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Generac Power Systems 004810-0 Owner's Manual

Standby generator
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POWER SYSTEMS, INC.
Owner's Manual
Standby Generator
Models: 004810-0 & 004811-0
This manual should remain with the unit.

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Summary of Contents for Generac Power Systems 004810-0

  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Standby Generator Models: 004810-0 & 004811-0 This manual should remain with the unit.

  • Page 2: Introduction

    Thank you for purchasing this model of the standby the operator read this Owner's Manual and thor- generator set product line by Generac Power Systems. oughly understand all instructions before using this Every effort was expended to make sure that the equipment.

  • Page 3: Table Of Contents

    Table of Contents Generac Standby Generator Sets Introduction ........Inside Front Cover 2.3 EMERGENCY CIRCUIT ISOLATION METHOD ..8 Read This Manual Thoroughly........IFC 2.4 TOTAL CIRCUIT ISOLATION METHOD ....9 Operation and Maintenance ........IFC 2.5 GROUNDING THE GENERATOR ......9 How to Obtain Service ..........IFC 2.6 GENERATOR AC NEUTRAL CONNECTIONS ..9 Authorized Service Dealer Locator Number....IFC 2.7 TRANSFER SWITCH START SIGNAL...

  • Page 4: Safety Rules

    Important Safety Instructions Generac Standby Generator Sets 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. SAVE THESE INSTRUCTIONS –...
  • Page 5 Important Safety Instructions Generac Standby Generator Sets • Inspect the generator regularly, and promptly • Generators installed with an automatic transfer repair or replace all worn, damaged or defective switch will crank and start automatically when parts using only factory-approved parts. normal (utility) source voltage is removed or is below an acceptable preset level.

  • Page 6: Section 1 - General Information

    Section 1 – General Information Generac Standby Generator Sets IDENTIFICATION RECORD ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for 1.1.1 DATA PLATE long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- Every generator set has a metal DATA PLATE that ture, oil pressure or rpm.

  • Page 7: Overcrank Shutdown

    Section 1 – General Information Generac Standby Generator Sets 1.3.6 OVERCRANK SHUTDOWN SPECIFICATIONS After a prespecified duration of cranking, this func- 1.6.1 GENERATOR tion ends the cranking if the engine has failed to start. Refer to the data plate on your particular generator for rated watts, amperes, frequency, voltage, phase 1.3.7 RPM SENSOR LOSS SHUTDOWN and other pertinent information.

  • Page 8: Engine Oil Recommendations

    Section 1 – General Information Generac Standby Generator Sets Engine Electrical System: GENERATOR AC LEAD DC Alternator Output ..........42 amps at 12 volts CONNECTIONS Starter Motor................12-volt DC The electrical wires in the unit’s AC connection Recommended Battery ........One 12-volt, 90 Ah, 27 F (lower) panel should be installed according to the Ground Polarity ..............Negative (–) number of leads and the voltage/phase required for...

  • Page 9: Starting Aids

    Section 2 – Installation Generac Standby Generator Sets STARTING AIDS Figure 1.3 – Typical Dual-rate Battery Charger This standby generator is equipped with the following starting aids that serve to provide quicker, easier starts under varying climactic conditions. This generator has been mounted with an engine coolant heater and a battery charger.

  • Page 10: Nfpa Standards

    Section 2 – Installation Generac Standby Generator Sets NOTE: • Permits the LOAD circuits to be connected to only one power supply at a time. For more information about the installation of a • Prevents electrical backfeed between the generator standby system, you can order Engine-Generator and the UTILITY power circuits.

  • Page 11: Total Circuit Isolation Method

    Section 2 – Installation Generac Standby Generator Sets TOTAL CIRCUIT ISOLATION GENERATOR AC NEUTRAL METHOD CONNECTIONS When a generator capable of powering all electrical Generac uses an UNGROUNDED AC neutral. loads in the circuit is to be installed, you may use the Grounding is recommended only at the main service “Total Circuit Isolation Method.”...

