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Generac Power Systems 04758-2, 04759-2, 04760-2 Installation And Owner's Manual

Generac air-cooled automatic standby generator installation and owner's manual
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*This manual should remain with the unit.*
Not intended for use as Primary Power in place of utility
!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
Owner's Manual
or in life-support applications.
DANGER
Installation and
Air-cooled Automatic
Models:
04758-2 (6 kW NG, 7 kW LP)
04759-2 (12 kW NG, 12 kW LP)
04760-2 (13 kW NG, 15 kW LP)
GENERAC
POWER SYSTEMS, INC.
Standby Generators
R
R
!

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Summary of Contents for Generac Power Systems 04758-2, 04759-2, 04760-2

  • Page 1 *This manual should remain with the unit.* Not intended for use as Primary Power in place of utility or in life-support applications. DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!! Installation and Owner’s Manual Air-cooled Automatic Models: 04758-2 (6 kW NG, 7 kW LP) 04759-2 (12 kW NG, 12 kW LP) 04760-2 (13 kW NG, 15 kW LP) GENERAC...

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing this Guardian model by Generac Power Systems Inc.. This model is a compact, high per- formance, 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 enclosure that is intended exclusively for outdoor installation.

  • Page 3: Table Of Contents

    Introduction ...Inside Front Cover Read This Manual Thoroughly ...IFC Contents ...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Dealer Locator Number ...IFC Safety Rules ...2 Standards Index ...3 Section 1 – General Information ...4 Unpacking/Inspection ...4 Protection Systems ...4 System Set LED ...4 The Generator ...5 Specifications ...6...

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.

  • Page 5: Standards Index

    ELECTRICAL HAZARDS • All 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.

  • Page 6: Section 1 - General Information

    Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators DANGER Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage.

  • Page 7: The Generator

    THE GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Exhaust Enclosure Figure 1.2 – 12 kW/15 kW, V-twin GT-990/760 Engine Exhaust Enclosure Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel Data Dipstick...

  • Page 8: Specifications

    Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 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...

  • Page 9: Fuel Requirements And Recommendations

    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.

  • Page 10: Kw And 15 Kw, 990Cc Engines

    Section 1 — General Information Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators ◆ 1.8.2 12KW AND 15KW, 990CC 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.

  • Page 11: Transfer Switch

    ◆ 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.

  • Page 12: Section 2 - Post Installation Start-Up And Adjustments

    Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators • 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;...

  • Page 13: Generator Tests Under Load

    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.

  • Page 14: Adjusting The Regulator (Natural Gas Only)

    Section 2 — Post Installation Start-up and Adjustments Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 4. Manually set the transfer switch to the UTILITY position, i.e., load terminals connected to the util- ity power source side. 5. Turn ON the utility power supply to the transfer switch, using the means provided (such as a util- ity main line circuit breaker).

  • Page 15: Engine Governor Adjustment

    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. ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low, adjust the engine governor as follows: ◆...

  • Page 16: Additional Corrosion Protection

    Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators ◆ 2.7.3 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack- ets with corrosion inhibiting spray such as WD-40 or a comparable product. VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62-63.5 Hertz, slowly turn the slotted potentiometer (Figure 2.6) until line...

  • Page 17: Automatic Transfer Operation

    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.

  • Page 18: Transfer Back To Utility Power Source

    Section 3 — Operation Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Figure 3.2 – Manual Transfer Switch Operation 3.5.2 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.

  • Page 19: Overcrank

    Figure 3.3 – Low Oil Pressure and High Temperature Switches Low Oil Switch Drain Hose Oil Filter 3.7.3 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.

  • Page 20: Changing The Engine Oil

    Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 4. Install the dipstick. 5. Reset the AUTO/OFF/MANUAL switch to its origi- nal position. Figure 4.3 — Oil Dipstick and Fill, 12 kW and 15 kW Oil Dipstick CHANGING THE ENGINE OIL 4.3.1 ENGINE OIL RECOMMENDATIONS...

  • Page 21: Spark Plug(S)

    Figure 4.6 — 7 kW, Engine Air Cleaner Location Air Cleaner Figure 4.7 — 12 kW and 15 kW Engine Air Cleaner Screw Cover 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.

