Generac Power Systems 005308-0 Owner'S Manual Download Page 32

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Section 8 — Electrical Data

Commercial-Industrial-Residential Portable Generator System

Schematic, Portable Generator – Drawing No. 0G0733

167

ACTUATOR

44C

RESET

TEST

GFCI

120V

120V/30A

120V/30A
TWISTLOK

TWISTLOK

CB1 - 10AMP AUTO RESET BREAKER

BCR2 - BATTERY CHARGE RECTIFIER

D2, D3 - ENGINE SHUTDOWN DIODE

CB2 - 6AMP AUTO RESET BREAKER

BCR1 - BATTERY CHARGE RECTIFIER, 10A

30A

LEGEND

LEGEND
BA - BRUSH ASSEMBLY

BA - BRUSH ASSEMBLY

F1 - 10A FUSE

D1 - 600V 12A DIODE

11C

120V

DUPLEX

11S

11
12

120V/30A

C.B.

44D

TWISTLOK

11D

SC - STARTER CONTACTOR

R1 - 25 OHM, 25W RESISTOR

IM2 - IGNITION MODULE, CYL. 2

FSS - FUEL SHUT OFF SOLENOID

LOP - LOW OIL PRESSURE

IM1 - IGNITION MODULE, CYL. 1

GND - GROUND BAR

GND - GROUND BAR
I.C.T. - IDLE CONTROL TRANSFORMER

I.C.T. - IDLE CONTROL TRANSFORMER

C.B.

50A/60A

120/240V

TWISTLOK

30A

44B

50A/60A

11A

120/240V

11B

C2-7

C2-2

BATTERY CHARGE WINDING

10A BATTERY CHARGE WINDING

TB1

15B

167

229

167

VOLTAGE

REGULATOR

ELECTRONIC

C1-10

77A

C1-8

C1-5

77A

C1-3

55A

CONTROL

PRINTED CIRCUIT

167

229

TR2

22S

8
9

6
7

TR1

15B

2
3
4

BOARD

11S

22S

11S

TB2

TB2 22S

22S

GOVERNOR

C2-1

15B

4 6
18

15B

229

5
14

229

10 9

SSR

BLK

167

229

15B

162

11S

11S
22S

22S

BLK

BCR1

IM2

SP2

IM1

SP1

167

C2-10

167

C2-4

C2-3

C2-8

SCR

C2-9

C2-11

C2-6

167

SW2

162

CB2

BCR2

13A

66A

77A

CB1

15A

C2-12

C2-5

12Vdc

POWER WINDING

C1-1

C1-9

11S

66A

C1-4

66A

66A 11S

11S

I.C.T.

BLK

22S

RED

I.C.

I.C.T.

C1-2

DPE WINDING

C1-7

C1-6

SCR - STARTER CONTACTOR RELAY

SW1 - START-RUN-STOP RELAY

SSR - START / STOP RELAY

SP2 - SPARK PLUG, CYL. 2

SP1 - SPARK PLUG, CYL. 1

SW2 - IDLE CONTROL SWITCH

SW2 - IDLE CONTROL SWITCH
TB1, TB2 - TERMINAL BLOCK

TB1, TB2 - TERMINAL BLOCK

SM - STARTER MOTOR

44A

44A 0

FSS

SW1

17 0

BATTERY

BLACK

12V

RED

LOP

C1-12

FIELD

C1-11

11S

22S

BLK

11B

C.B.

20A

C.B.

30A

C.B.

30A

C.B.

30A

C.B.

20A

Summary of Contents for 005308-0

Page 1: ...OUBLESHOOTING ELECTRICAL DATA PARTS WARRANTY 1 800 333 1322 Portable Generator COMMERCIAL INDUSTRIAL RESIDENTIAL MODEL 005308 0 17 500 Watt Portable Generator and 60 amp manual transfer switch with built in load center AUTHORIZED DEALER SUPPORT ...

Page 2: ... 2 9 Automatic Idle Control 12 2 10 Cold Weather Operation De Icer 12 2 11 Low Oil Pressure Shutdown 12 2 11 1 Initial Start up 12 2 11 2 Sensing Low Oil Pressure 12 2 11 3 Restarting 12 2 12 Charging a Battery 13 Section 3 Maintenance 14 3 1 Maintenance Schedule 14 3 2 Product Specifications 14 3 2 1 Generator Specifications 14 3 2 2 Engine Specifications 14 3 3 General Recommendations 15 3 3 1 G...

