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Dometic RM 123E Refrigerator User Manual

1. ENGINE WIRING DIAGRAM KEY 3 BRUSH ASSEMBLY C CHARGER 2 BCR BATTERY CHARGE RELAY UTILITY CB1 MAIN OUTPUT BREAKER 14 2 CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION 0 1 DIODE DSW PCB MOUNTED DIP SWITCH PT FS FUEL SOLENOID a F1 FUSE 15 AMP 224B F2 FUSE 5 AMP 13A 13 CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH 0 0 IC INLINE CONNECTOR 225B ICT INTERCONNECTION TERMINALS 0 IM IGNITION MODULE 224B LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SP SPARK PLUG 14 SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH 14 SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 14 olo l TB D 0 0 SP 14 0 gt 6 0 0 18 gt 5 85 85 86 gt HTO IC B 13 2 13 13 e 1 C1 BP 18 56 56 56 351 0 13 56 85 56 4 1 2 3 4 5 J2 4 Ji T lt eo 23 SC 194 CONTROL ES 56 PRINTED CIRCUIT BOARD ES 18 14 66A BLACK RED DSW em 1234 E 15A d muni gt 15 16 C 0 INDICATES 225 1 2
2. 225 224A CONTROL PANEL BOX 224 225A 224A 225A x CLOSEST TO BEARING BCR T T CB2 BA m na 4 s 0 o 79 2 13A 66 77 0 225 225 10 224 224 i as 6 11 66 8 lt 14 2 55 9 22 0 11 6 66 9 11 22 5 lt 77 66 66 225 13A 2 24 0 11 4 gt 4 3 0 77 2 lt 1 44 224 162 162 VOLTAGE REGULATOR 0 66A 0 0 66A 33 4 55 N2 22 N1 13 13 225 13 351 224 194 23 4 N2 23 N1 351 44 13 11 13A 351 194 n N2 22 13 ad 23 194 0 13 F2 F1 239 CB1 n bn rnm 17 13 239 0 MUN SW1 I A zo gt 1 as Q SW2 240V GENERATOR E AUTO OUTPUT TO TRANSFER 2 m B SWITCH CONTACTOR 5 Zz CUSTOMER MANUAL CONNECTION 25 Section 6 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL DATA gt Electrical Schematic 12 amp 15 kW Drawing 0D8501 B
3. 11 22 225 3 225A 2 224 1 BATTERY 225 2 225 gt 224 13 10 13 13A i F1 224 1 7 7 9 9 L Ber P 1 673 4 13A 77 13 2 0 66 14 12 WINDING 66 lt 2 2 22 0 0 C2 4 uro 0 C2 11 0 OB ARARA E 4 LOP 11 ENGINE RUN BA A WINDING 4 Sw2 22 STATOR 15 eB 0 ELECTRONIC 4 C2 10 C2 9 C2 3 VOLTAGE 4 4 REGULATOR 0 66 85 23 162 Cie A 86 194 O 6 4 cB2 0 351 225 i C27 224 BARAT 66A DPE WINDING 112 P 415 15 23 239 66 DIAGRAM KEY 2 gg 194 3 23 BA BRUSH ASSEMBLY x 191 BATTERY CHARGE RELAY m CB1 CIRCUIT BREAKER MAIN OUTPUT gt CB2 CIRCUIT BREAKER ALT EXCITATION 18 D DIODE 7 14 FS FUEL SOLENOID CONTROL 8 66A F1 FUSE 15 AMP PRINTED CIRCUIT 9 239 F2 FUSE 5 BOARD 10 15A HTO HIGH OIL TEMPERATURE SWITCH a 47 IGNITION MODULE CYLINDER 1 gt 45 IM2 IGNITION MODULE CYLINDER 2 P LOP LOW OIL PRESSURE SWITCH T i SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY 15 224 SP1 SP2 SPARK PLUGS 16 SW1 AUTO OFF MANUAL SWITCH 17 SW SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC Section 6 Electrical Data Air cooled 7 kW 12
4. 4 Check that utility power supply to the transfer switch is turned 15 OPERATION Section 3 Operation J gt Air cooled 7 kW 12 kW and 15 kW Generators AN 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 trans fer switch to move the main contacts back to their Utility position i e loads connected to the util ity power source Figure 3 2 6 Turn ON the utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 3 3 3 6 SETTING THE EXERCISE TIMER The 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 the following sequence is completed During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 3 1 allows for selection of the day and time for system exercise To select the desired day and time of day the follow ing sequence must be done at that time
5. WARRANTY SCHEDULE YEAR ONE and TWO one hundred percent 100 coverage on mileage labor and parts listed proof of purchase and maintenance required e Engine ALL COMPONENTS Alternator ALL COMPONENTS Transfer System ALL COMPONENTS Guidelines Travel allowance for Air and Liquid cooled units is limited to 60 miles maximum and 2 0 hours maximum or 100 00 maximum per occurrence which ever is less round trip to the nearest authorized Generac Service Facility and only applies to permanently wired and mounted units Any and all war ranty repairs and or concerns must be performed and or addressed by an Authorized Certified Generac Power Systems Dealer or branch thereof e A Generac Power Systems Inc Transfer Switch is highly recommended to be used in conjunction with the generator set If a Non Generac Power Systems Inc Transfer Switch is substituted for use and directly causes damage to the generator set no warranty coverage shall apply All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty Policies and Procedures Flat Rate Manual Units that have been resold are not covered under the Generac Power Systems Warranty as this Warranty is not transferable Unit enclosure is only covered against rust or corrosion the first year of the warranty provision Use of Non Generac replacement part s will void the warranty in its entirety Engine coolant heaters block heaters
6. 36 ITEM PART NO 1 0C5729 2 0 9843 3 090388 4 0C5372 5 0C3005 6 0E3372B 008067 8 071983 9 0 2981 10 045761 11 0 2985 12 021533 13 0 1466 14 004041 15 0C2983 16A 0C2985A 16B 0C2985B 17 0D4042 18 0A7811 19 0C2977 20 0C5943 21 0 4357 22 0 3223 23 002157 24 0 6098 25 0D4123A 26 078699E 27 0C3011 28 0C3009 29 0C3010 30 093873 31 0C5315 32 0C5998 33 0D1667 34 0C2991 35 0C2988 36 0C2992 1 N Section 7 Exploded Views and Parts Lists PARTS Ce LISTS Air cooled 7 kW 12 kW and 15 kW Generators D GT 990 Engine Drawing No 0E8774 M Part 1 0 DESCRIPTION ITEM PART QTY DESCRIPTION ASSEMBLY CRANKCASE HOUSING WITH 37 0C3971C 1 ASSEMBLY DIPSTICK WITH HANDLE SLEEVE 38 0C5305 1 TUBE DIPSTICK SEAL 38 1 0 CRANKSHAFT 39 0C3027 1 O RING OIL CLR 3 8 X 1 2 SCREW TAPTITE M6 1 0 X 12 YC 40 0 9842 1 SEAL 42 0 CRANKSHAFT ASSEMBLY BREATHER 41 0C5731 1 ASSEMBLY HOUSING COVER WITH GASKET BREATHER COVER SLEEVE SEPARATOR OIL BREATHER 42 0C3006 9 SCREW HHFC M10 1 5 X 55 ASSEMBLY HEAD 1 G amp S 43 080318 8 SCREW 6 1 0 X 25 RETAINER PISTON PIN 20 44 093064 1 ASSEMBLY OIL FILL CAP ROCKER COVER NO OIL FILL 45 0C8808 2 HOOK LIFTING STUD M8 1 25 10MM X 30 G5 ZINC 46 0D2723B 1 ROCKER COVER WITH OIL FILL PISTON HC 47 0C2979 2 GASKET VALVE COVER SET PISTON RING 90MM 48 086515 8 KEEPER VALVE SP
7. Starter 12Vdc Oil Capacity Including Filter Approx 1 7 Qts Recommended Oil Filter Part 070185B Recommended Air Filter Part 0C8127 Operating RPM 3 600 3 600 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 The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section 1 9 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water colum 0 18 to 0 25 psi and for liquid propane 10 inches to 12 inches of water column 0 36 to 0 43 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges 1 7 FUEL CONSUMPTION Nat 1 2 Load
8. heater controls and circulating pumps after the first year THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Any unit built manufactured prior to July 1 2004 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty 5 Failures caused by any external cause or act of God such as but not limited to collision fire theft freezing vandalism riot or wars lightning earthquake windstorm hail volcanic eruption water or flood tornado hurricane terrorist acts or nuclear holocaust 6 Products that are modified or altered in a manner not authorized by Generac Power Systems in writing 7 Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation or sizing 8 Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s 9 Damage related to rodent and or insect infestation 10 Failure due to misapplicat
9. 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Hold down the set timer switch until the genera tor starts approximately 10 seconds and then release 3 The generator will start and run for approximately 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is per formed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected The exerciser WILL NOT work if dip switch 2 Remote Not Auto on the controller printed circuit board is ON 16 5 7 PROTECTION SYSTEMS 5 71 LOW OIL PRESSURE SWITCH This switch Figure 3 3 has normally closed con tacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO 3 7 2 HIGH TEMPERATURE SWITCH This switch s contacts Figure 3 3 close if the tem perature should exceed approximately 1409 C 2849 F initiating an engine shutdown The generator will automatically restart and the LED will reset once the temperature has returned to a safe operating level Figure 3 3 Low Oil Pressure and High Temperature Switches Low Oil Switch
10. Full Load 1 2 Load 66 119 0382 0 04674 1 53 56 04675 1 58 58 2 40 88 Natural gas is cubic feet per hour LP is in gallons per hour cubic feet per hour 1 8 RECONFIGURING THE FUEL SYSTEM 1 8 1 7 KW 410CC To reconfigure the fuel system from NG to LP follow these steps Figure 1 3 NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator A fuel pres sure of 10 to 12 inches of water column 0 36 to 0 43 psi to the fuel inlet of the generator MUST BE SUPPLIED 1 Turn off the main gas supply if connected 2 Open the roof and remove the door Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators GENERAL INFORMATION 3 Remove the battery if installed 4 Disconnect wire 0 and wire 14 from the gas solenoid on top of the demand regulator 5 Remove the carburetor fuel hose from the outlet port of the demand regulator 6 Remove the demand regulator by removing the fastener that retains the regulator mounting bracket 7 Remove the square headed steel pipe plug from outlet port 1 and the brass hose barb fitting from outlet port 2 8 Refit the brass hose barb fitting to outlet port 1 and the square headed steel pipe plug to outlet port 2 9 Reverse procedure steps 1 5 to reinstall demand regulator 10 Take the plastic plug supplied in the poly bag with the generator and press it into the 3 4 hole on the bottom
11. X Action Inspect Change Clean W Weekly R Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections LUBRICATION Oil level M NENNEN AND Y AND Y M COOLING Enclosure louvers a W BATTERY Remove corrosion ensure dryness 6 6 Clean and tighten battery terminals Check charge state Electrolyte level unsealed batteries only ENGINE AND MOUNTING Air cleaner Spark plug s GENERAL CONDITION Vibration Noise Leakage Temperature COMPLETE TUNE UP TO BE COMPLETED BY AN AUTHORIZED DEALER ee 5 1 PROBLEM The engine will not crank The engine cranks but will not start The engine starts hard and runs rough The AUTO OFF MANUAL switch is set to OFE but the engine continues to run There is no AC output from the generator There is no transfer to standby after utility source failure Unit consumes large amounts of oil Section 5 Troubleshooting Air cooled 7 kW 12 kW and 15 kW Generators TROUBLESHOOTING GUIDE CAUSE 1 Fuse blown 2 Loose corroded or defective battery cables 3 Defective starter contactor 7 kW 4 Defective starter motor 5 Dead Battery 1 Out of fuel 2 Defective fuel solenoid F5 3 Open 14 wire from engine control board 4 Defective spark plug s 5 Valve lash out of adjustment l Air cleaner plugged or damaged 2 Defective
