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Generac Power Systems 004916-0 Portable Generator User Manual

1. 26 Section 9 Notes 38 Section 10 Warranty 40 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Air cooled 11 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not speci
2. CB3 5 CUSTOMER SUPPLIED _ 3 22 S 23 N1 EXTERNAL N2 GFCI OUTLET B 9 5 L ENGINE WIRING 240V GENERATOR NOLLO3NNOO TWHLNAN LAANI OVAOTO OUTPUT TO TRANSFER HH SWITCH CONTACTOR CUSTOMER CONNECTION 23 Section 7 Electrical Data ELECTRICAL Air cooled 11 kW Generators DATA Electrical Schematic Drawing No 0E7073 B BATTERY CHARGER gt ELECTRONIC 4 VOLTAGE 4 REGULATOR 0 MN NE EE GOVERNOR ACTUATOR MANUAL lt gt AUTO 194 EN 15A x 194 15A 12VDC ACCESSORY 194 4 56 15 SOCKET J 15A o 239 15 I 23 14 77 66 18 66A 85 0 86 ME RH i s 713 PRINTED CIRCUIT 239 E BOARD 85 13 16 14 23 194 225 228 77 66 224 4 225 Section 7 Electrical Data Air cooled 11 kW Generators ELECTRICAL Electrical Schematic Drawing No 0E7073 B lt DATA e 6 66 55 66A 7 ENGINE CHARGE 66 66 ENGINE AND RUN WINDING WINDING 66A Lm ALTERNATOR 77 D SP2 ii 18 6 ii FIELD 18 18 gt P gt D SP1 4 0 DE STATOR WINDING POWER WINDING 86 85 LOP HTO 6 2 0 0 6 2 4 4 13 13 ne 6 5 BATTERY 2
3. 7 IO LLOC Yr iu 2 E 7 ELUL Curi LL RR T 110 2 Translet SWIICI neos 8 1 11 Battery DInstallation 8 L I2 u una Mu aptat RUE 8 Section 2 Post Installation Start up and Adjustments 9 2 1 Before Initial Startup 9 2 2 Check Transfer Switch Operation 9 25 lee 9 2 4 Generator Tests Under Load 10 2 0 Checking Automatic Operation 10 2 6 Voltage Regulator Adjustmentl 11 TABLE OF CONTENTS Table of Contents Air cooled 11 kW Generators Section 3 Operation 11 ad Breakin Preeedd r6 11 3 2 Using the AUTO OFF MANUAL Switch 11 AHS POSILOU 11 9 22 OR POSION 12 3 2 3 Manual Position 12 3 3 Automatic Transfer Operation 12 3 4 Sequence of Automatic Operation 12 9 0 Setting the Exercise T HT aee espere repeto eret wasapasqa 13 BuO PEOUCCHOI 13 3 6 1 Low Oil Pressure Switch 13 3 6 2 High Temperature Switch 13 5002 RT S o S 13 UD
4. s 4 Charge or replace battery 1 Replenish fuel 2 3 4 Clean re gap or replace plug s 5 Reset valve lash 1 Check replace air cleaner 2 Clean re gap or replace plug s 3 Confirm fuel pressure to regulator is 5 7 water column 0 18 to 0 25 for natural gas 10 12 water col umn 0 36 to 0 43 psi for liquid propane vapor I 7 2 2 1 Reset circuit breaker to ON or closed gt 7 L o UE 9 4 l Contact the nearest Authorized Dealer for assistance 20 INSTALLATION Section 6 Installation Diagram Air cooled 11 kW Generators Installation Diagram Drawing No 0E7612 A S3HONI SH313NITIIN NI SNOISNSWIC T1V xx N3dO 3914439 3AVH9 V3d HV3H 391 LH9IH 00 2 92 LNOYS STOH NUIT ic s Fr l 0089 6121 7 5 xn 2 3 T mi j 60 1 06 Q 1 gt N 0 Sie toa 1 T w 0 k N ES N JHL 14 LON OG SNOLLO3NNOO HOLIMS lt 335 ONY 9 N 114100 01 SS300 N N N H31
5. EXTERNAL GF CI ACCESSOR CIRCUIT OUTLET BREAKER OUTLET FUSE T2VDC 5A MAX o gt 11 OPERATION Section 5 Operation 1r Air cooled 11 kW Generators 3 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 3 2 3 MANUAL POSITION set the switch to Manual to crank and start the engine Transfer to standby power will not occur unless there is a utility failure With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a pre set level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuses before working on or around the generator or transfer switch Then place DO NOT OPERATE tag on the generator panel and on the transfer switch 3 5 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their Utility position i e loads connected to the utility power source Figure 3 2 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs 1 and N2 3 Set the generator s AUTO OFF MANUAL switch to AUTO 4 Set the generator s main circui
6. A After this heading read instructions that if not strictly complied with will result in serious person al injury including death in addition to property damage waRNING amp After this heading read instructions that if not strictly complied with may result in serious person al injury or property damage amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufac
7. tor control panel Battery cables were factory connected at the genera tor Figure 1 5 Connect cables to battery posts as follows 4 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a nega tive NEG or NOTE Damage will result if battery connections are made in reverse Figure 1 5 Battery Cable Connections BLACK LEAD RED LEAD FROM STARTER CONTACTOR i Section 1 General Information NOTE The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation With the battery installed and utility power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charger is designed to help extend the life of the battery by maintain ing the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 12 THE Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries When replacing the battery use the following type of battery Group 26 26R 12 volt DC
8. 4 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker wARNING amp Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 5 Manually set the transfer switch to the STANDBY position e g load terminals connected to the generator s E1 E2 terminals The transfer switch operating lever should be down 10 Section 2 Post Installation Start up and Adjustments 6 Set the generator s AUTO OFF MANUAL switch to MANUAL The engine should crank and start immediately 7 Let the engine stabilize and warm up for a few minutes 8 Set the generator s main circuit breaker to its ON or closed position Loads are now powered by the standby generator 9 Turn ON electrical loads connected to transfer switch T1 and T2 Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 10 Connect an accurate AC voltmeter and a frequen cy meter across terminal lugs E1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 11 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for o
9. 82 0E6885 83 0D1366 84 035461 85 6301 86 0 9806 87 003026 88 0D9683A 89 0D6029 90 0C9764 91 0C3024 92 0E6314 93 0E3077 94 0388050AH0 95 0388040AMO 96 0E7351 97 003040 98 055934D 99 0C5136A 100 0C8127 101 04981 1 102 075763A PARTS ib ies 00 DESCRIPTION WS eb e cx as BO ck NS N 1 WRAPPER VALLEY SPCC WRAPPER UPPER 2 WITH M8 WELD NUT ASSEMBLY GROUNDING WIRE ASSEMBLY GROUND WIRE CONNECTOR ASSEMBLY IGNITION COIL SCREW HHTT M6 1 0 X 25mm BP SCREW SW 1 4 20 X 5 8 WITH WASHER BOLT CARB MOUNT M6 1 0 x85mm BASE AIR CLEANER BOOT INTAKE KEY WOODRFF 4 X 19D O RING 21 89 X 27 13 X 2 62mm O RING 59 92 X 66 98 X 3 53mm ADPTR OIL PAD FLARE TUBE ENGINE OIL RETURN TUBE ENGINE OIL OUT O RING 20 35 X 23 91 X 1 78mm BOLT OIL ADAPTOR WRAPPER CYLINDER 2 SPCC GASKET CARB TO ADAPTOR CARBURETOR GASKET CARB TO INTAKE MANIFOLD GASKET INTAKE PORT MANIFOLD INTAKE SCREW SHC 8 1 25 X 30mm G12 9 WASHER FLAT M8 SS WASHER LOCK M8 SS CLAMP HOSE HOSE 1 2 0 SPRING ANTI LASH BUSHING GOVERNOR ROD BARBED STRAIT 1 4 NPT X 3 8 CLAMP HOSE OETIKER 16 5mm 3 8 1 0 x 6 COOLER OIL DUCT OIL COOLER SPCC SCREW M6 1 0 X 16mm PLASTITE 1 4 15 X 3 4 COVER AIRBOX PLUG PANEL PLASTIC 0 562 SLEEVE 5 8 I D X 12 5 LONG CABLE BATTERY BLACK 6 48 CABL
