Generac Power Systems Portable Generator 04758 0 User Manual

Installation and  
Owner’s Manual  
Air-cooled Automatic  
Standby Generators  
Models:  
04758-0 (6 kW NG, 7 kW LP)  
04759-0 (12 kW NG, 12 kW LP)  
04760-0 (13 kW NG, 15 kW LP)  
Not intended for use as Primary Power in place of utility  
!
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or in life-support applications.  
DANGER  
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!  
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Table of Contents  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
3.2.2 “Off Position....................................14  
3.2.3 “Manual” Position ............................14  
3.3 Automatic Transfer Operation ....................14  
3.4 Sequence of Automatic Operation................14  
3.5 Manual Transfer Operation ........................15  
Introduction ........................Inside Front Cover  
Read This Manual Thoroughly ........................IFC  
Contents ..........................................................IFC  
Operation and Maintenance ............................IFC  
How to Obtain Service ....................................IFC  
Authorized Dealer Locator Number ....................IFC  
3.5.1 Transfer to Generator  
Safety Rules ........................................................2  
Standards Index..................................................3  
Power Source......................................15  
3.5.2 Transfer Back to Utility  
Section 1 – General Information ..................4  
1.1 Unpacking/Inspection ....................................4  
1.2 Protection Systems ........................................4  
1.3 System Set LED ............................................4  
1.4 Your Generator ..............................................5  
1.5 Specifications ................................................6  
1.5.1 Generator ..........................................6  
1.5.2 Engine ................................................6  
1.6 Fuel Requirements and Recommendations....7  
1.7 Fuel Consumption ........................................7  
1.8 Reconfiguring the Fuel System ......................7  
1.8.1 7 kW, 410CC ......................................7  
1.8.2 12 kW and 15 kW, 990cc Engines ......7  
1.9 Location ........................................................8  
1.9.1 Generator ..........................................8  
1.9.2 Transfer Switch..................................8  
1.10 Battery Installation ........................................9  
1.11 The Battery....................................................9  
Section 2 – Post Installation Start-up  
Power Source......................................15  
3.6 Setting the Exercise Timer ..........................16  
3.7 Protection Systems ......................................16  
3.7.1 Low Oil Pressure Switch ..................16  
3.7.2 High Temperature Switch ................16  
3.7.3 Overcrank ........................................16  
3.7.4 Overspeed ........................................16  
Section 4 – Maintenance ..............................17  
4.1 Fuse ............................................................17  
4.2 Checking the Engine Oil Level ....................17  
4.3 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  
Generators........................................18  
4.6 Spark Plug(s) ..............................................19  
4.7 Battery Maintenance....................................19  
4.8 Adjusting Valve Clearance............................20  
4.9 Cooling System............................................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 Schedule ........................................22  
and Adjustments ......................10  
2.1 Before Initial Start-up..................................10  
2.2 Check Transfer Switch Operation................10  
2.3 Electrical Checks ........................................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  
2.7.1 7 kW Units ......................................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 5 – Troubleshooting ........................23  
5.1 Troubleshooting Guide................................23  
Section 6 – Electrical Data............................24  
Section 7 – Exploded Views and  
Parts Lists....................................32  
Section 3 – Operation ....................................13  
3.1 Break-in Procedure......................................13  
3.2 Using the Auto/Off/Manual Switch ..............14  
3.2.1 Auto” Position..................................14  
Section 8 – Mounting Dimensions..............50  
Section 9 – Notes ............................................51  
Section 10 – Warranty....................................52  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Guardian 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.  
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GENERAL HAZARDS  
WARNING:  
The engine exhaust from this product  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
• For safety reasons, Generac recommends  
that the installation, initial start-up and  
maintenance of this equipment is carried out by a  
Generac 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 sys-  
tem must be installed properly, in strict compli-  
ance with applicable codes and standards.  
Following installation, you must do nothing that  
might render the system unsafe or in noncompli-  
ance 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 you  
are physically or mentally fatigued.  
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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  
installing, operating or servicing this equipment.  
Become familiar with this Owner’s Manual and with  
the unit. The generator can operate safely, efficiently  
and reliably only if it is properly installed, operated  
and maintained. Many accidents are caused by failing  
to  
follow  
simple  
and  
fundamental  
rules  
or precautions.  
Generac cannot possibly anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals  
affixed to the unit are, therefore, not all-inclusive. If  
you use a procedure, work method or operating tech-  
nique Generac does not specifically recommend, you  
must satisfy yourself that it is safe for you and others.  
