Generac Power Systems 004916-0 manual

Installation and Owner’ s Man ual Air -cooled, Prepac ka ged A utomatic Standb y Generator s Model No. 004916-0 (10 kW NG, 11 kW LP) D ANGER DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y! Not intended for use as Primary P ower in place of utility or in life-support applications.   *This manual should remain with the unit.[...]

I NTRODUCTION Thank you for purchasing this model of the Quiet Source product line by Generac P ower 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-w[...]

T able of Contents Air-cooled 1 1 kW Generators 1 Introduction ............................... Inside Front Cover Read This Manual Thoroughly ................................. IFC Contents .................................................................. IFC Operation and Maintenance ..................................... IFC How to Obtain Service [...]

2 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 ru[...]

3  ELECTRICAL HA Z AR DS  • 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. A void contact with bare wires, terminals, connections, etc[...]

D ANGER  Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. 1.1 U N P A CKI NG/I NSP ECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been factory sup - plied with a weather protective enclo[...]

Section 1 — General Information Air-cooled 1 1 kW Generators 5 1.5 TH E GEN ER A T OR Exh aust En c lo su r e O il Filte r Oil Di p stic k Air Filt er Batter y Compartmen t C ontrol Pane l D a t a D ecal Fuel Re g ulato r G F C I O utle t Figure 1.3 – 11 kW , V -twin GT -990 Engine 1.4.2 1 20 V OL T AC OUTLE T The generator is equipped with an [...]

6 Section 1 — General Information Air-cooled 1 1 kW Generators 1.6 SP E CI F ICA TIONS 1.6.1 GEN ERA T OR Model 04916-0 Rated Max. Continuous P ower Capacity (W atts*) 10,000 NG/11,000 LP Rated V oltage 120/240 Rated Max. Continuous Load Current (Amps) 120 V olts** 83.3 NG/91.7 LP 240 V olts 41.7 NG/45.8 LP Main Line Circuit Breaker 45 Amp Phase [...]

7 1.7 FUE L RE QUIRE MEN T S AN D R E COMM EN D A TIONS W ith LP gas, use only the vapor withdrawal sys - tem. 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[...]

1.1 0.2 TR ANSF ER SWIT CH This generator should only be installed with a com- patible transfer switch. A range of transfer switches are offered by the manufacturer . 1.1 1 BA TTER Y I NST ALLA TION  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[...]

9 The following procedur es are to be observed: • Wear full eye pr otection and protective clothing; • Where electr olyte contacts the skin, wash it off immediately with water; • Where electr olyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention; and • Spilled electrolyte is to be washed down with a[...]

10 D ANGER  Proceed 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 A C voltmeter and a fre - quency meter across transfer switch terminal lugs E1 and E2. V oltage should be 242-252 volts; [...]

11 W ith 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 V OL T A GE R E GU L A [...]

12 3.2.2 “OF F” POSITION This switch position shuts down the engine. This position also prevents automatic operation. 3.2.3 “MAN U AL ” 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 a[...]

13 Section 3 — Operation Air-cooled 1 1 kW Generators 3.5 SE T TI NG TH E EXERCISE TI M ER 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 fo[...]

14 Section 4 — Maintenance Air-cooled 1 1 kW Generators 3.6.5 L OW BA T TER Y 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 battery voltage rises abov[...]

15 Section 4 — Maintenance Air-cooled 1 1 kW Generators  Any attempt to crank or start the engine before it has been properly serviced with the r ecom- mended oil may result in an engine failur e. 4.3.2 OI L CHANGE PROCEDU R E T o change the oil, proceed as follows: 1. Run the engine until it is thoroughly warmed up then shut OFF the engine. 2[...]

16 Section 4 — Maintenance Air-cooled 1 1 kW Generators Figure 4.5 – Setting the Spark Plug Gap 4.7 B A T TER Y MAI NTENANCE 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 cle[...]

