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Generac Power Systems 7kW Installation And Owner's Manual

Air-cooled, automatic standby generators
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See also: Repair Manual , Owner's Manual
Installation
and
Owner's Manual
7, 10, 13, 16 & 18kW Air-cooled,
Automatic Standby Generators
C
US
LISTED
Not intended for use as Primary Power in place of utility or in
life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

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Summary of Contents for Generac Power Systems 7kW

  • Page 1 Installation Owner’s Manual 7, 10, 13, 16 & 18kW Air-cooled, Automatic Standby Generators LISTED   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

    INTRODUCTION  This symbol points out potential explosion haz- Thank you for purchasing this compact, high per- ard. formance, air-cooled, engine-driven generator. It is  This symbol points out potential fire hazard. designed to automatically supply electrical power to operate critical loads during a utility power failure. ...

  • Page 3: Table Of Contents

    Table of Contents Air-cooled Generators Introduction ......Inside Front Cover Section 3 – Operation ........15 Read This Manual Thoroughly ......IFC Using the AUTO/OFF/MANUAL Switch ..15 Contents ............IFC Automatic Transfer Operation ..... 15 Operation and Maintenance ......IFC Sequence of Automatic Operation ....15 How to Obtain Service ........

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 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 opera- tors and potential operators of this equipment. ...

  • Page 5: Standards Index

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 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 • All generators covered by this manual produce use on the standby electric system.

  • Page 6: Section 1 - General Information

    Section 1 — General Information Air-cooled Generators There are LED readouts on the control panel to notify DANGER personnel that one of these faults has occurred. There is also a System Set LED that is lit when all  Only qualified electricians or contractors should of the conditions described in section "System Set attempt such installations, which must comply LED"...

  • Page 7: The Generator

    Section 1 — General Information Air-cooled Generators THE GENERATOR Figure 1.1 – 7kW, Single Cylinder, GH-410 Engine Figure 1.2 – 10kW, V-twin, GT-530 Engine Control Panel de Panel contrrol Data Label Etiqueta de datos Varilla medidora (see sample) (consulte la muestra)

  • Page 8: Specifications

    Section 1 — General Information Air-cooled Generators SPECIFICATIONS 1.5.1 GENERATOR Model 7 kW 10 kW 13 kW 16 kW 18 kW Rated Max. Continuous Power 7,000 NG 9,000 NG 13,000 NG 15,000 NG 16,000 NG Capacity (Watts*) 6,000 LP 10,000 LP 13,000 LP 16,000 LP 18,000 LP...

  • Page 9: System Set Led

    Section 1 — General Information Air-cooled Generators SYSTEM SET LED Special considerations should be given when install- ing the unit where local conditions include flooding, The “System Set” LED is lit when all of the following tornados, hurricanes, earthquakes and unstable conditions are true: ground for the flexibility and strength of piping and 1.

  • Page 10: Reconfiguring The Fuel System

    Section 1 — General Information Air-cooled Generators RECONFIGURING THE NOTE: Use an approved pipe sealant or joint compound FUEL SYSTEM on all threaded fittings to reduce the possibility of leakage. 1.9.1 7 KW, 410CC ENGINE 9. Reverse procedure steps 1-6 to reinstall demand To reconfigure the fuel system from NG to LP , follow regulator.

  • Page 11: Location

    Section 1 — General Information Air-cooled Generators 1.10 LOCATION 3. Close the roof. 4. Reverse the procedure to convert back to natural 1.10.1 GENERATOR gas. Install the generator set, in its protective enclosure, Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) outdoors, where adequate cooling and ventilating air is always available (Figure 1.9).

  • Page 12: Battery Requirements

    Section 1 — General Information Air-cooled Generators • 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  If the AUTO/OFF/MANUAL switch is not set to its transfer switch.

  • Page 13: The Battery

    Section 1 — General Information Air-cooled Generators NOTE: The following procedures are to be observed: • Wear full eye protection and protective clothing; Dielectric grease should be used on battery posts • Where electrolyte contacts the skin, wash it off to aid in the prevention of corrosion.

