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Generac Power Systems 004810-0, Owner'S Manual

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Generac Power Systems 004810-0 Owner'S Manual Download Page 20

N/O

GROUND FROM ENGINE

0

BC3-12

BC3-6

TB4-5

BC3-10

POSITIVE DC FROM BATTERY

AUX. FUSED DC SUPPLY

POSITIVE DC FROM BATTERY

CHARGE ALT. W/L CONN.

49

13

15

13

BC3-7

BC2-11

BC4-1

BC4-7

BC2-10

BC2-8

BC2-9

BC3-4

BC3-3

BC3-9

GROUND FROM ENGINE

PRE-HEAT SOLENOID

STARTER SOLENOID

FUEL SOLENOID

14

0

56

150

FUEL SENDER -

FUEL 

COOLANT LEVEL DETECTOR

FUEL LEVEL SENSOR

OIL TEMP. SENSOR

OIL PRESSURE SENSOR

COOLANT TEMP. SENSOR

68

69

575

523

591

590

85

19

15

12

B

C

1-

N

3

L1 
CT

57

LOWER PANEL CONNECTOR

B

C

1-

H

S

15

B

C

1-

C

FIELD

2

6

S

16

AVR

EX
C

ITE
R

P

O

WE
R

AVR

S

EN
S

IN

G

B

C

1-

F

B

C

1-

G

B

C

1-

L

S2

L2 V

O

LT

S

183

17

8

S3

S

TAR

T

2-

WIRE

S

IG

NA
L

L3 V

O

LT

S

B

C

1-

B

B

C

1-

J

BC1-

M

58

59

L1 V

O

LT

S

L3 
CT

L2 
CT

B

C

1-

K

B

C

1-

P

B

C

1-

O

16

18

14

11

7

G

R

O

UND RETUR

N

C

T 

CO
MM
ON

B

C

1-

S

B

C

1-

A

0

0

ML
C

B 

O

PE
N

589

B

C

1-

R

PROG. INPUT 3

A3

2

PROG. INPUT 2

PROG. INPUT 1

GEN. POWER

BATT CHRG FAIL

A1

A2

544

RUPT. TANK

MLCB OPEN

LINE POWER

GROUND RETURN

GROUND RETURN

PROG. INPUT 8

PROG. INPUT 7

PROG. INPUT 5

A7

BC4-4

BC4-5

A5

A4

BC4-2

BC4-6

BC4-3

A8

567
0

0

PROG. RELAY 2

PROG. RELAY 1

N/O

COM

R1

R2

N/C

COM

R3

R4

R5

BC2-2

BC2-12

MAGNETIC RPM SENSOR

SHIELD

79

0

TB4-6

TB4-8

TB4-7

PROG. RELAY 3

N/O

N/C

COM

R6

R7

R8

N/C

R9

PRESSURE # 601

LOW FUEL

BASIN # 447

GEN. FLUID

15A

F1

L1

ES-3

ES-2

SW1

VR1

CB1

CON1-3

CON4-2

CO

N2-1

0

CO

N4-

4

CO

N4-

6

HZ

CON4-1

VM

AM

CON1-2

CON1-1

S

1

6

S

1

5

CON2-6

CON3-14

CON3-4

CON3-3

CON3-2

CON3-1

CON2-14

CON2-13

CON2-7

CON2-2

CON2-4

CON2-5

CON1-9

CON1-10

CON1-6
CON1-7
CON1-8

CON1-5

CON1-4

CON3-7

CON3-6

CON3-5

CON3-9

CON3-8

ES-1

AA

RS232 (Tx)/RS485-

RS232 (DSR)
RS232 (Rx)/RS485+

RS232 (DTR)

D

S

UB-

5

CON3-15

CON2-11

CON2-8
CON2-9

D

S

UB-

4

D

S

UB-

3

D

S

UB-

2

D

S

UB-

1

CON3-10

CON3-13

CON3-12

CON3-11

COMMON

AUT

O

MATI

C

(AVR

)

EX
C

ITATI

ON

ALTERNAT

OR

V

O

LTA

GE

RE

G

ULAT

OR

FIELD B

OOST

R1

D1

POWER

FIELD

4

1

2

6

D2

R2

SENSING

5

3

CO

NTR

O

L B

OX

M

C1

'E'
 PANEL

18 Generac

®

Power Systems, Inc.

Section 6 — Electrical Data

Generac Standby Generator Sets
Wiring Schematic - E Panel – Drawing No. 0D2379V-A

Summary of Contents for 004810-0

Page 1: ...Owner s Manual Standby Generator Models 004810 0 004811 0 POWER SYSTEMS INC This manual should remain with the unit...

