Page 1 Serial Number 4.6L 80kW Models EPA Certified STATIONARY EMERGENCY GENERATOR OWNER'S MANUAL A new standard of reliability   Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
Page 2: Table Of Contents
Electrical System .................6-1 Miscellaneous Maintenance ............10-3 Weather and Maintenance Kits .............6-2 Cleaning the Generator ...............10-3 4.6L Ignition Description ..............6-2 Battery ..................10-4 Ignition Shutdown on Loss of Crank or CAM Signals ....6-2 Battery Maintenance ..............10-4 Diagnostic Blink Patterns (Red LED Located Battery Replacement ..............10-4...
Page 3: Introduction
Safety Instructions SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION ...
Page 4: Safety Rules
Safety Instructions SAFETY RULES • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient Study these SAFETY RULES carefully before installing, operating concentrations, can cause unconsciousness or even death. For or servicing this equipment.
Page 5 Safety Instructions FIRE HAZARDS • If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the • Keep a fire extinguisher near the generator at all times. Do NOT equipment only while standing on such insulative mats.
Page 6: Identification Record
General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular model, please DATA LABEL refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit. Every generator set includes DATA LABEL that contains important information pertinent to the generator.
Page 7: Equipment Description
Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Use a mixture of half low silicate ethylene glycol base anti-freeze Emergency Generator. It is powered by a gaseous fueled engine and deionized water. Cooling system capacity is listed in the operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for specifications.
Page 8: Engine Protective Devices
Engine Protective Devices ENGINE PROTECTIVE DEVICES OIL PRESSURE SENSING The Stationary Emergency Generator may be required to operate An analog Oil Pressure Sender (OPS) is used for monitoring the for long periods of time without an operator on hand to monitor engine oil pressure.
Page 9: Fuel Systems
Fuel System FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid FUEL REQUIREMENTS fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor The Stationary Emergency Generator may be equipped with one of state.
Page 10: Specifications
Stationary Emergency Generator Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............Gear Oil Filter ............Full Flow, Cartridge STATIONARY EMERGENCY GENERATOR Crankcase Oil Capacity ..........6 U.S. qts. Type..............Synchronous Rotor Insulation .............Class H COOLING SYSTEM Stator Insulation ............Class H Type Closed Total Harmonic Distortion ..........<...
Page 11: Weather And Maintenance Kits
The 4.6L Ignition Module operates with an 8-cylinder. The 4.6L engine uses a 36-1 crank sensor, a CAM sensor and coil-on-plug If an Ignition fault occurs, a signal is sent to the H-panel and then ignition coils for each spark plug.
Page 12: General Information
General Information ALTERNATOR AC LEAD ALTERNATOR POWER WINDING CONNECTIONS CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel 3-PHASE ALTERNATORS ("Y" CONFIGURATION) should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label.
Page 13 General Information Figure 7.4 — Stator Power Winding 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Connections - 3-phase, 120/208V (6 Lead) The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna- INTERNAL CONNECTIONS tor power windings. These windings were connected at the factory to the main circuit breaker with a "Delta"...
