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Generac QT04524ANSX Portable Generator User Manual

1. 10 3 SERVICE SCHEDULE coser ranis uu uuu u u 11 1 TROUBLESHOOTING 12 1 Troubleshooting Guide 12 1 EMISSIONS WARRANTY 13 1 5 EXPLODED VIEWS amp PARTS LISTS WIRING DIAGRAMS amp SCHEMATICS 01 90 ed 801091002 Safety Instructions SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas Safely should be stressed to all operators potential operators and service and repair technicians for this equipment INTRODUCTION Thank you for purchasing this model of the stationary emergency generator product line Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written However the manufacturer reserves the right to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Service Dealer for starting operating and servicing procedures 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 abo
2. IS 4 WIRING DIAGRAM REVISION A G2 4L G2 NEXUS DATE 11 16 09 PAGE OF 4 DRAWING 0H6341 CENTER TERMINAL NOT USED 178 LVR 5 817 BWR 2 gt 818 BWR 3 15 16 sPucE 2 15 6 _ sprice 2 0 1 spiice 1 o U61_ spiice 1 0 1 2 0 MP2 2 820 BWR 1 SA HVR 5 183 LVR 6 SHLDA 2 1 SHLD 1 1 819 BWR 4 767 2 765 3 766 GOV 6 68 WTS 2 79A 2 3 79 MP1 3 SB HVR 6 N1 HVR 1 N2 HVR 2 WLS B WLS A LOS NC 9225 15 0 0 6 0 7 FSP 2 WIRE LOCATIONS MAY CHANGE ON GROUND BAR 5 LOCATED BACK OF CUSTOMER CONNECTION BOX GROUP G s Y ms 601 02 14 15 SPLICE 2 0 GND 14 EC 2 14 LVR 2 14 J2 8 PAGE 2 OF 4 REVISION 11 16 09 PAGE 2 OF 4 WIRING DIAGRAM 62 41 G2 NEXUS DRAWING 4 0H6341 GROUP G C CES MEET ic 1 COMPONENTS LOCATED ON ENGINE HVR LVR 1 1 CND 2 2 14
3. Lm pm EE 4 RED 4 2 6 DIRECT DRIVE AS 2 GENERATOR OUTPUT CUSTOMER CONNECTIONS ALTERNATOR STATOR Ero 5 776086 BRUSH ASSEMBLY MLCB LINE CIRCUIT BREAKER 1 2 OR TO NB 277 NOTE THE 8TH DIGIT OF THE MODEL NUMBER SPECIFIES NB NEUTRAL BLOCK OUTPUT VOLTAGE K 277 480VAC OPTION 4 THREE PHASE DELTA NEXUS CONTROL PANEL 7 WIRE 120 240 51 51 53 53 M rini 4 4 1 s 2 55 6 Jagal X Sd S4 00 DIRECT DRIVE x x 2 GENERATOR OUTPUT CUSTOMER CONNECTIONS 1 2 2 TO ES 240VAC E1 TO TO NB 120VAC NOTE THE BTH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE J 120 240 i WIRING DIAGRAM REVISION A NEXUS CPL ALTERNATOR PAGE 2 OF 2 DATE 11 19 09 DRAWING 0H6342 10 70
4. 826090 ONIM VNG 01 MASP 9 MYA 52172 AAHIA V 335 123 2 M3IA 3015 1441 LINGNOS 3915100 37DH 102 07313 5 41 9 231N39 NV G 33S 533914 lt gt EL NDISIADed 11311 1 7061 084 15 HD 3015 9349507 ONIIdNOD 319833 LdN NOILOANNOD 590 71 4 1 L e pb 9 5 NIN 91 cas 3IDN 335 IND24 1 9 335 G3SD 19N3 31 33 1 sa 093 079 3 ae SI 39 9 2 1198 T3NVd IDHINDO 01943135 30 3015 amp 000 440 1317 3ND 9009 aad 8 71 6 2191 01159 3SIA 7 79 71 2 41702 SZS 492 170 A3311v8 Lv L 6 89 06 1 001 NITE 31UN 335 50 1511 1394 1N3W3OV d33 21011434 304 19 S 3NMD 33N3233432 1431 199 LEZI 9 sion 1138 3 ses 9 xx 83 13 INN 69 1 2 261 LHI 0 14 9 2 33H113 ec8 2004 1331 350 Nivad 110 1 913 331114 a sor IIS 410110 1e S84
5. Standard Operating Fuel Pressure 5 in 14 in Water Column Fuel Consumption ft hr Natural Gas LPV Exercise 25 50 75 100 Load Load Load Load 45kW 65 25 210 83 380 151 545 216 730 290 ELECTRICAL SYSTEM Battery Charge Alternator 12V 30 Amp Static Battery 2 5 Amp Recommended Battery Group 26 525 System Voltage 12 Volts Voltage Regulator WY Electronic Single phase u a terc ch 196 teme Adjustable Voltage and Gain Power Adjustment for Ambient Conditions Temperature Deration 3 for every 10 C above 45KW 25 1 65 for every 10 above F 45KW 77 Altitude Deration 1 for every 100 m above m 45 183 3 for every 1000 ft above ft 45 600 u as unuy Nexus 01 60 V r8093dsu 5 Specifications WEATHER AND MAINTENANCE KITS To keep the generator running at its peak the following kits are offered Cold Weather Kit Recommended for climates with temperatures below 32 F Extreme Cold Weathe
6. 13 1 01 60 9 ed 1004 United States Environmental Protection Agency Compliance Requirements Purchaser s Owner s Recordkeeping Responsibilities The United States Environmental Protection Agency EPA and Generac Power Systems Inc Generac are pleased to explain your recordkeeping requirements for compliance with Subpart JJJJ Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60 As the engine purchaser owner who operates and maintains their certified emergency stationary engine and emission control system according to applicable emission related guidelines as specified in this Owner s Manual you are required to meet the fol lowing notification and recordkeeping requirements to demonstrate compliance 1 Maintain documentation that the engine is certified to meet emission standards 2 Recordkeeping of maintenance conducted 3 Recordkeeping of the provision allowing natural gas engines to operate using propane for a maximum of 100 hours per year as an alternate fuel solely dur ing emergency operations provided the engine is not certified to operate on propane 4 Meet all compliance notifications submitted to the purchaser owner and maintain all supporting documentation 5 Recordkeeping of hours of operation including what classified the operation as emergency and how many hours are spent for non emergency operation For e
7. 420 Exhaust Temp at Rated Output 45kW 1100 Combustion Air Requirements Natural Gas Flow at rated power 60 Hz 45 144 cfm Governor dne ete ar tt Electronic Frequency Regulation Isochronous Steady State Regulation sss 0 25 6 1 Engine Lubrication System Type of Oil Pump Gear Oil FINCH ette Full Flow Spin on Cartridge Crankcase Oil Capacity 5 25 U S qts including filter capacity COOLING SYSTEM A Pressurized Closed Recovery Walter akan kawaka Belt Driven 5 M 2150 rpm Lett 22 inches Fan MOE Puller Air Flow inlet air including alternator and combustion 2725 ft3 min Coolant Capacity 3 0 U S gal Heat Rejection to Coolant 45kW 193 000 Btu h Maximum Operating Air Temp on Radiator 60 C 150 Maximum Ambient Temperature 50 C 140 FUEL SYSTEM Type OF Ula nnno Natural Gas Propane Vapor DUFGEOT u kaqq ma tertie Down Draft Secondary Fuel Regulator Standard Fuel Shut off
8. I i nc dB 3 3 0202 12424 0088 Eg 21 11 c E ow X 5 3 3 5 1 TE E E jo 3 EM M P I 5 os TE 4 5 0200 a a 2 MEM o 2 8 de Se m 5 z 1 1 1 lt 5 I w gt 2 gt e ON 250 sak 525 e nux FEES n 2 4 109 895 SLON G lt mia 310N CL I x lt 180 2 98 PAGE 2 4 SCHEMATIC DIAGRAM 62 41 G2 NEXUS DRAWING 0H6340 PAGE 2 OF 4 REVISION A DATE 4 1 10 BWR WIRE TO FUNCTION 12 5V FOR BASIC REMOTE REMOTE DISPLAY SYSTEM READY REMOTE DISPLAY ALARM 91 17 REMOTE DISPLAY MAINTENANCE 5 GND 1 GROUP 5 1 WIRE 0 IS CHASSIS GROUND UNLESS NOTED OTHERWISE 2 WIRE 413 IS UNFUSED 12VDC BATTERY 3 WIRE 14 IS FUSED 12VDC WHEN GENERATOR 15 CRANKING OR RUNNING 4 WIRE 415 IS FUSED 12VDC FOR GENERAL USE 5 WIRE 15 IS FUSED
9. 97 4H0 8 Jo 9 9 0419 7 9120 192 23 NOILOANNOD Mal V UOISIA9M xog NOLLO3NNOO NOLLO3NNOO V 4104 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 APPLICABLE TO ITEM PART 0E7284 0H7356 0H7429 0 3664 097311 074908 036261 002454 gt 009693 0H6736 022158 0 0492 0H6734 022152 023897 0C2454 048927 0 7519 0H6738 040976 022129 0H6734 022145 023897 0C2454 042419 022152 022158 gt 005572 0H6737 081320 0 0199 0H6734 022473 022097 0C2454 022127 lt TO TITO O gt REVISION DATE 3 31 10 QTY GROUP DESCRIPTION UL CIRCUIT BREAKER QN CB 0175A 2P 240V S QN2 LL COVER CB C2 CPL COVER CB DISH 2P QN BASE QN CIRCUIT BREAKER STANDOFF CB BOX CONBOX SCREW HHTT 5 0 8 X 10 BP RIVET POP 125 X 275 SS SCREW HWHT M6 1 X 16 N WA Z JS UL CIRCUIT BREAKER ED CB 0125A 3P 480V S ED4 LL COVER CB 5 ED C2 CONBOX NUT HEX 10 32 STEEL INSULATOR CB S ED 3P STANDOFF CB MOUNT CONBOX WASHER LOCK 10 WASHER FLAT 10 ZINC SCREW HWHT M6 1 X 16 N WA Z JS SCREW RHM 10 32 X 4 1 2 UL CIRCUIT BREAKER VL CB 0300A 3P 600V S JG VL LL COVER CB 5 JG VL C2 CONBOX SCREW SHC 8 1 25 X 20 C12 9 WASHER LOCK M8 5 16 STANDOFF CB MOUNT CONBOX
10. The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be con nected to an approved earth ground This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampac ity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and pos sibly fatal electrical shock Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Stationary emergency generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible inju
11. 1 CIRCUIT BREARER ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS Y CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Y configuration as shown in Figures 7 2 through 7 6 The rated voltage between circuit breaker terminals E1 E2 E1 E3 2 is 480V 208V or 600V depending on the model The rated voltage between each circuit breaker terminal and the neutral point 00 is 277V 120V or 346V depending on the model Figure 7 2 Stator Power Winding Connections 3 phase 277 480V 6 Lead E1 INTERNAL CONNECTIONS 94 S6 00 NEUTRAL 52 22 53 1 Figure 7 3 Stator Power Winding Connections 3 phase 277 480V 12 Lead E1 2 2 3 E3 lt L N 7 1 01 60 8 00u0029V General Information Figure 7 4 Stator Power Winding Connections 3 phase 120 208V 6 Lead INTERNAL CONNECTIONS 51 51 54 54 E 00 NEUTRAL 53 Figure 7 5 Stator Power Winding Connections 3 phase 120 208V 12 Lead Figure 7 6 Stator Power Winding Connections 3 phase 346 600V 6 Lead E1 1 INTERNAL CONNECTIONS E3 27 E2 01 00 8 LOQUUODDY 3 PHASE ALTERNATORS DELTA
12. 25145 did TID ALIAVAD 34943 ONILNADW 490 1113 110 30 331N33 201923439 40 WDLLIUS wv WALI 33IA233S 493 1113 anividva OL 03419907 530 14 1 3 1111 155322 WALI 33IA233S lt 51229 4 SNILND N VIT GES D GROUP G 1 2 15 00 ALTERNATOR MAIN WIRES ALTERNATOR CONNECTIONS FOR 39 UNITS ALTERNATOR STATOR L 00 L3 MAIN WIRES ALTERNATOR CONNECTIONS FOR 19 UNITS 22 wae ri qali 2 y 9 2 2 80 ALTERNATOR CONNECTION BOX 4 r L x x x x Ox e 05 OPTIONAL ISSION CONTR 58 AFS EM ALON Ir S YTHS LOS Ir vo MP2 964 HS GENERATOR SET MP1 WLS Ir 89 ALON O 994 042 694 292 en 7 1 4 SCHEMATIC DIAGRAM 62 41 G2 NEXUS DRAWING 0H6340 PAGE OF 4 REVISION A DATE 4 1 10 GROUP G r SNOILO3NNOO YSAWOLSNO HOLIMS AM3LIVB M34JSNVHL 8034 INNSIS 324005 AV 133 1915 NIV Ainun OVAOZ M34SNVML p r 34 u adn 88 RB
13. 45JD1 CPL 0G6563 1 STR 390 35AD1 CPL 0G6565 1 STR 390 35GD1 CPL 0G6566 1 STR 390 35KD1 CPL 0G6567 1 STR 390 35JD1 CPL 0H0201 1 STR 2390 60JD2 CPL 0H1299 1 ASSY STR 390 36AD1 CPL 0H1300 1 ASSY STR 390 36JD1 CPL 0H1301 1 ASSY STR 390 36 GD1 CPL 3 0C9708 REF INSTR HYPOT TEST NOT SHOWN 4 SEE ENGINE EV REF ENGINE ADAPTER 5 SEE ENGINE EV REF FLEXPLATE 6 0F5767B 1 ASSY FLYWHEEL CPL W 40MM FAN B 7 0E5706 1 REAR BEARING CARRIER 390 DRCT 8 0F7874 1 ASSY BRUSH HOLDER 390 HSB 0F7874A 1 ASSY BRUSH HOLDER 390 HSB 9 060587 1 GUARD REAR BEARING CARRIER 10 038150 4 WASHER FLAT 8 ZINC 11 023454 1 KEY WOODRUFF 12 077043E 1 CONDUIT FLEX 1 0 ID 35 LG 13 04576100BU 4 STUD M14 2 0 570 G5 ZINC 14 052646 4 WASHER FLAT M14 15 043123 4 WASHER LOCK M14 16 051779 4 NUT HEX M14 2 0 G8 YEL CHR 17 0A2601 1 SCREW 16 2 0 45 68 8 18 072879 1 SPACER 69 X 2 75 X 37 STIZNC 19 0 8408 4 SCREW 10 1 50 X 16 610 9 20 046526 4 LOCK 10 21 0 3992 4 SCREW 4 0 7 X 16 22 022264 4 LOCK 88 14 23 047248 1 BALL BEARING 45 MM 24 070892 1 SLIP RING MACHINED 25 0G0588 1 GUARD REAR BEARING CARRIER 26 077043A 1 CONDUIT FLEX 38 ID 60 27 056326 1 TRIM VINYL BLACK 1 8GP 16 5 LG REVISION H 6438 M DATE 5 21 10 ROTOR REPLACEMENT PARTS GROUP A PAGE 2 OF 2 9 182 22 NOILO3NNOO LV gh 66 4 289 or
14. warning will automatically clear if the battery voltage rises above 12 2 volts NOTE The battery sentinel is a separate feature that monitors battery condition LOW COOLANT LEVEL ALARM This is a shutdown alarm The sensor will be continuously moni tored If an error condition is seen for five 5 consecutive sec onds the alarm will be displayed MISSING CAM PULSE ALARM This is a shutdown alarm The alarm will activate after five 5 seconds of continuously missing cam pulses 8 5 MISSING CRANK PULSE ALARM This is a shutdown alarm The alarm will activate after 12 con secutive revs where crank pulses are missing LOW FUEL PRESSURE WARNING Fuel pressure is monitored by a digital sensor with a fixed setpoint of below five 5 inches water column GOVERNOR SENSOR FAULT ALARM The governor position is monitored by an analog feedback signal If the throttle position is seen outside of the normal operating range a shutdown alarm is displayed If the throttle is commanded to move and no movement is seen a shutdown alarm is displayed WIRING ERROR ALARM When power is first apllied to the contoller the software will per form a check on the wiring of the transfer output and ensure it does not have high voltage on the wire If this is the case it will signal a miswire alarm and will not run The test can be skipped by use of the escape key UNDERVOLTAGE ALARM If the generator voltage falls below 60 fo