  • Page 12: Vented Batteries

    Section 2 – Installation Generac Standby Generator Sets Storage batteries give off explosive hydrogen • DO NOT SMOKE when near batteries, gas. This gas can form an explosive mixture • DO NOT cause flame or spark in battery area, and around the battery for several hours after •...

  • Page 13: Start-Up Inspection

    Section 2 – Installation Generac Standby Generator Sets 2.9.1.1 Transfer Switch 2.9.1.5 Belt Tension If this generator is used to supply power to any elec- Check the engine fan belt tension and condition prior trical system normally powered by an electric utility, to placing the unit into service and at recommended the National Electrical Code requires that a transfer intervals.

  • Page 14: Section 3 - Operation

    Section 4 – Maintenance Generac Standby Generator Sets GENERATOR CONTROL AND 4.1.2.2 Every Six Months or Every 200 Hours (whichever comes first) OPERATION • Change engine oil and filter. Refer to the appropriate control panel operator’s • Lubricate engine controls. manual for this unit.

  • Page 15: Section 4 - Maintenance

    Section 4 – Maintenance Generac Standby Generator Sets PERIODIC MAINTENANCE 4.2.2 INSPECT BATTERY A rigorous program of scheduled periodic mainte- DANGER nance should be established and maintained. Such a program, if adhered to diligently, will provide added Standby generators installed with automatic assurance that your power system functions proper- transfer switches will crank and start automati- ly when it is needed.

  • Page 16: Test Standby Generator System Operation And Components

    Section 4 – Maintenance Generac Standby Generator Sets 4.2.3 BATTERY REPLACEMENT REPAIR PARTS The latter portion of this manual consist of exploded When replacing batteries, use the same number and views, parts lists and electrical data pertaining to this the following type batteries. generator set.

  • Page 17: Section 5 - Installation Diagram

    Section 5 — Installation Generac Standby Generator Sets Installation Diagram – Drawing No. 0E5195 Generac ® Power Systems, Inc. 15...
  • Page 18 Section 6 — Electrical Data Generac Standby Generator Sets Wiring Diagram - E Panel – Drawing No. 0D2378V-B WIRE COLOR FUNCTION WIRE #'s LEGEND WHITE NEUTRAL 0,1,R15,591 BLACK/485+ NON-FUSED DC 4,13,29,218 CLEAR/485- ORANGE FUSED DC 14,15,219,220 BARE 56,56A,57-59,67,89 BROWN CONTROL 162,178,183,S1-3,590 2,49,150,A1-8,R1-9 BLUE...
  • Page 19 Section 6 — Electrical Data Generac Standby Generator Sets Wiring Diagram - E Panel – Drawing No. 0D2378V-B 14/219 SNDR RLY N/C PRG INPT 1 SNDR RLY N/O SNDR RLY COM PRG INPT 3 15/220 PRG RLY 3 NC PRG RLY 3 NO PRG INPT 5 PRG RLY 3 COM PRG RLY 2 NC...

