Generac Power Systems Stationary emergency generator Owner's Manual
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Generac Power Systems Stationary emergency generator Owner's Manual

Stationary emergency generator 2.4l 36kw models epa certified
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Owner's Manual
Stationary Emergency Generator
NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT
APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION

ONLY!
This manual should remain with the unit.
0J8644
No.
Part
2.4L
36kW Models
EPA Certified
02/12
A
Rev.
Cover209

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Summary of Contents for Generac Power Systems Stationary emergency generator

  • Page 1 Owner's Manual Stationary Emergency Generator 2.4L NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT  36kW Models APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  SHOULD ATTEMPT INSTALLATION! EPA Certified DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION  ONLY! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Menu System ...................8-7 Propane Vapor Withdrawal Fuel System ........5-1 OPERATION ..............9-1 LP Liquid Fuel System ..............5-1 Stationary Emergency Generator Control and Operation ....9-1 SPECIFICATIONS ............6-1 Operating Unit with Manual Transfer Switch ........9-1 Stationary Emergency Generator ..........6-1 Engine Start-up and Transfer ............9-1 Engine ..................6-1...

  • 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: Fire Hazards

    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: General Information

    Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be Stationary Emergency Generator Model and Serial found attached to the generator’s lower connection box, lists the Number unit’s serial number and its rated voltage, amps, wattage capacity,...

  • Page 7: Equipment Description

    Engines that have been operated with a chromate base rust inhibitor The Stationary Emergency Generator incorporates the following must be chemically cleaned before adding eth- alternator features: ylene glycol base anti-freeze. Using any high •...

  • Page 8: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate After a prespecified duration of cranking, this function ends the for long periods of time without an operator on hand to monitor cranking if the engine has failed to start. The overcrank message such engine conditions as coolant temperature, oil pressure or will turn ON.

  • Page 9: Fuel System

    FUEL REQUIREMENTS distribution company provides piping from the main gas distribu- tion line to the standby generator site. The following information The Stationary Emergency Generator may be equipped with one of applies to natural gas fuel systems. the following fuel systems: •...

  • Page 10: Specifications

    Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............Gear Oil Filter ......... Full Flow Spin-on, Cartridge STATIONARY EMERGENCY GENERATOR Crankcase Oil Capacity ...........5.25 U.S. qts. Type..............Synchronous (including filter capacity) Rotor Insulation ..............Class F Stator Insulation ............Class H COOLING SYSTEM Telephone Interference Factor (TIF) ........

  • Page 11: Weather And Maintenance Kits

    Specifications WEATHER AND MAINTENANCE KITS Install the previously removed NG jet into the jet keeper port on the side of the regulator housing. To keep the generator running at its peak, the following kits are Install the previously removed black pipe onto the outlet offered: port of the demand regulator.

  • Page 12: General Information

    The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label. The number of lead 3-phase electrical loads. Electric power is produced in the alterna- wires can be identified using the Specifications section and the tor power windings.

  • Page 13: 3-Phase Alternators ("Delta" Configuration)

    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- tor power windings. These windings were connected at the factory INTERNAL CONNECTIONS to the main circuit breaker with a “Delta”...

  • Page 14: Control Panel

    Control Panel CONTROL PANEL INTERFACE Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly USING THE AUTO/OFF/MANUAL SWITCH connects AC utility power sense wires into the DC terminal block.

  • Page 15: Activation Chart

    Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- If the wrong language is chosen, it can be guage. Press ENTER to select. changed later using the “edit” menu. Language English Escape Enter Display Reads: Press ENTER to begin the activation pro-...

  • Page 16: Setting The Exercise Timer

    Control Panel INSTALLATION ASSISTANT • If utility is still lost after the “line interrupt period”, run the engine up to normal RPM and transfer the load. At this time the con- Interconnect System Self Test Feature (follow the on-screen troller will exit the exercise routine and assume full automatic prompts).

