Generac QT07068ANAC manual

This manual should remain with the unit. QT 6.8L 70kW Models EP A Cer tified with Optional Catalyst Owner's Manual Stationar y Emergency Generator Cover200 Re v . A 10/10 Part No. 0J1617 n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. ONL Y QU ALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLA TION! DEADL Y EXHA UST [...]

SECTION P AGE INTRODUCTION .................................................................... 1-1 SAFETY RULES .................................................................... 1-2 IDENTIFICA TION RECORD .................................................... 2-1 EQUIPMENT DESCRIPTION .................................................. 3-1 Equipme[...]

INTRODUCTION Thank you for purchasing this model of the stationar y emergency generator product line. Ever y effor t was expended to make sure that the information and instr uctions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reser ves the right to change, alter or other wise improve [...]

SAFETY RULES Study these SAFETY RULES carefully before installing, operating or ser vicing 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 f[...]

If personnel must stand on metal or concrete while installing, • operating, ser vicing, adjusting or repairing this equipment, place insulative mats over a dr y wooden platform. Work on the equipment only while standing on such insulative mats. The National Electrical Code (NEC) requires the frame and • external electrically conductive par ts o[...]

IDENTIFICA TION RECORD DA T A L ABEL Ever y generator set includes DA T A L ABEL that contains impor tant information per tinent to the generator . The data label is attached to the lower connection box on the generator and lists the unit serial number , rated voltage, amps, wattage capacity , phase, frequency , rpm, power factor , and production d[...]

EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur rent Stationar y Emergency Generator set. It is powered by a 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. Th[...]

ENGINE PROTECTIVE DEVICES The Stationar y 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 s[...]

FUEL SYSTEM FUEL REQUIREMENTS The Stationar y Emergency Generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (LPV) 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[...]

6-1 SPECIFICA TIONS ST A TIONARY EMERGENC Y GENERATOR T ype...................................................................... Synchronous Rotor Insulation ............................................................. Class H Stator Insulation ............................................................ Class H T otal Har monic Distor tion .....[...]

WEA THER AND MAINTENANCE KITS T o keep the generator r unning at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32 °F . • Scheduled Maintenance Kit ~ Kit includes the recommended par ts to maintain the genera- tor . Refer to the Ser vice Schedule for regular maintenance inter val[...]

AL TERNA TOR AC LEAD CONNECTIONS The electrical wires in the unit’s 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 th[...]

Figure 7.4 — Stator P ower Winding Connections - 3-phase, 120/208V (6 Lead) 3-phase 120/208V 6 Lead E3 E2 00 (NEUTRAL) INTERNAL CONNECTIONS E1 L-L L-N S1 S1 S4 S4 S6 S6 S3 S3 S5 S5 S2 S2 Figure 7.5 — Stator P ower Winding Connections - 3-phase, 120/208V (12 Lead) 3-phase 120/208V 12 Lead E3 E2 E1 L-L L-N S7 S1 S10 S4 S12 S6 S9 S3 S5 S11 S2 S8 F[...]

CONTROL P ANEL INTERF ACE USING THE AUTO/OFF/MANUAL SWITCH  With the switch set to A UTO , the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. T o prevent possible injury that might be caused by such sudden sta[...]

8-2 CntrlNexus001 Rev . E 12/11 Control P anel ACTIVA TION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- guage. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Display Reads: Press ENTER to begin the activation pro- cess. If ESCAPE is pressed [...]

INST ALLA TION ASSIST ANT Interconnect System Self T est 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 termi[...]

SEQUENCE OF AUTOMA TIC OPERA TION Initial Conditions: Generator in Auto ready to r un, load being sup- plied by the Utility Source through the transfer switch. 1. When the utility voltage fails (falls below 60% of nominal), a 10-30 second (programmable) “line interr upt” delay timer is star ted. The factor y set time delay is 10 seconds. If at [...]

CHECK ENGINE MESSAGE The control system has detected an emissions related fault. This fault cannot be cleared using the control panel inter face. The unit will continue to operate in automatic mode. Contact your local ser vicing dealer . UNDER-FREQUENC Y SHUTDOWN AL ARM Af ter star ting, if the generator stays under frequency for more than 30 secon[...]