You also must make sure the procedure, work  
method or operating technique that you choose does  
not render the generator unsafe.  
• Inspect the generator regularly, and contact your  
nearest Generac Authorized Dealer for parts need-  
ing repair or replacement.  
• Before performing any maintenance on the genera-  
tor, disconnect its battery cables to prevent acci-  
dental start up. Disconnect the cable from the bat-  
tery 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.  
DANGER  
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.  
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.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
• Keep a fire extinguisher near the generator at all  
times. Extinguishers rated ABC” 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 you have any question pertaining to fire  
extinguishers, consult your local fire department.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce  
dangerous electrical voltages and can cause fatal  
electrical shock. Utility power delivers extremely  
high and dangerous voltages to the transfer switch  
as does the standby generator when it is in opera-  
tion. Avoid contact with bare wires, terminals, con-  
nections, etc., while the unit is running. Ensure all  
appropriate covers, guards and barriers are in  
place before operating the generator. If you must  
work around an operating unit, stand on an insu-  
lated, dry surface to reduce shock hazard.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure 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  
propane (LP) gas are extremely EXPLOSIVE.  
Install the fuel supply system according to applica-  
ble fuel-gas codes. Before placing the home stand-  
by electric system into service, fuel system lines  
must be properly purged and leak tested according  
to applicable code. After installation, you must  
inspect the fuel system periodically for leaks. No  
leakage is permitted.  
• 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 system.  
• After installing this home standby electrical sys-  
tem, the generator may crank and start at any time  
without warning. When this occurs, load circuits  
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.  
STANDARDS INDEX  
In the absence of pertinent standards, codes, regula-  
tions and laws, the published information listed  
below may be used as installation guide for this  
equipment.  
• 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 conductor. 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.  
1. NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES, available from  
the National Fire Protection Association, 470  
Atlantic Avenue, Boston, MA 02210.  
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-  
TEMS FOR HEALTH CARE FACILITIES, avail-  
able same as Item 1.  
3. NFPA No. 54, NATIONAL FUEL GAS CODE,  
available same as Item 1.  
4. NFPA No. 58, AMERICAN NATIONAL STANDARD  
FOR STORAGE AND HANDLING OF LIQUEFIED  
PETROLEUM GAS, available same as Item 1.  
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL  
ELECTRIC CODE, available same as Item 1.  
6. Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85  
John Street, New York, N.Y. 10038.  
7. AGRICULTURAL WIRING HANDBOOK, available  
from the Food and Energy Council, 909  
University Avenue, Columbia, MO 65201.  
8. ASAE EP-3634, INSTALLATION AND MAINTE-  
NANCE OF FARM STANDBY ELECTRICAL SYS-  
TEMS, available from the American Society of  
Agricultural Engineers, 2950 Niles Road, St.  
Joseph, MI 49085.  
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 regu-  
lations.  
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE, available same as Item 1.  
3
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Section 1 — General Information  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.2 PROTECTION SYSTEMS  
DANGER  
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  
protect it against potentially damaging conditions:  
Only qualified electricians or contractors should  
attempt such installations, which must comply  
strictly with applicable codes, standards and  
regulations.  
!
1. Low Oil Pressure Sensor  
2. High Temperature Sensor  
There are LED readouts on the control panel to noti-  
fy you that one of these faults has occurred. There is  
also a “System Set” LED that is described below.  
3. Overcrank  
4. Overspeed  
1.1 UNPACKING/INSPECTION  
After unpacking, carefully inspect the contents  
for damage.  
• This standby generator set has been factory sup-  
plied with a weather protective enclosure that is  
intended for outdoor installation only.  
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  
circuits normally powered by a utility power  
source, you are required by code to install a  
transfer switch. The transfer switch must effec-  
tively isolate the electrical system from the util-  
ity distribution system when the generator is  
operating (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 injury or death to utility power work-  
ers due to backfeed of electrical energy.  
1. The Auto/Off/Manual switch is set to the AUTO  
position.  
2. The utility voltage being supplied to the unit is  
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.  
3. The “Not In Auto” dip switch is set to the OFF  
position on the control board.  
If any loss or damage is noted at time of delivery, have  
the person(s) making the delivery note all damage on  
the freight bill or affix his or her signature under the  
consignor's memo of loss or damage.  
4. No alarms are present, for example, low oil pres-  
sure, high temperature, etc.  