10. position Push and hold the Set Exercise Time switch to the ON position for approximately three seconds and release All five red LED s will flash for 10 seconds The unit will perform the standard exer cise sequence then shut down The generator will now exercise every seven days at the time set NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is per formed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected 3 6 PROTECTION SYSTEMS 3 6 1 LOW OIL PRESSURE SWITCH This switch Figure 3 2 has normally closed con tacts that are held open by engine oil pressure dur ing cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added The AUTO OFF MANUAL switch must then be turned to OFF and then back to AUTO 3 6 2 HIGH TEMPERATURE SWITCH This switch s contacts Figure 3 3 close if the tem perature should exceed approximately 132 C 270 F initiating an engine shutdown The generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level Section 3 Operation OPERATION Air cooled 11 kW Generators 1 gt Figure 3 2 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE ENGINE OIL OIL P
11. uuu ua 13 LOW DULL u u ua sasata na 14 Section 4 Maintenance 14 14 Bo MeN To Amp FUSE 14 4 2 Checking the Engine Oil Level 14 4 9 Changing the Engine Oil 14 4 3 1 Engine Oil Recommendations 14 4 3 2 Oil Change Procedure 15 44 Changing the Oil Filtet uec stato dee oria pe 15 4 5 Changing the Engine Air 15 4 0 OPaK PIUS u u ua a ec connect sir pese ex Lex ped 15 4 4 Battery Maintenant u uu u x era 16 4 8 Adjusting GT 990 Valve Clearance 16 4 9 Cooling R 17 4 10 Attention After Submersion 17 4 11 Corrosion Protection 17 4 12 Out of Service Procedure 17 4 12 1 Removal From Service If 4 12 2 Return TO DOEVIOE 18 4 190 Service Schedule 19 Section 5 Troubleshooting 20 51 Troubleshooting 20 Section 6 Installation Diagram 21 Section 7 Electrical Data 22 Section 8 Exploded Views and Parts Lists
12. 12V 16 16 u s sn 14 EE E 5 r 225 224 EE Lu LL 721 L 69 69 T7 66 NEUTRAL poe G 224 240VAC GENERATOR 12Vdc 240VAC EXTERNAL OUTPUT TO TRANSFER UTILITY GFCI 14 TRANSFER SWITCH RELAY INPUT OUTLET CONTACTOR COIL DIAGRAM KEY BA BRUSH ASSEMBLY LOP LOW OIL PRESSURE SWITCH BCR BATTERY CHARGE RELAY SC STARTER CONTACTER CB1 CIRCUIT BREAKER MAIN OUTPUT SCR STARTER CONTACTOR RELAY CB2 CIRCUIT BREAKER ALT EXCITATION SP1 SP2 SPARK PLUGS CB3 CIRCUIT BREAKER EXTERNAL OUTLET PUSH PULL SW1 SWITCH AUTO OFF MANUAL D DIODE DPDT ON OFF ON 225 FS FUEL SOLENOID F1 FUSE 15 AMP SW2 SWITCH SET EXERCISE SPST N C ON OFF F2 FUSE 5 AMP SM STARTER MOTOR HTO HIGH OIL TEMPERATURE SWITCH TX TRANSFORMER 16 Vac 56 VA amp IM1 IGNITION MODULE CYLINDER 1 16 Vac 1 VA DUAL SEC IM2 IGNITION MODULE CYLINDER 2 25 Q us Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators 0 Enclosure Drawing No 0E4884 B ITEM PART NO 1 0E7325 4 0E6884 5 0E4706A 6 0D1131 7 0E4706 8 0C2824 9 039253 10 0 8250 11 0C3032 12 0C3031 13 0E4683 14 0E4378 15 0E6342 16 0E7570 17 0E2874 18 0E4808 19 083512 20 0 4809 21 0 43
13. Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 GENERAL Air cooled 11 kW Generators INFORMATION A Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage This standby generator set has been factory sup plied with a weather protective enclosure that is intended for outdoor installation only amp AN If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a transfer switch The transfer switch must effectively iso late the electrical system from the utility distri bution system when the generator is operating NEC 700 701 amp 702 Failure to isolate an electri cal system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix their signature under the consignor s memo of loss or damage If a loss or damage is noted after delivery separate the damaged materials and conta
14. FUSE FUSE 15 X AGC15 FUSE 7 5AMP X AGC7 5 SWITCH ROCKER SPST ON OFF N C SWITCH ROC DPDT ON OFF ON SCREW HHTT M5 0 8 X 10mm COVER CONTROL PANEL RIGHT COVER CONTROL PANEL LEFT COVER CONNECTION BOX SCREW HHTT 1 0 X 10mm CONNECTION BOX GROMMET 0 75 X 0 06 X 0 50 TERMINAL STRIP NUT HEX M4 0 7 WASHER LOCK 8 4 SCREW PPHM 4 0 7 X 16mm CIRCUIT BREAKER WASHER FLAT 10 CIRCUIT BREAKER MOUNTING BRACKET SCREW HHTT M8 1 2 X 16mm SCREW HHC 1 4 20 X 1 2 LONG WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ITEM PART NO 34 0D8502 35 045770 36 075475 37 049721 38 038750 39 049813 40 054502 41 075210A 42 0C1085 43 0C3910 44 043180 45 002174 46 031879 47 043182 48 051714 49 063617 50 036903 51 0 1658 52 059636 53 0 5280 54 0E6553 55 0E6553A 56 0912970063 082625 58 0 4381 59 0 5840 60 0 4261 61 0 7833 62 022985 63 0 9056 64 0912970064 65 0 9171 66 043182 PARTS qea 00 DESCRIPTION LP OD B 4 A BH BH R PO P NEUTRAL ISOLATOR SCREW HHC M5 0 8 X 10mm SCREW PPHM M4 0 7 X 10mm SCREW HHC M6 1 0 X 35mm SCREW HHC M6 1 0 X 30mm NUT HEX M6 X 1 0 CIRCUIT BREAKER 3 X 1 BLOCK 1 POSITION SCREW PPHM M3 0 5 X 8mm TRANSFORMER WASHER FLAT 4 RELAY 12V 25A SPST WASHER FLAT 4 WASHER LOCK M3 NUT HEX M3 0 5 RELAY PANEL 12VDC DPDT 10A 240VAC SCREW PPHM 6 32 X 5 8 WASHE
15. Frequency 60 Hz Power Factor 1 Recommended Air Filter Part Z C8127 Battery Requirement Group 26 26R 12 Volts and at 17 8 C O F 525 Cold cranking Amperes Minimum Weight 495 Pounds Output Sound Level 23 ft 7m at full load 62 2 db A Normal Operating Range 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature Load current values shown for 120 volts are maximum TOTAL values for two separate circuits The maximum current in each circuit must not exceed the value stated for 240 volts 1 6 2 ENGINE Model 04916 0 Type of Engine GT 990 Number of Cylinders 2 Rated Horsepower 30 3 600 rpm Displacement 992cc Cylinder Block Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid state w Magneto Recommended Spark Plug RC14YC Spark Plug Gap 0 76 mm 0 030 inch Compression Ratio 9 5 1 Starter 12Vdc Oil Capacity Including Filter Approx 1 7 Qts Recommended Oil Filter Part Z 70185 Recommended Air Filter Part Z 0C8127 Operating RPM 2 700 1 7 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal sys tem This type of system uses the vapors forme
16. QUIETSOURCE Installation and Owner s Manual Air cooled Prepackaged Automatic Standby Generators Model No 004916 0 10 kW NG 11 kW LP ICGUIETSOURCE This manual should remain with the unit Not intended for use as Primary Power in place of utility or in life support applications DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model of the Quiet Source product line by Generac Power Systems Inc This model is a compact high performance air cooled engine driven generator designed to auto matically supply electrical power to operate critical loads during a utility power failure This unit is factory installed in an all weather metal enclosure that is intended exclusively for outdoor instal lation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Authorized Dealer for starting operating and servicing procedures NOTE A fee may be charged if a service call is made Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tions are as follows
17. extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system MAINTENANCE S Section 4 Maintenance Air cooled 11 kW Generators Figure 4 7 Cooling Vent Locations Overhead View AIR AIR INTAKE OUTLET cz Um CECE caution amp The maximum ambient temperature for the gen erator is 40 C 104 P 4 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it MUST NOT be started and operated Following any submersion in water have an Authorized Dealer thor oughly clean and dry the generator 4 11 CORROSION PROTECTION Periodically wash and wax the enclosure using auto motive type products Frequent washing is recom mended in salt water coastal areas Spray engine linkages with a light oil such as WD 40 4 12 OUT OF SERVICE PROCEDURE 4 12 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and will 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