  • Page 14: Section 2 - Post Installation Start-Up And Adjustments

    E1 tion until all power voltage supplies to the and E2. 7kW voltage should be 242-252 volts at transfer switch have been positively turned off. a frequency of 61-63 Hertz. 10, 13, 16 and 18kW...

  • Page 15: Generator Tests Under Load

    E1 and E2. • About one minute after retransfer, the engine • 7kW voltage should be greater than 230 volts and should shut down. frequency should be greater than 58 Hz.

  • Page 16: Engine Governor Adjustment

    Then, tighten the governor lever clamp bolt to 70 inch-pounds ADJUSTMENT (8 N-m). 2.7.1 7KW UNITS Figure 2.1 — Engine Governor Adjustment With the frequency between 62-63 Hertz at no-load, Single Cylinder Engines slowly turn the slotted potentiometer (Figure 2.2) until line voltage reads 248-252 volts.

  • Page 17: Section 3 - Operation

    Section 3 — Operation Air-cooled Generators USING THE AUTO/OFF/MANUAL AUTOMATIC TRANSFER SWITCH (FIGURE 3.1) OPERATION To select automatic operation, do the following: 3.1.1 “AUTO” POSITION 1. Make sure the transfer switch main contacts are Selecting this switch position activates fully automatic set to their UTILITY position, i.e., loads con- system operation.

  • Page 18: Manual Transfer Operation

    Section 3 — Operation Air-cooled Generators C. Standby Voltage Sensor 7. Set the generator’s main circuit breaker to its ON (or CLOSED) position. The standby power source • This sensor monitors generator AC output volt- now powers the loads. age. When the voltage has reached 50 percent of the nominal rated voltage, transfer to standby Figure 3.2 –...

  • Page 19: Setting The Exercise Timer

    Section 3 — Operation Air-cooled Generators SETTING THE EXERCISE TIMER • If utility is still lost after 10 seconds, run the engine up to 3600 RPM and transfer the load. This generator is equipped with an exercise timer. At this time the controller will exit the exercise Once it is set, the generator will start and exercise routine and assume full automatic operation.

  • Page 20: Section 4 - Maintenance

    If the RPM signal is detected, the engine will start 3.7.3.1 Approximate Crank Cycle Times and run normally. If the RPM signal is subsequent- 7kW Units: ly lost again, the control board will try one more • 15 seconds ON re-crank attempt before latching out and flashing •...

  • Page 21: Checking The Engine Oil Level

    The oil level should be at the dipstick “Full” mark. If necessary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL ” MARK. Figure 4.2 — Oil Dipstick and Fill, 7kW Oil Fill Oil Dipstick and Fill CHANGING THE ENGINE OIL 4.3.1 OIL CHANGE INTERVALS...

  • Page 22: Changing The Engine Air Cleaner

    1. Start the engine by moving the AUTO/OFF/ cleaner. Use the following procedures (Figure 4.6, MANUAL switch to MANUAL and run until it 7kW; Figure 4.8, 13/16kW): is thoroughly warmed up. Then shut OFF the engine by moving the switch to the OFF position.

  • Page 23: Spark Plug(S)

    Section 4 — Maintenance Air-cooled Generators 4.4.2 10KW GENERATORS SPARK PLUG(S) Reset the spark plug(s) gap or replace the spark See Figure 1.2 for the location of the air cleaner. Use plug(s) as necessary. See the Service Schedule section the following procedure (Figure 4.7): for maintenance requirements.

  • Page 24: Adjusting

    Section 4 — Maintenance Air-cooled Generators ADJUSTING GH-410/GT-530/990 • Remove the 15A fuse from the generator control panel. VALVE CLEARANCE • Remove watches, rings or other metal objects; • Use tools with insulated handles; After the first six (6) months of operation, check •...

