Generac Power Systems Portable Generator 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)  
*This manual should  
remain with the unit.  
Not intended for use as Primary Power in place of utility or in  
life-support applications.  
DANGER  
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!  
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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  
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  
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 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 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 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
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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:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
GENERAL HAZARDS  
The engine exhaust from this product  
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 operating.  
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 specifically 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.  
• 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.  
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.  
• 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.  
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.  
2
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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.  
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 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 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, or may get caught in moving com-  
ponents causing injury.  
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 such 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.  
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.  
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.  
7. AGRICULTURAL WIRING HANDBOOK, avail-  
able from the Food and Energy Council, 909  
University Avenue, Columbia, MO 65201.  
8. ASAE  
EP-3634,  
INSTALLATION  
AND  
MAINTENANCEOFFARMSTANDBYELECTRICAL  
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  
1.3 SYSTEM SET LED  
DANGER  
The “System Set” LED is lit when all of the following  
conditions are true:  
Only qualified electricians or contractors should  
attempt such installations, which must comply  
strictly with applicable codes, standards and  
regulations.  
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.  
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.  
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-  
sure, high temperature, etc.  
If this generator is used to power electrical load  
circuits normally powered by a utility power  
1.4 ACCESSORY FEATURES  
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 & 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.  
1.4.1 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  
a 7.5 amp maximum current draw.  
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.  
Figure 1.1 — 12 Volt DC Outlet  
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 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  
4. Overspeed  
5. Low Battery  
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.  
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.  
4
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Section 1 — General Information  
Air-cooled 11 kW Generators  
Figure 1.2 — 120 Volt AC Outlet  
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 genera-  
tor in manual mode.  
120 VAC  
GFCI OUTLET  
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.  
Front View  
1.5 THE GENERATOR  
Figure 1.3 – 11 kW, V-twin GT-990 Engine  
Overhead View  
Exhaust  
Enclosure  
Data Decal  
Control Panel  
GFCI Outlet  
Right Side View  
Air Filter  
Oil Dipstick  
Oil Filter  
Battery Compartment  
Fuel Regulator  
5
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Section 1 — General Information  
Air-cooled 11 kW Generators  
1.6 SPECIFICATIONS  
1.6.1 GENERATOR  
Model 04916-0  
10,000 NG/11,000 LP  
120/240  
Rated Max. Continuous Power Capacity (Watts*)  
Rated Voltage  
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  
Phase  
45 Amp  
1
Number of Rotor Poles  
Rated AC Frequency  
Power Factor  
2
60 Hz  
1
Recommended Air Filter  
Part # C8127  
Battery Requirement  
at -17.8° C (0° F)  
Group 26/26R 12 Volts and  
525 Cold-cranking Amperes Minimum  
Weight  
495 Pounds  
Output Sound Level @ 23 ft (7m) at full load  
Normal Operating Range  
62.2 db (A)  
-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  
GT-990  
Type of Engine  
Number of Cylinders  
Rated Horsepower  
Displacement  
2
30 @ 3,600 rpm  
992cc  
Cylinder Block  
Valve Arrangement  
Ignition System  
Recommended Spark Plug  
Spark Plug Gap  
Compression Ratio  
Starter  
Aluminum w/Cast Iron Sleeve  
Overhead Valves  
Solid-state w/Magneto  
RC14YC  
0.76 mm (0.030 inch)  
9.5:1  
12Vdc  
Oil Capacity Including Filter  
Recommended Oil Filter  
Recommended Air Filter  
Operating RPM  
Approx. 1.7 Qts  
Part # 70185  
Part # 0C8127  
2,700  
6
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Section 1 — General Information  
Air-cooled 11 kW Generators  
3. Remove the pipe plug from the LP (left) outlet  
1.7 FUEL REQUIREMENTS  
port.  
AND RECOMMENDATIONS  
4. Install the brass hose fitting in the LP (left) outlet  
With 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.  
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.  
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.  
Figure 1.4 – Demand Regulator  
LP OUTLET  
PORT  
LP OUTLET  
PORT  
NG OUTLET  
PORT  
NG OUTLET  
PORT  
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-  
NG FUEL SYSTEM  
LP FUEL SYSTEM  
ed to assure proper gas pressure to the genera-  
tor. Low gas pressure can cause hard starting  
and could affect engine durability.  
1.10 LOCATION  
1.10.1 GENERATOR  
1.8 FUEL CONSUMPTION  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load 1/2 Load  
Full Load  
2.15/86.4  
04916  
115  
202  
1.38/55.6  
• 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.  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
DANGER  
• Install the generator on high ground where water  
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.  
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.  
1.9 RECONFIGURING THE  
• Install the generator as close as possible to the fuel  
supply, to reduce the length of piping.  