Page 14: Installation
Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide” supplied with the unit. For safety reasons, the manufacturer recommends that this equip- Prior to initially starting the generator, it must ment be installed, serviced and repaired by a Service Dealer or be properly prepared for use.
Page 15 Installation START-UP CHECKLIST • Connect a manometer to the gas line and record the static pres- sure. It must be as listed in the Specifications. • Insert the fuse into the control panel. • Move the AUTO/OFF/MANUAL switch to the manual position. Before working on the Stationary Emergency The engine should now crank and start.
Page 16: Operation
Operation STATIONARY EMERGENCY GENERATOR CONTROL AND Do not crank the engine continuously for lon- OPERATION ger than 30 seconds, or the heat may damage the starter motor. Refer to the appropriate control panel operator’s manual for this • Let engine stabilize and warm up. unit.
Page 17: Maintenance
Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES  The exhaust system parts from this product get extremely hot and remain hot after shut- down. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such mate-  Before working on the Stationary Emergency rials may ignite and burn from the heat of the Generator, ensure the following: exhaust system.
Page 18: Engine Coolant
Maintenance ENGINE COOLANT INSPECT EXHAUST SYSTEM Check coolant level in coolant recovery bottle. See the Inspect the exhaust system at least once every three months. “Specifications” section. Check all exhaust system pipes, mufflers, clamps, etc. for condi- tion, tightness, leaks, security, damage. •...
Page 19: Changing The Engine Air Cleaner
Maintenance SPARK PLUGS Remove OIL FILL CAP . Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK Reset the spark plug gap or replace the spark plugs as neces- “FULL” MARK. Crankcase oil capacity is listed in the sary.
Page 20: Battery
Maintenance BATTERY Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause All lead-acid storage batteries discharge when not in use. Refer to severe burns. Do not permit fluid to contact specific instructions and warnings that accompany the battery. If eyes, skin, clothing, painted surfaces, etc.
Page 21: Service Schedule
Service Schedule SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Page 22 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level 5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
Page 23 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
Page 24 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
Page 25: Troubleshooting
Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace batter cables battery cables. as necessary. 3. Defective starter contactor. 3. Replace contactor.* 4.
Page 26 Warranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo- nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace- ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
Page 27 (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
Page 29 0F9952 ASSY ROTOR 2390 80KB3 CPL 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F3417 ASSY ROTOR 390 2P 100K BRSHLS 092950 COLLAR SLIP FIT 390 MM 0F2984 ASSY ROTOR 390 2P 150K BRSHLS 04576100CF STUD M14-2.0 X 760 G5 ZINC 0F9949 ASSY STATOR 80KW 1PH 2P BRSHLS 052646...
Page 32 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 081008 GROMMET 1.25 X .25 X .75 0F6156 PLATE WIRE SNGL GALV 029289 TAPE ELEC 1/2 FOAM (AS REQ’D) 0F3685 STAND LH CONTROL C5 GRBX 0F2885 PANEL CB CONN BOX 051713...
