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Part No. 0H1530 

Revision C (09/22/11) 

Printed in U.S.A.

Warranty

GENERAC POWER SYSTEMS STANDARD TWO-YEAR BASIC 

LIMITED WARRANTY FOR STANDBY POWER SYSTEMS

NOTE:  ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER.

For a period of two (2) years or two thousand (2,000) hours of operation from the date of start up, which ever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, 

repair or replace any part(s) which, upon examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is found to be defective under 

normal use and service, in accordance with the warranty schedule set forth below. Repair or replacement pursuant to this limited warranty shall not renew or extend the original warranty 

period.  Any repaired product shall be warranted for the remaining original warranty period only.  Any equipment that the purchaser/owner claims to be defective must be examined by the 

nearest Authorized/Certified Generac Dealer, or branch thereof. This warranty applies only to Generac Generators used in "Standby" applications, as Generac has defined Standby, provided 

said generator has been initially installed and/or inspected on-site by an Authorized/Certified Generac Dealer, or branch thereof. It is highly recommended that scheduled maintenance, as 

outlined by the generator owner’s  manual, be performed by an Authorized/Certified Generac Dealer, or branch thereof.  This will verify service has been performed on the unit throughout 

the warranty period. This warranty is limited to and available only on Liquid-cooled units.

***This warranty only applies to units sold for use in the US and Canada.***

WARRANTY SCHEDULE

YEAR ONE — Limited comprehensive coverage on mileage, labor, and parts listed.

• ALL COMPONENTS — ENGINE, ALTERNATOR AND TRANSFER SWITCH

YEAR TWO — Limited comprehensive coverage on parts listed.

• ALL COMPONENTS — ENGINE, ALTERNATOR AND TRANSFER SWITCH PARTS ONLY

GEARBOX EQUIPPED UNITS - LIMITED GEARBOX COVERAGE

YEARS ONE THROUGH FIVE — Parts and labor coverage on gearbox and components.

YEARS SIX THROUGH TEN — Parts only coverage on gearbox and components.

GUIDELINES:

1.  Travel allowance is limited to 300 miles maximum, and 7.5 hours maximum (per occurrence), round trip, to the nearest authorized Generac Service Facility.

2.  Warranty only applies to permanently wired and mounted units.

3.  All warranty repairs, must be performed and/or addressed by an Authorized/Certified Generac Dealer, or branch thereof.

4.   A Generac Transfer Switch is highly recommended to be used in conjunction with the generator set. If a Non-Generac Transfer Switch is substituted for use and directly causes dam-

age to the generator set, no warranty coverage shall apply.

5.  All warranty expense allowances are subject to the conditions defined in Generac’s General Service Policy Manual.

6.  Units that have been resold are not covered under the Generac Warranty, as this Warranty is not transferable.

7.  Unit enclosure is only covered during the first year of the warranty provision.

8.  Use of Non-Generac replacement part(s) will void the warranty in its entirety.

9.  Engine coolant heaters (block-heaters), heater controls and circulating pumps are only covered during the first year of the warranty provision.

10.  Generac may chose to Repair, Replace or Refund a piece of equipment.

11.   Warranty Labor Rates are based on normal working hours.  Additional costs for overtime, holiday or emergency labor costs for repairs outside of normal business hours will be the 

responsibility of the customer.

12.  Warranty Parts shipment costs are reimbursed at ground shipment rates.  Costs related to requests for expedited shipping will be the responsibility of the customer.

13.  Batteries are warranted by the battery manufacturer.

14.  Verification of required maintenance may be required for warranty coverage.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Any unit built/manufactured prior to July 1, 2004.

1.  Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).

2.  Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.

3.   Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac has defined Prime Power,Trailer Mounted or Rental Unit. Contact a Generac 

Distributor for Prime Power, Trailer Mounted or Rental Unit definition and warranty.

4.   Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning, earthquake, windstorm, hail, volcanic 

eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.

5.  Products that are modified or altered in a manner not authorized by Generac in writing.

6.  Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation, maintenance, or sizing.

7.  Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).

8.  Damage related to rodent and/or insect infestation.

9.  Failure due to misapplication, misrepresentation, or bi-fuel conversion.

10.  Telephone, facsimile, cellular phone, satellite, Internet, or any other communication expenses.

11.  Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).

12.  Modes of transportation deemed abnormal (refer to Generac General Service Policy Manual).

13.  Steel enclosures that are rusting due to improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised.

14.  Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct cause of the problem.

15.  Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR 

FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express warranty provided herein. Some states 

do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL, OR 

CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S. NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or con-

sequential damages, so the above limitations may not apply to purchaser/ owner. Purchaser/owner agrees to make no claims against Generac based on negligence. This warranty gives 

purchaser/owner specific legal rights. Purchaser/owner also may have other rights that vary from state to state.