If you note loss or damage after delivery, separate the  
damaged materials and contact 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.  
4
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Section 1 — General Information  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.4 YOUR GENERATOR  
Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine  
Control Panel  
Data Decal  
Exhaust  
Enclosure  
Air Filter  
Fuel Regulator  
Battery Compartment  
Oil Filter  
Figure 1.2 – 12 kW/15 kW, V-twin GT-990 Engine  
Data  
Decal  
Control  
Panel  
Oil Dipstick  
Air Filter  
Exhaust  
Enclosure  
Fuel Regulator  
Battery Compartment  
Oil Filter  
5
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Section 1 — General Information  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
1.5 SPECIFICATIONS  
1.5.1 GENERATOR  
Model 04758  
6,000 NG/7,000 LP  
120/240  
Model 04759  
12,000 NG/12,000 LP 13,000 NG/15,000 LP†  
Model 04760  
Rated Max. Continuous Power Capacity (Watts*)  
Rated Voltage  
120/240  
120/240  
Rated Max. Continuous Load Current (Amps)  
120 Volts +  
50.0 NG/58.3 LP  
100.0 NG/100.0 LP  
108.3 NG/125.0 LP  
240 Volts  
25.0 NG/29.2 LP  
50.0 NG/50.0 LP  
54.2 NG/62.5 LP  
Main Line Circuit Breaker  
Phase  
Number of Rotor Poles  
Rated AC Frequency  
Power Factor  
30 Amp  
50 Amp  
70 Amp  
1
2
1
2
1
2
60 Hz  
1
60 Hz  
1
60 Hz  
1
Recommended Air Filter  
Battery Requirement  
Generac Part # C8127 Generac Part # C8127 Generac Part # C8127  
Group 26/26R  
12 Volts and  
Group 26/26R  
12 Volts and  
Group 26/26R  
12 Volts and  
350 Cold-cranking  
Amperes Minimum  
550 Cold-cranking  
Amperes Minimum  
550 Cold-cranking  
Amperes Minimum  
Weight  
452 Pounds  
68 db (A)  
470 Pounds  
70.5db (A)  
-20°F (-28.8°C) to 104°F (40°C)  
487 Pounds  
71.5 db (A)  
Output Sound Level @ 23 ft (7m) at full load  
Normal Operating Range  
* 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 (10° 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 04758  
GH-410  
Model 04759  
GT-990  
Model 04760  
GT-990  
Type of Engine  
Number of Cylinders  
Rated Horsepower  
Displacement  
1
2
2
14.5 @ 3,600 rpm  
410cc  
30 @ 3,600 rpm  
992cc  
30 @ 3,600 rpm  
992cc  
Cylinder Block  
Aluminum w/Cast  
Iron Sleeve  
Aluminum w/Cast  
Iron Sleeve  
Aluminum w/Cast  
Iron Sleeve  
Valve Arrangement  
Ignition System  
Recommended Spark Plug  
Spark Plug Gap  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
Overhead Valves  
Solid-state w/Magneto  
RC12YC  
0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.508 mm (0.020 inch)  
Compression Ratio  
Starter  
8.6:1  
12 Vdc  
9.5:1  
12 Vdc  
9.5:1  
12Vdc  
Oil Capacity Including Filter  
Recommended Oil Filter  
Recommended Air Filter  
Operating RPM  
Approx. 1.5 Qts  
Approx. 2.5 Qts  
Approx. 2.5 Qts  
Generac Part # 70185 Generac Part # 70185 Generac Part # 70185  
Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127  
3,600  
3,600  
3,600  
6
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Section 1 — General Information  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
3. Disconnect wire #0 and wire #14 from the gas  
1.6 FUEL REQUIREMENTS  
solenoid located on the top of the demand regu-  
lator.  
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.  
4. Remove the demand regulator by rotating coun-  
terclockwise.  
5. Remove the brass hose fitting from the outlet port  
of the demand regulator.  
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 1.8 for instructions on reconfiguration of the  
fuel system.  
Recommended fuels should have a Btu content of at  
least 1,000 BTU’s per cubic foot for natural gas; or at  
least 2,520 BTU’s per cubic foot for LP gas. Ask your  
fuel supplier for the BTU content of your fuel.  
6. Remove the brass metering jet (loosen counter-  
clockwise) from the housing port of the demand  
regulator located on the side of the regulator.  
