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Generac Power Systems 48kW, Owner'S Manual

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Generac Power Systems 48kW Owner'S Manual Download Page 31

EXPLODED VIEW: EV ALTCOMPRT DIRECT B-CAN  

DRAWING #: 0J5599A

 

 

GROUP A 

 

ITEM 

PART# 

QTY. 

DESCRIPTION

 

REVISION: J-1544-B 

 

Page 2 of 4 

DATE: 2/3/12

 

 

1 

0G1931 

1 

ROTOR 25KW 3PH DIRECT 390 1800 

 

 

0G2101 

1 

ROTOR 25KW 1PH DIRECT 390 1800 

 

 

0G6568 

1 

RTR 390 45AD1 CPL 

 

 

0G6570 

1     

RTR 390 45KD1 CPL   

 

 

 

 

2 

0G1932 

1 

ASSY STR 390 25 GD1 CPL 

 

 

0G2098 

1 

ASSY STR 390 25AD1 CPL 

 

 

 

 

0G2099 

1 

ASSY STR 390 25KD1 CPL 

 

 

0G2100 

1 

ASSY STR 390 25JD1 CPL 

 

 

0G6365 

1 

STR 390 45JD1 CPL 

 

 

0G6569 

1 

STR 390 45AD1 CPL 

 

 

0G6571 

1 

STR 390 45GD1 CPL 

 

 

0G6572 

1 

STR 390 45KD1 CPL 

 

 

0H1299 

1 

ASSY STR 390 36AD1 CPL 

 

 

0H1300 

1 

ASSY STR 390 36JD1 CPL 

 

 

0H1301 

1 

ASSY STR 390 36 GD1 CPL 

 

 

0J5243 

1 

STR 390 48GD1 CPL 

 

 

0J5427 

1 

STR 390 48AD1 CPL 

 

 

 0J6268 

1 

STR 390 48JD1 CPL 

 

 

0J6269 

1 

STR 390 48KD1 CPL 

 

3 

0C9708 

REF 

INSTR HYPOT TEST (NOT SHOWN) 

 

4 

SEE ENGINE EV 

REF 

ENGINE ADAPTER 

 

5 

SEE ENGINE EV 

REF 

FLEXPLATE 

 

6 

0F5767B 

1 

ASSY FLYWHEEL CPL W/40MM FAN B 

 

7 

0E5706 

1 

REAR BEARING CARRIER 390/DRCT 

 

8 

0F7874 

1 

ASSY BRUSH HOLDER 390/HSB 

 

 

0F7874A 

1 

ASSY BRUSH HOLDER 390/HSB 

 

 

(6) 0J7347 

1 

ASSY BRUSH HOLDER 390/HSB 

 

 

(6) 0J7347A 

1 

ASSY BRUSH HOLDER 390/HSB 

 

9 

077043A 

1 

CONDUIT FLEX .38" ID (60”)  

 

10 

038150 

4 

WASHER FLAT #8 ZINC  

 

11 

023454 

1 

KEY WOODRUFF #E 

 

12 

077043J 

1 

CONDUIT FLEX 2.0"ID (35” LG) 

 

13 

04576100BU 

4 

STUD M14-2.0 570 G5 ZINC 

 

 

(5) 04576100BF 

4 

STUD M14-2.0 X 540 G5 ZINC 

 

14 

052646 

4 

WASHER FLAT M14 

 

15 

043123 

4 

WASHER LOCK M14 

 

16 

051779 

4 

NUT HEX M14-2.0 G8 YEL CHR 

  (2) 17 

0A2601 

1 

SCREW HHC M16-2.0 X 45 G8.8 

 

18 

072879 

1 

SPACER .69 X 2.75 X .37 ST/ZNC 

  (2) 19 

059980 

4 

SCREW HHC M10-1.5 X 25 C10.9 

 

20 

046526 

4 

WASHER LOCK M10 

 

21 

0C3993 

4 

SCREW HHTT M4-0.7 X 25 BP 

 

22 

022264 

4 

WASHER LOCK #8-M4 

  (1) 23 

047248 

1 

BALL BEARING-45 MM 

  (1) 24 

070892 

1 

SLIP RING MACHINED 

  (3)25 

0J7077 

1 

BLOCK OFF, ALTERNATOR AIR 

 

 

(6)(7) 0J7348 

1 

BLOCK OFF, ALTERNATOR AIR QTA 

  (3)26 

0J7077A 

2 

BLOCK OFF, ALT AIR LH/RH 

  (3)27 

0J7007 

1 

BAFFLE-ALT INLET 

  (3)28 

0J7086 

1 

PLATE LEAD CLAMP 

  (3)29 

0C2454 

19 

SCREW HWHT M6-1 X 16 N WA Z/JS 

  (3)30 

052250 

1 

TAPE FOAM 1X1 (166” LG) 

 
 

 

Summary of Contents for 48kW

Page 1: ...tified Owner s Manual Stationary Emergency Generator Cover209 Rev A 02 12 Part No 0J8644 NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY ...

