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Generac 004917-5 manual

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Table of contents for the manual

  • Page 1

    Installation and Owner’ s Man ual DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y!! D ANGER This manual should remain with the unit. Liquid-cooled, Prepac kaged Standb y Generators Model Number 004917-5 27 kW NG, 30 kW LP V apor Not intended for use in life-support applications. ! ![...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the standby generator set product line by Generac P ower Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was writ- ten. However , the manufacturer reserves the[...]

  • Page 3

    T able of Contents QUIET SOURCE ™ Liquid-cooled 30 kW Generators Generac ® Pow er Systems, Inc. 1 INTRODUCTION ................................................ IFC SAFETY RULES .................................................... 2 Section 1 — GENERAL INFORMA TION ............4 1.1 Generator ....................................................[...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully befor e installing, operating or servicing this equipment. Become familiar with this Owner’ s Manual and with the unit. The gen- erator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing t[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 • Inspect the generator regularly , and promptly repair or replace all worn, damaged or defective parts using only factory-approved parts. • Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by[...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven gen- erator set. The generator is designed to supply elec- trical power that operates critical electrical loads during utility power failure. The unit has been facto- ry-installed in a weather resistant, all aluminum enclosure and is intended for[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 1.6 GEN ER A T OR F U EL SY S TEM The unit has been factory tested and adjusted using a natural gas fuel system. If propane (LP) gas is neces- sary . Refer to Section 1.12, Reconfiguring the F uel System. F uel pressure for a natural gas set up should be five inches to 14 inches of water column (0.18 to 0.5 psi) at[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Figure 1.6 - Low Coolant Level Sensor 1.7 .4 O VERSPEED SH UTDOWN The engine control board receives AC frequency sig- nals from an engine run winding in the alternator . Should AC frequency exceed about 72 Hertz for three seconds or 75 Hertz instantaneously , the engine shuts down and the overspeed LED turns on. Sh[...]

  • Page 9

    1.1 0 SP ECIF ICA TIONS 1.1 0.1 GEN ER A T OR SP ECIF ICA TIONS 1.1 0.2 ENGI N E SP E CI F ICA TIONS Make ......................................................................................F ord Displacement ..................................................................3.0 liters Cylinder Arrangement .........................................[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. NOTE: P ort 1 is for NG only and P ort 2 is for LP vapor only . No provision for dual fuel has been made. Serious injury or damage may occur if not con- figured pr operly . Please consult an authorized Generac Service Dealer with any questions. 1.1 3 T ORQU E SP ECIF ICA TIONS Cylinder Head ........................[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 Only qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regula- tions pertaining to the installation. After the syste[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. • Allows the LOAD circuits to be connected to only one power supply at a time. • Prevents electrical backfeed between the generator and the UTILITY power circuits. Both the ST ANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker . Figure 2.1 [...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 Failure to connect the generator neutral pr op- erly will result in unbalanced line-to-neutral voltages. Resulting high voltages will cause equipment damage. 2.9 TR ANSF ER SWIT CH SIGNAL CO N N EC T I O N S 2.9.1 P RE-P ACKAGED A TS If the generator is to be installed with a pre -packaged (non- control board base[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. • Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbon- ate of soda to one gallon (4 liters) of water . The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting [...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 2.1 1.7 ELECTRICAL SY STEM Make sure the generator is properly connected to an approved earth ground and/or ground rod. Make sure the generator battery is fully charged, properly installed and interconnected, and ready for use. Check to ensure that there are no loose electrical con- nections. Restrain any loose wi[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 3.2.2 F AU L T IN DICA T OR LED This LED goes ON when one or more of the following engine faults occurs and when engine shuts down. • Low Oil Pressure • Overcrank • Low Battery • Overspeed/RPM Sensor Loss • High Coolant T emperature/Low Coolant Level See Section 1.7 for further explanation of engine pro-[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 Section 3 - Operation QUIET SOURCE ™ Liquid-cooled 30 kW Generators 5. Reduce load to 3/4, 1/2, 1/4 and no load. Decrease the stability pot if there is instability at any load point. 6. Adjust differential pot to make the recovery to load changes even faster and minimize load change undershoot and overshoot. If [...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 4.1 MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE F ACILITI ES A. EVER Y THR EE MONTHS 1. Check battery state of charge and condition. 2. Inspect and test fuel system. 3. Check transfer switch. 4. Inspect exhaust system. 5. Check engine ignition system. 6. Check fan belts. B. ONCE EVER Y SIX MONTHS 1. T est E[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 4.4.3 ENGI NE COOLANT Check coolant level in coolant recovery bottle. See Specifications, Section 1.10. • Add recommended coolant mixture as necessary . • P eriodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly . Coolant should be at bottom of radiator filler[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. 7. Start engine and check for oil leaks. Figure 4.2 - Oil Filter 4.5.1 1 CHANGI NG TH E ENGI NE AI R CLEAN ER T o replace the engine air cleaner , (part number 059402), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover (Figure 4.3). Figure 4.[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 4.6.2 BA TTER Y All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery . If such information is not available, observe the following precautions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start t[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 4 — Maintenance QUIET SOURCE ™ Liquid-cooled 30 kW Generators 4.7 S CH EDU LED MAI NTENANCE F ollowing is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an averag[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance QUIET SOURCE ™ Liquid-cooled 30 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp. to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly In[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance QUIET SOURCE ™ Liquid-cooled 30 kW Generators Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp. to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly In[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 5 — T roubleshooting QUIET SOURCE ™ Liquid-cooled 30 kW Generators TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse . 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. D[...]

