Generac 04389-1, 04456-1, 04390-1 2.1BEFORE INITIAL START-UP, 2.2CHECK TRANSFER SWITCH OPERATION

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2.1BEFORE INITIAL START-UP

Section 2 — Post Installation Start-up and Adjustments

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

Be sure the utility power supply is turned off and the 5A and 15A fuses are removed from the generator control panel, or sparking may occur at the battery posts as you attach the cables and cause an explosion.

2.1BEFORE 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.Turn OFF all loads connected to the transfer switch terminals T1 and T2.

5.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.

6.Check the fuel supply. Gaseous fuel lines must have been properly purged and leak tested in accor- dance with applicable fuel-gas codes. All fuel shut- off valves in the fuel supply lines must be open.

Never operate the engine with the oil level

!below the “Add” mark on the dipstick. Doing this could damage the engine.

2.2CHECK TRANSFER SWITCH

OPERATION

Refer to Section 3.5 (Page 15), of the owner’s manual for manual operation procedures.

Never operate the engine with the oil level2.2CHECK TRANSFER SWITCH DANGER

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.

2.3ELECTRICAL CHECKS

Complete electrical checks as follows:

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 all loads connected to the transfer switch terminals T1 and T2.

4.Turn on the utility power supply to the transfer switch using the means provided (such as a utili- ty main line circuit breaker).

2.3ELECTRICAL CHECKSManual background 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.

5.Use an accurate AC voltmeter to check utility power source voltage across transfer switch ter- minals N1 and N2. Nominal line-to-line voltage should be 240 volts AC.

6.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.

7.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.

8.On the generator panel, set the Auto/Off/Manual switch to MANUAL. The engine should crank and start.

9.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.

Manual backgroundManual background 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.

10.Connect an accurate AC voltmeter and a frequen- cy meter across transfer switch terminal lugs E1 and E2. Voltage should be 242-252 volts; fre- quency should read about 61-63 Hertz.

11.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.

12.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.

13.Set the generator's Auto/Off/Manual switch to OFF. The engine should shut down.

NOTE:

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.

10 Generac® Power Systems, Inc.

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Contents POWER SYSTEMS, INC DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLYPOWER SYSTEMS DANGERINTRODUCTION AUTHORIZED DEALER LOCATIONDANGER ‹CONTENTSIntroduction GENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot ELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹STANDARDS INDEX1.1UNPACKING/INSPECTION 1.2PROTECTION SYSTEMS1.3SYSTEM SET LED 1.4YOUR GENERATOR Figure 1.1 - 7 kW, Single Cylinder GH-410EngineFigure 1.2 - 12 kW and 15 kW, V-twin GT-990Engine 1.5 SPECIFICATIONS ‹ 1.5.1 GENERATOR‹1.5.2 ENGINE 1.8RECONFIGURING THE FUEL SYSTEM 1.6FUEL REQUIREMENTS AND RECOMMENDATIONS1.7FUEL CONSUMPTION DANGER1.10 BATTERY INSTALLATION 1.9LOCATION1.9.2 TRANSFER SWITCH 1.9.1 GENERATOR1.11 THE BATTERY Figure 1.5 - Battery Cable ConnectionsWear rubber gloves and boots Do not open or mutilate the battery. Released2.2CHECK TRANSFER SWITCH OPERATION 2.1BEFORE INITIAL START-UP2.3ELECTRICAL CHECKS Never operate the engine with the oil level2.6ADJUSTING THE REGULATOR NATURAL GAS ONLY 2.4GENERATOR TESTS UNDER LOAD2.5CHECKING AUTOMATIC OPERATION 2.7ENGINE GOVERNOR ADJUSTMENT Figure 2.2 - Placement of RegulatorFigure 2.3 - Engine Governor Adjustment Do not make any unnecessary adjustments2.8VOLTAGE REGULATOR ADJUSTMENT 3.1BREAK-INPROCEDUREFigure 2.4 - Full Load Speed Adjust Screw Figure 2.5 - Voltage Adjustment Potentiometer3.3AUTOMATIC TRANSFER OPERATION 3.2USING THE AUTO/OFF/MANUAL SWITCH FIGUREWith the switch set to AUTO, the engine may 3.4SEQUENCE OF AUTOMATIC OPERATION3.6SETTING THE EXERCISE TIMER 3.5MANUAL TRANSFER OPERATION‹3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE Figure 3.2 - Manual Transfer Switch Operation3.7PROTECTION SYSTEMS 4.1FUSE‹3.7.1 LOW OIL PRESSURE SWITCH ‹3.7.2 HIGH TEMPERATURE SWITCH4.2CHECKING THE ENGINE OIL LEVEL 4.3CHANGING THE ENGINE OIL‹ 4.3.2 OIL CHANGE PROCEDURE ‹4.3.1 ENGINE OIL RECOMMENDATIONS4.5CHANGING THE ENGINE AIR CLEANER 4.4CHANGING THE OIL FILTER4.6SPARK PLUGS Figure 4.6 - 7 kW, Engine Air Cleaner Location4.7BATTERY MAINTENANCE 4.8ADJUSTING GH-410/GT-990VALVE CLEARANCEFigure 4.8 - Setting the Spark Plug Gap 4.9COOLING SYSTEM 4.10 ATTENTION AFTER SUBMERSION4.11 CORROSION PROTECTION Figure 4.10 - Valve Clearance Adjustment4.12 OUT OF SERVICE PROCEDURE ‹4.12.1 REMOVAL FROM SERVICE‹4.12.2 RETURN TO SERVICE 4.13 SERVICE SCHEDULE 5.1TROUBLESHOOTING GUIDE PROBLEMCAUSE CORRECTION24 Generac Power Systems, Inc Section 6 - Electrical DataCONTROL PANEL BOX CUSTOMERCONNECTION 26 Generac Power Systems, Inc C2-6 Wiring Diagram - 7 kW - Drawing No. 0D9013-A 28 Generac Power Systems, IncCUSTOMER CONNECTION CLOSEST TO BEA 4 0 STATOR30 Generac Power Systems, Inc Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 32 Generac Power Systems, IncPART NO.QTY. DESCRIPTION Control Panel - Drawing No. 0D8503-E DESCRIPTION Section 7 - Exploded Views and Parts Lists 0D4801 37 17 24 0D3086 Kit Contains Section 7 - Exploded Views and Parts Lists 42 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 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 Section 8 - Mounting Dimensions TRANSFER SWITCHGuardian Air NTAKE54 Generac Power Systems, Inc Generac Power Systems, Inc CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES Section 10 - WarrantyEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGWARRANTY SCHEDULE GENERAC POWER SYSTEMS, INCP.O. BOX WHITEWATER, WI