 LISTS 12 kW and 15 kW Generator Drawing No 0D3417 G O PART NO QTY DESCRIPTION 0C6934 1 ADAPTOR ENGINE 0C7930 1 STATOR 12KW 0D2359 STATOR 13KW 15KW 0C7944 1 ROTOR 12KW 0D2356 ROTOR 13KW 15KW 0C6043 1 CARRIER REAR BEARING 0D2336 1 FAN 12 CURVED BLADE 0D6634 1 MUFFLER 0D3220 1 TAIL PIPE MUFFLER 0C8101 1 PANEL MUFFLER BASE 056482 1 BEARING 1 1811 2 8346 0C3168 3 5 16 SPECIAL LOCK WASHER 0D1838 1 BOLT 3 8 24 x 15 50 0D1846 4 BOLT HHCS 8 1 25 x 345mm 0C7038 1 BRACKET ALTERNATOR
32. Disconnect charging source prior to connecting or dis connecting battery terminals wanNiNG amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive Generac Power Systems Inc s post 2 50 Section 2 Post Installation Start up and Adjustments INSTALLATION Air cooled 7 kW 12 kW 15 kW Generators ADJUSTMENTS The following procedures are to be observed e Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes immediately flush thoroughly with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire f because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause or spark in battery area and Disch
33. ER SP SPARK PLUG SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC Generac Power Systems Inc BATTERY CHARGE 66 WINDING 5 C2 2 ENGINE RUN HTO l0 WINDING STATOR C2 3 CONTROL PRINTED CIRCUIT BOARD 23 U 1 I 194 2 4 66 239 Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL Electrical Schematic 7 kW Drawing No 0D9014 C lt DATA lt C2 6 225A N2 NEM NI 240VAC UTILITY 56VA NE N2 X INPUT 12Vd mE 225 BE 3 5 TRANSFER 1VA RELAY COIL 224 N1 CUSTOMER CONNECTIONS 13 17 D C NEUTRAL ex 17 23 33 POWER 120V WINDING 120 STATOR 44 i 11 9 240V j 1 C1 1 BATTERY 12V 0 17 18 0 0 15 Vy 0 E CUSTOMER lt 8 SUPPLIED Generac Power Systems Inc 31 Section 7 Exploded Views and Parts Lists LISTS PARTS 0 Generac Air cooled 7 kW 12 kW and 15 kW Generators Enclosure Drawing No OF0080 C OG PRE PACKAGED UNITS ONLY 32 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators
34. ER FUSE FUSE 15AMP X AGC15 SWITCH ROCKER DPDT ON OFF ON CIRCUIT BREAKER MOUNTING BRACKET SNAP BUSHING SCREW PPHM 4 0 7 x 16mm NUT HEX LOCK M4 0 7 NYLON INSERT SCREW PPHM M3 0 5 X 8mm SCREW PPHM M3 0 5 X 8mm 7KW DECAL CONTROL PANEL NOT SHOWN CIRCUIT BREAKER 3 X 1 46 500 CIRCUIT BREAKER 2 5 X 1 ETA 46 500 P 7KW CONTROL PANEL BOTTOM CONTROL PANEL BOTTOM 7KW SCREW HHC M5 0 8 x 30mm SWITCH SPST ON ON N O NUT HEX LOCK M3 0 5 NYLON INSERT NUT HEX LOCK M3 0 5 NYLON INSERT 7KW PARTS 9 LISTS Control Panel Drawing 0E7974 G O ITEM PART NO QTY DESCRIPTION 24 26 0D8502 008441 0E0120 074908 082025 003910 022507 099727 046689 063617 075475 043180 008439 0 0119 092036 045770 0 7866 0 7867 0D3700 0912970069 0 2874 0 1658 022473 038750 022097 049813 031879 031879 023897 0F4793 CO CO NEUTRAL CONNECTOR HARNESS CONTROL PANEL NOT SHOWN HARNESS CONTROL PANEL WIRE NOT SHOWN 7KW SCREW TAPTITE M5 0 8 x 10 BP NUT HEX LOCK M5 0 8 NYLON INSERT TRANSFORMER SCREW HHC 1 4 20 x 1 2 FUSE 5A X AGC5 BLOCK TERMINAL STRIP 20A 4 X 6 X 1100V RELAY PANEL 12VDC DPDT 10A 240VAC SCREW PPHM 4 0 7 x 10mm WASHER FLAT M4 COVER CONTROL PANEL COMPONENT COVER CONTROL PANEL COMPONENT 7KW SCREW PPHMS LW 6 32 x 1 4 SCREW HHC 5 0 8 x10mm CO
35. FORMATION 3 Remove the battery if installed 4 Disconnect wire 0 and wire 14 from the gas solenoid on top of the demand regulator 5 Remove the carburetor fuel hose from the outlet port of the demand regulator 6 Remove the demand regulator by removing the fastener that retains the regulator mounting bracket 7 Remove the square headed steel pipe plug from outlet port 1 and the brass hose barb fitting from outlet port 2 8 Refit the brass hose barb fitting to outlet port 1 and the square headed steel pipe plug to outlet port 2 9 Reverse procedure steps 1 5 to reinstall demand regulator 10 Reverse the procedure to convert back to natural gas Figure 1 3 Demand Regulator HOSE amp PLUG SWITCHED SIDES FUEL HOSE PLUG BRASS HOSE FITTING FUEL HOSE BRASS HOSE FITTING OUTLET ADJUSTMENT PORT SCREW FUEL JET NG FUEL SYSTEM LP FUEL SYSTEM NOTE The natural gas adjustment screw is preset during installation and should not need any further adjustment 1 8 2 12KW AND 15KW V TWIN ENGINES To reconfigure the fuel system from NG to LP follow these steps NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator A fuel pres sure of 11 to 14 inches of water column 0 4 to 0 5 psi to the fuel inlet of the generator MUST BE SUPPLIED 1 Turn off the gas supply if connected 2 Open the roof and remove the door 3 Remov
36. GASKET FRONT DIVIDER GASKET FRONT DIVIDER 7KW COVER FRONT EXHAUST ENCLOSURE COVER BACK EXHAUST ENCLOSURE CLOTH HARDWARE 266 7mm x 146mm CLOTH HARDWARE 266 7mm x 146mm 7KW CLOTH HARDWARE 543mm x 146mm CLOTH HARDWARE 266 7mm x 387 4mm CLOTH HARDWARE 7KW FOAM FRONT INTAKE BAFFLE FOAM FRONT INTAKE BAFFLE 7KW FOAM TOP INTAKE BAFFLE FOAM BACK INTAKE BAFFLE FOAM BACK INTAKE BAFFLE 7KW FOAM BACK ENCL STRIP FOAM EXHAUST SIDE ENCLOSURE END FOAM EXHAUST SIDE ENCL FRONT FOAM EXHAUST FAN HOUSING WASHER SELF LOCKING WASHER SELF LOCKING 7KW FOAM FRONT EXHAUST ENCL COVER FOAM BACK EXHAUST ENCL COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE TYPE A WITH STUDS PIN HINGE TYPE B WITH STUDS PIN LATCH QUARTER TURN NON LOCKING WASHER NYLON 250 WASHER LOCK M6 1 4 RIVET POP 0 125 X 0 337 PARTS 9 LISTS Enclosure Drawing No 0 0080 O ITEM PART NO QTY DESCRIPTION 47 48 49 047411 047411 043116 043116 0D3700 0D3700 0D4662 090388 092120 003167 0 3328 055414 092079 0 1658 0C2937 086729 0388040AJ0 022127 022129 022129 074908 0D2346 0D2345 023484F 022142 0A7836 0A8475 0912970069 0912970070 055450 0 5968 003701 003472 0C8742 0C8911 0D8442 0D8652 036937 022152 051713 022158 0D3031 026850 049813 0F0164A 165 0 2874 043107 022145 045771 003906 0E4321 0E1330A 0E9692 042907 0 5241 0 5943 D D a N N a a a a ONON
37. GENERAG POVVER SYSTEMS INC Installation and Owner s Manual Air cooled Automatic Standby Generators Models 04673 2 6 kW NG 7 kW LP 04674 2 12 kW NG 12 kW LP 04675 3 13 kW NG 15 kW LP AAN NANANA AAA L VVVVVV VVVVVV GENERAC POWER SYSTEMS INC This manual should remain with the unit A Not intended for use as Primary Power in place of utility A or in life support applications DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is a compact high performance 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 enclo sure that is intended exclusively for outdoor installation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG 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 CAUTION and NOTE blocks are used to alert per sonnel to special instructions about a particular operation that may be hazardous if performed incor rectly or carelessly Observe the