Page 2: ...crank Shutdown 8 4 Auto Start 8 4 Manual Start 8 4 Alarm and Warning Messages 8 4 Low Oil Pressure Shutdown Alarm 8 4 High Coolant Temperature Shutdown Alarm 8 4 Overcrank Shutdown Alarm 8 4 Overspeed Shutdown Alarm 8 4 RPM Sensor Failure Shutdown Alarm 8 4 Under frequency Shutdown Alarm 8 5 Low Battery Alarm 8 5 Low Battery Warning 8 5 Low Coolant Level Alarm 8 5 Missing Cam Pulse Alarm 8 5 Missi...

Page 3: ...ends 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 operate the unit This prepares them if they need to operate the equipment in an emergency For safety reasons the manufacturer recommends that this equipment be installed serviced and repaired ...

Page 4: ...us gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed pr...

Page 5: ...t 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 medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com...

Page 6: ...m power factor production date etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when re...

Page 7: ...been properly serviced with the recom mended oil may result in an engine failure NOTE If not already equipped it is strongly recommended to use the optional Cold Weather Start Kit for temperatures below 32 F The part number for the Cold Weather Start Kit can be found in the Specifications section or by contacting an authorized dealer The oil grade for temperatures below 32 F is 5W 30 synthetic oil...

Page 8: ...not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this function ends the cranking if the engine has failed to start The overcrank message will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not...

Page 9: ...rom the main gas distribu tion line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility...

Page 10: ...36kW 106 cfm Governor Type Electronic Frequency Regulation Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Spin on Cartridge Crankcase Oil Capacity 5 25 U S qts including filter capacity COOLING SYSTEM Type Pressurized Closed Recovery Water Pump Belt Driven Fan Speed 1500 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air inc...

Page 11: ...o be removed before performing this operation Figure 6 1 6 Remove the NG fuel jet loosen counter clockwise from the outlet port 7 Remove the LP fuel jet loosen counter clockwise from the jet keeper port on the side of the regulator housing Install this jet into the outlet port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on ...

Page 12: ...e rated voltage between each circuit breaker terminal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS Y CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical loads Electric power is produced in the alterna tor power w...

Page 13: ...signed to supply 3 phase electrical loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 7 and 7 8 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 7 Stat...

Page 14: ...utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pas...

Page 15: ...2 If you already have your activation code wait 3 5 seconds for the next display ENTER ACTIVATION CODE Passcode TROUBLESHOOTING Display Reads Use ARROW keys to scroll and find the first number of your Activation Code Press ENTER to select Repeat this step until all digits have been entered Use ESCAPE to correct previous digits Display Reads Activation is complete when all digits are entered above ...

Page 16: ... is lost LOW SPEED EXERCISE The standard start sequence will be initiated All 1800 rpm units will exercise at 1400 RPM All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following Wait for the line interrupt period for utility to return If utility returns within the line interrupt period continue to exercise at low RPM If utility is still los...

Page 17: ...s the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset AUTO START This unit is designed to automatically start in the event of a util ity failure or brown out condition Brown out is defined as utility voltage less than 60 nominal while utility is considered good when it is restored to at least the pickup value 80 of nominal These levels are fixe...

Page 18: ...on is seen for five 5 consecutive sec onds the alarm will be displayed MISSING CAM PULSE ALARM This is a shutdown alarm The alarm will activate after five 5 seconds of continuously missing cam pulses MISSING CRANK PULSE ALARM This is a shutdown alarm The alarm will activate after 12 con secutive revs where crank pulses are missing LOW FUEL PRESSURE WARNING Fuel pressure is monitored by a digital s...

Page 19: ...ce counters for the condition annunciated The history log will reflect the maintenance warning ALARM CANCEL When the generator is shut down due to a latching alarm the Auto Off Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message COMMON ALARM RELAY The common alarm relay will be activated if there is a s...

Page 20: ...ERY VOLTAGE DEBUG INPUTS OUTPUTS DISPLAYS EDIT LANGUAGE TIME DATE EXERCISE TIME SPEED ESC Press the ESCAPE key to jump back up through the menu levels Use the key to navigate through the menu ENTER Use the ENTER key to select items or enter data ESC ESC ESC ESC ESC ESC RESET MAINTENANCE QT TEST MAIN MENU MENU SYSTEM CntrlNexus001 Rev E 12 11 ...

Page 21: ...s the utility source main line circuit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator nDo not crank the engine continuously for lon ger than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check a...

Page 22: ...ned install and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip tie or place the hose in its retaining clip 4 Turn OIL FILTER Figure 10 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil fil ter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil ...