  • Page 17: Sequence Of Automatic Operation

    Control Panel MANUAL START SEQUENCE OF AUTOMATIC OPERATION Initial Conditions: Generator in Auto ready to run, load being sup- Allows the user to start and run the generator manually. plied by the Utility Source through the transfer switch. Transfer of the load to the generator will occur if utility is lost while When the utility voltage fails (falls below 60% of nominal), a the unit is running in the manual mode (only if activated).

  • Page 18: Under-Frequency Shutdown Alarm

    Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This This is a shutdown alarm. The alarm will activate after five (5) fault cannot be cleared using the control panel interface. The unit seconds of continuously missing cam pulses.

  • Page 19: Overvoltage Alarm

    Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an When the generator is shut down due to a latching alarm, the Auto alarm will be issued. /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding If the generator voltage rises above 130% for >0.2 seconds, an fault alarm message.
  • Page 20 Control Panel 12/11 Rev. CntrlNexus001...

  • Page 21: Operation

    UTILITY.  Do not attempt manual operation until all If the Stationary Emergency Generator has been installed with an power supplies to the transfer switch have been automatic transfer switch, the engine may be started and stopped positively turned off, or extremely dangerous - automatically or manually.

  • Page 22: Maintenance

    Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change fre- quencies. Drain the oil while the engine is still warm from running. This  Before working on the Stationary Emergency means warm up the engine, shut it down and drain immediately as follows: Generator, ensure the following: •...

  • Page 23: Engine Coolant

    EXERCISE SYSTEM qualified service facilities should adjust the governor. Excessively high operating speeds Starts the Stationary Emergency Generator engine once every are dangerous and increase the risk of personal seven days and lets it run for 12 minutes. injury. Low speeds impose a heavy load on the...

  • Page 24: Spark Plugs

    DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. CLEANING THE STATIONARY EMERGENCY GENERATOR Have the state of charge and condition checked. This should Keep the generator as clean and as dry as possible. Dirt and be done with an automotive-type battery hydrometer.

  • Page 25: Service Schedule

    Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Inspect Change Clean Yearly - Y Fuel Fuel Lines & Connections Lubrication Oil Level Oil Filter Cooling Engine Coolant Lines & Connections Engine Coolant Level Engine Coolant Enclosure Louvers Engine...

  • Page 26: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 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 27 Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diag- nosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
  • Page 28 Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended 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.

