Generac Power Systems Stationary Emergency Generator Owner'S Manual Download Page 109

Page: 109 / 144

EXPLODED VIEW: CONBOX C2 CPL

DRAWING #: 0H7326

GROUP A

APPLICABLE TO:

REVISION: H-8120-D

DATE: 1/19/11

ITEM

PART#

QTY.

DESCRIPTION

UL CIRCUIT BREAKER (KG)

0H5582

CB 0300 3P 600V E KG LL

0H6740

COVER CB E KG C2 CONBOX

0D3700

NUT FLANGE M6-1.0 NYLOK

0H5581A

INSULATOR CB E 3P KG

0H6734

STANDOFF CB MOUNT CONBOX

022129

WASHER LOCK M8-5/16

0C2454

SCREW HWHT M6-1 X 16 N WA Z/JS

0D2157

SCREW SHC M6-1.0 X 50 C8.8

049897

SCREW SHC M8-1.25 X 20 G8

022145

WASHER FLAT 5/16-M8 ZINC

UL CIRCUIT BREAKER (FG)

0H5486

CB 0060 3P 480V E FG LL

0H7356

COVER CB C2 CPL

0H7434

COVER CB DISH 3P E FG

0H4698A

INSULATOR CB 3P E TYPE CC/FG

0H7311

STANDOFF CB BOX CONBOX

022471

NUT HEX #8-32 STEEL

036261

RIVET POP .125 X .275 SS

0C2454

SCREW HWHT M6-1 X 16 N WA Z/JS

0H5721

SCREW PPHM #8-32 X 1-3/4 ZINC

022264

WASHER LOCK #8-M4

038150

WASHER FLAT #8 ZINC

052619

SCREW HHC M5-0.8 X 20 G8.8

023897

WASHER FLAT #10 ZINC

049226

WASHER LOCK M5

UL CIRCUIT BREAKER (JG)

0H5580

CB 0250 3P 600V E JG LL

0H6739

COVER CB E JG C2 CONBOX

0H5576A

INSULATOR CB E 3P JG

0H6734

STANDOFF CB MOUNT CONBOX

022127

NUT HEX 1/4-20 STEEL

022097

WASHER LOCK M6-1/4

0C2454

SCREW HWHT M6-1 X 16 N WA Z/JS

022770

SCREW RHM 1/4-20 X 3

022473

WASHER FLAT 1/4-M6 ZINC

049897

SCREW SHC M8-1.25 X 20 G8

022145

WASHER FLAT 5/16-M8 ZINC

022129

WASHER LOCK M8-5/16

UL CIRCUIT BREAKER (CC)

0H4748

CB 0175A 2P 240V E CC LL

0H4915

CB 0150 3P 240V E CC LL

0H7356

COVER CB C2 CPL

0H7432

COVER CB DISH 2P E CC

0H7433

COVER CB DISH 3P E CC

(5)D

051716

2/3

NUT HEX M5-0.8 G8 CLEAR ZINC

0H7311

STANDOFF CB BOX CONBOX

(5)F

022471

2/4

NUT HEX #8-32 STEEL

036261

RIVET POP .125 X .275 SS

0C2454

SCREW HWHT M6-1 X 16 N WA Z/JS

(5)J

053640

2/4

SCREW RHM #8-32 X 3-1/4

(5)K

022264

2/4

WASHER LOCK #8-M4

(5)L

038150

2/4

WASHER FLAT #8 ZINC

(5)M

052619

2/3

SCREW HHC M5-0.8 X 20 G8.8

(5)N

023897

4/6

WASHER FLAT #10 ZINC

(5)P

049226

2/3

WASHER LOCK M5

(5) QTY. REQ. FOR 2 POLE BREAKER / QTY. REQ. FOR 3 POLE BREAKER.

PAGE 6 OF 8

Summary of Contents for Stationary Emergency Generator

Page 1: ...with Catalyst Owner s Manual Stationary Emergency Generator Cover196 Rev A 04 10 Part No 0H7683 nNOT 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: ...overnor 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 2150 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air including alterna...

Page 11: ...e 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 NG 8 Install the previously removed NG jet into the...

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: ...all 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 filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil capacity ...

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: ...01 1 STR 2390 60JD2 CPL 0H1299 1 ASSY STR 390 36AD1 CPL 0H1300 1 ASSY STR 390 36JD1 CPL 0H1301 1 ASSY STR 390 36 GD1 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 9 0G0587 1 GUARD ...

Page 32: ......

Page 33: ......

Page 34: ......

Page 35: ... 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 ...

Page 36: ...50A 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 37: ...H7311 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 SHIE...

Page 38: ...SHIELD 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 0J...

Page 39: ...42419 4 SCREW RHM 10 32 X 4 K 022152 4 WASHER LOCK 10 L 022158 4 NUT HEX 10 32 STEEL M 0J7874AST03 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 C...

