® POWER SYSTEMS, INC. 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 R POWER SYSTEMS, INC. R *This manual should remain with the unit.* ! Not intended for use as Primary Power in place of utility or in life-support applications. DANGER DEADLY EXHAUST FUMES.
INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc.. This model is a compact, high performance, 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. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
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 Contents ..........................................................IFC Operation and Maintenance ............................IFC How to Obtain Service ....................................IFC Authorized Dealer Locator Number ....................IFC 3.2.
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. ! ! WARNING: ! The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
IMPORTANT SAFETY INSTRUCTIONS Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 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 operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.
Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators DANGER ! 1.1 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. • This standby generator set has been factory supplied with a weather protective enclosure that is intended for outdoor installation only. 1.2 1. Low Oil Pressure Sensor 3.
Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.4 THE GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Oil Dipstick Control Panel Data Decal GFCI Outlet Exhaust Enclosure Fuel Regulator Fuel Inlet Battery Compartment Oil Filter Figure 1.
Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.5 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 Power Factor Recommended Air Filter Battery Requirement at -17.
Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.6 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.
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 lefthand 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. 5. Remove the small hose clamp and hose from the fuel regulator. It may be necessary to pry the hose off of the brass fitting using a screwdriver to gently lift up the hose edge. 6.
Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: 1.10 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it. Before installing and connecting the battery, complete the following steps: 1. Set the generator's AUTO/OFF/MANUAL switch to OFF. 2. Turn off utility power supply to the transfer switch. 3. Remove the 5 amp fuse from the generator control panel.
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; • Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical attention; and • Spilled electrolyte is to be washed down with an acid neutralizing agent.
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 frequency meter across transfer switch terminal lugs E1 and E2. Voltage should be 242-252 volts; frequency should read about 61-63 Hertz. 9. Connect the AC voltmeter test leads across terminal lug E1 and neutral; then across E2 and neutral. In both cases, voltage reading should be 121126 volts AC. 10.
Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 2.6 ADJUSTING THE REGULATOR (NATURAL GAS ONLY) Although the generator has been factory set to provide maximum power, it may be necessary in some areas to adjust this setting. Because natural gas has different BTU or power content across the country the engine may not perform as designed. 6. When the highest frequency is reached maximum power has been set.
Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment. Figure 2.3 — Single Cylinder Engine Governor Adjustment 7. Restart the unit. 8. Slowly turn the idle adjust screw to adjust the noload idle frequency to 63-63.5 Hz. 9. The governor is now set. Figure 2.
Section 3 — Operation Generac 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 direct proportion to frequency. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts. FUSE R POWER SYSTEMS, INC. 3.2 BREAK-IN PROCEDURE USING THE AUTO/OFF/MANUAL SWITCH (FIGURE 3.1) 3.2.
Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Upon restoration of utility source voltage above a preset level, generator circuit board action signals the transfer switch to transfer loads back to that power supply. After retransfer, the engine is signalled to shut down.
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. 5. Use the manual transfer handle inside the transfer switch to move the main contacts back to their “Utility” position, i.e.
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 necessary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL” MARK. 3.7.3.1 Approximate Crank Cycle Times • • • • • 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 3.7.
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 recommended oil may result in an engine failure. ! 4.5 CHANGING THE ENGINE AIR CLEANER 4.5.1 7 KW, 12 KW AND 15 KW GENERATORS See Figures 1.1 and 1.2, for the location of the air cleaner.
Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 4.6 SPARK PLUG(S) Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See Section 4.13 for maintenance requirements. 1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug(s) to clean. 2. Remove the spark plug(s) and check the condition.
Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 4.8 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 assistance. This is a very important step to insure longest life for the engine. To adjust valve clearance: • Make sure the engine is at room temperature.
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, it MUST NOT be started and operated. Following any submersion in water, have a Generac Authorized Dealer thoroughly clean and dry the generator. To return the unit to service after storage, proceed as follows: 4.11 CORROSION PROTECTION Periodically wash and wax the enclosure using automotive type products.
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.