  • Page 29: Notes

    Notes...
  • Page 31 EXPLODED VIEW: EV ALTCOMPRT DIRECT B-CAN GROUP A DRAWING #: 0J5599A ITEM PART# QTY. DESCRIPTION 0G1931 ROTOR 25KW 3PH DIRECT 390 1800 0G2101 ROTOR 25KW 1PH DIRECT 390 1800 0G6568 RTR 390 45AD1 CPL 0G6570 RTR 390 45KD1 CPL 0G1932 ASSY STR 390 25 GD1 CPL 0G2098 ASSY STR 390 25AD1 CPL...
  • Page 32 EXPLODED VIEW: EV ALTCOMPRT DIRECT B-CAN GROUP A DRAWING #: 0J5599A ITEM PART# QTY. DESCRIPTION • • REVISION: J-1544-B Page 3 of 4 DATE: 2/3/12...
  • Page 33 EXPLODED VIEW: EV ALTCOMPRT DIRECT B-CAN GROUP A DRAWING #: 0J5599A ITEM PART# QTY. DESCRIPTION This page left blank intentionally REVISION: J-1544-B Page 4 of 4 DATE: 2/3/12...
  • Page 37 EXPLODED VIEW: EV CONBOX C2 CPL GROUP A DRAWING #: 0J8319 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0J8300 BACK PANEL CONBOX SUPPORT C2 0H6265 TOP PANEL CONBOX SUPPORT C2 0H6160 COVER WIRE ENTRY CONBOX 057073 JUNCTION BLOCK 3/8-16 056739 RELAY SOLENOID 12VDC PNL MNT (6)6 0H67330ST0R BRACKET GIMBAL CONTROL PNL RAW...
  • Page 38 EXPLODED VIEW: EV CONBOX C2 CPL GROUP A DRAWING #: 0J8319 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (225AF) 0G5250 CB 175A 2 POLE 240V 225AF 0H7356 COVER CB C2 CPL 0F4186AGS0R COVER CB DISH 2P G 225AF 0F8432A INSULATOR CB 2P 225AF 0H7311...
  • Page 39 EXPLODED VIEW: EV CONBOX C2 CPL GROUP A DRAWING #: 0J8319 APPLICABLE TO: 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...
  • Page 40 EXPLODED VIEW: EV CONBOX C2 CPL GROUP A DRAWING #: 0J8319 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (CC(2P & 3P)) 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...
  • Page 41 EXPLODED VIEW: EV CONBOX C2 CPL GROUP A DRAWING #: 0J8319 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (VL) 0H7519 CB 0300A 3P 600V S JG-VL LL 0H6738 COVER CB S JG VL C2 CONBOX 040976 SCREW SHC M8-1.25 X 20 C12.9 022129 WASHER LOCK M8-5/16 0H6734...
  • Page 43 0F9517 WELDMENT FRAME 2.4L C2 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 45 0F3408B BATTERY TRAY C1 CPL 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 052212 SCREW HHC M10-1.25 X 25 G8.8 046526 WASHER LOCK M10 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLACK - 038805Y CABLE BATTERY BLACK #1 X 18.00 03880400AE...
  • Page 47 EXPLODED VIEW: AIR CLEANER 2.4L G2 TURBO GROUP D DRAWING #: 0H1955 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0E6586 GASKET BOSCH 32 & 40 0H0295 ADAPTOR PCV INTAKE 0A6593A ADAPTOR - CARBURETOR 0C8127 ELEMENT, AIR CLEANER 5(1) 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 022127 NUT HEX 1/4-20 STEEL 0G0190...
  • Page 50 0H30830ST03 WELDMENT RADIATOR SUPPORT C2 0F2608 RADIATOR 598 X 568 X 49 CPL RH 022195 WASHER LOCK 1/2 0E3256 V-BELT A58 (60IN O.C.) DDC S60 022196 NUT HEX 1/2-13 STEEL 046526 WASHER LOCK M10 0F8651 SCREW HHFC M8-1.25 X 20 W/M6 (1) 5 059981 SCREW HHC M10-1.5 X 30 G10.9...
  • Page 54 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H1619 ENGINE 2.4L G2 CERTIFIED 046526 WASHER LOCK M10 039414 SCREW HHC M8-1.25 X 35 G8.8 0G0149 SCREW SHC M14-1.5 X 35 G10.9 0E9868A ALTERNATOR DC W/OUT PULLEY 0H0723AST03...
  • Page 55 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 052265 1(REF) SCREW HHC M8-1.25 X 65 C8.8 0H07280ST03 BRKT-EXH MANF 2.4L 36KW 0H0723BST03 LWR BRKT ASM HT SHIELD G2 36KW 084750 PLUG SPARK 045772...
  • Page 57 ITEM PART# QTY. DESCRIPTION 0G9936 TURBOCHARGER 2.4L 36KW 1800RPM 0H0788 GASKET EXH MAN/TURBO 064096B OIL SUPPLY 3LHA(38") 0A4707F ADAPTER 1/2NPT X M16-1.5 0A4707B ADAPTER 1/4NPT X M12-1.5 0C4973C ADAPTER 90D JIC37 1/4NPT X 1/2 0A8830 WASHER FLAT .34ID X .75OD 070006 WASHER LOCK M8 SS 070010...
  • Page 59 EXPLODED VIEW: FUEL SYSTEM 2.4L 36KW TURBO GROUP E DRAWING #: 0H7579 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0F8274 ASSY RGLTR INLET NPT FITTINGS 0F6390K REGULATOR ASSY 2.4L 36KW 0E6586 GASKET, BOSCH 32 & 40 0E4394 ACTUATOR BOSCH 40, GOVERNOR 063225 ELBOW RUBBER 90 2"...
  • Page 61 EXPLODED VIEW: EV ENCLOSURE C2 2.4L G2 TURBO GROUP F DRAWING #: 0J8688 ITEM PART# QTY. DESCRIPTION (2)1 0G80180AL0R REAR WRAP C2 G2 60KW (1)2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS (2)3 0F58490AL0R DOOR C2 087233 RIVET POP .1875 X .450 SS (1)5 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W...
  • Page 63 ITEM PART# QTY. DESCRIPTION 0G86870ST03 BRACKET MUFFLER 0G8686 BRACKET STIFFENER 0G3919 UPPER EXHAUST PIPE ASM 0G6150 MUFFLER 60kW 0F2808D EXHAUST PIPE 0G0007 DIFFUSER EXHAUST WELDMENT 0H0748 EXHAUST PIPE 0G8685 STRAP MUFFLER 080762 BOLT U 3/8-16 X 2.62 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 022473 WASHER FLAT 1/4-M6 ZINC 022097...
  • Page 78 Notes...
  • Page 79 Notes...
  • Page 80 04/07 Rev. BackPg001...
  • Page 81 Owner's Manual Stationary Emergency Generator 2.4L NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT  36kW Models APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  SHOULD ATTEMPT INSTALLATION! EPA Certified DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION  ONLY! This manual should remain with the unit.

