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Generac Power Systems 04389-3, 04456-3, 04390-3, Installation And Owner'S Manual

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Generac Power Systems 04389-3, 04456-3, 04390-3 Installation And Owner'S Manual Download Page 1

GENERAC

POWER SYSTEMS,  INC.

R

R

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

  Models:
 

 

04389-3 (6 kW NG, 7 kW LP)

 

 

04456-3 (12 kW NG, 12 kW LP)

 

 

04390-3 (13 kW NG, 15 kW LP)

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

Not intended for use as Primary Power in place of utility or in

life-support applications.

LISTED

C

US

Summary of Contents for 04389-3, 04456-3, 04390-3

Page 1: ...packaged Automatic Standby Generators Models 04389 3 6 kW NG 7 kW LP 04456 3 12 kW NG 12 kW LP 04390 3 13 kW NG 15 kW LP DANGER DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY Not intended for use as P...

Page 2: ...ts 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 th...

Page 3: ...11 2 5 Checking Automatic Operation 11 2 6 Adjusting the Regulator Natural Gas Only 12 2 7 Engine Governor Adjustment 13 2 8 Voltage Regulator Adjustment 14 Section 3 Operation 14 3 1 Break in Procedu...

Page 4: ...d 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...

Page 5: ...ed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the a...

Page 6: ...d There are LED readouts on the control panel to notify personnel 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 ar...

Page 7: ...Decal Control Panel Fuel Regulator Fuel Inlet GFCI Outlet Oil Filter Battery Compartment Exhaust Enclosure Oil Filter Battery Compartment Fuel Inlet GFCI Outlet Control Panel Data Decal Oil Dipstick...

Page 8: ...uel 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 eac...

Page 9: ...be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges 1 8 FUEL CONSUMPTION Natural ga...

Page 10: ...ront of the unit and the second can be accessed from the back of the unit enclosure by removing the plastic hole plug The screw can be turned with a long flat blade screwdriver 13 To adjust the system...

Page 11: ...nd to the battery post indicated by a nega tive NEG or NOTE Damage will result if battery connections are made in reverse NOTE The generator is equipped with a battery trickle charger that is active w...

Page 12: ...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 sw...

Page 13: ...means provided such as a util ity 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 Fai...

Page 14: ...that the No Load Frequency with the roof open and door off is set to 63 63 5 Hz Transfer load to emergency circuits 3 Turn on appliances lights pumps etc that are on the emergency circuits in an atte...

Page 15: ...w to obtain a frequency of 62 5 Hz 6 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the volt age regulator may require adjustment Figure 2 3 Engine Governor...

Page 16: ...rt and the transfer switch will transfer to standby 4 Using the transfer switch s built in emergency load center turn on circuits to load the generator to approximately 25 rated load and run the unit...

Page 17: ...is outlet may be used to temporarily power low power accessories such as a work light cell phone radio or any other automotive style accessory This outlet is capable of delivering a MAXIMUM of 7 5 Amp...

Page 18: ...nsfer switch using the means provided such as a utility main line circuit breaker DANGER Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have bee...

Page 19: ...need to be reset every time the 12 volt battery is disconnected and then reconnected The exerciser WILL NOT work if dip switch 2 on the controller printed circuit board Remote Not Auto is ON 3 7 PROTE...

Page 20: ...lder cap down and rotate it counterclockwise Figure 4 1 Generator Control Panel 12 VDC ACCESSORY OUTLET 7 5A MAX EXERCISE SYST TIME SET AUTO 7 5A OUTLET FUSE OFF MAN F L A S H I N L E D 4 F L S H R E...

Page 21: ...Temp Switch Loosen 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean...

Page 22: ...e 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 batte...

Page 23: ...he front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine While watching the piston through the spark plug hole The piston s...

Page 24: ...indicating the viscosity and classification of the oil in the crankcase 8 Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug...