Page 33 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (225AF) 0F4173 COVER CB C5 225AF 0F4165$ CIRCUIT BREAKERS 200A FRAME 0F4186 COVER CB DISH 225AF 036261 RIVET POP .125 X .275 SS 053640 SCREW RHM #8-32 X 3-1/4 038150...
Page 34 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION NEUTRAL BLOCK 390 / 200-400A. 0D5466 BUS BAR NEUTRAL BLOCK 390 039287 SCREW HHC M8-1.25 X 45 G8.8 FT 022145 WASHER FLAT 5/16-M8 ZINC 022129 WASHER LOCK M8-5/16 045771...
Page 35 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: THIS PAGE LEFT INTENTIONALLY BLANK REVISION: H-5277-B Page 6 of 6 DATE: 11/18/09...
Page 37 COMPONENTS INCL UDED IN 0G4139E 0F1823CST 03 ENCL H/G CO NTROL PANEL 0F1824AST 03 CO VER CONTRO L PANEL 0F2606 HING E CONT INUOUS H PANEL 036261 RIVET POP .125 X .275 SS 0F5763 ASSY PROGRAMMED H- 100 0F1732 DECAL FUSES LO CAT ED INSIDE 0E9764 RAIL SNAPTRACK PCB HO LDER BULK ( 12”...
Page 39 0F3408 TRAY BATTERY 0F3411 STRAP BATTERY RETAINMENT 058208 BATT 12VDC 24F 625 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATT POST COVER RED + 050331 BATT POST COVER BLK - 038805U CABLE BATT BLK #1 X 18.00 038804U CABLE BATT RED #1 X 28.00 045771 NUT HEX M8-1.25 G8 YEL CHR 022129...
Page 41 055597 SCREW HHC M12-1.75 X 85 G8.8 052251A DAMPENER VIBRATION 50 WHITE 052860 NUT LOCKING M12-1.75 0F8864 SUPPORT ENG 4.6L LH 0F8865 SUPPORT ENG 4.6L RH 045764 SCREW HHTT M4-0.7 X 8 BP 061383 LUG SOLDERLESS 3/0-#4 X 13/32 CU 045757 SCREW HHC M6-1.0 X 25 G8.8...
Page 43 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) 0F2807E PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) 0F9207 PIPE EXH MANIFOLD 4.6L RH 0F2807B PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) 0F2807D PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) 0F9208 PIPE EXH MANIFOLD 4.6L LH...
Page 45 EXPLODED VIEW: EV AIR CLEANER GROUP D DRAWING #: 0F3569 ITEM PART# QTY. DESCRIPTION 0D2513D AIR CLNR BTM PLT W/CPLR 8.1L 0D2513E PLATE AIR CLEANER W/COUPLER 0F5419 ELEMENT AIR FILTER 0F4268 TOP PLATE VENTURI 0F4270A HOLD DOWN AIR CLEANER PLATED 0F6977 PLATE AIR CLEAN TOP 5.4L/6.8L 037561...
Page 47 EXPLODED VIEW: EV KIT GLASS PACK SHIP LOOSE GROUP DRAWING #: 0F6332A ITEM PART# QTY. DESCRIPTION 0F4462 RAIN CAP 2-1/2" AL 080762 BOLT U 3/8-16 X 2.62 0F4505A MUFF SEC 23.5" X 2.55IN/2.5OUT 0C2454 SCREW THF M6-1X16 N WA Z/JS (2) 5 0F4367 HEAT SHIELD EXHAUST STACK...
Page 49 EXPLODED VIEW: ENGCOMPRT LH 4.6L G3 GROUP D DRAWING #: 0H3914 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION CONNECTION WATER OUTLET (1)2 022145 WASHER FLAT 5/16-M8 ZINC GASKET THERMOSTAT HOUSING G3 THERMOSTAT ASSY (1)5 0G5515B ADAPTER THERMOSTAT 4.6L G3 0E0502 TEMPERATURE SENDER, DELPHI...
Page 51 EXPLODED VIEW: ENG COM PRT RH 4.6L G3 GROUP D DRAWING #:0H3914A APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 069860E HOSE DRAIN ASSY 28" 022158 NUT HEX #10-32 STEEL 0C7649 CLAMP HOSE .38-.87 0D2244M ASSY MAGPICKUP(3/8-24 MALE) 022129 WASHER LOCK M8-5/16 039253 SCREW HHC M8-1.25 X 20 G8.8...
Page 53 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H20530ST03 WELDMENT RADIATOR SUPPORT C5 0F2611 RADIATOR 680 X 680 X 70 CPL 0F5254 V-BELT 31/64" X 62-3/8" 046526 WASHER LOCK M10...
Page 54 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (5) 65 0D6029 SCREW HHTT M6-1.0 X 16 ZYC (5) 66 055934H CLAMP STL/VNL .62 X .406 Z (5) 67 072252 GROMMET 1.37 X .06 X 1.00...
Page 56 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0G15310GS0R PANEL C5 FRONT SIDES 0G15320GS0R PANEL C5 REAR SIDES 0G15300GS0R PANEL LOWER FRONT 0G15290GS0R PANEL C5 TOP (2) 0H30010GS0R PANEL C5 TOP...