Generac Power Systems, Inc.  •  P.O. Box 8  •  Waukesha, WI 53187

Ph: (262) 544-4811  •  Fax: (262) 544-4851

Part No. 0J4298 

Rev. B  08.11

Summary of Contents for 005342-6

Page 1: ...www generac com or 1 888 GENERAC Models 005342 6 005343 6 Owner s Manual Stationary Emergency Generator EPA Certified ...

Page 2: ...attery Chargers 8 Installation 9 STATIONARY EMERGENCY GENERATOR INSTALLATION 9 NFPA Standards 9 Other Published Standards 9 BASIC STATIONARY EMERGENCY GENERATOR ELECTRIC SYSTEM 9 EMERGENCY CIRCUIT ISOLATION METHOD 10 TOTAL CIRCUIT ISOLATION METHOD 10 GROUNDING THE STATIONARY EMERGENCY GENERATOR 10 GENERATOR AC NEUTRAL CONNECTIONS 10 TRANSFER SWITCH START SIGNAL CONNECTIONS 10 BATTERY INSTALLATION ...

Page 3: ... out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equip ment The manufacturer strongly recommends that the operator read this Owner s Manual and thoroughly understand all instruc tions before using this equipment The manufacturer also strongly recommends instructing other users to properly start and operat...

Page 4: ...be provided Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people animals etc will not be harmed This exhaust system must be installed properly in strict compliance with applicable codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while...

Page 5: ...he transfer switch In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medica...

Page 6: ...le phase unit 3 indicates three phase unit 6 Indicates unit rated 60 Hertz Hz 5 indicates 50 Hz 5 0 Engine is 5 0 liter 304 cubic inches D Unit has diesel fuel system N indicates natural gas L indi cates LP Liquid Withdrawal V indicates LP Vapor Withdrawal 18 Alternator rpm rating 1 800 rpm 36 indicates 3 600 rpm H Unit has an option H control panel R E and G panels are also available on some unit...

Page 7: ...re for the reader s convenience Also refer to the applicable control panel manual for additional automatic engine shutdown infor mation COOLANT TEMPERATURE SENDER This sender automatically shuts down the engine if the engine coolant temperature rises above a safe level LOW COOLANT LEVEL SENSOR Should the engine coolant level drop below the level of the high coolant temperature switch it is possibl...

Page 8: ...natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff solenoid should not exceed approximately 14 inches water column 0 6 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi COMBINATION LP...

Page 9: ...n Exhaust Outlet Size 2 2 5 in N P T Exhaust Temperature at Rated Output 565 C 1 050 F Engine Electrical System DC Alternator Output 15 amps at 12 volts Starter Motor 12 volt DC 3 kW Recommended Battery 12 volt 90 Ah 27 F Ground Polarity Negative ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD S...

Page 10: ...tible with the rated voltage phase and frequency of the connected electrical loads The gen erator connected electrical devices or both can be damaged if voltage phase and frequency are not compatible NOTE This manual assumes that the standby generator has been properly selected installed and interconnected by a competent qualified electrician or installation contractor Once the installa tion is co...

Page 11: ...ssociation NFPA Batterymarch Park Quincy MA 02269 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES NFPANo 220 STANDARDTYPESOFBUILDINGCONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTA...

Page 12: ...rries a flammable or explosive sub stance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in con nected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical GENERATOR AC NEUTRAL CO...

Page 13: ... that is harmful to the skin and eyes It is electrically conductive and corrosive The following pro cedures 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 water and seek medical attention and Spilled electrolyte is to be washed down ...

Page 14: ...e line may show no sign of leakage but may draw air into the system Stationary Emergency Generator Lubrication Check the engine crankcase oil level before operating and add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with 15W...

Page 15: ...uit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the Stationary Emergency Generator s main line circuit breaker to its OFF or OPEN position Start the generator Do not crank the engine continuously for lon ger than 30 seconds or the heat may dam age the starter motor Let engine stabilize and warm up Check all applicable ...

Page 16: ...refill gearbox If so equipped contact sales for avail ability Every Two Years Replace all rubber hoses Replace engine fan belts Inspect the Stationary Emergency Generator System Drain flush refill cooling system Every 1 000 Operating Hours Inspect engine DC alternator Inspect engine starter Retorque engine mounting brackets Remove test fuel injection pump Remove test cooling system thermostat As R...

Page 17: ...rns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immedi ately with clear water Do not dispose of the battery in a fire The battery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harm ful to the skin a...

Page 18: ...ion of a data card For actual information related to this particular model please refer to the construction document located at the end of this manual or to the data cards affixed to the unit HOW TO ORDER PARTS To order a replacement part locate the part in the applicable exploded view Contact an Authorized Service Dealer call 800 333 1322 to locate one in the area and provide the following inform...