  • Page 25: Cooling System

    Section 4 — Maintenance Air-cooled Generators • Re-attach the spark plug wire to the spark plug. • On the GT-530 and GT-990, repeat the process for the other cylinder.  The exhaust from this product gets extremely Figure 4.10 - Valve Clearance Adjustment hot and remains hot after shutdown.
  • Page 26 Section 4 — Maintenance Air-cooled Generators 7. Attach a tag to the engine indicating the viscosity 4. Clean and wipe the entire generator. and classification of the oil in the crankcase. 5. Make sure the 15A fuse is removed from the 8.

  • Page 27: Service Schedule

    Section 4 — Maintenance Air-cooled Generators 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action W = Weekly R = Replace as Necessary M = Monthly Inspect Change Clean...

  • Page 28: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Air-cooled Generators TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables.

  • Page 29: Section 6 - Electrical Data

    Section 6 — Electrical Data Air-cooled Generators Electrical Schematic – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9775 12Vdc TRANSER COIL TS TO OPEN GENERATOR CONTROL PANEL 240VAC OUTPUT BLACK TO GENERATOR OUTPUT CIRCUIT BREAKER NEUTRAL (WHITE) NEUTRAL CONNECTION INSIDE SWITCH...
  • Page 30 Section 6 — Electrical Data Air-cooled Generators Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822-A...
  • Page 31 Section 6 — Electrical Data Air-cooled Generators Wiring Diagram – 10, 13 & 16kW, V-Twin – Drawing No. 0F7822-A...
  • Page 32 Section 6 — Electrical Data Air-cooled Generators Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823-A...
  • Page 33 Section 6 — Electrical Data Air-cooled Generators Electrical Schematic – 10, 13 & 16kW, V-Twin – Drawing No. 0F7823-A...
  • Page 34 Section 6 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A...
  • Page 35 Section 6 — Electrical Data Air-cooled Generators Wiring Diagram – 7kW, Single Cylinder – Drawing No. 0F7820-A...
  • Page 36 Section 6 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A...
  • Page 37 Section 6 — Electrical Data Air-cooled Generators Electrical Schematic – 7kW, Single Cylinder – Drawing No. 0F7821-A...
  • Page 38 Section 6 — Electrical Data Air-cooled Generators Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-A...
  • Page 39 Section 6 — Electrical Data Air-cooled Generators Wiring Diagram – 8, 10, 12 and 16 Circuit Load Center – Drawing No. 0F9070-A...

