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PO WER SY STEMS, INC. ® GENERA C POWER SYSTEMS, INC. R R Installation and Owner’ s Man ual Air -cooled A utomatic Standb y 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) DEADL Y EXHAUST FUMES.
Generac ® Pow er Systems, Inc. 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.
T able of Cont ents Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Generac ® Pow er Systems, Inc. 1 Introduction ........................Inside F ront Cover Read This Manual Thoroughly ........................IFC Contents ....................
2 Generac ® Pow er Systems, Inc. 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.
Generac ® Pow er Systems, Inc. 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.
Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations.
Section 1 — General Information Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Generac ® Pow er Systems, Inc. 5 1.4 TH E GEN ER A T OR Exh aust En c lo su r e Oi l Di p stic k D a t a D eca.
6 Generac ® Pow er Systems, Inc. Section 1 — General Information Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1.5 SP E CI F ICA TIONS 1.5.
Generac ® Pow er Systems, Inc. 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.
4. Remove the engine air in baffle located on the left - hand side of the battery compartment. T wo 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 .
Generac ® Pow er Systems, Inc. 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.
10 Generac ® Pow er Systems, Inc. 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 immediate.
Generac ® Pow er Systems, Inc. 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.
12 Generac ® Pow er Systems, Inc. 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.
Generac ® Pow er Systems, Inc. 13 Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 6. When frequency is correct at no load, check the AC voltage reading . If voltage is incorrect, the volt- age regulator may require adjustment.
14 Generac ® Pow er Systems, Inc. Section 3 — Operation Generac Air-cooled 7 kW , 1 2 kW and 1 5 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 .
Generac ® Pow er Systems, Inc. 15 Upon restoration of utility source voltage above a pre- set 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.
16 Generac ® Pow er Systems, Inc. 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 extr emely hazardous and possibly fatal electrical shock.
Generac ® Pow er Systems, Inc. 17 3.7 .3.1 Approximat e Crank Cycle T imes • 15 seconds ON • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • Repeat for 45 seconds Approximately 90 seconds total 3.7 .4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit.
18 Generac ® Pow er Systems, Inc. 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 r ecom- mended oil may result in an engine failur e.
Generac ® Pow er Systems, Inc. 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 for mainte- nance requirements. 1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine.
20 Generac ® Pow er Systems, Inc. 4.8 ADJ US TI NG V AL VE CLEAR ANCE 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.
Generac ® Pow er Systems, Inc. 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 .
22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Generac 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 the nearest Generac Authorized Dealer .
Generac ® Pow er Systems, Inc. 23 Section 5 — T roubleshooting Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 5.1 TROU B LE SHOO TI NG GU I 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.
24 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 1 2 & 15 kW – Drawing No.
Generac ® Pow er Systems, Inc. 25 Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 1 2 & 15 kW – Drawing No.
26 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 1 2 & 1 5 kW – Drawing No.
Generac ® Pow er Systems, Inc. 27 Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 1 2 & 1 5 kW – Drawing No.
28 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 7 kW – Drawing No.
Generac ® Pow er Systems, Inc. 29 Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Wiring Diagram – 7 kW – Drawing No.
30 Generac ® Pow er Systems, Inc. Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 7 kW – Drawing No. 0D90 1 4-C 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.
Generac ® Pow er Systems, Inc. 31 Section 6 — Electrical Data Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Electrical Schematic – 7 kW – Drawing No.
32 Generac ® Pow er Systems, Inc. 35 68 49 52 PRE PA C KA G ED U NIT S O NL Y 2 0 2 4 9 46 4 3 4 3 37 33 2 5 35 34 2 6 74 77 7 9 35 4 9 82 80 51 4 6 8 80 4 7 2 87 5 86 76 4 8 39 92 1 8 94 91 63 21 1 .
Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0C6140 1 ASSEMBL Y , ENCLOSURE BASE 0D1901 1 ASSEMBL Y , ENCLOSURE BASE (7KW) 2 0C6735 2 SUPPOR T , ROOF FOLDING 3 0F0063 1 ENCLO.
34 Generac ® Pow er Systems, Inc. 31 19 3 7 38 22 8, 9 27 45 46 44 48 47 10 3 49 5 1 13 17 5 21 35 23 49 29 21 17 4 2 38 6 7 33 2 20 27 15 40 41 39 45 44 43 1 30 15 11 47 45 24 45 47 49 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Control Panel – Drawing No.
Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 1 0E7886A 1 CIRCUIT BREAKER 30A X 2P 240V (7KW) 0E7886C 1 CIRCUIT BREAKER 40A X 2P 240V (8.
36 Generac ® Pow er Systems, Inc. 1 4 3 47 , 48 , 49 , 50 , 51 , 52 , 53 , 54 , 56 , 57 , 58 , 59 , 60 , 62 , 63 , 64 7, 47 , 48 , 49 , 50 , 51 , 52 , 53 , 54 , 56 , 57 , 58 , 59 , 60 , 63 , 64 53 4 .
Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0E9843 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 3 SCREW , T APTITE M6-1.
38 Generac ® Pow er Systems, Inc. Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GT -990/760 Engine – Drawing No.
Generac ® Pow er Systems, Inc. 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.
40 Generac ® Pow er Systems, Inc. 5 1 23 11 5 3 1 21 53 7 30 13 33 5 2 1 38 3 2 17 28 3 1 3 1 20 14 19 10 17 15 32 2 10 19 16 39 8 6 3 3 2 3 4 30 40 46 45 47 36 1 3 2 4 25 26 34 3 4 48 10 28 27 28 3 2 3 1 18 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator – Drawing No.
Generac ® Pow er Systems, Inc. 41 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 7 kW Generator – Drawing No.
42 Generac ® Pow er Systems, Inc. 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 1 32 24 25 10 30 19 26 28 27 28 3 2 3 1 41 10 18 36 8 35 29 36 36 35 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator – Drawing No.
Generac ® Pow er Systems, Inc. 43 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators 1 2 kW and 1 5 kW Generator – Drawing No.
44 Generac ® Pow er Systems, Inc. 3 2 23 3 4 35 36 45 39 33 20 19 18 43 44 46 11 4 9 29 3 7 2 7 28 30 3 1 17 5 2 47 48 24 38 26 22 40 41 25 25 50 14 12 5 1 13 5 4 16 1 6 1 2 11 10 4 2 5 7 9 8 3 4 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine – Drawing No.
Generac ® Pow er Systems, Inc. 45 ITEM P AR T NO . QTY . DESCRIPTION 1 0E3221 1 ASSEMBL Y , CONNECTING ROD 2 0E1466 1 PIN, PIST ON D20 3 021533 1 SET , PIST ON RING 90MM 4 0E2985 1 PIST ON, HC 5 0719.
46 Generac ® Pow er Systems, Inc. 19 20 41 21 22 6 40 3 39 24 6 12 7 6 6 6 14 18 17 3 1 30 27 2 45 38 5 29 13 8 10 11 9 18 18 3 4 1 35 33 3 4 4 6 36 37 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine – Drawing No.
Generac ® Pow er Systems, Inc. 47 ITEM P AR T 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.
48 Generac ® Pow er Systems, Inc. 17 12 28 11 20 10 3 2 25 21 24 19 23 22 22 15 26 14 13 16 29 18 28 1 2 10 11 27 3 1 4 5 3 2 10 17 1 26 15 14 16 13 3 7 19 9 30 21 25 20 2 4 29 18 23 11 12 28 8 Section 7 — Exploded Views and P arts Lists Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Gas Regulator – Drawing No.
Generac ® Pow er Systems, Inc. 49 ITEM P AR T NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA T OR HOUSING 2 0F5022 1 SOLENOID COIL, 12VDC 3 0C4647 1 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0C6070 1 SPRING-SOLENOID , PLUNGER 8 0F4795 4 SCREW PPHM SEMS M4-0.
50 Generac ® Pow er Systems, Inc. Section 8 — Mounting Dimensions Generac 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 TR.
Generac ® Pow er Systems, Inc. 51 Section 9 — Notes Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators.
52 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OUR W AR RANT Y R IGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine.
Generac ® Pow er Systems, Inc. 53 EM IS SION CONTROL S Y S TEM W AR R ANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines.
Part No. 0F0084 Revision H (03/28/05) Printed in U.S.A. Section 1 0 – W arranty Generac Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GENERA C PO WER SYSTEMS ST AND ARD TWO-YEAR LIMITED W ARRANTY F.
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