Generac Power Systems SD050 Owner's Manual
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Generac Power Systems SD050 Owner's Manual

Stationary emergency industrial generator
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Model: 0062900
Type:
SD050
Engine: D4.5F.1
Owner's Manual
Stationary Emergency Industrial Generator
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!
This manual should remain with the unit.
C
US
LISTED

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Summary of Contents for Generac Power Systems SD050

  • Page 1 Model: 0062900 Type: SD050 Engine: D4.5F.1 Owner's Manual Stationary Emergency Industrial Generator ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  LISTED SHOULD ATTEMPT INSTALLATION! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Table of Contents Introduction ..............1 Installation ..............8 Read this Manual Thoroughly ...............1 Stationary Emergency Generator Installation .........9 Installation, Operation And Maintenance ..........1 Units with Enclosures...............9 How to Obtain Service .................1 Open Units for Indoor Installatin ............9 Authorized Service Dealer Locator Number ..........1 Basic Stationary Emergency Electric System ........9 Emergency Circuit Isolation Method .............9 Total Circuit Isolation Method ...............9...

  • Page 3: Introduction

    Introduction INTRODUCTION The operator is responsible for proper and safe use of the equip- ment. The manufacturer strongly recommends that the operator Thank you for purchasing this model of the stationary emergency read this Owner's Manual and thoroughly understand all instruc- generator set.

  • Page 4: Safety Rules

    Safety Rules • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in SAVE THESE INSTRUCTIONS – The manufac-  sufficient concentrations, can cause unconsciousness or even turer suggests that these rules for safe oper- death.

  • Page 5: Standards Index

    Safety Rules STANDARDS INDEX • Before installing or servicing this (and related) equipment, make sure that all power voltage supplies are positively turned off at Applicable national, state, or local laws, codes, and regulations their source. Failure to do so will result in hazardous and pos- pertaining to the installation of engine-generator power systems sibly fatal electrical shock.

  • Page 6: General Information

    General Information IDENTIFICATION RECORD • “Y” indicates a muffler has been mounted; N – Unit does not have an exhaust muffler; “L” indicates a muffler has been shipped loose with the unit). DATA LABEL • 3 – Emission designation (for factory use). Every generator set has a DATA LABEL that contains important Groups and Assembly Numbers information pertinent to the generator (Figure 1.1).

  • Page 7: Equipment Description

    General Information Generator Model Number AMBIENT CONDITION DERATE This number is the key to numerous engineering and manufactur- The maximum ambient temperature for the generator is indicated ing details pertaining to the unit. Always supply this number when on the unit data tag. De-rate values for Ambient Temperature in requesting service, ordering parts or seeking information.

  • Page 8: Overcrank Shutdown

    General Information OVERCRANK SHUTDOWN LP FUEL SYSTEM After a prespecified duration of cranking, this function ends the LP is supplied as a liquid in pressure tanks. It is usually made up cranking if the engine has failed to start. The default settings are: of propane, butane, or a mixture of the two gases.

  • Page 9: Specifications

    General Information SPECIFICATIONS DO NOT remove the radiator pressure cap  GENERATOR while the engine is hot or serious burns from Refer to the data plate on the generator for rated watts, amperes, boiling liquid or steam could result. frequency, voltage, phase and other pertinent information. Refer to Ethylene glycol base antifreeze is poisonous.

  • Page 10: Fuel System Requirements And Recommendations

    Installation FUEL SYSTEM REQUIREMENTS AND RECOMMENDATIONS ENGINE COOLANT HEATERS If the unit is equipped with an engine coolant (block) heater, it is Diesel Fuel System powered by a circuit normally fed by the utility power supply. This The manufacturer recommends the use of No. 2D diesel fuel when heats the engine coolant when the unit is not operating.