18. negative ground battery with a rating of 525 cold cranking amps mini mum at 17 8 C 0 F When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service Schedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly connected and terminals are tight Observe battery polarity when connecting the battery to the generator set A not dispose of the battery a fire The battery is capable of exploding A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries Remove the 7 5A and 15A fuses from the genera tor control panel Remove watches rings or other metal objects e Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and e Disconnect charging source prior to connecting or disconnecting battery terminals warninc amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive gt Section 2 Post Installation Start up a
19. or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 555 1522 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty ser vice evidence mu
20. outlet may also be used when utility power is present by running the genera tor in manual mode A dedicated push pull style circuit breaker is located on the control panel for this outlet Pull the breaker stem out to open the breaker push in to reset or close the breaker V VVVVVV LL Front View 1 5 THE GENERATOR Figure 1 3 11 kW V twin GT 990 Engine Overhead View Z a lt Cw M ZS d O us O Exhaust Enclosure 3 gall v Data Decal Outlet Control Panel Right Side View _ i Air Filter Oil Dipstick M Oil Filter Battery Compartment Fuel Regulator Section 1 General Information INFORMATION Air cooled 11 kW Generators GENERAL 1 6 SPECIFICATIONS 1 6 1 GENERATOR Model 04916 0 Rated Max Continuous Power Capacity Watts 10 000 NG 11 000 LP Rated Voltage 120 240 Rated Max Continuous Load Current Amps 120 Volts 83 9 NG 91 7 LP 240 Volts 41 7 NG 45 8 LP Main Line Circuit Breaker 45 Am Phase 1 Number of Rotor Poles 2 Rated AC
21. used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s e Overtime labor e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Revision 10 01 04 Part 0E4885 Revision E 12 06 05 Printed in U S A
22. 1983 4 RETAINER PISTON PIN 20 10 0 2950 2 PISTON 11 021533 2 SET PISTON RING 90mm 12 0E1466 2 PIN PISTON 13 0D4041 1 ASSEMBLY CAMSHAFT amp GEAR 14 0C2977 1 GASKET CRANK CASE 15 0C5943 1 SEAL OIL PASSAGE 16 0 4357 1 ASSEMBLY CRANKSHAFT 17 082774 1 KEY WOODRUFF 4 X 19D 18 0E3223 2 ASSEMBLY CONNECTING ROD 19 062978 2 GASKET HEAD 20 093873 3 WASHER LOCK RIB M6 21 021374 3 SCREW SHC M6 1 0 X 30 22 0C2994 1 SCREEN OIL PICKUP 23 062997 1 COVER GEROTOR 24 062995 1 GEROTOR INNER 25 0C2996 1 GEROTOR OUTER 26 063011 2 COVER OIL RELIEF 27 0C3009 2 SPRING OIL RELIEF 28 063010 2 BALL 1 20 OIL RELIEF 29 050873A 1 1 4 NPT PIPE PLUG 30 0E9842 1 SEAL 42 D CRANKSHAFT 31 0D9756 1 CONNECTOR 3 8NPT TO INVTD FLR 3 80D 32 0C5732A 1 ASSEMBLY SUMP WITH PLUG 33 0C3006 10 SCREW HHFC M10 1 5 X 55mm 34 080318 8 SCREW HHFC M6 1 0 X 25 35 0C2982 1 COVER ROCKER WITH OIL FILL 36 093064 1 ASSEMBLY OIL FILL CAP 37 062979 2 GASKET COVER 38 086515 8 KEEPER VALVE SPRING 39 0D2274 4 RETAINER VALVE SPRING 40 0D3867 4 SPRING VALVE 41 078672 2 SEAL VALVE STEM D7 42 0C5371 4 WASHER VALVE SPRING 43 0D3998 4 NUT HEX M8 1 0 G8 44 072694 4 STUD ROCKER ARM PIVOT 45 0D5313 4 ROCKER ARM 46 0E3273 1 SCREEN CRANKCASE BREATHER 47 0D6024 2 PLATE PUSH ROD GUIDE 48 002976 12 SCREW HHFC 8 1 25 X 65mm 49 008067 1 ASSEMBLY HEAD 2 50 0C2229 2 VALVE INTAKE 51 086516 2 VALVE EXHAUST 52 0D9853D 4 PUSHROD 147 53 083897 4 TAPPET S
23. 4 Set the AUTO OFF MANUAL switch to OFF and turn off the utility power to the transfer switch Remove the 7 5A and 15A fuses from the genera tor 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 6 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 17 MAINTENANCE Section 4 Maintenance Air cooled 11 kW Generators S 9 Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s 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 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 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
24. 77 22 0C2937 23 022129 24 0E1330A 25 0E4805 26 0E4811 27 0D3700 28 0 52990 29 0 5299 30 0 5297 31 0 4379 32 0 5273 33 0 0165 34 0F0165A 35 0F0164A 36 036261 37 0E7571 38 027028 39 0E7725 40 0E6513 41 0E5298F 42 0E5298E 43 0E4380 44 0E4382 45 0E5298 Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators TY DESCRIPTION 4 1 1 1 1 N 26 PO O PDO HHFS 1 4 20 X 5 8 GRADE 5 SEAL ALTERNATOR SHAFT SOUND BAFFLE INTAKE SCROLL GUARD FAN SCROLL INTAKE SCREW TAP R 10 32 X 9 16 SCREW HHC 8 1 25 X 20 SCREW HHC 3 8 24 X 2 G8 PLATE FAN FAN FLYWHEEL NYLON FAN HUB WITH D DRIVE ASSEMBLY AIR INTAKE DUCT LATCH ADJUSTABLE DRAW GAS SPRING SCREW 1 4 20 X 3 4 SUPPORT LOWER AIR INTAKE SEAL SCREW 8 1 2 X 16mm BASE PAD BASE ENCLOSURE BRACKET BATTERY HOLD DOWN WASHER LOCK M8 5 16 GROMMET 38 1 CROSS SLIT WITH HOLE BRACKET BATTERY POSITION BRACKET REGULATOR NUT FLANGE M6 1 0 NYLOK FOAM ENGINE SIDE PANEL ACOUSTIC FOAM ALTERNATOR SIDE PANEL ACOUSTIC FOAM ENGINE ENCLOUSURE BACK ENCLOSURE POWER HEAD RAIL ROOF STAY SUPPORT HINGE TYPE B WITH STUDS PIN HINGE TYPE B WITH STUDS SOCKET HINGE TYPE A WITH STUDS SOCKET RIVET POP 0 125 X 0 275 BALL STUD GAS SPRING MOUNT NUT LOCK HEX 5 16 18 NYL INSRT BRACKET GAS SPRING ASSEMBLY ROOF FOAM 400 X 220 THERMAL ACOUST
25. AM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY C1 8 POS DEUTSCH CONNECTOR 15C 0 C2 12 POS DEUTSCH CONNECTOR CB1 MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION CB3 CIRCUIT BREAKER EXTERNAL OUTLET PUSH PULL D DIODE DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE 15 F2 FUSE 7 5 GRD 1 CONTROL PANEL GROUND GRD 2 CONTROL PANEL GROUND ISOLATED HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR IM1 IM2 IGNITION MODULE CYLINDER 4 42 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY CONTROL PANEL BOX SM STARTER MOTOR SW1 SWITCH AUTO OFF MANUAL SW SWITCH SET EXERCISE SP1 SP2 SPARK PLUGS TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 12VDC ACCESSORY SOCKET ee Section 7 Electrical Data u 11 kW Generators ELECTRICAL Wiring Diagram Drawing No 0E7071 B lt DATA KH CLOSEST TO BEARING 2 a m ll l 16 16 2 66 2 66 77 167 11 1111 14 162 0 55 0 6 4 11 22 14 6 77 1 44 33 22 1 0 zs 22 M 0 Eg lt U NEIN EH 14 6 14 a LI d qq LLLI j 85 3 85 ppt of gt ee 194
26. B 1 BLOWER HOUSING 29 042633 1 SCREW HHC 3 8 24 X 1 30 022237 2 WASHER LOCK 3 8 31 049451 1 WASHER FLAT 0 406 0 1 62 O D 32 001441 1 SET BLOWER HOUSING GASKET 33 001112 1 BELT V RIB 4LX42 75 34 083512 4 SCREW HHTT M8 1 2 X 16mm 35 039288 2 SCREW HHC 8 1 25 X 55mm 36 029459 2 TENSION SPRING 37 075215 2 WASHER SPRING CENTER 38 052858 10 NUT LOCK FLANGE M8 1 25 39 075237 4 WASHER SPRING CENTER 40 075242 4 SPRING MOUNT 41 0A9202 2 SUPPORT SLIDE 42 0A9918 4 SLIDE NYLON 43 0 0575 3 5 FOAM SEALING STRIP 1 44 0A9226 1 BEARING CARRIER LOWER 45 0E4748 4 STUD STATOR 46 031971 1 BEARING 47 0E3233 1 ROTOR 48 073159 1 BEARING 49 0E3229 1 STATOR 50 0A9227 1 BEARING CARRIER UPPER 51 066386 1 ASSEMBLY BRUSH HOLDER 52 066849 2 SCREW HHTT M5 0 8 x 16mm 53 056326 3 4 TRIM VINYL BLACK 35 PARTS qe is 00 ee 36 D V Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators Regulator Drawing No 0 4881 Section 8 Exploded Views and Parts Lists Qi Air cooled 11 kW Generators Regulator Drawing No 0E4881 C O ITEM PART N TY DESCRIPTION 1 0D5694 1 CASTING TWIN REGULATOR HOUSING 2 0F5022 1 SOLENOID COIL 12VDC 3 004647 1 GASKET SOLENOID 4 0C4680 1 PLUNGER LP REGULATOR ASSEMBLY 5 0C6070 1 SPRING SOLENOID PLUNGER 8 0F4795 4 SCREW PPHM SEMS M4 0 7 X 10 9 0D3973 2 PLUG EXPANSION 16mm 10 0E6183 2 ELBOW 90D STREET 1 2 11 0E6184 1 PLUG PIPE 1 2 COUNTERSUN