  • Page 82: Exploded Views & Parts Lists Wiring Diagrams & Schematics

    Menu System ...................8-7 Propane Vapor Withdrawal Fuel System ........5-1 OPERATION ..............9-1 LP Liquid Fuel System ..............5-1 Stationary Emergency Generator Control and Operation ....9-1 SPECIFICATIONS ............6-1 Operating Unit with Manual Transfer Switch ........9-1 Stationary Emergency Generator ..........6-1 Engine Start-up and Transfer ............9-1 Engine ..................6-1...

  • Page 83: Introduction

    Standby Emergency Generator Important 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.
  • Page 84 Standby Emergency Generator Important Safety Instructions WARNING:   GENERAL HAZARDS   The engine exhaust from this product • For safety reasons, the manufacturer recommends that this contains chemicals known to the state equipment be installed, serviced and repaired by a Service of California to cause cancer, birth Dealer or other competent, qualified electrician or installation defects or other reproductive harm.

  • Page 85: Electrical Hazards

    Standby Emergency Generator Important Safety Instructions   ELECTRICAL HAZARDS FIRE HAZARDS   • All stationary emergency generators covered by this manual • Keep a fire extinguisher near the generator at all times. Do NOT produce dangerous electrical voltages and can cause fatal use any carbon tetra-chloride type extinguisher.

  • Page 86: General Information

    Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be Stationary Emergency Generator Model and Serial found attached to the generator’s lower connection box, lists the Number unit’s serial number and its rated voltage, amps, wattage capacity,...

  • Page 87: Equipment Description

    Engines that have been operated with a chromate base rust inhibitor The Stationary Emergency Generator incorporates the following must be chemically cleaned before adding ethyl- alternator features: ene glycol base anti-freeze. Using any high sili- •...

  • Page 88: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate After a prespecified duration of cranking, this function ends the for long periods of time without an operator on hand to monitor cranking if the engine has failed to start. The overcrank message such engine conditions as coolant temperature, oil pressure or will turn ON.

  • Page 89: Fuel System

    FUEL REQUIREMENTS distribution company provides piping from the main gas distribu- tion line to the standby generator site. The following information The Stationary Emergency Generator may be equipped with one of applies to natural gas fuel systems. the following fuel systems: •...

  • Page 90: Specifications

    Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............Gear Oil Filter ......... Full Flow Spin-on, Cartridge STATIONARY EMERGENCY GENERATOR Crankcase Oil Capacity ...........5.25 U.S. qts. Type..............Synchronous (including filter capacity) Rotor Insulation ..............Class F Stator Insulation ............Class H COOLING SYSTEM Telephone Interference Factor (TIF) ........

  • Page 91: Weather And Maintenance Kits

    Specifications WEATHER AND MAINTENANCE KITS Install the previously removed NG jet into the jet keeper port on the side of the regulator housing. To keep the generator running at its peak, the following kits are Install the previously removed black pipe onto the outlet offered: port of the demand regulator.