Page 25: ...epair is Needed FUEL Fuel lines and connections X M LUBRICATION Oil level X M Oil X AFTER BREAK IN AND Y Oil filter X AFTER BREAK IN AND Y COOLING Enclosure louvers X X W BATTERY Remove corrosion X X...

Page 26: ...d runs rough or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s 3 Fuel Regulator not set 3 Set Fuel Regulator 4 Fuel Pressure incorrect 4 Confirm fuel pressure to regulator is 10 12...

Page 27: ...25 Section 6 Notes Air cooled 7 kW 12 kW and 15 kW Generators...

Page 28: ...26 Section 6 Notes Air cooled 7 kW 12 kW and 15 kW Generators...

Page 29: ...27 Section 6 Notes Air cooled 7 kW 12 kW and 15 kW Generators...

Page 30: ...ATED TERMINAL BLOCK ICT INTERCONNECTION TERMINALS GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR SC STARTER CONTACTOR SP1 SP2 SPARK PLUGS FS FUEL SOLENOID F2 FUSE 7 5 AMP...

Page 31: ...162 0 6 SW2 239 AUTO SW1 1b 1a 1 0 0 CONNECTION CUSTOMER SWITCH CONTACTOR 240V GENERATOR CB1 23 351 N1 N2 194 0 66A 55 77 44 11 55 0 C2 3 1 2 CONTROL PANEL BOX N1 N2 225B 13 66 TX 224 225 224A 225A 11...

Page 32: ...ITCH SP1 SP2 SPARK PLUGS CB2 CIRCUIT BREAKER ALT EXCITATION BCR BATTERY CHARGE RELAY F2 FUSE 7 5 AMP D DIODE F1 FUSE 15 AMP 162 22 VOLTAGE REGULATOR ELECTRONIC 6 4 0 11 STATOR C2 8 2 C2 7 C2 11 C2 10...

Page 33: ...3 16 0 13 SC 0 SW1 15 15A 239 194 FS 0 14 C2 1 WINDING STATOR POWER 22 44 11 CB1 33 56VA 1VA 13 225 225A 224A 224 TX 17 N1 N2 11 22 C2 5 N2 N1 C2 6 11 194 23 N1 N2 CUSTOMER SUPPLIED BATTERY 12V BLACK...

Page 34: ...GNITION MODULE LOP LOW OIL PRESSURE SWITCH SW1 AUTO OFF MANUAL SWITCH FS FUEL SOLENOID GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR ICT INTERCONNECTION TERMINALS SC STA...

Page 35: ...17 15 SW1 239 CUSTOMER CONNECTION 351 11 66 N1 194 0 23 N2 162 6 4 66A 0 77 GRD 55 55 22 6 11 0 1 C2 4 3 2 6 7 5 CONTROL PANEL BOX 224B 224A 225B 224B 0 13 224 225 N2 N1 224A 66 TX 225A 66 BCR 225A C...

Page 36: ...ON MODULE FS FUEL SOLENOID SP SPARK PLUG F2 FUSE 7 5 AMP F1 FUSE 15 AMP D DIODE DIAGRAM KEY ELECTRONIC REGULATOR VOLTAGE CB2 C2 8 2 2 22 162 0 4 C2 10 6 4 0 11 22 11 2 85 0 PRINTED CIRCUIT BOARD CONTR...

Page 37: ...17 15A 17 0 0 56 13 15 SC 23 15A 15 SW1 SP 0 D IM BLACK 33 11 44 SM FS 14 C1 2 194 POWER STATOR WINDING 22 SC RED 240V CB1 120V 120V N1 22 225A 56VA 1VA 225 224 17 N1 TX 11 N2 C2 6 C2 5 11 240VAC 194...

Page 38: ...36 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 8 Circuit Load Center Drawing No 0E7687A...

Page 39: ...37 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 8 Circuit Load Center Drawing No 0E7687A...

Page 40: ...38 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 12 Circuit Load Center Drawing No 0E7687...