15. 0 SQ3A U 1 3D3VH3SIQ 219 ANY 15 1738 ANY 43733 15 559009 01 d3Nvd 3491 20 1441 3 9 1 411 403 IVANYW SS3NMD 432 444424 S Vd SNIISIX3 NV NO 01943 30 30 ONILNNOW 403 13411944 AANO SI 109 1313 1553006 S33ADO 1 3 SAOWSY 1 1 3 HOLIMS 34SNV31 OL 553339 NDIIO3NNDO XVN 67229 081 39 2 AS3IIV8 1103 00 JYALNAN 1103 00 LINGNOD 4931 4901 29 03 15 3015 lt SBS3NMD 133HS 119013103 5 335 438434 11024129 5 15 a3HlD S3ONVISIG WAWINIW 403 53003 090070 NV 31915 1943034 ASHLO Sv 711384 59 SISNVINVIS OZ VddN ANY ZE VddN 31892114449 1 3 HLIM 0 440009 NI G3 TIVISNI LSAW LINN ONIOIAS3S NV 3D SOLVSSNSD SHL 30 53015 119 NO WOD 1 341314 405 MOTY S3NI 30109 31382ND2 032 LINN HLIM 34114 5 38105 NOILVVIVISNI 39N323439 1 C 8 882 X 6 371 094 31382NDL2 G3UIN3WADO38 WAWINIW 16711 9 9 861 vv 166611 169 13318 S811 07 5411 5 S81 5 135 39 IIM4S 31V32 ANO 135 39 TIWIS3IVMW 0175 gt DNIddIHS N3DDM PPI 3NISN3 SNIddIHS 1HD13M 9190
16. 12VDC FOR THE AIR FUEL SOLENOID OPTION AND FOR THE IGNITION COILS EC CONNECTOR PIN WIRE TO FUNCTION i GND 1 6 804 34 OXYGEN SENSOR ENGINE CONTROL MODULE CONNECTIONS J1 PIN WIRE FUNCTION L6 15 Fri 4 J L8 GND L9 GND NOTE1 10 0 2 FLYWHEEL SENSOR 16 SHLD 1 1 _ FLYWHEEL SENSOR DRAN 17 819 BWR 4 REMOTE DISPLAY MAINTENANCE 18 767 GOV 2 POSITION FEEDBACK RETURN 19 765 0 3 THROTTLE POSITION FEEDBACK SOURCE 21 68 WTS 2 COOLANT TEMP SIGNAL 86 105 LOW PRESSURE SIGNAL LEGEND 00 NEUTRAL 5 AIR FUEL SOLENOID DC CHARGE ALTERNATOR BATTERY BASIC WIRELESS RECEPTACLE CIRCUIT BREAKER CYLINDER IGNITION COIL DIODE BRIDGE PAGE 4 REVISION 4 1 10 EMISSIONS CONNECTOR FUSE INLINE FUEL SOLENOID ELECTRONIC GOVERNOR ACTUATOR ENGINE CONTROL MODULE CONNECTOR LOW FUEL PRESSURE SWITCH LOW OIL PRESSURE SWITCH MAIN LINE CIRCUIT BREAKER EXCITER METAL OXIDE VARISTOR J2 PIN WIRE TO FUNCTION 1 770 GOV 4 THROTTLE DRIVE Hi 6 453 5 IGNITION COL DRIVE 3 8 14 DBI FS EC C2 NOTES j 771 1 THROTTLE DRIVE LO 16 6 DPE EXCITER RETURN 17 162 _ EXCITER OUTPUT BREAKER PROTECTED 18 4 FIELD BRUSH 191 1 FIE
17. 30hrs break in alert 100hrs Coolant change amp flush 100hrs 3mo 30hrs break in 100hrs 100hrs 3mo 30hrs break in 3mo 30hrs break in 1yr 100hrs 100hrs 100hrs 1yr 100hrs Inspect battery alert 100hrs 100hrs 1yr 100hrs 100hrs 01 00 ed Control Panel 01 90 00X9NHlU9 avol SYNOH NOI19313S e 40 swa 199 s 0 foy uauna enesn JONVNALNIVIN AONANOAYA YOLVYANAD 19939 E I 3Sl0d3X3 ayy lt dn dwnf 953 349953 941 56944 3LVO AWIL a gt 183110 SAV1dSIG SLNdLNO S1fldNI SNOISH3A QNVIAWOS AV1dSIG 501 901 WHV1V 1SVH1NO9 lt osa Qs 1 4 l NOLIVALLOV _ IWALSAS STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator s manual for this unit OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the Stationary Emergency Generator was installed in conjunction with a
18. AWG 34 8 GRN YEL 37 022447 2 WASHER SHAKEPROOF INT 1 4 38 0G5892B 1 INSULATION REAR WRAP 39 0 88690 1 KEY VISE ACTION LATCH SLOT CIR 40 0E5298L 1 FOAM 300 X 300 THERMAL ACO APPLIES TO 4 2L UNITS ONLY 4 066760 1 STRIP SEALANT 1 8 X 1 44 52 LG 42 0H1208A 3 RF COVER PLATE PLASTIC BISQUE 0H1208B 3 RF COVER PLATE PLASTIC GREY 1 ALUMINUM ENCLOSURE NOTE ALL ENCLOSURE PANELS THAT FASTEN TO THE BASE FRAME MUST BE SECURED USING ITEM 2 amp 5 THREAD FORMING FASTENER AND I N 10 LOCK NUT LOCK NUT IS TO BE INSTALLED AFTER THREAD FORMING FASTENER HAS PENETRATED THROUGH EXTRUSIONS IN ENCLOSURE PANELS ALL ROOF PANELS ARE TO BE SECURED IN THE SAME MANNER 2 SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER 5400 CUSTOMER FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER REPLACEMENT SHEET METAL PARTS ORDERING GUIDE 0H7169 INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE REVISION H 5821 C DATE 2 9 10 GROUP F PAGE 2 OF 2 965090 DNIA V zd MASY 9 MASE 5 AHIA QHGO Id XH D 01 11 lt 4 1609 JO HDVd M3IA INOJ 4452 ONILNNOW 41445 2 003 51114 YOHINY AANDSYW VIG G2 D 281 530914 3 DH QNILNNOW 910 ESY GEI 9 1 52418 ANY
19. CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 7 and 7 8 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and 2 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 7 Stator Power Winding Connections 3 phase 120 240V 6 Lead E2 S2 N S6 INTERNAL CONNECTIONS L L S5 S3 si 54 E3 L N 00 NEUTRAL Figure 7 8 Stator Power Winding Connections 3 phase 120 240V 12 Lead 00 NEUTRAL Control Panel CONTROL PANEL INTERFACE USING THE AUTO OFF MANUAL SWITCH A WARNING With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting occurs when utility power source voltage droops 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 fuse before work ing on or around the generator or transfer Switch Then place NOT OPERATE tag on the generator panel and on the trans fer switch 1 AUTO Position Selecting this switch activates fully auto matic system operation It also allows the unit to automati call
20. FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris These generators may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Diesel fuels are highly FLAMMABLE Gaseous fluids such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm 01 50 4 70025 General Information IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator The data label which can be found attached to the generator s lower connection box lists the unit s serial number and its rated voltage amps watt
21. G2 45KW Drawing No 0H7322 Revision H 6789 B Date 6 4 10 Page 1 of 4 GROUP D REMOVE amp REPLACE J 2 27 INDICATION IN 73 RATE OL 9 50 42 2202 84 26 S PONG gt 9 17 29 SS 7 REMOVE 1 gt Exploded View ENGINE COM PTS 2 4L G2 45KW Drawing No 0H7322 Revision H 6789 B Date 6 4 10 Page 2 of 4 EXPLODED VIEW ENGINE COMMON 2 4L G2 45 DRAWING 7 0H7322 APPLICABLE TO ITEM 1 0H1619 2 046526 3 039414 4 060149 45 0 9868 6 03217 7 042574 8 0H7435 9 057772 10 057765 11 043790 12 0 7649 13 069860 14 063076 15 061394 16 052830 17 025507 18 062963 19 049821 20 022129 21 006029 22 0 0502 23 022145 24 0 2664 25 045771 26 022131 27 068427 28 046525 29 058306 30 022097 31 022473 32 043116 33 026073 34 0 4507 35 08258 1 36 0445310244 37 068853 38 047290 39 049340 40 052265 41 063823 42 052213 43 034413 1 44 060951 45 063910 4 0G6093E 4 0D2244M 4 0F9420 49 0G7461 50 061472 51 061476 52 068488 1 53 060950 54 029583 55 0G92210AS0R 56 060792 57 068852 58 022152 59 09501 1 60 060952 61 060788 62 023897 3 63 069520 64 068854 1 65 052203 66 077043 67 067313 68 0H6689 REVISION H 6789 B DATE 6 4 10 QTY 4 REF 1 1 8 4 REF s 1 4 REF o 4 REF 1 8 4 RE
22. The oil grade for temperatures below 32 F is 5W 30 synthetic oil 3 1 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the specifications Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture A CAUTION Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chro mium hydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating The manufacturer also recommends that any soluble oil inhibitor is NOT used for this equipment A DANGER Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them 01 50 100403 Engine Protecti
23. WASHER FLAT 5 16 M8 ZINC WASHER FLAT 10 ZINC SCREW HWHT M6 1 X 16 N WA Z JS SCREW RHM 10 32 X 4 WASHER LOCK 10 NUT HEX 10 32 STEEL UL CIRCUIT BREAKER FD 0150A 600V FD6 LL COVER CB S FD6 C2 CONBOX SCREW SHC 1 4 20 X 4 5 G8 8 NZ INSULATOR CB FD FRAME 30MIL STANDOFF CB MOUNT CONBOX WASHER FLAT 1 4 M6 ZINC WASHER LOCK M6 1 4 SCREW HWHT M6 1 X 16 N WA Z JS NUT HEX 1 4 20 STEEL PAGE 7 OF 8 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO THIS PAGE LEFT INTENTIONALLY BLANK PAGE 8 OF 8 REVISION A DATE 3 31 10 GROUP VIEW MOUNTING 2 4L C2 1 6 7 SUPPORT 5 8 77 s 25 9 REVISION H 5218 E DATE 10 14 09 DRAWING 0F9807 PAGE 1 OF2 EXPLODED VIEW MOUNTING BASE 2 4L C2 DRAWING 0F9807 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F9517 1 WELDMENT FRAME 2 41 C2 2 052860 4 NUT FLANGED HEX M12 1 75 3 052251 4 DAMPENER VIBRATION 40 BLUE 4 052257 4 SPACER 49 X 62 X 1 87 PNDR ZNC 5 052252 4 DAMPENER VIBRATION 6 052259 4 WASHER FLAT M12 7 052891 4 SCREW 12 1 75 X 80 68 8 8 0536210410 1 ASSY WIRE 14 00 9 042909 1 SCREW HHC M8 1 25 X 30 G8 8 10 047411 1 SCREW HHC M6 1 0 X 16 G8 8 11 055414 1 LUG SLDLSS 42 88 X 17 64 CU 12 022447 1 WASHER SHAKEPROOF INT 1 4 13 022097 1 WASHER LOCK M6 1 4 14 022473 2 WASHER FLAT M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHE
24. alarm message COMMON ALARM RELAY The common alarm relay will be activated if there is a shutdown alarm It will not activate on warnings or indicate that the Auto Off Manual switch is in the OFF position The OFF position will clear the alarms and the relay The relay will not be used to indicate a generator is not activated MAINTENANCE ALERTS Maintenance alerts will be provided for these conditions see the Maintenance Alert Chart SERVICE SCHEDULE Inspect Accessory drive alert 100hrs Coolant change amp flush 100hrs Inspect spark plugs alert 1yr 100hrs Change oil amp filter alert 100hrs Inspect battery alert 100hrs Change Inspect air filter alert 100hrs SERVICE SCHEDULE B Change Inspect spark plugs alert 2yr 250hr CONDITION 1 6 CHERY 2 4 1800 MITSU 2 4 3600 MITSU 4 2 FORD Change oil amp filter alert 3mo 30hrs break in 1yr 100hrs Inspect clean air inlet amp 3mo 30hrs break in exhaust alert 6mo 50hrs Change Inspect air filter 1yr 100hr alert 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in 1yr 100hrs 1yr 100hrs 1yr 100hrs 3mo 30hrs break in 3mo 30hrs break in 3mo 30hrs break in 6mo 50hrs 6mo 50hrs 6mo 50hrs 1yr 100hr 1yr 100hr 1yr 100hr Inspect spark plugs alert 100hrs 100hrs 1yr 100hrs 1yr 100hrs 1yr 100hrs Change Inspect spark 2yr 250hr 2yr 250hr 2yr 250hr 2yr 250hr plugs alert Inspect Accessory drive 3mo
25. contractor Installation of this equipment is not do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact a Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a dealer about parts and service always supply the complete Model Number Serial Number and Type Code where applicable from the DATA LABEL that is affixed to the unit 01 50 4 70025 Safety Instructions SAFETY RULES 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 effi ciently 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 a procedure work method or operating technique is used that 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 A DANGER Despite the safe design of this generator operating this equipment imprudently negl
26. fuel jet loosen counter clockwise from the outlet port 7 Remove the LP fuel jet loosen counter clockwise from the jet keeper port on the side of the regulator housing Install this jet into the outlet port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on NG 01 80 V 8029080 0 6 2 8 Install the previously removed NG jet into the jet keeper port on the side of the regulator housing 9 Install the previously removed black pipe onto the outlet port of the demand regulator Use pipe sealant on the pipe threads 10 Reverse steps 1 4 in this procedure to reactivate the demand regulator 11 Follow the instructions in the Control Panel section A DANGER Serious injury including death or damage may occur if not configured properly Please consult an Authorized Dealer with any questions Figure 6 1 Reconfigure the Fuel System CARBURETOR FUEL HOSE nz DUM FUEL SOLENOID 4 WIRE CONNECTOR SCREW SPRING CLAMP OUTLET PORT FUEL ENRICHMENT LINE JET KEEPER PORT CONTROL PANEL The FUEL TYPE must be reconfigured in the control panel to final ize the conversion process To access the fuel selection menu select EDIT from the main control panel menu Scroll through the prompts until FUEL TYPE is displayed Press ENTER to select this field then toggle the proper fuel type and press ENTER again to accept Th