12. b Air cleaner Ly po CUL LLLIS Wall PBLALTLILTLILC LILCLUUT LILO 1U11U Wl1112 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 53 Section 10 Warranty WARRANTY 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 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 Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Certified Generac Power Systems Dealer or branch thereof This warranty applies only to Generac Power Systems Generators used in Standby applications as Generac Power Systems Inc has defined Standby Scheduled maintenance as outlined by the generators owners manual is highly recommended This should be performed by an Authorized Certified Generac Power Systems Dealer or branch thereof This will verify service has been performed on the unit throughout the warranty period
13. 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406ID X 1 6200 24 022237 4 WASHER LOCK 3 8 25 022511 4 BOLT HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 039287 4 SCREW HHC 8 1 25 X 45 08 8 28 022145 12 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX 8 1 25 NYL INSRT 30 090388 3 SCREW 6 1 0 12 BP 31 022129 13 WASHER LOCK 8 5 16 32 022259 8 NUT HEX 5 16 18 STEEL 33 059637 2 SCREW TAPTITE 3 8 16 3 4 BP 34 048031 3 BAND HOSE CLAMP 35 05 DIA 35 0C9592 1 BELLOWS 36 048031 2 HOSE CLAMP 3 4 37 040976 2 SCREW SHC 8 1 25 X 20 G12 9 38 0C2824 1 SCREW TAPR 10 32 X 9 16 39 025145 1 U BOLT 5 16 18 X 1 25 W SADDLE 40 090239 1 GASKET EXHAUST 41 0C6989 1 STINGER ENGINE AIR IN 42 0D1214 1 BASE CLEANER 43 0C8127 1 ELEMENT AIR CLEANER 44 0C3024 1 COVER CLEANER NG LP 45 002273 1 TUBE 1 25 0 D x 20Ga x 12 125 LONG 46 055934N 1 CLAMP VINYL 1 31 X 281 Z 47 0 7065 1 25 FT HOSE LP 1 2 1 0 48 0C5136A 2 KNOB AIR CLEANER 49 074906 4 SCREW TAPTITE M6 1 X 20 BP 50 022473 4 WASHER FLAT 1 4 ZINC 51 0D4662 6 SCREW M8 1 2 X 20 BP 52 0C8290 1 GASKET PANEL 53 066849 2 SCREW 5 0 8 X 16 41 PARTS qp is 00 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 31 32 Section 7 Exploded Views and Parts Lists Qi Air cooled 7 kW 12 kW and 15 kW Generator
14. 0C6067 2 SUPPORT DIAPHRAGM 24 0C4706 2 DIAPHRAGM TWIN REGULATOR 25 0 6068 2 CAP DIAPHRAGM SUPPORT 26 0C4643A 2 INLET TWIN REGULATOR 11 11 DIA 27 026073 1 PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD 026073 2 PLUG STANDARD 1 8 STEEL SQUARE HEAD 7KW 28 0A4032 2 PIN LIMITED ADJUSTMENT 29 0D3308 4 WASHER FLAT X 10mm O D 30 024310 1 PLUG STANDARD PIPE 1 2 STEEL SQUARE HEAD 7KW 31 028414A 1 BARBED STRAIGHT 1 8 NPT X 1 4 32 005698 1 JET IDLE PRIMER PHILLIPS HD V TWIN ONLY 37 003973 1 PLUG EXPANSION 16mm A QUANTITY OF 1 1 TO BE USED ON 7KW HOME STANDBY 49 imensions Mounting D 8 PARTS Section LISTS 00 12 kW 15 kW Generators Q o ry m a N o 2 os 5 xa SSHONI SH313NITIIN SNOISNAWIG WAWANIN MIIA MIIA 391 1H9IH MIIA LNO TA M3IA 391 1431 S 8 2621 Sg vc 229 82 91 SS399Y SAOWSY 53 1 55320 318 2 8611 5 16621709 H31VM 21 01 HOdVA 3NVdOtid AINON NINN109 H3 1VM 1 6 SVO aunssaud Tand aauinoau LIINI TAN LAN T JOOH JHL 1411 LON OQ SH3NHOO r S310H 39 3MVLINI HOLIMS H33JSNVH L 1 81 202 8 m 161714 uuu
15. 24 0C4391 2 VALVE SPRING LF 25 086025 1 SET GEROTOR 12 THK 26 0E3341 1 BALANCER 27 021714 1 ASSEMBLY CYLINDER HEAD SEATS amp GUIDES 28 086516 1 VALVE EXHAUST 29 086517 1 VALVE INTAKE 30 0D9853B 2 PUSH ROD 174 9 31 083897 2 32 077158 1 ASSEMBLY SCREEN OIL PICK UP 33 063150 1 GASKET ROCKER COVER 410 34 072694 2 STUD 020 PIVOT BALL 85 083907 2 36 072696 2 NUT JAM ROCKER ARM 37 078694 1 PLATE PUSH ROD GUIDE 38 021742 4 SCREW HHFL M10 1 5 X 105 39 0D6094 1 ASSEMBLY ROCKER COVER BREATHER 40 076329 1 PLUG OIL FILL PLASTIC 41 0E0057 1 O RING 17 8 x 2 4 42 0D4788 1 PLUG STANDARD PIPE 3 8 STEEL SQUARE HEAD 43 074908 1 SCREW TAPTITE M5 0 8 X 10 BP 44 086515 4 KEEPER VALVE SPRING 45 078606 4 SCREW amp LOCKWASHER M6 1 X 12 46 0A1442 8 SCREW HHFC M8 1 25 X 42 47 078672 1 SEAL VALVE STEM D7 48 089673 2 WASHER VALVE SPRING 49 0B2104 1 WASHER LARGE SPRING 50 078699C 2 DOWEL SEAMED SLEEVE 51 0A7627 1 SHAFT GOVERNOR RC55 52 043790A 1 BARBED ELBOW 90 3 8NPT X 3 8 LOCKTITE 53 088590 1 DOWEL DIA 12 X 181 54 078699B 1 DOWEL SLEEVE SEAMED 12 DIA 45 Q us Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 0 GN410 Engine Drawing 0F3981 A Part 2 lt 39 46 Section 7 Exploded Views and Parts Lists Qi Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing 0F3981 A Part 2 O ITEM PART N TY DESCR
16. 5 16 WASHER RUBBER 1 4 X 1 8 THICK 117 0C3018 1 WRAPPER UPPER CYLINDER 1 SWITCH OIL PRESS 118 0C3019 1 WRAPPER LOWER CYLINDER 1 ASSEMBLY OIL DRAIN HOSE 119 0D1142A 1 WRAPPER LOWER CYLINDER 2 NIPPLE 3 4 16 UNF 120 0D1143 1 WRAPPER UPPER CYLINDER 2 OIL FILTER 121 0E6043 2 SCREW TAPTITE M5 0 8 X 8 ZP SWITCH THERMAL 284F 122 0F1177 1 ASSEMBLY GROUND WIRE SCREW M3 0 5 X 6 SEMS 123 0C3052 1 ASSY IGNITION COIL GV 990 CYLINDER 2 BARBED STR 1 4 X 3 8 124 022097 4 WASHER LOCK 6 1 4 CLAMP HOSE OETIKER 16 5mm 125 092079 4 SCREW TAPTITE M6 1 0 X 25 BP HOSE 3 8 1 0 X 6 LONG 126 0E4271 1 STARTER COOLER OIL 127 0D4529 2 SPARKPLUG PLASTITE 1 4 15 X 3 4 128 022129 2 WASHER LOCK 8 5 16 GASKET MANIFOLD PORT 129 061906 2 SCREW HHC 8 1 25 X 85 G8 8 MANIFOLD CYLINDER 2 130 082774 1 KEY WOODRFF 4 X 19D MANIFOLD CYLINDER 1 131 0 5343 1 NUT HEX LOCK M10 1 50 SLEEVE RUBBER 132 0C8468 1 SPRING ANTI LASH WASHER FLAT 8 SS 133 0C3048 1 ROD GOVERNOR CONTROL WASHER LOCK 8 SSTL 134 0D3754 1 ASSEMBLY GOVERNOR LEVER SCREW SHC 8 1 25 X 20 G12 9 195 0D3742 1 SPRING GOVERNOR PLATE BACKING WITH OIL COOLER 136 008482 1 ASSEMBLY GOVERNOR ADJUSTER GROUND WIRE CONNECTOR 137 0E0486 1 SCREW SHC 10 1 5 X 75 G10 9 FLYWHEEL ASSEMBLY 138 0D3743 1 SPRING GOVERNOR IDLE FAN NYLON 139 0D3705 1 ASSEMBLY GOVERNOR ADJUSTER PLATE FAN BRACKET WASHER SHAKEPROOF INT M8 SS 140 002993 1 SEAL GOVERNOR SHAFT SCREW HHC 8 1 25 X 12 G8 8 142 04577
17. High Temp Switch 3 7 3 OVERCRANK This feature prevents the generator from damaging itself when it continually attempts to start and anoth er problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED will light indicating an overcrank failure The AUTO OFF MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the overcrank feature will continue to activate Section 4 Maintenance Air cooled 7 kW 12 kW and 15 kW Generators MAINTENANCE 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 4 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gen erator from supplying an output that could poten tially damage appliances connected to the generator circuit Contact the nearest Authorized Dealer if this failure occurs 4 1 FUSE The generator panels 15 amp fuse Figure 4 1 pro tects 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 the engine cannot crank or start Replace the fuse using only an identical 15 amp
18. OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 4 Check the engine crankcase oil level and if neces sary fill to the dipstick FULL mark with the rec ommended oil Do not fill above the FULL mark 5 Check the fuel supply Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel gas codes fuel shutoff valves in the fuel supply lines must be open cauroN amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 10 2 22 CHECK TRANSFER SWITCH OPERATION Refer to Section 3 5 of the owner s manual for manu al operation procedures A Do not attempt manual transfer switch tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 2 5 ELECTRICAL CHECKS Complete electrical checks as follows 1 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker AN The transfer switch is now electrically hot Contact with hot parts will result in extremely hazardous and possibly fatal electrical shock Proceed with caution 2 Use an accurate AC voltmet
19. Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period
20. component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 555 1522 IMPORTANT NOTE This warranty
21. engine for oil viscosity and classification Verify that the correct recommended oil is used in the engine see Section 4 3 1 If neces sary drain and refill with the proper oil 4 Checkthe state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery See Specifications section 1 5 for type and size o Clean and wipe the entire generator 6 Remove the 5A fuse from the generator control panel 7 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incor rectly Replace the 5A fuse in the generator control panel 8 Open the fuel shutoff valve 9 Start the unit by moving the AUTO OFF MANUAL switch to MANUAL Allow the unit to warm up thor oughly 10 Stop the unit and set the AUTO OFF MANUAL switch to AUTO Set the generator s main circuit breaker to its ON or closed position 11 Turn on the utility power to the transfer switch 12 The generator is now ready for service NOTE If the battery was dead or disconnected the exercise timer must be reset 21 Section 4 Maintenance MAINTENANCE Air cooled 7 kW 12 kW and 15 kW Generators S 4 13 SERVICE SCHEDULE ATTENTION It is recommended that all service work be performed by the nearest Authorized Dealer SYSTEM COMPONENT PROCEDURE FREQUENCY
22. ground to the battery post indicated by a nega tive NEG or 6 Replace the 5 amp fuse in the generator control panel NOTE Damage will result if battery connections are made in reverse Figure 1 5 Battery Cable Connections BLACK LEAD FROM FRAME RED LEAD FROM STARTER CONTACTOR N RED M BATTERY Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators NOTE The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation With the battery installed and utility power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charger is designed to help extend the life of the battery by maintain ing the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 11 THE BATTERY Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries When replacing the battery use the following type of battery Group 26 26R 12 volt battery with a rating of 350 cold cranking amps minimum for 7 kW 525 cold cranking amps minimum for 12 and 15 kW at 18 C 0 F minimum When using a maintenance free battery it is not nece
