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Generac Power Systems 004812-0, Owner'S Manual, Page: 92 / 94

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Generac Power Systems 004812-0 Owner'S Manual Download Page 92

Summary of Contents for 004812-0

Page 1: ...Owner s Manual Standby Generator Models 004812 0 004813 0 POWER SYSTEMS INC This manual should remain with the unit...

Page 2: ...explosion hazard 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 We strongly...

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: ...gen erator is installed operated and serviced in accor dance with the manufacturer s instructions and recommendations Following installation you must not do anything that might render the unit unsafe...

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 p...

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: ...ormance 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 allowed to fall...

Page 8: ...MENTS 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 el...

Page 9: ...ircuits and an automatic current limiter design The unit is equipped with automatic float and equalize control and uses an SCR to maintain proper charge voltage This type of sys tem precisely monitors...

Page 10: ...CTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYS TEMS available fro...

Page 11: ...ected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical 2 6 GENERATOR AC NEUTRAL CONNECT...

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: ...such as the utility source main line circuit break er Set the transfer handle to its Utility normal position with load circuits connected to the utility power supply Set the standby generator s main...

Page 15: ...Retorque fan bolts Drain and refill gearbox If so equipped contact sales for availability 4 1 2 4 Every Two Years Replace all rubber hoses Replace engine fan belts Inspect the Standby Generator Syste...

Page 16: ...o not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If you spill the fluid flush the affected area imme...

Page 17: ...esponds to an identical number on the exploded view drawing 4 3 1 HOW TO ORDER PARTS To order a replacement part locate the part in the applicable exploded view Contact your Generac Authorized Service...

Page 18: ...16 Generac Power Systems Inc Section 5 Installation Generac Standby Generator Sets Installation Diagram Models 004812 0 004813 0 Drawing No 0E3700...

Page 19: ...Generac Power Systems Inc 17 Section 5 Installation Generac Standby Generator Sets Installation Diagram Models 004812 0 004813 0 Drawing No 0E3700...

Page 20: ...69 14 15 150 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...

Page 21: ...WIRE COLOR BROWN 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...

Page 22: ...E 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 MAGNE...

Page 23: ...MATIC 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 049939 025192 0...

Page 24: ...200A E1 TO E3 240V 120 240V 1 PHASE CUSTOMER CONNECTION E3 TO 00 E1 TO 00 120V LEGEND CT2 CB2 NB B S1 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED W W X T V U S N P R Q O J L M K 0 178 S2 S3...

Page 25: ...R ARMATURE TP THERMAL PROTECTOR AUTO RESET LEGEND BRUSHLESS SERIES 4 WIRE DISPLACED PHASE WINDING VOLTAGE CODE A E1A AS 00 00 CUSTOMER CONNECTION 120 240V 1 PHASE 60HZ E1 CT1 K L l k 11 11 57 S1 22 CT...

Page 26: ...24 Generac Power Systems Inc Section 6 Electrical Data Generac Standby Generator Sets Wiring Diagram 3 9L Models 004812 0 004813 0 Drawing No 0E2647V A...

Page 27: ...OLENOID FUEL ENGINE HEATER GLOW PLUG SWITCH RUPTURE BASIN FLOAT GROUND 218 RED D 85 601 219 3 0 0 16 2 1 157 69 2 1 0 218 575 218 590 16 591 218 N C N O 0 GREEN BLACK WHITE 6 567 575 590 7 8 120VAC UT...

Page 28: ...TL 18 024310 1 PLUG STD PIPE 1 2 STEEL SQ HD 19 0536210098 1 ASSEMBLY GROUNDWIRE 10 3 8 20 043107 1 SCREW HHC M8 1 25 X 25 G8 8 21 022145 1 WASHER FLAT 5 16 M8 ZINC 22 022129 1 WASHER LOCK M8 5 16 23...