Page 2: ...d This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment Generac strongly recommends...

Page 3: ...7 2 1 STANDBY GENERATOR INSTALLATION 7 2 1 1 NFPA Standards 8 2 1 2 Other Published Standards 8 2 2 BASIC STANDBY ELECTRIC SYSTEM 8 2 3 EMERGENCY CIRCUIT ISOLATION METHOD 8 2 4 TOTAL CIRCUIT ISOLATION...

Page 4: ...or is installed operated and serviced in accor dance with the manufacturer s instructions and recommendations Following installation do noth ing that might render the unit unsafe or in non compliance...

Page 5: ...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...

Page 6: ...EMA MG1 22 All prototype tested models have passed three phase symmetrical short circuit test to ensure system protection and reliability 1 3 ENGINE PROTECTIVE DEVICES The standby generator may be req...

Page 7: ...ator per formance and reliability NOTE Appropriate care should be taken in applications where extremely low ambient temperatures are possible to ensure the temperature of the diesel fuel is not allowe...

Page 8: ...ENTS AND RECOMMENDATIONS Diesel Fuel System See Chapter 8 of Engine Generator Standby Electric Power Systems Installer s Guide and Reference Manual part 46622 1 7 GENERATOR AC LEAD CONNECTIONS The ele...

Page 9: ...matic float and equalize control and uses an SCR to maintain proper charge voltage This type of sys tem precisely monitors the charge rate Figure 1 3 The charger is rated at 10 amps DC Figure 1 3 Typi...

Page 10: ...MS available from the American National Standard Institute 1430 Broadway New York N Y 10018 2 2 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Bo...

Page 11: ...ungrounded devices Figure 2 2 Generator Grounding Lug typical 2 6 GENERATOR AC NEUTRAL CONNECTIONS Generac uses an UNGROUNDED AC neutral Grounding is recommended only at the main service entrance If t...

Page 12: ...ed The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire because they generate hydrogen gas The fol lowing procedure are to be followed DO NOT...

Page 13: ...hould be changed after 30 hours of operation The engine is equipped with a mechanical governor Make sure the governor is properly lubricated with clean engine oil 2 9 1 4 Engine Coolant Have the engin...

Page 14: ...NICIAN MAINTENANCE FUNCTIONS 4 1 2 1 After First 30 Hours of Operation Inspect wiring Change engine crankcase oil and oil filter Inspect engine fan belts Inspect battery batteries and cables 4 1 2 2 E...

Page 15: ...ours a Generac Authorized Service Technician should perform a system operational test 4 2 2 INSPECT BATTERY Standby generators installed with automatic transfer switches will crank and start automati...

Page 16: ...repaired or replaced immedi ately by a Generac Authorized Service Technician 4 3 REPAIR PARTS The latter portion of this manual consist of exploded views parts lists and electrical data pertaining to...

Page 17: ...Generac Power Systems Inc 15 Section 5 Installation Generac Standby Generator Sets Installation Diagram Drawing No 0E5195...

Page 18: ...0 17 18 TB1 575 567 19 20 S15 0 5 4 4 4 4 D1 AVR 2 3 162 89 1 14 219 0 2 162 89 R2 CB1 162 49 D2 2 15 220 14 219 15 220 14 219 49 CABLE 15 220 14 219 15 220 89 13 218 0 0 0 0 AVR AUTOMATIC VOLTAGE REG...

Page 19: ...ROWN RED 15 220 CABLE 15 220 14 219 89 13 218 0 0 0 0 0 56 WIRE s 4 13 29 218 0 1 R15 591 14 15 219 220 2 49 150 A1 8 R1 9 162 178 183 S1 3 590 56 56A 57 59 67 89 FUNCTION NEUTRAL FUSED DC NON FUSED D...

Page 20: ...LCB OPEN LINE POWER GROUND RETURN GROUND RETURN PROG INPUT 8 PROG INPUT 7 PROG INPUT 5 A7 BC4 4 BC4 5 A5 A4 BC4 2 BC4 6 BC4 3 A8 567 0 0 PROG RELAY 2 PROG RELAY 1 N O COM R1 R2 N C COM R3 R4 R5 BC2 2...

Page 21: ...WIRE s AUTOMATIC VOLTAGE REGULATOR 60Hz AUTOMATIC VOLTAGE REGULATOR 50Hz ES1 3 098426C HZ L1 MC1 R1 SW1 R2 0A4087 VARIOUS 061945 044213 070202 070042A 0C8481 070042 AA AM AVR D1 D2 ES CB1 VARIOUS 049...