27. E BATTERY RED 6 48 ENGINE HARNESS NOT SHOWN PRE CLEANER CLAMP VINYL 1 06 X 0 406 2 KNOB AIR CLEANER ELEMENT AIR CLEANER WASHER FLAT M6 BOOT BATTERY CABLE 33 PARTS qe gis 00 Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators Alternator amp Pulleys Drawing No 0E4880 Section 8 Exploded Views and Parts Lists Qi Air cooled 11 kW Generators Alternator amp Pulleys Drawing No 0E4880 O ITEM PART N TY DESCRIPTION 1 0E0196A 1 FRAME MOUNTING SS HSB 2 022129 7 WASHER LOCK M8 5 16 3 022145 8 WASHER FLAT 5 16 M8 ZINC 4 022259 4 NUT HEX 5 16 18 STEEL 5 0 7758 4 VIB MNT 1 5 X 1 38 X 5 16 18 6 0C3168 1 WASHER LOCK SPECIAL 5 16 7 002417 1 EARTH STRAP 8 0 2424 1 SKID MOUNT ALTERNATOR 9 0E2425 1 SKID MOUNT ENGINE 10 0E2421 1 MANIFOLD EXHAUST 11 0 1078 1 GASKET EXHAUST BASE 12 0E3020 1 BRACKET FRAME EXTENSION 13 040976 4 SCREW SHC 8 1 25 X 20mm 14 056893 6 SCREW CRIMPTITE 10 24 X 15 023897 5 WASHER FLAT 10 ZINC 16 0E1078 1 GASKET EXHAUST BASE 17 0C4138 2 GASKET EXHAUST PORT 18 043116 3 SCREW HHC M6 1 0 X 12 G8 8 19 022097 3 WASHER LOCK M6 1 4 20 022473 3 WASHER FLAT 1 4 M6 ZINC 21 001752 1 FAN NYLON 8 DIA 22 0C1753B 1 PULLEY ALTERNATOR 2200 RPM 23 075224D 1 PULLEY ENGINE 3600 RPM 24 073118 1 SCREW HHC 3 8 24 X 2 1 4 25 0E5984 1 DUCT ALTERNATOR COVER 26 022131 1 WASHER FLAT 3 8 M10 ZINC 21 0C2824 6 SCREW TAP R 10 32 X 9 16 28 0A9827
28. IC FOAM 421 5 X 220 THERMAL ACOUSTIC COVER BACK EXHAUST ENCLOSURE COVER FRONT EXHAUST ENCLOSURE FOAM 746 X 296 5 THERMAL ACOUSTIC PARTS Ce LISTS Enclosure Drawing 0 4884 0 ITEM PART DESCRIPTION 46 0 5297 1 FOAM BACK PANEL THERMAL ACOUSTIC 47 0E5297D 1 FOAM FRONT PANEL THERMAL ACOUSTIC 48 0E5297B 1 FOAM FRONT PANEL THERMAL ACOUSTIC 49 0E5297C 1 FOAM BACK PANEL THERMAL ACOUSTIC 50 0E4385 1 DUCT EXHAUST 91 0D3037A 1 LATCH 1 4 TURN NONLOCKING 52 0 7781 1 PAWL DOOR 53 0 5298 1 FOAM 646 X 447 THERMAL ACOUSTIC 54 0E5298D 1 FOAM 610 X 452 THERMAL ACOUSTIC 55 0E4813 1 BAFFLE FRONT EXHAUST DIVIDER 56 0E4384 1 BAFFLE BACK EXHAUST DIVIDER 0 4783 1 DEFLECTOR EXHAUST 58 0E6005 1 DEFLECTOR ALTERNATOR AIR 59 042907 2 SCREW HHC M8 1 25 X 16mm 60 022145 7 WASHER FLAT 5 16 M8 61 040976 4 SCREW SHC 8 1 25 X 20mm 62 0E5267 1 MUFFLER 63 0E3156 1 BRACKET MUFFLER 64 0D5823 2 BOLT U 5 16 18 X 1 62 WITH SADDLE 65 025145 1 BOLT U 5 16 18 X 1 25 WITH SADDLE 66 0E3206 1 TUBE MUFFLER INLET 67 0E7550 1 DEFLECTOR EXHAUST 68 0E5268 1 TAILPIPE SS HSB EXHAUST 69 0D9166 1 ASSEMBLY TWIN REGULATOR 70 0E5968 9 3 GASKET EXTRUDED TRIM 71 0E6820 1 GASKET SCROLL 72 087233 5 RIVET POP 0 187 X 0 450 7 0E5298A 1 FOAM 746 X 92 5 THERMAL ACOUSTIC 74 0E5298B 1 FOAM 746 X 42 5 THERMAL ACOUSTIC 75 0E5298G 1 FOAM 646 X 86 8 THERMAL ACOUSTIC 76 0E2833D 1 SHEET HARDWRE CLO
29. K 12 0D3308 4 WASHER FLAT M3 X 10mm O D 13 0C5761 2 LEVER REGULATOR 14 0C5968 2 SUPPORT INLET SEAL 15 0C6066 2 SEAL INLET 16 0C5759 2 PIN PIVOT ARM 17 0C5764 2 SPRING REGULATOR 18 070728 4 SCREW 5 M3 0 5 x 5 19 0C6069 2 GASKET DIAPHRAGM 20 0C5762 2 COVER TWIN REGULATOR 21 045764 16 SCREW TAPTITE M4X8 BP 22 0C6731 2 RIVET POP 118 X 125 23 066067 2 SUPPORT DIAPHRAGM 24 004706 2 DIAPHRAGM TWIN REGULATOR 25 0C6068 2 CAP DIAPHRAGM SUPPORT 26 0C4643A 2 INLET TWIN REGULATOR 11 11 DIA 27 026073 2 PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD 28 0 1010 1 JET GT990 LP GAS 29 0C5760G 1 GT990 GAS 30 0 6606 1 BARBED STR 1 2 X 1 2NPT 37 NOTES 38 Section 9 Notes Air cooled 11 kW Generators Section 9 Notes Air cooled 11 kW Generators NOTES 39 Section 10 Warranty WARRANTY Air cooled 11 kW Generators NOTE This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for t
30. OLID 54 0E9323 1 STARTER MOTOR 55 022129 2 WASHER LOCK 8 56 061906 2 SCREW HHC M8 1 25 X 85 31 PART Ce Section 8 Exploded Views and Parts Lists UE Air cooled 11 kW Generators KO Engine Accessories Drawing No 0F2001 D 1 cO 20 2 q ey E E co co EM Y rm NN N aa AX 72 REGULATOR ITEM PART NO 1 045756 2 0D1131 3 0F1169G 4 0C9763 5 0E4386 6 0E5079 7 003034 8 003033 9 051754 10 0A5992 11 0C3032 12 0 3031 13 0C3725A 14 0F1170A 15 0234845 16 009679 17 0E6481 18 OF1167A 19 056893 20 055934 21 074908 22 0E7585 23 0E0998 24 0E4871 25 043790 26 0D3083 27 0E0361A 28 0E0393 29 0C2824 30 065852 31 075246 32 0A4456 33 0A2311 34 070185B 35 0A8584 36 0 5360 37 043182 38 0 1085 39 0 1497 40 0E3305 41 0E5072 42 0E5108 43 047487 44 022097 45 0 4988 46 055173 47 022129 48 022145 49 009801 50 047411 51 022473 52 0C3018A Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators Engine Accessories Drawing No 0F2001 D TY DESCRIPTION 11 1 1 4 1 1 1 1 2 2 1 1 1 1 1 1 1 1 m RD R 2 N p n gt SCREW HHTT M6 1 0 X 10 YC GUARD FAN HOUSING BLOWER V TWIN RV NUT GROMMET 1 4 PLUG TUBE INTAKE H
31. OSE BREATHER NUT HEX M24 2 0 G8 YEL CHR WASHER BELLEVILLE 25MM BOLT SCREW HHC M8 1 25 X 12 G8 8 WASHER SHAKEPROOF INT M8 SS PLATE FAN FAN NYLON FLYWHEEL ASSEMBLY PLATE BACKING WITH OIL COOL BUSHING SNAP WRAP CRANKCASE SPCC GT990 VERTICAL SHAFT DUEL FUEL ENGINE WRAP CYLINDER 1 SPCC SCREW CRIMPTITE 10 24 X 1 2 CLAMP VINYL SCREW HHTT M5 0 8 X 10mm BP SPARK PLUG CLAMP VINYL 9 5 O D TUBE TUBE OIL PASSAGE BARBED ELBOW 90 3 8NPT X 3 8 ASSEMBLY OIL DRAIN HOSE OIL DRAIN DIPSTICK TUBE ASSEMBLY CAP amp DIP STICK SCREW TAP R 10 32 X 9 16 SPRING CLIP HOLDER 0 37 0 62 SCREW HHTT 3 8 16 X 1 1 4 WASHER LOCK SPECIAL 3 8 SCREW SWAGE 1 4 20 X 1 OIL FILTER SWITCH OIL PRESSURE SUPPORT OIL FLTR FLARE WASHER LOCK M3 SCREW PPHM M3 0 5 X 8mm SWITCH OIL HIGH TEMPERATURE BRACKET STEPPER MOTOR MOUNT ROD GOVERNOR CONTROLLER SCREW SHC M6 1 0 X 18mm WASHER LOCK M6 1 4 AIR BOX SUPPORT BRACKET SCREW HHC M8 1 25 X 20mm G10 9 WASHER LOCK 8 5 16 WASHER FLAT 5 16 M8 ZINC WRAP VALLEY UPPER SPCC SCREW HHC M6 1 0 X 16mm WASHER FLAT M6 WRAPPER UPPER 1 WITH M8 WELD NUT ITEM PART NO 53 0D9680A 54 0D1143A 55 0E7209 56 0E4997 57 009852 58 092079 59 0 7215 60 078643 61 0 4867 62 0 5293 63 082774 64 001547 65 001546 66 0A5358 67 0D9312 68 0D9314 69 001557 70 0A9028 71 009682 72 0 0573 73 0E1217A 74 0 0572 75 0C3043 76 0D8836 77 049821 78 070008 79 070006 80 048031M 81 0F7065
32. OUNTING Air cleaner __ __ R J Y Spark plug s x x R Y GENERAL CONDITION Temperature COMPLETE TUNE UP TO BE COMPLETED BY A Y GENERAC AUTHORIZED DEALER 19 TROUBLESHOOTING Section 5 Troubleshooting Air cooled 11 kW Generators 5 1 Problem The engine will not crank The engine cranks but will not start The engine starts hard and runs rough The AUTO OFF MANUAL switch is set to OFF but the engine continues to run There is no AC output from the generator There is no transfer to standby after utility source failure Unit consumes large amounts of oil Cause 1 Fuse blown 2 Loose corroded or defective battery cables 3 Defective starter motor 4 Dead Battery 1 Out of fuel 2 Defective fuel solenoid FS 3 Open 14 wire from engine control board 4 Defective spark plug s 5 Valve lash out of adjustment 1 Air cleaner plugged or damaged 2 Defective spark plug s 3 Fuel Pressure incorrect 1 Defective switch 2 AUTO OFF MANUAL switch wired incorrectly 3 Defective control board 1 Main line circuit breaker open 2 Generator internal failure 1 Defective transfer switch coil 2 Defective transfer relay 3 Transfer relay circuit open 4 Defective control logic board 1 Break in procedure TROUBLESHOOTING GUIDE not followed see Section 2 1 Correction 1 Replace 15A fuse in generator control panel 2 Tighten clean or replace as necessary