38. I TE O O N1 13A 66 2 162 0 4 225B 225B 15 224B 224B 0 82 2 i 2 8 lt i 14 14 4 6 7 ye 11 6 66A 11 11 22 5 lt 77 66 66 225 1 22 22 d 0 77 0 11 4 d 4 3 N2 0 0 gt 6 6 44 224 ns 1 lt 162 162 55 C2 VOLTAGE REGULATOR 4 66A 0 0 66A 4 is 55 N1 33 13 2 225 0 351 224 0 194 23 N2 66A n N1 44 28 351 E 13A 194 351 15A 25 E 194 0 N1 eiie 13 66A 239 pe CB 15A 0 OFF O 17 13 239 15 17 0 2 SW1 m I ma Se 3 ze 2 SW2 9 18 2 OZ S AUTO 240V GENERATOR m 6 E OUTPUT TO TRANSFER m lt SWITCH CONTACTOR 2 5 CUSTOMER MANUAL CONNECTION Generac Power Systems Inc Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic 7 kW Drawing No 0D9014 C ELECTRICAL DATA 11 22 225A 224B 13A 1 p 13 0 C 225A 224 9 9 7 7 2 1 673 4 224 19 17 C2 1 44 15 ELECTRONIC 4 VOLTAGE 4 REGULATOR DPE WINDING STATOR DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HTO HIGH OIL TEMPERATURE SWITCH HM HOUR RUN METER IM IGNITION MODULE LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACT
39. LASHING GREEN LED NO UTILITY SENSE EXERCISE ee 4 FLASHING RED LEDS EX TIME ERCISER NOT SET 4 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figure 4 2 1 Start the generator by moving the Auto Off Manual switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth AUTO OFF e MAINTENANCE 5 Section 4 Maintenance 3 Install the dipstick then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE FULL MARK caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 4 Install the dipstick o Reset the AUTO OFF MANUAL switch to its origi nal position Figure 4 2 Oil Dipstick and Fill 7 kW VA V Figure 4 3 Oil Dipstick and Fill 12 kW and 15 kW Oil Dipstick Cil Fill 4 3 CHANGING THE ENGINE OIL 4 51 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 oynthetic oil O
40. Let the engine stabilize and warm up for a few minutes 7 generator s main circuit breaker to its ON or closed position The standby power source now powers the loads Figure 3 2 Manual Transfer Switch Operation LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 5 5 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Letthe engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generator s AUTO OFF MANUAL switch to its OFF or open position The engine should shut down 4 Check that utility power supply to the transfer switch is turned OFF Generac Power Systems Inc 15 OPERATION Section 3 Operation J gt Generac Air cooled 7 kW 12 kW and 15 kW Generators A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 5 Use the manual transfer handle inside the trans fer switch to move the main contacts back to their Utility position
41. MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES avail able same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRICAL SYS TEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Generac Power Systems Inc 3 GENERAL INFORMATION Dita A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage This standby generator set has been factory sup plied with a weather protective enclosure that is intended for outdoor installation only wanNiNG amp A If this generator is used to power electrical load circuits normally powe
42. MOUNTING 0D1609 1 DUCT ALTERNATOR AIR 0D2559 1 GASKET ALTERNATOR AIR DUCT 0C7038A 1 BRACKET ENGINE MOUNTING 0C7758 4 RUBBER MOUNT 0388050AD0 1 CABLE 6 48 BLACK BATTERY 0C2417A 1 EARTH STRAP 3 8 3 8 082121C 1 CLIP J VYNL COAT 0 625 ID 066386 1 ASSEMBLY BRUSH HOLDER 029451 2 6 FT TAPE ELEC UL FOAM 1 8 X 1 2 049451 1 WASHER FLAT 406ID X 1 6200 022237 5 WASHER LOCK 3 8 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 022131 4 WASHER FLAT 3 8 ZINC 051731 4 SCREW HHC 8 1 25 X 50 G8 8 022145 12 WASHER FLAT 5 16 ZINC 049820 4 NUT LOCK HEX M8 1 25 NYL INSERT 045756 2 SCREW TAPTITE M6 1 0X10 BP 022129 10 WASHER LOCK M8 5 16 022259 8 NUT HEX 5 16 18 STEEL 059637 2 SCREW TAPTITE 3 8 16 X 3 4 BP 0D4662 4 SCREW 5 16 18X3 4 HH THD ROLL 074994 3 FT HOSE RES 1 2 LP GAS 057822 4 CLAMP HOSE 8 53 1 00 0 0462 4 NUT HEX W TOOTH WSHR 8 1 25 0C2824 1 SCREW TAP R 10 32 x 9 16 025145 1 U BOLT 5 16 18 X 1 25 WITH SADDLE 0C4138 2 GASKET EXHAUST PORT 048031C 2 CLAMP HOSE BAND 030340 1 33 FT HOSE 1 4 ID SAE 30R7 066849 2 SCREW HHTT M5 0 8 X 16 Generac Power Systems Inc 43 Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0 9180 Part 1 44 Generac Power Systems Inc ITEM N O O1 gt PART NO 0E3221 0E1466 021533 0E2985 071983 0E8440 0A7628 078658 078659 088261E 0E3812 0 6519 078645 0A7811 0A9877 076701 02171
43. ND Y COOLING W Enclosure louvers BATTERY i Remove corrosion ensure dryness EVERY 6M EVERY 6 Clean and tighten battery terminals Check charge state Electrolyte level unsealed batteries only ENGINE AND MOUNTING Air cleaner Spark plug s Y GENERAL CONDITION Vibration Noise Leakage M Temperature COMPLETE TUNE UP TO BE COMPLETED BY A GENERAC Y AUTHORIZED DEALER ee Generac Power Systems Inc 5 1 PROBLEM The engine will not crank The engine cranks but will not start The engine starts hard and runs rough The AUTO OFF MANUAL switch is set to OFE but the engine continues to run There is no AC output from the generator There is no transfer to standby after utility source failure Unit consumes large amounts of oil Section 5 Troubleshooting Generac Air cooled 7 kW 12 kW and 15 kW Generators TROUBLESHOOTING GUIDE CAUSE 1 Fuse blown 2 Loose corroded or defective battery cables 3 Defective starter contactor 7 kW 4 Defective starter motor 5 Dead Battery 1 Out of fuel 2 Defective fuel solenoid FS 3 Open 14 wire from engine control board 4 Defective spark plug s 5 Valve lash out of adjustment l Air cleaner plugged or damaged 2 Defective spark plug s Fuel regulator not set 4 Fuel pressure incorrect 1 Defective switch 2 AUTO OFF MANUAL switch x ui dE Gon m wired incorrectly Defective control board M
44. OUSING COVER WITH SLEEVE SCREW HHFC M10 1 5 X 55 SCREW HHFC M6 1 0 X 25 ASSEMBLY OIL FILL CAP HOOK LIFTING ROCKER COVER WITH OIL FILL GASKET VALVE COVER KEEPER VALVE SPRING RETAINER VALVE SPRING SPRING VALVE SEAL VALVE STEM 07 WASHER VALVE SPRING STUD ROCKER ARM PIVOT NUT HEX M8 1 0 G8 YEL CHR O RING 3 8 X 1 2 ROCKER ARM PLATE PUSH ROD GUIDE SCREW HHFC M8 1 25 X 65 VALVE EXHAUST VALVE INTAKE TAPPET SOLID ASSEMBLY HEAD 2 G amp S PUSHROD 147 GASKET HEAD BARBED ELBOW 90 3 8NPT X 3 8 KIT GASKET KIT PISTON amp RINGS KIT BREATHER ASSEMBLY KIT GOVERNOR ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OIL RELIEF KIT GEAR COVER Generac Power Systems Inc 37 Generac Air cooled 7 kW 12 kW and 15 kW Generators Section 7 Exploded Views and Parts Lists GT 990 760 Engine Drawing No 0E8774 K Part 2 2 lt 110 lt _ 138 WA Ns NDA ANN a N ff 22 INS xk MS NSA Mae VAZAN S N VONN 22 5 N VS CN NS Y NOE lt NN NN N st lt Y 9 9 NN N Ww a c e YEA 2 NN nd E j I I Jk 10 Z Taz Z 2 E Sa V Yl FR P 3 ie 38 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators GT 990 760 Engine Drawing No
