Generac Power Systems 04673-2 Installation And Owner's Manual
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Generac Power Systems 04673-2 Installation And Owner's Manual

Generac Power Systems 04673-2 Installation And Owner's Manual

Air-cooled automatic standby generators (6 kw ng, 7 kw lp) (12 kw ng, 12 kw lp) (13 kw ng, 15 kw lp)
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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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  • Page 1 Installation and Owner’s Manual Air-cooled Automatic Standby Generators 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. *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

    If any portion of this manual is not understood, contact • 04673-2 – 6 kW NG, 7 kW LP , single-cylinder GH- the nearest Authorized Dealer for starting, operating 410 Engine and servicing procedures.

  • Page 3: Table Of Contents

    Table of Contents 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 ....

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS 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. WARNING: GENERAL HAZARDS The engine exhaust from this product...

  • Page 5: Standards Index

    IMPORTANT SAFETY INSTRUCTIONS Air-cooled 7 kW, 12 kW and 15 kW Generators place before operating the generator. If work must be done around an operating unit, stand on an EXPLOSION HAZARDS insulated, dry surface to reduce shock hazard. • Do not handle any kind of electrical device while •...

  • Page 6: Section 1 - General Information

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators PROTECTION SYSTEMS DANGER Unlike an automobile engine, the generator may have to run for long periods of time with no operator pres- Only qualified electricians or contractors should ent to monitor engine conditions.

  • Page 7: Your Generator

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

  • Page 8: Specifications

    Section 1 — General Information 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 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP Capacity (Watts*) Rated Voltage 120/240 120/240 120/240...

  • Page 9: Fuel Requirements And Recommendations

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators FUEL REQUIREMENTS 3. Remove the battery (if installed). 4. Disconnect wire #0 and wire #14 from the gas AND RECOMMENDATIONS solenoid on top of the demand regulator. With LP gas, use only the vapor withdrawal 5.

  • Page 10: Location

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators 1. Turn off the gas supply. (if connected) 14. It may be necessary to make minor adjustments to the preset adjustment screw settings to achieve 2. Open the roof and remove the door. maximum power, particularly at higher altitudes.

  • Page 11: Battery Installation

    Section 1 — General Information Air-cooled 7 kW, 12 kW and 15 kW Generators 1.10 BATTERY INSTALLATION NOTE: Fill the battery with the proper electrolyte fluid if The generator is equipped with a battery trickle necessary 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 Air-cooled 7 kW, 12 kW and 15 kW Generators CHECK TRANSFER SWITCH The following procedures are to be observed: • 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 Air-cooled 7 kW, 12 kW and 15 kW Generators 8. Connect an accurate AC voltmeter and a fre- 8. Turn ON electrical loads. Apply an electrical load quency meter across transfer switch terminal equal to the full rated wattage/amperage capacity lugs E1 and E2.

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

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW, 12 kW and 15 kW Generators ADJUSTING THE REGULATOR 6. When the highest frequency is reached maximum power has been set. Then turn both adjustment (NATURAL GAS ONLY) screws 1/4 turn counterclockwise. Regulator is now set.

  • Page 15: Kw And 15 Kw Units

    Section 2 — Post Installation Start-up and Adjustments Air-cooled 7 kW, 12 kW and 15 kW Generators 6. When frequency is correct at no load, check the 7. Restart the unit. AC voltage reading. If voltage is incorrect, the volt- 8.

  • Page 16: Section 3 - Operation

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: Figure 3.1 – Generator Control Panel The voltage regulator is housed above the generator's control panel. The regulator maintains a voltage in FUSE L o c a t e y o u r n e a r e s t d e a le r a t : direct proportion to frequency.

  • Page 17: Manual Transfer Operation

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators Upon restoration of utility source voltage above a DANGER preset level, generator circuit board action signals the transfer switch to transfer loads back to that power Do not attempt to activate the transfer switch supply.

  • Page 18: Setting The Exercise Timer

    Section 3 — Operation Air-cooled 7 kW, 12 kW and 15 kW Generators PROTECTION SYSTEMS DANGER 3.7.1 LOW OIL PRESSURE SWITCH Do not attempt to activate the transfer switch This switch (Figure 3.3) has normally closed con- manually until all power voltage supplies tacts that are held open by engine oil pressure during to the switch have been positively turned off.

  • Page 19: Overspeed

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators 3.7.3.1 Approximate Crank Cycle Times 2. Remove the dipstick and wipe it dry with a clean cloth. • 15 seconds ON 3. Install the dipstick; then, remove it again. The oil •...

  • Page 20: Oil Change Procedure

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators CHANGING THE ENGINE OIL CHANGING THE OIL FILTER Change the engine oil filter as follows: 4.3.1 ENGINE OIL RECOMMENDATIONS 1. With the oil drained, remove the old oil filter by Use oil of American Petroleum Institute (API) Service turning it counterclockwise.

  • Page 21: Spark Plug(S)

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators BATTERY MAINTENANCE Figure 4.7 — 12 kW and 15 kW Engine Air Cleaner The battery should be inspected per the “Service Schedule,” Section 4.13. The following procedure Screw should be followed for inspection: 1.

  • Page 22: Adjusting Valve Clearance

    Section 4 — Maintenance Air-cooled 7 kW, 12 kW and 15 kW Generators following procedures are to be followed: Figure 4.10 - Valve Clearance Adjustment • DO NOT SMOKE when near the battery; Rocker • DO NOT cause flame or spark in battery area; and Pivot Ball •...