33. R LOCK SPECIAL 1 4 PLASTITE PH 4 X 0 37 BRACKET PCB HEADER SUPPORT ISOLATOR SHOULDER WASHER NYLON WASHER NYLON 0 50 X 0 32 X 0 12 GROUND WIRE NUT LOCK HEX 6 32 NYL INSERT PANEL TOP COMPARTMENT CIRCUIT BREAKER 15A PUSH PULL MAIN RESET OUTLET 15A GFCI DUPLEX PLATE WEATHERPROOF GFCI WASHER FLAT 6 SOCKET 12VDC ACCESSORY GROUND WIRE GASKET WEATHERPROOF GFCI WASHER LOCK M3 es Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators GT 990 Engine Drawing No 0F2000 5 2 T a E 2 lt lt am 0 GE pe a TN D 5 3 M E N Ai v SH f an MV 2 IUS Noy Weenie 4 JO Wie OS gt A PAX ER Wi amp E cO ss D 59 ca X E 249 gt NO A W i 6 i Dje D 55 O gt co 3 0 CN sr Section 8 Exploded Views and Parts Lists Qi Air cooled 11 kW Generators ie GT 990 Engine Drawing No 0 2000 O ITEM PART N TY DESCRIPTION 1 0C5730A 1 ASSEMBLY CRANKCASE RV 2 0E9843 1 SEAL 38 1 0 CRANKCASE 3 090388 6 SCREW M6 1 0 X 12mm 4 005372 1 ASSEMBLY BREATHER 5 003005 1 GASKET BREATHER COVER 6 0E3372A 1 SEPARATOR OIL BREATHER 008067 1 ASSEMBLY HEAD 1 8 0C2981C 1 COVER ROCKER 9 07
34. RESSURE FILTER SWITCH 3 6 3 OVERCRANK This feature prevents the generator from damaging itself when it continually attempts to start and anoth er problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED on the generator control panel will light indicating an overcrank failure The AUTO OFF MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the overcrank feature will continue to activate 3 6 3 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total 5 6 1 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gen erator from supplying an output that could poten tially damage appliances connected to the generator circuit Contact the nearest Authorized Dealer if this failure occurs 13 MAINTENANCE S Section 4 Maintenance Air cooled 11 kW Generators 3 6 5 LOW BATTERY The microprocessor will continually monitor the bat tery voltage and turn on the Low Battery LED if the battery voltage falls below 11 0 volts for one minute Low battery voltage is a non latching alarm which will automatically clear if the b
35. TH 787 X 267 17 0D7176 14 WASHER SELF LOCKING 79 045771 2 NUT HEX M8 1 25 G8 80 0A1658 1 WASHER LOCK SPECIAL 1 4 81 022237 1 WASHER LOCK 3 8 82 022131 1 WASHER FLAT 3 8 83 031791 2 CLAMP CABLE 0 48 X 0 204 PLASTIC 84 025034 1 PLUG STEEL 1 06 85 0 5298 1 110 X 452 THERMAL ACOUSTIC 86 0E5298J 1 FOAM 146 X 447 THERMAL ACOUSTIC 87 0E5298K 1 FOAM 146 X 86 8 THERMAL ACOUSTIC 27 Q us Section 8 Exploded Views and Parts Lists gt Air cooled 11 kW Generators 0 Control Panel Drawing No 0E4879 D 64 31 32 33 34 ITEM PART NO 1 0E3312 2 0A1801 3 083049 4 092036 5 0D3062A 6 075235 049226 8 051716 9 0234840 10 0 4387 11 032300 12 022676 13 0 9611 14 0E3928 15 0 4494 16 074908 17 0E4806 18 0 5206 19 0 6045 20 045756 21 0 6044 22 096021 23 046689 24 051715 25 022264 26 075476 27 0E7886D 28 023897 29 0E7890 30 083512 31 022507 32 022097 33 022473 Section 8 Exploded Views and Parts Lists Air cooled 11 kW Generators Control Panel Drawing No 0E4879 D TY DESCRIPTION 1 AD OD 0 BR BO Po O O BN N ASSEMBLY HOME STANDBY CONTROLLER ASSEMBLY BATTERY CHARGER ENGINE ASSEMBLY POTTED REGULATOR PPHM S LW 6 32 X 1 4 LONG HEX STAND OFF 6 32 X 3 4 SCREW HHC 5 0 8 X 30mm WASHER LOCK M5 NUT HEX M5 0 8 SNAP BUSHING 0 875 CONTROL PANEL HOLDER
36. VM 21 01 HOdVA 3NvdOHd AINON X ON H31VM 4 9 SVO VN E N N3dO JOOH 3unss3ud 1903 qauinoau LIINI TINA LAN i3 P dOL HOOQ 39IAH3S 9 0 621 30 i S o 7 i 17526 928 18677 6121 7 LINN aNnouv Tiv V3uv N3dO WAWINIW WM o 1 0961 141100 Ar s _ a _ _ J HIV 4l _ 2 HIV 21 Section 7 Electrical Data ELECTRICAL Air cooled 11 kW Generators DATA Wiring Diagram Drawing No 0E7071 B SCR 4 1 1 1b 15A SW 224 M NE 55 e 66A 2111 j 14 14 m H Jd 16 4 1 18 6 0 14 86 5 4 225 224A 225A GOVERNOR ACTUATOR CONTROL PRINTED CIRCUIT BOARD ON 23 66 aie 2 SW 1 ON 50Hz 1 Grane 4 2248 14 0 2258 77 86 85 18 0 15 2 SPARE 4 4 o j pM g EX 11 11 1 1 gc o C pP y 0 86 RE VOLTAGE REGULATOR x dm EN o O i 15 2 15 15 7 0 225B 0 N r T 13 F1 13 224B 13 13 13 N2 BATTERY in 42 Mie CHARGER es a 150 194 2258 DIAGR
37. anism lets the engine warm up for about 10 seconds before the load is transferred to the standby source C Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored above 70 per cent of the nominal source voltage a retransfer time delay starts timing D Retransfer Time Delay This timer runs for about 15 seconds At end of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs E Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts tim ing The timer will run for about one minute and the generator will then shut down 3 5 SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day the following sequence is completed During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 3 1 per mits selection of the day and time for the system to exercise At the chosen time perform the following sequence to select the desired day and time of day the system will exercise Place the AUTO OFF MANUAL switch in the AUTO
38. attery voltage rises above 11 0 volts The control system will not attempt to start the engine if there is a low battery condition however if the engine is already running when the low bat tery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 4 1 SYSTEM FUSE The generator panel s 15 amp fuse Figure 4 1 pro tects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open the engine cannot crank or start Replace the fuse using only an identical 15 amp replacement 4 1 1 7 5 AMP FUSE The generator panels 7 5 amp fuse protects the accessory outlet against overload If the fuse element has melted open there will not be power at the acces sory outlet Replace the fuse using only an identical 7 5 amp fuse To remove fuse push cap down and rotate counterclockwise Figure 4 1 Generator Control Panel lt OO O SYSTEM SE LOW BATTE LOW OIL HIGH TEMP OVER SPEE OVER CRA FLASHING GREEN LED NO UTILITY SENSE FIVE 5 FLASHING RED LEDS EXERCISER NOT SE WQUIETSOURCE NL MANUAL ACCESSOR OUTLET 14 42 CHECKING THE ENGINE OIL LEVEL For oil capacities se
39. ch as natural gas and liquid pro pane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applicable fuel gas codes Before placing the home standby electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation inspect the fuel system periodically for leaks No leakage is permit ted STANDARDS INDEX In the absence of pertinent standards codes regu lations and laws the published information listed below may be used as installation guide for this equipment l NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES available same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK avail able from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of
40. clockwise Apply a light coating of clean engine oil to the gasket of the new filter See Section 1 6 1 for rec ommended filter Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 4 3 Refill with the proper recommended oil see Section 4 3 1 See Section 1 6 2 for oil capaci ties Start the engine and check for leaks MAINTENANCE 2 Section 4 Maintenance Air cooled 11 kW Generators 4 5 CHANGING THE ENGINE AIR CLEANER See Figure 1 3 for the location of the air cleaner Use the following procedure Figure 4 4 1 2 3 4 5 Turn the two screws counterclockwise to loosen Remove the cover and air filter Wipe away dust or debris from inside of the air box and around edges Install the new air cleaner into the air box Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule Section 4 13 for air cleaner maintenance See Section 1 6 1 for air filter replacement part number Figure 4 4 Engine Air Cleaner d Filter Cover Screw 4 6 SPARK PLUGS Reset the spark plug gaps or replace the spark plugs as necessary See Section 4 13 for maintenance requirements 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and comme
