Generac 04389-1, 04456-1, 04390-1 owner manual The Battery, Danger, 5 - Battery Cable Connections

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Figure 1.5 – Battery Cable Connections

Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

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 (—).

NOTE:

Damage will result if battery connections are made in reverse.

Figure 1.5 – Battery Cable Connections

NOTE:

•Remove watches, rings or other metal objects;•Use tools with insulated handles; DANGER

Do not dispose of the battery in a fire. The battery is capable of exploding.

A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:

Remove the 5A and 15A fuses from the generator control panel.

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.

The following procedures are to be observed:

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.

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 DC, negative ground battery with a rating of 350 cold-cranking amps min- imum for 7 kW; 550 cold-cranking amps minimum for 12 and 15 kW at -17.8º 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 connect- ed and terminals are tight. Observe battery polarity when connecting the battery to the generator set.

Wear full eye protection and protective clothing;

Where electrolyte contacts the skin, wash it off immediately with water;

Where electrolyte contacts the eyes, flush thoroughly and immediately 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) of 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

Discharge static electricity from your body before touching the battery by first touching a grounded metal surface.

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.

Generac® Power Systems, Inc. 9

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Contents DANGER POWER SYSTEMS, INCDEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY POWER SYSTEMS‹CONTENTS INTRODUCTIONAUTHORIZED DEALER LOCATION DANGERIntroduction Parts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator ‹STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.3SYSTEM SET LED 1.1UNPACKING/INSPECTION1.2PROTECTION SYSTEMS Figure 1.2 - 12 kW and 15 kW, V-twin GT-990Engine 1.4YOUR GENERATORFigure 1.1 - 7 kW, Single Cylinder GH-410Engine ‹1.5.2 ENGINE 1.5 SPECIFICATIONS‹ 1.5.1 GENERATOR DANGER 1.8RECONFIGURING THE FUEL SYSTEM1.6FUEL REQUIREMENTS AND RECOMMENDATIONS 1.7FUEL CONSUMPTION1.9.1 GENERATOR 1.10 BATTERY INSTALLATION1.9LOCATION 1.9.2 TRANSFER SWITCHDo not open or mutilate the battery. Released 1.11 THE BATTERYFigure 1.5 - Battery Cable Connections Wear rubber gloves and bootsNever operate the engine with the oil level 2.2CHECK TRANSFER SWITCH OPERATION2.1BEFORE INITIAL START-UP 2.3ELECTRICAL CHECKS2.5CHECKING AUTOMATIC OPERATION 2.6ADJUSTING THE REGULATOR NATURAL GAS ONLY2.4GENERATOR TESTS UNDER LOAD Do not make any unnecessary adjustments 2.7ENGINE GOVERNOR ADJUSTMENTFigure 2.2 - Placement of Regulator Figure 2.3 - Engine Governor AdjustmentFigure 2.5 - Voltage Adjustment Potentiometer 2.8VOLTAGE REGULATOR ADJUSTMENT3.1BREAK-INPROCEDURE Figure 2.4 - Full Load Speed Adjust Screw3.4SEQUENCE OF AUTOMATIC OPERATION 3.3AUTOMATIC TRANSFER OPERATION3.2USING THE AUTO/OFF/MANUAL SWITCH FIGURE With the switch set to AUTO, the engine mayFigure 3.2 - Manual Transfer Switch Operation 3.6SETTING THE EXERCISE TIMER3.5MANUAL TRANSFER OPERATION ‹3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE‹3.7.2 HIGH TEMPERATURE SWITCH 3.7PROTECTION SYSTEMS4.1FUSE ‹3.7.1 LOW OIL PRESSURE SWITCH‹4.3.1 ENGINE OIL RECOMMENDATIONS 4.2CHECKING THE ENGINE OIL LEVEL4.3CHANGING THE ENGINE OIL ‹ 4.3.2 OIL CHANGE PROCEDUREFigure 4.6 - 7 kW, Engine Air Cleaner Location 4.5CHANGING THE ENGINE AIR CLEANER4.4CHANGING THE OIL FILTER 4.6SPARK PLUGSFigure 4.8 - Setting the Spark Plug Gap 4.7BATTERY MAINTENANCE4.8ADJUSTING GH-410/GT-990VALVE CLEARANCE Figure 4.10 - Valve Clearance Adjustment 4.9COOLING SYSTEM4.10 ATTENTION AFTER SUBMERSION 4.11 CORROSION PROTECTION‹4.12.2 RETURN TO SERVICE 4.12 OUT OF SERVICE PROCEDURE‹4.12.1 REMOVAL FROM SERVICE 4.13 SERVICE SCHEDULE CORRECTION 5.1TROUBLESHOOTING GUIDEPROBLEM CAUSESection 6 - Electrical Data 24 Generac Power Systems, IncCONNECTION CONTROL PANEL BOXCUSTOMER 26 Generac Power Systems, Inc C2-6 28 Generac Power Systems, Inc Wiring Diagram - 7 kW - Drawing No. 0D9013-ACLOSEST TO BEA 4 0 STATOR CUSTOMER CONNECTION30 Generac Power Systems, Inc C2-6 32 Generac Power Systems, Inc Section 7 - Exploded Views and Parts ListsPART NO.QTY. DESCRIPTION Control Panel - Drawing No. 0D8503-E DESCRIPTION Section 7 - Exploded Views and Parts Lists 0D4801 37 17 24 0D3086 Kit Contains DESCRIPTION 42 Generac Power Systems, Inc DESCRIPTION 44 Generac Power Systems, Inc 7 kW Generator - Drawing No. 0D3504-B 46 Generac Power Systems, Inc 12 kW and 15 kW Generator - Drawing No. 0D3417-B 48 Generac Power Systems, Inc GN410 Engine - Drawing No. 0D3539-BPart 50 Generac Power Systems, Inc 0C1069 PART NO. QTY NTAKE Section 8 - Mounting DimensionsTRANSFER SWITCH Guardian Air54 Generac Power Systems, Inc Generac Power Systems, Inc Section 10 - Warranty CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYP.O. BOX WHITEWATER, WI WARRANTY SCHEDULEGENERAC POWER SYSTEMS, INC