45. Sense Transformer 224 q 2 Remote Not Auto 2 12V 3 50 Hz Operation gt BATTERY 4 SPARE CUSTOMER SUPPLIED ee Generac Power Systems Inc L E D ALARM INDICATORS Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators op ELECTRICAL Wiring Diagram 7 kW Drawing No 0D9013 C DATA CONTROL PANEL BOX 225 224A 224 225A 224A CLOSEST TO BEARING 225A BA TX 4 BCR d T T b CB2 13 L
46. Systems Inc 49 PARTS Imensions Section 8 Mounting D LISTS OG 0D3739 Generac Air cooled 7 kW 12 kW and 15 kW Generators Drawing No SSHONI SHSLAWITIIN SNOISNAWIOC TIV eva d MAIA ACIS Les AAAAAA OfY1 SNIGNNOYE SS399Y uod 3AOW3U S310H SS322V 318VO NNNNNN LINN N3dO WNWININ 096 6 qauinoasd H31VM JO 38nsS3ud SVD I3 INI 1903 LdN t 11297162211 Poo YI aea annann ananannaa NUNN US lalalalalala aaa NNNNNN NNNNSNS L 6L 19 0 0 LE 64 1 067 MAIA LNOYS 169 eec Q ONI SWSLSAS HAMOd OVOANAD hala AAAAAA AA NNNNNN
47. TO the engine crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a pre set level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove both fuses before working on or around the generator or transfer switch Then place a Do Not Operate tag on the gen erator panel and on the transfer switch 3 3 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source Figure 3 2 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generator s AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Section 3 4 Sequence of Automatic Operation 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors utility power source voltage Should that voltage drop below a preset level circuit boar
48. TOR 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 wanNiNG amp A 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 POST CED INSTALLATION START UP ADJUSTMENTS 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 voltmeter and a frequen cy meter across terminal lugs E1 and E2 Voltage should be greater than 230 volts frequency should be
49. TR 1 4 20 X 3 4 SCREW HHC 8 1 25 X 25 WASHER FLAT 5 16 NUT M8 1 25 SELF ALIGN SCREW M6 HH PANEL EXHAUST ALIGNMENT GROMMET 38 1 CROSS SLIT WITH HOLE BRACKET REGULATOR MOUNTING SCREW HHC 8 1 25 X 16mm PLATE COVER GASKET COVER Generac Power Systems Inc 33 i us Section 7 Exploded Views and Parts Lists gt Generac Air cooled 7 kW 12 kW and 15 kW Generators KO Control Panel Drawing No 0E7974 G 34 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators ITEM PART NO QTY DESCRIPTION NOD O1 20 21 23 0 7886 0 7886 0 78860 0 7886 0 7886 0 78860 0A1801 083049 0C2174 075210A 0D3062 0D8615 0D8615A 032300 022676 0E4494 0E7890 023484E 075476 0E6480 001085 001085 0D8443 054502 053623 0E7870 0E7871 075235 0D5240 0D9784 0D9784 A cl ORA O CIRCUIT BREAKER 30A X 2P 240V 7KW CIRCUIT BREAKER 40A X 2P 240V 8 5KW CIRCUIT BREAKER 45A X 2P 240V 11KW CIRCUIT BREAKER 50A X 2P 240V 12KW CIRCUIT BREAKER 60A X 2P 240V 13KW CIRCUIT BREAKER 70A X 2P 240V 15KW ASSEMBLY BATTERY CHARGER ENGINE ASSEMBLY POTTED REGULATOR RELAY 12V 25A SPST BLOCK 1 POSITION HEX STAND OFF 46 32 x 3 8 ASSEMBLY HOME STANDBY CONTROLLER ASSEMBLY HOME STANDBY CONTROLLER 7KW HOLD
50. UP GASKET ROCKER COVER 410 STUD 020 PIVOT BALL ROCKER ARM NUT JAM ROCKER ARM PLATE PUSH ROD GUIDE SCREW HHFL M10 1 5 X 105 ASSEMBLY ROCKER COVER BREATHER PLUG OIL FILL PLASTIC O RING 17 8 I D x 2 4 PLUG STANDARD PIPE 3 8 STEEL SQUARE HEAD SCREW TAPTITE M5 0 8 X 10 BP KEEPER VALVE SPRING SCREW amp LOCKWASHER M6 1 X 12 SCREW 8 1 25 X 42 SEAL VALVE STEM D7 WASHER VALVE SPRING WASHER LARGE SPRING DOWEL SEAMED SLEEVE SHAFT GOVERNOR RC55 BARBED ELBOW 90 3 8NPT X 3 8 LOCKTITE DOWEL DIA 12 X 18L DOWEL SLEEVE SEAMED 12 DIA Generac Power Systems Inc LISTS OG 45 us Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators KO GN410 Engine Drawing No 0E9180 B Part 2 39 46 Generac Power Systems Inc ITEM N O gt WD PART NO 0C1069 0D2922 0C8435 0C9997 088434 045756 0C4176A 0D9004A 059985 022129 0C2458A 083512 0D1401A 091039 0C9619 049811 022097 040945 086999 0D5667A 049821 099236 070185B 082774 091222 067198 067890 0 7585 072734 072735 0C3978 0C6040 0D9760 092079 073100 083502 082025 0D3083 0E7887C 090072 075281 0 2094 0C4373 022717B QTY 1 BR BN BR B BR N Section 7 Exploded Views and Pa
51. VER CONTROL PANEL COVER CONTROL PANEL 7KW NUT FLANGE M6 1 0 NYLOK ASSEMBLY ROOF DOOR GROUND WIRE SCREW HHTR 1 4 20 X 3 4 WASHER LOCK SPECIAL 1 4 WASHER FLAT 1 4 M6 SCREW HHC M6 1 0 x 30mm WASHER LOCK M6 1 4 NUT HEX M6 1 0 WASHER FLAT 4 WASHER FLAT 44 7KW WASHER FLAT 10 SCREW PPHM M3 0 5 x 10mm Generac Power Systems Inc 35 Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators GT 990 Engine Drawing No 0E8774 K Part 1 LE Ss f te lt lt lt g SF CARS He NY Si GIT A did S Lea 7 x d gt 2 SS No QUEE 2107 9 Se ve ge ZE Z BLE aL 19 5929 09 69 95 7595 76 EG 06 16 06 90 p LZ 79 69 09 BG BG ZG OG pS EG ZG 1G 06 67 87 Zh L OL 81891 voL 69 2 9 99 ei Zh ll 9 79 56 99 p 07 66 02 619 99 36 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists PARTS 9 LISTS Generac Air cooled 7 kW 12 kW and 15 kW Generators GT 990 Engine Drawing No 0E8774 K Part 1 O ITEM PART NO QTY DESCRIPTION 0C5729 0 9843 090388 0C5372 0C3005 0E3372B 0D8067A 071983 0C2981C 045761A 0 2985 021533 0 1466 004041 0C2983 0C2985A 0C2985B 0D4042 0A7811 0C2977 0C5943 0 4357 0E3223 0D2157 0 6098 0D4123A 078699E 0C3011 0C3009 0C3010 093873 0C5315 0C5998 0D1667 0C2991 0C2988 0C2992 1
52. Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 4 9 for vent locations Figure 4 9 Cooling Vent Locations AIR OUTLET j j tt PE ttt E t AIR INTAKE WARNING A The exhaust from this product gets extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system caution amp The maximum ambient temperature for the generator is 48 9 C 104 F Generac Air cooled 7 kW 12 kW and 15 kW Generators 4 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it MUST NOT be started and operated Following any sub mersion in water have a Generac Authorized Dealer thor oughly clean and dry the generator 4 11 CORROSION PROTECTION Periodically wash and wax the enclosure using automo tive type products Frequent washing is recommended in salt water coastal areas Spray engine linkages with a light oil such as WD 40 4 12 OUT OF SERVICE PROCEDURE 4 12 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer than 90 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel
53. ain line circuit breaker open Generator internal failure Defective transfer switch coil Defective transfer relay Transfer relay circuit open Defective control logic board Break in procedure not followed see Section 2 1 TROUBLESHOOTING CORRECTION 1 Replace 15A fuse on generator control panel 2 Tighten clean or replace as necessary 2 7 Zo o Charge or replace battery 1 Replenish fuel 227 9 4 Clean re gap or replace plug s 5 Reset valve lash 1 Check replace air cleaner 2 Clean re gap or replace plug s 3 Set fuel regulator 4 Confirm fuel pressure is at 0 4 O 5 psi for LP and 5 7 water colum 0 18 0 25 psi for natural gas les 2 t 1 Reset circuit breaker to ON or closed 277 La t 2 7 dut dom Contact the nearest Generac Authorized Dealer for assistance Generac Power Systems Inc 23 Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL 321 2 bak DATA d Wiring Diagram 12 amp 15 kW Drawing No 0D8500 B 4 gt ENGINE WIRING DIAGRAM KEY BA BRUSH ASSEMBLY BATTERY BCR BATTERY CHARGE RELAY C L CHARGER gt CB1 MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION D DIODE DSW PCB MOUNTED DIP SWITCH 0 FS FUEL SOLENOID F1 FUSE 15 AMP 225B F2 FUSE 5 AMP FS GRD CONTROL PANEL GROUND 224B
54. aintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 555 1522 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe impor tant rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty serv ice e
55. al operation procedures A 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 2 5 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 A A 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 o 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 MAN UAL switch to MANUAL The engine should crank and start 7 Let
56. arge static electricity from body before touch ing the battery by first touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 2 1 BEFORE INITIAL START UP Before starting complete the following 1 Set the generator s main circuit breaker to its OFF or open position 2 Set the generator s AUTO OFF MANUAL switch to the OFF position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 4 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 5 Check the fuel supply Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel gas codes fuel shutoff valves in the fuel supply lines must be open caution amp Never operate the engine with the level below the Add mark on the dipstick Doing this could damage the engine 10 Generac Power Systems Inc 2 22 CHECK TRANSFER SWITCH OPERATION Refer to Section 3 5 of the owner s manual for manu
57. ate the nut and hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go Loosen the rocker jam nut Use an lOmm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in lbs torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 4 10 Valve Clearance Adjustment Rocker Pivot Ball Jam Nut Q eo Generac Power Systems Inc Generac Air cooled 7 kW 12 kW and 15 kW Generators Install new valve cover gasket Re attach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 4 9 COOLING SYSTEM Air inlet and outlet openings in the generator compart ment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow
58. ator Be cautious not to overload the generator Use the following chart as a guide 120 Volts 240 Volts 50 0 amps 25 0 amps 83 3 amps 41 6 amps 108 3 amps 4 When full load has been achieved Connect a fre quency meter to the output lugs of the generator s main line circuit breaker o The fuel regulator is fitted with one 7 kW or two 12 amp 15 kW adjustment screws While watching the frequency meter slowly turn the adjustment screw clockwise or counterclockwise one at a time until highest frequency is read on the meter Only limited adjustment is available between the set pins Under no circumstances should any of the pins be removed Figures 2 1 and 2 2 Figure 2 1 Dual Fuel Regulators Adjustment Adjustment MM Set Screw One Side Pin Both Sides Only Set Pin Both Sides 12 Generac Power Systems Inc 6 When the highest frequency is reached maximum power has been set Then turn both adjustment screws 1 4 turn counterclockwise Regulator is now set Figure 2 2 Placement of Regulator NKR KKK KRY RAS G8 89 9 5088 55 NNNM RY 5 6 SKY FARA 5 7 Turn utility power to the main distribution panel back on This can be done by switching the serv ice main breaker to the on or closed position Allow the generator to shut down WARNING amp Do not make an
59. d action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power sup ply load terminal lugs T1 T2 connect to terminal lugs E1 E2 OPERATION Section 5 Operation Generac Air cooled 7 kW 12 kW and 15 kW Generators J gt Upon restoration of utility source voltage above a pre set level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 70 per cent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a standby source C Standby Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored to above 70 percent of the nominal source v
60. e and then shut down Allow the unit to cool 10 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Replace the oil with synthetic oil as recommended in Section 4 3 Changing the Engine Oil 11 The generator is now ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 3 2 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also permits starting and exercising of the engine every seven days with the exercise timer see section 3 6 This position also is used for remote start ing when it is set up 3 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 3 2 5 MANUAL POSITION Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure d RE E x 14 Generac Power Systems Inc Figure 3 1 Generator Control Panel FUSE Locate your neares t GENERAC dealer at w w W generac com POWER SYSTEMS INC AUTO OFF SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK 15A SET FLASHING GREEN LED EXERCISE OOOO 4 FLA SUNG AED DEDE D TIME EXERCISER NOT SET waRNING amp With the switch set to AU