  • Page 92: General Information

    The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label. The number of lead 3-phase electrical loads. Electric power is produced in the alterna- wires can be identified using the Specifications section and the tor power windings.

  • Page 93: 3-Phase Alternators ("Delta" Configuration)

    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- tor power windings. These windings were connected at the factory INTERNAL CONNECTIONS to the main circuit breaker with a “Delta”...

  • Page 94: Control Panel

    Control Panel CONTROL PANEL INTERFACE Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly USING THE AUTO/OFF/MANUAL SWITCH connects AC utility power sense wires into the DC terminal block.

  • Page 95: Activation Chart

    Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- If the wrong language is chosen, it can be guage. Press ENTER to select. changed later using the “edit” menu. Language English Escape Enter Display Reads: Press ENTER to begin the activation pro-...

  • Page 96: Setting The Exercise Timer

    Control Panel INSTALLATION ASSISTANT • If utility is still lost after the “line interrupt period”, run the engine up to normal RPM and transfer the load. At this time the con- Interconnect System Self Test Feature (follow the on-screen troller will exit the exercise routine and assume full automatic prompts).

  • Page 97: Sequence Of Automatic Operation

    Control Panel MANUAL START SEQUENCE OF AUTOMATIC OPERATION Initial Conditions: Generator in Auto ready to run, load being sup- Allows the user to start and run the generator manually. plied by the Utility Source through the transfer switch. Transfer of the load to the generator will occur if utility is lost while When the utility voltage fails (falls below 60% of nominal), a the unit is running in the manual mode (only if activated).

  • Page 98: Under-Frequency Shutdown Alarm

    Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This This is a shutdown alarm. The alarm will activate after five (5) fault cannot be cleared using the control panel interface. The unit seconds of continuously missing cam pulses.

  • Page 99: Overvoltage Alarm

    Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an When the generator is shut down due to a latching alarm, the Auto alarm will be issued. /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding If the generator voltage rises above 130% for >0.2 seconds, an fault alarm message.
  • Page 100 Control Panel 12/11 Rev. CntrlNexus001...

  • Page 101: Operation

    TRANSFER SWITCH  Do not attempt manual operation until all power If the Stationary Emergency Generator has been installed with an supplies to the transfer switch have been posi- automatic transfer switch, the engine may be started and stopped tively turned off, or extremely dangerous - pos- automatically or manually.

  • Page 102: Maintenance

    Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change fre- quencies. Drain the oil while the engine is still warm from running. This  Before working on the Stationary Emergency means warm up the engine, shut it down and drain immediately as follows: Generator, ensure the following: •...

  • Page 103: Engine Coolant

    EXERCISE SYSTEM qualified service facilities should adjust the governor. Excessively high operating speeds Starts the Stationary Emergency Generator engine once every are dangerous and increase the risk of personal seven days and lets it run for 12 minutes. injury. Low speeds impose a heavy load on the...

  • Page 104: Spark Plugs

    DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. CLEANING THE STATIONARY EMERGENCY GENERATOR Have the state of charge and condition checked. This should Keep the generator as clean and as dry as possible. Dirt and be done with an automotive-type battery hydrometer.

  • Page 105: Service Schedule

    Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Inspect Change Clean Yearly - Y Fuel Fuel Lines & Connections Lubrication Oil Level Oil Filter Cooling Engine Coolant Lines & Connections Engine Coolant Level Engine Coolant Enclosure Louvers Engine...