27. no keys are pressed for 30 seconds This page normally shows the current Status message and the current date and time The highest priority active Alarm and or Warning will be automatically posted on this page as well as flashing the backlight when such an event is detected In the case of multiple Alarms or Warnings only the first message will be displayed To clear an Alarm or Warning see the Protection Systems section Clear Alarm The display backlight is normally off If the user presses any key the backlight will come on automatically and remain on for 30 seconds after the last key was pressed The Main Menu page will allow the user to navigate to all other pages or sub menus by using the Left Right and Enter keys This page can be accessed at any time with several presses of the dedicated Escape key Each press of the Escape key takes you back to the previous menu until the main menu is reached This page displays the following options HISTORY STATUS EDIT AND DEBUG See the Appendix Menu System 01 90 ed Control Panel ACTIVATION CHART CHOOSE LANGUAGE Display Reads Language English EF YE ALI Display Reads Activate me ENT or ESC to run in manual Display Reads To Activate go to www activategen com LY Ven Use ARROW keys to scroll to desired lan guage Press ENTER to select Press ENTER to begin the activation pro
28. on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Once each year have the generator cleaned and inspected by a Service Dealer That dealer will use dry low pressure air to clean internal windings Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the genera tor may require drying 01 70 SERVICE SCHEDULE Weekly W Monthly M Inspect Change Clean Yearly Y ss Ir W Jo o x w ute SOS SY w Engine Coolant nes amp Comectons m x EO v j x x x x T Sp v x gt j Battery Remove Corrosion Ensure Dryness Gmn amp TgenBaeyTemmds m x T x Check Charge State X J check Ekctrovielevel Xx x J General Condition Vibration Noise Leakage Temperature Generator System Complete Tune up and System Inspection To be completed by an Authorized Service Dealer Footnotes the oil level monthly or ever
29. tested contact a Service Facility Inspect cooling system and coolant recovery system for leaks COOLANT CHANGE Every year have a service facility drain flush and refill the cooling system See the Specifications and Service Schedule for cooling system recommendations OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via the control panel fuse This overcurrent protection device will open if the circuit is overloaded CAUTION If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse EXERCISE SYSTEM Starts the Stationary Emergency Generator engine once every seven days and lets it run for 12 minutes PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine genera tor monthly Look for obvious damage loose missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year Check all exhaust system pipes mufflers clamps etc for condition tight ness leaks security damage 070 V ed CHECK FAN BELT nspect fan belts every year Replace any damaged deterio rated worn or otherwise defective belt Check fan belt tension Th
30. 0 4186 50 1 COVER CB DISH 2 225AF D 0 8432 1 INSULATOR 2 225 0 7311 1 STANDOFF BOX 045771 2 8 1 25 68 CLEAR 036261 4 125 X 275 0 2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 053640 2 SCREW 78 32 X 3 1 4 K 038150 2 WASHER FLAT 8 ZINC L 022264 2 WASHER LOCK 8 M4 M 022471 2 NUT HEX 8 32 STEEL N 049897 4 SCREW SHC M8 1 25 X 20 G8 P 022129 6 WASHER LOCK M8 5 16 R 022145 4 WASHER FLAT 5 16 M8 ZINC s 058306 2 SCREW SHC M8 1 25 X 25 C12 9 OF8843 2 BUS BAR 200A LUG ADAPTOR U 0 8451 2 LUG SLDLSS 300 MCM 6 AL CU UL CIRCUIT BREAKER 400AF A 0 4153 1 0250A 480V 400AF 0 6735 1 400 2 047822 3 LUG 510155 600 250 1 0X1 4 28 D 0H6734 1 STANDOFF CB MOUNT CONBOX E 042419 4 SCREW RHM 10 32 X 4 F 022097 6 WASHER LOCK M6 1 4 G 052647 6 SCREW SHC M10 1 5 X 25 C12 9 H 002454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 046526 6 WASHER LOCK M10 K 023897 4 WASHER FLAT 10 ZINC L 022152 4 WASHER LOCK 10 M 022158 4 NUT HEX 10 32 STEEL N 023334 6 SCREW 1 4 28 X 1 2 65 022473 6 WASHER FLAT 1 4 6 ZINC ITEMS INCLUDED WITH HARNESS P N 0H6692 ITEMS INCLUDED WITH NEUTRAL BLOCK P N 0D5464B ITEMS INCLUDED WITH 4 2L MODELS ONLY SEE C2 DPE BREAKER SELECTION TABLE QTY REQ FOR 2 POLE BREAKER QTY REQ FOR 3 POLE BREAKER SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRE
31. 1 5 059981 4 SCREW HHC M10 1 5 X 30 G10 9 6 0F2776A 1 BRACKET SIGNAL CONDITIONER USED ONLY WITH QTA PRODUCT 7 0 5050 1 SHIELD RADIATOR C4 8 029032 1 HOSE 9 32 ID 27 LG 9 0F2573 1 PULLEY FAN V GROOVE 9 10 0F4011 1 FAN COOL 22 DIA 10 BLADE LH 11 0 206205 03 1 TENSIONER 1 12 0H2051 1 SHOULDER BOLT 1 2 X 2 14 REVISION H 4927 B DATE 8 17 09 ITEM 13 14 15 16 17 18 19 20 21 22 23 1 24 25 26 227 28 29 1 31 32 33 34 35 36 37 38 39 40 1 41 42 43 44 45 46 47 48 49 50 51 52 53 3 54 55 56 4 57 4 58 0 2862 0 2560 022131 0 2507 0 1827 035685 0 2561 0 8145 052250 0 7043 0 8165 022473 0 8146 022097 076749 048031 031971 0 4496 042911 0 2872 022304 022195 022196 0 8651 099502 0 9867 0 2461 022145 022129 039287 082774 060795 060816 0H1546 049813 052644 0 8566 0 2454 090283 080713 052677 0 308805 03 039253 0 2844 049820 0G53150ALOR 0H1851 029333A QTY 1 2 o L GROUP D DESCRIPTION SPRING TENSION CPL PULLEY V BELT 4 FLANGED WASHER FLAT 3 8 M10 ZINC PROBE COOLANT LEVEL 3 8NPTF PROBE COOLANT LEVEL 3 8 18NPTF CLAMP HOSE 28 1 32 2 25 HUB FLEX PLATE WASHER FLEX THIN TAPE FOAM 1 X 1 26 75 LG DISK FLEX NUT HEX LOCK 5 16 24 NY INS WASHER FLAT 1 4 6 ZINC SCREW 5 16 24 X 1 124 WASHER LO
32. 100 FUEL CONVERSION For fuel conversion steps refer to the GenSpec section RECONFIGURING THE FUEL SYSTEM OPERATION This system is intended to supply standby power in the event of a utility failure The control system will monitor the utility voltage to determine if stand by power is required Should the utility voltage fail the generator will start and run normally detaching from the utility and supplying the customer load from the generator When utilily power returns the controller will re transfer the customer load back to utility and shut down the generator 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 2 Be sure that normal UTILITY power source voltage is avail able to transfer switch terminal lugs N1 and N2 Refer to the Electrical Data section 3 Set the 5 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 auto matically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to the Sequence of Automatic Operation section 01 90 Control Panel SEQUENCE AUTOMATIC OPERATION Initial Conditio
33. 9 0 6586 20 0 4394 21 040105 22 0G4573B 23 0F7790E 24 0E7121 25 047290 26 022097 27 046580 28 035685 29 0H7436 REVISION A DATE 3 19 10 QTY GROUP E DESCRIPTION NIPPLE CLOSE 3 4 X 1 375 FLANGE FUEL INLET REGULATOR ASSY 2 4L SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 M8 ZINC WASHER LOCK M8 5 16 M8 1 25 G8 CLEAR CLAMP HOSE 5 5 62 62 STREET EL 45D 1 2 NPT BRASS ELBOW 90D 3 4 NPT NIPPLE PIPE 3 4 NPT 7 CLAMP HOSE 10 56 1 06 HOSE 3 4 ID SAE 30R2 18 LG BARBED STR 1 2 NPT X 3 4 DECAL INLET PRESSURE DECAL FUEL INLET NG NATURAL GAS APPLICATION DECAL FUEL INLET LPG LP VAPOR APPLICATION O RING 45 63 ID X 2 62 WIDTH GASKET BOSCH 32 ACTUATOR BOSCH 40 GOVERNOR HOSE COOL 2 IN ID 20R4 MIXER ACTUATOR 40MM MACHINED VENTURI THROTTLE 26MM O RING 47 625 ID X 2 38 WIDTH HOSE 3 8 ID SINGLE BRAID 18 LG WASHER LOCK M6 1 4 SCREW SHC M6 1 0 X 45 G12 9 CLAMP HOSE 28 1 32 2 25 HARN FUEL JUMPER SINGLE REG Page 2 of 2 971190 C dO 1 dDVd 90 82 9 ILYA 1S VHX3 M3 133nN 9578 9 NOISIASH G1O3INVW 1SnVHX3 SP 3qIS H H OL EXPLODED VIEW MUFFLER EXHAUST DRAWING 061146 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0F9794 2 MUFFLER 7 X9 X 12 12 2 INOUT 2 050113 1 EXHAUST ELBOW2 400 2 1200 3 051007 1 BRACKET
34. CK 6 1 4 TANK COOLANT RECOVERY CLAMP HOSE BAND 1 4 BEARING 6205 2NSE C3 E SRI2 S PULLEY 4 5 DIA MACHINED SCREW HHC M10 1 5 X 30 G8 8 SCREW 1 2 13 X 2 68 WASHER FLAT 1 2 ZINC WASHER LOCK 1 2 NUT HEX 1 2 13 STEEL SCREW HHFC M8 1 25 X 20 WIM6 CLAMP HOSE 24 B1 06 2 00 SHAFT FAN DRIVE RETAINER BEARING WASHER FLAT 5 16 M8 ZINC WASHER LOCK M8 5 16 SCREW HHC 8 1 25 X 45 C8 8 KEY WOODRUFF 4 X 19D HOSE LOWER RADIATOR G2 HOSE UPPER RADIATOR G2 USED WITH MANFLD PIN 0G0707 HOSE UPPER RADIATOR G2 USED WITH MANFLD PIN 0G8488 NUT HEX M6 X 1 0 G8 YEL CHR SPACER 5 X 1 5 X 25 STL ZINC SCREW HHFC M6 1 0 X 20 G8 8 SCREW THF M6 1 X 16 WA Z JS CAP RADIATOR 13 PSI BRACKET COOLANT TANK WASHER NYLON 50 X 87 X 06 BRACKET TENSIONER SPRING SCREW HHC M8 1 25 X 20 C8 8 BEARING SLEEVE 1 2 X 3 4 X 1 NUT HEX LOCK 8 1 25 NY INS SPACER CPL COOLING FAN 1 8 ASSY PCB LCL SENSOR USE WITH I N 16 P N 0H1827 ONLY TIE WRAP UL 7 4 X 19 BLK NOT SHOWN BEARING PRESS NOTE APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO BEARING SURFACE ON ITEM 37 PRIOR TO PRESSING ITEM 28 ONTO ITEM 37 ALSO APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO THE OUTSIDE OF 28 PRIOR TO INSTALLING ITEM 28 INTO ITEM 38 1 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS 2 INCLUDED WITH I N 26 3 ITEM 54 IS INCLUDED WITH ITEM 1 4 USE WITH R PANEL ONLY PAGE 2 OF 2 GROUP D Exploded View ENGINE COM PTS 2 4L
35. F 1 4 REF 2 REF 1 GROUP D DESCRIPTION ENGINE 2 4L G2 CERTIFIED WASHER LOCK M10 SCREW 8 1 25 X 35 68 8 SCREW 5 14 1 5 X 35 610 9 ALTERNATOR DC PULLEY SPACER DC ALTERNATOR PULLEY ADAPTOR 1 8 TO 1 8 BSPT HARN LOW OIL PRESS SWITCH ASSY WASHER NYLON 565 ADAPTER M14 1 50 X 3 8 NPT BARBED EL 90 3 8 NPT X 3 8 CLAMP HOSE 38 87 HOSE DRAIN ASSY 28 WASHER FLAT 531 ID X 1 062 OD SCREW HHC M12 1 25 X 20 G10 9 SCREW HHC M10 1 25 X 45 G8 8 WASHER SHAKEPROOF EXT 7 16 STL SCREW HHC M10 1 25 X 30 G8 8 SCREW SHC 8 1 25 X 30 G12 9 WASHER LOCK M8 5 16 SCREW THF M6 1 X 16 WA 71 95 TEMPERATURE SENDER WASHER FLAT 5 16 M8 ZINC ASSY DIPSTICK W TEXT GTH 530 NUT HEX M8 1 25 G8 CLEAR ZINC WASHER FLAT 3 8 M10 ZINC ASSY DIPSTICK TUBE 2 4 G2 NUT HEX M10 1 25 G8 YEL CHR SCREW SHC 8 1 25 X 25 G12 9 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW HHC M6 1 0 X 12 G8 8 PLUG STD PIPE 1 4 STEEL SQ HD SCREW HHC M10 1 5 X 120 C8 8 SCREW HHC M8 1 25 X 25 G10 9 FILTER 1 5L 2 4L G2 OIL COIL 2 4L G2 IGNITION HOSE 3 8 ID SINGLE BRAID 15 LG BARBED EL 90 1 4 NPT X 3 8 SCREW HHC 8 1 25 65 8 8 O RING SIZE 9 0 X 2 0 SCREW HHC 10 1 25 X 20 8 8 SCREW 10 32 X 1 1 4 MANIFOLD EXHAUST MANIFOLD G2 MACHINE FLEX PLATE 2 POLE 2 4L G2 ASSY MAGPICKUP 3 8 24 MALE ADAPTER ENGINE 2 4L MACHINE STARTER MOTOR 12V CAM SENSOR PIN ASSY COVER CAM GEAR
36. G2 REWORKED MANIFOLD INTAKE MACHINED GASKET INTAKE MANIFOLD SPACER 2 41 G2 FLEX PLATE SHIELD HEAT SHIELD HEAT SML BRACKET ASM 2 4L COIL G2 WASHER LOCK 10 ADAPTER 2 4L CRANKSHAFT MACH POLY V BELT G2 PULLEY DC ALTERNATOR WASHER FLAT 10 ZINC PLUG TAPER SPARK PLUG WIRE SET 2 4L G2 IG SCREW HHC 8 1 25 X 70 68 8 CONDUIT FLEX 25 ID DECAL EMISSION CTRL INFO 2 4L HARN ENG 62 41 G2 NEXUS Page3 of4 EXPLODED VIEW ENGINE COMMON 2 4L G2 45 DRAWING 7 097322 GROUP D APPLICABLE TO ITEM DESCRIPTION 69 029333A 3 WRAP UL 7 4 X 19 2 70 0H0015 1 HARN EMISSIONS OVERLAY 2 4L NOT SHOWN n 045772 1 NUT HEX M10 1 5 G8 YEL CHR 1 SUPPLIED WITH ENGINE 2 CALIFORNIA EMISSIONS COMPLIANT MODELS ONLY 3 APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO I N 72 4 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS REVISION H 6789 B Page4 of4 DATE 6 4 10 AIR B CLEANER CONNECT TO WIRE HARNESS ASSEMBLY PIN 0F8274 Revision A Exploded View FUEL SYSTEM 2 4L 45KW Drawing No 0H7580 Page 1 of 2 Date 3 19 10 EXPLODED VIEW FUEL SYSTEM 2 41 4SKW DRAWING 8 0H7580 APPLICABLE TO ITEM PART 1 026915 2 075580 3 OF6390B 4 039253 5 022145 6 022129 7 045771 8 040173 9 0 8286 10 026812 11 0 8379 13 057823 14 059057 15 047527 16 001509 17 050279 050280 18 0 2119 1