Page 29: ...M10 1 5 X 20 G8 8 6 038804T 1 CABLE BATT RED 1 X 31 00 7 046526 1 WASHER LOCK M10 8 022131 1 WASHER FLAT 3 8 M10 ZINC 9 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 10 075763 1 BOOT BATTERY CABLE USED ON...

Page 30: ...11 8 27 1 2 3 4 1 BASE FRAME 67 19 57 71 23 52 72 51 71 54 62 31 55 5 56 28 19 55 5 28 53 17 56 60 20 55 5 5 5 12 9 59 35 59 14 13 24 73 69 18 58 20 19 75 19 34 33 32 78 79 43 80 81 48 64 82 29 15 66...

Page 31: ...SULATION DUCT FRONT PANEL ITEM PART NO QTY DESCRIPTION 45 0C3157D 2 INSULATION REAR DUCT 47 0C3157F 1 INSULATION REAR PANEL 48 0C3157G 1 INSULATION REAR DUCT TOP 49 0C3157H 1 INSULATION FRONT ROOF TOP...

Page 32: ...30 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Standby Generator Sets Tank Models 004812 0 004813 0 Drawing No 0D5400V B...

Page 33: ...CHESTER 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...

Page 34: ...OF INNER WALL WITH 10 18 17 20 AC NEUT N AC HOT A G 28 G1 E4 E OUTSIDE TOP LOCATED ON 33 1 10 16 13 30 9 14 15 23 COVER GND STRAP STRAP GND H 19 23 19 2 USED AT LOCATIONS B D HEAT SHRINK TUBING TO BE...

Page 35: ...BLOCK TERM JUMPER FOR S142 542 17 022158 4 NUT HEX 10 32 STEEL 18 022152 4 WASHER LOCK 10 19 022097 3 WASHER LOCK M6 1 4 20 036934 4 SCREW PPHM 10 32 X 5 8 21 0D3633 1 DECAL BATTCHRG 12 24V WIRING 22...

Page 36: ...34 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Standby Generator Sets Radiator Models 004812 0 004813 0 Drawing No 0E3404 D...

Page 37: ...52250 1 TAPE FOAM 1 X 1 220 LG 31 0E4162 1 CAP RADIATOR 20 PSI 32 0E2671 2 RH LH SIDE AIR DUCT 3 9L MITSU ITEM PART NO QTY DESCRIPTION 33 0E2673 2 TOP BOTTOM AIR DUCT 3 9L MITSU 34 0A2110 4 SCREW SWAG...

Page 38: ...CREW SHC M10 1 25 X 25 G12 9 ITEM PART NO QTY DESCRIPTION 11 022145 18 WASHER FLAT 5 16 ZINC 12 022129 12 WASHER LOCK M8 5 16 13 022237 3 WASHER LOCK 3 8 14 0C4170 2 BRACKET EXHAUST SHIELD 15 0C3094 1...

Page 39: ...8 9 022131 10 WASHER FLAT 3 8 M10 ZINC 10 052859 4 NUT LOCK FL M10 1 50 ITEM PART NO QTY DESCRIPTION 11 046526 6 WASHER LOCK M10 12 0E2206 1 INSERT RUBBER REDUCER 3 X 2 25 13 051756 6 SCREW HHC M10 1...

Page 40: ...38 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Standby Generator Sets Circuit Breaker Models 004812 0 004813 0 Drawing No 0E3667 A...

Page 41: ...UNT S ED 390S B 0D5620 1 COVER CB TERMINALS S ED 3P C 022097 11 WASHER LOCK M6 1 4 D 022287 8 SCREW HHC 1 4 20 X 3 4 G5 E 022471 4 NUT HEX 8 32 STEEL F 022264 4 WASHER LOCK M4 G 038150 8 WASHER FLAT 8...

Page 42: ...40 Generac Power Systems Inc Section 7 Exploded Views and Parts Lists Generac Standby Generator Sets Engine Parts Models 004812 0 004813 0 Drawing No 0E3670 A...