23. of the air cleaner base Figure 4 6 11 Reverse the procedure to convert back to natural gas Figure 1 3 Demand Regulator HOSE amp PLUG SWITCHED SIDES FUEL HOSE l FUEL HOSE BRASS HOSE BRASS HOSE FITTING FITTING OUTLET PORT ADJUSTMENT SCREW FUEL JET NG FUEL SYSTEM LP FUEL SYSTEM NOTE The natural gas adjustment screw is preset dur ing installation and should not need any further adjustment 1 8 2 12KW AND 15KW V TWIN ENGINES To reconfigure the fuel system from NG to LP follow these steps NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator A fuel pres sure of 10 to 12 inches of water column 0 36 to 0 43 psi to the fuel inlet of the generator MUST BE SUPPLIED GENERAL INFORMATION 1 2 4 Turn the gas supply if connected Open the roof and remove the door Remove the battery if installed Remove the engine air in baffle located on the left hand 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 gen tly lift up the hose edge 6 Remove the small brass hose fitting from the regulator casting 7 Place the small fuel jet t
24. replacement The generator panel s 5 amp fuse protects the battery charge circuit against overload If the fuse element has melted open battery charging will not be possible Replace the fuse using only an identical 5 amp replace ment To remove fuse push cap down and rotate coun terclockwise Figure 4 1 Generator Control Panel FUSE x Locate your nearest GENERAC dealer at www generac com POWER SYSTEMS INC 5A AUTO OFF MAN SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK 15A SET FLASHING GREEN LED O UTILITY SENSE EXERCISE 4 RED LEDS TIME es O EX ERCISER NOT SET a 4 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figure 4 2 1 Start the generator by moving the Auto Off Manual switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth Install the dipstick then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE MARK amp Never operate the engine with the lev
25. statement explains your rights and obligations under the Emission Control System 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 Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner If there are any questions regarding the warranty rights and responsibilities contact Generac at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 340 EAGLE WI 55119 Part 1 5e Section 10 Warranty Air cooled 7 kW 12 kW and 15 kW Generators WARRANTY 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 Warra
26. 0 Vac Sense Transformer EH 224 O lt q 2 Remote Not Auto e 12V 3 50 Hz Operation gt BATTERY 4 SPARE CUSTOMER SUPPLIED L E D ALARM INDICATORS Section 6 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators an ELECTRICAL Wiring Diagram 7 kW Drawing No 0D9013 C E DATA CONTROL PANEL BOX 225 224A 224 225A 224A CLOSEST TO BEARING 225A BA TX 4 BCR T CB2 LJ 6 calo 2 13 66
27. 026850 85 049813 86 0F0164A 87 OF0165A 89 0 2874 90 043107 91 022145 92 045771 93 0C3906 94 0 4321 95 0E1330A 96 0 9692 97 042907 98 055241 99 0 5943 PARTS 00 TY DESCRIPTION Po N N ONON N L N po Bo AB N OT PO SCREW HHC 1 0 X 16 G8 8 SCREW HHC 1 0 X 16 G8 8 7KW SCREW HHC 6 1 0 X 12 G8 8 SCREW HHC M6 1 0 X 12 G8 8 7KW NUT LOCKING FLANGE M6 1 0 NUT LOCKING FLANGE M6 1 0 7KW SCREW HHTT M8 1 2 X 20 BP SCREW TAPTITE M6 1 0 X 12 BP SCREW TAPTITE M6 1 0 X 12 BP 7KW NUT LOCK TRIC M6 X 1 0 Y ZNC GASKET BATTERY SUPPORT BRACKET PLUG PLASTIC 0 593 LUG SLDLSS 2 8X17 64 CU SCREW TAPTITE 6 1 0 25 BP L WASH SPECIAL 4 BRACKET BATTERY HOLD DOWN 7KW CONTACTOR STARTER 7KW CABLE 6 RED BATTERY 38 5 NUT HEX 1 4 20 STEEL 7KW WASHER LOCK 5 16 WASHER LOCK 5 16 7KW SCREW TAPTITE M5 0 8 X 10 BP HARNESS ENGINE HARNESS ENGINE 7KW BUSHING SNAP SB 1000 12 SCREW HHC 5 16 18 X 3 4 G5 7KW RIVET 1 8 X 0 126 0 375 LSH SPECIAL 10 ASSEMBLY ROOF DOOR GROUND WIRE ASSEMBLY ROOF DOOR GROUND WIRE PLUG PLASTIC 1 375 GASKET EXTRUDED TRIM PLATE HOT GROMMET 2 75 X 1 16 EXTERNAL CONNECTION BOX POWER BLOCK HARNESS GENERATOR TO EXTERNAL CONNECTION BOX HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 7KW SCREW PPH
28. 0C8101B 0C8862 10 0C8283 11 0C8284A 12 0C8284B 13 0C8284C 14 0C8285 15 0C8899A 16 0D1128 0D1128A 17 0 4244 001605 18 001606 005264 19 001839 20 001840 21 002425 22 002588 002588 23 002676 24 002677 25 002979 002979 26 002979 27 0029790 002979 28 0 4245 003058 29 0 4245 30 0 4245 003058 31 0030570 32 003059 33 003059 34 003059 35 007176 36 0030590 37 003059 38 0C7781A 39 0D3037 40 0 0164 41 0 0165 42 0D3037A 43 0A2115 44 022097 46 0F0710 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Enclosure Drawing No 0 0080 TY DESCRIPTION ono NS po 5 18 ASSEMBLY ENCLOSURE BASE ASSEMBLY ENCLOSURE BASE 7KW SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE EXHAUST SIDE 7KW ENCLOSURE SIDE amp BACK ENCLOSURE SIDE amp BACK 7KW ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER PANEL ALTERNATOR DIVIDER 7KW PANEL MUFFLER BOX SIDE PANEL MUFFLER BOX SIDE 7KW COVER MUFFLER BOX COVER MUFFLER BOX 7KW GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 X48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER PANEL ENGINE DIVIDER
29. 1 1 NUT HEX 8 1 25 G8 WASHER 25mm 1 0 143 0D6147 7 SCREW HHFC M6 1 0 X 10mm NUT HEX M24 144 0E8152 1 O RING 0 49 I D X 0 07 THICK SNORKEL AIR INTAKE 145 0E7743 1 ASSY IGNITION COIL 270mm CYLINDER B B gt PO HOUSING BLOWER NG COOLER 1 39 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 7 kW Generator Drawing No 0D3504 E LISTS ONG PARTS Ce 40 51 RK QRS 21 Za Q v 53 31 Section 7 Exploded Views and Parts Lists Qi Air cooled 7 kW 12 kW and 15 kW Generators 7 kW Generator Drawing No 003504 O ITEM PART N TY DESCRIPTION 1 0C6934 1 ADAPTOR ENGINE 2 0C9935H 1 STATOR 3 0C9934H 1 4 0C6043A 1 CARRIER REAR BEARING 5 0C8096 1 8 CURVED BLADE 6 0C9593 1 MUFFLER 7 0D3220 1 TAIL PIPE MUFFLER 8 0C8860 1 PANEL MUFFLER BASE 9 031971 1 BEARING 6205 2RS C3 10 003168 3 5 16 SPECIAL LWASH 11 056147 1 BOLT ROTOR HHCS 5 16 24 X 13 1 2 G5 12 0D1847 4 BOLT STATOR HHCS 8 1 25 x 305mm 13 0C7038C 1 BRACKET ALTERNATOR MOUNTING 14 0D1647 1 DUCT ALTERNATOR AIR 15 0D2558 1 GASKET ALTERNATOR AIR DUCT 16 0C7038B 1 BRACKET ENGINE MOUNTING 17 0C7758 4 RUBBER MOUNT 18 0388050 0 1 CABLE 6 40 BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VINYL COAT 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22
30. 1 3 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true If this generator is used to power electrical load 1 The AUTO OFF MANUAL switch is set to the circuits normally powered by a utility power AUTO position source it is required by code to install a trans 2 The utility voltage being supplied to the unit is fer switch The transfer switch must effectively isolate the electrical system from the utility distribution system when the generator is oper ating NEC 700 701 and 702 Failure to isolate an electrical system by such means will result in damage to the generator and also may result in being sensed by the Control PCB If the utility sense voltage is not connected to the unit or if it is below 168 volts AC then the system set light will flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto posi tion the generator will start injury or death to utility power workers due to 3 The Not In Auto dip switch is set to the OFF backfeed of electrical energy position on the control board If any loss or damage is noted at time of delivery have 4 No alarms are present for example low oil pres the person s making the delivery note all damage on sure high temperature etc the freight bill or affix his or her signature under the consignor s memo of loss or damage If there is loss or damage after delivery separate the damaged materials and conta
31. 2 kW and 15 kW 990cc Engines 7 LO GEBOOGUOH 8 8 re ere 8 t 10 B tlery Inst 9 ll TI T 9 Section 2 Post Installation Start up and Adjustments 10 21 Before Initial Start up 10 2 2 Check Transfer Switch Operation 10 2 0 Electrical Check u u ua u 10 2 4 Generator Tests Under Load 11 2 5 Checking Automatic Operation 11 2 6 Adjusting the Regulator Natural Gas Only 12 2 7 Engine Governor Adjustment 12 A REW UniS ee era ere eer 12 2 7 2 12 kW and 15 kW Units 13 2 7 3 Additional Corrosion Protection 13 2 8 Voltage Regulator Adjustment 13 Section 3 Operation 14 3 1 Break in Procedure 14 3 2 Using the Auto Off Manual Switch 14 14 Table of Contents E CONTENTS 9 2 0 14 9 2 9 Manual Position 14 3 9 Automatic Transfer Operation 14 3 4 Sequence of Automatic Operation 14 3 5 Manual Transfer Operation 15 3 5 1 Transfer to Generator 15 3 5 2 Transfer Back to U
32. 3 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 4 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker o Set the AUTO OFF MANUAL switch to AUTO Then set the generator s main circuit breaker to its ON or closed position The system is now ready for automatic operation 6 Turn OFF the utility power supply to the transfer switch With the AUTO OFF MANUAL switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power supply to the transfer switch The following should occur After about 15 seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down 11 POST O Section 2 Post Installation Start up and Adjustments INSTALLATION START UP Air cooled 7 kW 12 kW and 15 kW Generators ADJUSTMENTS 6 When the highest frequency is reached maximum 2 6 ADJUSTING THE REGULATOR power has been set Then turn both adjustment NATURAL GAS ON LY screws 1 4 turn counterclockwise Regulator is Although the generat
33. 3058A 0E4245A 0E4245B 0D3058C 0D3057D 0D3059A 0D3059B 0D3059C 0D7176 0D3059D 0D3059E 0C7781A 0D3037 0D2537 0D2538 0D3037A 0A2115 022097 022473 2 26 04 N N l3 l3 l3 l3 l3 gt M DESCRIPTION ASSEMBLY ENCLOSURE BASE ASSEMBLY ENCLOSURE BASE 7KW SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE EXHAUST SIDE 7KW ENCLOSURE SIDE amp BACK ENCLOSURE SIDE amp BACK 7KW ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER PANEL ALTERNATOR DIVIDER 7KW PANEL MUFFLER BOX SIDE PANEL MUFFLER BOX SIDE 7KW COVER MUFFLER BOX COVER MUFFLER BOX 7KW GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 X48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER PANEL ENGINE DIVIDER 7KW BAFFLE INTAKE BAFFLE INTAKE 7KW HOUSING FAN BAFFLE EXHAUST 7KW BRACKET TOP SUPPORT BRACKET BOTTOM SUPPORT DUCT BASE AIR GASKET FRONT DIVIDER GASKET FRONT DIVIDER 7KW COVER FRONT EXHAUST ENCLOSURE COVER BACK EXHAUST ENCLOSURE CLOTH HARDWARE 266 7mm x 146mm CLOTH HARDWARE 266 7mm x 146mm 7KW CLOTH HARDWARE 543mm x 146mm CLOTH HARDWARE 266 7mm x 387 4mm CLOTH HARDWARE 7KW FOAM FRONT INTAKE BAFFLE FOAM FRONT INTAKE BAFFLE 7KW FOAM TOP INTAKE BAFFLE FOAM BACK INTAKE BAFFL