  • Page 11: Units With Enclosures

    Installation Only qualified, competent installation contractors or electricians Notice that both the STANDBY and the UTILITY power supplies to thoroughly familiar with applicable codes, standards and regula- the transfer switch are protected against overload by a main line tions should install this stationary emergency electric power sys- circuit breaker.

  • Page 12: Grounding The Generator

    Operation GROUNDING THE GENERATOR GENERATOR CONTROL AND The generator set must be grounded in accordance with the OPERATION National Electrical Code and any state or local requirements. The operation of this stationary emergency electrical system should only be performed by an Authorized Operator. An "Authorized Operator"...

  • Page 13: Retransfer And Shutdown

    Maintenance SERVICE SCHEDULE In order to manually transfer load from the utility source to the generator, follow these directions: This service schedule reflects the minimum tasks that need to be accomplished to ensure that the unit remains operational. Turn OFF or disconnect the utility power circuit to the transfer Some of the tasks can be performed by an authorized operator switch, using the means provided (such as the utility source and others must be performed by an Authorized Service Dealer...

  • Page 14: Periodic Maintenance

    Maintenance Annually or Every 200 Hours Many of the tests and checks listed in the schedule are to be per- (whichever comes first) formed only by an Authorized Service Technician. Fluid capacities • Change engine oil and filter. and recommendations, as well as other applicable specifications, •...

  • Page 15: The Battery

    Maintenance  The battery represents a risk of high short • Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice circuit current. When working on the battery, is to use a solution of 1 pound (500 grams) always remove watches, rings or other metal bicarbonate of soda to 1 gallon (4 liters) of objects, and only use tools that have insulated...

  • Page 16: Check Fluids

    Maintenance Maintenance NOTE: Gaseous Engine Battery Size Minimum CCA The generator is equipped with a battery trickle charger that is 2.4L GRP 26 active when the unit is set up for automatic operation. With the GRP 24F battery installed and utility power source voltage available, the 4.2L or GRP 27F battery receives a trickle charge while the engine is not run-...

  • Page 17: Inspect Exhaust System

    Maintenance INSPECT EXHAUST SYSTEM Add the recommended oil until it just starts to flow from the oil level check plug opening. See the following information for Every three months (or 30 hours), an authorized operator should the correct quantity of gear oil and Lucas additive to add to a inspect the entire exhaust system.

  • Page 18: Notes

    Notes 16 16...

  • Page 19: Warranty

    Warranty United States Environmental Protection Agency Warranty Statement (Stationary Emergency Compression-Ignition Generators) Warranty Rights, Obligations and Coverage Your emission-related warranty covers only components whose failure would increase an engine’s emissions of any regulated pollutant where they are designed, built, and equipped to be free from defects in materials and workmanship under applicable regulations of sec- tion 213 of the clean air act.
  • Page 20 The purchaser/owner shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs. Contact Generac Power Systems Inc. for additional Emission Control System Warranty related information, Generac Power Systems, Inc. P .O. Box 8, Waukesha, WI 53187, or call 1-800-333-1322 or www. generac.com.
  • Page 21 (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Recordkeeping 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 22 IMPORTANT NOTE: This Warranty statement explains your rights and obligations under the Emission Control System 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.