  • Page 20: Section 6 - Electrical Data

    Section 6 — Electrical Data Generac Standby Generator Sets Wiring Schematic - E Panel – Drawing No. 0D2379V-A LOWER PANEL CONNECTOR FIELD POWER SENSING BC3-10 CHARGE ALT. W/L CONN. TB4-5 AUX. FUSED DC SUPPLY PROG. INPUT 1 CON4-1 CON1-1 POSITIVE DC FROM BATTERY BATT CHRG FAIL BC3-12 PROG.
  • Page 21 Section 6 — Electrical Data Generac Standby Generator Sets Wiring Schematic - E Panel – Drawing No. 0D2379V-A CODE P/N: DESCRIPTION 061286 AUDIBLE ALARM VARIOUS AMMETER 067680 AUTOMATIC VOLTAGE REGULATOR 50Hz 092952 AUTOMATIC VOLTAGE REGULATOR 60Hz VARIOUS AVR CIRCUIT BREAKER 049939 FIELD BOOST DIODE 025192...
  • Page 22 Section 6 — Electrical Data Generac Standby Generator Sets Wiring Diagram - Battery Charger – Drawing No. 0D8610 COVER K6 K6 COVER ASSY # 67666 REV_G K1 K1 K4 K4 CHASSIS AC NEUT AC HOT 0D4698-T AC HOT AC NEUT LEGEND - DC AMMETER, 0-15A - FUSE, 250V,...
  • Page 23 Section 6 — Electrical Data Generac Standby Generator Sets Electrical Schematic - Battery Charger – Drawing No. 0D8611 Generac ® Power Systems, Inc. 21...
  • Page 24 Section 6 — Electrical Data Generac Standby Generator Sets Wiring Diagram - 3.0L Engine – Drawing No. 0E2005A 22 Generac ® Power Systems, Inc.
  • Page 25 Section 6 — Electrical Data Generac Standby Generator Sets Electrical Schematic - 3.0L Engine – Drawing No. 0E2006A Generac ® Power Systems, Inc. 23...
  • Page 26 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Mounting Base – Drawing No. 0C3711-H 24 Generac ® Power Systems, Inc.
  • Page 27 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Mounting Base – Drawing No. 0C3711-H ITEM PART NO. QTY. DESCRIPTION 0C3421 MOUNTING BASE 3.0L HA KIA 390 ALTERNATOR 0C4214 MOUNTING BASE 3.0L HA KIA 10" ALTERNATOR 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE...
  • Page 28 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Compartment – Drawing No. 0C4402-G 26 Generac ® Power Systems, Inc.
  • Page 29 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Compartment – Drawing No. 0C4402-G ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C3594 ASSEMBLY, M6 HINGE 0A5035A SELF ADHESIVE HANGER 3/4" 0A3359 SCREW BHSC M6-1.0 X 16 SS 0C4375S INSULATION, DUCT BOTTOM 0A3360...