Page 41: ...39 Section 7 Electrical Data Air cooled 7 kW 12 kW and 15 kW Generators Wiring Diagram 12 Circuit Load Center Drawing No 0E7687...

Page 42: ...ER CONTROL PANEL MAIN DISTRIBUTION NEUTRAL WHITE NEUTRAL WHITE RED MAIN 2 BLACK MAIN 1 E1 E2 VIO INSIDE SWITCH CONNECTION NEUTRAL RED 194 N1 N2 OPEN 23 BLACK N1 N2 23 194 PANEL TO GENERATOR 240VAC TO...

Page 43: ...2 N1 194 240VAC TO TO GENERATOR OUTPUT PANEL MAIN DISTRIBUTION LC CIRCUIT BREAKER LOADS F1 F2 5A 600V FUSE XA XB LIMIT SWITCHES TS TERMINAL STRIP TR TRANSFER RELAY C2 GENERATOR COIL RECTIFIER LEGEND C...

Page 44: ...72 87 5 86 76 48 39 92 18 94 91 63 21 15 51 71 42 69 10 52 49 35 51 49 11 31 9 50 99 98 72 46 41 57 27 91 1 56 5 44 60 40 19 12 71 6 97 22 65 68 63 16 69 14 54 47 55 75 49 30 17 3 93 25 29 28 1 Secti...

Page 45: ...0F0710 18 RIVET POP 0 125 X 0 337 ITEM PART NO QTY DESCRIPTION 47 047411 6 SCREW HHC M6 1 0 X 16 G8 8 047411 4 SCREW HHC M6 1 0 X 16 G8 8 7KW 48 043116 5 SCREW HHC M6 1 0 X 12 G8 8 043116 6 SCREW HHC...

Page 46: ...44 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Control Panel Drawing No 0E9162 J...

Page 47: ...NO QTY DESCRIPTION 27 074908 4 SCREW TAPTITE M5 0 8 x 10 BP 28 049226 6 WASHER LOCK M5 29 082025 6 NUT HEX LOCK M5 0 8 NYLON INSERT 30 0C3910 1 TRANSFORMER 31 022507 2 SCREW HHC 1 4 20 x 1 2 32 0A9611...

Page 48: ...1 26 20 21 8 4 34 35 32 34 23 9 13 15 36 27 30 29 22 3B 22 16 3A 31 7 9 16 3 6 11 5 2 33 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 7 kW 8 Circuit Load Center...

Page 49: ...10 17 064526 2 SCREW HWHS 6 25 X 3 8 18 0E6155 1 ARM EXTENDER PIN 19 063378 4 HOLDER CABLE TIE 20 0A2110 4 SCREW SWAGE 1 4 20 X 1 2 ZINC 21 074138 2 LUG QUICK DISCONNECT NI S 10X45 DEG BRASS TIN 22 03...

Page 50: ...48 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators 12 kW and 15 kW 12 Circuit Load Center Assembly Drawing No 0E7973 F...

Page 51: ...R CABLE TIE 20 0D3094 1 HARNESS GTS TO MAIN PANEL 21 074138 2 LUG QUICK DISCONNECT NI S 10X45 DEG BRASS TIN 22 036933 6 SCREW PPHM 10 32 X 3 8 23 077033 6 LUG SLDLSS 1 0 14X9 16 AL CU 24 048850 1 BLOC...

Page 52: ...4 140 32 3 35 55 33 36 20 57 19 58 59 61 60 64 62 63 65 1 2 6 3 32 33 34 35 36 40 72 27 28 29 16A 16B 17 18 4 5 6 8 11 12 13 2 5 19 20 39 40 47 64 93 140 16B 56 54 23 25 30 16A 34 34 21 15 16A 17 18 2...

Page 53: ...0C2988 1 THRUST WASHER GOVERNOR 36 0C2992 1 BUSHING GOVERNOR LOWER ITEM PART NO QTY DESCRIPTION 37 0C3971C 1 ASSEMBLY DIPSTICK WITH HANDLE 38 0C5305 1 TUBE DIPSTICK 39 0C3027 1 O RING OIL CLR 3 8 X 1...

