Generac Power Systems 04758-0, 04759-0, 04760-0 manual

GENERA C POWER SYSTEMS, INC. R R Installation and Owner’ s Man ual Air -cooled A utomatic Standb y Generators Models: 04758-0 (6 kW NG, 7 kW LP) 04759-0 (12 kW NG, 12 kW LP) 04760-0 (13 kW NG, 15 kW LP) DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y!! D ANGER Not intended f or use as Primary P o wer in place of utility or in life-support app[...]

I NTRODUCTION Thank you for purchasing this model by Generac P ower 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 enclo- sure that is [...]

T able of Cont ents Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 Introduction ........................Inside F ront Cover Read This Manual Thoroughly ........................IFC Contents ..........................................................IFC Operation and Maintenance ............................IFC How to Obtain Service ........[...]

2 Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rule[...]

3 ELE CTR ICAL HA Z AR DS • 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 opera- tion. A void contact with bare wires, terminals, con- nections, etc., w[...]

Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been factory sup- plied with a weather protective enclosure that is in[...]

Section 1 — General Information Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 5 1.4 Y OU R GEN ER A T OR Control P anel Battery Compartment Fuel Regulator Air Filter Exhaust Enclosure Oil Filter Data Decal Control Panel Air Filter Exhaust Enclosure Battery Compartment Fuel Regulator Oil Filter Oil Dipstick Data Decal Figure 1.2 – 12 k[...]

6 Section 1 — General Information Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1.5 SP E CI F ICA TIONS 1.5.1 GEN ERA T OR Model 04758 Model 04759 Mo de l 04760 Rated Max. Continuous P ower Capacity (W atts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP† Rated V oltage 120/240 120/240 120/240 Rated Max. Continuous Load Cu[...]

7 1 . 6 FUE L RE QUIRE MEN T S AN D R E C OM M EN D A TIONS W ith 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 dua[...]

3. 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 screw driver to gen- tly lift up the hose edge. 4. Remove the brass hose fitting screwed into the fuel regulator . 5. Locate and identify the brass idle jet. This will be located in the fuel regulator casting facing[...]

9 1.1 0 B A TTER Y INST ALLA TION Fill the battery with the proper electrolyte fluid if nec- essary 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. T urn off utility power supply to the transfer switch[...]

10 The following procedur es are to be observed: • Wear full eye pr otection and protective clothing; • Where electr olyte contacts the skin, wash it of f immediately with water; • Where electr olyte contacts the eyes, immediately flush thoroughly with water and seek medical attention; and • Spilled electrolyte is to be washed down with an [...]

11 8. Connect an accurate AC voltmeter and a frequen- cy meter across transfer switch terminal lugs E1 and E2. V oltage should be 242-252 volts; fre- quency should read about 61-63 Hertz. 9. Connect the AC voltmeter test leads across termi- nal lug E1 and neutral; then across E2 and neu- tral. In both cases, voltage reading should be 121- 126 volts[...]

12 2.6 ADJ US TI NG TH E R E GU L A T OR (NA TUR AL GAS ONL Y) Although the generator has been factory set to pro- vide 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. If you experience engine problems at high[...]

13 Section 3 — Operation Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Figure 2.3 — Engine Governor Adjustment 2.7 .2 1 2 KW AND 15 KW UN IT S 1. Loosen governor clamp bolt (See Figure 2.3). 2. Completely remove the idle spring . 3. W ith governor arm at wide open throttle position, rotate governor shaft fully clockwise. Tighten clamp[...]

14 Section 3 — Operation Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 8. T urn ON the utility power supply to the transfer switch, which will allow the transfer switch to transfer back to utility power . The unit will con- tinue to run for one minute and then shut down. 9. Allow the unit to cool. 10. Drain the oil and remove the oil fi[...]

15 D . Utility V oltage Pickup Sensor • 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 . E. Retransfer Time Delay • This timer runs for about 15 seconds. • At end of a 15- second delay , circuit board action de - ener[...]

16 3.6 SE T TI NG TH E EXERCISE TI M ER Y our generator is equipped with an exercise timer . Once it is set, the generator will start and exercise once every seven days, on the day of the week and at the time of day you complete the following sequence. During this exercise period, the unit runs for approx- imately 12 minutes and then shuts down. Tr[...]

17 4.1 F USE The generator panel’s 15 amp fuse (Figure 4.1) protects the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel. If the fuse element has melted open, you cannot crank or start the engine. Y ou should replace the fuse using only an identical 15-amp replacement. The generator panel[...]

18 4.3.2 OI L CHANGE PROCEDU R E T o change the oil, proceed as follows: 1. Run the engine until it is thoroughly warmed up then shut OFF the engine. 2. Immediately after the engine shuts OFF , pull the oil drain hose (Figure 4.4) free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container . Figure 4.4 – O[...]