61. e the battery if installed Generac Power Systems Inc 7 GENERAL INFORMATION 4 Remove the engine air in baffle located on the left hand side of the battery compartment Two M6 screws are located on top of the baffle and two M6 screws are located on the inside of the baffle towards the back 5 Remove the small hose clamp and hose from the fuel regulator It may be necessary to pry the hose off of the brass fitting using a screwdriver to gen tly lift up the hose edge 6 Remove the small brass hose fitting from the reg ulator casting 7 Place the small fuel jet thread side first into the threaded hole originally occupied by the brass hose fitting Figure 1 4 Figure 1 4 Demand Regulator OUTLET PORTS FUEL HOSE BRASS HOSE FITTING BRASS HOSE r pressure FITTING N ADJUSTER SCREWS IDLE CIRCUIT PORT SMALL FUEL JET REGULATOR HOUSING PORT 8 Using a short No 2 Phillips screw driver thread the small fuel jet into the regulator casting Do not over tighten 9 Apply thread sealant to the threads of the hose fit ting and replace it into the regulator body 10 Re attach the small hose and hose clamp and tighten as necessary 11 Replace the engine air in baffle using the four M6 Screws 12 Identify both brass adjustment screws on the reg ulator NOTE One adjustme
62. e voltage regulator Figure 2 6 Voltage Adjustment Potentiometer D D D Generac Power Systems Inc 13 OPERATION Section 3 Operation 17 Generac Air cooled 7 kW 12 kW and 15 kW Generators NOTE The voltage regulator is housed above the genera tors control panel The regulator maintains a volt age in direct proportion to frequency For example at 62 Hertz line to neutral voltage will be 124 volts 3 1 BREAK IN PROCEDURE Once the unit has been installed with utility power connected to the transfer switch and all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Setthe generator s AUTO OFF MANUAL switch to AUTO 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a utili ty main line circuit breaker The unit will start and the transfer switch will transfer to standby Run the unit for one hour at 25 percent load Run the unit for one hour at 50 percent load Run the unit for one hour at 75 percent load Run the unit for one hour at 100 percent load Turn ON the utility power supply to the transfer switch which will allow the transfer switch to transfer back to utility power The unit will con tinue to run for one minut
63. efore touch ing the battery by first touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off 2 and the 5A fuse is removed from the generator control panel or sparking may occur at the bat tery posts as the cables are attached causing an explosion Generac Power Systems Inc 19 MAINTENANCE S O Section 4 Maintenance 4 8 ADIJUSTING VALVE CLEARANCE After the first 50 hours of operation adjust the valve clearance in the engine Important If feeling uncomfortable about doing this procedure or the proper tools are not available contact the nearest Generac Authorized dealer for service assis tance This is a very important step to insure longest life for the engine To adjust valve clearance Make sure the engine is at room temperature Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen at the front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rot
64. enerators Electrical Schematic 12 amp 15 kW Drawing No 0D8501 B Section 6 Electrical Data ELECTRICAL T DATA 11 lt C2 6 22 TX C2 5 225A N2 N1 GO 240VAC UTILITY 56VA T N2 GO INPUT 224A Mi 225 12Vdc m 23 TRANSFER RELAY 194 224 N1 CUSTOMER CONNECTIONS 13 17 11 ptas 23 1 22 15A b 33 0 O SW1 15A 194 POWER 120V WINDING 120V 239 STATOR 13 47 15 a 44 194 n 11 959 6 15 239 4 0 240V 14 15 13 0 2 1 13 210 15 SOR 56 16 16 14 18 C1 1 0 Fs 0 0 0 i BLACK 15 CUSTOMER 0 1 2 SUPPLIED 18 T K SP D lt 18 C1 5 5 2 E SP2 NNN Generac Power Systems Inc 27 4 ELECTRICAL DATA Section 6 Electrical Data Generac Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 7 kW Drawing No 0D9013 C
65. f dip switch 2 Remote Not Auto on the controller printed circuit board is ON 16 Generac Power Systems Inc 5 PROTECTION SYSTEMS 3 7 1 LOW OIL PRESSURE SWITCH This switch Figure 3 3 has normally closed contacts that are held open by engine oil pressure during crank ing and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO 3 72 HIGH TEMPERATURE SWITCH This switch s contacts Figure 3 3 close if the tem perature should exceed approximately 140 C 2849 F initiating an engine shutdown The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level Figure 3 3 Low Oil Pressure and High Temperature Switches Low Oil Switch High Temp Switch 7 f AE aa asa 2 r gt N y 5 7 5 OVERCRANK This feature prevents the generator from damaging itself when it continually attempts to start and anoth er problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED will light indicating an overcrank failure The AUTO OFF MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired
66. filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 4 4 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 for oil capaci ties 5 Start the engine and check for leaks 18 Generac Power Systems Inc Generac Air cooled 7 kW 12 kW and 15 kW Generators 4 5 CHANGING THE ENGINE AIR CLEANER 4 51 7 KW 12 KW AND 15 KW GENERATORS oee Figures 1 1 and 1 2 for the location of the air cleaner Use the following procedure Figure 4 6 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box 5 Install the cover Turn the two cover screws clock wise to tighten the Service Schedule Section 4 13 for air cleaner maintenance See Section 1 5 1 for air filter replacement part number Figure 4 6 7 kW Engine Air Cleaner Location Fuel Air Cleaner Regulator Figure 4 7 12 kW and 15 kW Engine Air Cleaner Generac Air cooled 7 kW 12 kW and 15 kW Generators 4 6 SPARK PLUG S Reset the spark plug s gap or replace the spark plug s as necessary See Section 4 13 for mainte nance requirements 1 Clean the area around the base of the spark plug s to keep dirt and debris out of the engine
67. gine for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper m
68. ing A good rule is to allow three feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds Install the generator as close as possible to the fuel supply to reduce the length of piping Install the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DIS TANCE 1 9 2 TRANSFER SWITCH 1 9 2 1 7 kW 12 kW and 15 kW Units Transfer switches for use with these generators are sold separately and can be purchased from Generac Authorized Dealers Install the transfer switch on a firm sturdy sup porting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and mounting sur face Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors Failure to utilize a Generac transfer switch with this generator may void the warranty 1 10 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 Setthe generator s AUTO OFF MANUAL switch to OFF 2 Turn off utility power su
