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Generac Power Systems 04673-1 Installation And Owner's Manual

Air-cooled automatic standby generators
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POWER SYSTEMS, INC.
Not intended for use as Primary Power in place of utility
!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
*This manual should remain with the unit.*
or in life-support applications.
DANGER
Installation and
Owner's Manual
Models:
04673-1 (6 kW NG, 7 kW LP)
04674-1 (12 kW NG, 12 kW LP)
04675-2 (13 kW NG, 15 kW LP)
GENERAC
POWER SYSTEMS, INC.
Air-cooled Automatic
Standby Generators
R
R
!
®

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Summary of Contents for Generac Power Systems 04673-1

  • Page 1 Installation and Owner’s Manual Air-cooled Automatic Standby Generators Models: 04673-1 (6 kW NG, 7 kW LP) 04674-1 (12 kW NG, 12 kW LP) 04675-2 (13 kW NG, 15 kW LP) GENERAC POWER SYSTEMS, INC. *This manual should remain with the unit.* Not intended for use as Primary Power in place of utility or in life-support applications.

  • Page 2: Introduction

    Guardian models: If any portion of this manual is not understood, contact • 04673-1 – 6 kW NG, 7 kW LP , single-cylinder GH- the nearest Generac Authorized Dealer for starting, 410 Engine operating and servicing procedures.

  • Page 3: Table Of Contents

    Table of Contents Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Introduction ......Inside Front Cover 3.2.2 “Off” Position ........14 Read This Manual Thoroughly ......IFC 3.2.3 “Manual” Position ......14 Contents ............IFC Automatic Transfer Operation ....14 Operation and Maintenance ......IFC Sequence of Automatic Operation....14 How to Obtain Service ........IFC Manual Transfer Operation ......15...

  • Page 4: 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 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

    IMPORTANT SAFETY INSTRUCTIONS Generac Air-cooled 7 kW, 12 kW and 15 kW Generators • 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 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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: Your Generator

    Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators THE GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Oil Check/Fill Data Decal Control Panel Exhaust Enclosure Air Filter Fuel Regulator Fuel Inlet Battery Compartment Oil Filter Figure 1.2 –...

  • Page 8: Specifications

    Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators SPECIFICATIONS 1.5.1 GENERATOR Model 04673 Model 04674 Model 04675 Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP Rated Voltage 120/240 120/240 120/240...

  • Page 9: Fuel Requirements And Recommendations

    Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators FUEL REQUIREMENTS 3. Disconnect wire #0 and wire #14 from the gas solenoid located on the top of the demand regu- AND RECOMMENDATIONS lator. With LP gas, use only the vapor withdrawal 4.

  • Page 10: Location

    Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 5. Remove the small brass hose fitting from the idle LOCATION circuit port of the regulator housing. ◆ 1.9.1 GENERATOR 6. Remove the small jet (0D5698A) located in the side of the regulator housing and install it into the Install the generator set, in its protective enclosure, small threaded hole in the idle circuit port on the...

  • Page 11: Battery Installation

    Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.10 BATTERY INSTALLATION NOTE: Fill the battery with the proper electrolyte fluid if nec- The generator is equipped with a battery trickle essary and have the battery fully charged before charger that is active when the unit is set up for installing it.

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

    Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators The following procedures are to be observed: CHECK TRANSFER SWITCH • Wear full eye protection and protective clothing; OPERATION • Where electrolyte contacts the skin, wash it off Refer to Section 3.5 of the owner’s manual for manu- immediately with water;...

  • Page 13: Generator Tests Under Load

    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- 8. Turn ON electrical loads. Apply an electrical load cy meter across transfer switch terminal lugs E1 equal to the full rated wattage/amperage capacity and E2.

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

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators ADJUSTING THE REGULATOR Figure 2.2 — Placement of 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.

  • Page 15: Kw And 15 Kw Units

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators ◆ Figure 2.3 — Engine Governor Adjustment 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.

  • Page 16: Using The Auto/Off/Manual Switch

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 8. Turn ON the utility power supply to the transfer AUTOMATIC TRANSFER switch, which will allow the transfer switch to OPERATION transfer back to utility power. The unit will con- To select automatic operation, do the following: tinue to run for one minute and then shut down.

  • Page 17: Manual Transfer Operation

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators D.Utility Voltage Pickup Sensor Figure 3.2 – Manual Transfer Switch Operation • This sensor monitors utility power supply volt- age. When that voltage is restored to above 70 percent of the nominal source voltage, a retrans- fer time delay starts timing.

  • Page 18: Setting The Exercise Timer

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators SETTING THE EXERCISE TIMER Figure 3.3 – Low Oil Pressure and High Temperature Switches The generator is equipped with an exercise timer. Once it is set, the generator will start and exercise Low Oil Switch High Temp Switch once every seven days, on the day of the week and at...

  • Page 19: Section 4 - Maintenance

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators FUSE Figure 4.2 — Oil Dipstick and Fill, 7 kW The generator panel’s 15 amp fuse (Figure 4.1) protects Oil Dipstick and Fill the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel.

  • Page 20: Oil Change Procedure

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 4.3.2 OIL CHANGE PROCEDURE CHANGING THE ENGINE AIR CLEANER To change the oil, proceed as follows: 1. Run the engine until it is thoroughly warmed up 4.5.1 7 KW, 12 KW AND 15 KW then shut OFF the engine.