  • Page 40: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Air-cooled Generators Enclosure – Drawing No. 0G5050-E SHEET METAL PAINT/MATERIAL CODE LEGEND The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct color and material information must be included as a suffi...
  • Page 41 049813 NUT HEX M6-1.0 G8 0D1840 BRACKET, BOTTOM SUPPORT 0A1658 LOCK WASHER SPECIAL 1/4 047411 SCREW HHC M6-1.0 X 16 G8.8 (7KW) 0G0617 EXTERNAL CONNECTION BOX 047411 SCREW HHC M6-1.0 X 16 G8.8 092079 SCREW TAPTITE M6-1.0 X 25 BP 0F0710 RIVET POP 0.125”...
  • Page 42 Section 7 — Exploded Views and Parts Lists Air-cooled Generators Control Panel – Drawing No. 0F9695-F...
  • Page 43 Section 7 — Exploded Views and Parts Lists Air-cooled Generators Control Panel – Drawing No. 0F9695-F ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7886A CIRCUIT BREAKER 30A X 2P 240V (7KW) 0D8502 NEUTRAL BLOCK 0E7886D CIRCUIT BREAKER 45A X 2P 240V 031879...
  • Page 44 Section 7 — Exploded Views and Parts Lists Air-cooled Generators Transfer Switch Assembly – Drawing No. 0F9774-C...
  • Page 45 Section 7 — Exploded Views and Parts Lists Air-cooled Generators Transfer Switch Assembly – Drawing No. 0F9774-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0F8278 BOX LOAD CENTER 074138 LUG QUICK DISCONNECT NI-S 10X45 0D4800 COVER, 8 CIRCUIT LOAD CENTER DEG BRASS / TIN 0F5211 COVER, 10 CIRCUIT LOAD CENTER...
  • Page 46 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 13, 16 & 18kW, GT-990 Engine – Drawing No. 0G3071-L - Part 1...
  • Page 47 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 13, 16 & 18kW, GT-990 Engine – Drawing No. 0G3071-L - Part 1 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSY, CRANKCASE WITH SLEEVE 043790A BARBED ELBOW 90 3/8NPT X 3/8 VS 0E9843A SEAL, 38 I.D.
  • Page 48 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 13, 16 & 18kW, GT-990 Engine – Drawing No. 0G3071-L - Part 2...
  • Page 49 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 13, 16 & 18kW, GT-990 Engine – Drawing No. 0G3071-L - Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 022145 WASHER FLAT M8 – 5/16 0D1143 WRAPPER, UPPER CYLINDER 2 0C5136A KNOB, AIR CLEANER...
  • Page 50 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 1...
  • Page 51 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 1 ITEM PART NO. QTY. DESCRIPTION 0E9428B CRANKCASE 0E3812 SEAL D 35 X 48.2 0C8566 SCREW HHFC M6 – 1.0 X 20 0E9367A ASSY, BREATHER 0E9366...
  • Page 52 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 2...
  • Page 53 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 10kW, GT-530 Engine – Drawing No. 0F9429-N - Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 022097 WASHER LOCK M6-1/4 094090 THERMAL SWITCH 0E9561 INTAKE ADAPTER 0F2094 SCREW PPHM M3-0.5 X 6 SEMS 0E9472...
  • Page 54 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 1...
  • Page 55 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 1 ITEM PART NO. QTY. DESCRIPTION 0E3221 ASSEMBLY, CONNECTING ROD 0E1466 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0E2985 PISTON, HC...
  • Page 56 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 2...
  • Page 57 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9428-D - Part 2 ITEM PART NO. QTY. DESCRIPTION 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0F8426 TUBE, DIPSTICK 0C9997 GUARD, FAN...
  • Page 58 Section 7 — Exploded Views and Parts Lists Air-cooled Generators Generator – Drawing No. 0F9422-C...
  • Page 59 Section 7 — Exploded Views and Parts Lists Air-cooled Generators Generator – Drawing No. 0F9422-C ITEM PART NO. QTY. DESCRIPTION 0F8186 ADAPTOR, ENGINE 0F5540H STATOR 0C9934H ROTOR 0F7774A CARRIER, REAR BEARING 0C8096 FAN, 8” CURVED BLADE 0F6591 MUFFLER 0F8078 TAIL PIPE, MUFFLER 056482 BEARING 0C3168...
  • Page 60 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 10, 13, 16 & 18kW, V-twin Generators – Drawing No. 0G5051-B...
  • Page 61 Section 7 — Exploded Views and Parts Lists Air-cooled Generators 10, 13, 16 & 18kW, V-twin Generators – Drawing No. 0G5051-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 040976 SCREW SHC M8-1.25 X 20mm 059637 SCREW TAPTITE 3/8-16 X ¾ 0G2824C STATOR (16KW) 0E9591...

  • Page 62: Section 8 - Mounting Dimensions

    Section 8 — Mounting Dimensions Air-cooled Generators Drawing No. 0F9424-D...
  • Page 63 Section 8 — Mounting Dimensions Air-cooled Generators Drawing No. 0F9424-D...

  • Page 64: Section 9 - Notes

    Section 9 — Notes Air-cooled Generators...
  • Page 65 Section 9 — Notes Air-cooled Generators...

  • Page 66: 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 67 Section 10 – Warranty Air-cooled 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 continue for 24 consecutive months thereafter.
  • Page 68 ® GENERAC POWER SYSTEMS, INC. P.O. BOX 297 • WHITEWATER, WI 53190 Part No. 0G4869 Revision C (09/25/07) Printed in U.S.A. Catalog No. OMASPB07-3...

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