37. HE FUEL SYSTEM in manual Check oil and add oil as needed Engine is overheated Check cooling system for leaks Defective Low Oil Pressure Switch Replace switch Engine starts then shuts down 1 1 2 2 3 3 4 Defective Coolant Temperature Switch 4 Replace switch 5 5 6 6 7 7 Engine oil level is low Defective Control Module circuit board Replace board Coolant Level is Low Repair leak Add coolant Defective Low Coolant Level Switch Replace Switch AUTO OFF MANUAL Switch at OFF 1 Defective AUTO OFF MANUAL switch 1 Replace board engine continues to run 2 Defective Control Module circuit board 2 Replace board No AC output from generator 1 Main line circuit breaker is tripped open 1 Reset to ON CLOSED 2 Generator internal failure 3 Thermal circuit open 3 Auto reset Wait 5 min and attempt restart Contact the nearest Dealer for assistance 12 1 01 60 8 7 60014811 United States Environmental Protection Agency Warranty Statement Warranty Rights Obligations and Coverage The United States Environmental Protection Agency EPA and Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new stationary emergency engine If during the warranty period any emission control system or component on your engine is found defective in materials or workmanship Generac will repair your engine at no cost to you for diagnosi
38. LD FIELD BRUSH I N 00 NEUTRAL MAGNETIC PICKUP OXYGEN SENDER RESISTOR STARTER CONTACTOR SHIELD STARTER MOTOR SPARK PLUG COOLANT LEVEL SENDER COOLANT TEMPERATURE SENDER SCHEMATIC DIAGRAM G2 4L G2 NEXUS DRAWING 0H6340 PAGE 3 OF 4 GROUP G CYL3 CYL2 CYL1 CYL4 SCHEMATIC DIAGRAM 4 PAGE 4 OF 62 41 G2 NEXUS DRAWING 0H6340 PAGE 4 OF 4 REVISION A DATE 4 1 10 GROUP G 1 NOTE ALL WIRES 18 AIR FUEL SOLENOID ENGINE CONTROL MODULE 35 PIN CONNECTOR 300V UL LISTED UNLESS DC CHARGE ALTERNATOR ENGINE CONTROL MODULE 23 PIN CONNECTOR SHOWN OTHERWISE ALTERNATOR STATOR LOW FUEL PRESSURE SWITCH BRUSH ASSEMBLY LOW OIL PRESSURE SWITCH AWG SIZE LOW VOLTAGE PLUG 8 BULKHEAD nz BASIC WIRELESS RECEPTACLE LOW VOLTAGE RECEPTACLE 8 CIRCUIT BREAKER MAIN LINE CIRCUIT BREAKER CYLINDER IGNITION COIL METAL OXIDE VARISTOR SPLICE DIODE BRIDGE PICKUP NUMBER EMISSIONS CONNECTOR NEUTRAL BLOCK INLINE 25 OXYGEN SENDER FUEL SOLENOID RESISTOR FUEL SOLENOID PLUG STARTER CONTACTOR WIRE FUEL SOLENOID RECEPTACLE STARTER MOTOR SPLICE GROUND CONNECTION TERMINAL BLOCK CAGE CLAMP ELECTRONIC GOVERNOR COOLANT
39. LES SCREWTHF 1 16 2 5 WASHER 5 16 8 ZINC BATTERY 12V0C 75 25 GROUP C PAGE 2 OF 2 608630 ONIM V 1 DVd 10 81 01 O H3NV3TO AHIA 4 9 EXPLODED VIEW AIR CLEANER C2 DRAWING 0F9809 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 6586 1 GASKET BOSCH 32 amp 40 2 0 0519 1 ADAPTER CARBURETOR W PVC CONN 3 0C8127 1 ELEMENT AIR CLEANER 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 1 6 062974 1 STUD 1 4 20 X 4 1 2 622 7 0G0190 1 PLATE AIR CLEANER TOP 2 4L 8 037561 1 NUT WING 1 4 20 NYLK REVISION H 1248 A DATE 10 18 07 1 APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON ONE END OF 6 STUD THAT SCREWS INTO I N 2 CARB ADAPTER GROUP D PAGE 2 OF 2 GROUP D 27 43 UN 200 t E OTO lt u 2 a 259 PRESS NOTE 0H3075 2 COOLING SYTEM 4 FAN DRIVE EXPLODED VIEW DRAWING PAGE 1 OF 2 REVISION H 4927 B DATE 8 17 09 EXPLODED VIEW C2 COOLING SYTEM 8 FAN DRIVE DRAWING 0H3075 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 308305 03 1 WELDMENT RADIATOR SUPPORT C2 2 0 2608 1 RADIATOR 598 X 568 X 49 3 0 5263 1 V BELT 31 64 X 57 3 8 4 046526 5 WASHER LOCK M10
40. LEVEL SENDER HIGH VOLTAGE PLUG 12 BULKHEAD COOLANT TEMPERATURE SENDER HIGH VOLTAGE RECEPTACLE 12 BREE ARE BEDOV RATED COMPONENTS LOCATED IN CUSTOMER CONNECTION BOX Y 2 14 14 2 UTILITY FROM 49 BLUE LVP 3 TRANSFER SWITCH N2 HVP 2 DB1 DB2 o FUSED 120 T u SOURCE FOR B BATTERY CHARGER 49 2 14 5 TRANSFER RELAY 194 194 zs o m lt gt TRANSFER RELAY COIL 23 28 N 183 6 REMOTE ko START 178 LVP 5 11 11 d 44 44 1 BLACK 1 ien 4 16 _ 11 El 12 1 LVP ALTERNATOR STATOR GND SHOWN FOR 1 N1 TB2 4X 1 0 TBI 3X 3 2 2 182 2 2 14 DB1 5 5 DRAWING 096342 5 TB2 3x 3 49 DB1 5 SA TB1 1X 5 178 TB3 4x 1 2 6 SB TB1 2X 6 183 TB3 3X MEE 7 7 25 TB3 2X Bo N GND 5 yr UE adios 8 194 1 CUSTOMER 5 6 61 6 NOTE 4 SPLICE 11 FOR FIELD WIRING CUSTOMER 5 1 SFLICE 10 TERMINAL BLOCKS MAXIMUM WIRE SIZE 12 22212158 EN
41. M6 ZINC KNOB M6 1 0 CONTROL PANEL SCREW HWHT M6 1 X 16 N WA Z JS SCREW HHSP 10 X 3 8 HI LOW SCREW HHC M6 1 0 X 20 C8 8 SHIELD HIGH LOW C2 RAW SCREW PHTT 4 0 7 X 12 ZP ASSY PROG 2010 IGN MOD 6 CYL WASHER FLAT 10 ZINC SCREW PPHM 10 32 X 2 WASHER LOCK 10 NUT HEX 10 32 STEEL CLAMP STL VNL 1 06 X 406 Z NEUTRAL BLOCK 390 200 400A WASHER LOCK 3 8 NUT HEX 3 8 16 STEEL NUT FLANGE M6 1 0 NYLOK COVER VOLTAGE SHIELD RES WW 15R 5 25W CONN WASHER FLAT M3 WASHER LOCK M3 NUT HEX M3 0 5 G8 CLEAR ZINC DIODE BRIDGE 1P 35A 1000V WASHER FLAT M5 WASHER LOCK M5 NUT HEX 5 0 8 G8 CLEAR ZINC VINYL BLACK 1 8GP 3 LG DECAL CUSTOMER POWER CONNECT DECAL CUSTOMER CONTROL CONNECT DECAL CONBOX TB1 CONNECTIONS WASHER LOCK EXT 1 4 STL LUG SLDLSS 2 8 X 17 64 CU CIRCUIT BREAKER COVER DPE BREAKER NEXUS RAW DECAL NEUTRAL WASHER LOCK 8 M4 SCREW HHTT M4 0 7 X 8 ZP DECAL GROUND LUG TERM BLOCK UL 12 20AWG TERM BLOCK UL 12 20AWG MX150L SLRRMNT 22 18 8P W O GA MX150L SLRRMNT 22 18 12 W OGA LUG SLDLSS 600 250 1 0X1 4 28 WASHER LOCK 1 4 M6 SS SCREW HHC 1 4 28 X 3 4 G5 TAPE ELEC 1 2 FOAM 69 LG HANG TAG 2 WIRE START NOT SHOWN HARN CONBOX NEXUS NOT SHOWN SCREW HHTT M6 1 0 X 16 ZYC 2 OF 8 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER 225AF A 0G5250 1 CB 175A 2 POLE 240V 225AF B 0H7356 1 COVER CB C2 CPL
42. MUFFLER 4 022830 2 MUFFLER BRACKET STIFFENER 5 022962 2 MUFFLER STRAP 6 080762 5 BOLT 0 3 8 16 2 62 7 OEOT70A 1 EXHAUST BLANKET 988 2 8 2454 4 SCREWTHF 1 16 ZJ S 9 050776 1 PIPE EXHAUST G2 10 050007 1 DIFFUSER EXHAUST WELDIVENT 044149 1 GASKET EXHAUST RING 2 085917 2 WASHER LOCK 3855 B 00261 2 SCREWHHC 3 8 16 13 4SS 0 8816 1 EXHAUST FLANGE 2 PIPE 15 019721 4 SCREWHHC 1 0 35 G38 BLK 16 4 WASHER LOCK 1 4 7 22773 4 WASHER FLAT 1 4HV6 ZINC 18 086797 1 BOLTU5 16 18X 225 19 2 NUT HEX 16 18 STEEL 20 070006 2 WASHER LOCK MBSS 21 088775 2 WASHERFLAT 38SS 2 022241 10 8465 23 085917 0 WASHER LOCK 38SS aM 022809 1 EXHAUST CROSSOVER 2 28028 1 PIPE EXHAUST MUFFLER OUT NOT USEDONOPEN SET REVISION G 8436 A DATE 6 28 06 GROUP F PAGE 2 OF 2 GROUP F INSULATION AND RETAINERS 33 ROOF 7 22 LOCATED ON THE NEAR SIDE LOCATED ON THE FAR SIDE INSULATION FOR ROOFTOP INTAKE 7 SN INSULATION AND RETAINERS MOUNTING OF ACOUSTIC AND DISCHARGE AREAS ONLY SEE DETAIL A AND B FOR SPLITTER VARIATIONS N O TO BASE FRAME Hou 55 0 g 5 28 EIS 2 9 7 952 2 s 21 20 E 7 022 OO lt 53 2 639 522 uu 5 8 8 5 D m
43. N WA Z JS J 0H5721 4 SCREW PPHM 8 32 X 1 3 4 ZINC K 022264 4 WASHER LOCK 8 M4 L 038150 4 WASHER FLAT 8 ZINC M 052619 3 SCREW 5 0 8 X 20 68 8 023897 6 WASHER FLAT 10 ZINC P 049226 3 WASHER LOCK M5 R 051716 3 NUT HEX M5 0 8 G8 CLEAR ZINC UL CIRCUIT BREAKER JG A 0H5580 1 CB 0250 3P 600V E JG LL B 0H6739 1 COVER CB E JG C2 CONBOX 045771 3 NUT HEX 8 1 25 G8 CLEAR ZINC D 0H5576A 1 INSULATOR CB E 3P JG E 0H6734 1 STANDOFF CB MOUNT CONBOX F 022127 4 NUT HEX 1 4 20 STEEL G 022097 4 WASHER LOCK M6 1 4 H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 022770 4 SCREW RHM 1 4 20 X 3 K 022473 4 WASHER FLAT 1 4 M6 ZINC L 049897 3 SCREW SHC 8 1 25 X 20 G8 M 022145 6 WASHER FLAT 5 16 M8 ZINC N 022129 3 WASHER LOCK M8 5 16 UL CIRCUIT BREAKER CC A 0H4748 1 CB 0175A 2P 240V E CC LL 0H4915 1 0150 240V E CC LL B 0H7356 1 COVER CB C2 CPL 0H7432 1 COVER CB DISH 2P E CC 0H7433 1 COVER CB DISH 3P E CC 5 D 051716 2 3 NUT HEX 5 0 8 G8 CLEAR ZINC E 0H7311 1 STANDOFF CB BOX CONBOX 5 F 022471 2 4 NUT HEX 8 32 STEEL G 036261 4 RIVET POP 125 X 275 SS H 002454 12 SCREW HWHT M6 1 X 16 N WA Z JS 5 J 053640 2 4 SCREW RHM 8 32 X 3 1 4 5 K 022264 2 4 WASHER LOCK 8 M4 5 L 038150 2 4 WASHER FLAT 8 ZINC 5 M 052619 2 3 SCREW 5 0 8 X 20 68 8 5 023897 4 6 WASHER FLAT 10 ZINC 5 049226 2 3 WASHER LOCK 5 5 QTY REQ FOR 2 POLE BREAKER QTY REQ FOR 3 POLE BREAKER PAGE 5 OF 8 REVISION A DATE 3 31 10
44. ON ASSISTANT Interconnect System Self Test Feature follow the on screen prompts Upon power up this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Upon first power up of the generator the display interface will begin an installation assistant The assistant will prompt the user to set the minimum settings to operate These settings are simply Current Date Time and Exercise Day Time The maintenance inter vals will be initialized when the exercise time is entered The exercise settings can be changed at any time via the EDIT menu see Appendix Menu System If the 12 volt battery is disconnected or the fuse removed the Installation Assistant will operate upon power restoration The only difference is the display will only prompt the cust
45. Owner s Manual Stationary Emergency Generator CAUTION 2 41 INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS 45kW Models ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST ifi FUMES OUTDOOR INSTALLATION ONLY EPA Certified This manual should remain with the unit 816 0 ON Hed 0 70 V ed Table of Contents SECTION PAGE INTRODUCTION 2 cour 1 1 Read this Manual Thoroughly 1 1 Operation and 1 1 How to Obtain Service 1 1 SAFETY RULES ceri rdiet GENERAL Identification Record een Data Label DESCRIPTION Equipment DeScfIplOri 2 Engine Oil Recommendations Coolant Recommendations ENGINE PROTECTIVE DEVICES Engine Protective Devices sss High Coolant Temperature Sender Low Coolant Level 0 Low Oil Press
46. R SHAKEPROOF INT 3 8 17 0F9597A 1 SUPPORT LH ENGINE 2 4L 18 045764 1 SCREW HHTT M4 0 7 X 8 BP 19 062963 4 SCREW HHC M10 1 25 X 30 G8 8 20 022302 5 WASHER LOCK 7 16 21 022131 5 WASHER FLAT 3 8 M10 ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 0F9597 1 SUPPORT RH ENGINE 2 4L 24 022129 1 WASHER LOCK M8 5 16 25 026204 1 WASHER SHAKEPROOF INT 5 16 26 022145 1 WASHER FLAT 5 16 M8 ZINC 27 045771 1 NUT HEX M8 1 25 G8 CLEAR ZINC 29 0F9596 1 SPACER ENGINE MOUNT 2 41 G1 0F9596A 1 SPACER LH ENGINE MOUNT 2 4L G2 30 052212 1 SCREW HHC M10 1 25 X 25 C8 8 31 0C2454 3 SCREW HWHT 6 1 X 16 N WA 2195 32 0H5718 1 HEAT SHIELD 2 41 62 REVISION H 5218 E DATE 10 14 09 GROUP C PAGE 2 OF 2 618640 ONIM VAA C JO HDVd 90 r ALVA 140 17 AH3LLV8 lt 08 0 1 5 YALYVLS OL EXPLODED VIEW BATTERY 241 CPL DRAWING 0F9813 APPLICABLE TO PART lt REVISION G 7805 B DATE 4 3 06 QTY 1 1 REF REF REF REF REF REF 1 1 REF REF 1 4 REF REF DESCRIPTION BATTERY TRAY STRAP BATTERY RETAINVENT WASHER SHAKEPROOF EXT 71651 SCREWHHC MIO 125 X 25G88 WASHER LOCK MIO WASHER FLAT 3 amp MIO ZINC BATTERY POST COVER RED BATTERY POST COVER BLACK CABLE BATTERY BLACK X 1800 CABLE BATT RED 1X 1800 125 GBYEL CHR WASHER LOCK 516 BOOT CONTACTOR CAB
47. REVISION H 5821 C DATE 2 9 10 EXPLODED VIEW ENCLOSURE C2 DRAWING 0H0004 APPLICABLE TO ITEM PART QTY DESCRIPTION 2 1 0G00450STOR 1 REAR WRAP C2 CPL 2 0C2454 54 SCREW THF 6 1 X 16 WA 21 95 2 3 0 584905 0 2 DOOR 2 4 087233 2 POP 1875 450 SS 5 0E3257 4 SCREW TH FRM M6 W CAP SHKPRF W 2 6 0F58520STOR 2 DISCHARGE DUCT LH amp RH SIDE C2 2 7 0 983305 0 2 FRONT CORNERS C2 2 8 0F58510STOR 1 DISCHARGE CENTER DUCT C2 9 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 1 10 077992 21 NUT HEX LOCK M6 1 0 SS NY INS 2 11 0 983505 0 1 ROOF C2 12 0F2786 2 SLITTER C4 13 0F2785 1 SPLITTER LOWER C4 14 0F3364 1 SPLITTER STINGER C2 15 0 4880 2 SUPPORT SPLITTER LH 2 16 0F5049 2 TAB PULL 17 0 4487 1 ASSEMBLY COVER ACCESS 18 022473 3 WASHER FLAT 1 4 6 ZINC 19 022097 1 WASHER LOCK 6 1 4 20 022127 1 NUT HEX 1 4 20 STEEL 21 0F3072 10 INSULATION RETAINMENT HANGER 22 078115 26 WASHER SELF LOCKING DOME 4 40 23 0G5892 2 INSULATION DOOR C2 24 0G5892A 1 INSULATION ROOF TOP 25 0F5048D 2 VISE ACTION LATCH SLOTTED CIR 26 0E5968 1 GASKET EXTRUDED TRIM 328 LG 27 0G5892D 2 INSULATION SPLITTER 28 065892 2 INSULATION SPLITTER 29 0F4051C 2 INSULATION DUCT 30 0F3890B 4 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 078115A 6 WASHER SELF LOCKING DOME 48 32 34 0G5892E 1 INSULATION LOWER SPLITTER 35 042568 2 SCREW HHC M6 1 0 X 20 G8 8 36 0912970094 2 ASSY WIRE 14