  • Page 26

    BRUSH ASSEMLY ( GENERATOR ) A U T O MATI C V O LTA G E RE GU LAT OR BULKHEAD CONNECTOR 1 ( ENGINE ) CIRCUIT BREAKER ( EXCITATION ) FUSE, BAT. POWER ( 15A AGC TYPE ) CIRCUIT BREAKER ( OUTPUT ) DIODE [ FIELD BOOST ] BATTERY C HAR G E R B C 1 - F1 - D1 - C B2 - C B1 - AVR - BA - B /C - LE G END : NE U TRAL BL OCK TERMINAL BL OC K 1 TRANSFORMER 1 ( 56 [...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 LEGEND [ CONT. ]: J -2 - L OS - S M - J B - WL S - H C T - J -1 - IM - I C - ELE C . GO VERN O R A C T U AT OR GROUND ( SENSING/LOW AMP ) GROUND ( POWER/HIGH AMP ) D. C . C HAR G E ALTERNAT OR S TARTER CO NTA C T OR CONNECTOR 1 ( ENGINE ) DRIVER ELE C . GO VERN OR F U EL SO LEN O I D 12VD C BATTER Y DE G - G ND1 -[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. Section 6 - Electrical Data QUIET SOURCE ™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B A U T O MATI C V O LTA G E RE GU LAT OR BRUSH ASSEMLY ( GENERATOR ) CIRCUIT BREAKER ( EXCITATION ) DI S PLA C ED PHA S E EX C ITATI ON DPE - ALTERNAT O R S TAT OR ALTERNAT O R R O T [...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Section 6 - Electrical Data QUIET SOURCE ™ Liquid-cooled 30 kW Generators Electrical Schematic — Engine — Drawing No. 0E6200-B SC - I C - IM - L OS - S M - WL S - LEGEND [ CONT. ]: CONNECTOR (C1) SWITCH , HIGH COOLANT TEM P C RANKIN G CO NTA C T OR D. C . C HAR G E ALTERNAT OR CONNECTOR 1 ( ENGINE ) DRIVER E[...]

  • Page 30

    CONTACTOR WIRE H ARNE SS 7 5 6 16 E N G INE FOO T 2 4 3 41 40 16 7 6 5 35 9 13 17 12 8 18 16 43 BLOCK E N G INE 30 TO 44 35 3 4 3 36 33 44 42 22 20 3 2 38 18 31 20 TO S TARTER S TARTER BO LT TO B L OC K E N G INE 18 TO 11 1 12 10 14 R EAR BEARIN G 13 15 3 7 14 C ARRIER 3 4 16 2 28 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P art[...]

