Generac Power Systems 45kW Owner's Manual
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Generac Power Systems 45kW Owner's Manual

2.4 l epa sertified with catalyst stationary emergency generator
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2.4L
45kW Models
EPA Certified
with Catalyst
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!
This manual should remain with the unit.

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  • Page 1: Serial Number

    Serial Number 2.4L 45kW Models EPA Certified with Catalyst 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

    Stationary Emergency Generator Table of Contents SECTION PAGE Electrical System .................8-1 Initial Inspection for Genset Start-up ..........8-1 INTRODUCTION ................1-1 Start-up Checklist ................8-2 Read this Manual Thoroughly ............1-1 Operation and Maintenance ............1-1 Preparation for Start-up ..............8-2 How to Obtain Service ..............1-1 OPERATION ..................9-1 SAFETY RULES ................1-2 Stationary Emergency Generator Control and Operation ....9-1...

  • 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: 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

    Stationary Emergency Generator Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required After a prespecified duration of cranking, this func- to operate for long periods of time without an opera- tion ends the cranking if the engine has failed to tor on hand to monitor such engine conditions as start.

  • Page 9: Fuel Systems

    Fuel System FUEL SYSTEM NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state. In most cases, the gas 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.

  • Page 10: Specifications

    Type................Electronic Sensing ..............Single-phase Exhaust System Regulation ................± 1% Exhaust Flow at Rated Output 60 Hz (45kW) ....420 cfm Features ..........V/F Adjustable, Adjustable Exhaust Temp. at Rated Output (45kW) ......1100° F Voltage and Gain LED Indicators Combustion Air Requirements (Natural Gas) Power Adjustment for Ambient Conditions Flow at rated power, 60 Hz (45kW) ......144 cfm...

  • Page 11: Cold Weather Kit

    Stationary Emergency Generator Specifications Figure 6.1 — Interconnections ALTERNATOR CONNECTION Utility In Transfer Switch NEUTRAL Load 4- #14 GA WIRES TO ALTERNATOR CONNECTION TO ALTERNATOR CONNECTION BOX To Generator Control Panel This is a generic representation of the components contained in the transfer switch and connection box. Refer to the wiring and schematic diagrams for generator specific connections.

  • Page 12: Control Panel

    Stationary Emergency Generator Specifications Disconnect the power wires from the fuel solenoid located on top of the regulator assembly. Loosen the spring clamp on the small fuel enrichment line and IMPORTANT EXHAUST EMISSIONS  remove the hose from the hose barb. INFORMATION Remove the black pipe assembly from the outlet port of the This unit is equipped with an Active Exhaust...

  • Page 13: 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 14: 3-Phase Alternators ("Delta" Configuration)

    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 15: 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 16: Start-Up Checklist

    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 17: 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 18: Maintenance

    Maintenance MAINTENANCE PERFORMED BY COOLING SYSTEM Air intake and outlet openings in the generator compartment must SERVICE DEALERS/CONTRACTORS be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.  Before working on the Stationary Emergency Without sufficient cooling and ventilating air flow, the engine/gen- Generator, ensure the following: erator quickly overheats, which causes it to shut down.

  • Page 19: Battery Fluid

    Maintenance INSPECT COOLING SYSTEM • Remove oil dipstick and wipe dry with a clean, lint-free cloth. • Install oil dipstick, then remove again. • Inspect engine cooling system. See “Maintenance Schedule”. • Oil should be between FULL and ADD marks. •...

  • Page 20: Inspect Engine Governor

    Maintenance INSPECT ENGINE GOVERNOR Apply light coating of new engine oil to seal of new oil filter.-Install FILTER and tighten by hand only. DO NOT OVER Visually inspect electronic governor. TIGHTEN. Remove OIL FILL CAP and add recommended oil. Crankcase oil capacity is listed in the "Specifications"...

  • Page 21: Coolant Change

    Maintenance Figure 10.5 – Setting the Spark Plug Gap • Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for sev- eral hours after charging. Any spark, heat or flames can ignite the gas and cause an explosion which can shatter the battery, causing blindness or other serious injury.