Page 57 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: THIS PAGE LEFT INTENTIONALLY BLANK Page 6 of 6 REVISION: H-5378-B DATE: 12/16/09...
Page 59 EXPLODED VIEW: FUEL SYSTEM NG 4.6L 80KW GROUP E DRAWING #:0H3918 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0G9240B REG ASSY 4.6L 80KW NG CPL 057822 CLAMP HOSE #8 .53-1.00 059057 HOSE 3/4 ID SAE-30R2 (41.5” LG) 0F4408 Y CONNECTOR 500 SERIES BARBS 059057 HOSE 3/4 ID SAE-30R2 (11”...
Page 61 EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW GROUP E DRAWING #:0H3919 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0G9239D REG ASSY 4.6L 80KW LPV 2009CPL 057822 CLAMP HOSE #8 .53-1.00 0H3894 INTAKE ELBOW 4.6L G3 082121A CLIP-J VINYL COAT .375 ID 0H3921 GASKET AIR INTAKE 4.6L G3...
Page 63 (2) 1 0F58730ST01 REAR WRAP C5 (2) 2 0F58680ST01 DOOR C5 (2) 3 0F58720ST01 CENTER SUPPORT C5 (3) 4 0F58710AL01 DISCHARGE DUCT LH & RH SIDE C5 (2) 5 0F58690ST01 FRONT CORNERS C5 (2) 6 0F58700ST01 DISCHARGE CENTER DUCT C5 (3) 7 0F58670AL01 ROOF C5 ALUM...
Page 81 Serial Number 4.6L 80kW Models EPA Certified STATIONARY EMERGENCY GENERATOR OWNER'S MANUAL A new standard of reliability   Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
Page 82: Kw - 150 Kw Standby Gas Engine Driven Generator Sets
Changing the Engine Air Cleaner ......10-3 Cold Weather Kit ............6-2 Spark Plugs ............10-3 Coolant Heater Kit ............6-2 Coolant Change ............10-3 4.6L Ignition Description ..........6-3 Miscellaneous Maintenance ........10-3 Ignition Power-up Input (“56 Line Input”) ....6-3 Cleaning the Generator ...........10-3 Ignition Enable (“14 Line Input”) ......6-3 Battery ..............10-4...
Page 83: Introduction
Safety Instructions SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION ...
Page 84 Safety Instructions SAFETY RULES • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient Study these SAFETY RULES carefully before installing, operating concentrations, can cause unconsciousness or even death. For or servicing this equipment.
Page 85 Safety Instructions FIRE HAZARDS • If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the • Keep a fire extinguisher near the generator at all times. Do NOT equipment only while standing on such insulative mats.
Page 86: Identification Record
General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular model, please DATA LABEL refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit. Every generator set includes DATA LABEL that contains important information pertinent to the generator.
Page 87: Equipment Description
Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Use a mixture of half low silicate ethylene glycol base anti-freeze Emergency Generator. It is powered by a gaseous fueled engine and deionized water. Cooling system capacity is listed in the operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for specifications.
Page 88: Engine Protective Devices
Stationary Emergency Generator Engine Protective Devices ENGINE PROTECTIVE DEVICES OIL PRESSURE SENSING The Stationary Emergency Generator may be required An analog Oil Pressure Sender (OPS) is used for to operate for long periods of time without an opera- monitoring the engine oil pressure. This sender tor on hand to monitor such engine conditions as allows the control panel to measure and display the coolant temperature, oil pressure or rpm.
Page 89: Fuel Systems
Stationary Emergency Generator Fuel Systems FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid FUEL REQUIREMENTS fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor The Stationary Emergency Generator may be equipped with one of state.
Page 90: Engine