Page 23: ...ion of the entire engine genera tor monthly Look for obvious damage loose missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year Check all exhaust system pipes mufflers clamps etc for condition tight ness leaks security damage CHECK FAN BELT Inspect fan belts every year Replace any damaged det...

Page 24: ...nd gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water nDo not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging nBe sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is s...

Page 25: ...X X Check Charge State M X X Check Electrolyte Level M X X General Condition Vibration Noise Leakage Temperature M X Generator System Complete Tune up and System Inspection Y To be completed by an Authorized Service Dealer Footnotes Inspect the oil level monthly or every 12 hours during continuous operation Change oil and oil filter after the first 30 hours of operation and then every 100 hours or...

Page 26: ...nt fuel supply 4 Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS 5 Fuel system set to wrong fuel type 5 Reconfigure the fuel system See RECONFIGURING THE FUEL SYSTEM in manual 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 ...

Page 27: ...terfeit 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 ...

Page 28: ...ded 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 re...

Page 29: ...Notes ...

Page 30: ......

Page 31: ... FAN B 7 0E5706 1 REAR BEARING CARRIER 390 DRCT 8 0F7874 1 ASSY BRUSH HOLDER 390 HSB 0F7874A 1 ASSY BRUSH HOLDER 390 HSB 6 0J7347 1 ASSY BRUSH HOLDER 390 HSB 6 0J7347A 1 ASSY BRUSH HOLDER 390 HSB 9 077043A 1 CONDUIT FLEX 38 ID 60 10 038150 4 WASHER FLAT 8 ZINC 11 023454 1 KEY WOODRUFF E 12 077043J 1 CONDUIT FLEX 2 0 ID 35 LG 13 04576100BU 4 STUD M14 2 0 570 G5 ZINC 5 04576100BF 4 STUD M14 2 0 X 54...

Page 32: ...6 ZP NOTES UNLESS OTHERWISE SPECIFIED 1 ROTOR REPLACEMENT PARTS 2 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THREADS 3 NOT USED IN OPEN SETS 4 TORQUE VALUES FOR REFERENCE ONLY ITEM 16 45 ft lbs ITEM 17 144 ft lbs ITEM 19 56 ft lbs 5 5 4L ONLY 6 QTA ONLY 7 60KW ONLY 8 SHEET METAL PARTS LISTED IN THE BOM TABLE ARE REPRESENTING GENERIC PARTS NO COLOR MANUFACTURING FOR CORRECT MATERIAL AND COL...

Page 33: ...EXPLODED VIEW EV ALTCOMPRT DIRECT B CAN DRAWING 0J5599A GROUP A ITEM PART QTY DESCRIPTION REVISION J 1544 B Page 4 of 4 DATE 2 3 12 This page left blank intentionally ...

Page 34: ......

Page 35: ......

Page 36: ......

Page 37: ...NYLOK 27 0H6267 1 COVER VOLTAGE SHIELD 28 0F5752F 1 RES WW 15R 5 25W QK CONN 29 052777 3 WASHER FLAT M3 30 043182 3 WASHER LOCK M3 31 051714 3 NUT HEX M3 0 5 G8 CLEAR ZINC 32 0D7177V 2 DIODE BRIDGE 1P 35A 1000V 33 051713 2 WASHER FLAT M5 34 049226 2 WASHER LOCK M5 35 051716 2 NUT HEX M5 0 8 G8 CLEAR ZINC 36 056326 1 TRIM VINYL BLACK 1 8GP 3 LG 37 0J0489 1 DECAL CUSTOMER POWER CONNECT 38 0H7292 1 D...

Page 38: ...0A 3P 480V G 400AF B 0H6735 1 COVER CB 400AF C2 CONBOX C 0A7822 3 LUG SLDLSS 600 250 1 0X1 4 28 D 0H6734 1 STANDOFF CB MOUNT CONBOX E 042419 4 SCREW RHM 10 32 X 4 F 022097 6 WASHER LOCK M6 1 4 G 052647 6 SCREW SHC M10 1 5 X 25 C12 9 H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 046526 6 WASHER LOCK M10 K 023897 4 WASHER FLAT 10 ZINC L 022152 4 WASHER LOCK 10 M 022158 4 NUT HEX 10 32 STEEL N 023334 ...

Page 39: ...311 1 STANDOFF CB BOX CONBOX F 022471 4 NUT HEX 8 32 STEEL G 036261 4 RIVET POP 125 X 275 SS H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 0H5721 4 SCREW PPHM 8 32 X 1 3 4 ZINC K 022264 4 WASHER LOCK 8 M4 L 038150 4 WASHER FLAT 8 ZINC M 052619 3 SCREW HHC M5 0 8 X 20 G8 8 N 023897 3 WASHER FLAT 10 ZINC P 049226 3 WASHER LOCK M5 6 R 0J78740ST0R 1 SHIELD SM CIRCUIT BREAKER S 0J7872 1 GASKET CB SHIELD...