Page 19: ...17 17 17 Notes ...

Page 20: ...18 Installation Diagram Drawing No 0G6991 B ...

Page 21: ...19 Drawing No 0G6991 B Installation Diagram ...

Page 22: ...erfeit and or gray market parts not made supplied or approved by Generac Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer 1 800 333 1322 for the dealer nearest you The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection o...

Page 23: ...ed by Federal State or local government Generac or the insurance company associated with the en gine Maintenance checks and readiness testing of such units is limited to 100 hours per year There is no time limit on the use of emergency stationary ICE in emergency situations The purchaser owner may petition the Administrator for approval of additional hours to be used for maintenance checks and rea...

Page 24: ...s for repairs outside of normal business hours will be the responsibility of the customer 12 Warranty Parts shipment costs are reimbursed at ground shipment rates Costs related to requests for expedited shipping will be the responsibility of the customer 13 Batteries are warranted by the battery manufacturer 14 Verification of required maintenance may be required for warranty coverage THIS WARRANT...

Page 25: ...modification or improper maintenance or the use of counterfeit and or gray market parts not made supplied or approved by Generac Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service dealer 1 800 333 1322 for the dealer nearest you The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and o...

Page 26: ... local government Generac or the insurance company associated with the engine Maintenance checks and readiness testing of such units is limited to 100 hours per year There is no time limit on the use of emer gency stationary ICE in emergency situations The purchaser owner may petition the Administrator for approval of additional hours to be used for maintenance checks and readiness testing but a p...

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Page 28: ...ASHER LOCK M8 5 16 2 25 022145 12 8 WASHER FLAT 5 16 M8 ZINC 2 26 042907 6 4 SCREW HHC M8 1 25 X 16 G8 8 4 27 0F7185 REF MOUNT GOV CONTROL H 100 28 047411 4 SCREW HHC M6 1 0 X 16 G8 8 29 022097 4 REF WASHER LOCK M6 1 4 30 022473 4 REF WASHER FLAT 1 4 M6 ZINC 31 022127 REF NUT HEX 1 4 20 STEEL 32 022287 REF SCREW HHC 1 4 20 X 3 4 G5 33 082982 REF RELAY CONTACTOR 24VDC 056739 REF RELAY SOLENOID 12VD...

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Page 30: ...HHC M12 1 75 X 60 G10 9 26 070274 1 KEY SQ 3 8 X 2 3 4 STEEL 27 087271 1 ASSY EXCITER 1 25 STK 087272 1 ASSY EXCITER 2 00 STK 28 068404 1 EXCITER FIELD 1 25 STK 068405 1 EXCITER FIELD 15 2 LG 29 092950 1 COLLAR SLIP FIT 390 MM 30 020151 1 CLAMP VINYL 312 X 203 Z 31 090063 1 BRIDGE SUPPORT DIODE 15 32 090152 1 ASSY BRIDGE RECTIFIER 33 023365 3 WASHER SHAKEPROOF INT 8 34 033143 2 SCREW HHM 8 32 X 7 ...

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Page 32: ...T SIDE LEVEL 1 GUARDING 4 0D5627 1 BRACKET LEVEL 1 GUARDING 5 0A2110 16 SCREW SWAGE 1 4 20 X 1 2 Z YC 6 047411 16 SCREW HHC M6 1 0 X 16 G8 8 7 022097 16 WASHER LOCK M6 1 4 8 022473 16 WASHER FLAT 1 4 ZINC 9 0D6633 1 BOTTOM LEVEL 1 GUARDING 6 8L 10 0E4629 2 GUARD ACCESS COVER SMALL L ONE ...

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Page 34: ...BATTERY BOX GROUP 27 W COVER 19 096500V 1 DETECTOR ALARM FUEL LEAK W CON 20 038805J 1 CABLE BATT BLK 1 X 30 00 21 038804J 1 CABLE BATT RED 1 X 40 50 22 075763 1 BOOT BATTERY CABLE 23 049814 1 SCREW HHC M10 1 5 X 25 G8 8 24 045771 1 NUT HEX M8 1 25 G8 YEL CHR 25 052243 4 SCREW HHC M10 1 5 X 60 G8 8 26 059980 4 SCREW HHC M10 1 5 X 25 G10 9 27 022131 9 WASHER FLAT 3 8 M10 ZINC 28 046526 9 WASHER LOCK...