Section 5 — Troubleshooting Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 5.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 1. Fuse blown 1. Replace 15A fuse on generator control panel. 2. Tighten, clean or replace as necessary. 3. * 4. * 5. Charge or replace battery. 2. Loose, corroded or defective battery cables 3. Defective starter contactor (7 kW) 4. Defective starter motor 5. Dead Battery The engine cranks but will not start. 1. Out of fuel 2.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 12 & 15 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Wiring Diagram – 7 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No.
Section 6 — Electrical Data Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Schematic – 7 kW – Drawing No.
Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Enclosure – Drawing No.
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.
Section 7 — Exploded Views and Parts Lists 5 44 17 51 29 22 37 8,9 38 27 34 Generac® Power Systems, Inc. 19 46 10 47 45 44 48 49 6 38 7 21 2 4 17 49 23 27 13 2 33 40 15 20 49 43 45 39 21 1 41 15 35 3 11 30 47 45 24 45 31 47 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Control Panel – Drawing No.
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.
36 Generac® Power Systems, Inc.
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.
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.
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.
Section 7 — Exploded Views and Parts Lists 32 31 28 13 33 11 23 5 31 53 7 21 51 52 1 39 6 8 31 3 17 38 40 34 46 45 30 3 20 47 14 2 15 36 1 19 10 17 322 10 32 19 30 34 25 4 16 26 34 48 28 27 18 10 28 31 32 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 7 kW Generator – Drawing No. 0D3504-D 40 Generac® Power Systems, Inc.
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.
Section 7 — Exploded Views and Parts Lists 28 27 28 17 13 11 2 5 24 43 7 21 34 12 33 39 6 8 31 37 32 31 28 40 38 3 20 14 2 22 15 1 19 10 17 32 10 19 32 30 25 24 16 26 29 35 8 18 36 29 10 41 31 36 32 35 36 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.
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 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PART NO. QTY.
Section 7 — Exploded Views and Parts Lists 42 17 31 25 30 29 28 27 37 24 35 36 23 33 45 43 39 19 18 20 34 46 44 11 32 22 48 47 26 41 38 40 51 25 12 13 14 50 49 1 6 54 16 52 1 2 5 10 4 3 7 11 8 9 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No. 0E9180-B Part 1 44 Generac® Power Systems, Inc.
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 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 PART NO.
Section 7 — Exploded Views and Parts Lists 35 22 46 Generac® Power Systems, Inc. 6 12 7 19 6 20 6 41 45 21 40 3 39 5 38 6 14 17 18 13 8 29 31 24 30 6 10 9 11 27 1 34 18 18 34 33 2 36 37 4 6 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GN410 Engine – Drawing No.
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 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 PART NO. QTY.
Section 7 — Exploded Views and Parts Lists 21 13 13 26 48 Generac® Power Systems, Inc. 11 10 32 28 12 20 21 25 24 23 22 19 17 12 28 10 15 14 11 3 27 31 4 2 5 16 29 18 8 17 1 26 15 14 37 16 9 30 19 22 10 23 29 18 24 11 25 12 20 28 Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No.
Section 7 — Exploded Views and Parts Lists Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Gas Regulator – Drawing No. 0D8720-G ITEM 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 37 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 QTY.
50 Generac® Power Systems, Inc. 716 [28 743 [29 M6PEM M6P M6PEM-T PE T LEFT SIDE VIEW 622 [24.5"] 604 [23.5"] 76.2mm [3.00"] PEA GRAVEL MINUMUM 704 [27.7"] 207 [8.14"] TRANSFER SWITCH (IF SUPPLIED) 308 [12"] FRONT VIEW 1232 [48.5"] 1193 [47"] "DO NOT LIFT BY THE ROOF" LIFTING HOLES 4-CORNERS Ø30.2mm [Ø1.19"] 149 [5.9"] RIGHT SIDE VIEW 490.7 [ AIR 260 [10.2"] **ALL DIMENSIONS IN: MILLIMETERS [INCHES] REAR VIEW ROUNDING LUG CABLE ACCESS HOLES.
Section 9 — Notes Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Generac® Power Systems, Inc.
Section 10 – Warranty Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine.
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 continue for 24 consecutive months thereafter.
Section 10 – Warranty Generac Air-cooled 7 kW, 12 kW and 15 kW Generators GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY 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.