  • Page 23: Attention After Submersion

    Section 4 — Maintenance 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 The exhaust from this product gets extremely follows: hot and remains hot after shutdown. High grass, 1.

  • Page 24: Service Schedule

    Section 4 — Maintenance 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 Authorized Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly...

  • Page 25: Section 5 - Troubleshooting

    Section 5 — Troubleshooting 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. Tighten, clean or replace battery cables as necessary.

  • Page 26: Section 6 - Electrical Data

    Section 6 — Electrical Data 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 D - DIODE...
  • Page 27 Section 6 — Electrical Data 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 240V GENERATOR...
  • Page 28 Section 6 — Electrical Data 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 C1-4...
  • Page 29 Section 6 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B C2-6 C2-5 240VAC 225A UTILITY 56VA INPUT 224A 12Vdc TRANSFER RELAY COIL CUSTOMER CONNECTIONS NEUTRAL 120V POWER 120V...
  • Page 30 Section 6 — Electrical Data Air-cooled 7 kW, 12 kW and 15 kW Generators 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...
  • Page 31 Section 6 — Electrical Data 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 OUTPUT TO TRANSFER...
  • Page 32 Section 6 — Electrical Data 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 WINDING C1-4 (STATOR) FIELD...
  • Page 33 Section 6 — Electrical Data 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 (STATOR)

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

    Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0F0080-C PRE PACKAGED UNITS ONLY...
  • Page 35 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No. 0F0080-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C6140 ASSEMBLY, ENCLOSURE BASE 047411 SCREW HHC M6-1.0 X 16 G8.8 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 047411...
  • Page 36 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E7974-G...
  • Page 37 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No. 0E7974-G ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7886A CIRCUIT BREAKER 30A X 2P 240V (7KW) 0D8502 NEUTRAL CONNECTOR 0E7886C...
  • Page 38 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No. 0E8774-M Part 1...
  • Page 39 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990 Engine – Drawing No. 0E8774-M 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 Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-M Part 2 123, 145 97 98...
  • Page 41 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GT-990/760 Engine – Drawing No. 0E8774-M Part 2 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5136A KNOB, AIR CLEANER 0D1131 GUARD, FAN 0C3024 COVER, AIRBOX NG/LP...
  • Page 42 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-E...
  • Page 43 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-E 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 Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-L...
  • Page 45 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators 12 kW and 15 kW Generator – Drawing No. 0D3417-L ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0C7930 STATOR 12KW 0D2359 STATOR 13KW / 15KW 0C7944 ROTOR 12KW 0D2356...
  • Page 46 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 1...
  • Page 47 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 1 ITEM PART NO. QTY. DESCRIPTION 0E3221 ASSEMBLY, CONNECTING ROD 0E1466 PIN, PISTON D20 021533 SET, PISTON RING 90MM 0E2985 PISTON, HC 071983...
  • Page 48 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 2...
  • Page 49 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0F3981-A Part 2 ITEM PART NO. QTY. DESCRIPTION 0C1069 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME 0D2922 HOUSING, BLOWER 0C8435 TUBE, DIPSTICK 0C9997 GUARD, FAN...
  • Page 50 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-H...
  • Page 51 Section 7 — Exploded Views and Parts Lists Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-H ITEM PART NO. QTY. DESCRIPTION 0D5694 CASTING, TWIN REGULATOR HOUSING 0F5022 SOLENOID COIL, 12VDC 0C4647 GASKET , SOLENOID 0D4166 PLUNGER, LP REGULATOR ASSEMBLY 0C6070...

  • Page 52: Section 8 - Mounting Dimensions

    Section 8 — Mounting Dimensions Air-cooled 7 kW, 12 kW and 15 kW Generators Drawing No. 0D3739-C CBHOM-F CBHOM-F CBHOM-F CBHOM-F CBHOM-F CBHOM-F TYPE HOM 120/240v TYPE HOM 120/240v TYPE HOM 120/240v TYPE HOM 120/240v TYPE HOM 120/240v TYPE HOM 120/240v...

  • Page 53: Section 9 - Notes

    Section 9 — Notes Air-cooled 7 kW, 12 kW and 15 kW Generators...

  • 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 Section 10 – Warranty 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 continue 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.

  • Page 57: Important Information

    ERRATA SHEET ALL 8.5 kW THROUGH 15 kW HOME STAND-BY GENERATORS WITH GT-990/760 ENGINES 2/24/06 ! IMPORTANT INFORMATION ! THE SPARK PLUG GAP FOR ALL 8.5 kW THROUGH THE 15 kW HOME STAND-BY GENERATORS WITH THE GT-990/760 ENGINES SHOULD BE SET AT 1.02 mm (0.040 inch).
  • Page 58 PRE PACKAGED UNITS ONLY 49 49...
  • Page 59 0C6140 ASSEMBLY, ENCLOSURE BASE 0F0710 RIVET POP 0.125 X 0.337 0D1901 ASSEMBLY, ENCLOSURE BASE (7KW) 047411 SCREW HHC M6-1.0 X 16 G8.8 0C6735 SUPPORT, ROOF FOLDING 047411 SCREW HHC M6-1.0 X 16 G8.8 (7KW) 0F0063 ENCLOSURE, FRONT 043116 SCREW HHC M6-1.0 X 12 G8.8 0C7062 ENCLOSURE, EXHAUST SIDE 043116...

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