  • Page 31

    ITEM P ART NO . QTY . DESCRIPTION 1 0E5822 1 BASEFRAME, WELDMENT 3.0L FORD 2 052860 4 NUT FLANGED HEX M12-1.75 3 052251 4 DAMPENER VIBRA TION 40 BLUE 4 052257 4 SP ACER .49 X .62 X 1.87 PWDR/ZNC 5 052252 4 DAMPENER VIBRA TION 6 052259 4 W ASHER FLA T M12 7 052891 4 SCREW HHC M12-1.75 X 80 G8.8 8 0536210213 1 ASSY GRNDWIRE 11"/3/8 & 5/16 LU[...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. S TATE S F O AM I S O N NEAR S IDE S TATE S F O AM I S O N FAR S ID E 3 7 17 L AT C H DETAIL 30 1 3 1 3 4 38 3 2 3 45 18 27 40 4 2 S EE LAT CH 7 DETAIL 25 "B " 5 2 11 9 4 6 53 5 4 5 TO "A" S E CU RE A S S H O WN. R E Q UIRE INSULATION. T YPI C AL O F R OO F PANEL THAT 4 53 35 R ADIAT OR 33 4 25[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 ITEM P ART NO . QTY . DESCRIPTION 1 0E8418 1 DUCT INT AKE MID AL 2 0E8414 1 DUCT DISCHARGE RH AL 3 0E8413 1 DUCT DISCHARGE LH AL 4 0C2454 62 SCREW TH-FRM M6-1 X 16 N W A Z/JS 5 0E8402 1 BAFFLE REAR BOTT OM 6 0E5902 1 POST CORNER LH REAR HSB AL 7 0E5903 1 POST CORNER RH REAR HSB AL 8 0E8387 1 BAFFLE REAR T OP 9 0E5[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. Section 7 - Exploded Views and P arts QUIET SOURCE ™ Liquid-cooled 30 kW Generators Control Panel — Drawing No. 0E7 11 8-K[...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0E7195 1 CONTROL BO X HSB 2 0E7196 1 CO VER FR ONT P ANEL HSB 3 0E7197 1 CO VER TOP P ANEL HSB 4 0E7193 1 DECAL W ARNINGS HSB 5 0E7194 1 DECAL CONTROLS HSB 6 0E4494 1 SWITCH ROC DPDT ON-OFF-ON 7 082573 1 SWITCH R OCKER DPST 125V SPD 8 032300 2 HOLDER FUSE 9 022676 1 FUSE 15A X A[...]

  • Page 36

    48 5 7 68 24 61 60 25 58 WIRE 66 3 1 64 35 39 63 36 30 3 2 G R OU N D 39 65 17 16 18 19 & REPLA C E 86 35 53 5 4 43 2 42 38 55 6 1 24 14 5 1 69 5 25 60 R EM O VE 88 15 78 8 7 21 47 46 20 49 46 4 4 43 38 85 36 42 1 4 7 4 2 6 7 2 8 1 42 3 2 48 42 41 44 45 3 1 28 72 35 8 40 R EAR U PPER BAFFLE 5 36 3 7 29 12 34 3 8 10 8 2 33 36 42 73 3 4 27 Sectio[...]

  • Page 37

    ITEM P ART NO . QTY . DESCRIPTION 1 0E6201 1 ENGINE 3.0L FORD (FD) (MAKE) 2 0E8824 2 ST AMPING ENG FOO T 3.0L FORD 3 0E8963 1 PULLEY CRANKSHAFT 3.0L FORD RD 4 0E9020 1 BRA CKET DC AL T 3.0L FORD 5 0A1232 1 D .C. AL TERNA T OR ASSY 6 0A7801B 1 PULLEY POL Y -V 82 OD . 7 0A5610 1 BRA CKET AL TERNA T OR 8 0E6308 1 PULLEY W A TERPUMP 3.0L FORD (RD) 9 **[...]

  • Page 38

    28 15 5 25 FRAME 11 10 9 8 9 3 21 27 12 12 4 TO WATER PUMP 6 17 7 1 15 20 "A " 3 22 24 24 2 12 TO "A" 18 13 14 T HERM OS TAT 30 33 29 12 33 3 4 HOUS IN G E N G INE TO TO 3 1 32 Section 7 - Exploded Views and P arts QUIET SOURCE ™ Liquid-cooled 30 kW Generators Radiator — Drawing No. 0F6848 36 Generac ® Pow er Systems, Inc.[...]