19 4.6 SP AR K P L UG(S) Reset the spark plug(s) gap or replace the spark plug(s) as necessary . See Section 4.13 (P age 22) 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 pl[...]

20 4.8 ADJ US TI NG V AL VE CLEAR ANCE After the first 50 hours of operation, you should adjust the valve clearance in the engine. Important: If you feel uncomfortable about doing this procedure or you don't have the proper tools, please contact your Generac Authorized dealer for service assistance. This is a very important step to insure long[...]

21 4.1 0 A TTENTION AF TER S U B M ERSION If the generator has been submerged in water , it MUST NOT be started and operated. F ollowing any sub- mersion in water , have a Generac Authorized Dealer thor- oughly clean and dry the generator . 4.1 1 C OR ROSION P RO TECTION P eriodically wash and wax the enclosure using automo- tive type products. F r[...]

22 Section 4 — Maintenance Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 4.1 3 SERVICE S CH EDU LE A TTENTION: It is recommended that all service work be performed by your nearest Generac Authorized Dealer . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = W eekly R = Replace as Necessary M = Monthly * = Notify D[...]

23 Section 5 — T roubleshooting Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 5.1 TROU B LE SHOO TI NG GUI DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. F use blown 1. Replace 15A fuse on generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective sta[...]

24 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 1 2 & 15 kW – Drawing No. 0D85 00-B TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA ( DUAL SEC. ) 0 CUS T O MER SU PPLIE D BLA CK BATTERY 12V L OP HT O 0 S P 2 S P 1 IM2 86 85 IM1 D D DIA G RAM KE Y D S W - P C B M OU NTED DIP S WIT CH[...]

25 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 1 2 & 15 kW – Drawing No. 0D85 00-B C L OS E S T T O BEARIN G G R D 0 4 S TAT OR 1 94 224 224 22 5 1 5 224 17 4 22 5 224B 22 5 0 0 OU TP U T T O TRAN S FE R 22 22 MAN U A L F2 0 1 5A 66A 2 39 1 3 1 5 1 3 1 3 0 F1 1 5 17 17 V O LTA GE RE[...]

26 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 1 2 & 1 5 kW – Drawing No. 0D85 0 1 -B IM1 - IGNITION MODULE , CYLINDER # 1 IM2 - IGNITION MODULE , CYLINDER # 2 L O P - L O W O IL PRE SSU RE S WIT CH SP1 , SP2 - SPARK PLUG S S W1 - A U T O / O FF / MAN U AL S WIT CH S W2 - S ET[...]

27 Section 6 — Electrical Data Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 1 2 & 1 5 kW – Drawing No. 0D85 0 1 -B 2 39 IM2 1 5 1 8 S P 2 24 0V IM1 0 1 94 17 1 5 2 3 1 5 2 39 S W 1 1 94 1 5A 22 11 2 3 11 22 11 S P 1 44 WINDIN G 12 0V 12 0V 33 NEUTRAL N2 N1 2 3 CUS T O ME R CO NNE C TI O N S 1 94 0 0 SC F [...]

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA ( DUAL SEC. ) CB2 - CIRCUIT BREAKER , ALTERNATOR EXCITATIO N BLA CK CUS T O MER SU PPLIE D BATTERY 12V L OP HT O SP 86 85 IM D D S W - P C B M OU NTED DIP S WIT CH C B1 - MAIN OU TP U T BREAKE R BA - BR US H A SS EMBL Y B C R - BATTERY C HAR G E RELA Y D - DI O D E SC - S TARTER CO NTA C T OR I C T -[...]

29 0 4 C L OS E S T T O BEARI N G R D S TAT OR OU TP U T T O TRAN S FE R 24 0 V G ENERAT OR S WIT C H CO NTA C T OR 8 2 0 66A 1 94 1 5 0 66A 1 5A 2 39 2 3 1 5 1 5A F2 1 3A 1 3 0 1 3 F1 1 3 351 14 N2 0 22 4 22 5 0 351 1 3 224 4 0 22 5 14 N2 N1 1 3A N1 V O LTA GE RE GU LAT OR 0 66A 0 1 62 2 2 0 4 6 11 4 4 11 2 2 4 MAN U A L A U T O 1 7 1 5 S W 1 2 39[...]

CB1 - CIRCUIT BREAKER , MAIN OUTPU T HT O - HI G H O IL TEMPERAT U RE S WIT CH S W1 - A U T O / O FF / MAN U AL S WIT CH CB2 - CIRCUIT BREAKER , ALT. EXCITATIO N TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA ( DUAL SEC. ) B C R - BATTERY C HAR G E RELA Y BA - BR US H A SS EMBL Y F1 - F US E 1 5 AM P F2 - F US E 5 AM P S P - S PARK PL UG F S - F [...]