Stationary Emergency Generator Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............Gear Oil Filter ............Full Flow, Cartridge STATIONARY EMERGENCY GENERATOR Crankcase Oil Capacity ..........6 U.S. qts. Type..............Synchronous Rotor Insulation .............Class H COOLING SYSTEM Stator Insulation ............Class H Type Closed Total Harmonic Distortion ..........<...
Page 91: Cold Weather Kit
The LED fault code blink pattern is displayed for a minimum of two 4.6L IGNITION DESCRIPTION minutes after a fault has occurred and then the ignition will power The 4.6L Ignition Module operates with an 8-cylinder. The 4.6L itself down. engine uses a 36-1 crank sensor, a CAM sensor and coil-on-plug If an Ignition fault occurs, a signal is sent to the H-panel and then ignition coils for each spark plug.
Page 92: General Information
General Information ALTERNATOR AC LEAD ALTERNATOR POWER WINDING CONNECTIONS CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel 3-PHASE ALTERNATORS ("Y" CONFIGURATION) should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label.
Page 93 General Information Figure 7.4 — Stator Power Winding 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Connections - 3-phase, 120/208V (6 Lead) The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna- INTERNAL CONNECTIONS tor power windings. These windings were connected at the factory to the main circuit breaker with a "Delta"...
Page 94: Installation
Stationary Emergency Generator Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide” supplied with the unit. For safety reasons, the manufacturer recommends that this equip- ment be installed, serviced and repaired by a Service Dealer or  Prior to initially starting the generator, it must other competent, qualified electrician or installation technician who be properly prepared for use.
Page 95 Stationary Emergency Generator Installation START-UP CHECKLIST • Open the generator main line circuit breaker. • Connect a manometer to the gas line and record the static pres- sure. It must be as listed in the Specifications. • Insert the fuse into the control panel. ...
Page 96: Operation
Operation STATIONARY EMERGENCY GENERATOR CONTROL AND Do not crank the engine continuously for lon- OPERATION ger than 30 seconds, or the heat may damage the starter motor. Refer to the appropriate control panel operator’s manual for this • Let engine stabilize and warm up. unit.
Page 97: Maintenance
Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES  The exhaust system parts from this product get extremely hot and remain hot after shut- down. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such mate-  Before working on the Stationary Emergency rials may ignite and burn from the heat of the Generator, ensure the following: exhaust system.
Page 98: Engine Coolant
Maintenance ENGINE COOLANT INSPECT EXHAUST SYSTEM Check coolant level in coolant recovery bottle. See the Inspect the exhaust system at least once every three months. “Specifications” section. Check all exhaust system pipes, mufflers, clamps, etc. for condi- tion, tightness, leaks, security, damage. •...
Page 99: Changing The Engine Air Cleaner
Maintenance SPARK PLUGS Remove OIL FILL CAP . Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK Reset the spark plug gap or replace the spark plugs as neces- “FULL” MARK. Crankcase oil capacity is listed in the sary.
Page 100 Maintenance BATTERY Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause All lead-acid storage batteries discharge when not in use. Refer to severe burns. Do not permit fluid to contact specific instructions and warnings that accompany the battery. If eyes, skin, clothing, painted surfaces, etc.