Page 40: ......

Page 41: ... 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 42: ......

Page 43: ... 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 44: ......

Page 45: ... 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 1 6 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 7 0G0190 1 PLATE AIR CLEANER TOP 2 4L 8 037561 1 NUT WING 1 4 20 NYLK 1 APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON ONE END OF I N 6 STUD THAT SCREWS INTO I N 2 CARB ADAPTER ...

Page 46: ......

Page 47: ... STEEL 35 0F8651 9 SCREW HHFC M8 1 25 X 20 W M6 36 099502 2 CLAMP HOSE 24 B1 06 2 00 37 0F9867 1 SHAFT FAN DRIVE 38 0F2461 1 RETAINER BEARING 39 022145 14 WASHER FLAT 5 16 M8 ZINC 40 022129 10 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 ...

Page 48: ......

Page 49: ...KET EXHAUST RING 12 085917 12 WASHER LOCK 3 8 SS 13 0D2611 2 SCREW HHC 3 8 16 X 1 3 4 SS 15 049721 2 SCREW HHC M6 1 0 X 35 G8 8 BLK 16 022097 4 WASHER LOCK M6 1 4 17 022473 4 WASHER FLAT 1 4 M6 ZINC 18 036797 1 BOLT U 5 16 18 X 2 25 19 022259 2 NUT HEX 5 16 18 STEEL 20 070006 2 WASHER LOCK M8 SS 21 088775 2 WASHER FLAT 3 8 SS 22 022241 10 NUT HEX 3 8 16 STEEL 23 047411 2 SCREW HHC M6 1 0 X 16 G8 8...

Page 50: ......

Page 51: ......

Page 52: ... 3 WASHER LOCK M6 1 4 31 022473 3 WASHER FLAT 1 4 M6 ZINC 32 043116 3 SCREW HHC M6 1 0 X 12 G8 8 33 026073A 2 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 047290 1 HOSE 3 8 ID SINGLE BRAID 15 LG 39 049340 1 BARBED EL 90 1 4 NPT X 3 8 40 052265 1 REF ...

Page 53: ... QTY DESCRIPTION 69 029333A 3 TIE WRAP UL 7 4 X 19 BLK 2 70 0H0015 1 HARN EMISSIONS OVERLAY 2 4L NOT SHOWN 71 045772 1 NUT HEX M10 1 5 G8 YEL CHR 1 SUPPLIED WITH ENGINE 2 CALIFORNIA EMISSIONS COMPLIANT MODELS ONLY 3 APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO I N 72 4 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS ...

Page 54: ......

Page 55: ... PIPE 3 4 NPT X 7 12 0H7436 1 HARN FUEL JUMPER SINGLE REG 13 057823 2 CLAMP HOSE 10 56 1 06 14 057147 1 HOSE 3 4 ID LPG NG 16 LG 15 047527 1 BARBED STR 1 2 NPT X 3 4 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 0F2119 1 O RING 45 63 ID X 2 62 WIDTH 19 0E6586 1 GASKET BOSCH 32 20 0E4394 1 ACTUATOR BOSC...

Page 56: ......

Page 57: ...LATION DUCT 30 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 0G5892B 1 INSULATION REAR WRAP 39 0F8869D 1 KEY VISE ACTION LATCH SLOT C...

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Page 59: ......

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Page 72: ...BackPg001 Rev A 04 07 ...

Page 73: ...with Catalyst Owner s Manual Stationary Emergency Generator Cover196 Rev A 04 10 Part No 0H7683 nNOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY ...

Page 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...overnor 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 2150 rpm Fan Diameter 22 inches Fan Mode Puller Air Flow inlet air including alterna...

Page 83: ...e 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 NG 8 Install the previously removed NG jet into the...

Page 84: ...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 85: ... 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 86: ...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 87: ...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 88: ... 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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...all 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 filter Install FILTER and tighten by hand only DO NOT OVER TIGHTEN 6 Remove OIL FILL CAP and add recommended oil Crankcase oil capacity ...

Page 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...Stationary Emergency Generator Notes ...

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Page 103: ...01 1 STR 2390 60JD2 CPL 0H1299 1 ASSY STR 390 36AD1 CPL 0H1300 1 ASSY STR 390 36JD1 CPL 0H1301 1 ASSY STR 390 36 GD1 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 9 0G0587 1 GUARD ...

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Page 107: ...267 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 DECAL CUSTOME...

Page 108: ...A 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 6...

Page 109: ...023897 3 WASHER FLAT 10 ZINC P 049226 3 WASHER LOCK M5 UL CIRCUIT BREAKER JG A 0H5580 1 CB 0250 3P 600V E JG LL B 0H6739 1 COVER CB E JG C2 CONBOX D 0H5576A 1 INSULATOR CB E 3P JG E 0H6734 1 STANDOFF CB MOUNT CONBOX F 022127 4 NUT HEX 1 4 20 STEEL G 022097 4 WASHER LOCK M6 1 4 H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 022770 4 SCREW RHM 1 4 20 X 3 K 022473 4 WASHER FLAT 1 4 M6 ZINC L 049897 3 S...