41. ct the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is discovered later 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 1 Low Oil Pressure Sensor 2 High Temperature Sensor 3 Overcrank There are LED readouts on the control panel to notify the user that one of these faults has occurred There is also a System Set LED that is lit when all of the conditions describe in Section 1 3 are true 4 Overspeed 5 Low Battery Section 1 General Information 13 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true 1 The AUTO OFF MANUAL switch is set to the AUTO position 2 The utility voltage being supplied to the unit is being sensed by the PCB If the utility sense volt age is not connected to the unit or if it is below 168 volts AC then the system set light will flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto position the generator will start 3 The Not In Auto dip switch is set to the OFF position on the control board 4 No alarms are present for example low oil pres sur
42. cts to the part as described in the engine manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary Shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under
43. d above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section 1 8 for instructions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water column 0 18 to 0 25 and for liquid propane vapor 10 inches to 12 inches of water column 0 36 to 0 43 psi wanNiNG amp A seperate gas line and regulator may be need ed to assure proper gas pressure to the genera tor Low gas pressure can cause hard starting and could affect engine durability 1 8 FUEL CONSUMPTION Full Load 04916 1 38 55 6 2 15 86 4 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour A Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is permitted Natural gas which is ligh
44. d with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dan gerous and possibly fatal electrical shock 10 Connect an accurate AC voltmeter and a fre quency meter across transfer switch terminal lugs 1 and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz 11 Connect the AC voltmeter test leads across ter minal lug E1 and neutral then across E2 and neutral In both cases voltage reading should be 121 126 volts AC 12 Set the generator s main circuit breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 13 Set the generator s AUTO OFF MANUAL switch to OFF The engine should shut down NOTE It is important not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is cor rect but voltage is high or low the generator s voltage regulator requires adjustment 2 4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Turn OFF all loads connected to the transfer switch terminals T1 and T2 3 Set the generator s AUTO OFF MANUAL switch to OFF
45. e Specifications Section 1 5 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figures 4 2 1 Start the generator by moving the AUTO OFF MANUAL switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth 3 Install the dipstick then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE MARK caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 4 Install the dipstick 5 Reset the AUTO OFF MANUAL switch to its origi nal position Figure 4 2 Oil Dipstick and Fill CL Oil Fill 3 Oil Dipstick m 1 OO 24 i L EA 4 5 CHANGING THE ENGINE OIL 4 5 1 ENGINE OIL RECOMMENDATIONS Use oil of American P
46. e high temperature etc 1 4 ACCESSORY FEATURES 141 12 VOLT DC OUTLET The generator is equipped with a 12 volt DC accesso ry outlet located in the system control panel Figure 1 1 With the generator running or in standby mode this outlet may be used to temporarily power low power accessories such as an inspection light cell phone radio or other automotive style accessory with 7 5 amp maximum current draw Figure 1 1 12 Volt DC Outlet f N AUTO SET EXERCISE TIME OFF SYSTEM FUSE i el MANUAL EXTERNAL ACCESSORY CIRCUIT OUTLET BREAKER OUTLET FUSE 7 5A 12VDC 7 5A MAX waRNING amp The 12 volt DC accessory socket is not intended for continuous use Power for this socket is drawn from the engine battery Extended use will drain the battery and the engine may not start Power available at this socket is limited to 7 5 amps maximum Section 1 General Information Air cooled 11 kW Generators 1 4 2 120 VOLT AC OUTLET Figure 1 2 120 Volt AC Outlet The generator is equipped with an external 15 amp 120 VAC 120 volt GFCI convenience outlet located on the front of the unit Figure 1 2 When the generator is running in the absence of utility power this outlet s may be used to power items outside the home such as lights or power tools This
47. en it is as forward as it can go Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in lbs torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 4 6 Valve Clearance Adjustment Pivot Ball Stud Rocker Arm Install new valve cover gasket Re attach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 4 9 COOLING SYSTEM Air inlet and outlet openings in the generator com partment must be open and unobstructed for con tinued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 4 7 for vent loca tions waRnNING The exhaust from this product gets
48. etroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 oynthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with break in oil See the Procedure Section 3 1 for the first required oil change caution amp Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 4 5 2 CHANGE PROCEDURE To change the oil proceed as follows 1 2 Run the engine until it is thoroughly warmed up then shut OFF the engine Immediately after the engine shuts OFF pull the oil drain hose Figure 4 3 free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip Refill with the proper recommended oil see Section 4 3 1 See Section 1 6 2 for oil capaci ties Figure 4 3 Oil Drain Hose and Filter Oil Drain Hose Loosen il U J ae Oil Filter 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 2 With drained remove the old oil filter by turning it counter
49. fically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique uti lized does not render the generator unsafe DIG A AN Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment AN Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and main tenance of this equipment is carried out by an Authorized Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operat
50. he periods of time listed below provided there has been no abuse neglect unapproved modifica tion or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance
51. ice does not normally exist e Costs of normal maintenance adjustments installation and start up e Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts e Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine e Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane e Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing e Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s e Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found e Rental equipment
52. il leaks evidence of overheating etc 12 When testing under load is complete turn OFF electrical loads 13 Set the generator s main circuit breaker to its OFF or open position 14 Let the engine run at no load for a few minutes 15 Set the AUTO OFF MANUAL switch to OFF The engine should shut down 25 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Check that the AUTO OFF MANUAL switch is set to OFF 3 Turn OFF the utility power supply to the transfer switch using means provided such as a utility main line circuit breaker 4 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 5 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker 6 Set the AUTO OFF MANUAL switch to AUTO The system is now ready for automatic operation 7 Turn OFF the utility power supply to the transfer switch With the AUTO OFF MANUAL switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the ut