34. 40 0 7866 1 COVER CONTROL PANEL 0E7867 1 COVER CONTROL PANEL 7KW 41 0D3700 8 NUT FLANGE 6 1 0 NYLOK 42 0912970069 1 ASSEMBLY ROOF DOOR GROUND WIRE 43 0 2874 1 SCREW HHTR 1 4 20 X 3 4 44 0 1658 2 WASHER LOCK SPECIAL 1 4 45 022473 3 WASHER FLAT 1 4 M6 46 038750 1 SCREW M6 1 0 x 30mm 47 022097 3 WASHER LOCK M6 1 4 48 049813 1 6 1 0 49 031879 6 WASHER FLAT 4 031879 4 WASHER FLAT 4 7KW 50 023897 2 WASHER FLAT 10 51 0F4793 2 SCREW PPHM M3 0 5 x 10mm 35 PART Qo ism Exploded Views and Parts tists __ I 0 UP Air cooled 7 kW 12 kW and 15 kW Generators 0 990 Engine Drawing No 0E8774 M Part 1 O gt n lt os co LO LO a LO 16 lt co e LO gt amp co LO id lt co LO co LO S LO tO lt gt lt oy S ep SM 169 e a Tr m US oY c F lt cNi NI N N N CNI CO wo 5 0 iu co co I d O gt 51 LO NECS BUS ONS f N W eE xu lio 5502 9 55 2 K NOH 9 T 27 6 9
35. 6 UN J2 CONTROL PRINTED CIRCUIT BOARD 1 20 Vac Sense Transformer 2 Remote Not Auto 3 50 Hz Operation 4 SPARE J1 1 86 194 18 66A 15A 15 225 1711611514 1311211101 9 8 7 6 5 4 312 L E D ALARM INDICATORS 224 Section 6 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL Wiring Diagram 12 amp 15 kW Drawing No 0D8500 B 4 lt
36. 7KW BAFFLE INTAKE BAFFLE INTAKE 7KW HOUSING FAN BAFFLE EXHAUST 7KW BRACKET TOP SUPPORT BRACKET BOTTOM SUPPORT DUCT BASE AIR GASKET FRONT DIVIDER GASKET FRONT DIVIDER 7KW COVER FRONT EXHAUST ENCLOSURE COVER BACK EXHAUST ENCLOSURE CLOTH HARDWARE 266 7mm x 146mm CLOTH HARDWARE 266 7mm x 146mm 7KW CLOTH HARDWARE 543mm x 146mm CLOTH HARDWARE 266 7mm x 387 4mm CLOTH HARDWARE 7KW FOAM FRONT INTAKE BAFFLE FOAM FRONT INTAKE BAFFLE 7KW FOAM TOP INTAKE BAFFLE FOAM BACK INTAKE BAFFLE FOAM BACK INTAKE BAFFLE 7KW FOAM BACK ENCL STRIP FOAM EXHAUST SIDE ENCLOSURE END FOAM EXHAUST SIDE ENCLSURE FRONT FOAM EXHAUST FAN HOUSING WASHER SELF LOCKING WASHER SELF LOCKING 7KW FOAM FRONT EXHAUST ENCL COVER FOAM BACK EXHAUST ENCLSURE COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE TYPE A WITH STUDS PIN HINGE TYPE B WITH STUDS PIN LATCH QUARTER TURN NON LOCKING WASHER NYLON 250 WASHER LOCK M6 1 4 RIVET POP 0 125 X 0 337 ITEM PART NO 47 047411 047411 48 043116 043116 49 0D3700 0D3700 50 0D4662 51 090388 52 092120 54 003167 55 0 3328 56 055414 Ti 092079 58 0A1658 59 0C2937 60 086729 61 0388040AJ0 62 022127 63 022129 022129 64 074908 65 0D2346 0D2345 66 023484F 67 022142 68 0A7836 69 0A8475 70 0912970069 71 0912970070 rf 055450 73 0 5968 74 003701 75 003472 76 0C8742 77 0C8911 78 0D8442 0D8652 79 036937 80 022152 81 051713 82 022158 83 003031 84
37. 94 2 SCREW 3 0 5 X 6 SEMS 44 0C4373 1 SPACER ENDFRAME 45 022717B 1 46 023865 1 SPRING SECONDARY 47 023855 1 BRACKET SECONDARY GOVERNOR SPRING 48 039253 1 SCREW HHC 8 1 25 x 20 49 0D3751 1 SPRING IDLE RETURNING 50 0F3921 1 BARREL GOVERNOR ADJUSTMENT 51 0C8493 1 SCREW SHC M5 0 8 x 30 52 0D8758 1 ENGINE LIFT HOOK 47 i us Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Gas Regulator Drawing 0D8720 H Lf LO N 10 Section 7 Exploded Views and Parts Lists Qi Air cooled 7 kW 12 kW and 15 kW Generators Gas Regulator Drawing No 0D8720 H O ITEM PART N TY DESCRIPTION 1 0D5694 1 CASTING TWIN REGULATOR HOUSING 2 0F5022 1 SOLENOID COIL 12VDC 3 004647 1 GASKET SOLENOID 4 004166 1 PLUNGER LP REGULATOR ASSEMBLY 5 0C6070 1 SPRING SOLENOID PLUNGER 8 0 4795 4 SCREW PPHM SEMS 4 0 7 X 10 9 0C5760J 1 GN 410 ENGINE 7KW 10 0C6606 2 BARBED STRAIGHT 1 2NPT x 1 2 11 097934 O RING CHECK VALVE 12 0C4645 2 ADJUSTER SCREW TWIN REGULATOR 13 0C5761 2 LEVER REGULATOR 14 0C5968 2 SUPPORT INLET SEAL 15 0C6066 2 SEAL INLET 16 065759 2 PIN PIVOT ARM 17 0 5764 2 SPRING REGULATOR 0C5764A 2 SPRING REGULATOR 7KW 18 070728 4 SCREW 5 0 5 x 5 19 0C6069 2 GASKET DIAPHRAGM 20 0C5762 2 COVER TWIN REGULATOR 21 045764 16 SCREW TAPTITE M4X8 BP 22 0 6731 2 RIVET POP 118 X 125 23
38. AP WATER IN BATTER IES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A Do not dispose of the battery fire battery is capable of exploding A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or disconnecting battery terminals wanNiNG Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed e Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes immediately flush thoroughly with water and seek medical attention and Spilled electrolyte is to be washed down with acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate o
39. ASKET BATTERY SUPPORT BRACKET PLUG PLASTIC 0 593 LUG SLDLSS 2 8X17 64 CU SCREW TAPTITE M6 1 0X25 BP LIWASH SPECIAL 7 BRACKET BATTERY HOLD DOWN 7KW CONTACTOR STARTER 7KW CABLE 6 RED BATTERY 38 5 NUT HEX 1 4 20 STEEL 7KW WASHER LOCK 5 16 WASHER LOCK 5 16 7KW SCREW TAPTITE M5 0 8 X 10 BP HARNESS ENGINE HARNESS ENGINE 7KW BUSHING SNAP SB 1000 12 SCREW HHC 5 16 18 X 3 4 G5 7KW RIVET 1 8 X 0 126 0 375 LSH POP LIWASH SPECIAL 10 ASSEMBLY ROOF DOOR GROUND WIRE ASSEMBLY ROOF DOOR GROUND WIRE PLUG PLASTIC 1 375 GASKET EXTRUDED TRIM PLATE HOT GROMMET 2 75 X 1 16 EXTERNAL CONNECTION BOX POWER BLOCK HARNESS GENERATOR TO EXTERNAL CONNECTION BOX HARNESS GENERATOR TO EXTERNAL CONNECTION BOX 7KW SCREW PPHM 10 32 X 1 WASHER LOCK 10 WASHER FLAT M5 NUT HEX 10 32 STEEL FUEL LINE 3 4 OUTDOOR NOT SHOWN WASHER SHAKPROOF EXT 1 4 STEEL NUT HEX M6 1 0 G8 YELLOW CHROME HINGE LIFT OFF TYPE A KNUCKLE HINGE LIFT OFF TYPE B KNUCKLE SCREW HHTR 1 4 20 X 3 4 SCREW HHC M8 1 25 X 25 WASHER FLAT 5 16 NUT HEX M8 1 25 SELF ALIGN SCREW M6 HH PANEL EXHAUST ALIGNMENT GROMMET 38 1 CROSS SLIT WITH HOLE BRACKET REGULATOR MOUNTING SCREW HHC M8 1 25 X 16mm PAGE 2 OF2
40. DUAL SEC 3Q q 225 224 13A O 1 BATTERY CHARGE 66 WINDING 4 C2 2 ENGINE RUN 22 225A 224A 225A 224 14 0 0 HTO 0 WINDING STATOR C2 3 14 23 o 7 cO AR N 2 BA 66A 239 CONTROL PRINTED CIRCUIT BOARD Air cooled 7 kW 12 kW and 15 kW Generators Electrical Schematic 7 kW Drawing No 0D9014 C Section 6 Electrical Data ELECTRICAL DATA lt 2 6 2 lt 225A N2 EN NI 240VAC UTILITY 56VA 2 N2 INPUT NI E 12Vd C 225 69 TRANSFER 1VA RELAY d 224 1 CUSTOMER CONNECTIONS 13 17 lt gt NEUTRAL 23 OK 17 33 POWER 120V WINDING 120V STATOR 4 L sm p Ll 5 240V M 13 RED i C1 2 0 SC ENS lt 56 C1 1 BATTERY 15 1 6 BLACK SUPPLIED SP 31 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Enclosure Drawing No 0 0080 LISTS PARTS der G PRE PACKAGED UNITS ONLY ITEM PART NO 1 0C6140 0D1901 2 0C6735 3 0 0063 4 0C7062 0C7062A 5 0 8811 0 8811 6 0 9873 T 0 7065 0 7065 8 0C8101A 0C8861 9
41. E FOAM BACK INTAKE BAFFLE 7KW FOAM BACK ENCL STRIP FOAM EXHAUST SIDE ENCLOSURE END FOAM EXHAUST SIDE ENCLOSURE FRONT FOAM EXHAUST FAN HOUSING WASHER SELF LOCKING WASHER SELF LOCKING 7KW FOAM FRONT EXHAUST ENCLOSURE COVER FOAM BACK EXHAUST ENCLOSURE COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE LIFT OFF TYPE A PIN HINGE LIFT OFF TYPE B PIN LATCH QUARTER TURN NON LOCKING WASHER NYLON 250 WASHER LOCK M6 1 4 WASHER FLAT 1 4 ZINC 047411 047411 043116 043116 0D3700 0D3700 0D4662 090388 092120 0D3167 0A3328 055414 092079 0A1658 002937 086729 0388040AJ0 022127 022129 022129 074908 0D2346 0D2345 023484F 022142 0A7836 0A8475 0912970069 0912970070 055450 0E5968 0D3701 0D3472 008742 0 8911 008442 008652 036937 022152 051713 022158 003031 026850 049813 002537 002538 0 2874 043107 022145 045771 0C3906 0E4321 0E1330A 0E9692 042907 NN N ONON N N OO Rh cl lI N GROUP DESCRIPTION RIVET POP 0 125 X 0 337 SCREW HHC M6 1 0 X 16 G8 8 SCREW M6 1 0 X 16 68 8 7KW SCREW HHC M6 1 0 X 12 G8 8 SCREW HHC M6 1 0 X 12 68 8 7KW NUT LOCKING FLANGE M6 1 0 NUT LOCKING FLANGE M6 1 0 7KW SCREW 8 1 2 X 20 BP SCREW TAPTITE 1 0 X 12 BP SCREW TAPTITE 6 1 0 12 BP 7KW NUT LOCK TRIC M6 X 1 0 YIZNC G
42. E ASSEMBLY POTTED REGULATOR RELAY 12V 25A SPST BLOCK 1 POSITION HEX STAND OFF 46 32 x 3 8 ASSEMBLY HOME STANDBY CONTROLLER ASSEMBLY HOME STANDBY CONTROLLER 7KW HOLDER FUSE FUSE 15AMP X AGC15 SWITCH ROCKER DPDT ON OFF ON CIRCUIT BREAKER MOUNTING BRACKET SNAP BUSHING SCREW PPHM 4 0 7 x 16mm NUT HEX LOCK M4 0 7 NYLON INSERT SCREW M3 0 5 X 8mm SCREW PPHM M3 0 5 X 8mm 7KW DECAL CONTROL PANEL NOT SHOWN CIRCUIT BREAKER 3 X 1 ETA 46 500 CIRCUIT BREAKER 2 5 X 1 ETA 46 500 P 7KW CONTROL PANEL BOTTOM CONTROL PANEL BOTTOM 7KW SCREW HHC M5 0 8 x 30mm SWITCH SPST ON ON N O NUT HEX LOCK M3 0 5 NYLON INSERT NUT HEX LOCK M3 0 5 NYLON INSERT 7KW PARTS Ce LISTS Control Panel Drawing 0E7974 G 0 ITEM PART NO QTY DESCRIPTION 24 0D8502 1 NEUTRAL CONNECTOR 26 0D8441 1 HARNESS CONTROL PANEL NOT SHOWN 0 0120 1 HARNESS CONTROL PANEL WIRE NOT SHOWN 7KW 27 074908 4 SCREW M5 0 8 x 10 BP 29 082025 6 NUT HEX LOCK M5 0 8 NYLON INSERT 30 0C3910 1 TRANSFORMER 31 022507 2 SCREW HHC 1 4 20 x 1 2 32 099727 1 FUSE 5A X AGC5 33 046689 1 BLOCK TERMINAL STRIP 20 4 X 6 X 1100V 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 35 075475 2 SCREW PPHM 4 0 7 x 10mm 36 043180 2 WASHER FLAT M4 37 0D8439 1 COVER CONTROL PANEL COMPONENT 0 0119 1 COVER CONTROL PANEL COMPONENT 7KW 38 092036 8 SCREW PPHMS LW 46 32 x 1 4 39 045770 2 SCREW 5 0 8 x10mm
43. GENERAG POVVER 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 NARRAR AA AAA DN VVVVVV VVVVVV GENERAC POWER SYSTEMS INC This manual should remain with the unit N Not intended for use as Primary Power in place of utility N or in life support applications DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY 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 instal lation This generator will operate using either vapor withdrawn liquid propane LP or natural gas READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them
44. Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold
45. ING HANDBOOK avail able from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCEOFFARM STANDBYELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Section 1 General Information GENERAL INFORMATION A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and Air cooled 7 kW 12 kW and 15 kW Generators 1 22 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that regulations protect it against potentially damaging conditions 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage 1 Low Oil Pressure Sensor 3 Overcrank 2 High Temperature Sensor 4 Overspeed There are LED readouts on the control panel to notify personnel that one of these faults has occurred There is also a System Set LED that is described below This standby generator set has been factory sup plied with a weather protective enclosure that is intended for outdoor installation only
46. IPTION 1 0C1069 5 SCREW TAPTITE M6 1 0X8 YELLOW CHROME 2 0D2922 1 HOUSING BLOWER 3 0C8435 1 TUBE DIPSTICK 4 0C9997 1 GUARD FAN 5 088434 1 WRAPPER BOTTOM 6 045756 11 SCREW TAPTITE M6 1X10 YELLOW CHROME 7 0C4176A 1 WRAPPER TOP 8 0D9004A 1 ASSY STARTER 9 059985 2 SCREW SHC M8 1 25 X 45 12 9 10 022129 3 WASHER LOCK M8 5 16 11 0C2458A 1 BACKPLATE L F D F 12 083512 1 SCREW TAPTITE M8 1 25 X 16 BP 13 0D1401A 1 BREATHER TUBE 14 091039 1 GASKET INTAKE ADAPTER 15 0C9619 1 ASSEMBLY PLASTIC CARB 16 049811 2 WASHER FLAT M6 022097 4 WASHER LOCK M6 1 4 18 040945 2 SCREW SHC M6 1 0 X 20 G12 9 19 086999 1 GASKET OIL FILTR ADAPTER 20 0D5667A 1 ADAPTER OIL FILTER 21 049821 5 SCREW SHC 8 1 25 X 30 612 9 22 099236 1 SWITCH OIL 8 0 PSI 23 070185B 1 OIL FILTER 24 082774 1 KEY WOODRFF 4 X 19D 25 091222E 1 FLYWHEEL WITH RING GEAR 32DEG 26 067198N 1 WASHER BELV 20 X 2 2 27 067890 1 NUT HEX FLYWHEEL 28 0E7585 1 SPARKPLUG 29 072734 1 ASSEMBLY GOVERNOR LEVER 12 HP 30 072735 1 ROD GOVERNOR CONTROL 31 063978 1 SPRING ANTI LASH 32 0C6040 1 ASSEMBLY WIRE 33 0D9760 1 ASSEMBLY IGNITION COIL 34 092079 2 SCREW 6 1 0 X 25 BP 35 0 3800 1 SPRING GOVERNOR 36 083502 1 BOLT GOVERNOR ADJUST M5 37 082025 1 NUT HEX LOCK 5 0 8 NYINS ZINC 38 0D3083 1 ASSEMBLY OIL DRAIN HOSE 39 0E7887C 1 ASSEMBLY CAP amp DIPSTICK 40 090072 1 O RING 9 16 X 3 4 X 3 32 41 075281 1 SWITCH THERMAL 42 022145 1 WASHER FLAT 5 16 M8 43 0 20
47. LP 13 000 NG 15 000 LP 120 240 120 240 120 Volts 50 0 NG 58 3 LP 100 NG 100 0 LP 108 3 NG 125 0 LP 240 Volts 25 0 NG 29 2 LP 50 NG 50 0 LP 54 2 NG 62 5 LP Main Line Circuit Breaker 65 Amp Phase 1 Number of Rotor Poles 2 Rated AC Frequenc 60 Hz 60 Hz 60 Hz Power Factor 1 Recommended Air Filter Part 4 0C8127 Battery Requirement Group 26 26R Group 26 26R Group 26 26R 12 Volts and 12 Volts and 12 Volts and 350 Cold cranking 525 Cold cranking 525 Cold cranking Amperes Minimum Amperes Minimum Amperes Minimum Weight 487 Pounds Output Sound Level 23 ft 7m at full load 71 5 db A Normal Operating Range 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 42 F above 16 C 60 F Total current in TWO separate curcuits Current in each curcuit must not exceed the value stated for 240V 1 5 2 ENGINE Model 04673 Model 04674 Model 04675 Type of Engine GT 990 Number of Cylinders 2 Rated Horsepower 30 3 600 rpm Displacement 992cc Cylinder Block Aluminum w Cast Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Ignition System Solid state w Magneto Recommended Spark Plug RC12YC Spark Plug Gap 0 508 mm 0 020 inch Compression Ratio 9 5 1
48. M 410 32 X 1 WASHER LOCK 10 WASHER FLAT M5 NUT HEX 10 32 STEEL FUEL LINE 3 4 OUTDOOR NOT SHOWN WASHER SHAKPROOF EXT 1 4 STEEL NUT HEX M6 1 0 G8 YELLOW CHROME HINGE TYPE A WITH STUDS SOCKET HINGE TYPE B WITH STUDS SOCKET SCREW HHTR 1 4 20 X 3 4 SCREW HHC 8 1 25 X 25 WASHER FLAT 5 16 NUT HEX M8 1 25 SELF ALIGN SCREW M6 HH PANEL EXHAUST ALIGNMENT GROMMET 38 1 CROSS SLIT WITH HOLE BRACKET REGULATOR MOUNTING SCREW HHC 8 1 25 X 16mm PLATE COVER GASKET COVER 33 i us Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 0 Control Panel Drawing 0 7974 ITEM PART NO 1 0 7886 0 7886 0 78860 0 7886 0 7886 0 78860 2 0 1801 3 083049 4 0C2174 5 075210 6 003062 7 008615 008615 8 032300 9 022676 10 0 4494 11 0 7890 12 023484 13 075476 15 0 6480 17 001085 001085 18 0D8443 19 054502 053623 20 0E7870 0E7871 21 075235 22 0D5240 23 0D9784 0D9784 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators DESCRIPTION cl cl cl cl a a Da CIRCUIT BREAKER 30A X 2P 240V 7KW CIRCUIT BREAKER 40A X 2P 240V 8 5KW CIRCUIT BREAKER 45A X 2P 240V 11KW CIRCUIT BREAKER 50A X 2P 240V 12KW CIRCUIT BREAKER 60A X 2P 240V 13KW CIRCUIT BREAKER 70A X 2P 240V 15KW ASSEMBLY BATTERY CHARGER ENGIN
49. NC NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against Generac Power Systems Inc based on negligence This warranty gives purchaser owner specific legal rights Purchaser owner also may have other rights that vary from state to state Generac Power Systems Inc 8 Waukesha WI 53187 Ph 262 544 4811 Fax 262 544 4851 Bulletin 0166550SBY Printed U S A 6 04 Part No OF 33983 Revision C 11 03 05 Printed in U S A 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 THE RECOMMENDED SPARK PLUG IS CHAMPION ZRCI2YC PART NO 0G0767A P N 0G0730 REV A PRE PACKAGED UNITS ONLY EXPLODED VIEW ENCLOSURE DRAWING 0F0080 APPLICABLE TO 004674 REVISION G 2336 PART 0C6140 0D1901 0C6735 0F0063 0C7062 0C7062A 050066 0 0066 0 9873 0 7065 0 7065 0C8101A 0C8861 0C8101B 0C8862 0C8283 0C8284A 0C8284B 0C8284C 0C8285 0C8899A 0D1128 0D1128A 0E4244 0D1605A 0D1606 0D5264 0D1839 0D1840 0D2425 0D2588 0D2588A 0D2676 0D2677 0D2979B 0D2979B 0D2979C 0D2979D 0D2979E 0E4245 0D
50. RING PIN PISTON 49 0D2274 4 RETAINER VALVE SPRING ASSEMBLY CAMSHAFT amp GEAR 50 0D3867 4 SPRING VALVE SHAFT GOVERNOR 51 078672 2 SEAL VALVE STEM 07 ROLLER BEARING GOVERNOR PLATE 52 0C5371 4 WASHER VALVE SPRING ROLLER BEARING GOVERNOR 53 072694 4 STUD ROCKER ARM PIVOT ASSEMBLY GOVERNOR GEAR 54 0D3998 4 NUT HEX M8 1 0 G8 YEL CHR SPOOL GOVERNOR MACHINED 55 0C3027 2 O RING 3 8 X 1 2 GASKET CRANK CASE 56 0D5313 4 ROCKER ARM SEAL OIL PASSAGE Br 006024 2 PLATE PUSH ROD GUIDE ASSEMBLY CRANKSHAFT HORIZONTAL 58 0C2976 12 SCREW HHFC 8 1 25 X 65 DIRECT DRIVE 59 086516 2 VALVE EXHAUST ASSEMBLY CONNECTING ROD 60 0C2229 2 VALVE INTAKE SCREW SHC 6 1 0 X 50 G8 8 61 083897 4 SOLID SCREEN OIL PICKUP 62 0D8067B 1 ASSEMBLY HEAD 2 G amp S ASSEMBLY OIL PUMP 63 0098530 4 PUSHROD 147 SLEEVE SEAMED DOWEL 10 DIA 64 0C2978 2 GASKET HEAD COVER OIL RELIEF 65 043790 1 BARBED ELBOW 90 3 8NPT X 3 8 SPRING OIL RELIEF 66 0D4010 1 KIT GASKET BALL 1 2D OIL RELIEF 67 0D4011 1 KIT PISTON amp RINGS WASHER LOCK RIB M6 68 0D4012 1 KIT BREATHER ASSEMBLY GEROTOR OUTER 69 0D4013 1 KIT GOVERNOR ASSEMBLY CLAMP OIL TUBE 70 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1 ARM GOVERNOR 71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2 E RING GOVERNOR ARM 72 004015 1 KIT OIL RELIEF THRUST WASHER GOVERNOR 73 0D4016 1 po n5 n BUSHING GOVERNOR LOWER 37 Section 7 Expl
51. RT UP ADJUSTMENTS 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz 9 The governor is now set Figure 2 5 V twin Full Load Speed Adjust Screw Full Load Speed Adjust Screw 2 7 5 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corrosion inhibiting spray such as WD 40 or a comparable product 2 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62 63 5 Hertz slowly turn the slotted potentiometer Figure 2 6 until line voltage reads 244 252 volts NOTE Remove the access panel on top of the control panel to adjust the voltage regulator Figure 2 6 Voltage Adjustment Potentiometer 43 OPERATION Section 3 Operation J gt Air cooled 7 kW 12 kW and 15 kW Generators NOTE 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 5 1 BREAK IN PROCEDURE Once the unit has been installed with utility power connected to the transfer switch and all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1
52. Set the AUTO OFF MANUAL switch to AUTO 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker The unit will start and the transfer switch will transfer to standby Run the unit for one hour at 25 percent load Run the unit for one hour at 50 percent load Run the unit for one hour at 75 percent load Run the unit for one hour at 100 percent load Turn 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 Allow the unit to cool 10 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Replace the oil with synthetic oil as recommended in Section 4 3 Changing the Engine Oil 11 The generator is now ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 3 2 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also permits starting and exercising of the engine every seven days with the exercise timer see Section 3 6 This position also is used for remote starting when it is set up 3 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation Ps 3 2 3 MANUAL POSITION Set the
53. TOR ICT INTERCONNECTION TERMINALS IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC Section 6 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 12 amp 15 kW Drawing 0D8500 B ENGINE WIRING 0 IM1 IM2 85 FS BATTERY CHARGER D 224B 13A 225B 13A 225B 224B 14 14 TB 85 86 86 13 2 18 13 BLACK 12V BATTERY CUSTOMER SUPPLIED RED SM SC gt i C1 16 16 SCR 13 351 351 18 56 56 8
54. W TOOTH WSHR M8 1 25 38 0C2824 1 SCREW 10 32 x 9 16 39 025145 1 U BOLT 5 16 18 X 1 25 WITH SADDLE 40 0C4138 2 GASKET EXHAUST PORT 41 040173 2 CLAMP HOSE 5 5 0 62 0 62 42 074995 1 44 FT HOSE 1M ID LPG 350 1 UL21 43 066849 2 SCREW HHTT M5 0 8 X 16 43 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 eeu Section 7 Exploded Views and Parts Lists Qi Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Drawing No 0F3981 A Part 1 O ITEM PART N TY DESCRIPTION 1 0E3221 1 ASSEMBLY CONNECTING ROD 2 0 1466 1 PISTON 020 3 021533 1 SET PISTON RING 90MM 4 0E2985 1 PISTON HC 5 071983 2 RETAINER PISTON PIN 20 6 0E8440 1 ASSEMBLY CRANKSHAFT GH410 SMALL TAPER 7 0A7628 1 ARM GOVERNOR RC45 8 078658 1 PIN GOVERNOR ARM 9 078659 2 WASHER GOVERNOR ARM THRUST 10 088261E 1 CRANKCASE SUBASSEMBLY WITH PLUGS GH410 11 0E3812 2 SEAL 35 I D CRANKSHAFT 12 0E6519 1 ASSEMBLY GOVERNOR GEAR 13 078645 1 C RING GOVERNOR GEAR RETAINER 14 0A7811 1 SPOOL GOVERNOR MACHINE 15 0A9877 1 ASSEMBLY CAMSHAFT amp GEAR 16 076701 1 GASKET CRANKCASE 17 021713B 1 GASKET HEAD 410 18 078691 1 COVER OIL PRESSURE RELIEF 19 5771 1 SPRING OIL RELIEF 360 20 0A5776 1 BALL DIA 11 32 PRESSURE RELIEF 21 076361 1 WASHER THRUST GOVERNOR GEAR 22 0A8898D 1 ASSEMBLY COVER GEAR TOP CHECK FILL 23 0D2274 2 RETAINER VALVE SPRING
55. acts 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 A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and e Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 2 1 BEFORE INITIAL START UP Before starting complete the following 1 Set the generator s main circuit breaker to its OFF or open position 2 Setthe generator s AUTO OFF MANUAL switch to the OFF position 3 Turn
56. affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique uti lized does not render the generator unsafe Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment N Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators waRnNING A Please read hazards carefully N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and main tenance of this equipment is carried out by an Authorized Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in
57. al supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a standby source C Standby Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage 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 energizes the transfer relay in the transfer switch Retransfer to utility power source then occurs Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts tim ing The timer will run for about one minute and the generator will then shut down 5 5 MANUAL TRANSFER OPERATION 3 5 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Set the generators AUTO OFF MANUAL switch to OFF 3 Turn OFF the utility power supply to the transfer swit
58. carefully Their defini tions are as follows 19 After this heading read instructions that if not strictly complied with will result in serious person al injury including death in addition to property damage warnings amp After this heading read instructions that if not strictly complied with may result in serious person al injury or property damage After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly und
59. ch using the means provided such as a utility main line circuit breaker A AN 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 elec trical shock 4 Use the manual transfer handle inside the trans fer switch to move the main contacts to their Standby position i e loads connected to the standby power source Figure 3 2 5 To crank and start the engine set the AUTO OFF MANUAL switch to MANUAL 6 Let the engine stabilize and warm up for a few minutes 7 Set the generator s main circuit breaker to its ON or closed position The standby power source now powers the loads Figure 3 2 Manual Transfer Switch Operation LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 3 5 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generators main circuit breaker to its OFF or open position 2 Letthe engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generator s AUTO OFF MANUAL switch to its OFF or open position The engine should shut down
60. ct the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is discovered later Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators INFORMATION GENERAL 1 4 THE GENERATOR Figure 1 1 7 kW Single Cylinder GH 410 Engine La Control Oi Data eas Dipstick Decal 2 GFCI Outlet Exhaust Enclosure 5 Fuel 4 Regulator gt gt Fuel 4 Inlet U q L o o 7 Battery Composite Base Oil Filter Compartment Figure 1 2 12 kW 15 kW V twin GT 990 760 Engine Control Dipstick Outlet Exhaust Enclosure Fuel Regulator Fuel Inlet Battery Composite Base Cil Filter Compartment Section 1 General Information INFORMATION Air cooled 7 kW 12 kW and 15 kW Generators GENERAL 1 5 SPECIFICATIONS 1 5 1 GENERATOR Model 04673 Rated Max Continuous Power 6 000 NG 7 000 LP Capacity Watts Rated Voltage 120 240 Rated Max Continuous Load Current Amps Model 04674 Model 04675 12 000 NG 12 000
61. ction 6 Electrical Data 24 Section 7 Exploded Views Parts Lists 32 Section 8 Mounting Dimensions 50 Section 9 Notes 51 Section 10 Warranty 52 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 The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing 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 rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals
62. ctor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regula tions Keep a fire extinguisher near the generator at all times Extinguishers rated by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extin guisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Air cooled 7 kW 12 kW and 15 kW Generators EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure
63. e preset adjustment screw settings to achieve maximum power particularly at higher altitudes If experiencing problems with the unit producing maximum power follow the procedure in Section 2 6 Adjusting the Fuel Regulator 1 9 LOCATION 1 9 1 GENERATOR Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet open ings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drifting consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow three feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds Install the generator as close as possible to the fuel supply to reduce the length of piping Install the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE 1 9 2 TRANSFER SWITCH 1 9 2 1 7 kW 12 kW and 15 kW Units Transfer switches for use with these generators are sold separately and can be purchased from Authorized Dealers Install the transfer switch on a firm sturdy sup porting s
64. el below the Add mark on the dipstick Doing this could damage the engine Install the dipstick Reset the AUTO OFF MANUAL switch to its origi nal position Figure 4 2 Oil Dipstick and Fill 7 kW Figure 4 3 Oil Dipstick and Fill 12 kW and 15 kW Cil Dipstick Cil Fill 17 MAINTENANCE Section 4 Maintenance 45 CHANGING THE ENGINE OIL 4 5 1 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 oynthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with break in oil See the 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 recom mended oil may result in an engine failure 4 3 2 CHANGE PROCEDURE To 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 OFE 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 Oil Drain Hose and Filter AA gy S 55 N 4 UN Hose Oil Filter m 3 After the oil has drained replace the cap on
65. ency reading of 61 5 Hz Turn the secondary adjust screw to obtain a frequency reading of 62 5 Hz Set Pin Both Sides 12 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 AC voltage reading If voltage is incorrect the volt age regulator may require adjustment Figure 2 3 Single Cylinder Engine Governor Adjustment SECONDARY ADJUST SCREW GOVERNOR amp 67 pesa SHAFT m GOVERNOR 49 1 PRIMARY CLAMP ADJUST BOLT SCREW 2 1 2 12 KW AND 15 KW UNITS 1 Loosen governor clamp bolt See Figure 2 4 Figure 2 4 V twin Engine Governor Adjustment Idle Spring mU Clockwise No Load Idle Adjustment Screw Governor Clamp Bolt 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 2 5 to adjust frequency to 58 Hz o Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6 Using a hand push the governor arm to the closed throttle position Make sure the idle spring does not stretch at all POST INSTALLATION STA
66. ents be careful to avoid overspeeding the engine 4 When 3 4 load has been achieved Connect a fre 221 oj If this procedure or equipment are not available 5 The fuel regulator is fitted willvome 12 locate the nearest Authorized Dealer and they can u Or tw erform the adjustments 12 amp 15 kW adjustment screws While watching pou J the frequency meter slowly turn the adjustment screw clockwise or counterclockwise one at a time until highest frequency is read on the meter Only limited adjustment is available between the 2 ENGINE GOVERNOR ADJUSTMENT set pins Under no circumstances should any of If both AC frequency and voltage are correspondingly A service fee may be charged for this adjustment the pins be removed Figures 2 1 and 2 2 high or low adjust the engine governor as follows Figure 2 1 Dual Fuel Regulators 271 7 KW UNITS VM M 1 Loosen the governor clamp bolt Figure 2 3 2 Hold the governor lever at its wide open throttle position and rotate the governor shaft clockwise as far as it will go Then tighten the governor lever clamp bolt to 70 inch pounds 8 N m Set 3 Start the generator let it stabilize and warm up Adjustment Adjustment Screw One Side Pin at no load Both Sides P Only y 4 Connect an AC frequency meter across the gen erators AC output leads 5 Turn the primary adjust screw to obtain fre qu
67. er to check utility power source voltage across terminals N1 and N2 Nominal line to line voltage should be 240 volts AC 3 Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 4 When certain that utility supply voltage is compat ible with transfer switch and load circuit ratings turn OFF the utility power supply to the transfer switch o Set the generator s main circuit breaker to its OFF or open position Initial tests will be con ducted at no load condition 6 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 7 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator s main circuit breaker to its ON or closed position Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dan gerous and possibly fatal electrical shock 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 quency meter across transfer switch terminal lugs 1 and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz 9 Connect the AC voltmeter test leads across ter minal lug El and neutra
68. erstand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for three different models 04673 2 6 kW NG 7 kW LP single cylinder GH 410 Engine 04674 2 12 kW NG 12 kW LP V twin GT 990 Engine 04675 3 13 kW NG 15 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See the Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Dealer for assistance service technicians are factory t
69. f soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The 19 MAINTENANCE Section 4 Maintenance following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off and the 5A fuse is removed from the generator control panel or sparking may occur at the battery posts as the cables are attached causing an explosion 4 8 ADJUSTING VALVE CLEARANCE After the first six months 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 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 Make sure that the spark plug wire is removed from the
