5.1TROUBLESHOOTING GUIDE, Cause | Generac 04389-1, 04456-1, 04390-1

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Generac 04389-1, 04456-1, 04390-1 owner manual 5.1TROUBLESHOOTING GUIDE, Problem, Cause, Correction

Contents

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY POWER SYSTEMS, INCPOWER SYSTEMS DANGER AUTHORIZED DEALER LOCATION INTRODUCTIONDANGER ‹CONTENTS Introduction Despite the safe design of this generator GENERAL HAZARDSParts of the generator are rotating and/or hot FIRE HAZARDS ELECTRICAL HAZARDSEXPLOSION HAZARDS ‹STANDARDS INDEX 1.2PROTECTION SYSTEMS 1.1UNPACKING/INSPECTION1.3SYSTEM SET LED Figure 1.1 - 7 kW, Single Cylinder GH-410Engine 1.4YOUR GENERATORFigure 1.2 - 12 kW and 15 kW, V-twin GT-990Engine ‹ 1.5.1 GENERATOR 1.5 SPECIFICATIONS‹1.5.2 ENGINE 1.6FUEL REQUIREMENTS AND RECOMMENDATIONS 1.8RECONFIGURING THE FUEL SYSTEM1.7FUEL CONSUMPTION DANGER 1.9LOCATION 1.10 BATTERY INSTALLATION1.9.2 TRANSFER SWITCH 1.9.1 GENERATOR Figure 1.5 - Battery Cable Connections 1.11 THE BATTERYWear rubber gloves and boots Do not open or mutilate the battery. Released 2.1BEFORE INITIAL START-UP 2.2CHECK TRANSFER SWITCH OPERATION2.3ELECTRICAL CHECKS Never operate the engine with the oil level 2.4GENERATOR TESTS UNDER LOAD 2.6ADJUSTING THE REGULATOR NATURAL GAS ONLY2.5CHECKING AUTOMATIC OPERATION Figure 2.2 - Placement of Regulator 2.7ENGINE GOVERNOR ADJUSTMENTFigure 2.3 - Engine Governor Adjustment Do not make any unnecessary adjustments 3.1BREAK-INPROCEDURE 2.8VOLTAGE REGULATOR ADJUSTMENTFigure 2.4 - Full Load Speed Adjust Screw Figure 2.5 - Voltage Adjustment Potentiometer 3.2USING THE AUTO/OFF/MANUAL SWITCH FIGURE 3.3AUTOMATIC TRANSFER OPERATIONWith the switch set to AUTO, the engine may 3.4SEQUENCE OF AUTOMATIC OPERATION 3.5MANUAL TRANSFER OPERATION 3.6SETTING THE EXERCISE TIMER‹3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE Figure 3.2 - Manual Transfer Switch Operation 4.1FUSE 3.7PROTECTION SYSTEMS‹3.7.1 LOW OIL PRESSURE SWITCH ‹3.7.2 HIGH TEMPERATURE SWITCH 4.3CHANGING THE ENGINE OIL 4.2CHECKING THE ENGINE OIL LEVEL‹ 4.3.2 OIL CHANGE PROCEDURE ‹4.3.1 ENGINE OIL RECOMMENDATIONS 4.4CHANGING THE OIL FILTER 4.5CHANGING THE ENGINE AIR CLEANER4.6SPARK PLUGS Figure 4.6 - 7 kW, Engine Air Cleaner Location 4.8ADJUSTING GH-410/GT-990VALVE CLEARANCE 4.7BATTERY MAINTENANCEFigure 4.8 - Setting the Spark Plug Gap 4.10 ATTENTION AFTER SUBMERSION 4.9COOLING SYSTEM4.11 CORROSION PROTECTION Figure 4.10 - Valve Clearance Adjustment ‹4.12.1 REMOVAL FROM SERVICE 4.12 OUT OF SERVICE PROCEDURE‹4.12.2 RETURN TO SERVICE 4.13 SERVICE SCHEDULE PROBLEM 5.1TROUBLESHOOTING GUIDECAUSE CORRECTION Section 6 - Electrical Data 24 Generac Power Systems, Inc CUSTOMER CONTROL PANEL BOXCONNECTION 26 Generac Power Systems, Inc C2-6 28 Generac Power Systems, Inc Wiring Diagram - 7 kW - Drawing No. 0D9013-A CLOSEST TO BEA 4 0 STATOR CUSTOMER CONNECTION 30 Generac Power Systems, Inc Section 6 - Electrical Data 32 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 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 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 TRANSFER SWITCH Section 8 - Mounting DimensionsGuardian Air NTAKE 54 Generac Power Systems, Inc Generac Power Systems, Inc YOUR WARRANTY RIGHTS AND OBLIGATIONS CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES Section 10 - Warranty EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTY GENERAC POWER SYSTEMS, INC WARRANTY SCHEDULEP.O. BOX WHITEWATER, WI