53. ility power supply to the transfer switch The following should occur After about six seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down 2 6 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 60 60 5 Hertz slowly turn the slotted potentiometer Figure 2 1 until line voltage reads 247 252 volts NOTE The access panel on top of the control panel must be removed to adjust the voltage regulator Figure 2 1 Voltage Adjustment Potentiometer 4m e NOTE The voltage regulator is housed inside the gen erator s control panel The regulator maintains voltage in direct proportion to frequency at a 2 to 1 ratio For example at 62 Hertz line to neutral voltage will be 124 volts 3 1 BREAK IN PROCEDURE Once the unit has been installed and all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Set the generator s AUTO OFF MANUAL switch to AUTO 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker 3 The unit will start and the transfer switch will transfer to standby Section 3 Operation OPERATION Air cooled 11 kW Ge
54. ing Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator The generator MUST be installed outdoors When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Dealer for parts needing repair or replacement Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera tion Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If w
55. nd Adjustments POST CED INSTALLATION Air cooled 11 kW Generators STARTUP ADJUSTMENTS The following procedures are to be observed e Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and e Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off and the 7 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts a
56. nerator s main circuit breaker to its OFF or open position 2 Set the generator s AUTO OFF MANUAL switch to the OFF position 3 Turn OFF all loads connected to the transfer switch terminals T1 and T2 4 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A AN The transfer switch is now electrically hot Contact with hot parts will result in extremely hazardous and possibly fatal electrical shock Proceed with caution 5 Use an accurate AC voltmeter to check utility power source voltage across transfer switch ter minals N1 and N2 Nominal line to line voltage should be 240 volts AC 6 Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 7 When certain that utility supply voltage is compat ible with transfer switch and load circuit ratings turn OFF the utility power supply to the transfer switch 8 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 9 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator s main circuit breaker to its ON or closed position 9 POST CE INSTALLATI N START UP ADJUSTMENTS Air cooled 11 kW Generators A N Procee
57. nerators 1 gt Run the unit for one hour at 25 rated load Run the unit for one hour at 50 rated load Run the unit for one hour at 75 rated load Run the unit for one hour at 100 rated load Turn ON the utility power supply to the transfer switch which will allow the transfer switch to transfer back to utility power The unit will con tinue to run for one minute and then shut down Allow the unit to cool 10 Set the generator s AUTO OFF MANUAL switch to OFF Remove the 7 5A and 15A fuses from the generator control panel Disconnect the battery cables as outlined in General Hazards page 2 11 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Replace the oil with synthetic oil as recommended in Section 4 3 Changing the Engine Oil 12 Reconnect the battery cables as outlined in General Hazards page 2 and insert the 5A and 15A fuses into the generator control panel The generator is now ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 3 2 1 AUTO POSITION Selecting this switch position activates fully automat ic system operation It also allows personnel to start and exercise the engine every seven days with the set ting of the exercise timer see Section 3 5 p IX EM ys Figure 3 1 Generator Control Panel AUTO SET EXERCISE TIME SS FUSE MANUAL C gt
58. on all sides of the generator for maintenance and servicing A good rule is to allow three feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds Install the generator as close as possible to the fuel supply to reduce the length of piping Install the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE The genset must be installed on a level surface The base frame must be level within two 2 inches all around 7 Air cooled 11 kW Generators 1 10 2 TRANSFER SWITCH This generator should only be installed with a com patible transfer switch A range of transfer switches are offered by the manufacturer 1 11 BATTERY INSTALLATION warninc A If the AUTO OFF MANUAL switch is not set to its OFF position the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off spark ing can occur at the battery posts and cause an explosion Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Set the generator s AUTO OFF MANUAL switch to OFF 2 Turn off utility power supply to the transfer switch 3 Remove the 7 5A and 15A fuses from the genera
59. ork must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical sys tem After installing this home standby electrical sys tem the generator may crank and start at any time without warning When this occurs load circuits are transferred to the STANDBY GENERATOR power source To prevent possible injury if such a start and transfer occur always set the generator s AUTO OFF MANUAL switch to its OFF position before working on equipment and remove the 7 5A and 15A fuses from the generator control panel In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock o
60. r may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and rec ommendations Following proper installation do nothing that might alter a safe installation and ren der the unit in noncompliance with the aforemen tioned codes standards laws and regulations SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Air cooled 11 kW Generators Keep a fire extinguisher near the generator at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extin guisher properly charged and be familiar with its use Consult the local fire department with any questions pertaining to fire extinguishers EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids su
61. rcial solvent Do not blast the spark plugs to clean Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See Section 4 13 for recommended inspection Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 inch by carefully bending the ground electrode Figure 4 5 15 MAINTENANCE S Section 4 Maintenance Air cooled 11 kW Generators Figure 4 5 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm 2 4 Cue CU VES S S 4 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 13 The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer A A Do not dispose of the battery in a fire The battery is capable of exploding A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries Remove the 7 5A and 15A fuses from the genera tor control panel e Remove watches rings or other metal object
62. s Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and e Disconnect charging source prior to connecting or disconnecting battery terminals warninc amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed e Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water 16 e Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and e Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause or spark in battery area and e Discharge static electricity from body before touch ing the battery by fir
