Generac Power Systems 04679-1 Installation And Owner's Manual
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Generac Power Systems 04679-1 Installation And Owner's Manual

Generac Power Systems 04679-1 Installation And Owner's Manual

Air-cooled, prepackaged automatic standby generator
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®
!
Not intended for use as Primary Power in place of utility or
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
Installation and
Owner's Manual
in life-support applications.
DANGER
Air-cooled, Prepackaged
Automatic Standby Generator
Model:
04679-1 (6 kW NG, 7 kW LP)
GENERAC
R
POWER SYSTEMS, INC.
R
®
!

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Summary of Contents for Generac Power Systems 04679-1

  • Page 1 ® Installation and Owner’s Manual Air-cooled, Prepackaged Automatic Standby Generator Model: 04679-1 (6 kW NG, 7 kW LP) GENERAC POWER SYSTEMS, INC. ® Not intended for use as Primary Power in place of utility or in life-support applications. DANGER DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

  • Page 2: Introduction

    READ THIS MANUAL THOROUGHLY • 04679-1 – 6 kW NG, 7 kW LP , single-cylinder GH- If any portion of this manual is not understood, contact 410 Engine the nearest Generac Authorized Dealer for starting, operating and servicing procedures.

  • Page 3: Table Of Contents

    Table of Contents Air-cooled 7 kW Generator Introduction ......Inside Front Cover Section 3 – Operation ........12 Read This Manual Thoroughly ......IFC Break-in Procedure........12 Contents ............IFC Using the Auto/Off/Manual Switch ....12 Operation and Maintenance ......IFC 3.2.1 “Auto” Position ........12 How to Obtain Service ........IFC Authorized Dealer Locator Number ....IFC 3.2.2 “Off”...

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 7 kW Generator SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment. WARNING: GENERAL HAZARDS The engine exhaust from this product...

  • Page 5: Standards Index

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 7 kW Generator • Keep a fire extinguisher near the generator at all ELECTRICAL HAZARDS times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extin- •...

  • Page 6: Section 1 - General Information

    Section 1 — General Information Air-cooled 7 kW Generator PROTECTION SYSTEMS DANGER Unlike an automobile engine, the generator may have Only qualified electricians or contractors should to run for long periods of time with no operator pres- attempt such installations, which must comply ent to monitor engine conditions.

  • Page 7: The Generator

    Section 1 — General Information Air-cooled 7 kW Generator THE GENERATOR Figure 1.2 – 7 kW, Single Cylinder GH-410 Engine Control Panel Data Decal Exhaust Enclosure Air Filter Fuel Regulator 12 Volt Battery Oil Filter Generac ® Power Systems, Inc.

  • Page 8: Specifications

    1/2 Load Full Load 1/2 Load Full Load Weight ............452 Pounds 04679-1 0.91/33 1.21/44.1 * Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. *Natural gas is in cubic feet per hour.

  • Page 9: Location

    Section 1 — General Information Air-cooled 7 kW Generator Figure 1.3 – Demand Regulator (7 kW) 1.9.2 TRANSFER SWITCH 1.9.2.1 7 kW Unit FUEL HOSE FUEL HOSE The transfer switch shipped with this generator is BRASS HOSE BRASS HOSE FITTING FITTING enclosed in a NEMA 1 enclosure.

  • Page 10: The Battery

    Section 1 — General Information Air-cooled 7 kW Generator Figure 1.4 – Battery Cable Connections self-discharge. The trickle charger is designed to help extend the life of your battery by maintaining the battery when the unit is not running. The trickle charge feature cannot be used to recharge a discharged battery.

  • Page 11: Section 2 - Post Installation Start-Up And Adjustments

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW Generator Be sure the AUTO/OFF/MANUAL switch is set to 4. Turn on the utility power supply to the transfer switch using the means provided (such as a utili- the OFF position before connecting the battery ty main line circuit breaker).

