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Generac Power Systems 04389-3, 04456-3, 04390-3 User Manual

Generac Power Systems 04389-3, 04456-3, 04390-3
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GENERAC
POWER SYSTEMS, INC.
R
R
Installation and
Owner’s Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
04389-3 (6 kW NG, 7 kW LP)
04456-3 (12 kW NG, 12 kW LP)
04390-3 (13 kW NG, 15 kW LP)
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
Not intended for use as Primary Power in place of utility or in
life-support applications.
L
I
S
T
E
D
C
U
S

Table of Contents

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Generac Power Systems 04389-3, 04456-3, 04390-3 Specifications

General IconGeneral
BrandGenerac Power Systems
Model04389-3, 04456-3, 04390-3
CategoryInverter
LanguageEnglish

Summary

Introduction

Read This Manual Thoroughly

Emphasizes the importance of reading the entire manual.

Operation and Maintenance

How to Obtain Service

Safety Rules

General Hazards

Outlines general safety precautions for installation and operation.

Electrical Hazards

Fire Hazards

Explosion Hazards

Standards Index

Section 1 - General Information

1.1 Unpacking/Inspection

Instructions for inspecting contents upon delivery for damage.

1.2 Protection Systems

Describes engine protection systems against damaging conditions.

1.3 NEC Requirement for Arc Fault Circuit Interruption Breaker for Bedrooms

Explains the National Electrical Code requirement for AFCI breakers.

1.4 The Generator

Identifies key components of the generator via diagrams.

1.5 Specifications

Provides detailed technical specifications for generator and engine models.

1.5.1 Generator

Lists electrical specifications for different generator models.

1.5.2 Engine

Lists engine specifications for different generator models.

1.6 System Set LED

Explains the conditions under which the "System Set" LED is illuminated.

1.7 Fuel Requirements and Recommendations

Details fuel types, pressures, and recommendations for operation.

1.8 Fuel Consumption

Provides fuel consumption rates for different loads and fuel types.

1.9 Reconfiguring the Fuel System

Step-by-step instructions for switching between natural gas and propane.

1.9.1 7 KW, 410CC Engine

Specific reconfiguration steps for the 7kW engine.

1.9.2 12KW and 15KW, V-Twin Engines

Specific reconfiguration steps for 12kW and 15kW engines.

1.10 Location

Guidelines for selecting an optimal and safe installation location.

1.10.2 Transfer Switch

Rules for indoor installation of the transfer switch enclosure.

1.10.2.1 7 kW, 12 kW and 15 kW Units

Specific installation rules for the transfer switch.

1.11 Battery Installation

Step-by-step procedure for installing the generator battery.

1.12 The Battery

Safety warnings and precautions for handling the battery.

Section 2 – Post Installation Start-up and Adjustments

2.1 Before Initial Start-up

Pre-start checks and procedures before initial generator operation.

2.2 Check Transfer Switch Operation

Procedure to verify the proper functioning of the transfer switch.

2.3 Electrical Checks

Performing essential electrical checks before generator operation.

2.4 Generator Tests Under Load

Steps for testing the generator with electrical loads applied.

2.5 Checking Automatic Operation

Verifying the generator's ability to operate automatically.

2.6 Adjusting the Regulator (Natural Gas Only)

Procedure to adjust the fuel regulator for optimal performance.

2.7 Engine Governor Adjustment

Adjusting the engine governor for correct frequency and voltage.

2.7.1 7 KW Units

Specific governor adjustment steps for 7kW units.

2.7.2 12 KW and 15 KW Units

Specific governor adjustment steps for 12kW and 15kW units.

2.8 Voltage Regulator Adjustment

Adjusting the voltage regulator for correct output voltage.

Section 3 – Operation

3.1 Break-in Procedure

Recommended steps for the initial generator break-in period.

3.2 Using the Auto/Off/Manual Switch (Figure 3.1)

Explains the function and use of the main operating switch.

3.2.1 "Auto" Position

Details how to set the switch for automatic system operation.

3.2.2 "Off" Position

Describes how to shut down the engine and prevent automatic operation.

3.2.3 “Manual” Position

Explains how to start the engine manually.

3.3 Automatic Transfer Operation

Steps to select and initiate automatic operation.

3.3.1 12 VDC Accessory Outlet

Information on the 12VDC accessory outlet and its limitations.

3.3.2 120 VAC GFCI Outlet

Details the 120VAC GFCI outlet for external power.

3.4 Sequence of Automatic Operation

Outlines the step-by-step process of automatic generator startup and shutdown.

3.5 Manual Transfer Operation

Procedures for manually transferring power between utility and standby sources.

3.5.1 Transfer to Generator Power Source

Steps to start the generator and activate the transfer switch manually.

3.5.2 Transfer Back to Utility Power Source

Steps to transfer power back to utility and shut down the generator.

3.6 Setting the Exercise Timer

How to set the timer for automatic weekly generator exercise.

3.7 Protection Systems

Describes built-in safety features that protect the generator.

3.7.1 Low Oil Pressure Switch

Explains the function of the low oil pressure shutdown switch.

3.7.2 High Temperature Switch

Details the high temperature shutdown switch and its reset.

3.7.3 Overcrank

Describes the overcrank protection feature and its reset procedure.

3.7.4 Overspeed

Explains the overspeed protection that prevents engine damage.

Section 4 – Maintenance

4.1 Fuses

Identifies and explains the purpose of the generator's fuses.

4.2 Checking the Engine Oil Level

Procedure to check the engine oil level using the dipstick.