  • Page 30: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Tank – Drawing No. 0E5125 28 Generac ® Power Systems, Inc.
  • Page 31 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Tank – Drawing No. 0E5125 ITEM PART NO. QTY. DESCRIPTION 0E5118 TANK A GRP DW 132 GAL VERIZON 052645 SCREW HHC M12-1.75 X 30 G8.8 049808 WASHER FLAT M12 052860 NUT LOCKING M12-1.75 0E5124...
  • Page 32 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Generator – Drawing No. 0E5165 30 Generac ® Power Systems, Inc.
  • Page 33 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Generator – Drawing No. 0E5165 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 051768 SCREW HHC M12-1.75 X 25 G8.8 087271 ASSEMBLY EXCITER 1.25" STACK 051769 WASHER LOCK M12 068404 EXCITER FIELD 1.25"...
  • Page 34 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Radiator – Drawing No. 0E5161-A 32 Generac ® Power Systems, Inc.
  • Page 35 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Radiator – Drawing No. 0E5161-A ITEM PART NO. QTY. DESCRIPTION 0C3829 RADIATOR 14 FIN 3 LHA (UNITS 25KW & ABOVE) 0C3417 RADIATOR SIDE SUPPORT 3.0L HA 0C3418 VENTURI 3.0L HA 0A8583A ADAPTOR M20-2.0 X 3/8 NPT 051753...
  • Page 36 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Muffler – Drawing No. 0E5157-A ITEM PART NO. QTY. DESCRIPTION 059937 MUFFLER 2 NPT BXU 060366 MUFFLR STRAP 6IN DIA 059933 ELBOW 90D 2 NPT 059109 NIPPLE TOE 2 NPT X 9 BLK IRON 039253 SCREW HHC M8-1.25 X 20 G8.8 052858...
  • Page 37 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Turbo – Drawing No. 0E5033 1/8" NPT CROSS ON OIL PUMP REMOVE FACTORY LIFTING EYE REMOVE & REPLACE 2 FACTORY BOLTS REMOVE & REPLACE 2 FACTORY BOLTS GASKET REMOVE FACTORY STUDS TO OIL...
  • Page 38 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Circuit Breaker – Drawing No. 0E5163 BOTTOM OF CONTROL PANEL FD 3 POLE (600V) (150-250A) ALT. LEADS & SENSING WIRE ALT. LEADS & SENSING WIRE AMPERAGE CABLE WIRE SIZE DESCRIPTION: RATING SCREW TORQUE...
  • Page 39 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Circuit Breaker – Drawing No. 0E5163 ITEM PART NO. QTY. DESCRIPTION 068115 PANEL LOWER (390 BOX) 068147 COVER LOWER PANEL BLANK 022473 WASHER FLAT 1/4 022097 WASHER LOCK M6-1/4 022287 SCREW HHC 1/4-20 X 3/4 G5 022127...
  • Page 40 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Engine Parts – Drawing No. 0E5031-A 38 Generac ® Power Systems, Inc.
  • Page 41 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Engine Parts – Drawing No. 0E5031-A ITEM PART NO. QTY. DESCRIPTION 0C2920 ENGINE KIA 3.0L KIA 0C2947L FOOT LH ENGINE MOUNTING 0C2947R FOOT RH ENGINE MOUNTING (NOT SHOWN) 022302 WASHER LOCK 7/16 022315...
  • Page 42 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Control Panel – Drawing No. 0E5158 40 Generac ® Power Systems, Inc.
  • Page 43 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Control Panel – Drawing No. 0E5158 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E3681 PANEL,BACK & BOTTOM E-PNL VRZN 0D3471 DECAL COVER DEUTSCH (RECT) 0E3679 E-PANEL FRONT, W/ SILK SCREEN (ELECTRONIC GOVERNOR HARNESS 0E3683...
  • Page 44 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Exhaust (Model 004810-0) – Drawing No. 0E5167 2.5" Dia. Clamp Assembly Engine Compartment Front ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 080762 BOLT U 3/8-16 X 2.62...
  • Page 45 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Air Duct – Drawing No. 0E1280 ITEM PART NO. QTY. DESCRIPTION 0A6984 BRACKET AIR DUCT TOP/BOTTOM 0A6982 BRACKET AIR DUCT RH SIDE 0A6983 BRACKET AIR DUCT LH SIDE 022413 SCREW HHC 1/4-20 X 1 G5 022097...
  • Page 46 Section 7 — Exploded Views and Parts Lists Generac Standby Generator Sets Electronic Governor – Drawing No. 0E1818-A TO CONTROLLER (BLACK / WHITE STRIPE & WHITE) CHASSIS INSIDE CONTROL PANEL TO FLYWHEEL HOUSING FACTORY THROTTLE CONTROL ARM TO CONTROLLER (PURPLE WIRES) 76.2±1.6 [3±1/16"] ITEM PART NO.

  • Page 47: Section 8 - Notes

    Section 8 — Notes Generac Standby Generator Sets Generac ® Power Systems, Inc. 45...
  • Page 48 Section 8 — Notes Generac Standby Generator Sets 46 Generac ® Power Systems, Inc.
  • Page 49 Section 8 — Notes Generac Standby Generator Sets Generac ® Power Systems, Inc. 47...

  • Page 50: Section 9 - Warranty

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to federal and California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new non-road diesel engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circum- stances where the Generac Warranty may provide a longer warranty period.
  • Page 51 Section 9 – Warranty Generac Standby Generator Sets EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1996 and later model year non-road diesel engines: (a) Applicability: This warranty shall apply to 1996 and later model year non-road diesel engines. The ECS Warranty shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 60 months, or 3,000 hours of use, thereafter, whichever occurs first.
  • Page 52 Generac Service Facility, and only applies to permanently wired and mounted units. • A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

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004811-0

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