Page 40: ...IELD SM CIRCUIT BREAKER S 0J7872 1 GASKET CB SHIELD C2 T 0E3257 2 SCREW HWHTF M6 1 0 X 16 UL CIRCUIT BREAKER QN A 0E7284 1 CB 0175A 2P 240V S QN2 LL B 0H7356 1 COVER CB C2 CPL C 0H7429 1 COVER CB DISH 2P S QN D 0E3664 1 BASE QN CIRCUIT BREAKER E 0H7311 1 STANDOFF CB BOX CONBOX F 074908 2 SCREW HHTT M5 0 8 X 10 BP G 036261 4 RIVET POP 125 X 275 SS H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS 6 J 0J78...

Page 41: ...19 4 SCREW RHM 10 32 X 4 K 022152 4 WASHER LOCK 10 L 022158 4 NUT HEX 10 32 STEEL 6 M 0J7874AST0R 1 SHIELD LGE CIRCUIT BREAKER N 0J7872 1 GASKET CB SHIELD C2 P 0E3257 2 SCREW HWHTF M6 1 0 X 16 UL CIRCUIT BREAKER FD A 0D5572 1 CB 0150A 3P 600V S FD6 LL B 0H6737 1 COVER CB S FD6 C2 CONBOX C 081320 4 SCREW SHC 1 4 20 X 4 5 G8 8 NZ D 0F0199 1 INSULATOR CB FD FRAME 30MIL E 0H6734 1 STANDOFF CB MOUNT CO...

Page 42: ......

Page 43: ... M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHER SHAKEPROOF INT 3 8 17 0F9597A 1 SUPPORT LH ENGINE 2 4L 18 045764 1 SCREW HHTT M4 0 7 X 8 BP 19 062963 4 SCREW HHC M10 1 25 X 30 G8 8 20 022302 5 WASHER LOCK 7 16 21 022131 5 WASHER FLAT 3 8 M10 ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 0F9597 1 SUPPORT RH ENGINE 2 4L 24 022129 1 WASHER LOCK M8 5 16 25 0C3168 1 WASHER LOCK SPE...

Page 44: ......

Page 45: ... FLAT 3 8 M10 ZINC 7 050331A REF BATTERY POST COVER RED 8 050331 REF BATTERY POST COVER BLACK 9 038805Y 1 CABLE BATTERY BLACK 1 X 18 00 10 03880400AE 1 CABLE BATT RED 1 X 18 00 11 045771 REF NUT HEX M8 1 25 G8 YEL CHR 12 022129 REF WASHER LOCK M8 5 16 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC 17 077483 REF BATTERY 12VDC 75 AH...

Page 46: ......

Page 47: ... 6 1 FTG VNT VALVE COVER 36 60KW G2 0G10080103 6 1 REF GASKET PCV VALVE 12 057822 2 CLAMP HOSE 8 53 1 00 13 059057 1 HOSE 3 4 ID SAE 30R2 17 5 LG 14 047527 1 BARBED STR 1 2NPT X 3 4 15 5 0H1787 1 PIPE INSULATION 17 LG 16 4 5 0H1787A 1 PIPE INSULATION ELBO 17 0E8286 1 ELBOW 45D STREET 1 2NPT BRASS 18 5 0H1801 1 PIPE INSULATION TAPE 14 LG 1 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THRE...

Page 48: ......

Page 49: ......

Page 50: ...F2461 1 RETAINER BEARING 39 022145 13 WASHER FLAT 5 16 M8 ZINC 40 022129 9 WASHER LOCK M8 5 16 1 41 039287 1 SCREW HHC M8 1 25 X 45 C8 8 42 082774 1 KEY WOODRUFF 4 X 19D 43 0G0795 1 HOSE LOWER RADIATOR G2 44 0G0816 1 HOSE UPPER RADIATOR G2 USED WITH MANFLD P N 0G0707 0H1546 1 HOSE UPPER RADIATOR G2 USED WITH MANFLD P N 0G8488 45 049813 8 NUT HEX M6 X 1 0 G8 YEL CHR 46 052644 1 SPACER 5 X 1 5 X 25 ...

Page 51: ......

Page 52: ......

Page 53: ......

Page 54: ...388 9 SCREW HHTT M6 1 0 X 12 ZINC 33 026073A 3 PLUG STD PIPE 1 4 STEEL SQ HD 34 0E4507 1 SCREW HHC M10 1 5 X 120 C8 8 35 0A8258 9 SCREW HHC M8 1 25 X 25 G10 9 1 36 0A45310244 1 REF FILTER 1 5L 2 4L G2 OIL 37 0G8853 4 COIL 2 4L G2 IGNITION 38 046525 2 NUT HEX M10 1 25 G8 YEL CHR 39 0H0593A 1 HEAT SHEILD INNER 2 4L G2 36K 40 0F0710 2 RIVET POP 125 X 0 337 STEEL 41 0G3823 2 O RING SIZE 9 0MM X 2 0MM ...