Page 3: ...equipment in an emergency CAUTION Always disconnect spark plug wire and place the wire where it cannot contact the spark plug to prevent accidental starting when setting up transporting adjusting or making repairs to your generator The generator produces dangerously high voltage that can cause extremely hazardous electrical shock Avoid contact with bare wires terminals etc Never permit any unquali...

Page 4: ... of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS Never operate in an enclosed area or indoors For safety reasons GENERAC recommends that the maintenance of this equipment is carried out by a GENERAC Authorized Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in sufficient conce...

Page 5: ... local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is operated in accordance with the manufacturer s instructions and recommendations Do not alter the construction of generator or change controls which might create an unsafe operating condition Keep a fire extinguisher...

Page 6: ...ver the road use Refer to Figure 2 shown on opposite page and install the wheel kit as follows Place the generator on a hard flat surface Stand at the engine end of the unit and gently tilt the generator forward high enough to place wooden blocks beneath the cradle This will allow space to install the wheel assemblies Attach an axle bracket assembly with attached sleeve to either side of the frame...

Page 7: ... Positive terminal After making sure that the connection is tight slip the rubber boot over the terminal connection Connect the BLACK battery cable to the battery Negative terminal Make sure the connection is tight Double check all connections to ensure they are in the correct location and secure See Figure 3 at right Figure 3 Battery Connections Section 1 General Information Residential Portable ...

Page 8: ...ghting appliance tool and motor loads 5 120 240 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 and or 240 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 6 120 240 Volt AC 50 Amp Receptacle Located on underside of control panel Supplies electrical power for the operation of 120 240 Volt AC 50 Amp single phase 60 Hz welder o...

Page 9: ...njury Definition Instead of following its normal safe path electricity passes through a persons body to reach the ground For example a defective appliance can cause a ground fault A GFCI receptacle does NOT protect against circuit overloads short circuits or shocks For example electric shock can still occur if a person touches charged electrical wires while standing on a non conducting surface suc...

Page 10: ...t is protected by two 30 Amp push to reset circuit breakers 2 2 5 12 VOLT DC 10 AMP RECEPTACLE This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery See the section Charging a Battery page 13 before attem...

Page 11: ...nected at one time This total should not be greater than a the rated wattage amperage capacity of the generator or b circuit breaker rating of the receptacle supplying the power See Don t Overload the Generator below 2 4 DON T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices Observe the ...

Page 12: ...Table Saw 10 1750 to 2000 Television 200 to 500 Toaster 1000 to 1650 Weed Trimmer 500 Allow 3 times the listed watts for starting these devices 10 Section 2 Operation Residential Portable Generator System 2 6 BEFORE STARTING THE GENERATOR Prior to operating the generator engine oil and gasoline will need to be added as follows 2 6 1 ADDING ENGINE OIL NOTE When adding oil to the engine crankcase in...

Page 13: ...ing storage Alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer See Storage on page 18 Never use engine or carburetor cleaner products in the fuel ...

Page 14: ...fast governed engine speed when electrical load is connected When the load is removed the engine will run at a reduced speed of 2100RPM With the switch Off the engine runs at the normal fast engine speed all the time Always have the switch OFF when starting and stopping the engine 2 10 COLD WEATHER OPERATION DE ICER Under certain weather conditions temperatures below 40 F 4 C and a high dew point ...

Page 15: ...ry The voltage measured at the outlet should be 8 12 VDC This is normal and does not indicate a faulty charging system To recharge 12 Volt batteries proceed as follows Check fluid level in all battery cells If necessary add ONLY distilled water to cover separators in battery cells Do not use tap water If the battery is equipped with vent caps make sure they are installed and are tight If necessary...

Page 16: ...ge 1 5 Qts w o Filter Change 1 2 Qts Run Time Fuel 10 Hours 1 6 gallons per hour Consumption 1 2 Load Check Oil Level Service Air Pre Cleaner Change Oil and Oil Filter Clean Spark Arrestor Screen Adjust Valve Clearance Service Air Cleaner Replace Spark Plugs Change oil after first 8 hours of operation then every season Change oil and oil filter every month when operating under heavy load or in hig...

Page 17: ... these windings 3 3 2 TO CLEAN THE GENERATOR Use a damp cloth to wipe exterior surfaces clean A soft bristle brush may be used to loosen caked on dirt oil etc A vacuum cleaner may be used to pick up loose dirt and debris Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and openings on the generator These openings must be kept clean and unobstructed 3 3 ...

