Generac Power Systems 004916-0 User Manual
Installation and
Owner’s Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Model No. 004916-0
(10 kW NG, 11 kW LP)
Not intended for use as Primary Power in place of utility or in
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
life-support applications.
DANGER
*This manual should
remain with the unit.
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, aircooled, engine-driven generator designed to automatically 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 installation. 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withdrawn liquid propane (LP) or natural gas (NG).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 personnel to special instructions about a particular operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death, in addition to property
damage.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use
of the equipment. The manufacturer strongly recommends that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly 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.
After this heading, read instructions that, if not
strictly complied with, may result in serious personal injury or property damage.
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 compliance 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.
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 capable of handling all service needs.
When contacting an Authorized Dealer about parts
and service, always supply the complete model number and serial number of the unit as given 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
Table of Contents
Air-cooled 11 kW Generators
Introduction ............................... Inside Front Cover
Read This Manual Thoroughly ................................. IFC
Contents .................................................................. IFC
Operation and Maintenance ..................................... IFC
How to Obtain Service ............................................. IFC
Authorized Dealer Locator Number ............................. IFC
Safety Rules ............................................................... 2
Standards Index .................................................. 3
Section 1 – General Information .......................... 4
1.1 Unpacking/Inspection ............................................ 4
1.2 Protection Systems ................................................4
1.3 System Set LED .................................................... 4
1.4 Accessory Features ................................................4
1.4.1 12 Volt DC Outlet ...................................... 4
1.4.2 120 Volt AC Outlet .................................... 5
1.5 The Generator ....................................................... 5
1.6 Specifications ........................................................ 6
1.6.1 Generator ..................................................6
1.6.2 Engine ....................................................... 6
1.7 Fuel Requirements and Recommendations ...........7
1.8 Fuel Consumption ................................................. 7
1.9 Reconfiguring the Fuel System .............................. 7
1.10 Location ................................................................7
1.10.1 Generator .................................................. 7
1.10.2 Transfer Switch ........................................8
1.11 Battery Installation ................................................8
1.12 The Battery ........................................................... 8
Section 2 – Post Installation Start-up
and Adjustments ................................ 9
2.1 Before Initial Startup............................................. 9
2.2 Check Transfer Switch Operation .........................9
2.3 Electrical Checks................................................... 9
2.4 Generator Tests Under Load ...............................10
2.5 Checking Automatic Operation ............................10
2.6 Voltage Regulator Adjustment .............................. 11
Section 3 – Operation ...........................................11
3.1 Break-in Procedure ............................................. 11
3.2 Using the AUTO/OFF/MANUAL Switch ................ 11
3.2.1 “Auto” Position ........................................ 11
3.2.2 “Off” Position .......................................... 12
3.2.3 “Manual” Position .................................... 12
3.3 Automatic Transfer Operation ............................. 12
3.4 Sequence of Automatic Operation .......................12
3.5 Setting the Exercise Timer ..................................13
3.6 Protection Systems ..............................................13
3.6.1 Low Oil Pressure Switch ......................... 13
3.6.2 High Temperature Switch........................ 13
3.6.3 Overcrank ............................................... 13
3.6.4 Overspeed ............................................... 13
3.6.5 Low Battery ............................................. 14
Section 4 – Maintenance ...................................... 14
4.1 System Fuse ........................................................ 14
4.1.1 7.5 Amp Fuse .......................................... 14
4.2 Checking the Engine Oil Level ............................. 14
4.3 Changing the Engine Oil ...................................... 14
4.3.1 Engine Oil Recommendations ................. 14
4.3.2 Oil Change Procedure ............................. 15
4.4 Changing the Oil Filter ........................................15
4.5 Changing the Engine Air Cleaner ......................... 15
4.6 Spark Plugs .........................................................15
4.7 Battery Maintenance ............................................16
4.8 Adjusting GT-990 Valve Clearance ....................... 16
4.9 Cooling System.................................................... 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 ............................ 17
4.12.2 Return to Service .................................... 18
4.13 Service Schedule ................................................. 19
Section 5 – Troubleshooting ................................20
5.1 Troubleshooting Guide ........................................20
Section 6 – Installation Diagram ........................ 21
Section 7 – Electrical Data ................................... 22
Section 8 – Exploded Views and
Parts Lists ........................................... 26
Section 9 – Notes ................................................... 38
Section 10 – Warranty ...........................................40
1
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.