7. Install new LP metering jet (tighten clockwise) in  
the outlet port of the demand regulator.  
8. Refit the brass hose fittings to the outlet port of  
the demand regulator.  
9. Reverse procedure steps 1-4 to reinstall demand  
regulator.  
10. Reverse the procedure to convert back to natural  
gas.  
Figure 1.3 – Demand Regulator  
Fuel pressure for both natural gas and liquid  
propane set ups should be 11 inches to 14 inches  
of water column (0.6 psi) at all load ranges.  
FUEL HOSE  
FUEL HOSE  
BRASS HOSE  
FITTING  
BRASS HOSE  
FITTING  
NOTE:  
FUEL JET  
HOUSING  
PORTS  
HOUSING  
PORTS  
A separate gas line and regulator may be needed  
to assure proper gas pressure (11-14”) to the gen-  
erator. Low gas pressure can cause hard starting  
and could affect engine durability.  
1.7 FUEL CONSUMPTION  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load 1/2 Load  
Full Load  
1.21/44.1  
2.17/79.0  
2.80/102.3  
NG FUEL SYSTEM  
04758  
04759  
04760  
74  
105  
185  
240  
0.91/33  
1.34/48.9  
1.73/63.2  
LP FUEL SYSTEM  
114  
NOTE:  
148.5  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
The natural gas adjustment screw is preset during  
installation and should not need any further  
adjustment.  
DANGER  
Gaseous fuels such as natural gas and liquid  
propane (LP) gas are highly explosive. Even the  
slightest spark can ignite such fuels and cause  
an explosion. No leakage of fuel is permitted.  
Natural gas, which is lighter than air, tends to  
collect in high areas. LP gas is heavier than air  
and tends to settle in low areas.  
1.8.2 12KW AND 15KW, 990CC 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. You must sup-  
ply a fuel pressure of 11 to 14 inches of water col-  
umn (0.6 psi) to the fuel inlet of the generator.  
1.8 RECONFIGURING THE  
FUEL SYSTEM  
1. Turn off the main gas supply.  
2. Remove the three carburetor fuel hoses from the  
outlet ports of the demand regulator.  
3. Disconnect wire #0 and wire #14 from the gas  
solenoid located on the top of the demand regu-  
lator.  
1.8.1 7 KW, 410CC  
To reconfigure the fuel system from NG to LP,  
follow these steps:  
1. Turn the main gas supply off.  
2. Remove the carburetor fuel hose from the outlet  
4. Remove the demand regulator from the enclosure  
port of the demand regulator (Figure 1.3).  
by rotating counterclockwise.  
7
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Section 1 — General Information  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
5. Remove the small brass hose fitting from the idle  
1.9 LOCATION  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
circuit port of the regulator housing.  
6. Remove the small jet (0D5698A) located in the  
side of the regulator housing and install it into the  
small threaded hole in the idle circuit port on the  
regulator.  
1.9.1 GENERATOR  
7. Refit the brass hose fitting to the idle circuit port  
of the regulator. Use pipe thread sealant to reseal  
the threads on the hose fitting.  
8. Identify both adjustment screws.  
NOTE:  
• Install the unit where air inlet and outlet openings  
will not become obstructed by leaves, grass, snow,  
etc. If prevailing winds will cause blowing or drift-  
ing, you may need to consider using a windbreak  
to protect the unit.  
One adjustment screw can be accessed from the  
front of the unit and the second can be accessed  
from the back of 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 3 feet of space on all sides.  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings to  
the prevailing winds.  
9. To adjust the system to run on LP fuel, turn the  
adjuster screw that is accessed from inside the  
front of the unit 1/4 turn clockwise. This will set  
the system for max power and best performance  
on LP fuel.  
10. The fuel system will now allow the engine to run  
on LP fuel. It may be necessary to make minor  
adjustments to the preset screw settings to  
achieve maximum power. If there are problems  
with the unit producing maximum power, follow  
the procedure in Section 2.6 Adjusting the  
Regulator”.  
• 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 DIS-  
TANCE.  
1.9.2 TRANSFER SWITCH  
11. Reverse procedure steps 1-4 to reinstall the  
demand regulator.  
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 Generac  
Authorized Dealers.  
Figure 1.4 - Demand Regulator  
FUEL HOSE  
• Install the transfer switch on a firm, sturdy sup-  
porting structure.  
To prevent switch distortion, level the switch if nec-  
essary. This can be done by placing washers  
between the switch enclosure and mounting sur-  
face.  