Page 22: ...C INPUT ARD GND GROUND POST VM VOLTMETER 0 15V 12V OR 0 30V 24V AC HOT TB1 LEGEND AC NEUT CHASSIS F1 FUSE 250V GND GND 1 GND GND TB 2 3 1 2 AC NEUT 2 1 L1 2 2 1 TB2 13 35 13B F2 2 13B 1 1 AM COVER GND...

Page 23: ...EL F2 FUSE 32V 12A 4A 12V OR 7A 24V FUSE 32V 12A FUSE 32 F1 FUSE 250V AM DC AMMETER 0 15A LEGEND L1 F1 GND TB2 2 TB1 3 TB1 2 TB1 1 TB2 3 TB2 4 TB2 1 12 AMP 32V F2 0 15V 0 15A 0 30V 4A 7A 250V SLOW BLO...

Page 24: ...22 Generac Power Systems Inc Section 6 Electrical Data Generac Standby Generator Sets Wiring Diagram 3 0L Engine Drawing No 0E2005A...

Page 25: ...Generac Power Systems Inc 23 Section 6 Electrical Data Generac Standby Generator Sets Electrical Schematic 3 0L Engine Drawing No 0E2006A...

Page 26: ...8 TO RADIATOR 19 DRAIN 20 23 20 20 TO FUEL FILTER 20 21 41 11 20 To Fuel 42 40 33 39 32 6 31 12 29 51 37 38 47 52 1 TO OIL 15 34 TO STARTER 51 14 48 52 53 36 PAN 44 46 45 24 Generac Power Systems Inc...

Page 27: ...L 24 030340 30 HOSE 1 4 ID SAE 30R7 25 047411 1 SCREW HHC M6 1 0 X 16 G8 8 26 022473 1 WASHER FLAT M6 1 4 ZINC 27 055414 1 LUG SLDLSS 2 8 X 17 64 CU 28 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 29 022097...

Page 28: ...2 43 9 47 37 12 25 67 19 51 52 22 55 5 5 56 19 55 5 54 62 27 28 53 17 66 56 55 52 20 51 24 67 20 19 21 55 5 5 49 19 49 58 60 59 18 32 33 77 78 83 29 that require insulation Secure as shown 48 39 64 15...

Page 29: ...DUCT REAR TOP 40 0C4375R 1 INSULATION FRONT DUCT ITEM PART NO QTY DESCRIPTION 41 0A5035A 48 SELF ADHESIVE HANGER 3 4 43 0C4375S 2 INSULATION DUCT BOTTOM 44 0C4375J 1 INSULATION DUCT FRONT PANEL 45 0C4...

Page 30: ...28 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Standby Generator Sets Tank Drawing No 0E5125...

Page 31: ...FUEL LEVEL GAUGE 14F 0E4352 1 GASKET ADAPTER PLATE 15 0A1492 1 CAP FUEL FILL 16 0D2670 1 NECK FUEL FILL STANDARD 4 17 063831 1 PLUG STD PIPE 1 25 NPT STEEL SQ HD 18 021178 1 VENT OEM 2 NPT 19 0A7238 1...

Page 32: ...ENSOR 8 UNTIL CONTACT 1 2 TO 3 4 TURN AND TIGHTEN NUT CAUTION TO ENGINE FLYWHEEL HOUS 8 8 36 42 42 8 8 35 37 32 31 30 28 26 9 2 46 1 20 19 27 21 3 3 11 10 2 6 7 5 1 34 17 20 9 TO ENGINE FLYWHEEL 4 22...

Page 33: ...73 2 WASHER FLAT 1 4 M6 ZINC 28 068406 3 SCREW HHC M12 1 75 X 60 G10 9 29 070274 1 KEY SQ 3 8 X 2 3 4 STEEL ITEM PART NO QTY DESCRIPTION 30 087271 1 ASSEMBLY EXCITER 1 25 STACK 31 068404 1 EXCITER FIE...

Page 34: ...6 30 2 18 29 34 27 18 36 18 MOUNTING BASE RIGHT RAIL 14 16 C TO HOSE RADIATOR LOWER LOWER RADIATOR HOSE TURBO CHARGED 21 TO OIL COOLER 35 6 12 23 5 21 Overflow Drain 1 21 TO A 16 RADIATOR 11 24 DRAIN...

Page 35: ...D 30 LONG 24 033437 1 SPACER 41 X 75 X 56 STL ZNC 25 046627 1 CAP RADIATOR 26 084918A 1 HEATER ENG 1000W 120V 27 084427 1 BRACKET HEATER W WELDNUTS 28 047411 4 SCREW HHC M6 1 0 X 16 G8 8 29 022097 4 W...

