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Generac 6519 manual

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Table of contents for the manual

  • Page 1

    Reference all appropriate documentation. This manual should remain with the unit. n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. n ONL Y QUALIFIED ELECTRICIANS OR CONTRACT ORS SHOULD A TTEMPT INST ALLA TION. n DEADL Y EXHAUST FUMES! OUTDOOR INST ALLA TION ONL Y! LISTED C US T o lo ca te in Spanish, go to http:// www.gener ac.com/ser[...]

  • Page 2

    ii W ARNING! California Proposition 65 Engine exhaust and some of its constituents are known to the state of California to cause cancer , birth defects, and other reproductive harm. W ARNING! California Proposition 65 This product contains or emits chemicals known to the state of California to cause cancer , birth defects, and other reproductive ha[...]

  • Page 3

    T able of Content s iii Section 1 — Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 — General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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    iv This p age intentionally lef t blank.[...]

  • Page 5

    Automatic S tandby Gene rator Owner ’s Manual 1 Section 1 Safety INTRODUCTION: Thank you for purchasing this compact, high performance, air-cooled , engine-driven stationary automatic standby generator set. Every effort was made to make sure that the information and instructions in this manual were both accurate and current at the time the man- u[...]

  • Page 6

    2 Automati c S tandby Genera tor Owner ’s Manual 1.1 — General Safety Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Manual and w ith the unit. The generator can operate safely , efficiently and reliably only if it is properly insta lled, operated and maintained. Many acciden[...]

  • Page 7

    Automatic S tandby Gene rator Owner ’s Manual 3 1.3 — Exhaust Hazards • Generator engine exhaust contains DEADL Y carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, w eakness, sleepiness, inability to think clearly , fainting[...]

  • Page 8

    4 Automati c S tandby Genera tor Owner ’s Manual If this generator is used to po wer electrical load ci rcuits normally po wered by a utility power sou rce, it is required by code to install a transfer switch. The transf er switch must effectively isola te the electrical sy stem from the utility distribution system when the generator is operating[...]

  • Page 9

    Automatic St andby Genera tor Owner ’s Manual 5 Section 2 General Information 2.1 — The Generator Figure 2-1: GA-420 Engine 7 kW Unit 2.2 — Protection Systems The generator may have to run for long periods of time with no operator present to monitor the engine/generator conditions. The refore, the gen- erator is equipped with a number of syst[...]

  • Page 10

    6 Automatic St a ndby Generator Owner ’s Manual 2.3 — Emission Information The U.S. Environmental Protection Agency (E P A) requires that this generator comply wi th exhaust emission standards. This genera tor is certified to meet the applicable EP A emission levels , and is certified for use as a stationary engine for standby power generation.[...]

  • Page 11

    Automatic St andby Genera tor Owner ’s Manual 7 2.4 — S pecifications 2.4.1 — Generator 2.4.2 — Engine The specification sheet for your generator was included in the documentation provided with the unit at the time of purchase. Fo r additional copies, consult your local Authorized Servic e Dealer for your s pecific generator model. 2.4.3 ?[...]

  • Page 12

    8 Automatic St a ndby Generator Owner ’s Manual Gaseous fuels such as natu ral gas and liquid prop ane gas are highly explosive. Even the slightest sp ark can ignit e such fuels and c ause an explo sion. No leak age of fuel is p ermitted. Natural ga s, which is lighter than air , tends to collect in high areas. LP gas is heavier than air and tend[...]

  • Page 13

    Section 3 Operation Automatic S tandby Gene rator Owner ’s Manual 9 3.1 — Controller Lid Operation • Lift lid from bottom to open. Lid will secure in place when opened. Figure 3-1: Open Control Panel Lid • Pull on lid slightly to close. Figure 3-2: Close Control Panel Lid OPEN COVER PULL THE COVER T O UNL OCK AND CL OSE[...]

  • Page 14

    10 Automati c S tandby Genera tor Owner ’s Manual 3.2 — Circuit Breaker The Main Line Circuit Breaker (MLCB) and control panel are located under the side panel cover . Open the side cover door to acce ss both the control panel and circuit breaker . Figure 3-3: Control Panel / Circuit Breaker Location Set to AUTO , the engine may crank and start[...]

  • Page 15

    Automatic S tandby Gene rator Owner ’s Manual 11 3.3.1— Using the Auto/Off/Manual Buttons NOTE: Damage caused by mis-wiring of th e interconnect wires is not warrantable. NOTE: Loss of utility power will cause either the AUTO or OFF or MANUAL button to flash. Whichever mode the generator is in at the time of utility loss. 3.3.2— Using the LED[...]

  • Page 16

    12 Automati c S tandby Genera tor Owner ’s Manual 3.4.1— Clearing an Alarm/W arning Cond ition T o clear an alarm or warning condition from the Control Panel, press the OFF button. Press OFF button again. The flashing or so lid indicator LED will turn off. NOTE: Clearing a code will not correct the pr oblem. It will simply turn off the LED in d[...]

  • Page 17

    Automatic S tandby Gene rator Owner ’s Manual 13 3.5.1.3 — Load T ransfer The transfer of load when the generator is running is dependent upon the operating mode: 3.6 — T urn ing the Generator Off When Operating Under Load NOTE: Important! T o turn the generator off during prolonged utility outages to perform maintenance or conserve fuel, fol[...]

  • Page 18

    14 Automati c S tandby Genera tor Owner ’s Manual 3.7.1— T r ansfer to Generator Power Source 1. Press the Control Panel OFF button. 2. Set the Main Circuit Breaker (Generator Disconnect) to its OFF (OPEN) position. 3. T urn off the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker[...]