Page 55: ...T QTY DESCRIPTION 73 052265 1 REF SCREW HHC M8 1 25 X 65 C8 8 74 0H07280ST03 1 BRKT EXH MANF 2 4L 36KW 75 0H0723BST03 1 LWR BRKT ASM HT SHIELD G2 36KW 76 084750 4 PLUG SPARK 77 045772 1 NUT HEX M10 1 5 G8 YEL CHR 78 0F3217 1 SPACER DC ALTERNATOR PULLEY 1 SUPPLIED WITH ENGINE 2 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS ...

Page 56: ......

Page 57: ...M12 1 5 6 0C4973C 1 ADAPTER 90D JIC37 1 4NPT X 1 2 7 0A8830 2 WASHER FLAT 34ID X 75OD 8 070006 4 WASHER LOCK M8 SS 9 070010 4 SCREW HHC M8 1 25 X 35 SS FTH 10 0C4975 1 ADAPTOR 1 2 NPT X 37JIC 3 4 16 11 064094 1 ADAPTER 90D JIC37 1 8NPT X 1 2 12 0C2454 2 SCREW THF M6 1 X 16 N WA Z JS 13 055934C 2 CLAMP STL VNL 5 X 406 Z 14 0H0746 1 BRKT EXH MANF 2 4L G2 36KW 15 090388 2 SCREW HHTT M6 1 0 X 12 ZINC ...

Page 58: ......

Page 59: ...T TENSION 1 75 2 625 13 057147 1 HOSE 3 4 ID LPG NG 35 LG 14 057822 2 CLAMP HOSE 8 53 1 00 15 086133C 3 CLAMP HI TORQUE 1 75 2 625 16 0H09080ST03 1 BRACKET INTAKE REINFORCEMENT 17 022097 4 WASHER LOCK M6 1 4 18 046580 4 SCREW SHC M6 1 0 X 45 19 022145 3 WASHER FLAT 5 16 M8 ZINC 20 039253 2 SCREW HHC M8 1 25 X 20 G8 8 21 0F7790C 1 VENTURI THROTTLE 24MM 22 0E7121 1 O RING 47 625 ID X 2 38 WIDTH 23 0...

Page 60: ......

Page 61: ... 0F3890B 4 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 078115A 6 WASHER SELF LOCKING DOME 8 32 34 0G5892E 1 INSULATION LOWER SPLITTER 35 042568 2 SCREW HHC M6 1 0 X 20 G8 8 36 0912970094 2 ASSY WIRE 14 AWG 34 8 GRN YEL 37 022447 2 WASHER SHAKEPROOF INT 1 4 38 0G9473 1 DEFLECTOR INTAKE 2 4L G2 TURBO 39 0F8869D 1 KEY VISE ACTION LATCH SLOT CIR 40...

Page 62: ......

Page 63: ...T U 3 8 16 X 2 62 10 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 11 022473 2 WASHER FLAT 1 4 M6 ZINC 12 022097 2 WASHER LOCK M6 1 4 13 049721 2 SCREW HHC M6 1 0 X 35 G8 8 BLK 14 0H0789 1 GASKET TURBO EXHAUST 2 4L 36KW 15 070006 3 WASHER LOCK M8 SS 16 070002 3 SCREW HHC M8 1 25 X 25 SS 17 022237 6 WASHER LOCK 3 8 18 022241 6 NUT HEX 3 8 16 STEEL 19 0H1310 1 BOLT U 3 8 16 X 2 30 W SADDLE 20 0G3770 1 EXHA...

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Page 78: ...Notes ...

Page 79: ...Notes ...

Page 80: ...BackPg001 Rev A 04 07 ...

Page 81: ...tified Owner s Manual Stationary Emergency Generator Cover209 Rev A 02 12 Part No 0J8644 NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY ...

Page 82: ...crank Shutdown 8 4 Auto Start 8 4 Manual Start 8 4 Alarm and Warning Messages 8 4 Low Oil Pressure Shutdown Alarm 8 4 High Coolant Temperature Shutdown Alarm 8 4 Overcrank Shutdown Alarm 8 4 Overspeed Shutdown Alarm 8 4 RPM Sensor Failure Shutdown Alarm 8 4 Under frequency Shutdown Alarm 8 5 Low Battery Alarm 8 5 Low Battery Warning 8 5 Low Coolant Level Alarm 8 5 Missing Cam Pulse Alarm 8 5 Missi...

Page 83: ...r 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 operate the unit This prepares them if they need to operate the equipment in an emergency For safety reasons the manufacturer r...

