Generac 04389-1, 04456-1, 04390-1 Out Of Service Procedure, ‹4.12.1 REMOVAL FROM SERVICE

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4.12 OUT OF SERVICE PROCEDURE

Section 4 — Maintenance

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

4.12 OUT OF SERVICE PROCEDURE

‹4.12.1 REMOVAL FROM SERVICE

If you cannot exercise the generator 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.Set the Auto/Off/Manual switch to OFF and turn off the utility power to the transfer switch. Remove the 5A and 15A fuses from the generator control panel. Disconnect the battery cables as outlined in “General Hazards” (page 2).

5.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 (Page 17).

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.

‹4.12.2 RETURN TO SERVICE

To return the unit to service after storage, proceed as follows:

1.Verify that utility power is turned off and that the Auto/Off/Manual switch is set to OFF.

2.Check the tag on the engine for oil viscosity and classification. Verify that the correct recommend- ed oil is used in the engine (see Section 4.3.1, Page 17). If necessary, drain and refill with the proper oil.

3.Check the state of the battery. Fill all cells of unsealed batteries to the proper level with dis- tilled 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 (Page 6), for type and size.

4.Clean and wipe the entire generator.

5.Remove the 5A and 15A fuses from the generator control panel. Reconnect the battery. Observe bat- tery polarity. Damage may occur if the battery is connected incorrectly.

6.Open the fuel shutoff valve.

7.Insert the 5A and 15A fuses into the generator control panel. Start the unit by moving the Auto/Off/Manual switch to MANUAL. Allow the unit to warm up thoroughly.

8.Stop the unit by setting the Auto/Off/Manual switch to OFF.

9.Turn on the utility power to the transfer switch.

10.Set the Auto/Off/Manual switch to AUTO.

11.Your generator is now ready for service.

NOTE:

If the battery was dead or disconnected, you must reset the exercise timer.

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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