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Generac Power Systems 004991-0, Owner'S Manual

The Generac Power Systems 004991-0 Owner's Manual is a comprehensive guide that provides detailed instructions and important safety information for operating and maintaining your generator. Download this manual for free on manualshive.com, ensuring you have all the necessary knowledge to maximize the performance and longevity of your Generac product.

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CIRCUIT BREAKER (EXCITATION)

BULKHEAD CONNECTOR 1 (ENGINE)

AUTOMATIC VOLTAGE REGULATOR
BRUSH ASSEMLY (GENERATOR)

FUSE, BAT. POWER (15A AGC TYPE)

BATTERY CHARGER

CIRCUIT BREAKER (OUTPUT)

DIODE [FIELD BOOST]

CB1 -
CB2 -

F1 -

D1 -

BC1 -

LEGEND:

BA -

AVR -

B/C -

SET EXERCISER SWITCH
TERMINAL BLOCK 1

AUTO/OFF/MANUAL SWITCH

FUSE, B/C (4A AGC TYPE)

NEUTRAL BLOCK

INTERCONNECT. TERMINAL BLOCK

TRANSFORMER 2 (6 VA 240/16 VAC)

TRANSFORMER 1 (56 VA 240/16 VAC)

SW2 -
TB1 -

TR2 -

TR1 -

SW1 -

LEGEND {CONT.]:
F2 -

NB -
RL1 -

ICT -

RELAY 1

B/C

19

4

NEUTRAL

CUSTOMER CONNECTION

44

NO

 - REM

O

TE 

START

UTILITY FR

O

M T

/S

W

C  - REM

O

TE 

START

UTILITY FR

O

M T

/S

W

TRAN

SFER RELAY 

CO

IL

TRAN

SFER RELAY 

CO

IL

TRANSFER SWITCH

15

E

N2

N1

13A

19

4

23

183

17

8

13

13

A

0

14

14A

15

IC

13
13

11

13A

15A

239

1b

1a

15

1

15

2a

2b

1

15

224

14

14

22

5

OA

BA

66

33

44

22

11

STATOR

TR1

17

8

183

19

4

17

8

N1

225A
224A

178

178

44

4
2

6

5

55

11

N2

1

N1

N2

23
66

23
66

11

BC1

0

15A

225

224

15E

239

14

14A

0A

13

0
0

55

0
0

44

6

4

1

7

10

11

12

9

8

4
5
6

2
3

2

1

CB2

14

55

225
224

TR2

TB1

14

0

0

0

AVR

14

55

0

0

162

2

0

4

4

6

5

4

3

44

6

11

4

162

1

1

2

2

3

2

1

4

5

6

85

87

1

2

1

6

5

4

2

1

2

3

1

CB1

NB

F2

RL1

F1

SW2

S

W1

D1

24 Generac

®

Power Systems, Inc.

Section 7 - Electrical Data

Generac Liquid-cooled Generators
Wiring Diagram — Engine — Drawing No. 0E8115

Summary of Contents for 004991-0

Page 1: ...R SYSTEMS INC Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Number 004991 0 ...

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 Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing other users to properly ...

Page 3: ... Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 13 3 3 Manual Transfer and Startup 14 3 4 Engine Governor Adjustments...

Page 4: ...e that the gener ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient con...

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 power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below a...

Page 6: ...ive moisture dust dirt lint construction grit and cor rosive vapors If a transfer switch is not included one may be pur chased separately from a Generac Authorized Dealer 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with a transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors UTILITY power source voltage Should that voltage dro...

Page 7: ...ESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close the engine shuts down automatically and the low oil pressure LED is turned ON Figure 1 4 NOTE The Low Oil Pressure High Coolant Temperature and Low Coolant Level are not monitored for the first 10 ...

Page 8: ...ady running when the low battery condition occurs the engine will continue to run as long as possible Battery voltage is NOT monitored during the crank cycle 1 7 8 ALARM RESET If the engine control board shuts down the generator for any of the above reasons the engine remains stopped until the alarm is cleared by placing the AUTO OFF MANUAL switch into the OFF position 1 7 9 DC FUSE These fuses ar...

Page 9: ...er cubic foot Actual fuel consump tion obtained may vary depending on such vari ables as applied load ambient temperature engine conditions and other environmental fac tors 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP vapor follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fue...

Page 10: ... Circuit Isolation Method in the installation manual Part No 079699 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power The critical essential loads may need to be grouped together and wired into a sepa rate emergency distribution panel This generator can be installed in conjunction with a standard Generac GTS type transfer switc...