  • Page 23: Emission Control System Warranty

    Warranty United States Environmental Protection Agency & California Warranty Statement (Stationary Compression-Ignition Generators) 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 five years, or 3,000 hours of use, thereafter, whichever occurs first.
  • Page 24 NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER. For a period of two (2) years or two thousand (2,000) hours of operation from the date of start up, which ever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.
  • Page 25 Notes...
  • Page 27 EXPLODED VIEW: EV H-PNL 10A BC NO E-GOV DSL24 GROUP B DRAWING #: 0J0288 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (1)1 0H84230ST0R BRACKET H-PNL MOUNTIN CCI IND 0H4733E ASSY H-PANEL 2.5A BATC 12V 0G4140E ASSY H-PANEL 10A BATC 12V 0G4141E ASSY H-PANEL NO BATC NO E-GOV 0E9764 RAIL SNAPTRACK PCB HOLDER BULK...
  • Page 31 EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390 GROUP H DRAWING #: 0J1027 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION NO CIRCUIT BREAKERS (1)1 0H93780ST0R MD1,MODULE COVER 390 G-FRAME 0C2454 SCREW HWHT M6-1 X 16 N WA Z/JS 0J0679 DECAL, CANADIAN SAFETY CODE 0J0546 DECAL, HV CUSTOMER CONN INSIDE 0D3719C...
  • Page 32 EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390 GROUP H DRAWING #: 0J1027 APPLICABLE TO: 0J4465 SCREW SHC M4-0.7 X 80 C12.9 043180 WASHER FLAT M4 022264 WASHER LOCK #8-M4 051715 NUT HEX M4-0.7 G8 YEL CH ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (F -FRAME) (1)1...
  • Page 33 EXPLODED VIEW: EV, CB MOUNTING KIT MD1 390 GROUP H DRAWING #: 0J1027 APPLICABLE TO: 046580 SCREW SHC M6-1.0 X 45 C12.9 022473 WASHER FLAT 1/4-M6 ZINC 022097 WASHER LOCK M6-1/4 049813 NUT HEX M6-1.0 G8 CLEAR ZINC ITEM PART# QTY.
  • Page 35 EXPLODED VIEW: EV CONBOX 390 MODULE GROUP A DRAWING #: 0J1339 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (1)1 0H95790ST0R MD1 / MD2 CB MODULE 390 ALT (1)2 0J17560ST0R WIRE TUNNEL, MD1-2 390 ALT 0A4456 WASHER LOCK SPECIAL 3/8 061383 LUG SLDLSS 3/0-#4 X 13/32 CU 0E1534A PLUG PLASTIC 1.50"...
  • Page 37 EXPLODED VIEW: 390, BOARD SOLID LEAD TERM BRL GROUP A DRAWING #: 0J1479 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 051769 WASHER LOCK M12 049808 WASHER FLAT M12 VARIES FLEX PLATE 055173 SCREW HHC M8-1.25 X 20 G10.9 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16-M8 ZINC 0G0724...
  • Page 39 EXPLODED VIEW: EV 390 ALTERNATOR TOWER ASM GROUP A DRAWING #: 0J7594 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (1)1 0J75960ST0R MAIN, ALT TOWER 390 W/ SHROUD (1)2 0H94310ST0R TOP, ALT TOWER 390 SINGLE CB 0H9431BST0R TOP ALT TOWER 390 SNGL CB RH (1)2A 0H9431AST0R TOP, ALT TOWER 390 DUAL CB...
  • Page 41 EXPLODED VIEW: EV,CB ASSEMBLY 225AF GROUP A DRAWING #: 0J8468 ITEM PART# QTY. DESCRIPTION MAIN CIRCUIT BREAKER (1)2 045771 NUT HEX M8-1.25 G8 CLEAR ZINC (1)3 049897 SCREW SHC M8-1.25 X 20 G8 (1)4 022129 8/12 WASHER LOCK M8-5/16 (1)5 022145 8/12 WASHER FLAT 5/16-M8 ZINC...
