Generac Power Systems 04673-2 Installation And Owner's Manual
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Generac Power Systems 04673-2 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:
04673-2 (6 kW NG, 7 kW LP)
04674-2 (12 kW NG, 12 kW LP)
04675-3 (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 04673-2

  • Page 1 DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!! Installation and Owner’s Manual Air-cooled Automatic 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) GENERAC POWER SYSTEMS, INC. DANGER ®...

  • Page 2: Introduction

    Guardian models: • 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 •...

  • Page 3: Table Of Contents

    Section 3 – Operation ...14 Break-in Procedure...14 Using the Auto/Off/Manual Switch ...14 3.2.1 “Auto” Position ...14 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 3.2.2 “Off” Position ...14 3.2.3 “Manual” Position ...14 Automatic Transfer Operation ...14 Sequence of Automatic Operation...14 Manual Transfer Operation ...15...

  • Page 4: Important Safety Instructions

    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: Electrical Hazards

    IMPORTANT SAFETY INSTRUCTIONS Generac Air-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.

  • Page 6: Section 1 - General Information

    Section 1 — General Information Generac 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

    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 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel Data Dipstick Decal Battery...

  • Page 8: Specifications

    12 Vdc 12 Vdc Approx. 1.5 Qts Approx. 1.7 Qts Generac Part # 70185 Generac Part # 70185 Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127 3,600 3,600 Model 04675 13,000 NG/15,000 LP 120/240 108.3 NG/125.0 LP 54.2 NG/62.5 LP...

  • Page 9: Fuel Requirements And Recommendations

    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 3. Remove the battery (if installed). 4. Disconnect wire #0 and wire #14 from the gas 5.

  • Page 10: Location

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

  • Page 11: Battery Installation

    Figure 1.5 – Battery Cable Connections Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation.

  • 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: • Wear full eye protection and protective clothing; • Where electrolyte contacts the skin, wash it off immediately with water;...

  • Page 13: Generator Tests Under Load

    (or closed) position. Loads are now powered by the standby generator. Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 8. Turn ON electrical loads. Apply an electrical load equal to the full rated wattage/amperage capacity of the installed generator.

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

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

  • Page 15: Kw And 15 Kw Units

    Make sure the idle spring does not stretch at all. Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 7. Restart the unit. 8. Slowly turn the idle adjust screw to adjust the no- load idle frequency to 63-63.5 Hz.

  • Page 16: Section 3 - Operation

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: The voltage regulator is housed above the genera- tor's 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.

  • Page 17: Manual Transfer Operation

    (such as a utility main line circuit breaker). Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off.

  • Page 18: Setting The Exercise Timer

    Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators DANGER 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.

  • Page 19: Overspeed

    2. Remove the dipstick and wipe it dry with a clean cloth. Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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”...

  • Page 20: Oil Change Procedure

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: The unit is supplied with “break-in” oil. See the “Break-in Procedure,” Section 3.1, for the first required oil change. Any attempt to crank or start the engine before it has been properly serviced with the recom- mended oil may result in an engine failure.

  • Page 21: Spark Plug(S)

    Section 4 — Maintenance Generac 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;...

  • Page 22: Adjusting Valve Clearance

    Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators ADJUSTING 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.

  • Page 23: Attention After Submersion

    9. Clean and wipe the entire generator. Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 4.12.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: 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 X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed.

  • Page 25: Section 5 - Troubleshooting

    Unit consumes large amounts of oil. *Contact the nearest Generac Authorized Dealer for assistance. Section 5 — Troubleshooting Generac Air-cooled 7 kW, 12 kW and 15 kW Generators CAUSE 1. Fuse blown 2. Loose, corroded or defective battery cables 3.

  • 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 DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER...
  • Page 27 225A 225B 225B 224B 224B VOLTAGE REGULATOR 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 AUTO MANUAL Section 6 — Electrical Data...
  • 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 C2-11 FIELD ELECTRONIC C2-10 VOLTAGE REGULATOR C2-8 (STATOR) DIAGRAM KEY BA - BRUSH ASSEMBLY...
  • Page 29 225A 56VA 224A C1-1 C1-5 Generac 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...
  • 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 DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER...
  • Page 31 225B 225B 224B 224B VOLTAGE REGULATOR 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 225A AUTO MANUAL CLOSEST TO BEARIN STATOR...
  • 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 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 Generac 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...

  • 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. 0F0080-C PRE PACKAGED UNITS ONLY 32 Generac ® Power Systems, Inc.
  • Page 35 022097 WASHER LOCK M6-1/4" 0F0710 RIVET POP 0.125 X 0.337 Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0F0080-C ITEM PART NO. QTY. DESCRIPTION 047411 047411...
  • 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-G 34 Generac ® Power Systems, Inc.
  • Page 37 NUT HEX LOCK M3-0.5 NYLON INSERT 0D9784 NUT HEX LOCK M3-0.5 NYLON INSERT (7KW) Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E7974-G ITEM PART NO. QTY. DESCRIPTION 0D8502 0D8441...
  • 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-K Part 1 36 Generac ® Power Systems, Inc.
  • Page 39 THRUST WASHER, GOVERNOR 0C2992 BUSHING, GOVERNOR LOWER 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 ITEM PART NO. QTY. DESCRIPTION 0C3971C 0C5305...
  • 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-K Part 2 38 Generac ® Power Systems, Inc.
  • Page 41 SNORKEL, AIR INTAKE 0C3022A HOUSING, BLOWER NG COOLER 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-K Part 2 ITEM PART NO. QTY. DESCRIPTION 0D1131...
  • 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 0C5136A 074906 022473 0D4662 0C8290 066849 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 QTY. DESCRIPTION ADAPTOR, ENGINE STATOR ROTOR CARRIER, REAR BEARING 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 025145 0C4138 048031C 030340 066849 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-G QTY. DESCRIPTION ADAPTOR, ENGINE STATOR 12KW STATOR 13KW / 15KW...
  • 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-B Part 1 44 Generac ® Power Systems, Inc.
  • Page 47 078699C 0A7627 043790A 088590 078699B Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-B Part 1 QTY. DESCRIPTION ASSEMBLY, CONNECTING ROD PIN, PISTON D20 SET, PISTON RING 90MM...
  • 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-B Part 2 46 Generac ® Power Systems, Inc.
  • Page 49 090072 075281 0F2094 0C4373 022717B Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-B Part 2 QTY. DESCRIPTION SCREW, TAPTITE M6-1.0X8 YELLOW CHROME HOUSING, BLOWER...
  • 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-G 48 Generac ® Power Systems, Inc.
  • Page 51 0D3973 * A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-G QTY. DESCRIPTION...

  • 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

    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.

  • Page 55: Emission Control System Warranty

    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/or “grey market”...

  • Page 56: Warranty Schedule

    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.

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