Page 18: ...filter service if necessary and remove paper filter Clean paper filter by tapping it gently on a solid surface If the filter is too dirty replace it with a new one Dispose of the old filter properly Clean air cleaner cover then slip pre cleaner over filter Next insert new paper filter into the base of the air cleaner Re install air cleaner cover Note To order a new air filter please contact the ne...

Page 19: ...e nut and hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE You mus...

Page 20: ...ine until engine stops from lack of fuel While engine is still warm drain oil from crankcase Refill with recommended grade Remove spark plugs and pour about 1 2 ounce 15 ml of engine oil into the cylinders Cover spark plug hole with rag Press the Start button and allow engine to crank for 2 seconds Then press the Stop button CAUTION Avoid spray from spark plug holes when cranking engine Install an...

Page 21: ... plug 6 Water in gasoline 6 Drain fuel tank fill with fresh fuel 7 Overchoking 7 Put choke knob to No Choke position 8 Low oil level 8 Fill crankcase to proper level 9 Excessive rich fuel mixture 9 Contact Authorized Service Facility 10 Intake valve stuck open or closed 10 Contact Authorized Service Facility 11 Engine has lost compression 11 Contact Authorized Service Facility Engine shuts down du...

Page 22: ...d length will be determined by the materials you will be drilling and cutting open end wrenches or adjustable wrenches socket wrenches or nut drivers standard and Phillips screwdrivers sledge hammer level pencil channel lock pliers wire cutters strippers and safety goggles ITEMS YOU MUST PURCHASE 60 AMP double pole circuit breaker must be the same type as in your main electrical distribution panel...

Page 23: ...le through the wall to mark the location With hole saw drill hole through the sheathing and siding 4 Measure the lengths of wire and conduit needed to reach the Manual Transfer Switch Allow extra length to clear the joists studs While adhering to all local electrical codes route the customer supplied conduit and wiring along ceiling floor joists and wall studs to the location where the conduit wil...

Page 24: ...ng 9 Locate manual transfer switch with built in emergency load center within one foot of main distribution panel The manual transfer switch should be located to the right of the main distribution panel Hold transfer switch against the mounting surface Level the transfer switch and mark the mounting holes Drill the appropriate size pilot holes Mount the manual transfer switch to mounting surface w...

Page 25: ...ire from a circuit breaker that protects a circuit you want to have powered in the event of a power failure Wire nut the black wire to the matching circuit lead wire from the emergency circuit breaker from load center in the transfer switch All circuit wires are color coded and labeled for easy identification Repeat this process with remaining circuits to be powered by the generator Trace each bla...

Page 26: ...mp female receptacle which is inserted and twist locked into the power inlet box At the other end is the male connector NEMA 14 50 which plugs into the portable generator s control panel and is locked in place by the supplied spring retainer The power inlet box must be locked to ensure safety and to discourage tampering 24 Section 6 Operation of Generator with Manual Transfer Switch 17 500 WATT PO...

Page 27: ...supplying power to the load center circuits in the manual transfer switch TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored you will want to transfer back to that power source and shut down the generator This can be accomplished as follows 1 Switch the 50 Amp circuit breaker on the generator control panel to the OFF or Open position 2 Release the retainer clip from the NEM...

Page 28: ...6 Operation of Generator with Manual Transfer Switch INTERCONNECTION DRAWING GENERAC 17 5 KW GENERATOR CONNECTED TO THE EXTERNAL CONNECTION BOX MANUAL TRANSFER SWITCH AND HOME S MAIN ELECTRICAL DISTRIBUTION PANEL ...

Page 29: ...27 Section 7 Notes Residential Portable Generator System ...

Page 30: ...ISTLOK WHITE WHITE 0 4 5 WHITE WHITE 2 WHITE WHITE 120V 20A 120V 20A GFCI GFCI X Y G C B C B CONTRO SWITC IDL ON OF 60A 60A 50A 60A OUTLET 50A 60A OUTLET 120 240V 120 240V 50A 50A 22 11 44 15B 229 14 167 0 86 0 0 15 15 0 55A 55 0 14 18 18 14 14 44A 44A 11A 11A 44A 44A 11A 11A 11 11 44 44 22 22 44 44 44 44 44 44 11 11 11 11 11 11 11 11 44 44 11 11 44 44 44B 44B 44 44 11B 11B 11 11 22 22 0 0 22 22 2...