70. he generator s 1 2 terminals The transfer switch operating lever should be down o Set the generators AUTO OFF MANUAL switch to MANUAL The engine should crank and start immediately 6 Let the engine stabilize and warm up for a few minutes 7 Set the generator s main circuit breaker to its ON or closed position Loads are now powered by the standby generator POST INSTALLATION START UP ADJUSTMENTS 8 Turn ON electrical loads Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 9 Connect an accurate AC voltmeter and a frequen cy meter across terminal lugs 1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 10 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 11 When testing under load is complete turn OFF electrical loads 12 Set the generator s main circuit breakers to their OFF or open positions 13 Let the engine run at no load for a few minutes 14 Set the AUTO OFF MANUAL switch to OFF The engine should shut down 2 5 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set the generator s main circuit breaker to it s OFF or open position 2 Check that the AUTO OFF MANUAL switch is set to OFF
71. hread side first into the threaded hole originally occupied by the brass hose fitting Figure 1 4 Figure 1 4 Demand Regulator OUTLET PORTS FUEL HOSE BRASS HOSE d 4 FITTING IDLE CIRCUIT BRASS HOSE PORT r FITTING p SMALL A ts FUEL JET REGULATOR O HOUSING PORT ADJUSTER SCREWS 8 Using a short No 2 Phillips screw driver thread the small fuel jet into the regulator casting Do not over tighten 9 Apply thread sealant to the threads of the hose fitting and replace it into the regulator body 10 Re attach the small hose and hose clamp and tighten as necessary 11 Replace the engine air in baffle using the four M6 SCrews 12 Identify both brass adjustment screws on the regulator NOTE One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit enclosure by removing the plastic hole plug The screw can be turned with a long flat blade screwdriver 13 To adjust the system to run on LP fuel turn BOTH adjuster screws 1 2 TURN CLOCKWISE The system should now be set for maximum power and best perfomance DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE SET PINS FROM THE REGULATOR HOUSING THIS WILL VOID THE WARRANTY Section 1 General Information Air cooled 7 kW 12 kW and 15 kW Generators 14 It may be necessary to make minor adjustments to th
72. ion misrepresentation or bi fuel conversion 11 Telephone facsimile cell phone satellite Internet or any other communication expenses 12 Rental equipment used while warranty repairs are being performed i e rental generators cranes etc 13 Overtime holiday or emergency labor 14 Modes of transportation deemed abnormal refer to Generac Power Systems Warranty Policies Procedures and Flat Rate Manual 15 Steel enclosures that are rusting due to improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised 16 Any and all expenses incurred investigating performance complaints unless defective Generac materials and or workmanship were the direct cause of the problem 17 Starting batteries fuses light bulbs engine fluids and overnight freight cost for replacement part s THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED IMPLIED SPECIFICALLY GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to purchaser owner GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS I
73. kW and 15 kW Generators Electrical Schematic 12 amp 15 kW Drawing No 0D8501 B C2 6 22 lt TX C2 5 225A N2 N1 240VAC UTILITY 56VA T N2 GO INPUT 224A is 225 12Vdc 1VA TRANSFER RELAY 194 5 224 N1 CUSTOMER CONNECTIONS 13 17 11 23 22 15A r 33 O 0 A SW1 15A 194 POWER 120V WINDING 120V 239 STATOR 13 17 15 44 194 11 9 6 15 239 0 240V 14 15 e 13 RED e 0 C2 1 13 sc i 56 16 lt 16 14 18 C1 1 m mem 0 0 0 BLACK 15 CUSTOMER 0 IM1 SUPPLIED 18 w SP D lt 18 1 5 gt SP2 NNN ELECTRICAL DATA 27 lt ELECTRICAL DATA gt Section 6 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 7 kW Drawing 0D9013 C
74. ket is in place e Re attach the spark plug wire to the spark plug e Repeat the process for the other cylinder 4 9 COOLING SYSTEM Air inlet and outlet openings in the generator compart ment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 4 9 for vent locations Figure 4 9 Cooling Vent Locations AIR 4 4 d e e ttt AIR INTAKE Air cooled 7 kW 12 kW and 15 kW Generators wanNiNG amp The exhaust from this product gets extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system caution amp The maximum ambient temperature for the generator is 48 9 C 104 F 4 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it MUST NOT be started and operated Following any submersion in water have an Authorized Dealer thoroughly clean and dry the generator 4 11 CORROSION PROTECTION Periodically wash and wax the enclosure using automo tive type products Frequent washing is recommended in salt water coastal areas Spray engi
75. l then across E2 and neutral In both cases voltage reading should be 121 126 volts AC 10 Set the generator s main circuit breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 11 Set the generator s AUTO OFF MANUAL switch to OFF The engine should shut down NOTE It is important not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is cor rect but voltage is high or low the generator s voltage regulator requires adjustment 2 4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Set the generators AUTO OFF MANUAL switch to OFF 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker waRNING Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 4 Manually set the transfer switch to the STANDBY position i e load terminals connected to t
76. lla sil 77 162 0 I I 4 225B 225B 10 lt 224B 224B 0 m 2 66 6 11 14 14 8 lt 4 6 7 T 55 11 6 lt 66 11 11 22 5 lt 77 225 1 Bs T 66 I 66 0 77 0 11 4 4 3 2 0 0 2 lt 224 M i 1 44 162 162 55 C2 VOLTAGE REGULATOR 4 66A 0 0 66A 4 55 N2 N1 33 13 225 0 351 224 0 194 23 N2 66A is N1 1 44 23 i 11 13A 194 351 15A 22 m 194 0 1 13 66 239 F2 F1 _ i lt 2 5 17 13 239 0 2 SW1 m po 15 mv ele 8 B 2 8 Gd AUTO 240V GENERATOR m gt OUTPUT TO TRANSFER m lt SWITCH CONTACTOR CUSTOMER MANUAL CONNECTION Section 6 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators ELECTRICAL DATA gt Electrical Schematic 7 kW Drawing 0D9014 C gt BATTERY CHARGER 11 4 FIELD J ELECTRONIC 4 C2 10 C2 9 VOLTAGE 4 REGULATOR DPE WINDING STATOR DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HTO HIGH OIL TEMPERATURE SWITCH HM HOUR RUN METER IM IGNITION MODULE LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SP SPARK PLUG SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA
77. n opera tion Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical sys tem After installing this home standby electrical sys tem the generator may crank and start at any time without warning When this occurs load cir cuits are transferred to the STANDBY generator power source To prevent possible injury if such a start and transfer occur always set the generator s AUTO OFF MANUAL switch to its OFF position before working on equipment and remove the 5A and 15A fuses from the generator control panel In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live condu
78. ne linkages with a light oil such as WD 40 4 12 OUT OF SERVICE PROCEDURE 4 12 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer than 90 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 Once the unit has shut down it will signal a low oil fault 4 Setthe AUTO OFF MANUAL switch to OFF and turn off the utility power to the transfer switch o While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations Section 4 3 1 6 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 7 Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s 8 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 9 Clean and wipe the entire generator MAINTENANCE S Section 4 Maintenance 4 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Verify that utility power is turned off and that the AUTO OFF MANUAL switch is set to OFF 3 Check the tag on the
79. ner Location Fuel Air Cleaner Regulator Air cooled 7 kW 12 kW and 15 kW Generators Figure 4 7 12 kW and 15 kW Engine Air Cleaner 4 6 SPARK PLUG 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 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 condi tion Replace the spark plug s if worn or if reuse is questionable See Section 4 13 for recommend ed inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 inch for 7 kW and 0 50 mm 0 020 inch for 12 15 kW by carefully bending the ground electrode Figure 4 8 Figure 4 8 Setting the Spark Plug Gap SET PLUG GAP AT 0 76 mm 0 50 mm 0 030 inch 0 020 inch was 7 lt VAS w oe A X MAINTENANCE S Section 4 Maintenance 4 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 13 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE T
80. noncompliance with such codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator The generator MUST be installed outdoors When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Dealer for parts needing repair or replacement Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS A 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 i
81. nty 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 b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS
82. oded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators GT 990 760 Engine Drawing No 0E8774 M Part 2 110 9 NS 9 j TESH N gt VNI lt KG NO 7 A SEE a Y Xo SC IN N MB SN VOS 2 0 lt 7 7 2 2 ITEM PART NO 74 0C5136A 75 003024 76 003040 77 068127 78 008564 0D8564B 79 0D2595 80 0D4417 81 003025 82 0D3083 83 007292 84 070185B 85 075281 86 0 2094 87 88 035461 89 0 6301 90 0 9806 91 003026 92 009764 93 0C3043 94 0C7694 95 0C7693 96 0C3041A 97 070008 98 070006 99 040976 100 0C3016A 101 0E4997 102 0C3725B 103 0 3031 104 0C3032 105 0A5992 106 051754 107 0C3033 108 0C3034 109 0C8549A 110 0C3022A A Po Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators PARTS Ce LISTS GT 990 760 Engine Drawing No 0E8774 M Part 2 0 DESCRIPTION ITEM PART NO QTY DESCRIPTION KNOB AIR CLEANER 111 0D1131 1 GUARD COVER AIRBOX NG LP 112 045756 25 SCREW TAPTITE M6 1X10 YELLOW PRE CLEANER CHROME ELEMENT AIR CLEANER 113 0 9763 4 NUT GROMMET 1 4 PLUG ASSEMBLY MIXER AIRBOX 990 114 0C3036A 1 HOSE BREATHER ASSEMBLY MIXER AIRBOX 760 115 022145 1 WASHER FLAT 5 16 M8 ZINC SCREW SHOULDER 8MM M6 1 0 X 18 116 022129 1 WASHER LOCK M8