Page 84: ...and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided This...

Page 85: ...rgency generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start cir cuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the genera...

Page 86: ...roduction date etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Stationary Emergency Generator Model and Serial Number This number is the key to numerous engineering and manufactur ing details pertaining to your unit Always supply this number when requesting service...

Page 87: ...ced with the recom mended oil may result in an engine failure NOTE If not already equipped it is strongly recommended to use the optional Cold Weather Start Kit for temperatures below 32 F The part number for the Cold Weather Start Kit can be found in the Specifications section or by contacting an authorized dealer The oil grade for temperatures below 32 F is 5W 30 synthetic oil COOLANT RECOMMENDA...

Page 88: ...not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this function ends the cranking if the engine has failed to start The overcrank message will turn ON Turn OFF the AUTO OFF MANUAL switch then turn switch back to AUTO to reset the generator control board NOTE If the fault is not...

Page 89: ...rom the main gas distribu tion line to the standby generator site The following information applies to natural gas fuel systems Gas pressure in a building is usually regulated by national state and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility...

Page 90: ...36kW 106 cfm Governor Type Electronic Frequency Regulation Isochronous Steady State Regulation 0 25 Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Spin on Cartridge Crankcase Oil Capacity 5 25 U S qts including filter capacity COOLING SYSTEM Type Pressurized Closed Recovery Water Pump Belt Driven Fan Speed 1500 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air inc...

Page 91: ...o be removed before performing this operation Figure 6 1 6 Remove the NG fuel jet loosen counter clockwise from the outlet port 7 Remove the LP fuel jet loosen counter clockwise from the jet keeper port on the side of the regulator housing Install this jet into the outlet port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on ...

Page 92: ...between each circuit breaker terminal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS Y CONFIGURATION The Stationary Emergency Generator is designed to supply 3 phase electrical loads Electric power is produced in the alterna tor power windings These wi...

Page 93: ... 3 phase electrical loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 7 and 7 8 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 240V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 7 Stator Power Winding...

Page 94: ...utility power sense wires into the DC terminal block If utility voltage is detected the controller will display a warning message and lock out the generator preventing damage to the controller Power to the controller must be removed to clear this warning Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pas...

Page 95: ...2 If you already have your activation code wait 3 5 seconds for the next display ENTER ACTIVATION CODE Passcode TROUBLESHOOTING Display Reads Use ARROW keys to scroll and find the first number of your Activation Code Press ENTER to select Repeat this step until all digits have been entered Use ESCAPE to correct previous digits Display Reads Activation is complete when all digits are entered above ...

Page 96: ... is lost LOW SPEED EXERCISE The standard start sequence will be initiated All 1800 rpm units will exercise at 1400 RPM All 3600 rpm units will exercise at 1800 RPM If utility is lost during exercise the controller will do the following Wait for the line interrupt period for utility to return If utility returns within the line interrupt period continue to exercise at low RPM If utility is still los...

Page 97: ...s the Overcrank Shutdown Alarm will display and the unit will not attempt to crank until the alarm is reset AUTO START This unit is designed to automatically start in the event of a util ity failure or brown out condition Brown out is defined as utility voltage less than 60 nominal while utility is considered good when it is restored to at least the pickup value 80 of nominal These levels are fixe...

Page 98: ...on is seen for five 5 consecutive sec onds the alarm will be displayed MISSING CAM PULSE ALARM This is a shutdown alarm The alarm will activate after five 5 seconds of continuously missing cam pulses MISSING CRANK PULSE ALARM This is a shutdown alarm The alarm will activate after 12 con secutive revs where crank pulses are missing LOW FUEL PRESSURE WARNING Fuel pressure is monitored by a digital s...

Page 99: ...ce counters for the condition annunciated The history log will reflect the maintenance warning ALARM CANCEL When the generator is shut down due to a latching alarm the Auto Off Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message COMMON ALARM RELAY The common alarm relay will be activated if there is a s...

Page 100: ...ERY VOLTAGE DEBUG INPUTS OUTPUTS DISPLAYS EDIT LANGUAGE TIME DATE EXERCISE TIME SPEED ESC Press the ESCAPE key to jump back up through the menu levels Use the key to navigate through the menu ENTER Use the ENTER key to select items or enter data ESC ESC ESC ESC ESC ESC RESET MAINTENANCE QT TEST MAIN MENU MENU SYSTEM CntrlNexus001 Rev E 12 11 ...

Page 101: ...ty source main line circuit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable...

Page 102: ...ned install and tighten OIL DRAIN HOSE CAP and secure drain hose with a new zip tie or place the hose in its retaining clip 4 Turn OIL FILTER Figure 10 1 counterclockwise and remove Properly dispose of old filter 5 Apply light coating of new engine oil to seal of new oil fil ter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil ...

