Service Schedule | Generac 04389-1, 04456-1, 04390-1 guide

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Generac 04389-1, 04456-1, 04390-1 owner manual Service Schedule

Contents

POWER SYSTEMS, INC DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLYPOWER SYSTEMS DANGER INTRODUCTION AUTHORIZED DEALER LOCATIONDANGER ‹CONTENTS Introduction GENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot ELECTRICAL HAZARDS FIRE HAZARDSEXPLOSION HAZARDS ‹STANDARDS INDEX 1.1UNPACKING/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 DANGER 1.10 BATTERY INSTALLATION 1.9LOCATION1.9.2 TRANSFER SWITCH 1.9.1 GENERATOR 1.11 THE BATTERY Figure 1.5 - Battery Cable ConnectionsWear rubber gloves and boots Do not open or mutilate the battery. Released 2.2CHECK TRANSFER SWITCH OPERATION 2.1BEFORE INITIAL START-UP2.3ELECTRICAL CHECKS Never operate the engine with the oil level 2.6ADJUSTING 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 adjustments 2.8VOLTAGE REGULATOR ADJUSTMENT 3.1BREAK-INPROCEDUREFigure 2.4 - Full Load Speed Adjust Screw Figure 2.5 - Voltage Adjustment Potentiometer 3.3AUTOMATIC TRANSFER OPERATION 3.2USING THE AUTO/OFF/MANUAL SWITCH FIGUREWith the switch set to AUTO, the engine may 3.4SEQUENCE OF AUTOMATIC OPERATION 3.6SETTING THE EXERCISE TIMER 3.5MANUAL TRANSFER OPERATION‹3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE Figure 3.2 - Manual Transfer Switch Operation 3.7PROTECTION SYSTEMS 4.1FUSE‹3.7.1 LOW OIL PRESSURE SWITCH ‹3.7.2 HIGH TEMPERATURE SWITCH 4.2CHECKING THE ENGINE OIL LEVEL 4.3CHANGING THE ENGINE OIL‹ 4.3.2 OIL CHANGE PROCEDURE ‹4.3.1 ENGINE OIL RECOMMENDATIONS 4.5CHANGING THE ENGINE AIR CLEANER 4.4CHANGING THE OIL FILTER4.6SPARK PLUGS Figure 4.6 - 7 kW, Engine Air Cleaner Location 4.7BATTERY 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 Adjustment 4.12 OUT OF SERVICE PROCEDURE ‹4.12.1 REMOVAL FROM SERVICE‹4.12.2 RETURN TO SERVICE 4.13 SERVICE SCHEDULE 5.1TROUBLESHOOTING GUIDE PROBLEMCAUSE CORRECTION 24 Generac Power Systems, Inc Section 6 - Electrical Data CONTROL PANEL BOX CUSTOMERCONNECTION 26 Generac Power Systems, Inc C2-6 Wiring Diagram - 7 kW - Drawing No. 0D9013-A 28 Generac Power Systems, Inc CUSTOMER CONNECTION CLOSEST TO BEA 4 0 STATOR 30 Generac Power Systems, Inc Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 32 Generac Power Systems, Inc PART 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 NTAKE 54 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 - Warranty EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING WARRANTY SCHEDULE GENERAC POWER SYSTEMS, INCP.O. BOX WHITEWATER, WI