Page 31: ...IFIER CHARGE CHARGE BATTERY BATTERY CHARGE CHARGE BATTERY BATTERY RECTIFIER RECTIFIER D2 D2 R1 R1 22 22 ENGINE SHUTDOWN P C B ENGINE SHUTDOWN P C B ELECTRONIC GOVERNOR ELECTRONIC GOVERNOR CONTROL CONTROL SWITCH SWITCH IDLE IDLE ON OFF ON OFF 22S 22S 55 55 11S 11S 55A 55A TB2 TB2 TB1 TB1 BLK BLK CB1 CB1 BLK BLK RED RED 1 2 11 11 44 44 OUTLET IDLE CONTROL IDLE CONTROL TRANSFORMERS TRANSFORMERS 8 PIN...

Page 32: ...R ELECTRONIC ELECTRONIC C1 10 C1 10 77A 77A 77 77 77 77 C1 8 C1 8 55 55 C1 5 C1 5 77A 77A C1 3 C1 3 55A 55A CONTROL CONTROL PRINTED CIRCUIT PRINTED CIRCUIT 167 167 5 229 229 TR2 TR2 86 86 22S 22S 8 9 10 10 6 7 83 83 TR1 TR1 0 15B 15B 2 3 4 1 BOARD BOARD 11S 11S 22S 22S 11S 11S TB2 TB2 22S 22S 18 18 GOVERNOR GOVERNOR C2 1 C2 1 D3 D3 D2 D2 15 15 15B 15B 4 6 18 18 15B 15B 229 12 12 0 5 14 14 14 14 22...

Page 33: ... NEUTRAL NEUTRAL NEUTRAL NEUTRAL NEUTRAL NEUTRAL CIRCUIT 13 CIRCUIT 13 CIRCUIT 11 CIRCUIT 11 CIRCUIT 3 CIRCUIT 3 CIRCUIT 1 CIRCUIT 1 CIRCUIT 7 CIRCUIT 7 CIRCUIT 5 CIRCUIT 5 CIRCUIT 15 CIRCUIT 15 CIRCUIT 15 CIRCUIT 15 CIRCUIT 11 CIRCUIT 11 GROUND BAR GROUND BAR ORG ORG LT BLU LT BLU DRK BLU DRK BLU PNK PNK YEL WHT YEL WHT YEL YEL BRN WHT BRN WHT BRN BRN WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT GRN G...

Page 34: ...32 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Manual Transfer Switch with Load Center Drawing No 0G0939 B ...

Page 35: ...RCUIT BREAKER 20A 1P 6 0E7888D 1 CIRCUIT BREAKER 40A 2P 7 0E7888E 2 CIRCUIT BREAKER 50A 2P 8 0E7888F 1 CIRCUIT BREAKER 60A 2P 9 0G0863 1 HARNESS 50 AMP PLUGS 10 0G0750 1 HARNESS LOAD CENTER TO MAIN PANEL 11 0G1494 1 POWER INLET BOX Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Manual Transfer Switch with Load Center Drawing No 0G0939 B ...

Page 36: ... 39 40 44 43 41 42 46 45 35 37 36 38 27 33 32 34 160 3 29 24 3 25 26 48 31 30 47 58 53 50 52 49 51 54 55 57 17 56 18 10 1 15 2 6 7 4 5 6 8 11 12 13 25 26 27 3 30 35 65 7 41 42 43 44 45 46 47 49 50 51 52 53 54 57 58 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 58 2 5 17 18 34 35 40 57 139 153 59 19 28 21 23 20 60 61 63 65 62 64 14 13 11 8 12 160 4 5 9 16 ...

Page 37: ...O RING OIL CLR 35 0E9842 1 SEAL 42 I D CRANKSHAFT ITEM PART NO QTY DESCRIPTION 36 0C5731 1 ASSEMBLY HOUSING COVER WITH SLEEVE 37 0C3006 10 SCREW HHFC M10 1 5 X 55 38 080318 8 SCREW HHFC M6 1 0 X 25 39 0C8808 2 HOOK LIFTING 40 0D2723D 1 COVER ROCKER W OIL FILL GENERAC TEXT 41 0C2979 2 GASKET VALVE COVER 42 086515 8 KEEPER VALVE SPRING 43 0D2274 4 RETAINER VALVE SPRING 44 0D3867 4 SPRING VALVE 45 07...