Page 11: ...se blowing or drift ing consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it This genset must be installed on a level surface The base frame must be level within 1 2 inch all around Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow five feet of space on all sides ...

Page 12: ...ROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground f...

Page 13: ... handles 2 10 1 VENTED BATTERIES The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following proce dures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thor oughly and immediately with wate...

Page 14: ... system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Specifications Section 1 10 and Coolant Section 1 15 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys...

Page 15: ...l overload If the fuse has melted open because of an overload engine cranking and startup cannot occur If the fuse needs to be replaced use only an identical 15 amp replacement fuse Type AGC 3 2 4 4 0 AMP INLINE FUSE This fuse protects the battery charger against electri cal overload If the fuse needs to be replaced use only an identical 4 amp replacement fuse type AG NOTE This fuse will not remov...

Page 16: ...erator engine run at no load for a few minutes to stabilize internal unit temperatures On the generator console set the AUTO OFF MANUAL switch to OFF Wait for engine to come to a complete stop For transfer to utility position refer to the Owner s Manual of the particular transfer switch Turn on the utility power supply to the transfer switch using whatever means provided such as a utility main lin...

Page 17: ...per operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See Section 6 for installation drawings and vent locations The exhaust system parts from this product get extremely hot and remain hot after shutdown High grass weeds brush leaves etc must re...

Page 18: ...eck hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness 4 5 5 CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels in Section 4 4 4 5 6 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for fuel oil or coola...

Page 19: ... plugs as necessary See Section 6 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule Section 6 for recommended in...

Page 20: ...ER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery ...

Page 21: ...oving the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to ensure it is ready to operate and carry the load when required and to identify any poten...

Page 22: ...ection level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check th...

Page 23: ...components and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the e...

Page 24: ...ugs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 De...

Page 25: ...Generac Power Systems Inc 23 Section 6 Installation Diagram Generac Liquid cooled Generators Installation Diagram Drawing No 0E8422 A ...

Page 26: ...OTE START UTILITY FROM T SW C REMOTE START UTILITY FROM T SW TRANSFER RELAY COIL TRANSFER RELAY COIL TRANSFER SWITCH 15E N2 N1 13A 194 23 183 178 13 13A 0 14 14A 15 IC 13 13 11 13A 15A 239 1b 1a 15 1 15 2a 2b 1 15 224 14 14 225 OA BA 66 33 44 22 11 STATOR TR1 178 183 194 178 N1 225A 224A 178 178 44 4 2 6 5 55 11 N2 1 N1 N2 23 66 23 66 11 BC1 0 15A 225 224 15E 239 14 14A 0A 13 0 0 55 0 0 44 6 4 1 7...

Page 27: ...OIL MP1 14 766 765 770 767 766 771 767 768 769 767 770 765 766 N C 771 765 0 6 86 23 66 0 0 C1 15E 14A 225 239 225 239 224 15A 15E 14A 2 8 10 12 11 9 3 5 4 7 6 12 14 13 1 7 10 11 9 8 0 14 13 0 0A 0 66 85 SM GND1 BLK RED FS 0 85 85 14 0 0 0 0A GND2 0 13 0 0 HCT WLS ALT 0 0 769 PCB J2 767 765 224 15A N C PCB J1 768 766 2 4 3 5 1 7 8 5 6 2 3 4 1 23 86 56 14 0 13 13 BAT 13 56 0 16 13 13 16 CC JB 14 14...

Page 28: ...WITCH AUTO OFF MANUAL FUSE B C 4A AGC TYPE TERMINAL BLOCK INTERCONNECT TRANSFORMER 1 56 VA 240 16 VAC NEUTRAL BLOCK LEGEND CONT RL1 SW1 SW2 TR1 NB F2 ICT F1 RELAY 1 2 4 3 5 6 TRANSFER SWITCH 5 CUSTOMER CONNECTION 120 240V 1 PHASE CB1 E1 NB 00 DPE AS 2 CONNECTION N2 E3 N1 23 194 183 178 CB2 11 44 162 N1 N2 D1 BA 55 AR 4 6 1 66 14 1 194 178 183 15 ICT N2 225A 183 178 23 194 224A TR1 N1 15 N1 SW1 224...

Page 29: ... RUN POWER JUNCTION 2 ON PCB STARTER MOTOR MAGNETIC PICK UP 50 WATT RESISTOR IGNITION COIL IGNITION MODULE 765 771 N C 766 765 770 767 769 768 767 771 766 767 770 765 766 14 6 0 86 23 66 0 0 14A 15E 15A 224 239 225 239 225 14A 15E C1 2 8 9 11 12 10 6 7 4 5 3 12 13 14 1 8 9 11 10 7 0 14 13 0A 0 0 66 85 GND1 0 85 85 0 14 0 0A 0 GND2 13 WLS 0 0 766 768 PCB J1 N C 15A 224 765 767 PCB J2 769 5 3 4 2 1 ...