17 • 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 piv[...]

18 7. Remove the spark plug(s) and spray fogging agent into the spark plug(s) threaded openings. Reinstall and tighten the spark plug(s). 8. 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 . 9. Clean and wipe the entire generator . 4.1 2.2 R ETUR N T O SERVICE T o retur[...]

19 Section 4 — Maintenance Air-cooled 1 1 kW Generators 4.1 3 SERVICE SCHEDU LE A TTENTION: It is recommended that all service work be performed by the nearest Authorized Dealer . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = W eekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Y early if Repair is Needed.[...]

20 Section 5 — T roubleshooting Air-cooled 1 1 kW Generators 5.1 TROU B LE SHOO TI NG GU I DE Problem Cause Correction The engine will not crank. 1. F use blown. 1. Replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary . 3. Defective starter motor . 3. * 4. Dead Batt[...]

AIR OUTLET AIR INT AKE REAR VIEW RIGHT S IDE VIEW FRONT VIEW TOP VIEW (WITH ROOF OPEN) ( S ERVICE DOOR OPEN) "DO NO T LIFT BY THE ROOF" LIFTING HOLE S 4-CORNER S GROUNDING LUG **ALL DIMEN S ION S IN: MILLIMETER S [INCHE S ] ACCE SS TO OUTPUT CIRCUIT BREAKER AND TRAN S FER S WITCH CONNECTION S (REMOVE PLUG FOR A CCE SS ) 914mm [ 36.0"[...]

22 Section 7 — Electrical Data Air-cooled 1 1 kW Generators Wiring Diagram – Drawing No. 0E7 071- B 14 66A 16 194 66 77 86 85 18 22 162 14 224B 2 1 L.E.D - ALARM INDICA TOR S 13 0 162 REGULA TOR BA TTERY CHARGER 13 3 1 2 VOLT A GE 0 6 0 162 4 6 0 OFF=60Hz 2 - S PA R E 1 - ON=50Hz 22 11 4 ON 22 4 11 2 D S W 1 15A J1 PRINTED CIRCUIT BOARD 13 2 56[...]

23 Section 7 — Electrical Data Air-cooled 1 1 kW Generators Wiring Diagram – Drawing No. 0E7 071- B CLO S E S T TO BEARING GRD 1 GRD 2 S TAT O R ENGINE WIRING 85 44 S WITCH CONT ACTOR OUTPUT TO TRAN S FER 240V GENERA TOR 11 EXTERNAL WHITE WHITE G G L 194 11 OUTLET HOT HO T L 3 1 LINE LOAD CB3 GFCI CONNECTION CU S TOMER CB1 4 G 5 2 N 11 11 44 0 [...]

24 Section 7 — Electrical Data Air-cooled 1 1 kW Generators Electrical Schematic – Drawing No. 0E7 0 7 3-B 225B 224B 13 15 56 16 15B 56 239 86 15B PRINTED CIRCUIT 11 13 14 12 CONTROL BOARD 5 8 9 10 6 7 J1 2 3 4 1 VOLT AG E REGULA TOR ELECTRONIC MANUAL S W2 AUT O 239 15 S W1 194 194 15A F2 15A 194 6 162 4 0 4 11 22 56 15 0 0 13 0 CHARGER 2 1 0 B[...]

25 Section 7 — Electrical Data Air-cooled 1 1 kW Generators Electrical Schematic – Drawing No. 0E7 0 7 3-B WINDING CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET , PU S H/PULL 22 22 225A 56V A 225A 224A 224 225 225 224 14 77 66 224A N1 1V A 14 TX N2 0 0 23 224B 225B 194 22 0 1 7 2 16 14 11 0 0 4 6 0 0 0 BCR 6 7 3 9 4 9 G 22 0 F S 62 0 0 11 16 13 4 BCR [...]