Page 101 Stationary Emergency Generator Service Schedule SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Page 102 Stationary Emergency Generator Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level 5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
Page 103 Stationary Emergency Generator Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
Page 104 Stationary Emergency Generator Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp.
Page 105 Stationary Emergency Generator Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3.
Page 106 Warranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or compo- nent on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diagnosis, replace- ment parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
Page 107 (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain your record keeping requirements for compliance with Subpart JJJJ- Standards of Performance for Stationary Spark Ignition Internal Combustion Engines as listed in the Electronic Code of Federal Regulations Title 40 Part 60.
Page 108 Notes...
Page 110 0F9952 ASSY ROTOR 2390 80KB3 CPL 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F3417 ASSY ROTOR 390 2P 100K BRSHLS 092950 COLLAR SLIP FIT 390 MM 0F2984 ASSY ROTOR 390 2P 150K BRSHLS 04576100CF STUD M14-2.0 X 760 G5 ZINC 0F9949 ASSY STATOR 80KW 1PH 2P BRSHLS 052646...
Page 113 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 081008 GROMMET 1.25 X .25 X .75 0F6156 PLATE WIRE SNGL GALV 029289 TAPE ELEC 1/2 FOAM (AS REQ’D) 0F3685 STAND LH CONTROL C5 GRBX 0F2885 PANEL CB CONN BOX 051713...
Page 114 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (225AF) 0F4173 COVER CB C5 225AF 0F4165$ CIRCUIT BREAKERS 200A FRAME 0F4186 COVER CB DISH 225AF 036261 RIVET POP .125 X .275 SS 053640 SCREW RHM #8-32 X 3-1/4 038150...
Page 115 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION NEUTRAL BLOCK 390 / 200-400A. 0D5466 BUS BAR NEUTRAL BLOCK 390 039287 SCREW HHC M8-1.25 X 45 G8.8 FT 022145 WASHER FLAT 5/16-M8 ZINC 022129 WASHER LOCK M8-5/16 045771...
Page 116 EXPLODED VIEW: CPL H CONTROL CB CONNECTION GROUP A DRAWING #: 0H3917 APPLICABLE TO: THIS PAGE LEFT INTENTIONALLY BLANK REVISION: H-5277-B Page 6 of 6 DATE: 11/18/09...
Page 118 COMPONENTS INCL UDED IN 0G4139E 0F1823CST 03 ENCL H/G CO NTROL PANEL 0F1824AST 03 CO VER CONTRO L PANEL 0F2606 HING E CONT INUOUS H PANEL 036261 RIVET POP .125 X .275 SS 0F5763 ASSY PROGRAMMED H- 100 0F1732 DECAL FUSES LO CAT ED INSIDE 0E9764 RAIL SNAPTRACK PCB HO LDER BULK ( 12”...
Page 120 0F3408 TRAY BATTERY 0F3411 STRAP BATTERY RETAINMENT 058208 BATT 12VDC 24F 625 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATT POST COVER RED + 050331 BATT POST COVER BLK - 038805U CABLE BATT BLK #1 X 18.00 038804U CABLE BATT RED #1 X 28.00 045771 NUT HEX M8-1.25 G8 YEL CHR 022129...
Page 122 055597 SCREW HHC M12-1.75 X 85 G8.8 052251A DAMPENER VIBRATION 50 WHITE 052860 NUT LOCKING M12-1.75 0F8864 SUPPORT ENG 4.6L LH 0F8865 SUPPORT ENG 4.6L RH 045764 SCREW HHTT M4-0.7 X 8 BP 061383 LUG SOLDERLESS 3/0-#4 X 13/32 CU 045757 SCREW HHC M6-1.0 X 25 G8.8...
Page 124 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) 0F2807E PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) 0F9207 PIPE EXH MANIFOLD 4.6L RH 0F2807B PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) 0F2807D PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) 0F9208 PIPE EXH MANIFOLD 4.6L LH...