Page 30: ...16 6 7 5 19 16 30 27 35 34 36 33 27 29 22 20 32 38 18 31 20 21 TO STARTER STARTER BOLT TO ENGINE BLOCK 18 TO 11 1 12 10 14 REAR BEARING 15 37 13 CARRIER 3 4 16 2 28 Generac Power Systems Inc Section 8 Exploded Views and Parts Generac Liquid cooled Generators Mounting Base Drawing No 0E8084 A ...

Page 31: ...OCK M8 5 16 22 045771 1 NUT HEX M8 1 25 G8 YEL CHR 23 051756 1 SCREW HHC M10 1 5 X 20 G8 8 24 046526 1 WASHER LOCK M10 25 022131 1 WASHER FLAT 3 8 M10 ZINC 26 055934M 1 CLAMP VINYL 75 X 343 Z 27 049820 2 NUT HEX LOCK M8 1 25 NY INS 28 059473 1 HOLD DOWN BATTERY 29 061902 1 HOLD DOWN BATTERY 30 058665 REF BATT 12VDC 90 AH 27F 31 038804D 1 CABLE BATT RED 4 X 20 00 32 038805J 1 CABLE BATT BLK 1 X 30 ...

Page 32: ...5 54 TO A SECURE AS SHOWN REQUIRE INSULATION TYPICAL OF ROOF PANEL THAT 4 RADIATOR 53 35 33 4 44 34 55 55 53 4 32 36 4 57 5 5 5 5 18 4 4 29 A 22 9 8 12 13 16 17 20 52 54 B 53 7 11 56 5 5 6 6 5 10 14 15 19 51 21 58 28 1 16 42 40 17 18 23 57 5 5 5 5 41 17 4 2 PLCS TO B 10 39 26 18 Section 8 Exploded Views and Parts Generac Liquid cooled Generators Enclosure Drawing No 0E8439 E ...

Page 33: ...PPING 91 LG 26 0E7869 2 BRACKET STIFFENING BACK 27 0E8001 1 MUFFLER BOX 28 0E8060 1 ROOF W GAS SPRING MNT 3 0L FRD 29 0E7966 1 BRACE FRONT TOP 30 0D3037A 1 LATCH 1 4 TURN NONLOCKING 31 0C7781 2 PAWL DOOR HSB 32 0E7794 1 SUPPORT LH SIDE 33 0E8052 1 MUFFLER BOX TOP 34 0D3037 1 LATCH QUARTER TURN LOCKING 35 0E8007 1 POST CORNER LH FRONT 36 0E8008 1 POST CORNER RH FRONT 37 0E7992 1 BRACE FRONT BOTTOM ...

Page 34: ...32 Generac Power Systems Inc Section 8 Exploded Views and Parts Generac Liquid cooled Generators Control Panel Drawing No 0E7118 G ...

Page 35: ...ASE QN CIRCUIT BREAKER 33 0E7539A 1 DECAL TB1 HSB CONTROL PANEL ITEM PART NO QTY DESCRIPTION 34 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V 35 0E7252 1 BRACKET CB 221 5 X 102 36 0C1229 1 DECAL WARNING ELECTRICAL SHOCK 37 0C1127 1 DECAL AVR COVER 38 0A1441B 1 COVER PLATE AVR 39 0E7128 1 HARNESS CNTRL PNL 3 0L FORD NOT SHOWN 40 0E7358 8 SCREW PPPH HI LO 4 24 X 3 8 41 074908 6 SCREW HHTT M5 0 8 X 10 BP 4...

Page 36: ...Section 8 Exploded Views and Parts Generac Liquid cooled Generators Engine Drawing No 0E8121 C 34 Generac Power Systems Inc ...

Page 37: ...SSURE 10PSI 2POL ITEM PART NO QTY DESCRIPTION 39 050873A 1 PLUG PIPE 1 4 CSK W VIBRA SL 40 031919 1 PLUG STD PIPE 3 8 COUNTER SUNK 41 022145 6 WASHER FLAT 5 16 M8 ZINC 42 030795 6 SCREW HHC 5 16 18 X 1 G5 43 051756 5 SCREW HHC M10 1 5 X 20 G8 8 44 046526 6 WASHER LOCK M10 45 0A1232A 1 ASSEMBLY D C ALTERNATOR 46 0A7801B 1 PULLEY POLY V 82 OD 47 045772 1 NUT HEX M10 1 5 G8 YEL CHR 48 022403 2 SCREW ...