26 60 9 5 7 3 60 2 0 72 21 1 5 51 5 3 54 6 9 7 6 77 7 5 17 4 8 47 4 9 52 5 0 55 46 17 67 3 1 8 5 7 3 44 74 42 38 27 1 8 2 6 7 0 2 5 2 8 2 3 2 9 9 17 22 " A" 1 5 14 3 7 3 4 " A" 41 17 17 8 7 8 6 3 0 1 6 3 7 4 3 1 7 60 27 8 4 33 33 17 3 2 3 5 4 0 9 6 6 3 6 24 11 5 8 8 8 83 7 64 62 65 1 3 4 8 3 6 7 9 2 3 66 5 1 64 6 8 8 Section 8 ?[...]

27 ITEM P ART NO . QTY . DESCRIPTION 1 0E7325 4 HHF S , 1/4"-20 X 5/8" GRADE 5 4 0E6884 1 S EAL, AL TERNA T OR S HAFT 5 0E4706A 1 S OUND BAFFLE INT AKE S CROLL 6 0D1131 1 GUARD ,F AN 7 0E4706 1 S CROLL, INT AKE 8 0C2824 11 S CREW T AP-R #10-32 X 9/16" 9 039253 6 S CREW HHC M8-1.25 X 20 10 0A8250 1 S CREW HHC 3/8"-24 X 2" G8[...]

28 2 9 47 4 3 4 2 5 24 4 0 2 5 2 5 33 54 4 8 8 7 4 8 46 47 4 3 3 8 7 1 8 2 1 0 11 , 1 3 9 50 60 3 6 3 2 3 5 39 50 3 2 33 39 61 62 3 1 3 2 2 6 57 1 9 9 22 6 3 1 6 11 , 1 2 5 9 5 8 17 1 6 15 2 0 56 2 0 22 2 4 3 0 51 3 1 3 2 27 21 8 8 7 20 1 6 64 65 6 52 Section 8 — Exploded Views and P arts Lists Air-cooled 1 1 kW Generators Control Panel – Drawi[...]

29 ITEM P ART NO . QTY . DESCRIPTION 1 0E3312 1 A SS EMBL Y , HOME S T ANDBY CONTROLLER 2 0A1801 1 A SS EMBL Y , BA TTER Y CHARGER ENGINE 3 083049 1 A SS EMBL Y , PO TTED REGULA TOR 4 092036 8 PPHM S /L W #6-32 X 1/4" LONG 5 0D3062A 4 HEX S T AND-OFF #6-32 X 3/4" 6 075235 4 S CREW HHC M5-0.8 X 30mm 7 049226 6 WA S HER LOCK M5 8 051716 6 N[...]

30 5 3 4 0 3 5 3 7 39 38 54 41 42 56 55 50 51 17 2 33 3 1 3 0 3 4 2 6 2 8 27 3 2 9 1 8 4 2 5 5 4 1 3 2 3 6 44 45 4 3 47 4 9 1 6 14 52 1 9 1 5 6 2 3 21 22 12 9 1 0 7 11 8 Section 8 — Exploded Views and P arts Lists Air-cooled 1 1 kW Generators GT -990 Eng ine – Drawing No. 0F2000[...]

31 ITEM P ART NO . QTY . DESCRIPTION 1 0C5730A 1 A SS EMBL Y , CRANKCA S E RV 2 0E9843 1 S EAL, 38 I.D . CRANKCA S E 3 090388 6 S CREW , HHTT M6-1.0 X 12mm 4 0C5372 1 A SS EMBL Y , BREA THER 5 0C3005 1 GA S KET , BREA THER COVER 6 0E3372A 1 S EP ARA TOR, OIL BREA THER 7 0D8067A 1 A SS EMBL Y , HEAD #1 8 0C2981C 1 CO VER, ROCKER 9 071983 4 RET AINER[...]