  • Page 22: Battery Replacement

    Maintenance REPAIR PARTS BATTERY REPLACEMENT The later portion of this manuals consists of exploded views, NOTE: parts lists and electrical data pertaining to this generator set. The Unit DOES NOT include battery. parts list consists of: (a) an Item Number, (b) a Part Number, (c) Quantity required, and (d) a Description of the part.

  • Page 23: Service Schedule

    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 24 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 25 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 26 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 27: Troubleshooting

    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 28 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 29 (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 30 Notes...
  • Page 32 STATOR-390 45K 2P 1PH DIRECT 0G0057 STATOR-2390-35AD1 CPL 0G0058 STATOR-2390-35KD1 CPL 0G0059 STATOR-2390-35GD1 CPL 0G0183 STATOR-2309-45KW 2P 3PH 208V 0G0184 STATOR-2309-45-KD1 CPL 0G1932 ASSY STR 390 25GD3 CPL 0G2098 ASSY STR 390 25AD1 CPL 0G2099 ASSY STR 390 25KD3 CPL...
  • Page 36 EXPLODED VIEW: EV CPL C2&C4 R200C CB CONN GROUP A DRAWING #: 0H1730 ITEM PART# QTY. DESCRIPTION PAGE 1 0F3137 PAN CB CONN BOX 0F3188 STAND RH CONTROL 0F3189 STAND LH CONTROL 023484N BUSHING SNAP SB-2.5-31 0F6366B XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS) 0F6366A XFMR DUAL 104V/16V (FOR 120/208V UNITS) 043180...
  • Page 37 EXPLODED VIEW: EV CPL C2&C4 R200C CB CONN GROUP A DRAWING #: 0H1730 ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (FD) 0F3138 COVER CB CONN BOX 0D5572 CB 0150A 3P 600V S FD6 LL 0D5573 CB 0175A 3P 600V S FD6 LL 0D5574 CB 0200A 3P 600V S FD6 LL 0D5575...
  • Page 38 EXPLODED VIEW: EV CPL C2&C4 R200C CB CONN GROUP A DRAWING #: 0H1730 ITEM PART# QTY. DESCRIPTION 0F8432A INSULATOR CB 225AF (2P) 0C2454 SCREW THF M6-1 X 16 N WA Z/JS (2) R 0F8451 LUG SLDLSS 300 MCM-6 AL/CU (2) S 049821 SCREW SHC M8-1.25 X 30 C12.9 (2) T...
  • Page 39 EXPLODED VIEW: EV CPL C2&C4 R200C CB CONN GROUP A DRAWING #: 0H1730 ITEM PART# QTY. DESCRIPTION 036261 RIVET POP .125 X .275 SS (2) F 038150 WASHER FLAT #8 ZINC (2) G 022264 WASHER LOCK #8-M4 (2) H 022471 NUT HEX #8-32 STEEL 0H4698 INSULATOR CB 2P E TYPE CC...
  • Page 40 EXPLODED VIEW: EV CPL C2&C4 R200C CB CONN GROUP A DRAWING #: 0H1730 ITEM PART# QTY. DESCRIPTION This page left blank intentionally REVISION: J-9104-D Page 8 of 8 DATE: 6/23/14...
  • Page 42 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 44 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 46 EXPLODED VIEW: EV AIR CLEANER GROUP D DRAWING #: 0F9809 ITEM PART# QTY. DESCRIPTION 0E6586 GASKET BOSCH 32 & 40 0E0519A ADAPTER CARBURETOR W/PVC CONN 0C8127 ELEMENT AIR CLEANER 049815 SCREW HHC M5-0.8 X 16 G8.8 022127 NUT HEX 1/4-20 STEEL (1) 6 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC...