4.3 Changing the Engine Oil

Step-by-step guide for performing an engine oil change.

4.3.1 Engine Oil Recommendations

Specifies recommended oil types and viscosity for the engine.

4.3.2 Oil Change Procedure

Detailed steps for draining and refilling engine oil.

4.4 Changing the Oil Filter

Procedure for replacing the engine oil filter.

4.5 Changing the Engine Air Cleaner

Instructions for cleaning or replacing the engine air cleaner.

4.6 Spark Plug(s)

Guidance on inspecting, cleaning, gapping, or replacing spark plugs.

4.7 Battery Maintenance

Procedures for inspecting and maintaining the generator's battery.

4.8 Adjusting GH-410/GT-990/760 Valve Clearance

Instructions for adjusting valve clearance on specific engine models.

4.9 Cooling System

Importance of clear air inlets and outlets for proper cooling.

4.10 Attention After Submersion

Precautions and actions required if the generator is submerged in water.

4.11 Corrosion Protection

Recommendations for protecting the enclosure and linkages from corrosion.

4.12 Out of Service Procedure

Steps for preparing the generator for extended storage.

4.12.1 Removal from Service

Detailed procedure for taking the generator out of service.

4.12.2 Return to Service

Procedures for returning the generator to service after storage.

4.13 Service Schedule

Provides a schedule for routine inspection, change, and cleaning tasks.

Section 5 – Troubleshooting

5.1 Troubleshooting Guide

A guide to common problems, their causes, and suggested corrections.

Section 6 – Notes

Section 7 – Electrical Data

Engine Wiring

Diagram illustrating the wiring connections for the engine.

Diagram Key

Explains the symbols and abbreviations used in the wiring diagrams.

Control Panel Box

Diagram showing the electrical components within the control panel box.

Closest to Bearing

Indicates a specific location relative to the bearing.

Electronic Voltage Regulator

Diagram of the electronic voltage regulator and its connections.

Control Printed Circuit Board

Diagram of the control printed circuit board and its connectors.

Customer Connection

Shows how the generator connects to the customer's electrical system.

Engine Wiring

Diagram illustrating the wiring connections for the engine.

Diagram Key

Explains the symbols and abbreviations used in the wiring diagrams.

Control Panel Box

Diagram showing the electrical components within the control panel box.

Customer Connection

Shows how the generator connects to the customer's electrical system.

Engine Wiring

Diagram illustrating the wiring connections for the engine.

Diagram Key

Explains the symbols and abbreviations used in the wiring diagrams.

Control Panel Box

Diagram showing the electrical components within the control panel box.

Customer Connection

Shows how the generator connects to the customer's electrical system.

Engine Wiring

Diagram illustrating the wiring connections for the engine.

Diagram Key

Explains the symbols and abbreviations used in the wiring diagrams.

Control Panel Box

Diagram showing the electrical components within the control panel box.

Customer Connection

Shows how the generator connects to the customer's electrical system.

Wiring Diagram – 8 Circuit Load Center

Shows the wiring for an 8-circuit load center.

Wiring Diagram – 8 Circuit Load Center

Shows the wiring for an 8-circuit load center.

Legend

Explains abbreviations used in the load center wiring diagram.

Wiring Diagram – 12 Circuit Load Center

Shows the wiring for a 12-circuit load center.

Wiring Diagram – 12 Circuit Load Center

Shows the wiring for a 12-circuit load center.

Legend

Explains abbreviations used in the load center wiring diagram.

Section 8 – Exploded Views and Parts Lists

Enclosure – Drawing No. 0F0080-C

Exploded view of the generator enclosure with numbered parts.

Control Panel - Drawing No. 0E9162-J

Exploded view of the control panel with numbered parts.

7 kW, 8 Circuit Load Center Assembly – Drawing No. 0E7975-B

Exploded view of the 7kW load center assembly.

12 kW and 15 kW, 12 Circuit Load Center Assembly – Drawing No. 0E7973-F

Exploded view of the 12/15kW load center assembly.

GT-990/760 Engine - Drawing No. 0E8774-M Part 1

Exploded view of the GT-990/760 engine (part 1).

GT-990/760 Engine – Drawing No. 0E8774-M Part 2

Exploded view of the GT-990/760 engine (part 2).

7 kW Generator – Drawing No. 0D3504-E

Exploded view of the 7kW generator assembly.

12 kW and 15 kW Generator – Drawing No. 0D3417-L

Exploded view of the 12/15kW generator assembly.

GN410 Engine – Drawing No. 0F3981-A Part 1

Exploded view of the GN410 engine (part 1).

GN410 Engine – Drawing No. 0F3981-A Part 2

Exploded view of the GN410 engine (part 2).

Section 9 – Mounting Dimensions

Drawing No. 0D3739-C

Diagrams showing overall dimensions and installation clearances.

Section 10 – Warranty

California Emission Control Warranty Statement

Details warranty rights and obligations for California emissions.

Your Warranty Rights and Obligations

Outlines responsibilities of manufacturer and owner regarding warranty.

Manufacturer's Emission Control System Warranty Coverage

Specifies coverage details for emission control system components.

Purchaser's/Owner's Warranty Responsibilities

Lists owner's responsibilities for maintaining warranty coverage.

Emission Related Parts Include the Following

Lists specific parts covered under the emission control system warranty.

Warranty Schedule

Outlines warranty coverage periods for different generator components.

This Warranty Shall Not Apply to the Following

Lists exclusions from the warranty coverage.

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