OVERVOL T AGE AL ARM If the generator voltage rises above 110% for >3 seconds, an alarm will be issued. If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued. INTERNAL F AILURE SHUTDOWN ALARM Any internal failure that can be detected such as cor r upted firmware will cause this shutdown alar m. This alarm cannot [...]

8-7 Control P anel ACTIV A TION RUN LOG ALARM LOG HISTOR Y STA TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA TOR FREQUENCY ENGINE HOURS ENGINE RPM BA TTERY VO LTAG E DEBUG INPUTS OUTPUTS DISPLA YS EDIT LANGU AGE TIME/DA TE EXERCISE TIME/SPEED ESC Press the “ESCAPE” key to jump back up through the menu levels. + / - Use the “+/-” key to navig[...]

ST A TIONARY EMERGENCY GENERA TOR CONTROL AND OPERA TION Refer to the appropriate control panel operator’s manual for this unit. OPERA TING UNIT WITH MANUAL TRANSFER SWITCH If the Stationar y Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only , the fol- lowing procedure applies. A manually ope[...]

GENERAL MAINTENANCE  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[...]

ENGINE COOLANT Check coolant level in coolant recover y bottle. See the Specifications and Ser vice Schedule sections. Add recommended coolant mixture as necessar y . • P eriodically remove radiator pressure cap (only when engine • has cooled down) to make sure the coolant recover y system is functioning properly . Coolant should be at bottom o[...]

Figure 10.3 – Engine Air Filter Air Filter SP ARK PLUGS Reset the spark plug gap or replace the spark plugs as neces- sar y . 1. Clean the area around the base of the spark plugs to keep dir t and debris out of the engine. Clean by scraping or washing using a wire br ush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the[...]

SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Y early - Y Inspect Change Clean Fuel Fuel Lines & Connections M X Lubrication Oil Level M X* Oil Y X** Oil Filter Y X** Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y X Enclosure Louvers W X X Engine Air Cleaner Y X X***[...]

T roubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. R eplace fuse.* 2. Loose or corroded or defective 2. Tighten, clean or replace batter y cables. batter y cables as necessar y .* 3. Defective star ter contactor . 3. Replace contactor .* 4. Defective star ter motor . 4. R ep[...]

United St ates Environmental Protection Agency W arranty St atement (St ationary Emergency Sp ark-Ignited Generators) W arranty Right s, Obligations and Coverage The United S tates Environment al Protection Agency (EP A) and Generac Power Systems, In c. (Generac) are pleased to explain the Em ission Control System Warranty on your new st ationary e[...]

United St ates Environmental Protect ion Agency Compliance Requirement s (St ationary Emergency Sp ark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities The United S t ates Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac) are pleased to explain your r ecord keeping requirements for com[...]

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EXPLODED VIEW: EV CPL ALTERNAT OR BRUSHLESS DRAWING #: 0F5924 GROUP A ITEM PART# QTY. DESCRIPTION REVISION: K-1254-L Page 2 of 2 DATE: 2/9/15 1 0F3182 1 ROTOR 390 70AB3 CPL 0F6194 1 R TR 390 70KB3 CPL 2 0F3183 1 STATOR 390 70AB3 CPL 0F6195 1 S TR 390 70KB3 CPL 0F6203 1 S TR 390 70GB3 CPL 3 068405C 1 EXITER FIELD 2" LG SPD CON N 4 087272 1 ASSY[...]

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EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 3 of 6 DATE: 8/4/15 ITEM PART# QTY. DESCRIPTION 1 0H9742 1 BACK PANEL CONBOX SUPPORT C3 2 0H6265 1 TOP PANEL CONNBOX SUPPORT C2 (2)3 0F5376S0AR 1 MX150L SLRRM NT 22-18 8P W/O GA (2)4 0F5396S0AR 1 MX150L SLRRM NT 22-18 12P W/OGA 5 0H6169D 1 ASSY PROG [...]

EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 4 of 6 DATE: 8/4/15 ITEM PART# QTY. DESCRIPTION 63 0J 3060 1 GASKET WIRE ENTRY COVER 64 0A9457 1 DECAL N EUTRAL 65 067210A 1 DECAL GROUND LUG UL CIRCUIT BREAKER (225AF) A 0H9750 1 COVER CB G 225AF C3 B 0F4186 1 COVER CB DISH 3P G 225A F C 0F4148 REF [...]

EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 5 of 6 DATE: 8/4/15 ITEM PART# QTY. DESCRIPTION UL CIRCUIT BRAEAKER (FG) A 0H9758 1 COVER CB E FG C3 B 0F4186 1 COVER CB DISH 3P G 225A F C 0H5491 REF CB 0125 3P 600V E FG LL D 0H4698A 1 INSULATOR CB 3P E TYPE CC/FG E 0H7311 1 STANDOFF CB BOX CONBOX [...]

EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 6 of 6 DATE: 8/4/15 THIS PAGE LEFT INTENTIONALLY BLANK[...]

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1 0F340 8 1 TRA Y BATTER Y 2 0F3 411 1 STRAP BA T TE RY RETAI NM ENT 3 058208 1 BATT 12VDC 24F 625 4 02213 1 1 W ASHER FLAT 3/8-M1 0 ZIN C 5 050331A 1 BATT POST COVER RED + 6 05033 1 1 BATT POST COVER BLK - 7 038805 T 1 CABLE BA TT BLK #1 X 4 0.00 8 038 804Y 1 CABL E BATT R ED #1 X 35 .00 9 045771 1 NU T HEX M8-1.25 G8 YEL CHR 10 02212 9 1 W ASHER [...]

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EXPLODED VIEW: E V MTG BASE C3 5.4L 55KW DRAWING #: 0H5677 GROUP C ITEM PART# QTY. DESCRIPTION REVISION: K-2274-C Page 2 of 2 DATE: 3/17/15 (2)1 0 L0574BST0R 1 MTG BASE C5 5.4/ 55KW 6.8/70KW 2 065852 1 SPRING CLIP HOLDER .37-.62 3 052252 4 DAMPENER VIBRATION 4 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZINC 5 052259 4 WASHER FLAT M12 6 055597 4 SCREW HH[...]

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EXPLODED VIEW: E V ENGCOMPRT R/H 6.8 (CPL) DRAWING #: 0F3058 GROUP D ITEM PART# QTY. DESCRIPTION REVISION: J-4243-L Page 2 of 2 DATE: 2/19/13 1 0D5623 2 HEAT SHIELD EXHAUST 2 0D5418 1 STARTER MOTOR FORD V-10 ENGINE 3 022131 1 WASHER FLAT 3/8-M10 ZINC 4 0F3514 1 SPACER FLEXPLATE 5.4L/6.8L (1 800 RPM UNITS ONLY) (3) 5 02247 3 1 / 2 WASHER FLAT 1/4-M6[...]

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EXPLODED VIEW: E V AIR CLEANER DRAWING #: 0F3569 GROUP D ITEM PART# QTY. DESCRIPTION REVISION: J-9801-E Page 2 of 2 DATE: 9/19/14 1 0 D251 3D 1 A IR CLNR B TM PLT W/CPLR 8.1L 0D2513E 1 PLATE AIR CLEANER W/COUPLER 2 0F5419 1 ELEMENT AIR FILTER 3 0F4268 1 TOP PLATE VENTURI 4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED 5 0F6977 1 PLATE AIR CLEAN TOP 5.4L/6[...]

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EXPLODED VIEW: E V ENGINE COM PRT L/H S IDE 6.8L DRAWING #: 0J0212 GROUP D APPLICABLE TO: REVISION: K-3804-C Page 2 of 2 DATE: 9/3/15 ITEM PART# QTY. DESCR I PT I ON 1 0F3017 1 BRACKET ,D.C. ALTERNATOR LOWER 2 039253 3 SCREW HHC M8-1.25 X 20 C8.8 (2)3 02212 9 4/5 W ASHER LOCK M8-5/16 (2)4 02214 5 4/5 W ASHER FLAT 5/16-M8 Z INC (1)5 0D5419 REF O IL [...]