Page 43: ...7 057642 12 SCREW HHC M10 1 5 X 40 G8 8 28 022131 14 WASHER FLAT 3 8 M10 ZINC 29 043107 4 SCREW HHC M8 1 25 X 25 G8 8 30 022129 8 WASHER LOCK M8 5 16 31 022145 4 WASHER FLAT 5 16 M8 ZINC 32 046579 4 S...

Page 44: ...OUND T 13717 NOTE 6 10 11 35 34 33 36 32 30 31 26 28 29 27 12 3 20 49 19 21 45 48 45 5 2 18 4 9 46 16 17 13 39 15 22 14 44 38 24 23 25 43 38 22 40 42 41 42 Generac Power Systems Inc Section 7 Exploded...

Page 45: ...RING 15 23 068115 1 PANEL LOWER 15 24 043123 4 WASHER LOCK M14 25 051779 4 NUT HEX M14 2 0 G8 YEL CHR 26 052259 2 WASHER FLAT M12 27 051769 3 WASHER LOCK M12 28 068406 3 SCREW HHC M12 1 75 X 60 G10 9...

Page 46: ...50V 082404 25 OHM 25W 75 OHM 25W P N 086266 P N 083364 50 OHM 25W P N 057405 5 OHM 25W P N 048352 0 300V 0 300V 0 600V 0 300V 0 300V 0 600V 0 300V 0 300V 0 300V METER RANGE VOLTAGE 070043 070043 07004...

Page 47: ...SHOWN 43 0D3243 1 CBL ASSY RS485 E PNL W SEALED 44 0D3471 2 DECAL COVER DEUTSCH RECT 45 0D3471 2 DECAL COVER DEUTSCH RECT ELECTRONIC GOVERNOR HARNESS IF EQUIPPED ITEM PART NO QTY DESCRIPTION 46 0C514...

Page 48: ...T X 8 6 0E3298 1 REDUCER 2 5 TO 3 COUPLER 7 057646C 1 FLEX EXH 2 5 X 15 44 LONG 8 0E2668 1 ELBOW EXHAUST TURBO OUTLET 9 0E3495 3 SCREW SHC M10 1 25 X 25 G12 9 10 022237 3 WASHER LOCK 3 8 10 9 7 6 4 SU...

Page 49: ...BLOCK HEATER 5 057822 4 CLAMP HOSE 8 53 1 00 6 047411 4 SCREW HHC M6 1 0 X 16 G8 8 7 022473 4 WASHER FLAT 1 4 M6 ZINC 8 022097 4 WASHER LOCK M6 1 4 9 049813 2 NUT HEX M6 1 0 G8 YEL CHR USED ON R VOLTA...

Page 50: ...12 AWG X 8 LONG 3 022206 1 FITTING CONDUIT STRAIGHT 3 8 48 Generac Power Systems Inc 3 1 2 BLACK WHITE GRD GND GND AC NEUT AC NEUT AC HOT AC HOT POS 34 0D3514 0D3733 Section 7 Exploded Views and Parts...

Page 51: ...Generac Power Systems Inc 49 Section 8 Notes Generac Standby Generator Sets...

Page 52: ...50 Generac Power Systems Inc Section 8 Notes Generac Standby Generator Sets...

Page 53: ...Generac Power Systems Inc 51 Section 8 Notes Generac Standby Generator Sets...

Page 54: ...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 55: ...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 56: ...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...

Page 57: ......

Page 58: ...A 0D5618 1 PLATE CB MOUNT S ED 390S B 0D5620 1 COVER CB TERMINALS S ED 3P C 022097 11 WASHER LOCK M6 1 4 D 022287 8 SCREW HHC 1 4 20 X 3 4 G5 E 022471 4 NUT HEX 8 32 STEEL F 022264 4 WASHER LOCK M4 G...

Page 59: ...E FLYWHEEL 37 27 TO ENGINE TORQUE ITEM 6 24 FT LB AND USE THREAD LOCKING COMPOUND T 13717 NOTE 6 10 11 35 34 33 36 32 30 31 26 28 29 27 12 3 20 49 19 21 45 48 45 5 2 18 4 9 46 16 17 13 39 15 22 14 44...