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Page 36: ... 10 32 X 5 16 Z YC 15 026073A 1 PLUG STD PIPE 1 4 STEEL SQ HD 16 080712 1 BRACKET COOLANT RECOVERY TANK 17 076749 1 TANK COOLANT RECOVERY 18 048031C 2 CLAMP HOSE BAND 1 4 19 029032 2FT HOSE 9 32 ID 20 049340 1 BARBED EL 90 1 4NPT X 3 8 21 047290 2FT HOSE 3 8 ID SINGLE BRAID 22 036865 1 DRAINCOCK 23 0C7649 2 CLAMP HOSE 38 87 24 065852 1 SPRING CLIP HOLDER 37 62 25 090388 1 SCREW HHTT M6 1 0 X 12 ZI...

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Page 38: ...HER FLAT 1 4 ZINC 23 0D2608 10 SCREW HHC 5 16 18 X 1 2 SSTL 24 0D5623 2 HEAT SHIELD EXHAUST 25 0D5417 REF SCREW HHC M10 1 0 X 25 G10 9 2 26 0D3808 2 EXH MANIFOLD MACH 6 8L V 10 27 0D4255 2 GASKET EXHAUST MANIFOLD 28 070010 2 SCREW HHC M8 1 25 X 35 SS G8 8 29 0D6344 1 ASSEMBLY 6 8L FLYWHEEL 30 0D3803 1 FLYWHEEL HOUSING MACH 6 8L V10 31 0D3805 1 COVER FLYWHEEL MACH 6 8L V 10 32 0A8240 3 FLEX PLATE S...

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Page 40: ...PLATE VENTURI 4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED 5 0F6977 1 PLATE AIR CLEAN TOP 5 4L 6 8L 6 037561 1 NUT WING 1 4 20 NYLK 7 047411 4 SCREW HHC M6 1 0 X 16 G8 8 8 022097 4 WASHER LOCK M6 1 4 9 049811 4 WASHER FLAT M6 10 0F4269 1 GASKET MIXER BODY 11 022473 1 WASHER FLAT 1 4 M6 ZINC ...

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Page 42: ...142 4 SCREW HHC 5 16 18 X 3 4 G5 24 064416 1 SCREW HHC M10 1 5 X 45 G8 8 FT 25 0D8025 1 BOLT GROOVED IDLER PULLEY 26 057796 1 GROMMET 27 0F3216 1 PULLEY 80 OD DC ALTERNATOR 1800 RPM 28 0F3217 1 SPACER DC ALTERNATOR PULLEY 29 039253 3 SCREW HHC M8 1 25 X 20 G8 8 30 0D8026 3 BOLT BELT TENSIONER 31 022145 5 WASHER FLAT 5 16 M8 ZINC 32 0F3017 1 BRACKET D C ALTERNATOR LOWER 33 0D8028 1 PULLEY GROOVED E...

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Page 44: ... THROT BODY 13 057823 4 CLAMP HOSE 10 56 1 06 14 059057 2 HOSE 3 4 ID SAE 30R2 40 5 LG 15 049811 2 WASHER FLAT M6 16 0D1509 1 DECAL INLET PRESSURE 17 050279 1 DECAL FUEL INLET NG NATURAL GAS APPLICATION 050280 1 DECAL FUEL INLET LPG LP VAPOR APPLICATION 18 0H2353 1 ASSY ADAPTER THROTTLE BODY 19 0E4390 1 GASKET GOVERNOR ACTUATOR 20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR 21 0F0960 1 REDUCER 3 0 TO 2 75...

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Page 66: ... TOP 2 0D3680A 1 DUCT RADIATOR SIDE LH 3 0D3680 1 DUCT RADIATOR SIDE RH 4 045756 2 SCREW HHTT M6 1 0 X 10 YC 5 0E7652 1 DUCT RADIATOR BOTTOM 6 052250 1 TAPE FOAM 1 X 1 114 LG NOT SHOWN 7 0A2110 6 SCREW SWAGE 1 4 20 X 1 2 Z YC ...

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Page 68: ...IRE 6 077043E 1 CONDUIT FLEX 1 0 ID 30 LG 7 084427 1 BRACKET HEATER W WELDNUTS 8 035467 1 NIPPLE CLOSE 3 8NPT X 1 VIBRA 9 052857 2 NUT TOP LOCK FL M6 1 0 10 050967 1 HOSE COOL 5 8 ID 20R3 31 LG 11 0G5212B 1 VALVE 3 8 12 0C4905 1 BARBED EL 45 3 8NPT X 5 8OD 1 13 0A6283 1 HOSE PREFORMED BLOCK HEATER 1 14 0G5212B 1 VALVE 3 8 1 15 0G0015 2 CLAMP HOSE 7 8 OD DOUBLE WIRE 1 16 044117 1 BARBED STR 3 8NPT ...

Page 69: ...to July 1 2004 2 Costs of normal maintenance i e tune ups associated part s adjustments loose leaking clamps 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 has defined Prime Power Trailer M...

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