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EXPLODED VIEW: E V COOL PKG 6.8L C3 DRAWING #: 0J6324 GROUP D ITEM PART# QTY. DESCRIPTION REVISION: K-1082-B Page 2 of 2 DATE: 11/12/14 1 0F3144 1 WELDMENT RAD SUP PORT C3 (22") 2 035685 4 CLAMP HOSE #28 1.32-2.25 3 0F2857A 1 RADIATOR 581 X 585 X 70 CPL LH 4 0F4168 1 HOSE UPPER RADIATOR C 3 5 0F4169 1 HOSE LOWER RADIATO R C3 6 0J618 0 1 ADAPTO[...]

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EXPLODED VIEW: E V EXHUAST CPL 7OKW C3 DRAWING #: 0J6343 GROUP D APPLICABLE TO: REVISION:-A - PAGE 2 OF 2 DATE: 9/13/11 ITEM PART# QTY. DESCR I PT I ON 1 0J6177 1 PIPE, EXH MANIFOLD 6.8L C3 R H (6.8L 70KW) 2 0J6179 1 PIPE EXH MANIFOLD 6.8L C3 L H (6.8L 70KW) 3 0F2808B 2 PIPE EXHAUST MUFFLER OUT 4 0A 6765 2 RING GASKET, 2.5DIA 5 0F4710 6 W ASH ER LO[...]

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EXPLODED VIEW: E V EXHAUST CPL 7OKW C3 DRAWING #: 0J6343A GROUP D APPLICABLE TO: ITEM PART# QTY. DESCR I PT I ON REVISION: K-1591-C PAGE 2 OF 2 DATE: 1/28/15 1 0J6177 1 PIPE, EXH MANIFOLD 6.8L C3 R H (6.8L 70KW) 2 0J6179 1 PIPE EXH MANIFOLD 6.8L C3 L H (6.8L 70KW) 3 0F2808B 2 PIPE EXHAUST MUFFLER OUT 4 0A 6765 2 RING GASKET, 2.5DIA 5 0F4710 6 W ASH[...]

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EXPLODED VIEW: E V FUEL 6.8L NG LPV CPL EMSN DRAWING #: 0J1704 GROUP E APPLICABLE TO: REVISION: J-8381-D PAGE 2 OF 2 DATE: 4/22/14 ITEM PART# QTY. DESCR I PT I ON 1 0497 21 4 SCREW HHC M6-1.0 X 35 G8.8 BLK 2 0755 80 1 FLANGE FUEL INLET 3 0H0651 1 REG 6.8L CPL 70K W LPV EMSN 0H0651A 1 REG 6.8L CPL 70K W NG EMSN 4 0392 53 2 SCREW HHC M8-1.25 X 20 G8.[...]

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EXPLODED VIEW: E V FUEL SYSTEM 6.8L NG/L P V CPL DRAWING #: 0J1705 GROUP E APPLICABLE TO: REVISION: K-3796-E PAGE 2 OF 2 DATE: 8/31/15 ITEM PART# QTY. DESCR I PT I ON 1 0497 21 4 SCREW HHC M6-1.0 X 35 G8.8 BLK 2 0755 80 1 FLANGE FUEL INLET 3 0G9189A 1 REG ASSY 6.8L 70K W LPV CPL 0G9189B 1 REG ASSY 6.8L 70K W NG CPL 4 0392 53 2 SCREW HHC M8-1.25 X 2[...]

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EXPLODED VIEW: E V ENCLOSURE C3 DRAWING #: 0G2898 GROUP F ITEM PART# QTY. DESCRIPTION REVISION: J-4499-K Page 2 of 2 DATE: 4/1/13 (2) 1 0F58660AL0R 1 REAR WRAP AL (2) 2 0 F5861A AL0R 4 DOOR AL (2) 3 0F58650AL0R 2 CENTER SUPPORT AL (3) 4 0F58640AL0R 2 DUCT, DISCHRG AL (2) 5 0F58620ALOR 2 FRONT CRNR AL (2) 6 0F58630AL0R 1 DUCT, CNTR DISCHRG AL (2) 7 [...]

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BackPg001 Re v . A 04/07[...]

This manual should remain with the unit. QT 6.8L 70kW Models EP A Cer tified with Optional Catalyst Owner's Manual Stationar y Emergency Generator Cover200 Re v . A 10/10 P ar t No . 0J1617 n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLATION! DEADL Y EXHAUST [...]