Page 60: ...2 12 SCREW HHC M10 1 5 X 40 G10 9 22 068113 1 CARRIER REAR BEARING 15 23 068115 1 PANEL LOWER 15 24 043123 4 WASHER LOCK M14 25 051779 4 NUT HEX M14 2 0 G8 YEL CHR 26 052259 2 WASHER FLAT M12 27 05176...

Page 61: ......

Page 62: ...5 E PNL W SEALED 44 0D3471 2 DECAL COVER DEUTSCH RECT 45 0D3471 2 DECAL COVER DEUTSCH RECT ELECTRONIC GOVERNOR HARNESS IF EQUIPPED 46 0C5141 2 CONN DEUTSCH GASKET 8 12 POS DT 50 022155 14 WASHER LOCK...

Page 63: ......

Page 64: ...14D 097962 4 SCREW SHC M6 1 0 X 25 G12 9 IN KIT 0G8108 14E 0E4351 1 GASKET ROCHESTER FUEL LEVEL GAUGE 14F 0E4352 1 GASKET ADAPTER PLATE 15 0A1492 1 CAP FUEL FILL 16 0D2670 1 NECK FUEL FILL STANDARD 4...

Page 65: ...MOUNTING TO LOWER RADIATOR HOSE TO THERMOSTAT HOUSING 5 3 8 9 7 2 5 5 4 6 1 5 BASE 7 8 6...

Page 66: ...ATER W WELDNUTS 3 050967 1 HOSE 5 8 ID RIA 250F 24 LG 4 0A6283 1 HOSE PREFORMED BLOCK HEATER 5 057822 4 CLAMP HOSE 8 53 1 00 6 047411 4 SCREW HHC M6 1 0 X 16 G8 8 7 022473 4 WASHER FLAT 1 4 M6 ZINC 8...

Page 67: ......

Page 68: ...HOSE 5 5 62 62 30 052250 1 TAPE FOAM 1 X 1 220 LG 31 0E4162 1 CAP RADIATOR 20 PSI 32 0E2671 2 RH LH SIDE AIR DUCT 3 9L MITSU 33 0E2673 2 TOP BOTTOM AIR DUCT 3 9L MITSU 34 0A2110 4 SCREW SWAGE 1 4 20 X...

Page 69: ...9 2 8 5 7 2 RED 6 4 1 TO FLYWHEEL HOUSING BLACK OLENOID TO STARTER 2 RED 4 1 4 2...

Page 70: ...E BATT BLK 1 X 18 00 4 065314C 1 JUMPER CABLE 33 IN 5 051756 1 SCREW HHC M10 1 5 X 20 G8 8 6 038804T 1 CABLE BATT RED 1 X 31 00 7 046526 1 WASHER LOCK M10 8 022131 1 WASHER FLAT 3 8 M10 ZINC 9 025507...

Page 71: ......

Page 72: ...10 1 5 X 20 G8 8 15 022131 3 WASHER FLAT 3 8 M10 ZINC 16 046526 2 WASHER LOCK M10 17 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 18 024310 1 PLUG STD PIPE 1 2 STEEL SQ HD 19 0536210098 1 ASSEMBLY GROUNDWI...

Page 73: ......

Page 74: ...5 PPHTC SCREW M4 2 X 16 16 023827 2 BLOCK TERM JUMPER FOR S142 542 17 022158 4 NUT HEX 10 32 STEEL 18 022152 4 WASHER LOCK 10 19 022097 3 WASHER LOCK M6 1 4 20 036934 4 SCREW PPHM 10 32 X 5 8 21 0D36...

Page 75: ......

Page 76: ...3 8 16 X 3 4 G8 8 NZ 26 071623 12 SCREW SHC M10 1 5 X 55 G12 9 27 057642 12 SCREW HHC M10 1 5 X 40 G8 8 28 022131 14 WASHER FLAT 3 8 M10 ZINC 29 043107 4 SCREW HHC M8 1 25 X 25 G8 8 30 022129 8 WASHE...