Page 103: ...ion of the entire engine genera tor monthly Look for obvious damage loose missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every year Check all exhaust system pipes mufflers clamps etc for condition tight ness leaks security damage CHECK FAN BELT Inspect fan belts every year Replace any damaged det...

Page 104: ...nd gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water nDo not use any jumper cables or booster bat tery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging nBe sure the AUTO OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is s...

Page 105: ...X X Check Charge State M X X Check Electrolyte Level M X X General Condition Vibration Noise Leakage Temperature M X Generator System Complete Tune up and System Inspection Y To be completed by an Authorized Service Dealer Footnotes Inspect the oil level monthly or every 12 hours during continuous operation Change oil and oil filter after the first 30 hours of operation and then every 100 hours or...

Page 106: ...nt fuel supply 4 Confirm fuel pressure to regualtor is as recommended in SPECIFICATIONS 5 Fuel system set to wrong fuel type 5 Reconfigure the fuel system See RECONFIGURING THE FUEL SYSTEM in manual 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 ...

Page 107: ...terfeit 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 ...

Page 108: ...ded 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 re...

Page 109: ...Stationary Emergency Generator Notes ...

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Page 111: ... M6 1 4 ZINC 15 049813 1 NUT HEX M6 1 0 G8 YEL CHR 16 022261 1 WASHER SHAKEPROOF INT 3 8 17 0F9597A 1 SUPPORT LH ENGINE 2 4L 18 045764 1 SCREW HHTT M4 0 7 X 8 BP 19 062963 4 SCREW HHC M10 1 25 X 30 G8 8 20 022302 5 WASHER LOCK 7 16 21 022131 5 WASHER FLAT 3 8 M10 ZINC 22 065852 1 SPRING CLIP HOLDER 37 62 23 0F9597 1 SUPPORT RH ENGINE 2 4L 24 022129 1 WASHER LOCK M8 5 16 25 026204 1 WASHER SHAKEPRO...

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Page 113: ... FLAT 3 8 M10 ZINC 7 050331A REF BATTERY POST COVER RED 8 050331 REF BATTERY POST COVER BLACK 9 038805Y 1 CABLE BATTERY BLACK 1 X 18 00 10 03880400AE 1 CABLE BATT RED 1 X 18 00 11 045771 REF NUT HEX M8 1 25 G8 YEL CHR 12 022129 REF WASHER LOCK M8 5 16 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC 17 077483 REF BATTERY 12VDC 75 AH...

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Page 115: ... 6 1 FTG VNT VALVE COVER 36 60KW G2 0G10080103 6 1 REF GASKET PCV VALVE 12 057822 2 CLAMP HOSE 8 53 1 00 13 059057 1 HOSE 3 4 ID SAE 30R2 17 5 LG 14 047527 1 BARBED STR 1 2NPT X 3 4 15 5 0H1787 1 PIPE INSULATION 17 LG 16 4 5 0H1787A 1 PIPE INSULATION ELBO 17 0E8286 1 ELBOW 45D STREET 1 2NPT BRASS 18 5 0H1801 1 PIPE INSULATION TAPE 14 LG 1 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THRE...

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Page 118: ...AFT FAN DRIVE 38 0F2461 1 RETAINER BEARING 39 022145 13 WASHER FLAT 5 16 M8 ZINC 40 022129 9 WASHER LOCK M8 5 16 1 41 039287 1 SCREW HHC M8 1 25 X 45 C8 8 42 082774 1 KEY WOODRUFF 4 X 19D 43 0G0795 1 HOSE LOWER RADIATOR G2 44 0G0816 1 HOSE UPPER RADIATOR G2 USED WITH MANFLD P N 0G0707 0H1546 1 HOSE UPPER RADIATOR G2 USED WITH MANFLD P N 0G8488 45 049813 8 NUT HEX M6 X 1 0 G8 YEL CHR 46 052644 1 SP...

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Page 124: ...90388 9 SCREW HHTT M6 1 0 X 12 ZINC 33 026073A 3 PLUG STD PIPE 1 4 STEEL SQ HD 34 0E4507 1 SCREW HHC M10 1 5 X 120 C8 8 35 0A8258 9 SCREW HHC M8 1 25 X 25 G10 9 1 36 0A45310244 1 REF FILTER 1 5L 2 4L G2 OIL 37 0G8853 4 COIL 2 4L G2 IGNITION 38 046525 2 NUT HEX M10 1 25 G8 YEL CHR 39 0H0593A 1 HEAT SHEILD INNER 2 4L G2 36K 40 0F0710 2 RIVET POP 125 X 0 337 STEEL 41 0G3823 2 O RING SIZE 9 0MM X 2 0M...