31 INP UT 12V dc U TILIT Y CO I L RELAY TRAN S FE R NE U TRA L 120 V 24 0 VA C CUS T O ME R SU PPLIE D 2 3 S W 1 2 39 C 1- 6 0 1 5 17 0 1 8 C 1- 5 0 1 8 0 17 56 1 8 14 1 5A 17 0 1 5 0 C 1- 1 56 2 39 1 3 1 5 SC 14 1 5A 1 94 2 3 1 5 IM 0 D BLA CK SP P O WE R WINDIN G ( STATOR ) F S 14 C 1- 2 1 94 22 RED SC SM 24 0V 44 11 C B 1 33 12 0V C 2- 5 N2 22 5[...]

32[...]

33 ITEM P ART NO .QTY . DESCRIPTION 1 0C6140 1 ASSEMBL Y , ENCLOSURE BASE 0D1901 1 ASSEMBL Y , ENCLOSURE BASE (7KW) 2 0C6735 2 SUPPORT , ROOF FOLDING 3 0C7061 1 ENCLOSURE, FRONT 4 0C7062 1 ENCLOSURE, EXHA UST SIDE 0C7062A 1 ENCLOSURE, EXHAUST SIDE (7KW) 5 0C7063 1 ENCLOSURE, SIDE & BA CK 0C7063A 1 ENCLOSURE, SIDE & BACK (7KW) 6 0C7064 1 ENC[...]

34 46 22 37 7 38 83 2 8, 9 27 44 47 0 13 19 14 15 35 15 17 49 14 15 5 3 4 16 23 36 39 38 45 48 2 28 29 17 16 4 6 7 23 27 42 12 45 44 20 40 11 1 43 35 14 30 3 41 24 45 47 3 1 47 45 31 3 13[...]

35 ITEM P ART NO . QTY . DESCRIPTION 1 0A9947E 1 CIRCUIT BREAKER 30 X 2 240V SQD QOU230 (7KW) 0A9947G 1 CIRCUIT BREAKER 40 X 2 240V SQD QOU240 (8.5KW) 0A9947F 1 CIRCUIT BREAKER 50 X 2 240V SQD QOU250 (12KW) 0A9947C 1 CIRCUIT BREAKER 60 X 2 240V SQD QOU260 (13KW) 0A9947D 1 CIRCUIT BREAKER 70 X 2 240V SQD QOU260 (15KW) 2 0A1801 1 ASSEMBL Y , BA TTER [...]

36 17 15 18 22 13 12 9 7 8 24 3 27 32 19 6 5 65 6 4 63 6 2 6 1 60 59 58 5 2 51 50 49 48 47 46 45 44 43 57 1 42 38 3 7 36 35 3 4 33 3 40 2 3 26 10 4 34 25 11 30 20 66 2, 5 , 19 , 20 , 39 , 40 , 47 , 64 , 93 , 14 0 8, 11 , 12 , 13 6 7 4, 5 , 6 68 1 6A , 16B , 17 , 18 69 7, 47 , 48 , 49 , 50 , 51 , 52 , 53 , 54 , 56 , 57 , 58 , 59 , 60 , 63 , 64 70 4 [...]

37 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0C3008 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 8 SCREW , T APTITE M6-1.0 X 12 YC 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0E3372B 1 SEP ARA TOR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 G&S 8 071983 4 RET AINER, PISTON PI[...]

38[...]

39 ITEM P ART NO . QTY . DESCRIPTION 74 0C5136A 2 KNOB, AIR CLEANER 75 0C3024 1 CO VER, AIRBO X NG/LP 76 0C3040 1 PRE-CLEANER, 77 0C8127 1 ELEMENT , AIR CLEANER 78 0D8564A 1 ASSEMBL Y , MIXER/AIRBO X 990 0D8564B 1 ASSEMBL Y , MIXER/AIRBO X 760 79 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18 80 0D4417 4 W ASHER,R UBBER 1/4" X 1/8" THICK 81 0C[...]

40 3 7 6 51 7 8 21 53 9 3 2 1 4 5 23 11 3 1 3 1 12 5 22 14 20 38 15 3 0 24 26 32 10 19 16 28 27 17 10 1 28 3 1 3 2 17 3 2 3 1 33 28 13 39 18 4 0 28 3 4 35 3 4 44 48 30 45 46 3 4 36 47 5 2 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator – Drawing No. 0D35 04-C[...]