Page 110: ...R FLAT 10 ZINC H 0C2454 12 SCREW HWHT M6 1 X 16 N WA Z JS J 048927 4 SCREW RHM 10 32 X 4 1 2 UL CIRCUIT BREAKER VL A 0H7519 1 CB 0300A 3P 600V S JG VL LL B 0H6738 1 COVER CB S JG VL C2 CONBOX C 040976 3 SCREW SHC M8 1 25 X 20 C12 9 D 022129 3 WASHER LOCK M8 5 16 E 0H6734 1 STANDOFF CB MOUNT CONBOX F 022145 3 WASHER FLAT 5 16 M8 ZINC G 023897 4 WASHER FLAT 10 ZINC H 0C2454 12 SCREW HWHT M6 1 X 16 N...

Page 111: ...EXPLODED VIEW CONBOX C2 CPL DRAWING 0H7326 GROUP A APPLICABLE TO REVISION H 8120 D DATE 1 19 11 THIS PAGE LEFT INTENTIONALLY BLANK PAGE 8 OF 8 ...

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Page 113: ... 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 115: ... 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 117: ... 4 049815 4 SCREW HHC M5 0 8 X 16 G8 8 5 022127 1 NUT HEX 1 4 20 STEEL 1 6 062974 1 STUD TH 1 4 20 X 4 1 2 G2 ZNC 7 0G0190 1 PLATE AIR CLEANER TOP 2 4L 8 037561 1 NUT WING 1 4 20 NYLK 1 APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON ONE END OF I N 6 STUD THAT SCREWS INTO I N 2 CARB ADAPTER ...

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Page 119: ...6 1 NUT HEX 1 2 13 STEEL 35 0F8651 9 SCREW HHFC M8 1 25 X 20 W M6 36 099502 2 CLAMP HOSE 24 B1 06 2 00 37 0F9867 1 SHAFT FAN DRIVE 38 0F2461 1 RETAINER BEARING 39 022145 14 WASHER FLAT 5 16 M8 ZINC 40 022129 10 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 0G0...

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Page 121: ...KET EXHAUST RING 12 085917 12 WASHER LOCK 3 8 SS 13 0D2611 2 SCREW HHC 3 8 16 X 1 3 4 SS 15 049721 2 SCREW HHC M6 1 0 X 35 G8 8 BLK 16 022097 4 WASHER LOCK M6 1 4 17 022473 4 WASHER FLAT 1 4 M6 ZINC 18 036797 1 BOLT U 5 16 18 X 2 25 19 022259 2 NUT HEX 5 16 18 STEEL 20 070006 2 WASHER LOCK M8 SS 21 088775 2 WASHER FLAT 3 8 SS 22 022241 10 NUT HEX 3 8 16 STEEL 23 047411 2 SCREW HHC M6 1 0 X 16 G8 8...

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Page 124: ...097 3 WASHER LOCK M6 1 4 31 022473 3 WASHER FLAT 1 4 M6 ZINC 32 043116 3 SCREW HHC M6 1 0 X 12 G8 8 33 026073A 2 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 047290 1 HOSE 3 8 ID SINGLE BRAID 15 LG 39 049340 1 BARBED EL 90 1 4 NPT X 3 8 40 052265 1 R...

Page 125: ... QTY DESCRIPTION 69 029333A 3 TIE WRAP UL 7 4 X 19 BLK 2 70 0H0015 1 HARN EMISSIONS OVERLAY 2 4L NOT SHOWN 71 045772 1 NUT HEX M10 1 5 G8 YEL CHR 1 SUPPLIED WITH ENGINE 2 CALIFORNIA EMISSIONS COMPLIANT MODELS ONLY 3 APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO I N 72 4 APPLY MEDIUM STRENGTH BLUE THREAD LOCKING FLUID TO THE THREADS ...

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Page 127: ...E 3 4 NPT X 7 12 0H7436 1 HARN FUEL JUMPER SINGLE REG 13 057823 2 CLAMP HOSE 10 56 1 06 14 059057 1 HOSE 3 4 ID SAE 30R2 16 LG 15 047527 1 BARBED STR 1 2 NPT X 3 4 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 0F2119 1 O RING 45 63 ID X 2 62 WIDTH 19 0E6586 1 GASKET BOSCH 32 20 0E4394 1 ACTUATOR BOSCH ...

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Page 129: ... 2 INSULATION DUCT 30 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 0G5892B 1 INSULATION REAR WRAP 39 0F8869D 1 KEY VISE ACTION LATCH...

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