69. ings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and e Disconnect charging source prior to connecting or dis connecting battery terminals waRNING amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic y The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes immediately flush thoroughly with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire f because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body b
70. k 6 1 6 Fuel Requirements and Recommendations 7 1 7 Fuel Consumption T 1 8 Reconfiguring the Fuel System 7 Lo Z KW 0CC 7 1 8 2 12 kW and 15 kW 990cc Engines 4 8 1 9 8 1 9 2 Transfer Switch 8 1 10 Battery Installation 9 DAL The BRAWL T 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 6 Adjusting the Regulator Natural Gas Only 12 2 7 Engine Governor Adjustment 12 2l ZEW UNIS 12 2 7 2 12 kW 15 kW Units 13 2 7 3 Additional Corrosion Protection 13 2 8 Voltage Regulator Adjustment 13 Section 3 Operation 14 3 1 Bredk in Procedure 14 3 2 Using the Auto Off Manual Switch 14 92 1 Auto Posiliom 14 Table of Contents a
71. m carefully Their definitions are as follows A 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 A warnings amp After this heading read instructions that if not strictly complied with may result in serious person al injury or property damage caution A 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 compli ance with the special 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 is as follows A 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 This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and
72. nd condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 42 F above 16 C 60 F Total current in TWO separate curcuits Current in each curcuit must not exceed the value stated for 240V 1 5 2 ENGINE Type of Engine Number of Cylinders Rated Horsepower Displacement Cylinder Block Valve Arrangement Ignition System Recommended Spark Plug opark Plug Gap Compression Ratio otarter Oil Capacity Including Filter Recommended Oil Filter Recommended Air Filter Operating RPM 6 Generac Power Systems Inc Model 04673 Model 04674 Model 04675 GT 990 2 30 3 600 rpm 992cc Iron Sleeve Iron Sleeve Iron Sleeve Overhead Valves Solid state w Magneto RC12YC 0 508 mm 0 020 inch 9 5 1 12Vdc Approx 1 7 Qts Generac Part 70185 Generac Part 0C8127 Generac Part 0C8127 3 600 1 6 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section
73. nt screw can be accessed from the front of the unit and the second can be accessed from the back of the unit enclosure by removing the plastic hole plug The screw can be turned with a long flat blade screwdriver 13 To adjust the system to run on LP fuel turn BOTH adjuster screws 1 2 TURN CLOCKWISE The system should now be set for maximum power and best perfomance DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE SET PINS FROM THE REGULATOR HOUSING THIS WILL VOID THE WARRANTY 8 Generac Power Systems Inc Section 1 General Information Generac Air cooled 7 kW 12 kW and 15 kW Generators 14 It may be necessary to make minor adjustments to the preset adjustment screw settings to achieve maximum power particularly at higher altitudes If experiencing problems with the unit producing maximum power follow the procedure in Section 2 6 Adjusting the Fuel Regulator 1 9 LOCATION 1 9 GENERATOR Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servic
74. oltage a retrans fer time delay starts timing E Retransfer Time Delay This timer runs for about 15 seconds At end of a 15 second delay circuit board action de energizes the transfer relay in the transfer switch Retransfer to utility power source then occurs Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down 5 5 MANUAL TRANSFER OPERATION 5 5 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Set the generators AUTO OFF MANUAL switch to 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 4 Use the manual transfer handle inside the trans fer switch to move the main contacts to their Standby position i e loads connected to the standby power source Figure 3 2 o To crank and start the engine set the AUTO OFF MANUAL switch to MANUAL 6
75. or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Generac Power Systems Inc 53 Section 10 Warranty WARRANTY Generac Air cooled 7 kW 12 kW and 15 kW Generators GENERAC POWER SYSTEMS STANDARD TWO YEAR LIMITED WARRANTY FOR GENERAC RESIDENTIAL AND LIGHT COMMERCIAL UNITS For a period of two 2 years or two thousand 2 000 hours of operation from the date of sale which ever occurs first Generac Power Systems Inc will at its option repair or replace any part s which upon examination inspection and testing by Generac Power Systems or an Authorized Certified Generac Power Systems Dealer or branch thereof is found to be defecti
76. pply to the transfer switch 3 Remove the 5 amp fuse from the generator con trol panel wanNiNG amp 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 connect ed 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 5 Connect cables to battery posts as follows 4 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a nega tive NEG or 6 Replace the 5 amp fuse in the generator control panel NOTE Damage will result if battery connections are made in reverse Figure 1 5 Battery Cable Connections BLACK LEAD RED LEAD FROM STARTER CONTACTOR Section 1 General Information Generac Air cooled 7 kW 12 kW and 15 kW Generators GENERAL INFORMATION NOTE The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation 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 charger is designed to help extend
77. r cooled 7 kW 12 kW and 15 kW Generators Keep a fire extinguisher near the generator at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applica ble fuel gas codes Before placing the home stand by electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation inspect the fuel system periodically for leaks No leakage is permitted STANDARDS INDEX In the absence of pertinent standards codes regula tions and laws the published information listed below may be used as installation guide for this equipment l NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston
78. red by a utility power source it is required by code to install a trans fer switch The transfer switch must effectively isolate the electrical system from the utility dis tribution system when the generator is operat ing NEC 700 701 and 702 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage If there is loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is discovered later e Generac Power Systems Inc Section 1 General Information Generac Air cooled 7 kW 12 kW and 15 kW Generators 1 22 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 1 Low Oil Pressure Sensor 3 Overcrank 2 High Temperature Sensor 4 Overspeed There are LED readouts on the control panel
79. 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 anticipate every possible circum stance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a proce dure work method or operating technique Generac does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique chosen does not ren der the generator unsafe DX A 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 A 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 rotating and or hot during operation Exercise care near running generators e Generac Power Systems Inc operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment wanNiNG Please read all hazards carefully GENERAL HAZARDS A For safety reasons Generac recommends
80. rganic break in oil is required before using synthetic oil Generac Power Systems Inc 17 MAINTENANCE S O Section 4 Maintenance NOTE The unit is supplied with break in oil See the Break in Procedure Section 3 1 for the first required oil change A caution amp Any attempt to crank or start the engine before A it has been properly serviced with the recom mended oil may result in an engine failure 4 5 2 OIL CHANGE PROCEDURE To change the oil proceed as follows 1 Run the engine until it is thoroughly warmed up then shut OFF the engine 2 Immediately after the engine shuts OFE pull the oil drain hose Figure 4 4 free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container Figure 4 4 Oil Drain Hose and Filter W EROS AUN EX a y Drain 2 Hose 22 17 Oil Filter Sw 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 for oil capaci ties 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Applya light coating of clean engine oil to the gas ket of the new filter See Section 1 5 1 for recom mended
81. rt and transfer occur always set the generator s AUTO OFF MANUAL switch to its OFF position before working on equipment and remove the 5A and 15 fuses from the generator control panel In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Generac Ai
82. rts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0E9180 B Part 2 DESCRIPTION SCREW TAPTITE M6 1 0X8 YELLOW CHROME HOUSING BLOWER TUBE DIPSTICK GUARD FAN WRAPPER BOTTOM SCREW TAPTITE M6 1X10 YELLOW CHROME WRAPPER TOP ASSY STARTER SCREW SHC M8 1 25 X 45 G12 9 WASHER LOCK M8 5 16 BACKPLATE L F D F SCREW TAPTITE M8 1 25 X 16 BP BREATHER TUBE GASKET INTAKE ADAPTER ASSEMBLY PLASTIC CARB WASHER FLAT M6 WASHER LOCK M6 1 4 SCREW SHC M6 1 0 X 20 G12 9 GASKET OIL FILTR ADAPTER ADAPTER OIL FILTER SCREW SHC M8 1 25 X 30 G12 9 SWITCH OIL 8 0 PSI OIL FILTER KEY WOODRFF 4 X 19D FLYWHEEL WITH RING GEAR 32DEG WASHER BELV 20 X 2 2 NUT HEX FLYWHEEL SPARKPLUG ASSEMBLY GOVERNOR LEVER 12 ROD GOVERNOR CONTROL SPRING ANTI LASH ASSEMBLY WIRE ASSEMBLY IGNITION COIL SCREW TAPTITE M6 1 0 X 25 BP SPRING GOVERNOR BOLT GOVERNOR ADJUST M5 NUT HEX LOCK M5 0 8 NYINS ZINC ASSEMBLY OIL DRAIN HOSE ASSEMBLY CAP amp DIPSTICK O RING 9 16 X 3 4 X 3 32 SWITCH THERMAL SCREW M3 0 5 X 6 SEMS SPACER ENDFRAME GROMMET age LISTS Generac Power Systems Inc 47 i us Section 7 Exploded Views and Parts Lists Generac Air cooled 7 kW 12 kW and 15 kW Generators KO Gas Regulator Drawing No 0D8720 G co x p werd wa ON D a y N 43 Generac Power Systems Inc PART NO 0D5694 0F5022 0C4647 0D4166 0C6070 0F
83. shutoff valve in the fuel supply line and allow the unit to shut down 3 Once the unit has shut down it will signal a low oil fault 4 Setthe AUTO OFF MANUAL switch to OFF and turn off the utility power to the transfer switch o While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations Section 4 3 1 6 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 7 Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s 8 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 9 Clean and wipe the entire generator MAINTENANCE S Section 4 Maintenance 4 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Verify that utility power is turned off and that the AUTO OFF MANUAL switch is set to OFF 3 Check the tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in the engine see Section 4 3 1 If nec essary drain and refill with the proper oil 4 Check the state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE B
84. sion fire theft freezing vandalism riot or wars lightning earthquake windstorm hail volcanic eruption water or flood tornado hurricane terrorist acts or nuclear holocaust 6 Products that are modified or altered in a manner not authorized by Generac Power Systems in writing 7 Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing 8 Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s 9 Damage related to rodent and or insect infestation 10 Failure due to misapplication misrepresentation or bi fuel conversion 11 Telephone facsimile cell phone satellite Internet or any other communication expenses 12 Rental equipment used while warranty repairs are being performed i e rental generators cranes etc 13 Overtime holiday or emergency labor 14 Modes of transportation deemed abnormal refer to Generac Power Systems Warranty Policies Procedures and Flat Rate Manual 15 Steel enclosures that are rusting due to improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised 16 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem 17 Starting batteries fuses ligh
85. sistance Service technicians are factory trained and are capable of handling all service needs When contacting a Generac Authorized Dealer 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 loca tion Model No Serial No AUTHORIZED DEALER LOCATION To locate the nearest GENERAC AUTHORIZED DEALER please call this number 1 800 333 1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER Generac Air cooled 7 kW 12 kW and 15 kW Generators Introduction Inside Front Cover Read This Manual Thoroughly IFC eus qs 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 Proteclon SyYSteS L uuu uuu et or URP LEVEL Ve 4 Io Det LED 4 1 4 Your Generator 5 I 5 Specifications 6 1 5 1 QGeneralOr uu upas apup edun bes 6 1 522 ENGINE uya a