SECTION P AGE INTRODUCTION .................................................................... 1-1 SAFETY RULES .................................................................... 1-2 IDENTIFICA TION RECORD .................................................... 2-1 EQUIPMENT DESCRIPTION .................................................. 3-1 Equipme[...]

INTRODUCTION Thank you for purchasing this model of the stationar y emergency generator product line. Ever y effor t was expended to make sure that the information and instr uctions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reser ves the right to change, alter or other wise improve [...]

SAFETY RULES Study these SAFETY RULES carefully before installing, operating or ser vicing 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 f[...]

If personnel must stand on metal or concrete while installing, • operating, ser vicing, adjusting or repairing this equipment, place insulative mats over a dr y wooden platform. Work on the equipment only while standing on such insulative mats. The National Electrical Code (NEC) requires the frame and • external electrically conductive par ts o[...]

IDENTIFICA TION RECORD DA T A L ABEL Ever y generator set includes DA T A L ABEL that contains impor tant information per tinent to the generator . The data label is attached to the lower connection box on the generator and lists the unit serial number , rated voltage, amps, wattage capacity , phase, frequency , rpm, power factor , and production d[...]

EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur rent Stationar y Emergency Generator set. It is powered by a 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. Th[...]

ENGINE PROTECTIVE DEVICES The Stationar y 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 s[...]

FUEL SYSTEM FUEL REQUIREMENTS The Stationar y Emergency Generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (LPV) 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[...]

6-1 SPECIFICA TIONS ST A TIONARY EMERGENC Y GENERATOR T ype...................................................................... Synchronous Rotor Insulation ............................................................. Class H Stator Insulation ............................................................ Class H T otal Har monic Distor tion .....[...]

WEA THER AND MAINTENANCE KITS T o keep the generator r unning at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32 °F . • Scheduled Maintenance Kit ~ Kit includes the recommended par ts to maintain the genera- tor . Refer to the Ser vice Schedule for regular maintenance inter val[...]

AL TERNA TOR AC LEAD CONNECTIONS The electrical wires in the unit’s 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 th[...]

Figure 7.4 — Stator P ower Winding Connections - 3-phase, 120/208V (6 Lead) 3-phase 120/208V 6 Lead E3 E2 00 (NEUTRAL) INTERNAL CONNECTIONS E1 L-L L-N S1 S1 S4 S4 S6 S6 S3 S3 S5 S5 S2 S2 Figure 7.5 — Stator P ower Winding Connections - 3-phase, 120/208V (12 Lead) 3-phase 120/208V 12 Lead E3 E2 E1 L-L L-N S7 S1 S10 S4 S12 S6 S9 S3 S5 S11 S2 S8 F[...]

CONTROL P ANEL INTERF ACE USING THE AUTO/OFF/MANUAL SWITCH  With the switch set to A UTO , the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. T o prevent possible injury that might be caused by such sudden sta[...]

8-2 CntrlNexus001 Rev . E 12/11 Control P anel ACTIVA TION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- guage. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Display Reads: Press ENTER to begin the activation pro- cess. If ESCAPE is pressed [...]

INST ALLA TION ASSIST ANT Interconnect System Self T est 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 termi[...]

SEQUENCE OF AUTOMA TIC OPERA TION Initial Conditions: Generator in Auto ready to r un, load being sup- plied by the Utility Source through the transfer switch. 1. When the utility voltage fails (falls below 60% of nominal), a 10-30 second (programmable) “line interr upt” delay timer is star ted. The factor y set time delay is 10 seconds. If at [...]

CHECK ENGINE MESSAGE The control system has detected an emissions related fault. This fault cannot be cleared using the control panel inter face. The unit will continue to operate in automatic mode. Contact your local ser vicing dealer . UNDER-FREQUENC Y SHUTDOWN AL ARM Af ter star ting, if the generator stays under frequency for more than 30 secon[...]

OVERVOL T AGE AL ARM If the generator voltage rises above 110% for >3 seconds, an alarm will be issued. If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued. INTERNAL F AILURE SHUTDOWN ALARM Any internal failure that can be detected such as cor r upted firmware will cause this shutdown alar m. This alarm cannot [...]