Page 38: ...26 24 25 21 3 A 13 1 15 19 22 TO THERMOSTAT HOUSING 10 5 10 20 10 4 16 16 2 14 8 15 7 14 18 6 9 17 14 Section 8 Exploded Views and Parts Generac Liquid cooled Generators Radiator Drawing No 0E8102 D 36 Generac Power Systems Inc ...

Page 39: ...14 058443 17 SCREW CRIMPTITE 1 4 20 X 5 8 15 0C2454 5 SCREW TH FRM M6 1X16 N WA Z JS 16 052250 2 TAPE FOAM 1 X 1 27 LG 17 048031C 1 CLAMP HOSE BAND 1 4 18 029032 1 HOSE 9 32 ID 30 LG 19 0A2111 1 SCREW SWAGE 10 32 X 5 16 Z YC 20 0E7640A 1 RADIATOR SUPPORT R H SIDE 21 035461 1 BARBED STR 1 4NPT X 3 8 22 065852 1 SPRING CLIP HOLDER 37 62 23 051756 4 SCREW HHC M10 1 5 X 20 G8 8 24 022131 8 WASHER FLAT...

Page 40: ...5 1 6 VALVE COVE TO R H 13 41 40 11 42 9 8 12 6 15 28 13 27 31 14 19 29 30 32 B TO B 13 36 37 38 20 19 18 35 34 MANIFOLD INTAKE TO 44 43 25 22 6 1 39 33 Section 8 Exploded Views and Parts Generac Liquid cooled Generators Fuel System Drawing No 0E8122 E ...

Page 41: ...OR BOSCH 40 GOVERNOR 21 040105 1 HOSE COOL 2IN ID 20R4 2 LG 22 0E6382B 1 VENTURI HOLDER W 40MM ACTUATOR 23 0F2119 2 O RING 45 63 ID X 2 62 WIDTH 24 0E6376B 1 VENTURI 28 ID THROTTLE W CHOK 25 042561 2 CLAMP HOSE 36 1 88 2 75 26 057822 1 CLAMP HOSE 8 53 1 00 27 0E7929 1 BASE AIR CLEANER PLATE 28 0A4637 1 FILTER AIR 11 5 CA326 29 0E6406 1 HOLDER VENTURI 30 0E7702 1 HOLD DOWN AIR CLEANER 31 0A4632A 1 ...

Page 42: ...0 Generac Power Systems Inc 4 15 7 17 8 7 1 18 20 31 30 5 21 19 LEADS 6 2 14 12 24 9 22 23 13 3 10 13 11 Section 8 Exploded Views and Parts Generac Liquid cooled Generators Alternator Drawing No 0E5146 B ...

Page 43: ...TUD M14 2 0 X 540 G5 ZINC 3 9L CHRYSLER 10 043123 4 WASHER LOCK M14 11 051779 4 NUT HEX M14 2 0 G8 YEL CHR 12 0E7587 1 ASSY BRUSH HOLDER 390 HSB 13 023365 5 WASHER SHAKEPROOF INT 8 14 092980 4 SCREW PPHM M4 0 7 X 25 15 052625 4 SCREW SHC M10 1 5 X 35 G12 9 16 0A2602 1 WASHER FLAT 688 ID X 3 25 OD 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A2601 1 SCREW HHC M16 2 0 X 45 G8 8 19 0E7226 1 GUARD STATOR 390 ...

Page 44: ... 052860 4 NUT TOP LOCK FL M12 1 75 15 052891 4 SCREW HHC M12 1 75 X 80 G8 8 16 0E8816 2 EXHAUST FLANGE 2 PIPE 17 051769 4 WASHER LOCK M12 18 0E0170 1 EXHAUST BLANKET 705MM 19 049808 8 WASHER FLAT M12 20 024114 6 NUT HEX 5 16 24 STEEL 21 080762 2 BOLT U 3 8 16 X 2 62 22 0E8726 2 STRAP MUFFLER 23 039288 1 SCREW HHC M8 1 25 X 55 G8 8 24 0F0170A 1 EXHAUST BLANKET 875MM 25 082361 REF INSULATION EXAUST ...

Page 45: ...Section 9 Notes Generac Liquid cooled Generators Generac Power Systems Inc 43 ...

Page 46: ...44 Generac Power Systems Inc Section 9 Notes Generac Liquid cooled Generators ...

Page 47: ...Generac Power Systems Inc 45 Section 9 Notes Generac Liquid cooled Generators ...

Page 48: ...ps installation and start up 3 Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 4 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rent...

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