48. RM During cranking If the board does not see a valid RPM signal within four 4 seconds of cranking it will shut down and lock out on RPM sensor loss During running If the RPM signal is lost for one full second the board will shut the engine down wait 15 seconds then re crank the engine if in AUTO it will not re crank in MANUAL If no RPM signal is detected within the first four 4 seconds of cranking the control board will shut the engine down and latch out on RPM sensor loss If the RPM signal is detected the engine will start and run normally If the RPM signal is subsequently lost the control board will try two more re cranks before latching out and flashing the RPM Sensor Failure message if it is in AUTO Control Panel Figure 1 Generator Control Panel GENERAC Nexus CONTROLLER GENERATOR MAINTENANCE SCHEDULE System Component Sprem Component pd UNDER FREQUENCY SHUTDOWN ALARM After starting if the generator stays under frequency for more than 30 seconds it will shutdown LOW BATTERY ALARM While running if the average battery voltage falls below 11 9 volts for one 1 minute the low battery alarm will be displayed LOW BATTERY WARNING The microprocessor will continually monitor the battery voltage and display the Low Battery Voltage message if the battery voltage falls below 12 2 Volts for one 1 minute No other action is taken on a low battery warning condition The
49. SENTING GENERIC PARTS NO COLOR e MANUFACTURING FOR CORRECT MATERIAL AND COLOR REFER TO 5400 e CUSTOMER FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO REPLACEMENT SHEET METAL PARTS ORDERING GUIDE 0H7169 INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE 1 2 3 4 5 6 OF 8 REVISION DATE 3 31 10 142 NOLLO3NNOO V 4104 xoa NOILO3NNOO 8 Jo oDeg xoa NOILO3NNO2 dE 9 dz 22 01 0 L9 T eyeq J UOISIA93I EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO ITEM PART QTY DESCRIPTION UL CIRCUIT BREAKER KG A 0H5582 1 CB 0300 3P 600V E KG LL B 0H6740 1 COVER CB E KG C2 CONBOX 003700 4 NUT FLANGE 6 1 0 NYLOK D 0H5581A 1 INSULATOR CB E 3P KG E 0H6734 1 STANDOFF CB MOUNT CONBOX F 045771 3 NUT HEX 8 1 25 G8 CLEAR ZINC G 022129 3 WASHER LOCK M8 5 16 H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 0D2157 4 SCREW SHC M6 1 0 X 50 C8 8 K 049897 3 SCREW SHC 8 1 25 X 20 G8 L 022145 6 WASHER FLAT 5 16 M8 ZINC UL CIRCUIT BREAKER FG A 0H5486 1 CB 0060 480V E FG LL B 0H7356 1 COVER CB C2 CPL 0 7434 1 COVER CB DISH 3P FG D 0H4698A 1 INSULATOR CB 3P E TYPE CC FG E 0H7311 1 STANDOFF CB BOX CONBOX F 022471 4 NUT HEX 8 32 STEEL G 036261 4 RIVET POP 125 X 275 SS H 002454 12 SCREW HWHT M6 1 X 16
50. SPLICE 5 3 3 49 ALT 4 4 5 5 178 1 1 6 6 183 J1 14 7 7 23 42 12 8 8 194 42 13 9 BWR 1 820 J1 12 2 817 J1 4 3 818 J1 5 4 819 J1 17 5 0 CND 6 HVR 9 J2 17 42 7 J2 6 53 42 5 52 J2 4 451 42 23 16 154 5 15 6 GND SPLICE 5 SPLICE 6 J2 2 35 J1 34 OO I GaN J2 9 J1 18 91 19 42 1 41 20 4 J WIRING DIAGRAM REVISION A G2 4L G2 NEXUS DATE 11 16 09 PAGE 3 OF 4 DRAWING 0 6341 GROUP G DR CLE S PTY i 1 COMPONENTS LOCATED ON ENGINE GND LOS J1 33 2 68 GND 0 SEIN m WTS 1 32 573 31 573A WLS A OW PM 5 c WIRING DIAGRAM REVISION A G2 4L G2 NEXUS DATE 11 16 09 PAGE 4 OF 4 DRAWING 0H6341 GROUP 2 WIRING DIAGRAM p m OPTION 1 SINGLE PHASE NE
51. XUS CONTROL PANEL 240 u TB1 n Janaj 4 _ 44 1 BLACK 1 4 11 2 44 6 5 22 35 DIRECT DRIVE 5 GENERATOR OUTPUT CUSTOMER CONNECTIONS LEGEND E2 240 PT ED S BUE ALTERNATOR STATOR E SINB BRUSH ASSEMBLY MLCB LINE CIRCUIT BREAKER NB NEUTRAL BLOCK OPTION 2 THREE PHASE NEXUS CONTROL 120 208 5 s ELI 5 53 1 BLACK 1 Taug 4 4 JEREJ 57 2 51 6 58 52 59 53 p 54 DIRECT DRIVE 55 5 56 510 5115 512 2 857 512 EXIST ONLY ON A 12 WIRE ALTERNATOR GENERATOR OUTPUT CUSTOMER CONNECTIONS E1 TO E2 E2 TO E3 208VAC E1 E2 TO NB 120VAC NOTE THE BTH DIGIT OF THE MODEL NUMBER SPECIFIES OUTPUT VOLTAGE G 120 208 rus ufum J REVISION A PAGE OF 2 DATE 11 19 09 NEXUS CPL ALTERNATOR DRAWING 0H6342 GROUP 2 DOS LS OPTION 3 THREE PHASE NEXUS CONTROL PANEL 6 WIRE 277 480 3 TB1 1 ss 212
52. age capacity phase frequency rpm power factor production date etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when requesting service ordering parts or seeking information Data Label MODEL _____ PROD DATE SERIAL Kw SSS SS SSS asss a J X J PWRFAT JjALTRPM ENG RPM TYPE CODE ALTSUBTRANSREACTANCE TRANS CLASS STATOR WINDING INS 25 AMB a 062110 2 1 01 50 ed Equipment Description EQUIPMENT DESCRIPTION This equipment is a revolving field alternating current Stationary Emergency Generator It is powered by gaseous fueled engine operating at 1800 rpm for 4 pole direct drive units 3600 rpm for 2 pole direct drive units and 2300 3000 rpm for quiet drive gear units See the Specifications section for exact numbers The unit comes complete with a sound attenuated enclosure internally mounted muffler control console mainline circuit breaker b
53. arm Relay Maintenance Alerts Menu System OPERATION mec Stationary Emergency Generator Control and 9 1 Operating Unit with Manual Transfer Switch Engine Start up and Transfer Retransfer and Operating Unit with Automatic Transfer Switch General Check Engine Changing Engine Oil Cooling Intake Outlet Inspect Cooling System ER ire GOOlAIN Coolant Change ironiari nnan Overload Protection for Engine DC Electrical System 10 2 Exercise System a 10 2 Perform Visual Inspection 10 2 Inspect Exhaust System m Check Fam Belt repetentes Inspect Engine Changing the Engine Air Filter m SES Battery Maintenance Battery Replacement Battery FILII crece i ee Cleaning the Stationary Emergency Generator
54. at tery charger and protective alarms as explained in the following paragraph All AC connections including the power leads from the alterna tor 120 volt battery charger input and control connections to the transfer switch are available in the main connection box The Stationary Emergency Generator incorporates the following alternator features Rotor and Stator insulation class is rated as defined by NEMA MG1 32 6 NEMA MG1 1 66 The generator is self ventilated and drip proof constructed Refer to the Specifications section or the data label for the class ratings The voltage waveform deviation total harmonic content of the AC waveform and telephone influence factor have been evalu ated and are acceptable according to NEMA MG1 32 ENGINE OIL RECOMMENDATIONS The unit has been filled with 5W 20 engine oil at the factory Use a high quality detergent oil classified For Service SJ or SH Detergent oils keep the engine cleaner and reduce carbon deposits When changing the engine oil be sure to use 5W 30 engine oil CAUTION Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure NOTE If not already equipped it is strongly recommended to use the optional Cold Weather Start Kit for temperatures below 32 The part number for the Cold Weather Start Kit can be found in the Specifications section or by contacting an authorized dealer
55. cess If you do not have your activation code go to www activategen com or call 1 888 9ACTIVATE 922 8482 If you already have your activation code wait 3 5 seconds for the next display TROUBLESHOOTING the wrong language is chosen it can be changed later using the edit menu If ESCAPE is pressed instead of ENTER your generator will only run in manual mode for test purposes and NOT ACTIVATED will be displayed You will need to reconnect the battery and begin with Step 1 ENTER ACTIVATION CODE Passcode TROUBLESHOOTING Display Reads Use ARROW keys to scroll and find the first Serial 123456789 Passcode TA TW kes Display Reads SELECT HOUR 0 23 _ 6 Y Yee 01 90 ed number of your Activation Code Press ENTER to select Repeat this step until all digits have been entered Use ESCAPE to correct previous digits Activation is complete when all digits are entered above and your screen shows this display Follow the controller prompts to continue setting the time function Refer to your Owner s Manual with questions 8 2 What happens if Wrong Passcode Try Again appears Re enter the activation code If a second attempt is unsuccessful check the number against the code given on activategen com If it is correct and the generator will not accept it contact 1 888 9ACTIVATE 922 8482 Control Panel INSTALLATI
56. cot t e ene teh User Adjustable Settings Fuel GOMVERSION s iicet teer re eee 2 C UR Automatic Transfer Operation Sequence of Automatic Operation Crank Cycles and Overcrank Auto Start Manual Alarm and Warning 5 5 Low Oil Pressure Shutdown Alarm High Coolant Temperature Shutdown Alarm 8 4 Overcrank Shutdown Alarm Overspeed Shutdown Alarm RPM Sensor Failure Shutdown Alarm Under frequency Shutdown Low Battery Low Battery Warning Low Coolant Level Alarm Missing Cam Pulse Alarm Missing Crank Pulse Alarm Low Fuel Pressure Warning Governor Sensor Fault Alarm Wiring Error Alarm Undervoltage Alarm Overvoltage Alarm Internal Failure Shutdown Alarm Canbus lgnitiori Alar uu es Maintenance Warning Alarm Common Al
57. d the unit will start when 2 wire start is active 01 00 ed 8 4 MANUAL START Allows the user to start and run the generator manually Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode only if activated ALARM AND WARNING MESSAGES Alarms are defined as Latching which means they must be cleared before the alarm message on the screen will clear They can be of type Shutdown or not and are logged in the alarm log Alarms are all annunciated on the display Warnings are Non Latching meaning the message automati cally clears when the warning condition goes away Warnings can not be of type Shutdown but they are logged in the alarm log Warnings are all annunciated on the display LOW OIL PRESSURE SHUTDOWN ALARM There is a 10 second delay before oil pressure is monitored HIGH COOLANT TEMPERATURE SHUTDOWN ALARM There is a 10 second delay before engine temperature is moni tored Once running there is a 1 4 second delay before shut down The limit is set at 125 or 257 F OVERCRANK SHUTDOWN ALARM Occurs if the engine has not started within the specified crank cycle OVERSPEED SHUTDOWN ALARM Warning indicator is measured and calculated by the microproces sor Overspeed is defined as 20 of nominal engine speed for 3 seconds or 25 immediate Nominal engine speed 60 0 Hz RPM SENSOR FAILURE SHUTDOWN ALA
58. d the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this function ends the cranking if the engine has failed to start The overcrank message will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not corrected the overcrank feature will continue to activate Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat for 45 seconds Approximately 90 seconds total OVERSPEED SHUTDOWN speed circuit controls engine cranking start up operation and shutdown Engine speed signals are delivered to the circuit board whenever the unit is running Should the engine overspeed above a safe preset value the circuit board initiates an automatic engine shutdown Contact the nearest Authorized Dealer if this failure OCCUIS RPM SENSOR LOSS SHUTDOWN If the speed signal to the control panel is lost engine shutdown will occur DC FUSES A fuse 7 5 amp is located on the control panel It protects the panel components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown A fuse 25 amp is located in the engine wire harness adjacent to the DC alternator It i
59. e fuel conversion is now complete A CAUTION Whenever the Generator s Fuel Regulator is converted from one Fuel type to the other make sure to configure the Control Panel for the correct Fuel type General Information ALTERNATOR AC LEAD CONNECTIONS The electrical wires in the units AC connection lower panel should be installed according to the number of leads and the voltage phase required for the application The voltage and phase are described on the generator data label The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label For example if the generator produces 130kW 277 480 Volt 3 phase power the generator has 12 alternator output leads Figure 7 3 describes the stator power winding connection for the generator FOUR LEAD SINGLE PHASE STATOR Four lead alternators see Figure 7 1 are designed to supply elec trical loads with voltage code 240V 1 phase 60 Hz Electrical power is produced in the stator power windings These windings were connected at the factory to the main circuit breaker as shown in Figure 7 1 The rated voltage between each circuit breaker terminal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator d 120 10115 1 33 rNEURAL 10015 120 10118 11 Y