  • Page 22: Adjusting Valve Clearance

    Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators • Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical atten- tion; and • Spilled electrolyte is to be washed down with an acid neutralizing agent.

  • Page 23: Attention After Submersion

    Figure 4.9 – Cooling Vent Locations The maximum ambient temperature for the generator is 48.9° C (104° F). 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.

  • Page 24: Service Schedule

    Section 4 — Maintenance Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 4.13 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Generac Authorized Dealer. SYSTEM/COMPONENT X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed.

  • Page 25: Section 5 - Troubleshooting

    TROUBLESHOOTING GUIDE 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 OFF , but the engine continues to run. There is no AC output from the generator.

  • Page 26: Section 6 - Electrical Data

    Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE DSW - PCB MOUNTED DIP SWITCH...
  • Page 27 224A 225A 225B 225B 224B 224B VOLTAGE REGULATOR Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B CONTROL PANEL BOX 224A 225A AUTO MANUAL Section 6 — Electrical Data CLOSEST TO BEARING 240V GENERATOR OUTPUT TO TRANSFER...
  • Page 28 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B C2-11 FIELD ELECTRONIC C2-10 VOLTAGE REGULATOR C2-8 (STATOR) DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB2 - CIRCUIT BREAKER, ALT.
  • Page 29 225A 56VA 224A C1-1 C1-5 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B C2-6 C2-5 POWER WINDING (STATOR) C2-1 Section 6 — Electrical Data 240VAC UTILITY INPUT 12Vdc TRANSFER RELAY...
  • Page 30 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No. 0D9013-C DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE DSW - PCB MOUNTED DIP SWITCH...
  • Page 31 224A 225A 224A 225B 225B 224B 224B VOLTAGE REGULATOR Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No. 0D9013-C CONTROL PANEL BOX 225A AUTO MANUAL CLOSEST TO BEARIN STATOR 240V GENERATOR OUTPUT TO TRANSFER...
  • Page 32 Section 6 — Electrical Data Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D9014-C ELECTRONIC C2-10 VOLTAGE REGULATOR C2-8 DPE WINDING (STATOR) DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB2 - CIRCUIT BREAKER, ALT.
  • Page 33 C2-6 225A 56VA 224A C1-1 C1-5 Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D9014-C C2-5 POWER WINDING (STATOR) C1-2 C1-6 Section 6 — Electrical Data 240VAC UTILITY INPUT 12Vdc TRANSFER RELAY COIL...