  • Page 12: Generator Tests Under Load

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW Generator GENERATOR TESTS UNDER LOAD CHECKING AUTOMATIC To test the generator set with electrical loads applied, OPERATION proceed as follows: To check the system for proper automatic operation, 1. Set generator’s main circuit breaker to its OFF proceed as follows: (or open) position.

  • Page 13: Engine Governor Adjustment

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW Generator 3. Turn on appliances, lights, pumps, etc., that are on the emergency circuits in an attempt to fully load the generator. Be cautious not to overload Do not make any unnecessary adjustments. the generator.

  • Page 14: Additional Corrosion Protection

    Section 3 — Operation Air-cooled 7 kW Generator 2.7.2 ADDITIONAL CORROSION 4. Using the transfer switch’s built-in emergency load center, turn on circuits to load the generator PROTECTION to approximately 25% load and run the unit for Periodically spray all engine linkage parts and brack- one hour.

  • Page 15: Manual" Position

    Section 3 — Operation Air-cooled 7 kW Generator 3.2.3 “MANUAL” POSITION A. Utility Voltage Dropout Sensor • This sensor monitors utility source voltage. Set the switch to MANUAL to crank and start the • If utility source voltage drops below about 60 per- engine.

  • Page 16: Transfer Back To Utility Power Source

    Section 3 — Operation Air-cooled 7 kW Generator 4. Use the manual transfer handle inside the trans- 6. Turn ON the utility power supply to the transfer fer switch to move the main contacts to their switch using the means provided. “Standby”...

  • Page 17: Overcrank

    Section 4 — Maintenance Air-cooled 7 kW Generator Figure 3.3 – Low Oil Pressure and The generator panel’s five amp fuse protects the bat- tery charge circuit against overload. If the fuse ele- High Temperature Switches ment has melted open, there will not be battery charging capability.

  • Page 18: Changing The Engine Oil

    Section 4 — Maintenance Air-cooled 7 kW Generator CHANGING THE OIL FILTER Change the engine oil filter as follows: Never operate the engine with the oil level 1. With the oil drained, remove the old oil filter by below the “Add” mark on the dipstick. Doing turning it counterclockwise.

  • Page 19: Spark Plug(S)

    Section 4 — Maintenance Air-cooled 7 kW Generator SPARK PLUG(S) • Do not lay tools or metal parts on top of the battery; and Reset the spark plug(s) gap or replace the spark • Disconnect charging source prior to connecting or dis- plug(s) as necessary.

  • Page 20: Attention After Submersion

    Section 4 — Maintenance Air-cooled 7 kW Generator Figure 4.9 – Cooling Vent Locations 5. 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.

  • Page 21: Service Schedule

    Section 4 — Maintenance Air-cooled 7 kW Generator 4.11 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Generac Authorized Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly...

  • Page 22: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Air-cooled 7 kW Generator TROUBLESHOOTING GUIDE SYMPTOM CAUSE CORRECTION The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary. 3. Defective starter contactor (7 kW) 3. * 4.

  • Page 23: Section 6 - Notes

    Section 6 — Notes Air-cooled 7 kW Generator Generac ® Power Systems, Inc. 21...
  • Page 24 Section 6 — Notes Air-cooled 7 kW Generator 22 Generac ® Power Systems, Inc.
  • Page 25 Section 7 — Installation Diagram Air-cooled 7 kW Generator Drawing No. 0D3739-B Generac ® Power Systems, Inc. 23...