FUEL SYSTEM  
• Install the generator as close as possible to  
the transfer switch. HOWEVER, REMEMBER  
THAT LAWS OR CODES MAY REGULATE THE  
DISTANCE.  
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).  
The genset must be installed on a level surface. The  
base frame must be level within two (2) inches all  
around.  
7
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Section 1 — General Information  
Air-cooled 11 kW Generators  
NOTE:  
1.10.2 TRANSFER SWITCH  
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.  
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  
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.  
1.12 THE BATTERY  
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.  
Fill the battery with the proper electrolyte fluid if  
necessary and have the battery fully charged before  
installing it.  
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 mini-  
mum at -17.8º C (0º 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.  
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-  
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 (—).  
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 pre-  
cautions are to be observed when working on  
batteries:  
NOTE:  
Damage will result if battery connections are made  
in reverse.  
• Remove the 7.5A and 15A fuses from the genera-  
tor 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  
Figure 1.5 – Battery Cable Connections  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
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.  
8
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 11 kW Generators  
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 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.  
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.  
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.  
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 touch-  
ing the battery by first touching a grounded metal  
surface.  
2.3 ELECTRICAL CHECKS  
Complete electrical checks as follows:  
1. Set the generator's main circuit breaker to its  
OFF (or open) position.  
Be sure the AUTO/OFF/MANUAL switch is set to  
the OFF position before connecting the battery  
2. Set the generator's AUTO/OFF/MANUAL switch to  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
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).  
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.  
DANGER  
The transfer switch is now electrically “hot.”  
2.1 BEFORE INITIAL START-UP  
Contact with “hot” parts will result in extremely  
Before starting, complete the following:  
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.  
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 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.  
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
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 11 kW Generators  
6. Set the generator's AUTO/OFF/MANUAL switch  
DANGER  
to MANUAL. The engine should crank and start  
immediately.  
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.  
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 oil leaks, evidence of overheating, etc.  
12. When testing under load is complete, turn OFF  
electrical loads.  
10. Connect an accurate AC voltmeter and a fre-  
quency 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 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.  
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  
OPERATION  
2.4 GENERATOR TESTS UNDER LOAD  
To test the generator set with electrical loads applied,  
proceed as follows:  
To check the system for proper automatic operation,  
proceed as follows:  
1. Set generator’s main circuit breaker to its OFF  
(or open) position.  
1. Set generator’s main circuit breaker to its OFF  
(or open) position.  
2. Check that the AUTO/OFF/MANUAL switch is set  
2. Turn OFF all loads connected to the transfer  
to OFF.  
switch terminals T1 and T2.  
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.  
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 util-  
ity main line circuit breaker).  
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.  
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  
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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:  
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 con-  
tinue 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).  
• 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.  
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.  
NOTE:  
The access panel on top of the control panel must  
be removed to adjust the voltage regulator.  
Figure 2.1 – Voltage Adjustment Potentiometer  
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).  
Figure 3.1 – Generator Control Panel  
NOTE:  
The voltage regulator is housed inside the gen-  
erator's control panel. The regulator maintains a  
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.  
11  
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Section 3 — Operation  
Air-cooled 11 kW Generators  
3.2.2 “OFF” POSITION  
3.4 SEQUENCE OF AUTOMATIC  
This switch position shuts down the engine. This  
position also prevents automatic operation.  
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).  
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  
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.  
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 a “DO NOT OPERATE” tag on the generator  
panel and on the transfer switch.  
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.  
3.3 AUTOMATIC TRANSFER  
OPERATION  
To select automatic operation, do the following:  
B. Engine Warm-up Time Delay  
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.  
• 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 volt-  
age. When that voltage is restored above 70 per-  
cent of the nominal source voltage, a retransfer  
time delay starts timing.  
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.  
D. Retransfer Time Delay  
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.”  
• 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.  
12  
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Section 3 — Operation  
Air-cooled 11 kW Generators  
Figure 3.2 – Low Oil Pressure and  
High Temperature Switches  
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  
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.  
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:  
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  
NOTE:  
3.6.1 LOW OIL PRESSURE SWITCH  
If the fault is not repaired, the overcrank feature  
will continue to activate.  
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.  
3.6.3.1 Approximate Crank Cycle Times  
• 15 seconds ON  
• 7 seconds OFF  
• 7 seconds ON  
• 7 seconds OFF  
• Repeat for 45 seconds  
Approximately 90 seconds total  
3.6.2 HIGH TEMPERATURE SWITCH  
This switch’s contacts (Figure 3.3) close if the tem-  
perature should exceed approximately 132º C (270º  
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.  
3.6.4 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  
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