63. s the cables are attached and cause an explosion 2 1 BEFORE INITIAL START UP Before starting complete the following 1 Set the generators main circuit breaker to its OFF or OPEN position 2 Set the generator s AUTO OFF MANUAL switch to the OFF position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 4 Turn OFF all loads connected to the transfer switch terminals T1 and T2 5 Check the engine crankcase oil level and if neces sary fill to the dipstick FULL mark with the rec ommended oil Do not fill above the FULL mark 6 Check the fuel supply Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel gas codes All fuel shutoff valves in the fuel supply lines must be open caution amp Never operate the engine with the oil level below the ADD mark on the dipstick Doing this could damage the engine 2 2 CHECK TRANSFER SWITCH OPERATION Refer to the transfer switch owner s manual for man ual operation procedures 1091 A Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 2 5 ELECTRICAL CHECKS Complete electrical checks as follows 1 Set the ge
64. st be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at one of the following addresses For Air cooled Product For Liquid cooled Product ATTENTION WARRANTY DEPARTMENT ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC GENERAC POWER SYSTEMS INC P O BOX 297 211 MURPHY DRIVE WHITEWATER WI 53190 EAGLE WI 53119 Part 1 40 Section 10 Warranty Air cooled 11 kW Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year engines a Applicability This warranty shall apply to 1995 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respe
65. st touching a grounded metal surface Be sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off and the 5A and 15A fuses are removed from the generator control panel or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 8 ADJUSTING GT 990 VALVE CLEARANCE After the first six months of operation adjust the valve clearance in the engine Figure 4 6 Important If feeling uncomfortable about doing this procedure or the proper tools are not available please contact the Authorized Dealer for service assistance This is a very important step to insure longest life for the engine To adjust valve clearance Make sure the engine is at room temperature between 60 and 80 Make sure that the spark plug s are removed Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the screen at the top of the intake scroll to gain access to the intake fan Rotate the engine by hand by rotating the fan while watching the piston through the spark plug hole The piston should move back and forth The pis ton is at TDC wh
66. t breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Section 3 4 Sequence of Automatic Operation 12 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors util ity power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to acti vate and connect load circuits to the standby power supply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility source voltage above a preset level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 70 percent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mech
67. t which upon examination inspection and testing by Generac or an Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the pur chaser owner This warranty applies only to Generac Quietsource prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and main tenance is required Engine All Components Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING e Quietsource generators that utilize non Generac Quietsouce replacement parts e Quietsource generators utilizing non Generac Quietsource automatic transfer switches e Repairs performed by individuals other than Guardian Generac authorized dealers e Any Quietsource generators used as rental or trailer mounted applications Air cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power serv
68. ted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 41 Section 10 Warranty WARRANTY Air cooled 11 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR QUIETSOURCE PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Quietsource gen erator will be free from defects in material and workmanship for the items and period set forth below Generac will at its option repair or replace any par
69. ter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 9 RECONFIGURING THE FUEL SYSTEM To reconfigure the fuel system from NG to LP follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose and the brass hose fitting from the NG right outlet port of the demand regulator Figure 1 4 Section 1 General Information GENERAL Air cooled 11 kW Generators INFORMATION 3 Remove the pipe plug from the LP left outlet port 4 Install the brass hose fitting in the LP left outlet port 5 Install the pipe plug in the NG right outlet port 6 Connect the carburetor fuel hose to the LP left outlet port of the demand regulator 7 Reverse the procedure to convert back to natural gas Figure 1 4 Demand Regulator LP OUTLET LP OUTLET PORT PORT NG OUTLET NG OUTLET NG FUEL SYSTEM LP FUEL SYSTEM 1 10 LOCATION 1 10 1 GENERATOR Install the generator set its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet open ings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drifting consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room
70. the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warran
71. to 100 percent state of charge or if defective replace the battery oee Specifications Section 1 6 for type and size 18 8 9 Clean and wipe the entire generator Remove the 7 5A and 15 fuses from the genera tor control panel Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly Open the fuel shutoff valve Insert the 7 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 Stop the unit by setting the AUTO OFF MANUAL switch to OFF Turn on the utility power to the transfer switch 10 Set the AUTO OFF MANUAL switch to AUTO 11 The generator is now ready for service NOTE If the battery was dead or disconnected the exer cise timer must be reset Section 4 Maintenance Air cooled 11 kW Generators MAINTENANCE S 4 13 SERVICE SCHEDULE ATTENTION It is recommended that all service work be performed by the nearest Authorized Dealer SYSTEM COMPONENT PROCEDURE FREQUENCY X Action Inspect Change Clean W Weekly R Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections M LUBRICATION Oil level x M AND Y AND Y COOLING Enclosure louvers x x _ W BATTERY ensure dryness battery terminals Check charge state EVERY 6 unsealed batteries only ENGINE AND M
72. turer also strong ly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for model 04916 0 10 kW NG 11 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Dealer for assistance service technicians are factory trained and are capa ble of handling all service needs When contacting an Authorized Dealer about parts and service always supply the complete model num ber and serial number of the unit as gi
73. ven on its data decal which is located on the generator See Figure 1 3 for decal location Model No Serial No AUTHORIZED DEALER LOCATION To locate the nearest AUTHORIZED DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com Introduction Inside Front Cover Read This Manual Thoroughly IFC Bo cites E IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC Safety Rules 2 Standards uuu u 3 Section 1 General Information 4 LI 4 1 2 ProlecHon SYSICINS ees rie eeu o ERE Pu eoe Ru EP 4 kao System DELL Ubi dient SA 4 lat Accessory Features 4 1 4 1 12 Volt DC Outlet 4 1 4 2 120 Volt AC Quel uu u uu uu 5 5 LO 6 LO PEE L yy u quads 6 LO2 c 6 1 7 Fuel Requirements and Recommendations 7 Lo 7 19 Reconbgurmg the Fuel System

Generac Power Systems 004916-0 Portable Generator User Manual

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