83. or has been factory set to pro now set vide maximum power it may be necessary in some areas to adjust this setting Because natural gas has Figure 2 2 Placement of Regulator different BTU or power content across the country the engine may not perform as designed If experiencing engine problems at high or full load conditions follow these steps It will require a fre quency meter to perform this procedure 1 Turn off utility power to the main distribution panel in the house This can be done by switching 555950006 YAY RASA AI KX YY the service main breaker to the off or open posi tion WAQ 2 Allow the generator to start before loading the generator Confirm the no load frequency with the roof open and door off is set at 63 63 5 Hz Transfer load to emergency circuits N Turi on appliances lights JH etc that are 7 Turn utility power to the main distribution panel on the emergency circuits in an attempt to fully back on This can be done by switching the ser load the generator Be ner te overload vice main breaker to the on or closed position the generator Use the following chart as a guide Allow the generator to shut down 240 Volts warninc amp Do not make unnecessary adjustments Factory settings are correct for most applica tions However when making adjustm
84. rained and are capa ble of handling all service needs When contacting an Authorized Dealer about parts and service always supply the complete model num ber and serial number of the unit as given on its data decal which is located on the generator See Figure 1 1 or Figure 1 2 in Section 1 4 for decal location Model No Serial No AUTHORIZED DEALER LOCATION locate the nearest AUTHORIZED DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com Air cooled 7 kW 12 kW and 15 kW Generators Introduction Inside Front Cover Read This Manual Thoroughly IFC IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC Safety Rules 2 Standards Index 3 Section 1 General Information 4 1 1 Hu packmeslnspecuUOli 2 122 Proteccion SysteMS sessen 4 L3 System Sel LED 4 LA VOU Gen Tal uuu uka Q ass 5 6 I 6 1222 Fi il T I 6 1 6 Fuel Requirements Recommendations 7 1 7 Fuel Consumption 7 1 8 Reconfiguring the Fuel System 7 P MED E D pom 7 1 8 2 1
85. rator s AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Section 3 4 Sequence of Automatic Operation 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors util ity power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to acti vate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs 1 2 OPERATION Section 5 Operation Air cooled 7 kW 12 kW and 15 kW Generators J gt 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 The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 60 percent of the nomin
86. s 12 kW and 15 kW Generator Drawing No 0D3417 L O ITEM PART N TY DESCRIPTION 1 0C6934 1 ADAPTOR ENGINE 2 0C7930 1 STATOR 12KW 0D2359 STATOR 13KW 15KW 3 0C7944 1 12KW 002356 ROTOR 13KW 15KW 4 0C6043 1 CARRIER REAR BEARING 5 002336 1 FAN 12 CURVED BLADE 6 006634 1 MUFFLER 7 0D3220 1 TAIL PIPE MUFFLER 8 068101 1 PANEL MUFFLER 9 056482 1 BEARING 1 1811 2 8346 10 003168 5 5 16 SPECIAL LOCK WASHER 11 001838 1 BOLT HHCS 3 8 24 x 15 50 12 0D1846 4 BOLT 8 1 25 x 345mm 13 0C7038 1 BRACKET ALTERNATOR MOUNTING 14 0D1609 1 DUCT ALTERNATOR AIR 15 0D2559 1 GASKET ALTERNATOR AIR DUCT 16 0C7038A 1 BRACKET ENGINE MOUNTING 17 0 7758 4 RUBBER MOUNT 18 0388050AD0 1 CABLE 6 48 BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VYNL COAT 0 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 2 6 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 40610 X 1 6200 24 022237 5 WASHER LOCK 3 8 25 022511 4 SCREW 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 051731 4 SCREW HHC 8 1 25 X 50 G8 8 28 022145 12 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX M8 1 25 NYL INSERT 30 045756 2 SCREW M6 1 0X10 31 022129 10 WASHER LOCK 8 5 16 32 022259 8 NUT 5 16 18 STEEL 33 059637 2 SCREW TAPTITE 3 8 16 X 3 4 BP 34 0D4662 4 SCREW 5 16 18 3 4 HH THD ROLL 35 0 7065 HOSE RES 1 2 LP GAS 36 048031M 4 HOSE CLAMP 3 4 I D 37 0 0462 4 NUT HEX
87. spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen at the front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in lbs torque After tightening the jam nut recheck valve clearance to make sure it did not change eo Air cooled 7 kW 12 kW and 15 kW Generators Figure 4 10 Valve Clearance Adjustment Rocker Pivot Ball Jam Nut S 2 SD Install new valve cover gasket e Re attach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gas
88. spark plug s 3 Fuelregulator not set 4 Fuel pressure incorrect 1 Defective switch 2 AUTO OFF MANUAL switch cA P m wired incorrectly Defective control board Main line circuit breaker open Generator internal failure Defective transfer switch coil Defective transfer relay Transfer relay circuit open Defective control logic board Break in procedure not followed see Section 2 1 TROUBLESHOOTING CORRECTION 1 Replace 15A fuse on generator control panel 2 Tighten clean or replace as necessary o 4 o Charge or replace battery 1 Replenish fuel 7 a 4 Clean re gap or replace plug s 5 Reset valve lash 1 Check replace air cleaner 2 Clean re gap or replace plug s 3 Set fuel regulator 4 Confirm fuel pressure is at 10 12 water column 0 36 0 43 psi for LP and 5 7 water colum 0 18 0 25 psi for natural gas 2 5 1 Reset circuit breaker to ON or closed PES be 2 9 4 1 Contact the nearest Authorized Dealer for assistance 23 ELECTRICAL DATA lt 5 2 SP1 DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION D DIODE DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNEC
89. ssary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service Schedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly connected and terminals are tight Observe battery polarity when connecting the battery to the generator set A Do not dispose of the battery fire battery is capable of exploding A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles e Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or disconnecting battery terminals wanNiNG Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive POST Section 2 Post Installation Start up and Adjustments INSTALLATION Air cooled 7 kW 12 kW and 15 kW Generators ADJUSTMENTS The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte cont
90. switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure Figure 3 1 Generator Control Panel FUSE Locate your nearest GENERAC dealer at www generac com GENER AC power systems INC AUTO OFF MAN SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK 15A SET FLASHING GREEN LED EXERCISE 4 FLA SHING RED LEDS _ TIME XERCISER NOT SET amp With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a pre set level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove both fuses before working on or around the generator or transfer switch Then place a Do Not Operate tag on the generator panel and on the transfer switch 5 5 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source Figure 3 2 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the gene
91. that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids such as natural gas and liquid pro pane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applicable fuel gas codes Before placing the home standby electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation inspect the fuel system periodically for leaks No leakage is permit ted STANDARDS INDEX In the absence of pertinent standards codes regu lations and laws the published information listed below may be used as installation guide for this equipment l NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIR
92. tility 1 1 15 9 0 Setting Exercise Timer 16 9 7 Protec on 16 3 7 1 Low Oil Pressure Switch 16 3 7 2 High Temperature Switch 16 9 9 16 rrr ene 17 Section 4 Maintenance 17 Ak PUG c 17 4 2 Checking the Engine Level 4 9 Changing the Engine Oil 17 4 3 1 Engine Oil Recommendations 17 4 3 2 Oil Change Procedure 18 4 4 Changing the Oil Filter 18 4 5 Changing the Engine Air Cleaner 18 4 5 1 7 kW 12 kW and 15 kW 18 ee eee 19 4 7 Battery Maintenance 19 4 8 Adjusting Valve Clearance 20 Cooling SyS 20 4 10 Attention After Submersion 21 4 11 Corrosion Protection 21 4 12 Out of Service Procedure 21 4 12 1 Removal From Service 21 4 12 2 Return to Service 21 4 13 Service SeDedule uuu us uu n 22 Section 5 Troubleshooting 23 5 1 Troubleshooting Guide 23 Se
93. to the end of the oil drain hose Retain the hose in the clip 4 with the proper recommended oil see section 4 3 1 See Section 1 5 2 for oil capaci ties 18 Air cooled 7 kW 12 kW and 15 kW Generators 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean engine oil to the gasket of the new filter See Section 1 5 1 for rec ommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 4 4 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 for oil capaci ties 5 Start the engine and check for leaks 4 5 CHANGING THE ENGINE AIR CLEANER 4 51 7 KW 12 KW AND 15 KW GENERATORS See Figures 1 1 and 1 2 for the location of the air cleaner Use the following procedure Figure 4 6 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule Section 4 13 for air cleaner maintenance See Section 1 5 1 for air filter replacement part number Figure 4 6 7 kW Engine Air Clea
94. tructure To prevent switch distortion level the switch if necessary This can be done by placing washers between the switch enclosure and mounting sur face Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors Failure to utilize the manufacturer s transfer switch with this generator may void the warranty 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 Setthe 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 con trol panel If the AUTO OFF MANUAL switch is not set to its OFF position the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off spark ing can occur at the battery posts and cause an explosion Battery cables were factory connected at the genera tor Figure 1 5 Connect cables to battery posts as follows 4 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame
95. z 08 22 16262 v02 E LINN GNNOYV TIV V3uv 340 WANININ 0 98 6 131110 uiv 50 Section 9 Notes Air cooled 7 kW 12 kW and 15 kW Generators NOTES 5 Section 10 Warranty WARRANTY 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 In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modifica tion or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related

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