60. ect ing its maintenance or being careless can cause possible injury or death Permit only respon sible and capable persons to install 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 this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations Installation operation servicing and repair of this and related equipment must always comply with applicable codes stan dards 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 operat ed and serviced in accordance with the manufacturer s instruc tions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations 01 60 4 049125 The engine exhaus
61. fuel system Thereafter the owner operator must make certain that only the proper fuel is supplied NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state In most cases the gas distribution company provides piping from the main gas distribu tion line to the standby generator site The following information applies to natural gas fuel systems e Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches water column 0 5 psi 5 1 PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state The vapor withdrawal system is generally best suited for smaller engines that require less fuel The installer should be aware of the following When ambient temperatures are low and engine fuel consump tion is high the vapor withdrawal system may not function efficiently Ambient temperatures around the supply tank must be high enoug
62. h to sustain adequate vaporization or the system will not deliver the needed fuel volume In addition to the cooling effects of ambient air the vaporization process itself provides an additional cooling effect LP LIQUID FUEL SYSTEM LP is supplied as a liquid in pressure tanks It is usually made up of propane butane or a mixture of the two gases Propane tends to vaporize readily even at temperatures as low as 20 F 29 C However butane reverts to its liquid state when temperatures drop below 32 F 0 C LP in a liquid withdrawal system must be converted to its gaseous state before it is introduced into the engine carburetor A vaporizer converter is generally used to accomplish this In such a converter heated engine coolant is ported through the converter to provide the necessary heat for conversion of the fuel from a liquid to a gaseous state 01 50 3 LOOSAS an4 Specifications SPECIFICATIONS STATIONARY EMERGENCY GENERATOR OE Synchronous Rotor Irisulatiori Class H Stator Insulation sees Class H Telephone Interference Factor 50 Alternator Output Leads 3 phase 4 wire sm EET Sealed Ball COUPIING aai coe oi Flexible Disc Load Capacity Standby Rating 45kW NOTE Gene
63. hereof if it has failed due to abuse neglect unapproved modification or improper maintenance or the use of counterfeit and or gray market parts not made supplied or approved by Generac Warranty service scheduled maintenance can be arranged by contacting your selling dealer or an Authorized Warranty Service dealer The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs Emission Related Parts Include the Following if so equipped 1 Fuel Metering System 3 Ignition System including 1 1 Gasoline Carburetor assembly and internal components a Spark plug b Ignition module a Fuel filter b Carburetor c Fuel Pump C ignition coil d Spark plug wirers 1 2 Carburetion assembly and its components 4 Exhaust system a Fuel controller b Carburetor and its gaskets a Catalyst assembly b Exhaust manifold Mixer and it gaskets d Primary gas regulator c Muffler d Exhaust pipe e Muffler gasket Liquid vaporizer 5 Crankcase Breather Assembly including 1 3 Fuel Regulator a Breather connection tube b PCV valve 2 Air Induction System including 6 Oxygen Sensor a Intake pipe manifold b Air cleaner 7 Diagnostic Emission Control System
64. lt 0 75 7 R 01 9 eyeq V UOISIA9M xog NOIL JNNO9 ai e SS3NMNVH 3NI9N3 V 4 EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 APPLICABLE TO ITEM 1 0H6266 1 2 0H6265 1 3 0H6160 1 4 057073 2 5 056739 1 6 6 0H67330S TOR 1 7 0 7668 1 8 0 2115 2 9 022097 3 10 022473 8 11 0 7115 2 12 0 2454 13 13 0F5458 12 14 042568 2 6 15 0H88390STOR 1 16 0C2265 4 3 17 0H6169A 1 318 023897 4 3 19 036943 2 3 20 022152 2 3 21 022158 2 3 22 0559340 1 2 23 0054648 1 24 022237 2 25 022241 2 26 003700 6 27 0H6267 1 28 0F5752F 1 29 052777 3 30 043182 3 31 051714 3 32 0D7177V 2 33 051713 2 34 049226 2 35 051716 2 36 056326 1 37 0 7291 1 38 7292 1 39 0 7293 1 40 026850 1 41 055414 1 4 42 1 6 43 0H81040ASOR 1 44 0A9457 1 45 022264 4 46 045764 2 47 067210A 1 148 0D7393T REF 149 0D7393U REF 1 50 0F5376S0AR REF 1 51 0F5396S0AR REF 2 52 047822 2 53 083896 2 54 045335 55 029289 1 56 0F6146 1 57 0H6692 1 58 0D6029 5 REVISION A DATE 3 31 10 GROUP A DESCRIPTION BACK PANEL CONBOX SUPPORT C2 TOP PANEL CONBOX SUPPORT C2 COVER WIRE ENTRY CONBOX JUNCTION BLOCK 3 8 16 RELAY SOLENOID 12VDC PNL MNT BRACKET GIMBAL CONTROL PNL RAW ASSY CTRL 2010 CPL PROGRAMMED WASHER FLAT NYLON 0 257 X 0 625 WASHER LOCK M6 1 4 WASHER FLAT 1 4
65. mergency engines greater than or equal to 130 recordkeeping of hours of operation begins January 1 2011 For emer gency engines less than 130 HP recordkeeping of hours of operation begins January 1 2009 Engines are equipped with non resettable hour meters to facilitate recordkeeping Specific Air Quality Management or Air Pollution Control Districts may have different and additional record keeping reporting requirements Your permit to construct and or operate the engine may be contingent upon compliance with those require ments Check with your local Air Quality Management or Air Pollution Control District for specific requirements Emergency stationary internal combustion engines ICE may be operated for the purpose of maintenance checks and readi ness testing provided that the tests are recommended by Federal State or local government Generac or the insurance com pany associated with the engine Maintenance checks and readiness testing of such units is limited to 100 hours per year There is no time limit on the use of emergency stationary ICE in emergency situations The purchaser owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing but a petition is not required if the owner maintains records indicating that Federal State or local standards require maintenance and testing of emergency ICE beyond 100 hours per year Emergency stationary ICE may operate up to 50 ho
66. ns Generator in Auto ready to run load being sup plied by the Utility Source through the transfer switch 1 When the utility voltage fails falls below 6096 of nominal a 10 30 second programmable line interrupt delay timer is started The factory set time delay is 10 seconds If at the end of the line interrupt time the utility voltage is above 6096 the engine will not crank If the utility voltage is still below the 6096 of nominal at the end of the line interrupt time the unit will crank and start If the unit cranks for more than 10 seconds and the utility voltage rises above 8096 of nominal programmed pickup voltage and the unit has not started the crank cycle will abort 2 As soon as the unit starts a 5 second warm up timer is initi ated When the warm up timer expires the control will transfer the load to the generator through the RTS switch if the utility voltage is less than 8096 of nominal If the utility voltage is greater than the 8096 of nominal at the end of the warm up time the load will not be transferred to the generator and a one minute low speed cool down period will start At the end of the one minute cool down period the generator will stop 3 Once the unit is running and the switch has transferred the load to the generator the unit will monitor utility voltage When utility voltage returns above the programmable pickup voltage normally 80 of nominal a 15 second Return to Utility timer will star
67. of utility voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT WIRES IS NOT WARRANTABLE This test will be performed each time the controller is powered up Next the user must enter the minimum settings to operate These settings are current date and time and exercise day and time The maintenance intervals will be initialized i e started the first time the clock is set If the clock is never set at power up the mainte nance intervals will be reset every time power is applied If a subsequent power loss loss of battery power occurs the Installation assistant will operate upon power restoration The self test routine will be run and then the customer will be required to re enter the time and date as this is not retained during a power loss The unit will not require re activation DISPLAY INTERFACE MENUS The LCD display is organized as detailed below The Home page this page is the default page which will be displayed if
68. omer for the current Time and Date IF THE INSTALLER TESTS THE GENERATOR PRIOR TO INSTALLATION PRESS THE ENTER KEY TO AVOID SETTING UP THE EXERCISE TIME THIS WILL ENSURE THAT WHEN THE CUSTOMER POWERS UP THE UNIT HE WILL STILL BE PROMPTED TO ENTER AN EXERCISE TIME SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise every seven days on the day of the week and at the time of day specified During this exercise period the unit runs for approximately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost LOW SPEED EXERCISE The standard start sequence will be initiated All 1800 rpm units will exercise at 1400 RPM All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following Wait for the line interrupt period for utility to return If utility returns within the line interrupt period continue to exercise at low RPM 8 3 If utility is still lost after the line interrupt period run the engine up to normal RPM and transfer the load At this time the con troller will exit the exercise routine and assume full automatic operation USER ADJUSTABLE SETTINGS Factory Maximum Default Setting Exercise 23 59 Exercise Current 23 59 Current Current Current 2008 2008 2100 English
69. ot blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule section for recommended inspection 3 Check the spark plug gap using a wire feeler gauge See the Specifications section for the required spark plug gap BATTERY MAINTENANCE The battery should be inspected per the Service Schedule section The following procedure should be followed for inspection 1 Inspect the battery posts and cables for tightness and corro sion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type battery hydrometer A DANGER Storage batteries give off explosive hydrogen sAgas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smok ing open flame sparks or any spark producing tools or equipment near the battery 10 3 Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eye
70. parts Before performing any maintenance on the generator discon nect 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 dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS All stationary emergency generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dan gerous voltages to the transfer switch as well as the generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable 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 stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT Safety Instructions If personnel must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats
71. r gt 5 seconds an alarm will be issued 01 90 Control Panel OVERVOLTAGE ALARM If the generator voltage rises above 11096 for gt 3 seconds an alarm will be issued If the generator voltage rises above 130 for 0 2 seconds an alarm will be issued INTERNAL FAILURE SHUTDOWN ALARM Any internal failure that can be detected such as corrupted firmware will cause this shutdown alarm This alarm cannot be cleared CANBUS ALARM Where applicable if the Canbus communications link fails to com municate a Canbus alarm will be generated This only applies to systems with external ignition modules The alarm may be generated if 1 The physical link is broken 2 The ignition module fails or resets 3 The Nexus module fails or resets IGNITION ALARM When an ignition alarm occurs a generic message Ignition Fault will be displayed as the fault code MAINTENANCE WARNING When a maintenance period expires a warning message will be posted The warning can be reset by hitting the Enter key Resetting will clear the warning and reset the maintenance counters for the condition annunciated The history log will reflect the maintenance warning MAINTENANCE ALERT CHART ALARM CANCEL When the generator is shut down due to a latching alarm the Auto Off Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault
72. r Kit Recommended Block Heater Kit for protection in tempera tures below 32 F Scheduled Maintenance Kit Kit includes the recommended parts to maintain the genera tor Refer to the Service Schedule for regular maintenance intervals For additional information or to order any of these kits please contact an Authorized Service Dealer or Customer Service Representative RECONFIGURING THE FUEL SYSTEM NOTE All models are configured to run on natural gas from the fac tory Before the generator can be operated using a LP fuel source the fuel system and control panel refer to the installation drawing for location must be reconfigured The steps to reconfigure the gen erator from a natural gas NG to a liquidified petroleum LP fuel source are as follows FUEL SYSTEM 1 the main gas supply off and disconnect the battery 2 Remove the carburetor fuel hose from the outlet port of the demand regulator see Figure 6 1 3 Disconnect the power wires from the fuel solenoid located on top of the regulator assembly by removing the screw on the front of the connector and pulling the connector forward away from the solenoid body 4 Loosen the spring clamp on the small fuel enrichment line and remove the hose from the hose barb 5 Remove the black pipe assembly from the outlet port of the demand regulator The solenoid assembly may need to be removed before performing this operation Figure 6 1 6 Remove the NG
73. ranty Statement or can be arranged by contacting your sell ing dealer or an Authorized Warranty Service dealer Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law 40 CFR 1068 105 b subject to fines or penalties as described in the Clean Air Act 01 60 9 ed LOOQUIMUSUI3 13 2 d 9 6 608640 DNIM VIG NOLLV LLIOX3 194810 HOLVNSALTV 149 AHIA QHGO Id XH 7 L r V 4 t IO HDVd 01 12 65 JA78 v97H NOISIAS3I EXPLODED VIEW ALTERNATOR DIRECT EXCITATION DRAWING 0F9803 APPLICABLE TO ITEM PART QTY DESCRIPTION 1 0 9677 1 ROTOR 2390 45KD1 CPL 060056 1 ROTOR 2390 35KD1 CPL 0G0959 1 ROTOR 2390 45KD1 CPL G2 061155 1 ROTOR 2390 35KD1 CPL 62 061931 1 25KW 3PH DIRECT 390 1800 062101 1 ROTOR 25KW 1PH DIRECT 390 1800 063734 1 RTR 2390 60KD2 CPL 066562 1 390 35AD1 CPL 066564 1 RTR 390 35KD1 CPL 2 0 9664 1 5 390 45 2 DIRECT 060057 1 STATOR 2390 35AD1 CPL 0G0058 1 STATOR 2390 35KD1 CPL 060059 1 STATOR 2390 35GD1 CPL 060183 1 STATOR 2309 45KW 208V 060184 1 STATOR 2309 45 KD1 CPL 061932 1 55 STR 390 25603 CPL 062098 1 ASSY STR 390 25AD1 CPL 062099 1 ASSY STR 390 25KD3 CPL 062100 1 ASSY STR 390 25 03 CPL 063736 1 ASSY STR 2390 60402 CPL 063737 1 ASSY STR 390 60KW 2P 3PH 208V 0G3738 1 ASSY STR 390 60KW 2P 3PH 480V 0G6104 1 STR 2390
74. rator rating and performance in accordance with 1508528 5 55514 SAE J1349 1503046 and DIN 6271 Standards KW rating is based on LPG fuel and may derate with natural gas Excitation Direct Generator Output Voltage KW 60 Hz kW Amp CB Size 120 240V 1 phase 1 0 pf 45 188 200 120 208V 3 phase 0 8 pf 45 156 175 120 240V 3 phase 0 8 pf 45 135 150 277 480V 3 phase 0 8 pf 45 68 80 Generator Locked Rotor KVA Available Voltage Dip of 35 Single phase or 208 3 phase 45KW 72 KVA 480V 3 phase 4 80 KVA ENGINE In Line Cylinders and 4 DISPIACOMOM 2 4 Liter u u s sS sss sss 3 41 SUOKG Siac 3 94 in Compression Ratio u 9 540 1 Air Intake System Naturally Aspirated Seals ia cain iere n t RF oie Hardened Litter ts Hydraulic Spark Plug Gap 1 07 1 17mm 0 042 0 046 inch Engine Parameters Rated Synchronous 60 Hz 3600 Exhaust System Exhaust Flow at Rated Output 60 Hz 45kW
75. rk 9 Dispose of used oil at a proper collection center COOLING INTAKE OUTLET Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine gen erator quickly overheats which causes it to shut down See the installation diagram AWARNING AN The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system INSPECT COOLING SYSTEM e Inspect engine cooling system See the Service Schedule e Check hoses for damage deterioration leaks etc Correct any discrepancies found e Check hose clamps for tightness 01 70 v 720 ENGINE COOLANT Check coolant recovery bottle See the Specifications and Service Schedule sections Add recommended coolant mixture as necessary Periodically remove radiator pressure cap only when engine has cooled down to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radia tor filler neck If coolant level is low inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap
76. rovided such as the utility source main line circuit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Setthe generator s main line circuit breaker to its OFF or OPEN position Start the generator 9 1 CAUTION Do not crank the engine continuously for lon ger than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge readings When certain that all readings are correct move the transfer switch manual handle to the STANDBY or EMERGENCY STANDBY position i e load circuits supplied by the generator Set the generator s main line circuit breaker to its ON CLOSED position Load circuits are now powered by the generator RETRANSFER AND SHUTDOWN For additional information refer to the applicable control panel manual for this unit as well as any literature pertaining to the specific transfer switch To transfer the load back to the utility power source and shut down the generator follow these directions Setthe generator s main line circuit breaker to its OFF or OPEN position Manually move the transfer switch handle to its UTILITY NORMAL position i e load circuits connected to the utility Turn ON the utility power supply to the transfer switch using the means provided such as the utility power source main line circuit breaker Let
77. ry to personnel disable the generator s automatic start cir cuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible 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 1 3 FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are toxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Properly ventilate any room or building housing the generator to prevent build up of explosive gas 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
78. s replacement parts and labor provided it be done by an Authorized Warranty Service Facility Your emission control system may include parts such as the fuel metering ignition and exhaust systems and other related emission related components listed below Generac will warrant the emissions control systems on your 2009 and later model year engines provided there has been no abuse neglect unapproved modification or improper main tenance of your engine For engines less than 130 HP the warranty period is two years from the date of sale to the ultimate purchaser For engines greater than or equal to 130 HP the warranty period is three year from the date of the engine being placed into service Purchaser s Owner s Warranty Responsibilities As the engine purchaser owner you are responsible for the following 1 The engine must be installed and configured in accordance to the installation specifications 2 The completion of all maintenance requirements listed in your Owner s Manual 3 Any engine setting adjustment must be done in accordance and consistent with the instructions in the Owner s Manual 4 Any emission control system or component must be maintained and operated appropriately in order to ensure proper operation of the engine and control system to minimize emissions at all times Generac may deny any or all Emission Control System Warranty coverage or responsibility of the engine or an emission control system or component on your engine t
79. s skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging AWARNING 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 120VAC power supply to the battery is turned OFF or sparking may occur at the bat tery posts as the cables are attached and cause an explosion BATTERY REPLACEMENT NOTE Unit DOES NOT include battery When supplying or replacing the battery the recommended num ber and type of battery is listed in the Specifications Section NOTE The BCI number should be located directly on the battery BATTERY FLUID Check battery electrolyte fluid based on the Service Schedule Fluid should cover separators in all battery cells If fluid level is low add distilled water to cover tops of separators DO NOT USE TAP WATER IN BATTERY CLEANING THE STATIONARY EMERGENCY GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal generator windings have an adverse effect
80. s used to prevent circuit failure due to DC alternator falure It will also protect the system in the event of a wiring short dircuit If this fuse is blown the generator will not operate Replace these fuses with the same size type and rating 01 80 8 Fuel System FUEL SYSTEM FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems Natural gas fuel system Propane vapor PV fuel system Liquid propane LP fuel system Recommended fuels should have a Btu content of at least 1 000 Btu s per cubic foot for natural gas or at least 2 520 Btu s 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 14 inches water column 0 18 to 0 5 psi and for liquid propane 5 inches to 14 inches of water column 0 18 to 0 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below five inches water column for natural gas or 5 inches water column for propane vapor for all load ranges The fuel supply piping shall be sized according to the installation manual using the fuel consumption requirements identified in the Specifications section of the Owner s Manual NOTE It is the responsibility of the installer to make sure that only the correct recommended fuel is supplied to the generator
81. t At the end of the return to utility time if the utility voltage is still above the pickup voltage the unit will transfer the load back to the utility source and run the unit through a one minute cool down period When the cool down period is over the unit will shut down and be ready for the next outage 4 If during the cool down period utility voltage should fall below 6096 of nominal for the line interrupt delay period the unit will transfer the load back to the generator and continue to moni tor the utility CRANK CYCLES AND OVERCRANK SHUTDOWN If the unit fails to start during a cranking period it will display the Overcrank Shutdown Alarm The system will control the cranking cycles as follows The first crank cycle is a 16 second crank time followed by a 7 second rest The next 5 cycles will be 7 seconds of cranking time each followed by a 7 second rest time If the unit fails to start by the end of the 6 crank rest cycles the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset AUTO START This unit is designed to automatically start in the event of a util ity failure or brown out condition Brown out is defined as utility voltage less than 6096 nominal while utility is considered good when it is restored to at least the pickup value 8096 of nominal These levels are fixed The Line Interrupt period is an adjustable parameter by the dealer If 2 wire start mode is activate