  • Page 48 0E6586 GASKET BOSCH 32 & 40 0E0519A ADAPTER CARBURETOR W/PVC CONN 0C8127 ELEMENT AIR CLEANER 049815 SCREW HHC M5-0.8 X 16 G8.8 022127 NUT HEX 1/4-20 STEEL (1) 6 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 0G0190 PLATE, AIR CLEANER TOP 2.4L 037561 NUT WING 1/4-20 NYLK (1) APPLY MEDIUM STRENGTH BLUE TREAD LOCKING FLUID TO THREADS ON...
  • Page 51 034413 SCREW HHM #10-32 X 1-1/4 (1) 44 0G0951 1(REF) GASKET EXHAUST MANIFOLD 0G3910 EXHAUST MANIFOLD G2 (MACHINE) (25KW, 35KW & 45KW) 0G6093E FLEX PLATE 2 POLE 2.4L G2 0D2244M ASSY MAGPICKUP(3/8-24 MALE) 0F9420 ADAPTER ENGINE 2.4L MACHINE 0G7461 STARTER MOTOR 12V...
  • Page 54 EXPLODED VIEW: EV COOLING SYSTEM & FAN DRIVE GROUP D DRAWING #: 0H3075 ITEM PART# QTY. DESCRIPTION 0H30830ST03 WELDMENT RADIATOR SUPPORT C2 0F2608 RADIATOR 598 X 568 X 49 CPL RH 0F5263 V-BELT 31/64" X 57-3/8" 046526 WASHER LOCK M10 (1) 5 059981 SCREW HHC M10-1.5 X 30 G10.9...
  • Page 55 EXPLODED VIEW: EV COOLING SYSTEM & FAN DRIVE GROUP D DRAWING #: 0H3075 ITEM PART# QTY. DESCRIPTION 048031C CLAMP HOSE BAND .50 085662 TIE WRAP UL 14.6 X .14 BLK (NOT SHOWN) BEARING PRESS NOTE: APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND TO BEARING SURFACE ON ITEM 37 PRIOR TO PRESSING ITEM 28 ONTO ITEM 37.
  • Page 56 EXPLODED VIEW: EV COOLING SYSTEM & FAN DRIVE GROUP D DRAWING #: 0H3075 ITEM PART# QTY. DESCRIPTION This page left blank intentionally REVISION: K-1082-D Page 4 of 4 DATE: 11/12/14...
  • Page 58 EXPLODED VIEW: EV EXH 2.4L 45KW G2 EMISSIONS GROUP F DRAWING #:0H4989 ITEM PART# QTY. DESCRIPTION 0F9794 MFLR 7"X9"X18-1/2"2-1/2"IN/OUT 0G0113 EXHAUST ELBOW 2"ID X 2-1/2"OD 0G1007 BRACKET MUFFLER 0F2830 MUFFLER BRACKET STIFFENER 0F2962 MUFFLER STRAP 080762 BOLT U 3/8-16 X 2.62...
  • Page 60 EXPLODED VIEW: FUEL SYSTEM 2.4L 45KW EMSN GROUP E DRAWING #:0H4988 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 026490 NIPPLE PIPE 3/4 NPT X 2 075580 FLANGE FUEL INLET 0F6390P REGULATOR ASSY 2.4L 45KW EMSN 039253 SCREW HHC M8-1.25 X 20 G8.8...
  • Page 62 EXPLODED VIEW: EV ENCLOSURE C2 GROUP F DRAWING #: 0H0004 ITEM PART# QTY. DESCRIPTION (2)1 0G00450AL0R REAR WRAP C2 CPL (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 74 COMPONENTS INCL UDED IN 0H1434E 0F1823B ENCL HSB CO NTROL PANEL 0F3078BST 03 CO VER CONTRO L PANEL R-200B 0F2606 HING E CONT INUOUS H-PANEL 036261 RIVET POP .125 X .275 SS 0E7358 SCREW PPPH HI-LO #4-24 X 3/8 052777 WASHER FLAT M3 0H1176B ASSY PCB R- 200C CNT RL 3600 RPM...
  • Page 76 C2 UNITS 0F9832 SHIELD CONN BOX C2 0F9832GGS0R SHIELD CONTROL STAND C2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS C3 UNITS 0F9832B SHIELD CONTROL STAND C3 0F9832KGS0R SHIELD CONTROL STAND C3 0C2454 SCREW THF M6-1 X 16 N WA Z/JS C4 UNITS 0F9832A SHIELD CONTROL STAND C4...

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