Page 77: ......

Page 78: ...2 25 3 125 8 049814 4 SCREW HHC M10 1 5 X 25 G8 8 9 022131 10 WASHER FLAT 3 8 M10 ZINC 10 052859 4 NUT LOCK FL M10 1 50 11 046526 6 WASHER LOCK M10 12 0E2206 1 INSERT RUBBER REDUCER 3 X 2 25 13 051756...

Page 79: ......

Page 80: ...SIDE SUPPORT 57 0C3157R 1 INSULATION FRONT BRACE TOP 58 0C3157S 1 INSULATION REAR PANEL 59 0C3157T 2 INSULATION REAR CORNER POSTS 5 60 0C2643 2 DUCT DOOR GEN 2000 61 078115 48 WASHER SELF LOCKING DOME...

Page 81: ...10 9 7 6 4 SUPPLY 3 NPT NIPPLE CUSTOMER TO 8 1 2 4 5 3...

Page 82: ...3 059940 1 RAIN CAP 3 50 3 69 4 059936 2 ELBOW 90 D 3 NPT 5 059941 1 NIPPLE TOE 3 NPT X 8 6 0E3298 1 REDUCER 2 5 TO 3 COUPLER 7 057646C 1 FLEX EXH 2 5 X 15 44 LONG 8 0E2668 1 ELBOW EXHAUST TURBO OUTLE...

Page 83: ......

Page 84: ...3 00 3 19 9 055978 2 BOLT U 3 8 16 X 3 25 10 0E3495 3 SCREW SHC M10 1 25 X 25 G12 9 11 022145 18 WASHER FLAT 5 16 ZINC 12 022129 12 WASHER LOCK M8 5 16 13 022237 3 WASHER LOCK 3 8 14 0C4170 2 BRACKET...

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Page 87: ...B 4 TB4 7 TB4 6 TB4 8 DSUB 2 DSUB 1 CON3 4 CON2 6 CON2 5 CON2 4 CON3 3 CON3 2 CON3 14 CON3 1 CON4 1 CON4 2 CON2 13 CON2 7 CON2 14 CON2 2 SENSING 5 3 S16 S15 CON4 4 CON2 10 CON4 6 19 R4 PROG RELAY 2 PR...

Page 88: ...CY STOP BUTTON CHARGE ALT EXCITER DIODE FIELD BOOST DIODE AVR CIRCUIT BREAKER AUDIBLE ALARM AUTOMATIC VOLTAGE REGULATOR ES1 3 D1 HZ L1 D2 ES CB1 AVR AM AA AMMETER 56 56A 57 59 67 89 CONTROL BROWN SIGN...

Page 89: ......

Page 90: ...R FLUID BASIN STARTER MOTOR BATTERY ALTERNATOR DC SOLENOID FUEL ENGINE HEATER GLOW PLUG SWITCH RUPTURE BASIN FLOAT GROUND 218 RED D 85 601 219 3 0 0 16 2 1 157 69 2 1 0 218 575 218 590 16 591 218 N C...

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Page 93: ...T TRANSFORMER CB2 CIRCUIT BREAKER 100A AS ALTERNATOR STATOR CB1 CIRCUIT BREAKER 200A E1 TO E3 240V 120 240V 1 PHASE CUSTOMER CONNECTION E3 TO 00 E1 TO 00 120V LEGEND CT2 CB2 NB B S1 NOT USED NOT USED...

Page 94: ...XCITER FIELD TWS TWO WIRE START EA BRUSHLESS EXCITER ARMATURE TP THERMAL PROTECTOR AUTO RESET LEGEND BRUSHLESS SERIES 4 WIRE DISPLACED PHASE WINDING VOLTAGE CODE A E1A AS 00 00 CUSTOMER CONNECTION 120...

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