Page 126 PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) 0F2807E PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) 0F9207 PIPE EXH MANIFOLD 4.6L RH 0F2807B PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) 0F2807D PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) 0F9208 PIPE EXH MANIFOLD 4.6L LH...
Page 128 EXPLODED VIEW: EV AIR CLEANER GROUP D DRAWING #: 0F3569 ITEM PART# QTY. DESCRIPTION 0D2513D AIR CLNR BTM PLT W/CPLR 8.1L 0D2513E PLATE AIR CLEANER W/COUPLER 0F5419 ELEMENT AIR FILTER 0F4268 TOP PLATE VENTURI 0F4270A HOLD DOWN AIR CLEANER PLATED 0F6977 PLATE AIR CLEAN TOP 5.4L/6.8L 037561...
Page 130 EXPLODED VIEW: EV KIT GLASS PACK SHIP LOOSE GROUP DRAWING #: 0F6332A ITEM PART# QTY. DESCRIPTION 0F4462 RAIN CAP 2-1/2" AL 080762 BOLT U 3/8-16 X 2.62 0F4505A MUFF SEC 23.5" X 2.55IN/2.5OUT 0C2454 SCREW THF M6-1X16 N WA Z/JS (2) 5 0F4367 HEAT SHIELD EXHAUST STACK...
Page 132 EXPLODED VIEW: ENGCOMPRT LH 4.6L G3 GROUP D DRAWING #: 0H3914 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION CONNECTION WATER OUTLET (1)2 022145 WASHER FLAT 5/16-M8 ZINC GASKET THERMOSTAT HOUSING G3 THERMOSTAT ASSY (1)5 0G5515B ADAPTER THERMOSTAT 4.6L G3 0E0502 TEMPERATURE SENDER, DELPHI...
Page 134 EXPLODED VIEW: ENG COM PRT RH 4.6L G3 GROUP D DRAWING #:0H3914A APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 069860E HOSE DRAIN ASSY 28" 022158 NUT HEX #10-32 STEEL 0C7649 CLAMP HOSE .38-.87 0D2244M ASSY MAGPICKUP(3/8-24 MALE) 022129 WASHER LOCK M8-5/16 039253 SCREW HHC M8-1.25 X 20 G8.8...
Page 136 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H20530ST03 WELDMENT RADIATOR SUPPORT C5 0F2611 RADIATOR 680 X 680 X 70 CPL 0F5254 V-BELT 31/64" X 62-3/8" 046526 WASHER LOCK M10...
Page 137 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (5) 65 0D6029 SCREW HHTT M6-1.0 X 16 ZYC (5) 66 055934H CLAMP STL/VNL .62 X .406 Z (5) 67 072252 GROMMET 1.37 X .06 X 1.00...
Page 139 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0G15310GS0R PANEL C5 FRONT SIDES 0G15320GS0R PANEL C5 REAR SIDES 0G15300GS0R PANEL LOWER FRONT 0G15290GS0R PANEL C5 TOP (2) 0H30010GS0R PANEL C5 TOP...
Page 140 EXPLODED VIEW: COOLSYS/FAN DRIVE 5.4L & 4.6L CP GROUP D DRAWING #: 0H3915 APPLICABLE TO: THIS PAGE LEFT INTENTIONALLY BLANK Page 6 of 6 REVISION: H-5378-B DATE: 12/16/09...
Page 142 EXPLODED VIEW: FUEL SYSTEM NG 4.6L 80KW GROUP E DRAWING #:0H3918 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0G9240B REG ASSY 4.6L 80KW NG CPL 057822 CLAMP HOSE #8 .53-1.00 059057 HOSE 3/4 ID SAE-30R2 (41.5” LG) 0F4408 Y CONNECTOR 500 SERIES BARBS 059057 HOSE 3/4 ID SAE-30R2 (11”...
Page 144 EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW GROUP E DRAWING #:0H3919 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0G9239D REG ASSY 4.6L 80KW LPV 2009CPL 057822 CLAMP HOSE #8 .53-1.00 0H3894 INTAKE ELBOW 4.6L G3 082121A CLIP-J VINYL COAT .375 ID 0H3921 GASKET AIR INTAKE 4.6L G3...
Page 146 (2) 1 0F58730ST01 REAR WRAP C5 (2) 2 0F58680ST01 DOOR C5 (2) 3 0F58720ST01 CENTER SUPPORT C5 (3) 4 0F58710AL01 DISCHARGE DUCT LH & RH SIDE C5 (2) 5 0F58690ST01 FRONT CORNERS C5 (2) 6 0F58700ST01 DISCHARGE CENTER DUCT C5 (3) 7 0F58670AL01 ROOF C5 ALUM...

Generac Power Systems 4.6L Owner's Manual

Section 1

Introduction

Identification Record

Equipment Description

Engine Protective Devices

Fuel Systems

Specifications

General Information

Installation

Operation

Maintenance

Service Schedule

Troubleshooting

Section 2

Introduction

Identification Record

Equipment Description

Engine Protective Devices

Specifications

Fuel Systems

General Information

Installation

Operation

Maintenance

Quick Links

Chapters

Related Manuals for Generac Power Systems 4.6L

Summary of Contents for Generac Power Systems 4.6L

Table of Contents