Page 125: ...88 9 SCREW HHTT M6 1 0 X 12 ZINC 33 026073A 3 PLUG STD PIPE 1 4 STEEL SQ HD 34 0E4507 1 SCREW HHC M10 1 5 X 120 C8 8 35 0A8258 9 SCREW HHC M8 1 25 X 25 G10 9 1 36 0A45310244 1 REF FILTER 1 5L 2 4L G2 OIL 37 0G8853 4 COIL 2 4L G2 IGNITION 38 046525 2 NUT HEX M10 1 25 G8 YEL CHR 39 0H0593A 1 HEAT SHEILD INNER 2 4L G2 36K 40 0F0710 2 RIVET POP 125 X 0 337 STEEL 41 0G3823 2 O RING SIZE 9 0MM X 2 0MM N...

Page 126: ...T QTY DESCRIPTION 73 052265 1 REF SCREW HHC M8 1 25 X 65 C8 8 74 0H07280ST03 1 BRKT EXH MANF 2 4L 36KW 75 0H0723BST03 1 LWR BRKT ASM HT SHIELD G2 36KW 76 084750 4 PLUG SPARK 77 045772 1 NUT HEX M10 1 5 G8 YEL CHR 78 0F3217 1 SPACER DC ALTERNATOR PULLEY 1 SUPPLIED WITH ENGINE 2 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS ...

Page 127: ...ATE 8 10 10 ITEM PART QTY DESCRIPTION 73 052265 1 REF SCREW HHC M8 1 25 X 65 C8 8 74 0H07280ST03 1 BRKT EXH MANF 2 4L 36KW 75 0H0723BST03 1 LWR BRKT ASM HT SHIELD G2 36KW 76 084750 4 PLUG SPARK 77 045772 1 NUT HEX M10 1 5 G8 YEL CHR 1 SUPPLIED WITH ENGINE 2 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS ...

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Page 129: ...M12 1 5 6 0C4973C 1 ADAPTER 90D JIC37 1 4NPT X 1 2 7 0A8830 2 WASHER FLAT 34ID X 75OD 8 070006 4 WASHER LOCK M8 SS 9 070010 4 SCREW HHC M8 1 25 X 35 SS FTH 10 0C4975 1 ADAPTOR 1 2 NPT X 37JIC 3 4 16 11 064094 1 ADAPTER 90D JIC37 1 8NPT X 1 2 12 0C2454 2 SCREW THF M6 1 X 16 N WA Z JS 13 055934C 2 CLAMP STL VNL 5 X 406 Z 14 0H0746 1 BRKT EXH MANF 2 4L G2 36KW 15 090388 2 SCREW HHTT M6 1 0 X 12 ZINC ...

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Page 131: ...NSION 1 75 2 625 13 059057 1 HOSE 3 4 ID SAE 30R2 35 LG 14 057822 2 CLAMP HOSE 8 53 1 00 15 086133C 3 CLAMP HI TORQUE 1 75 2 625 16 0H09080ST03 1 BRACKET INTAKE REINFORCEMENT 17 022097 4 WASHER LOCK M6 1 4 18 046580 4 SCREW SHC M6 1 0 X 45 19 022145 3 WASHER FLAT 5 16 M8 ZINC 20 039253 2 SCREW HHC M8 1 25 X 20 G8 8 21 0F7790C 1 VENTURI THROTTLE 24MM 22 0E7121 1 O RING 47 625 ID X 2 38 WIDTH 23 0F2...

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Page 133: ... 0F3890B 4 RETAINER INSULATION 820 31 0F4051B 2 INSULATION DUCT SIDES 32 0F3890 4 RETAINER INSULATION 450 33 078115A 6 WASHER SELF LOCKING DOME 8 32 34 0G5892E 1 INSULATION LOWER SPLITTER 35 042568 2 SCREW HHC M6 1 0 X 20 G8 8 36 0912970094 2 ASSY WIRE 14 AWG 34 8 GRN YEL 37 022447 2 WASHER SHAKEPROOF INT 1 4 38 0G9473 1 DEFLECTOR INTAKE 2 4L G2 TURBO 39 0F8869D 1 KEY VISE ACTION LATCH SLOT CIR 40...

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Page 135: ...T U 3 8 16 X 2 62 10 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 11 022473 2 WASHER FLAT 1 4 M6 ZINC 12 022097 2 WASHER LOCK M6 1 4 13 049721 2 SCREW HHC M6 1 0 X 35 G8 8 BLK 14 0H0789 1 GASKET TURBO EXHAUST 2 4L 36KW 15 070006 3 WASHER LOCK M8 SS 16 070002 3 SCREW HHC M8 1 25 X 25 SS 17 022237 6 WASHER LOCK 3 8 18 022241 6 NUT HEX 3 8 16 STEEL 19 0H1310 1 BOLT U 3 8 16 X 2 30 W SADDLE 20 0G3770 1 EXHA...

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