Page 54: ...5 107 108 104 103 106 111 109 143 125 123 145 96 95 143 130 114 75 78 77 76 99 100 118 98 97 121 124 124 119 122 125 137 120 127 126 115 116 131 136 138 132 142 129 134 139 135 Section 8 Exploded View...

Page 55: ...022A 1 HOUSING BLOWER NG COOLER ITEM PART NO QTY DESCRIPTION 111 0D1131 1 GUARD FAN 112 045756 25 SCREW TAPTITE M6 1X10 YELLOW CHROME 113 0C9763 4 NUT GROMMET 1 4 PLUG 114 0C3036A 1 HOSE BREATHER 115...

Page 56: ...14 19 10 17 15 32 10 19 16 22 39 4 8 9 6 31 37 3 2 34 30 40 46 45 47 36 42 41 1 50 49 32 24 25 26 44 43 34 35 34 48 10 28 27 28 32 31 29 18 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12...

Page 57: ...049451 1 WASHER FLAT 406ID X 1 62OD 24 022237 4 WASHER LOCK 3 8 25 022511 4 BOLT HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 039287 4 SCREW HHC M8 1 25 X 45 G8 8 28 022145 12 WASHER FLAT...

Page 58: ...31 20 19 10 17 15 32 16 22 39 4 9 8 6 37 14 3 2 40 1 32 24 25 10 30 19 26 28 27 28 32 31 41 10 18 36 28 35 41 29 42 36 36 35 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Ge...

Page 59: ...6 48 BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VYNL COAT 0 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 2 6 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406ID...

Page 60: ...44 46 11 49 29 37 27 28 30 31 17 52 47 48 24 38 26 22 40 41 25 25 50 14 12 51 13 54 16 1 6 1 2 11 10 42 5 7 9 8 3 4 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators...

Page 61: ...6 0E3341 1 BALANCER 27 021714 1 ASSEMBLY CYLINDER HEAD SEATS GUIDES 28 086516 1 VALVE EXHAUST 29 086517 1 VALVE INTAKE 30 0D9853B 2 PUSH ROD 174 9 31 083897 2 TAPPET 32 077158 1 ASSEMBLY SCREEN OIL PI...

Page 62: ...39 28 4 24 6 12 7 6 1 14 18 17 27 31 30 2 45 5 13 8 52 6 11 9 48 42 10 25 26 18 32 18 34 6 34 33 6 37 Section 8 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine D...

Page 63: ...H RING GEAR 32DEG 26 067198N 1 WASHER BELV 20 X 2 2 27 067890 1 NUT HEX FLYWHEEL 28 0E7585 1 SPARKPLUG 29 072734 1 ASSEMBLY GOVERNOR LEVER 12 HP 30 072735 1 ROD GOVERNOR CONTROL 31 0C3978 1 SPRING ANT...

Page 64: ...M PART NO QTY DESCRIPTION 22 0C6731 2 RIVET POP 118 X 125 23 0C6067 2 SUPPORT DIAPHRAGM 24 0C4706 2 DIAPHRAGM TWIN REGULATOR 25 0C6068 2 CAP DIAPHRAGM SUPPORT 26 0C4643A 2 INLET TWIN REGULATOR 11 11 D...

Page 65: ...20 240v M6PEM T M6PEM T M6PEM T M6PEM T REAR VIEW LEFT SIDE VIEW TRANSFER SWITCH RIGHT SIDE VIEW FRONT VIEW AIR OUTLET AIR INTAKE IF SUPPLIED DO NOT LIFT BY THE ROOF LIFTING HOLES 4 CORNERS 30 2mm 1 1...

Page 66: ...mproper maintenance 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 War...

Page 67: ...low Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such...

Page 68: ...nclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminate...

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