Page 38: ...119 116 125 127 122 78 84 149 143 146 145 143 140 144 142 67 86 66 80 71 37 72 74 75 DETAIL A 153 87 69 81 73 68 70 82 83 151 150 85 79 135 141 138 137 154 128 129 108 132 131 130 134 133 126 155 DETAIL A 104 96 152 108 97 139 101 160 100 90 107 93 91 92 77 94 76 95 105 108 106 109 89 103 102 92 99 98 93 110 160 121 155 157 147 112 113 113 114 157 115 161 114 124 111 123 ...

Page 39: ...022097 4 WASHER LOCK M6 1 4 ITEM PART NO QTY DESCRIPTION 114 092079 4 SCREW TAPTITE M6 1 0 X 25 BP 115 0F1338B 1 ASSY IGN COIL W DIODE NO ADV 116 0F6263 1 PUMP IMPULSE 118 0G0926 2 SCREW HHFCS M6 1 0 X 16 G8 8 119 0G0832 1 ELBOW RUBBER 90 DEG GASOLINE 120 0E7585 2 SPARKPLUG CHAMPION RC14YC 121 0E4271 1 STARTER DELCO REMY SD80 122 022129 3 WASHER LOCK M8 5 16 123 061906 2 SCREW HHC M8 1 25 X 85 G8 ...

Page 40: ...dustrial Residential Portable Generator System Generator Drawing No 0D4488 F 10 33 11 38 8 39 24 12 14 23 21 46 34 31 13 32 31 39 17 28 42 43 44 19 32 10 17 16 2 4 9 3 15 37 35 5 30 20 6 1 7 25 40 19 32 22 24 26 31 36 28 32 31 28 27 45 29 29 18 28 10 40 41 30 ...

Page 41: ...1 SCREW TAP R 10 32 X 9 16 ITEM PART NO QTY DESCRIPTION 23 0A2038 1 WASHER FLAT 3 8 ZINC 24 022237 5 WASHER LOCK 3 8 25 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 M10 ZINC 27 051731 4 SCREW HHC M8 1 25 X 50 G8 8 28 022145 21 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX M8 1 25 NYLON INSERT 30 079246 5 SCREW HHC M6 1 0 X 16 WITH LOCK WASHER 31 022129 18 WASHER LOCK M8 5 16 3...

Page 42: ...40 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Control Panel Drawing No 0G0727 B ...

Page 43: ...2097 1 WASHER LOCK M6 1 4 37 049813 1 NUT HEX M6 1 0 G8 ITEM PART NO QTY DESCRIPTION 38 065795 2 RECTIFIER BATTERY CHARGER 39 0D4804 2 TRANSFORMER IDLE CURRENT 40 0C1085 4 SCREW PPHM M3 0 5 X 8 41 051715 12 NUT HEX M4 0 7 G8 15 KW 8 NUT HEX M4 0 7 G8 17 5 KW 42 022264 14 WASHER LOCK M4 43 048505 1 CIRCUIT BREAKER 6 X 1 44 087962 1 CIRCUIT BREAKER 10 X 1 12VDC 1 4 QC 45 036261 2 RIVET POP 125 X 250...

Page 44: ...enerator System Frame Handle Wheel Kit Drawing No 0E0695 B 42 33 14 15 7 34 6 11 35 10 49 8 5 7 9 12 13 39 40 26 24 38 39 20 17 19 22 21 36 6 7 42 6 5 7 26 32 52 47 46 45 50 25 17 17 18 16 44 43 48 3 7 6 36 41 4 23 29 51 30 29 27 28 2 31 37 1 ENGINE WIRE TO POWER Detail of Battery Tray ...

Page 45: ... 12 26 064101 6 NUT LOCK FL 3 8 16 27 039214 6 BOLT CARR 3 8 16 X 1 28 0D9165 1 AXLE 3 4 DIA X 30 15 kW ITEM PART NO QTY DESCRIPTION 29 045900 2 WASHER FLAT 3 4 15 kW 30 0D7668 2 12 3 PNEUM WHEEL 3 4 AXLE 15 kW 31 0D4999 2 PIN COTTER 1 8 X 1 1 4 32 0D4044 2 BRACKET WHEEL SPACER 33 0D3700 4 NUT FLANGE M6 1 0 NYLOK 34 0D2497 1 HANDLE 35 022532 4 SCREW HHC 5 16 18 X 2 1 2 G5 36 027028 6 NUT LOCK HEX ...

Page 46: ... or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and ox grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Facility as soon as a problem occurs The warranty repairs should be complet...

Page 47: ...emissions related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When ...

Page 48: ...orized dealers not authorized in writing by Generac Power Systems Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper use As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any ...

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