82. t fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer s instruction and in strict compli ance with applicable 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 ventilating air is critical in any room or building housing the generator to prevent buildup of explosive gases and to ensure 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 Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous 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 promptly repair or replace all worn damaged or defective parts using only factory approved
83. the generator run at no load for a few minutes to stabilize internal temperatures Shut down the generator OPERATING UNIT WITH AUTOMATIC TRANSFER SWITCH If the Stationary Emergency Generator has been installed with an automatic transfer switch the engine may be started and stopped automatically or manually NOTE Refer to the applicable manual for your transfer switch and to Transfer Switch Start Signal Connections In addition please note the dangers under Engine Start up and Transfer 01 60 ed 1001900 GENERAL MAINTENANCE WARNING Before working on the Stationary Emergency Generator ensure the following The AUTO OFF MANUAL switch is in the OFF position The control panel fuse has been removed from the control box The 120VAC supply to the battery charger is switched OFF The negative battery cable has been removed CHECK ENGINE OIL Check engine crankcase oil level Figure 10 1 according to the Service Schedule Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again e Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Engine Oil Recommendations for recommended oils Figure 10 1 Oil Dipstick and Oil Fill Cap Oil Dips
84. tick CHANGING ENGINE OIL A CAUTION Hot oil may cause burns Allow engine to cool before draining oil Avoid prolonged or repeat ed skin exposure with used oil Thoroughly wash exposed areas with soap 10 1 Refer to the Service Schedule for engine oil and filter change fre quencies Drain the oil while the engine is still warm from running This means warm up the engine shut it down and drain immediately as follows 1 Remove the drain hose from its retaining clip or cut the zip tie securing the oil drain hose 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil com pletely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip tie or place the hose in its retaining clip 4 Turn OIL FILTER Figure 10 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil capacity is listed in the Specifications section CAUTION After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK 7 Start engine and check for oil leaks 8 Shut OFF engine and wait 10 minutes for the oil to settle down into the oil pan Recheck oil level on dipstick DO NOT fill above the dipstick FULL ma
85. transfer switch capable of manual operation only the fol lowing procedure applies A manually operated transfer switch is one that will not provide automatic start up and does not include an intelligence circuit ENGINE START UP AND TRANSFER For additional information refer to the applicable control panel manual for this unit as well as any literature pertaining to the specific transfer switch A DANGER The Maintenance Disconnect Switch and the AUTO OFF MANUAL switches if so equipped must be set properly or the generator will crank and start as soon as the utility power to the transfer switch is turned off Refer to appli cable control panel and transfer switch manuals for more information Do not proceed until certain that utility source voltage is available to the transfer switch and the transfer switch main contacts are set to UTILITY Do not attempt manual operation until all power supplies to the transfer switch have been positively turned off or extremely dangerous possibly lethal electrical shock will result 2 switch enclosure doors should be kept closed and locked Only authorized personnel should be allowed access to the transfer switch interior Extremely high and dangerous voltages are present in the transfer switch In order to transfer load from the utility source to the generator follow these directions Turn OFF or disconnect the utility power circuit to the transfer switch using the means p
86. umb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 of an inch Adjust belt tension as required Check fan belt alignment see Figure 10 3 Figure 10 3 Fan Belt INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only quali fied service technicians should adjust the gov erned speed CHANGING THE ENGINE AIR FILTER To replace the engine air filter remove the air filter cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 10 4 See the Service Schedule for air filter maintenance Figure 10 4 Engine Air Filter Air Filter Nest SPARK PLUGS Reset the spark plug gap or replace the spark plugs as neces 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do n
87. ure Switch Overcrank Shutdown Overspeed Shutdown ess RPM Sensor Loss Shutdown Fuel Requirements Natural Gas Fuel System Propane Vapor Withdrawal Fuel System Liquid Fuel SPECIFICATIONS uu uu uiaiia assa c sas Stationary Emergency Generator ENQING us Cooling 5 Fuel System Weather Maintenance Kits Reconfiguring the Fuel System Fuel System Control Panel GENERAL INFORMATION Alternator AC Lead Four lead Single phase 1 Alternator Power Winding Connections 3 phase Alternators Y Configuration 3 phase Alternators Delta Configuration CONTROL PANELIL J Q Control Panel 1 Using the Auto Off Manual Switch Activate the Display Interface Menus Activation Chart Setting the Exercise Timer LOW Speed EXGrCISB
88. urs per year in non emergen situations but those 50 hours are counted towards the 100 hours per year provided for maintenance and testing The 50 hours per year for non emergency situations cannot be used for peak shaving or to generate income for a facility to supply power to an electric grid or otherwise supply power as part of a financial arrangement with another entity For purchaser owner of emergency engines any operation other than emergency operation maintenance and testing and operation in non emergency situations for 50 hours per year as permitted in this section is prohibited If you operate and maintain your certified emergency stationary SI internal combustion engine and emissions control sys tems in accordance with the specifications and guidelines in the Owner s Manual EPA will not require engine performance testing If not your engine will be considered non certified and you must demonstrate compliance according to Subpart JJJJ Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60 Emission Related Installation Instructions Your certified emergency stationary engine has pre set emission control systems or components that require no adjustment Inspection and replacement of an emissions related component is required to be done in accordance with the requirements cited in the United States Environmental Protection Agency War
89. ut a particular service or operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their definitions as follows A DANGER INDICATES A HAZARDOUS SITUATION OR ACTION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY A WARNING Indicates a hazardous situation or action which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation or action which if not avoided could result in minor or moderate injury NOTE Notes contain additional information important to a procedure and will be found within the regular text body of this manual 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 prevent ing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others A This symbol points out potential explosion hazard 1 1 This symbol points out potential fire hazard Q This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equip ment The manufacturer strongly recommends that the operator read this O
90. ve Devices ENGINE PROTECTIVE DEVICES The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature oil pressure or rpm For that reason the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low the coolant temperature is too high the coolant level is too low or the engine is running too fast NOTE Engine protective switches and sensors are mentioned here for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown infor mation HIGH COOLANT TEMPERATURE SENDER An analog coolant temperture sender located in the engine s cooling system will cause an engine shutdown if the temperature should exceed approximately 125 C 257 F The generator will automatically restart once the temperature has returned to a safe operating level LOW COOLANT LEVEL SENSOR To prevent overheating the engine has a low coolant level sensor If the level of engine coolant drops below the level of the low cool ant level sensor the engine automatically shuts down LOW OIL PRESSURE SWITCH This switch has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil pres sure drop below the 8 psi range switch contacts close an
91. wner s Manual and thoroughly understand all instruc tions 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 For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations OPERATION AND MAINTENANCE 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 a Service 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 con tribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the generator electric system has been installed by a Service Dealer or other competent qualified
92. y 12 hours during continuous operation Change oil and oil filter after the first 30 hours of operation and then every 100 hours or annually thereafter whichever occurs first Change when operating under heavy 1044 or a dusty or dirty environment or in high ambient temperatures Replace as necessary 11 1 01 90 8 5 Troubleshooting TROUBLESHOOTING GUIDE CAUSE CORRECTION Engine won t crank 1 Control panel 7 5 amp fuse blown 1 Replace fuse 2 Loose or corroded or defective 2 Tighten clean or replace battery cables battery cables as necessary 3 Defective starter contactor 3 Replace contactor 4 Defective starter motor 4 Replace starter motor 5 Dead or Defective Battery 5 Remove change or replace battery Engine cranks but won t start 1 Out of fuel 1 Replenish fuel turn on fuel valve 2 Fuel solenoid FS is defective 2 Replace solenoid 3 Spark plugs defective 3 Clean regap or replace plugs Engine starts hard runs rough 1 Air cleaner plugged or damaged 1 Clean or replace as needed 2 Defective spark plugs 2 Clean regap or replace plugs 3 Fuel pressure incorrect 3 Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS 4 Insufficient fuel supply 4 Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS 5 Fuel system set to wrong fuel type 5 Reconfigure the fuel system See RECONFIGURING T
93. y start and exercise the engine every seven days with the setting of the exercise timer see the Setting the Exercise Timer section 2 OFF Position This switch position shuts down the engine This position also prevents automatic operation 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 ACTIVATE THE GENERATOR When battery power is applied to the generator during the instal lation process the controller will turn ON and the LCD screen will illuminate However the generator still needs to be activated before it will automatically run in the event of a power outage Activating the generator is a simple one time process that is guided by the controller screen prompts Once the product is activated the controller screen will not prompt you again even if you discon nect the generator battery To obtain the activation code record the generator serial number and log onto www activategen com or call 1 888 9ACTIVATE and follow the steps to retrieve the activation code After obtaining your activation code please complete the following steps at the generator s control panel in the Activation Chart on the following page NOTE The generator will only run in manual until the passcode has been entered 8 1 Upon power up this controller will go through a system self test which will check for the presence

Generac QT04524ANSX Portable Generator User Manual

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