BRASS HOSE  
FITTING  
BRASS HOSE  
IDLE CIRCUIT  
FITTING  
SMALL  
FUEL JET  
PORT  
RE  
R
1
NP  
REGULATOR  
HOUSING PORT  
ADJUSTER  
SCREWS  
• 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.  
TURN CLOCKWISE  
1/4 TURN TO SET  
FOR LP FUEL.  
• Failure to utilize a Generac/Guardian transfer  
switch with this generator will void the warranty.  
Transfer switches available for these generators are:  
• Model 004678-0 — 100 Amp, 2 Pole, 250 Volt  
NEMA 1 (indoor rated) or  
• Model 004635-0 — 200 Amp, 2 Pole, 250 Volt  
NEMA 3R (outdoor rated)  
8
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Section 1 — General Information  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
NOTE:  
1.10 BATTERY INSTALLATION  
Fill the battery with the proper electrolyte fluid if nec-  
essary and have the battery fully charged before  
installing it.  
Your generator is equipped with a battery trickle  
charger that is active when your 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 your battery by maintaining  
the battery when the unit is not running. The  
trickle charge feature cannot be used to recharge  
a discharged battery.  
Before installing and connecting the battery, complete  
the following steps:  
1. Set the generator's Auto/Off/Manual switch to  
OFF.  
2. Turn off utility power supply to the transfer  
switch.  
3. Remove the 5 amp and 15 amp fuses from the  
generator control panel.  
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.  
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,  
sparking can occur at the battery posts and  
cause an explosion.  
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; 550  
cold-cranking amps minimum for 12 and 15 kW at  
-18º C (0º F) minimum. When using a maintenance-  
free battery, it is not necessary 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.  
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  
ground) to the battery post indicated by a nega-  
tive, NEG or (—).  
6. Replace the 5 amp and 15 amp fuses in the gen-  
erator control panel.  
DANGER  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
NOTE:  
Damage will result if battery connections are made  
in reverse.  
A battery presents a risk of electrical shock  
and high short circuit current. The following  
precautions are to be observed when working  
on batteries:  
Figure 1.5 – Battery Cable Connections  
• 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 dis-  
connecting battery terminals.  
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.  
9
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Section 2 — Post Installation Start-up and Adjustments  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
The following procedures are to be observed:  
2.2 CHECK TRANSFER SWITCH  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, immediately  
flush thoroughly with water and seek medical  
attention; and  
OPERATION  
Refer to Section 3.5 (Page 15), of the owner’s manual  
for manual operation procedures.  
DANGER  
• 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.  
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.  
2.3 ELECTRICAL CHECKS  
Lead-acid batteries present a risk of fire  
because they generate hydrogen gas. The  
following procedures are to be followed:  
Complete electrical checks as follows:  
1. Turn on the utility power supply to the transfer  
switch using the means provided (such as a utili-  
ty main line circuit breaker).  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from your body before  
touching the battery by first touching a grounded  
metal surface.  
DANGER  
The transfer switch is now electrically “hot.”  
Contact with “hot” parts will result in extreme-  
ly hazardous and possibly fatal electrical shock.  
Proceed with caution.  
Be 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.  
2. Use an accurate AC voltmeter 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 com-  
patible with transfer switch and load circuit rat-  
ings, turn OFF the utility power supply to the  
transfer switch.  
5. 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.  
Be sure the utility power supply is turned off,  
or sparking may occur at the battery posts as  
you attach the cables 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. Set the generator's Auto/Off/Manual switch to the  
OFF position.  
3. Turn 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 nec-  
essary, fill to the dipstick FULL mark with the  
recommended 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. All  
fuel shutoff valves in the fuel supply lines must be  
open.  
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.  
DANGER  
Proceed with caution! Generator power voltage  
is now supplied to the transfer switch. Contact  
with live transfer switch parts will result in  
dangerous and possibly fatal electrical shock.  
Never operate the engine with the oil level  
below the “Add” mark on the dipstick. Doing  
!
this could damage the engine.  
10  
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Section 2 — Post Installation Start-up and Adjustments  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
8. Connect an accurate AC voltmeter and a frequen-  
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 E1 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.  
cy meter across transfer switch terminal lugs E1  
and E2. Voltage should be 242-252 volts; fre-  
quency should read about 61-63 Hertz.  