  • Page 39

    ITEM P ART NO . QTY . DESCRIPTION 1 0E9947 1 RADIA TOR R-IN,L-OUT 658X489X49 2 0E6340 1 VENTURI 3.0L FORD HSB 3 0E8531 2 SIDE SUPPORT RADIA T OR HSB 4 0E6398 1 TUBE LOWER RAD 3.0L FORD HSB 5 0F6630 1 HOSE RADIA TOR UPPER 6 080713 1 BRACKET COOLANT T ANK 7 076749 1 T ANK COOLANT RECO VER Y 8 049814 4 SCREW HHC M10-1.5 X 25 G8.8 9 022131 8 W ASHER FL[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. "B " 3 1 10 16 4 2 17 5 9 1 7 6 29 3 2 30 11 29 15 8 3 6 13 R O L EANER 3 4 33 29 14 TO "B" 19 26 2 7 18 43 41 40 20 42 39 Section 7 - Exploded Views and P arts QUIET SOURCE ™ Liquid-cooled 30 kW Generators Fuel Syst em — Drawing No. 0F6849[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E7691 1 ASSY REGULA TOR 3.0L NG OR LPV 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 4 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 042907 2 SCREW HHC M8-1.2[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. 3 LOC KTI G HT LOC KTI G HT 7 1 5 17 8 7 6 18 4 16 L EAD S 5 2 9 13 21 19 20 14 10 11 1 2 30 1 3 1 Section 7 - Exploded Views and P arts QUIET SOURCE ™ Liquid-cooled 30 kW Generators Alternator — Drawing No. 0F5 092-A[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0F1659A 1 RO T OR 390 15KW 1P DIRECT HSB (2.5L FORD) 0F1657A 1 RO T OR 390 20KW 1P DIRECT HSB (2.5L FORD) 0F1655A 1 RO T OR 390 25KW 1P DIRECT HSB (2.5L FORD) 0F5073A 1 RO T OR 390__30AD1 HSB TECUM 0E7413A 1 RTR 390 40KW 1P DIRECT HSB 2 0F1660A 1 STR 390 15AD HSB (382MM LONG) (2[...]

  • Page 44

    ITEM P ART NO . QTY . DESCRIPTION 1 0F0738 1 MUFFLER 7"X9"-(2)2"IN/2.5"OUT 2 0F6258 1 PIPE MUFFLER OUT 3 044149 2 GASKET EXHA UST RING 4 0F1008 1 EXHA UST PIPE LH 3.0L HSB 5 0F1009 1 EXHA UST PIPE RH 3.0L HSB 6 039288 1 SCREW HHC M8-1.25 X 55 G8.8 7 0E5914 1 BRA CKET MUFFLER 3.0L FORD HSB 8 0E8726 2 STRAP MUFFLER 9 0E0170 2 EXHA[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 0E5193 1 PLA TE AIR CLEANER ADAPTER 2 0E0519A 1 ADAPTER CARBURET OR W/PVC CONN 3 049226 4 W ASHER LOCK M5 4 049815 4 SCREW HHC M5-0.8 X 16 G8.8 5 0C8127 1 ELEMENT AIR CLEANER 6 022127 1 NUT HEX 1/4-20 STEEL 7 062974 1 STUD TH 1/4-20 X 4-1/2 G2 ZNC 8 0A5547 1 CO VER - AIR CLEANER[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. Section 8 — Installation Diagram QUIET SOURCE ™ Liquid-cooled 30 kW Generators Installation Diagram — Drawing No. 0E8696[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 Section 9 — Notes QUIET SOURCE ™ Liquid-cooled 30 kW Generators[...]

  • Page 48

    Part No. 0F6867 Revision 0 (05/31/05) Printed in U.S.A. Section 1 0 – W arranty QUIET SOURCE ™ Liquid-cooled 30 kW Generators GENER AC PO WER SY STEMS "TWO YEAR" LIMITED WARR ANTY FOR QU I E TS OU RCE™ "PR EP A CKAGED EMERGENCY AUT OMA TIC ST ANDBY GENER A T ORS" F or a period of two years from the date of original sale, G[...]