32 50 25 7 19 1 19 24 23 18 19 21 22 2 19 1 16 5 15 17 1 14 13 12 11 8 3 20 1 67 65 58 44 34 28 27 26 32 31 29 39 30 35 33 38 57 53 37 52 "B" 49 36 51 1 92 54 55 19 40 43 44 44 50 44 48 47 46 101 91 97 41 100 99 42 82 76 69 66 6 64 56 63 10 9 4 71 68 70 75 74 62 73 43 77 79 78 98 44 51 85 84 87 89 81 45 "B" 72 80 88 83 86 59 80 [...]

33 Section 8 — Exploded Views and P arts Lists Air-cooled 1 1 kW Generators Engine Accessories – Drawing No. 0F200 1 -D ITEM P ART NO . QTY . DESCRIPTION 1 045756 11 S CREW HHTT M6-1.0 X 10 YC 2 0D1131 1 GUARD , F AN 3 0F1169G 1 HOU S ING, BLO WER V -TWIN R V 4 0C9763 4 NUT ,GROMMET 1/4 PLUG 5 0E4386 1 TUBE, INT AKE 6 0E5079 1 HO S E, BREA THER[...]

34 26 3 0 24 9 1 2 3 10 22 21 11 2 8 27 3 1 42 41 44 40 39 38 51 5 20 1 8 14 15 3 1 7 16 33 3 2 1 9 8 6 4 2 3 4 3 3 4 5 12 4 38 4 3 47 46 4 8 5 3 50 4 9 25 3 7 38 3 6 3 5 3 Section 8 — Exploded Views and P arts Lists Air-cooled 1 1 kW Generators Alternator & Pulleys – Drawing No. 0E4880[...]

35 Section 8 — Exploded Views and P arts Lists Air-cooled 1 1 kW Generators Alternator & Pulleys – Drawing No. 0E4880 ITEM P ART NO . QTY . DESCRIPTION 1 0E0196A 1 FRAME, MOUNTING SS H S B 2 022129 7 W A S HER LOCK M8-5/16 3 022145 8 W A S HER FLA T 5/16-M8 ZINC 4 022259 4 NUT HEX 5/16-18 S TEEL 5 0C7758 4 VIB MNT 1.5 X 1.38 X 5/16-18 6 0C3[...]

36 17 9 20 28 25 21 24 19 11 10 23 22 22 15 26 14 13 16 12 18 8 29 9 30 27 4 5 3 2 17 1 26 15 14 16 13 19 21 25 20 24 12 18 23 Section 8 — Exploded Views and P arts Lists Air-cooled 1 1 kW Generators Regulator – Drawing No. 0E488 1 -C[...]

37 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CA S TING, TWIN REGULA TOR HOU S ING 2 0F5022 1 S OLENOID COIL, 12VDC 3 0C4647 1 GA S KET , S OLENOID 4 0C4680 1 PLUNGER, LP REGULA T OR A SS EMBL Y 5 0C6070 1 S PRING- S OLENOID , PLUNGER 8 0F4795 4 S CREW PPHM S EM S M4-0.7 X 10 9 0D3973 2 PLUG, EXP AN S ION 16mm 10 0E6183 2 ELBOW 90D S TREET 1/2”[...]

38 Section 9 — Notes Air-cooled 1 1 kW Generators[...]

39 Section 9 — Notes Air-cooled 1 1 kW Generators[...]

40 CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEMENT Y OU R W AR RANT Y R IGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and garden equipment engines must be d[...]

41 EM IS SION CONTROL S YSTEM W AR R ANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchas[...]

Part No. 0E4885 Revision E (12/06/05) Printed in U.S.A. Section 1 0 – W arranty Air-cooled 1 1 kW Generators GENERA C PO WER SYSTEMS “TWO YEAR” LIMITED W ARRANTY FOR QUIETSOURCE™ “PREP ACKA GED EMERGENCY A UT OMA TIC ST ANDBY GENERA T ORS” F or a period of two years from the date of original sale, Generac P ower Systems , Inc. (Generac)[...]