  • Page 26: Section 7 - Electrical Data

    Section 8 — Electrical Data Air-cooled 7 kW Generator Wiring Diagram - 7 kW – Drawing No. 0D9013-C ENGINE WIRING DIAGRAM KEY BATTERY BA - BRUSH ASSEMBLY CHARGER BCR - BATTERY CHARGE RELAY (UTILITY) CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE DSW - PCB MOUNTED DIP SWITCH 225B...
  • Page 27 Section 8 — Electrical Data Air-cooled 7 kW Generator Wiring Diagram - 7 kW – Drawing No. 0D9013-C CONTROL PANEL BOX 224A 225A CLOSEST TO BEARIN 224A 225A STATOR 225B 225B 224B 224B VOLTAGE REGULATOR AUTO 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR CUSTOMER MANUAL...
  • Page 28 Section 8 — Electrical Data Air-cooled 7 kW Generator Electrical Schematic - 7 kW – Drawing No. 0D9014-C 225A 224A BATTERY 225B CHARGER 224B 225A 224A C2-1 BATTERY CHARGE WINDING C2-2 C2-4 ENGINE RUN WINDING C1-4 (STATOR) FIELD C1-3 C2-3 ELECTRONIC C2-10 C2-9...
  • Page 29 Section 8 — Electrical Data Air-cooled 7 kW Generator Electrical Schematic - 7 kW – Drawing No. 0D9014-C C2-6 C2-5 240VAC 225A UTILITY 56VA INPUT 224A 12Vdc TRANSFER RELAY COIL CUSTOMER CONNECTIONS NEUTRAL 120V POWER 120V WINDING (STATOR) 240V C1-2 C1-1 BATTERY C1-6...

  • Page 30: Section 8 - Exploded Views And Parts Lists

    Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator Enclosure – Drawing No. 0D3416-Q PRE PACKAGED UNITS ONLY 28 Generac ® Power Systems, Inc.
  • Page 31 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator Enclosure – Drawing No. 0D3416-Q ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C6140 ASSMBLY, ENCLOSURE BASE (12KW/15KW) 0A2115 WASHER NYLON .250" 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 022097 WASHER LOCK M6-1/4"...
  • Page 32 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator Control Panel – Drawing No. 0D8503-F 30 Generac ® Power Systems, Inc.
  • Page 33 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator Control Panel – Drawing No. 0D8503-F ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A9947E CIRCUIT BREAKER 30 X 2 240V SQD 051714 NUT HEX M3-0.5 (8.5KW/ 12KW/ 13KW) QOU230 (7KW) 051714 NUT HEX M3-0.5 (7KW)
  • Page 34 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator GH-410 Engine – Drawing No. 0D3539-F Part 1 32 Generac ® Power Systems, Inc.
  • Page 35 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator GH-410 Engine – Drawing No. 0D3539-F Part 1 ITEM PART NO. QTY. DESCRIPTION 071978 ASSEMBLY, CONNECTING ROD 071980 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0C5848 PISTON, HC 071983 RETAINER, PISTON PIN 20 0D4287...
  • Page 36 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator GH-410 Engine – Drawing No. 0D3539-F Part 2 34 Generac ® Power Systems, Inc.
  • Page 37 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator GH-410 Engine – Drawing No. 0D3539-F Part 2 ITEM PART NO. QTY. DESCRIPTION 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0C8435 TUBE, DIPSTICK 0C9997 GUARD, FAN 088434 WRAPPER, BOTTOM 045756...
  • Page 38 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator 7 kW Generator – Drawing No. 0D3504-C 36 Generac ® Power Systems, Inc.
  • Page 39 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator 7 kW Generator – Drawing No. 0D3504-C ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0C9935H STATOR 0C9934H ROTOR 0C6043A CARRIER, REAR BEARING 0C8096 FAN, 8" CURVED BLADE 0C9593 MUFFLER 0D3220...
  • Page 40 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator GTS Load Center Assembly – Drawing No. 0D3997-E 38 Generac ® Power Systems, Inc.
  • Page 41 Section 9 — Exploded Views and Parts Lists Air-cooled 7 kW Generator GTS Load Center Assembly – Drawing No. 0D3997-E ITEM PART NO. QTY. DESCRIPTION 0D4801 BOX GTS LOAD CENTER 0D4800 COVER, 8 POSITION GTS LOAD CENTER 0C2237 TRANSFER SWITCH HOME STANDBY 100A2P250V 077220 COIL UTILITY 077220A...

  • Page 42: Section 9 - Warranty

    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.
  • Page 43 Section 10 – Warranty Air-cooled 7 kW Generator 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.
  • Page 44 "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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