8-7 Control P anel ACTIV A TION RUN LOG ALARM LOG HISTOR Y STA TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA TOR FREQUENCY ENGINE HOURS ENGINE RPM BA TTERY VO LTAG E DEBUG INPUTS OUTPUTS DISPLA YS EDIT LANGU AGE TIME/DA TE EXERCISE TIME/SPEED ESC Press the “ESCAPE” key to jump back up through the menu levels. + / - Use the “+/-” key to navig[...]

ST A TIONARY EMERGENCY GENERA TOR CONTROL AND OPERA TION Refer to the appropriate control panel operator’s manual for this unit. OPERA TING UNIT WITH MANUAL TRANSFER SWITCH If the Stationar y Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only , the fol- lowing procedure applies. A manually ope[...]

GENERAL MAINTENANCE  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[...]

ENGINE COOLANT Check coolant level in coolant recover y bottle. See the Specifications and Ser vice Schedule sections. Add recommended coolant mixture as necessar y . • P eriodically remove radiator pressure cap (only when engine • has cooled down) to make sure the coolant recover y system is functioning properly . Coolant should be at bottom o[...]

Figure 10.3 – Engine Air Filter Air Filter SP ARK PLUGS Reset the spark plug gap or replace the spark plugs as neces- sar y . 1. Clean the area around the base of the spark plugs to keep dir t and debris out of the engine. Clean by scraping or washing using a wire br ush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove the[...]

SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Y early - Y Inspect Change Clean Fuel Fuel Lines & Connections M X Lubrication Oil Level M X* Oil Y X** Oil Filter Y X** Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y X Enclosure Louvers W X X Engine Air Cleaner Y X X***[...]

T roubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. R eplace fuse.* 2. Loose or corroded or defective 2. Tighten, clean or replace batter y cables. batter y cables as necessar y .* 3. Defective star ter contactor . 3. Replace contactor .* 4. Defective star ter motor . 4. R ep[...]

United St ates Environmental Protection Agency W arranty St atement (St ationary Emergency Sp ark-Ignited Generators) W arranty Right s, Obligations and Coverage The United S tates Environment al Protection Agency (EP A) and Generac Power Systems, In c. (Generac) are pleased to explain the Em ission Control System Warranty on your new st ationary e[...]

United St ates Environmental Protect ion Agency Compliance Requirement s (St ationary Emergency Sp ark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities The United S t ates Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac) are pleased to explain your r ecord keeping requirements for com[...]

Notes[...]

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EXPLODED VIEW: EV CPL ALTERNAT OR BRUSHLESS DRAWING #: 0F5924 GROUP A ITEM PART# QTY. DESCRIPTION REVISION: K-1254-L Page 2 of 2 DATE: 2/9/15 1 0F3182 1 ROTOR 390 70AB3 CPL 0F6194 1 R TR 390 70KB3 CPL 2 0F3183 1 STATOR 390 70AB3 CPL 0F6195 1 S TR 390 70KB3 CPL 0F6203 1 S TR 390 70GB3 CPL 3 068405C 1 EXITER FIELD 2" LG SPD CONN 4 087272 1 ASSY [...]

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EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 3 of 6 DATE: 8/4/15 ITEM PART# QTY. DESCRIPTION 1 0H9742 1 BACK PANEL CONBOX SUPPORT C3 2 0H6265 1 TOP PANEL CONNBOX SUPPORT C2 (2)3 0F5376S0AR 1 MX150L SLRRM NT 22-18 8P W/O GA (2)4 0F5396S0AR 1 MX150L SLRRM NT 22-18 12P W/OGA 5 0H6169D 1 ASSY PROG [...]

EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 4 of 6 DATE: 8/4/15 ITEM PART# QTY. DESCRIPTION 63 0J 3060 1 GASKET WIRE ENTRY COVER 64 0A9457 1 DECAL N EUTRAL 65 067210A 1 DECAL GROUND LUG UL CIRCUIT BREAKER (225AF) A 0H9750 1 COVER CB G 225AF C3 B 0F4186 1 COVER CB DISH 3P G 225A F C 0F4148 REF [...]

EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 5 of 6 DATE: 8/4/15 ITEM PART# QTY. DESCRIPTION UL CIRCUIT BRAEAKER (FG) A 0H9758 1 COVER CB E FG C3 B 0F4186 1 COVER CB DISH 3P G 225A F C 0H5491 REF CB 0125 3P 600V E FG LL D 0H4698A 1 INSULATOR CB 3P E TYPE CC/FG E 0H7311 1 STANDOFF CB BOX CONBOX [...]

EXPLODED VIEW: E V CONBOX C3 NEXUS DRAWING #: 0H9747 GROUP A APPLICABLE TO: REVISION: K-3487-H Page 6 of 6 DATE: 8/4/15 THIS PAGE LEFT INTENTIONALLY BLANK[...]

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1 0F340 8 1 TRA Y BATTER Y 2 0F3 411 1 STRAP BA T TE RY RETAI NM ENT 3 058208 1 BATT 12VDC 24F 625 4 02213 1 1 W ASHER FLAT 3/8-M1 0 ZIN C 5 050331A 1 BATT POST COVER RED + 6 05033 1 1 BATT POST COVER BLK - 7 038805 T 1 CABLE BA TT BLK #1 X 4 0.00 8 038 804Y 1 CABL E BATT R ED #1 X 35 .00 9 045771 1 NU T HEX M8-1.25 G8 YEL CHR 10 02212 9 1 W ASHER [...]

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EXPLODED VIEW: E V MTG BASE C3 5.4L 55KW DRAWING #: 0H5677 GROUP C ITEM PART# QTY. DESCRIPTION REVISION: K-2274-C Page 2 of 2 DATE: 3/17/15 (2)1 0 L0574BST0R 1 M TG BASE C5 5.4/55KW 6.8/70KW 2 065852 1 SPRING CLIP HOLDER .37-. 62 3 052252 4 DAMPENER VIBRATION 4 052257 4 SPACER .49 X .62 X 1.87 P WDR/ZINC 5 052259 4 WASHER FLAT M12 6 055597 4 SCREW [...]

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EXPLODED VIEW: E V ENGCOMPRT R/H 6.8 (CPL) DRAWING #: 0F3058 GROUP D ITEM PART# QTY. DESCRIPTION REVISION: J-4243-L Page 2 of 2 DATE: 2/19/13 1 0D5623 2 H EAT SHIELD EXHAUST 2 0D5418 1 S TARTER M OTOR FORD V-10 ENGINE 3 022131 1 WASHER FLAT 3/8-M10 ZIN C 4 0F3514 1 SPACER FLEXPLATE 5.4L / 6.8L (1800 RPM UNITS ONLY) (3) 5 02247 3 1 / 2 WASHER FLAT 1[...]

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EXPLODED VIEW: E V AIR CLEANER DRAWING #: 0F3569 GROUP D ITEM PART# QTY. DESCRIPTION REVISION: J-9801-E Page 2 of 2 DATE: 9/19/14 1 0 D251 3D 1 AIR CLN R BTM PLT W/CPLR 8.1L 0D2513E 1 PLATE AIR CLEANER W/COUPLER 2 0F5419 1 ELEMENT AIR FILTER 3 0F4268 1 TOP PLATE VENTURI 4 0F4270A 1 HOLD DOWN AIR CLE ANER PLATED 5 0F6977 1 PLATE AIR CLEAN TOP 5.4L/6[...]

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EXPLODED VIEW: E V ENGINE COM PRT L/H S IDE 6.8L DRAWING #: 0J0212 GROUP D APPLICABLE TO: REVISION: K-3804-C Page 2 of 2 DATE: 9/3/15 ITEM PART# QTY. DESCR I PT I ON 1 0F3017 1 BRACKET ,D.C. ALTERNATOR LOWER 2 039253 3 SCREW HHC M8-1.25 X 20 C8. 8 (2)3 02212 9 4/5 W ASHER LOCK M8-5/16 (2)4 02214 5 4/5 W ASHER FLAT 5/16-M8 Z INC (1)5 0D5419 REF O IL[...]

