Generac Power Systems 04389-3, 04456-3, 04390-3 Troubleshooting Guide, Problem Cause Correction

Page 26

Section 5 — Troubleshooting

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

5.1TROUBLESHOOTING GUIDE

Problem

Cause

Correction

The engine will not crank.

1. Fuse blown.

1. Replace 15A fuse in generator

 

 

control panel.

2.Loose, corroded or defective battery cables.

2.Tighten, clean or replace as necessary.

 

3.

Defective starter contactor. (7 kW) 3.

*

 

4.

Defective starter motor.

4.

*

 

5.

Dead Battery.

5.

Charge or replace battery.

 

 

 

 

 

The engine cranks but

1.

Out of fuel.

1.

Replenish fuel.

will not start.

2.

Defective fuel solenoid (FS).

2.

*

 

3.

Open #14 wire from

3.

*

 

 

engine control board.

 

 

4.Defective spark plug(s).

5.Valve lash out of adjustment.

4.Clean, re-gap or replace plug(s).

5.Reset valve lash.

The engine starts hard

1.

Air cleaner plugged

1.

Check, replace air cleaner.

and runs rough.

 

or damaged.

 

 

 

2.

Defective spark plug(s).

2.

Clean, re-gap or replace plug(s).

 

3.

Fuel Regulator not set.

3.

Set Fuel Regulator.

 

4.

Fuel Pressure incorrect.

4.

Confirm fuel pressure to regulator

 

 

 

 

is 10-12” water column (0.36-0.43

 

 

 

 

psi) for LP, and 5-7” water colum

 

 

 

 

(0.18-0.25 psi) for natural gas.

 

 

 

 

 

The Auto/Off/Manual switch

1.

Defective switch.

1.

*

is set to OFF, but the engine

2.

Auto/Off/Manual switch

2.

*

continues to run.

 

wired incorrectly.

 

 

 

3.

Defective control board.

3.

*

 

 

 

 

 

There is no AC output from

1.

Main line circuit breaker open.

1.

Reset circuit breaker

the generator.

 

 

 

to ON (or closed).

 

2.

Generator internal failure.

2.

*

 

 

 

 

 

There is no transfer to

1.

Defective transfer switch coil.

1.

*

standby after utility

2.

Defective transfer relay.

2.

*

source failure.

3.

Transfer relay circuit open.

3.

*

 

4.

Defective control logic board.

4.

*

 

 

 

 

 

Unit consumes large

1.

Break-in procedure

1.

*

amounts of oil.

 

not followed (see Section 3.1).

 

 

*Contact the nearest Authorized Dealer for assistance.