  • Page 19

    Automatic S tandby Gene rator Owner ’s Manual 15 3.8.1— Main Circuit Breaker (Generator Disconnect) This is a 2-pole breaker rated acco rding to relevant specifications. 3.9 — Battery Charger NOTE: The battery charger is integrated into the control panel. Battery Problem LE D is illuminated when battery needs service. The battery charger oper[...]

  • Page 20

    16 Automati c S tandby Genera tor Owner ’s Manual This p age intentionally lef t blank.[...]

  • Page 21

    Automatic S tandby Gene rator Owner ’s Manual 17 Section 4 Maintenance NOTE: Proper maintenance and proper and safe operation is crucial to the life of the ge nerator . Genuine Generac par ts MUST be u sed to ensure warranty coverage. NOTE: All service to this generator must be performed by a qualif ied service p erson only . 4.1 — Performing S[...]

  • Page 22

    18 Automati c S tandby Genera tor Owner ’s Manual 4.2 — Service Schedule A TTENTION: All service work must be performed by a qualified service person only . 4.2.1 — Maintenance Log 1. Battery inspection and charge check (recommended every year (1) for the life of the battery) NOTE: Check electrolyte level (unseal ed batteries only) every 6 mo[...]

  • Page 23

    Automatic S tandby Gene rator Owner ’s Manual 19 3. V alve Adjustment (recommended after the first 20 hours of operation and then after every 3 00 hours of operation) Dates Performed: 4.3 — Checking Engine Oil Level When power outages necessitate running the generator for extended per iods, the oil level should be checked daily . T o check the [...]

  • Page 24

    20 Automati c S tandby Genera tor Owner ’s Manual Figure 4-2: Recommended Oi l Based on T emperature • SAE 30 above 32 ºF (0 ºC) • 10W-30 between 40 ºF and -10 ºF (4 ºC and -23 ºC) • Synthetic 5W-30 for all temperature ranges* NOTE: *Synthetic oil should only be used after 100 hours of operation. Any attempt to crank or start the engi[...]

  • Page 25

    Automatic S tandby Gene rator Owner ’s Manual 21 Figure 4-3: Oil Drain Location 4.4 — Changing the Engine Air Cleaner 1. With the generator shut down, remove the top lid. 2. Disengage the wire clip and remove the air cleaner access cover . See Figure 4-4. 3. Remove the old air filter and discard. 4. Thoroughly clean the air cleaner enclosure of[...]

  • Page 26

    22 Automati c S tandby Genera tor Owner ’s Manual 4. Clean the plug by scraping or washing with a wire brus h and commercial solvent. Do not blast the plug to clean. 5. Check the spark plug gap using a wire feeler gauge. See Figure 4-5. Adjust t he gap by carefully bending the ground electrode to: •7 kW units - 0.76 mm (0.030 in) 6. Install spa[...]

  • Page 27

    Automatic S tandby Gene rator Owner ’s Manual 23 9. Install the rubber plug into the fan screen. 10. Install the spark plug and attach the spark plug wire. 1 1. Install the back panel. Ensure that the alternator intake bel low is captured by the frame on back panel securely with out an y kinks. Install enclosure top lid. Tighten all fasteners sec[...]

  • Page 28

    24 Automati c S tandby Genera tor Owner ’s Manual Lead-acid batteries pres ent a risk of fire because they generate h ydrogen gas. Strictly observe the following pre- cautions: • DO NOT smoke when near the battery . • DO NOT cause flame or spark in the battery area. • Discharge static electricity from the body before touching the battery by[...]

  • Page 29

    Automatic S tandby Gene rator Owner ’s Manual 25 Figure 4-8: Battery Location and T erminals 4. Check the battery fluid level of unsealed batteries, and if neces sary , fill with distilled water only . DO NOT use tap water . Also, have the Dealer or a qualified Service T echnici an check the state of charge and condition. 5. Place the battery int[...]

  • Page 30

    26 Automati c S tandby Genera tor Owner ’s Manual 4.10.2 — Return to Service T o return the unit to service after storage: 1. V erify that utility power is turned off. 2. Check the tag on the engine for oil viscosity and classi ficat ion. If necessary , drain and refill with proper oil. 3. Check the state of the battery . Fill all cells of unse[...]

  • Page 31

    Automatic S tandby Gene rator Owner ’s Manual 27 Section 5 T roubleshooting Problem Cause Correction Engine will not crank. 1. Fuse blown. 2. Loose, corroded or defective battery cables. 3. Defective starter contact. 4. Defective starte r motor . 5. Dead Bat tery . 1. Correct short circuit condition by replacing 7.5 Amp fuse in generator control [...]

  • Page 32

    28 Automatic S tandby Generator Owner ’s Manual This p age intentionally lef t blank.[...]

  • Page 33

    Automatic S tandby Gene rator Owner ’s Manual 29 Section 6 Quick Reference Guide Problem Things to Check Ac tive Alarm Solution Unit running in AUTO but no power in house . Check MLCB NONE Check MLCB. Contact servi cing dealer if MLCB is in the ON position. Unit shuts down during operation. Check for alarms HIGH TEMPERA TURE Check ventilatio n ar[...]

  • Page 34

    30 Automatic S tandby Generator Owner ’s Manual This p age intentionally lef t blank.[...]

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  • Page 36

    Part No. 0K6020 Rev . A 07/29/2014 Printed in USA © Generac Power Systems, Inc. All rights reserved S pecificati ons are subje c t to change without notice. No reproduction allow ed in any form without prior written consent from Ge ne ra c Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy . 59 W aukesha, WI 53189 1-888-GENERAC (1-888-[...]