Page 36: ...2 NPT X 9 BLK IRON 5 039253 4 SCREW HHC M8 1 25 X 20 G8 8 6 052858 4 NUT LOCK FL M8 1 25 7 058943H 1 FLEX EXH 2 X 16 8 059939 1 RAIN CAP 2 37 I D 9 0E5097 1 BLANKET MUFFLER 3 0L VERIZON 7 3 6 5 2 2 1...

Page 37: ...N 19 057759 1 ELBOW RUBBER 90 2 5 ID 20 042561 1 CLAMP HOSE SIZE 36 21 057822 2 CLAMP HOSE SIZE 8 22 064948 1 REDUCER RUBBER 5 8 TO 1 2 23 039294 2 CLAMP HOSE 44 2 31 3 25 24 0D2324 1 LABEL HOT TURBO...

Page 38: ...E DESCRIPTION 29 WIRE 27 32 ALT 1 1 2 UP TO 4 0 500kcmil 28 150 250A FD 3 POLE 1 2 4 0 500kcmil Al 1 2 3 0 500kcmil Cu 29 275 IN LBS 228 IN LBS SCREW TORQUE 31 CABLE 28 31 17 3 600V 25 WIRE SIZE RANGE...

Page 39: ...022287 4 SCREW HHC 1 4 20 X 3 4 G5 22 058318 2 TRANSFORMER CURRENT 150 5 23 022145 4 WASHER FLAT M8 5 16 ZINC 24 022129 4 WASHER LOCK M8 5 16 25 022259 4 NUT HEX 5 16 18 STEEL 26 022142 4 SCREW HHC 5...

Page 40: ...NE OIL SUPPLY TO TURBO HOSE FITTING TO RADIATOR 12 52 43 44 41 45 18 17 48 40 16 33 2 23 7 5 6 22 17 18 47 34 36 CONNECTION 1 1 30 29 46 16 11 50 TO UPPER RADIATOR 35 18 39 20 38 21 18 20 38 Generac P...

Page 41: ...9 0C3759 1 ADAPTER THERMOSTAT 3L HA 30 031919 1 PLUG STD PIPE 3 8 COUNTERSUNK 31 035606 1 SENSOR HI COOLANT SHUTDOWN 32 053667 1 SENDER WATER TEMP 33 0E0561 1 ASSYEMBLY WATER LEVEL SENSOR C E PL 34 02...

Page 42: ...40 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Standby Generator Sets Control Panel Drawing No 0E5158...

Page 43: ...215005 NOT SHOWN 43 0D3243 1 CBL ASSY RS485 E PNL W SEALED 44 0D3471 2 DECAL COVER DEUTSCH RECT ITEM PART NO QTY DESCRIPTION 45 0D3471 2 DECAL COVER DEUTSCH RECT ELECTRONIC GOVERNOR HARNESS IF EQUIPPE...

Page 44: ...FRM M6 1X16 N WA Z JS 13 0C3433A 2 CLAMP BAND 2 5 14 022129 15 WASHER LOCK M8 5 16 15 022145 12 WASHER FLAT 5 16 ZINC 16 039253 3 SCREW HHC M8 1 25 X 20 G8 8 18 042907 12 SCREW HHC M8 1 25 X 16 G8 8 1...

Page 45: ...ET AIR DUCT RH SIDE 3 0A6983 1 BRACKET AIR DUCT LH SIDE 4 022413 4 SCREW HHC 1 4 20 X 1 G5 5 022097 8 WASHER LOCK M6 1 4 6 022473 8 WASHER FLAT 1 4 ZINC 7 024655 4 SCREW HHTT 1 4 20 X 1 CZ 1 5 4 6 7 5...

Page 46: ...10 32 14 0E1779 1 ASSY GOVERNOR CONTROLLER 15 0C7237 1 BRACKET ACTUATOR 16 045757 4 SCREW HHC M6 x 1 0 x 25 17 080534 2 CLEVIS 10 32 18 0D2244M 1 ASSY MAGPICKUP 3 8 24 MALE 19 074908 4 SCREW HHTT M5...

Page 47: ...Generac Power Systems Inc 45 Section 8 Notes Generac Standby Generator Sets...

Page 48: ...46 Generac Power Systems Inc Section 8 Notes Generac Standby Generator Sets...

Page 49: ...Generac Power Systems Inc 47 Section 8 Notes Generac Standby Generator Sets...

Page 50: ...anty coverage or responsibility if your non road diesel engine or a part component thereof has failed due to abuse neg lect improper maintenance or unapproved modifications or the use of counterfeit a...

Page 51: ...time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection...

Page 52: ...l maintenance i e tune ups associated part s adjustments loose leaking clamps installation and start up 4 Use of Non Generac replacement part s will void the warranty in its entirety 5 Any failure cau...

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