Instruction/ maintenance manual of the product 04760-0 Generac Power Systems
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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.
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 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 ...................................................
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.
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 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.
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.
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.
5. Remove the small brass hose fitting from the idle circuit port of the regulator housing . 6. Remove the small jet (0D5698A) located in the side of the regulator housing and install it into the small threaded hole in the idle circuit port on the regulator .
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 .
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 .
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 BATTERY CUSTOMER SUPPLIED 12V HTO BLACK 86 LOP 85 IM2 1 - 20 Vac Sense Transformer L.
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 CLOSEST TO BEARING 0 4 STATOR GRD 225 225 14 16 17 1.
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 IM1 - IGNITION MODULE, CYLINDER #1 IM2 - IGN.
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 2 15 34 J2 2 1 3 2 1 8 14 16 17 15 11 13 12 .
0 4 STATOR CLOSEST TO BEARING GRD TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) ENGINE WIRING IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SP - SPARK PLUG SW1 - AUTO / OFF / MANUA.
29 0 4 STATOR STATOR CLOSEST TO BEARING CLOSEST TO BEARING GRD GRD 239 MANUAL 15 AUTO 17 SW1 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR SW2 18 14 56 23 194 0 15A 13A 13 351 N1 N2 351 224 225 1.
IM - IGNITION MODULE LOP - LOW OIL PRESSURE SWITCH SP - SPARK PLUG SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.
31 2 15 34 J2 2 1 3 2 1 8 14 16 17 15 11 13 12 10 9 J1 7 5 6 3 4 2 1 224A 239 15A 0 15 18 240V IM 0 15 194 13 17 17 15 23 15 239 SW1 194 15A N1 N2 22 11 23 11 22 11 SP 44 POWER WINDING 120V 120V 33 NE.
32 A A 51 23 36 24 37 49 35 26 47 46 49 2 43 49 43 32 33 34 18 50 7 51 4 35 25 51 15 51 48 21 1 90 91 70 93 13 49 42 39 10 3 93 25 35 14 88 54 9 8 27 35 22 51 49 50 51 49 49 11 50 16 17 51 5 47 19 12 .
33 ITEM P ART NO . QTY . DESCRIPTION 1 0C6140 1 ASSEMBL Y , ENCLOSURE BASE (12KW / 15KW) 0D1901 1 ASSEMBL Y , ENCLOSURE BASE (7KW) 2 0C6735 2 SUPPORT , ROOF FOLDING 3 0C7061 1 ENCLOSURE, FRONT 4 0C706.
34 46 22 37 7 38 83 2 8, 9 27 44 47 0 13 19 14 15 35 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 29 28 3 41 24 4 5 47 3 1 47 45 31 3 13 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Control Panel – Drawing No.
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 .
36 17 15 18 21 22 14 13 12 9 7 8 31 24 3 27 29 28 32 19 23 6 5 65 64 63 62 61 60 59 58 52 51 50 49 48 47 46 45 44 43 57 1 42 41 38 37 36 35 34 33 39 3 3 40 2 3 26 10 4 34 25 11 30 20 66 2, 5, 19, 20, .
37 ITEM P AR T 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.
38 112 112 111 108 107 106 105 104 103 102 100 109 99 92 95 96 91 89 90 89 88 86 85 83 84 82 81 130 99 118 114 126 94 93 117 79 78 76 77 75 74 122 125 123 125 119 120 137 136 134 133 132 131 127 129 1.
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 37 6 51 7 8 21 38 9 3 2 1 4 5 23 11 31 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 28 13 39 18 10 40 29 28 34 35 34 41 42 43 44 48 49 30 45 46 34 36 47 31 50 52 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.
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-B ITEM P ART NO .
42 36 35 37 6 34 7 8 21 38 9 3 2 1 4 5 2 11 24 31 1 2 2 5 22 14 2 0 38 1 5 30 24 2 6 32 1 0 1 9 1 6 2 8 27 17 10 19 2 8 31 3 2 17 32 31 33 2 9 2 8 1 3 39 1 8 1 0 4 0 2 9 41 42 41 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.
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-B ITEM P ART NO .
44 11 47 33 34 36 35 37 27 45 43 39 18 19 20 23 32 44 48 24 46 11 22 29 28 31 30 17 52 1 14 13 26 38 25 25 40 41 12 21 15 16 6 1 2 4 42 10 5 7 3 8 9 49 51 50 54 53 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine – Drawing No.
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 , PISTON RING 90MM 4 0C5848 1 PISTON, HC 5 071983 2 RET AINER, PISTON PIN 20 6 0D4.
46 20 22 6 24 23 21 29 25 3 40 41 42 43 44 2 4 1 6 6 6 5 13 7 9 8 10 11 14 15 16 17 19 12 6 38 37 36 27 28 18 26 33 18 35 34 35 18 30 31 32 39 6 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators GN4 1 0 Engine – Drawing No.
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 0.
1 2 5 4 10 3 6 7 8 12 11 28 26 15 14 17 13 22 23 24 25 19 20 18 29 16 21 31 18 29 16 26 14 15 17 13 21 20 19 24 22 25 23 10 9 28 11 12 27 37 35 32 10 33 34 37 36 FOR GT 760 ENGINE ONLY 32 48 Section 7 — Exploded Views and P arts Lists Guardian Air-cooled 7 kW , 1 2 kW and 1 5 kW Generators Gas Regulator – Drawing No.
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.
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.
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 .
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.
Part No. 0E1370 Revision A (07/31/02) 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" L.
An important point after buying a device Generac Power Systems 04760-0 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac Power Systems 04760-0 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac Power Systems 04760-0 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac Power Systems 04760-0 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac Power Systems 04760-0 will certainly help you make a decision on the purchase.
If you already are a holder of Generac Power Systems 04760-0, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac Power Systems 04760-0.
However, one of the most important roles played by the user manual is to help in solving problems with Generac Power Systems 04760-0. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac Power Systems 04760-0 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