41 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator – Drawing No. 0D35 04-C ITEM P ART NO . QTY . DESCRIPTION 1 0C6934 1 AD APT OR, ENGINE 2 0C9935H 1 ST A TOR 3 0C9934H 1 RO TOR 4 0C6043A 1 CARRIER, REAR BEARING 5 0C8096 1 F AN, 8" CUR VED BLADE 6 0C9593 1 MUFFLER 7 0D3220 [...]

42 29 3 4 11 2 5 24 43 21 7 13 33 12 38 17 3 2 3 1 28 3 1 20 19 10 17 15 32 16 22 39 8 6 37 14 3 2 40 32 24 25 10 30 19 26 28 27 28 3 2 3 1 41 10 18 36 35 29 41 42[...]

43 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator – Drawing No. 0D3 4 1 7-E ITEM P ART NO . QTY . DESCRIPTION 1 0C6934 1 AD APT OR, ENGINE 2 0C7930 1 ST A TOR 12KW 0D2359 ST A T OR 13KW / 15KW 3 0C7944 1 RO TOR 12KW 0D2356 R O T OR 13KW / 15KW 4 0C6043 1 CARRIER, R[...]

44 11 47 33 3 4 36 35 3 7 27 45 43 39 18 19 20 23 3 2 44 48 2 4 46 11 22 29 28 3 1 30 17 5 2 1 14 13 26 38 25 25 40 41 12 16 6 1 2 4 42 10 5 7 3 8 9 4 9 5 1 50 5 4[...]

45 ITEM P ART NO . QTY . DESCRIPTION 1 071978 1 ASSEMBL Y , CONNECTING ROD 2 071980 1 PIN, PIST ON D20 3 021533 1 SET , PIST ON RING 90MM 4 0C5848 1 PIST ON, HC 5 071983 2 RET AINER, PIST ON PIN 20 6 0D4287 1 ASSEMBL Y , CRANKSHAFT GH410 SMALL T APER 7 0A7628 1 ARM, GO VERNOR RC45 8 078658 1 PIN, "R" GO VERNOR ARM 9 078659 2 W ASHER, GO V[...]

46[...]

47 ITEM P ART NO . QTY . DESCRIPTION 1 0C1069 5 SCREW , T APTITE M6-1.0X8 YELLO W CHROME 2 0D2922 1 HOUSING, BLO WER 3 0C8435 1 TUBE, DIPSTICK 4 0C9997 1 GU ARD , F AN 5 088434 1 WRAPPER, BO TT OM 6 045756 11 SCREW , T APTITE M6-1X10 YELLO W CHROME 7 088433B 1 WRAPPER, T OP 8 0D9004A 1 ASSY , ST AR TER 9 059985 2 SCREW , SHC M8-1.25 X 45 G12.9 10 0[...]

1 2 5 4[...]

49 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA T OR HOUSING 2 0C5765 1 SOLENOID , TWIN REGULA T OR 3 0C4647 1 GASKET , SOLENOID 4 0C4680 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0C6070 1 SPRING-SOLENOID , PLUNGER 6 022985 4 W ASHER, FLA T #6 7 022264 4 W ASHER, LOCK M4 8 075475 4 SCREW PPHM M4-0.7 X 10 9 0C5760A 1 JET , GN 410 EN[...]

50 Section 8 — Mounting Dimensions Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Drawing No. 0D3 7 3 9-B T M6PEM-T M6P M6PEM PE REAR VIEW L EFT S IDE VIEW TRANSFER SWITCH R I G HT S IDE VIE W F R O NT VIEW AIR NTAKE ( IF SUPPLIED ) " D O N O T LIFT BY THE R OO F" L IFTIN G H O LE S 4- CO RNER S Ø 3 0.2mm [ Ø 1 .19" ] R [...]

51 Section 9 — Notes Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators[...]

52 Section 1 0 – W arranty Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators NOTE: This Emission Control W arranty Statement pertains to this product only IF the generator size is 15 kW or below . CALIFORNIA AND FEDERAL EMISSION CONTR OL W ARRANTY ST A TEMENT Y OUR W ARRANTY RIGHTS AND OBLIGA TIONS The California Air Resources Board (CARB) [...]

53 Section 1 0 – W arranty Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators EMISSION CONTROL SYSTEM W ARRANTY Emission Control System Warranty (ECS W arranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engi[...]

Part No. 0E1370 Revision F (09/16/03) Printed in U.S.A. Section 1 0 – W arranty Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GEN ERAC PO WER SY STEMS S T AN D AR D "T WO YEAR" LIM ITED W ARR ANT Y FOR GU AR DIAN “EM ERGENCY AUT OMA TIC S T AN DBY GENER A T ORS” F or a period of two years from the date of original sale, Ge[...]