  • Page 21: Spark Plug(S)

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators SPARK PLUG(S) • Remove watches, rings or other metal objects; • Use tools with insulated handles; Reset the spark plug(s) gap or replace the spark • Wear rubber gloves and boots; plug(s) as necessary.

  • Page 22: Adjusting Valve Clearance

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators ADJUSTING VALVE CLEARANCE • Install new valve cover gasket. • Re-attach the valve cover. After the first 50 hours of operation, adjust the valve NOTE: clearance in the engine. Start all four screws before tightening or it will not Important: If feeling uncomfortable about doing this be possible to get all the screws in place.

  • Page 23: Attention After Submersion

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 4.10 ATTENTION AFTER SUBMERSION 4.12.2 RETURN TO SERVICE If the generator has been submerged in water, To return the unit to service after storage, proceed it MUST NOT be started and operated. Following any sub- as follows: mersion in water, have a Generac Authorized Dealer thor- 1.

  • Page 24: Service Schedule

    Section 4 — 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...

  • Page 25: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Generac Air-cooled 7 kW, 12 kW and 15 kW Generators TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 1. Fuse blown 1. Replace 15A fuse on generator control panel. 2. Loose, corroded or defective 2.

  • Page 26: Section 6 - Electrical Data

    Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B ENGINE WIRING DIAGRAM KEY BA - BRUSH ASSEMBLY BATTERY BCR - BATTERY CHARGE RELAY CHARGER CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION...
  • Page 27 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B CONTROL PANEL BOX 224A 225A 224A 225A CLOSEST TO BEARING STATOR 225B 225B 224B 224B VOLTAGE REGULATOR...
  • Page 28 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B 225A 225A 224A 224A BATTERY 225B CHARGER 224B C2-1 BATTERY CHARGE WINDING C2-2 C2-4 C2-11 ENGINE RUN WINDING...
  • Page 29 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B C2-6 C2-5 225A 240VAC UTILITY 56VA INPUT 224A 12Vdc TRANSFER RELAY COIL CUSTOMER CONNECTIONS NEUTRAL 120V POWER...
  • Page 30 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No. 0D9013-C ENGINE WIRING DIAGRAM KEY BATTERY CHARGER BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY (UTILITY) CB1 - MAIN OUTPUT BREAKER CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE...
  • Page 31 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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...
  • Page 32 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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 C1-4 WINDING (STATOR)
  • Page 33 Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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...

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

    Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0D3416-R PRE PACKAGED UNITS ONLY 44 85 79 80 49 49 32 Generac ® Power Systems, Inc.
  • Page 35 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0D3416-R ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C6140 ASSEMBLY, ENCLOSURE BASE 0D3037A LATCH, QUARTER TURN NON-LOCKING 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 0A2115...
  • Page 36 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E7974-D 34 Generac ® Power Systems, Inc.
  • Page 37 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E7974-D ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7886A CIRCUIT BREAKER 30A X 2P 240V 0D5240 SWITCH, SPST (ON)-ON N/O (7KW)
  • Page 38 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No. 0E8774-F Part 1 36 Generac ® Power Systems, Inc.
  • Page 39 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No. 0E8774-F Part 1 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH 0C3971C ASSEMBLY, DIPSTICK WITH HANDLE SLEEVE...
  • Page 40 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-F Part 2 123, 145 38 Generac ® Power Systems, Inc.
  • Page 41 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-F Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5136A KNOB, AIR CLEANER 0C3022A HOUSING, BLOWER NG COOLER 0C3024...
  • Page 42 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-D 40 Generac ® Power Systems, Inc.
  • Page 43 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-D ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0C9935H STATOR 0C9934H ROTOR 0C6043A CARRIER, REAR BEARING 0C8096 FAN, 8"...
  • Page 44 Section 7 — Exploded Views and Parts Lists Generac 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 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-J ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0C7930 STATOR 12KW 0D2359 STATOR 13KW / 15KW 0C7944 ROTOR 12KW...
  • Page 46 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-A Part 1 44 Generac ® Power Systems, Inc.
  • Page 47 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-A Part 1 ITEM PART NO. QTY. DESCRIPTION 0E3221 ASSEMBLY, CONNECTING ROD 0E1466 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0E2985 PISTON, HC...
  • Page 48 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-A Part 2 46 Generac ® Power Systems, Inc.
  • Page 49 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-A Part 2 ITEM PART NO. QTY. DESCRIPTION 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0C8435 TUBE, DIPSTICK 0C9997...
  • Page 50 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-B 48 Generac ® Power Systems, Inc.
  • Page 51 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-B ITEM PART NO. QTY. DESCRIPTION 0D5694 CASTING, TWIN REGULATOR HOUSING 0C5765 SOLENOID, TWIN REGULATOR 0C4647 GASKET , SOLENOID 0C4680 PLUNGER, LP REGULATOR ASSEMBLY 0C6070...

  • Page 52: Section 8 - Mounting Dimensions

    Section 8 — Mounting Dimensions Generac 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 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Generac ® Power Systems, Inc. 51...

  • Page 54: Section 10 - 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 55: Emission Control System Warranty

    Section 10 – Warranty Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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 56 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 defective under normal use and service, in accordance with the warranty schedule set forth below.

This manual is also suitable for:

04674-104675-2

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