The engine exhaust from this product
contains chemicals known to the state
defects or other reproductive harm.
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 installing, 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 warnings 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 specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the generator unsafe.
WARNING:
of California to cause cancer, birth
WARNING:
DANGER
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.
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.
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and maintenance 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 compliance with applicable codes and standards.
Following installation, do nothing that might render 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 operating.
• 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 seriously 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 conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
2
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 operation. 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 work 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 system.
• After installing this home standby electrical system, 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, immediately 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 equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components 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 recommendations. Following proper installation, do
nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.
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 extinguisher 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 combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid propane (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 permitted.
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and laws, the published information listed
below may be used as installation guide for this
equipment.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, avail-
able from the Food and Energy Council, 909
University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND
MAINTENANCE OF FARM STANDBY ELECTRICAL
SYSTEMS, available from the American Society
of Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
3
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Section 1 — General Information
Air-cooled 11 kW Generators
DANGER
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 supplied with a weather protective enclosure that is
intended for outdoor installation only.
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 isolate the electrical system from the utility distribution system when the generator is operating
(NEC 700, 701 & 702). Failure to isolate an electrical 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 contact 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 present 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 4. Overspeed
2. High Temperature Sensor 5. Low Battery
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
1.3 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 voltage 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 pressure, high temperature, etc.
1.4 ACCESSORY FEATURES
1.4.1 12 VOLT DC OUTLET
The generator is equipped with a 12 volt DC accessory 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
a 7.5 amp maximum current draw.
Figure 1.1 — 12 Volt DC Outlet
AUT
EXERCI
F
1
TLE
F
7.
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.
MANUA
ACCE
12VD
7.5A MAX
TLE
Section 1 — General Information
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Air-cooled 11 kW Generators
1.4.2 120 VOLT AC OUTLET
The generator is equipped with an external, 15 amp,
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
may be used to power items outside the home such
as lights or power tools. This outlet may also be used
when utility power is present by running the generator 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.
1.5 THE GENERATOR
Figure 1.3 – 11 kW, V-twin GT-990 Engine
Overhead View
Figure 1.2 — 120 Volt AC Outlet
120 VA
TLE
Front View
Exh
Enclosur
Right Side View
Air Filt
Oil Dipstic
utle
il Filte
Fuel Regulato
Data D
ontrol Pane
Battery Compartmen
5
Section 1 — General Information
Air-cooled 11 kW Generators
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** 83.3 NG/91.7 LP
240 Volts 41.7 NG/45.8 LP
Main Line Circuit Breaker 45 Amp
Phase 1
Number of Rotor Poles 2
Rated AC Frequency 60 Hz
Power Factor 1
Recommended Air Filter Part # C8127
Battery Requirement Group 26/26R 12 Volts and
at -17.8° C (0° 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 # 70185
Recommended Air Filter Part # 0C8127
Operating RPM 2,700
6
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Section 1 — General Information
Air-cooled 11 kW Generators
1.7 FUEL REQUIREMENTS
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed
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).
A seperate gas line and regulator may be need-
ed to assure proper gas pressure to the generator. Low gas pressure can cause hard starting
and could affect engine durability.
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 OUTLE
POR
NG FUEL SYSTE
NG OUTLE
POR
LP OUTLE
POR
LP FUEL SYSTE
NG OUTLE
POR
1.10 LOCATION
1.8 FUEL CONSUMPTION
Model # Nat. Gas (*) LP Vapor (**)
1/2 Load Full Load 1/2 Load Full Load
04916 115 202 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.