  • Page 106: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 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 107 Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diag- nosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
  • Page 108 Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended 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.
  • Page 109 Stationary Emergency Generator Notes...
  • Page 111 0F9517 WELDMENT FRAME 2.4L C2 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 113 0F3408B BATTERY TRAY C1 CPL 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 052212 SCREW HHC M10-1.25 X 25 G8.8 046526 WASHER LOCK M10 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLACK - 038805Y CABLE BATTERY BLACK #1 X 18.00 03880400AE...
  • Page 115 EXPLODED VIEW: AIR CLEANER 2.4L G2 TURBO GROUP D DRAWING #: 0H1955 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0E6586 GASKET BOSCH 32 & 40 0H0295 ADAPTOR PCV INTAKE 0A6593 ADAPTOR - CARBURETOR 0C8127 ELEMENT, AIR CLEANER 5(1) 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 022127 NUT HEX 1/4-20 STEEL 0G0190...
  • Page 118 0H30830ST03 WELDMENT RADIATOR SUPPORT C2 0F2608 RADIATOR 598 X 568 X 49 CPL RH 022195 WASHER LOCK 1/2 0E3256 V-BELT A58 (60IN O.C.) DDC S60 022196 NUT HEX 1/2-13 STEEL 046526 WASHER LOCK M10 0F8651 SCREW HHFC M8-1.25 X 20 W/M6 (1) 5 059981 SCREW HHC M10-1.5 X 30 G10.9...
  • Page 124 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H1619 ENGINE 2.4L G2 CERTIFIED 046526 WASHER LOCK M10 039414 SCREW HHC M8-1.25 X 35 G8.8 0G0149 SCREW SHC M14-1.5 X 35 G10.9 0E9868A ALTERNATOR DC W/OUT PULLEY 0H0723AST03...
  • Page 125 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H1619 ENGINE 2.4L G2 CERTIFIED 046526 WASHER LOCK M10 039414 SCREW HHC M8-1.25 X 35 G8.8 0G0149 SCREW SHC M14-1.5 X 35 G10.9 (2)5 0E9868A ALTERNATOR DC W/OUT PULLEY...
  • Page 126 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 052265 1(REF) SCREW HHC M8-1.25 X 65 C8.8 0H07280ST03 BRKT-EXH MANF 2.4L 36KW 0H0723BST03 LWR BRKT ASM HT SHIELD G2 36KW 084750 PLUG SPARK 045772...
  • Page 127 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 TURBO 36K GROUP D DRAWING #: 0H7321 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 052265 1(REF) SCREW HHC M8-1.25 X 65 C8.8 0H07280ST03 BRKT-EXH MANF 2.4L 36KW 0H0723BST03 LWR BRKT ASM HT SHIELD G2 36KW 084750 PLUG SPARK 045772...
  • Page 129 ITEM PART# QTY. DESCRIPTION 0G9936 TURBOCHARGER 2.4L 36KW 1800RPM 0H0788 GASKET EXH MAN/TURBO 064096B OIL SUPPLY 3LHA(38") 0A4707F ADAPTER 1/2NPT X M16-1.5 0A4707B ADAPTER 1/4NPT X M12-1.5 0C4973C ADAPTER 90D JIC37 1/4NPT X 1/2 0A8830 WASHER FLAT .34ID X .75OD 070006 WASHER LOCK M8 SS 070010...
  • Page 131 EXPLODED VIEW: FUEL SYSTEM 2.4L 36KW TURBO GROUP E DRAWING #: 0H7579 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0F8274 ASSY RGLTR INLET NPT FITTINGS 0F6390K REGULATOR ASSY 2.4L 36KW 0E6586 GASKET, BOSCH 32 & 40 0E4394 ACTUATOR BOSCH 40, GOVERNOR 063225 ELBOW RUBBER 90 2"...
  • Page 133 EXPLODED VIEW: EV ENCLOSURE C2 2.4L G2 TURBO GROUP F DRAWING #: 0J8688 ITEM PART# QTY. DESCRIPTION (2)1 0G80180AL0R REAR WRAP C2 G2 60KW (1)2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS (2)3 0F58490AL0R DOOR C2 087233 RIVET POP .1875 X .450 SS (1)5 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W...
  • Page 135 ITEM PART# QTY. DESCRIPTION 0G86870ST03 BRACKET MUFFLER 0G8686 BRACKET STIFFENER 0G3919 UPPER EXHAUST PIPE ASM 0G6150 MUFFLER 60kW 0F2808D EXHAUST PIPE 0G0007 DIFFUSER EXHAUST WELDMENT 0H0748 EXHAUST PIPE 0G8685 STRAP MUFFLER 080762 BOLT U 3/8-16 X 2.62 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 022473 WASHER FLAT 1/4-M6 ZINC 022097...
  • Page 150 04/07 Rev. BackPg001...

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