  • Page 34: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0F0080-B PRE PACKAGED UNITS ONLY 32 Generac ® Power Systems, Inc.
  • Page 35 ITEM PART NO. QTY. DESCRIPTION 0C6140 ASSEMBLY, ENCLOSURE BASE 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 0C6735 SUPPORT, ROOF FOLDING 0F0063 ENCLOSURE, FRONT 0C7062 ENCLOSURE, EXHAUST SIDE 0C7062A ENCLOSURE, EXHAUST SIDE (7KW) 0F0066 ENCLOSURE, SIDE & BACK 0F0066A ENCLOSURE, SIDE & BACK (7KW) 0E9873 ENCLOSURE, ROOF 0C7065...
  • Page 36 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E7974-G 34 Generac ® Power Systems, Inc.
  • Page 37 ITEM PART NO. QTY. DESCRIPTION 0E7886A CIRCUIT BREAKER 30A X 2P 240V (7KW) 0E7886C CIRCUIT BREAKER 40A X 2P 240V (8.5KW) 0E7886D CIRCUIT BREAKER 45A X 2P 240V (11KW) 0E7886E CIRCUIT BREAKER 50A X 2P 240V (12KW) 0E7886F CIRCUIT BREAKER 60A X 2P 240V (13KW) 0E7886G CIRCUIT BREAKER 70A X 2P 240V (15KW) 0A1801...
  • Page 38 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No. 0E8774-J Part 1 36 Generac ® Power Systems, Inc.
  • Page 39 ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE 0E9843 SEAL, 38 I.D. CRANKSHAFT 090388 SCREW, TAPTITE M6-1.0 X 12 YC 0C5372 ASSEMBLY, BREATHER 0C3005 GASKET, BREATHER COVER 0E3372B SEPARATOR, OIL BREATHER 0D8067A ASSEMBLY, HEAD #1 G&S 071983 RETAINER, PISTON PIN 20 0C2981C ROCKER, COVER NO OIL FILL...
  • Page 40 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-J Part 2 38 Generac ® Power Systems, Inc. 123, 145...
  • Page 41 ITEM PART NO. QTY. DESCRIPTION 0C5136A KNOB, AIR CLEANER 0C3024 COVER, AIRBOX NG/LP 0C3040 PRE-CLEANER, 0C8127 ELEMENT, AIR CLEANER 0D8564A ASSEMBLY, MIXER/AIRBOX 990 0D8564B ASSEMBLY, MIXER/AIRBOX 760 0D2595 SCREW SHOULDER (8MM) M6-1.0 X 18 0D4417 WASHER,RUBBER 1/4" X 1/8" THICK 0C3025 SWITCH, OIL PRESS 0D3083...
  • Page 42 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-D 40 Generac ® Power Systems, Inc.
  • Page 43 ITEM PART NO. 0C6934 0C9935H 0C9934H 0C6043A 0C8096 0C9593 0D3220 0C8860 031971 0C3168 056147 0D1847 0C7038C 0D1647 0D2558 0C7038B 0C7758 0388050AE0 0C2417A 082121C 066386 029451 049451 022237 022511 022131 039287 022145 049820 090388 022129 022259 059637 048031K 0C9592 057822 040976 0C2824 025145 090239...
  • Page 44 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-J 42 Generac ® Power Systems, Inc.
  • Page 45 ITEM PART NO. 0C6934 0C7930 0D2359 0C7944 0D2356 0C6043 0D2336 0D6634 0D3220 0C8101 056482 0C3168 0D1838 0D1846 0C7038 0D1609 0D2559 0C7038A 0C7758 0388050AD0 0C2417A 082121C 066386 029451 049451 022237 022511 022131 051731 022145 049820 045756 022129 022259 059637 0D4662 074994 057822 0F0462 0C2824...
  • Page 46 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-B Part 1 44 Generac ® Power Systems, Inc.
  • Page 47 ITEM PART NO. 0E3221 0E1466 021533 0E2985 071983 0E8440 0A7628 078658 078659 088261E 0E3812 0E6519 078645 0A7811 0A9877 076701 021713B 078691 0A5771 0A5776 076361 0A8898D 0D2274 0C4391 086025 0E3341 021714 086516 086517 0D9853B 083897 077158 0C3150 072694 083907 072696 078694 021742 0D6094 076329...
  • Page 48 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-B Part 2 46 Generac ® Power Systems, Inc.
  • Page 49 ITEM 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 091222E 067198N 067890 0E7585 072734 072735 0C3978 0C6040 0D9760 092079 073100 083502 082025 0D3083 0E7887C 090072...
  • Page 50 Section 7 — Exploded Views and Parts Lists Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-F 48 Generac ® Power Systems, Inc.
  • Page 51 ITEM PART NO. 0D5694 0F5022 0C4647 0D4166 0C6070 0F4795 0C5760J 0C6606 097934 0C4645 0C5761 0C5968 0C6066 0C5759 0C5764 0C5764A 070728 0C6069 0C5762 045764 0C6731 0C6067 0C4706 0C6068 0C4643A 026073 026073 0A4032 0D3308 024310 028414A 0D5698A 0D3973 * A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY Section 7 —...

  • Page 52: Section 8 - Mounting Dimensions

    Section 8 — Mounting Dimensions Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Drawing No. 0D3739-B 50 Generac ® Power Systems, Inc.

  • Page 53: Section 9 - Notes

    Section 9 — Notes Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators Generac® Power Systems, Inc. 51...

  • Page 54: Section 10 - Warranty

    (ECS Warranty), which is provided to you by Generac pursuant to California and federal 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.
  • Page 55 Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 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 continue for 24 consecutive months thereafter.
  • Page 56 "PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS" For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be defective.

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