DANGER
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 lighter 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).
1.10.1 GENERATOR
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
• Install the unit where air inlet and outlet openings 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 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
Section 1 — General Information
Air-cooled 11 kW Generators
1.10.2 TRANSFER SWITCH
This generator should only be installed with a compatible transfer switch. A range of transfer switches
are offered by the manufacturer.
1.11 BATTERY INSTALLATION
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, sparking 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 generator control panel.
Battery cables were factory connected at the generator (Figure 1.5). Connect cables to battery posts as
follows:
4. Connect the red battery cable (from starter contactor) 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 negative, NEG or (—).
NOTE:
Damage will result if battery connections are made
in reverse.
Figure 1.5 – Battery Cable Connections
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 maintaining the battery when the unit is not running. The
trickle charge feature cannot be used to recharge
a discharged battery.
1.12 THE BATTERY
Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.
When replacing the battery, use the following type of
battery: Group 26/26R 12-volt DC, negative ground
battery with a rating of 525 cold-cranking amps minimum at -17.8º C (0º F). When using a maintenancefree 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.
DANGER
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 precautions are to be observed when working on
batteries:
• Remove the 7.5A and 15A fuses from the generator control panel.
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
8
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.
Section 2 — Post Installation Start-up and Adjustments
The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• 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 bicarbonate 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
• Discharge static electricity from body before touching 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 as the cables are
attached and cause an explosion.
Air-cooled 11 kW Generators
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 manual operation procedures.
DANGER
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.
2.3 ELECTRICAL CHECKS
Complete electrical checks as follows:
1. Set the generator'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).
DANGER
2.1 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Set the generator’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 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 necessary, fill to the dipstick FULL mark with the recommended 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.
.
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 terminals N1 and N2. Nominal line-to-line voltage
should be 240 volts AC.
6. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-toneutral voltage should be 120 volts AC.
7. When certain that utility supply voltage is compatible 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
Section 2 — Post Installation Start-up and Adjustments
Air-cooled 11 kW Generators
DANGER
Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in dangerous and possibly fatal electrical shock.
10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal
lugs E1 and E2. Voltage should be 242-252 volts;
frequency should read about 61-63 Hertz.
11. Connect the AC voltmeter test leads across terminal 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 noload 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 correct, but voltage is high or low, the generator’s
voltage regulator requires adjustment.
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 frequency 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 oil 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.
2.5 CHECKING AUTOMATIC
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.
4. Turn OFF the utility power supply to the transfer
switch, using the means provided (such as a utility main line circuit breaker).
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
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 utility power source side.
5. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a utility 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.
Section 3 — Operation
Air-cooled 11 kW Generators
With the generator running and loads powered by
generator AC output, turn ON the utility 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
4. Run the unit for one hour at 25% rated load.
5. Run the unit for one hour at 50% rated load.
6. Run the unit for one hour at 75% rated load.
7. Run the unit for one hour at 100% rated load.
8. 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 continue to run for one minute and then shut down.
9. 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
NOTE:
The voltage regulator is housed inside the generator's control panel. The regulator maintains a
voltage in direct proportion to frequency at a 2-to1 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.
SWITCH (FIGURE 3.1)
3.2.1 “AUTO” POSITION
Selecting this switch position activates fully automatic system operation. It also allows personnel to start
and exercise the engine every seven days with the setting of the exercise timer (see Section 3.5).
Figure 3.1 – Generator Control Panel
11
Section 3 — Operation
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 preset 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 a “DO NOT OPERATE” tag on the generator
panel and on the transfer switch.
3.3 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 N1
and N2.
3. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
4. Set the generator’s main circuit 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.”
3.4 SEQUENCE OF AUTOMATIC
OPERATION
The generator’s control panel houses a control logic
circuit board. This board constantly monitors utility 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 activate 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 mechanism 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 voltage. When that voltage is restored above 70 percent 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 timing.
• The timer will run for about one minute, and the
generator will then shut down.
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