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Contents US Listed Introduction Authorized Dealer LocationTroubleshooting Post Installation Start-up AdjustmentsMaintenance Introduction Inside Front Cover Warning   Electrical Hazards  ‹ Standards IndexBreaker for Bedrooms UNPACKING/INSPECTIONProtection Systems Generator Gfci‹ 1.5.2 Engine Specifications‹ 1.5.1 Generator Fuel Requirements Recommendations Reconfiguring the Fuel SystemSystem SET LED Fuel Consumption‹ 1.10.1 Generator Location‹ 1.9.2 12KW and 15KW, V-TWIN Engines ‹ 1.10.2 Transfer Switch Battery InstallationBattery 10.2.1 7 kW, 12 kW and 15 kW UnitsElectrical Checks Check Transfer Switch OperationBefore Initial START-UP Generator Tests Under Load Checking Automatic OperationAdjusting the Regulator Natural GAS only Adjustment Screw‹ 2.7.1 7 KW Units Engine Governor Adjustment‹ 2.7.2 12 KW and 15 KW Units ‹ 3.2.1 Auto Position Voltage Regulator AdjustmentBREAK-IN Procedure Sequence of Automatic Operation ‹ 3.3.1 12 VDC Accessory OutletAutomatic Transfer Operation ‹ 3.2.2 OFF Position‹ 3.5.2 Transfer Back to Utility Power Source Manual Transfer Operation‹ 3.7.1 LOW OIL Pressure Switch Setting the Exercise Timer‹ 3.7.2 High Temperature Switch ‹ 3.7.3 Overcrank‹ 3.7.4 Overspeed FusesChecking the Engine OIL Level Changing the OIL Filter ‹ 4.3.2 OIL Change ProcedureChanging the Engine OIL ‹ 4.3.1 Engine OIL RecommendationsBattery Maintenance Spark PlugsValve Clearance Cooling System‹ 4.12.2 Return to Service OUT of Service Procedure‹ 4.12.1 Removal from Service Corrosion ProtectionService Schedule Be performed by the nearest Authorized DealerTroubleshooting Guide Problem Cause CorrectionAir-cooled 7 kW, 12 kW and 15 kW Generators Air-cooled 7 kW, 12 kW and 15 kW Generators Air-cooled 7 kW, 12 kW and 15 kW Generators Electrical Data Customer Connection Battery 1VA Engine Wiring Control Panel BOX Electronic Voltage Regulator Utility Electrical Data Electrical Data Electrical Data Electrical Data ATS N1A N2A Exploded Views and Parts Lists Part NO. QTY. Description Exploded Views and Parts Lists Part NO. QTY Description Exploded Views and Parts Lists QTY Description Exploded Views and Parts Lists COVER, 12 Circuit GTS Load Center 1310 Sleeve 124 125 139 136 135 123 120 137 143 133 134 132 KNOB, AIR Cleaner Exploded Views and Parts Lists QTY 32 31 Stator 12KW Exploded Views and Parts Lists PIN, Piston D20 Exploded Views and Parts Lists SCREW, Taptite M6-1.0X8 Yellow Chrome 7KW Mounting Dimensions PURCHASER’S/OWNER’S Warranty Responsibilities Your Warranty Rights and ObligationsMANUFACTURER’S Emission Control System Warranty Coverage Emission Control System Warranty Emission Related Parts Include the FollowingWarranty Schedule

04389-3, 04456-3, 04390-3 specifications

Generac Power Systems has established itself as a leading name in power generation equipment, and models 04389-3, 04456-3, and 04390-3 exemplify the company’s commitment to reliability and technology. These models are particularly popular among homeowners and businesses that need dependable backup power solutions.

The Generac 04389-3 is a 22 kW standby generator designed to provide seamless power during outages. It boasts a powerful 999cc engine that can handle heavy loads, making it suitable for larger homes or commercial settings. The generator features Generac’s patented True Power Technology, which ensures clean and stable power delivery, making it safe for sensitive electronics. It also comes equipped with an innovative shutdown system that prevents damage during low oil conditions and features a five-year limited warranty for added peace of mind.

Similarly, the 04456-3 model also serves as a robust standby generator, offering 24 kW of power output. This model highlights an advanced alternator that provides a reliable source of energy for running essential appliances like refrigerators, air conditioners, and heating systems. The 04456-3 includes an automatic exercise mode, allowing it to run tests periodically to ensure it’s always ready to operate when needed. Additionally, it utilizes a user-friendly digital controller that simplifies monitoring and operational management.

The Generac 04390-3 model offers a slightly lower output at 20 kW but retains high efficiency and reliability. Like its counterparts, it features an innovative design that operates quietly while delivering consistent power. This model is particularly aimed at residential users who require dependable backup solutions without the noise commonly associated with generators. It incorporates Generac’s Smart Management modules, enabling users to manage power loads effectively and avoid overloading the system.

All three models benefit from Generac’s Mobile Link technology, which enables remote monitoring via mobile devices. This feature allows users to check the status of their generators, including maintenance alerts and operational history, providing a convenient way to manage energy needs. In summary, Generac models 04389-3, 04456-3, and 04390-3 offer cutting-edge features, dependable technology, and robust capabilities, making them an ideal choice for anyone seeking reliable backup power solutions.
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