9. Connect the AC voltmeter test leads across termi-  
nal lug E1 and neutral; then across E2 and neu-  
tral. In both cases, voltage reading should be 121-  
126 volts 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.  
12. Set the generator's main circuit breakers to their  
NOTE:  
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.  
It is important that you do not proceed until you  
are certain that generator AC voltage and frequen-  
cy are correct and within the stated limits.  
Generally, if both AC frequency and voltage are  
high or low, the engine governor requires adjust-  
ment. If frequency is correct, but voltage is high or  
low, the generator’s voltage regulator requires  
adjustment.  
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.  
2.4 GENERATOR TESTS UNDER LOAD  
To test the generator set with electrical loads applied,  
proceed as follows:  
2. Check that the Auto/Off/Manual switch is set to  
OFF.  
1. Set generator’s main circuit breaker to its OFF  
(or open) position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as a utili-  
ty main line circuit breaker).  
4. Manually set the transfer switch to the UTILITY  
position, i.e., load terminals connected to the util-  
ity power source side.  
5. Turn ON the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
2. Set the generator's 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).  
6. 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.  
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.  
7. 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.  
4. Manually set the transfer switch to the STANDBY  
position, i.e., load terminals connected to the  
generator's E1/E2 terminals. The transfer switch  
operating lever should be down.  
5. Set the generator's Auto/Off/Manual switch to  
MANUAL. The engine should crank and start  
immediately.  
With the generator running and loads powered by gen-  
erator AC output, turn ON the utility power supply to  
the transfer switch. The following should occur:  
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.  
• After about six seconds, the switch should transfer  
loads back to the utility power source.  
• About one minute after retransfer, the engine  
should shut down.  
11  
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Section 3 — Operation  
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators  
Figure 2.2 — Placement of Regulator  
2.6 ADJUSTING THE REGULATOR  
(NATURAL GAS ONLY)  
Although the generator has been factory set to pro-  
vide maximum power, it may be necessary in some  
areas to adjust this setting. Because natural gas has  
different BTU or power content across the country  
the engine may not perform as designed.  
If you experience engine problems at high 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 the  
service main breaker to the off or open position.  
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.  
3. Turn on appliances, lights, pumps, etc., that are  
on the emergency circuits in an attempt to fully  
load the generator. Be cautious not to overload  
the generator. Use the following chart as a guide:  
Adjustment Screw  
7. Turn utility power to the main distribution panel  
back on. This can be done by switching the serv-  
ice main breaker to the on or closed position.  
Allow the generator to shut down.  
Unit  
7 kW  
12 kW  
15 kW  
120 Volts  
50.0 amps  
100.0 amps  
108.3 amps  
240 Volts  
25.0 amps  
50.0 amps  
54.2 amps  
Do not make any unnecessary adjustments.  
Factory settings are correct for most applica-  
tions. However, when making adjustments, be  
careful to avoid overspeeding the engine.  
!
If this procedure or equipment are not available to  
you, locate the Generac Guardian Dealer nearest you  
and they can perform the adjustments.  
4. When full load has been achieved. Connect a fre-  
quency meter to the output lugs of the generator’s  
main line circuit breaker.  
NOTE:  
5. The fuel regulator is fitted with one (7 kW), or two  
(12 & 15 kW) adjustment screws. While watching  
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  
set pins. Under no circumstances should any of  
the pins be removed (Figures 2.1 and 2.2).  
A service fee may be charged for this adjustment.  
2.7 ENGINE GOVERNOR ADJUSTMENT  
If both AC frequency and voltage are correspondingly  
high or low, adjust the engine governor as follows:  
2.7.1 7 KW UNITS  
Figure 2.1 — Dual Fuel Regulators  
1. Loosen the governor clamp bolt (Figure 2.3 on  
6 and 7 kW  
12, 13, and 15 kW  
page 13).  
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).  
3. Start the generator; let it stabilize and warm up  
at no-load.  
Adjustment  
Set  
Pins  
Adjustment  
Screw  
(Both sides)  
Screw  
(One Side  
Only)  
4. Connect a frequency meter across the generators  
AC output leads.  
5. Turn the speed adjust nut to obtain a frequency  
reading of 63 Hz.  
6. When frequency is correct at no load, check the  
AC voltage reading. If voltage is incorrect, the volt-  
age regulator may require adjustment.  
6. When the highest frequency is reached maximum  
power has been set. Then turn both adjustment  
screws 1/4 turn counterclockwise. Regulator is  
now set.  
12  
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