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EXPLODED VIEW: E V COOL PKG 6.8L C3 DRAWING #: 0J6324 GROUP D ITEM PART# QTY. DESCRIPTION REVISION: K-1082-B Page 2 of 2 DATE: 11/12/14 1 0F3144 1 WELDMENT RAD SUP PORT C3 (22") 2 035685 4 CLAMP HOSE #28 1.32-2.25 3 0F2857A 1 RADIATOR 581 X 585 X 70 CPL LH 4 0F4168 1 HOSE UPPER RADIATOR C 3 5 0F4169 1 HOSE LOWER RADIATO R C3 6 0J618 0 1 ADAPTO[...]

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EXPLODED VIEW: E V EXHUAST CPL 7OKW C3 DRAWING #: 0J6343 GROUP D APPLICABLE TO: REVISION:-A - PAGE 2 OF 2 DATE: 9/13/11 ITEM PART# QTY. DESCR I PT I ON 1 0J6177 1 PIPE, EXH MANIFOLD 6.8L C3 R H (6.8L 70KW) 2 0J6179 1 PIPE EXH MANIFOLD 6.8L C3 L H (6.8L 70KW) 3 0F2808B 2 PIPE EXHAUST MUFFLER OUT 4 0A 6765 2 RING GASKET, 2.5DIA 5 0F4710 6 W ASH ER LO[...]

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EXPLODED VIEW: E V EXHAUST CPL 7OKW C3 DRAWING #: 0J6343A GROUP D APPLICABLE TO: ITEM PART# QTY. DESCR I PT I ON REVISION: K-1591-C PAGE 2 OF 2 DATE: 1/28/15 1 0J6177 1 PIPE, EXH MANIFOLD 6.8L C3 R H (6.8L 70KW) 2 0J6179 1 PIPE EXH MANIFOLD 6.8L C3 L H (6.8L 70KW) 3 0F2808B 2 PIPE EXHAUST MUFFLER OUT 4 0A 6765 2 RING GASKET, 2.5DIA 5 0F4710 6 W ASH[...]

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EXPLODED VIEW: E V FUEL 6.8L NG LPV CPL EMSN DRAWING #: 0J1704 GROUP E APPLICABLE TO: REVISION: J-8381-D PAGE 2 OF 2 DATE: 4/22/14 ITEM PART# QTY. DESCR I PT I ON 1 0497 21 4 SCREW HHC M6-1.0 X 35 G8.8 BLK 2 0755 80 1 FLANGE FUEL INLET 3 0H0651 1 REG 6.8L CPL 70K W LPV EMSN 0H0651A 1 REG 6.8L CPL 70K W NG EMSN 4 0392 53 2 SCREW HHC M8-1.25 X 20 G8.[...]

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EXPLODED VIEW: E V FUEL SYSTEM 6.8L NG/L P V CPL DRAWING #: 0J1705 GROUP E APPLICABLE TO: REVISION: K-3796-E PAGE 2 OF 2 DATE: 8/31/15 ITEM PART# QTY. DESCR I PT I ON 1 0497 21 4 SCREW HHC M6-1.0 X 35 G8.8 BLK 2 0755 80 1 FLANGE FUEL INLET 3 0G9189A 1 REG ASSY 6.8L 70K W LPV CPL 0G9189B 1 REG ASSY 6.8L 70K W NG CPL 4 0392 53 2 SCREW HHC M8-1.25 X 2[...]

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EXPLODED VIEW: E V ENCLOSURE C3 DRAWING #: 0G2898 GROUP F ITEM PART# QTY. DESCRIPTION REVISION: J-4499-K Page 2 of 2 DATE: 4/1/13 (2) 1 0F58660AL0R 1 REAR WRAP AL (2) 2 0 F5861A AL0R 4 DOOR AL (2) 3 0F58650AL0R 2 CENTER SUPPORT AL (3) 4 0F58640AL0R 2 DUCT, DISCHRG AL (2) 5 0F58620ALOR 2 FRONT CRNR AL (2) 6 0F58630AL0R 1 DUCT, CNTR DISCHRG AL (2) 7 [...]

REPLACEMENT SHEET META L P A RTS ORDERING GUIDE Parts listed in t he manual Bill of Material on the EV drawings/Manuals a re listed in the unfinished form with the default material – usually s teel or plain six or seven digit number. 0XXXXXX S T 0R or 0X XXXX X Base number Suffix1 Raw After entering seri al number or model number of the unit to s[...]

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