86. t bulbs engine fluids and overnight freight cost for replacement part s THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED IMPLIED SPECIFICALLY GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to purchaser owner GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS INC NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against Generac Power Systems Inc based on negligence This warranty gives purchaser owner specific legal rights Purchaser owner also may have other rights that vary from state to state Generac Power Systems Inc 8 Waukesha WI 53187 Ph 544 4811 Fax 262 544 4851 Bulletin 0166550SBY Printed in U S A 6 04 Part No OFOOS4 Revision H 03 28 05 Printed in U S A
87. 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 19 A A 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 Section 2 Post Installation Start up and Adjustments Generac Air cooled 7 kW 12 kW and 15 kW Generators 8 Connect an accurate AC voltmeter and a frequen cy meter across transfer switch terminal lugs 1 and E2 Voltage should be 242 252 volts fre quency should read about 61 63 Hertz 9 Connect the AC voltmeter test leads across termi nal lug 1 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 not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is cor rect but voltage is high or low the generator s voltage regulator requires adjustment 2 4 GENERA
88. the generator set If a Non Generac Power Systems Inc Transfer Switch is substituted for use and directly causes damage to the generator set no warranty coverage shall apply All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty Policies and Procedures Flat Rate Manual Units that have been resold are not covered under the Generac Power Systems Warranty as this Warranty is not transferable Unit enclosure is only covered against rust or corrosion the first year of the warranty provision Use of Non Generac replacement part s will void the warranty in its entirety Engine coolant heaters block heaters heater controls and circulating pumps after the first year THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Any unit built manufactured prior to July 1 2004 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty 5 Failures caused by any external cause or act of God such as but not limited to colli
89. to noti fy personnel that one of these faults has occurred There is also a System Set LED that is described below 1 5 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true 1 The AUTO OFF MANUAL switch is set to the AUTO position 2 The utility voltage being supplied to the unit is being sensed by the Control PCB If the utility sense voltage is not connected to the unit or if it is below 168 volts AC then the system set light wil flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto position the generator will start 3 The Not In Auto dip switch is set to the OFF position on the control board 4 No alarms are present for example low oil pres sure high temperature etc Section 1 General Information Generac Air cooled 7 kW 12 kW and 15 kW Generators INFORMATION GENERAL 1 4 THE GENERATOR Figure 1 1 7 kW Single Cylinder GH 410 Engine L CL Cc 7 1 Control Oi Data Panel Dipstick Decal Outlet ji Fuel d p Feau Fuel Inlet em e N 2 omposite Base Exhaust Enclosure oe Battery Oil Filter Compartment Figure 1 2 12 kW
90. uled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and
91. ve under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Certified Generac Power Systems Dealer or branch thereof This warranty applies only to Generac Power Systems Generators used in Standby applications as Generac Power Systems Inc has defined Standby Scheduled maintenance as outlined by the generators owners manual is highly recommended This should be performed by an Authorized Certified Generac Power Systems Dealer or branch thereof This will verify service has been performed on the unit throughout the warranty period WARRANTY SCHEDULE YEAR ONE and TWO one hundred percent 100 coverage on mileage labor and parts listed proof of purchase and maintenance required Engine ALL COMPONENTS Alternator ALL COMPONENTS Transfer System ALL COMPONENTS Guidelines Travel allowance for Air and Liquid cooled units is limited to 60 miles maximum and 2 0 hours maximum or 100 00 maximum per occurrence whichever is less round trip to the nearest authorized Generac Service Facility and only applies to permanently wired and mounted units Any and all warranty repairs and or concerns must be performed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof A Generac Power Systems Inc Transfer Switch is highly recommended to be used in conjunction with
92. vidence must be presented showing the date of the sale to the original purchaser owner If there are any questions regarding the warranty rights and responsibilities contact Generac at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 340 EAGLE WI 55119 Part 1 5e Generac Power Systems Inc Section 10 Warranty Generac Air cooled 7 kW 12 kW and 15 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall con tinue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS
93. y unnecessary adjustments Factory settings are correct for most applica tions However when making adjustments be careful to avoid overspeeding the engine If this procedure or equipment are not available locate the nearest Generac Guardian Dealer and they can perform the adjustments NOTE A service fee may be charged for this adjustment 2 7 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low adjust the engine governor as follows 2 71 7 KW UNITS 1 Loosen the governor clamp bolt Figure 2 3 2 Hold the governor lever at its wide open throttle position and rotate the governor shaft clockwise as far as it will go Then tighten the governor lever clamp bolt to 70 inch pounds 8 N m 3 Start the generator let it stabilize and warm up at no load 4 Connect an AC frequency meter across the gener ators AC output leads 5 Turn the speed adjust nut to obtain a frequency reading of 63 Hz Section 2 Post Installation Start up and Adjustments Generac Air cooled 7 kW 12 kW and 15 kW Generators 6 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the volt age regulator may require adjustment Figure 2 3 Single Cylinder Engine Governor Adjustment GOVERNOR SHAFT GOVERNOR i ADJUST CLAMP BOLT ct E A im 4 2 7 2 12 KW AND

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