  • Page 42 DPE Breaker and Field Boost Resistor Table for Gensets with H-Panel Control & 12V Battery DPE BREAKER FIELD BOOST RESISTOR VOLTAGE FREQUENCY EXCITATION SIZE kW RATING PART NO. SIZE PART NO. SIZE 1kW - 8.9kW 048512 direct 0F5752E 5 ohm 9kW - 45kW 048467 1kW - 15kW...
  • Page 45 EXPLODED VIEW: EV HUIO H-PNL COMM/PWR GROUP B DRAWING #: 0G4076D APPLICABLE TO:CO 1330102 ITEM PART# QTY. DESCRIPTION 020911 SCREW PPHM M5-0.8 X 30 ZINC 049226 WASHER LOCK M5 051713 WASHER FLAT M5 051716 NUT HEX M5-0.8 G8 CLEAR ZINC 0G3226 H-PNL I/O EXPANSION MOD PROG 0E8599A...
  • Page 47 COMPONENTS INCLUDED IN 0G4141E COMPONENTS NOT INCLUDED IN 0G4141E OR WIRE HARNESS 0F1823CST03 ENCL H/G CONTROL PANEL 056739 RELAY CONTACTOR 12VDC 0F1824AST03 COVER CONTROL PANEL 022287 SCREW HHC 1/4-20 X 3/4 G5 0F2606 HINGE CONTINUOUS H-PANEL 022473 WASHER FLAT 1/4-M6 ZINC 036261 RIVET POP .125 X .275 SS 022097...
  • Page 49 EXPLODED VIEW: BLOCK HEATER 4.5L G4 GROUP C DRAWING #: 0H4603A APPLICABLE TO: 0062900 ITEM PART# QTY. DESCRIPTION 084918Q HEATER BLOCK 1500W 120V 60/80F 084427 BRACKET HEATER W/WELDNUTS 042568 SCREW HHC M6-1.0 X 20 C8.8 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC 052857 NUT TOP LOCK FL M6-1.0...
  • Page 51 EXPLODED VIEW: AIR DUCT AND STONE GUARD GROUP C DRAWING #: 0H8598 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H8596 (KIT, STONE GUARD) (1)1 0H85930ST0R STONE GUARD 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0H8597 OR 0H8597A (KIT, AIR DUCT) (1)1 0H85950ST0R AIR DUCT, SIDES...
  • Page 53 EXPLODED VIEW: EV LEVEL-1 GUARDING, 4.5L G17 GROUP C DRAWING #: 0J3088 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (1)1 0J30450ST0R GUARD, 4.5L G17 LEVEL-1 LOWER (1)2 0J30430ST0R GUARD, 4.5L G17 LEVEL-1 LEFT (1)3 0J30440ST0R GUARD, 4.5L G17 LEVEL-1 RIGHT (1)4 0J30420ST0R GUARD, 4.5L G17 LEVEL-1 UPPER 0C2454...
  • Page 55 EXPLODED VIEW: EV MOUNTING BASE, 4.5L 50KW W/ BATTERY BOX GROUP C DRAWING #: 0J3110C APPLICABLE TO: 0062900 ITEM PART# QTY. DESCRIPTION (1)1 0J0639CST0R MTG BASE 4.5L G17 BATT BOX 052860 NUT FLANGED HEX M12-1.75 052251A DAMPENER VIB 50 WHITE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252...
  • Page 57 EXPLODED VIEW: EV BASETANK B GRP W/FLUID CONTAINMENT GROUP C DRAWING #: 0J8723 APPLICABLE TO: 0062900 ITEM PART# QTY. DESCRIPTION (2)1 0J87210ST0R BASETANK BD210U2N TELCO O/S 0C6789 SCREW HHC M12-1.75 X 30 SS FT 087171 WASHER FLAT 1/2 SS 051548 NUT HEX M12-1.75 G8 SS 0D3747V COVER STUB-UP B-GRP VERIZON...
  • Page 59 EXPLODED VIEW: ENGINE COM PARTS D4.5L G17 60KW GROUP D DRAWING #: 0H8623 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0J7314 ENGINE D4.5L G17 60KWE 0J7313 ENGINE D4.5L G17 50KWE (59KWM) 0H22980ST03 ENGINE MOUNT, 0H23000ST03 ENGINE MOUNT, 0H22990ST03 ENGINE MOUNT, 0H3201 ENGINE FOOT SPACER 0H8622 FAN SPACER, 4.5L 60KW 18"FAN...
  • Page 61 EXPLODED VIEW: EV COOLING SYSTEM, 4.5L 50KW GROUP D DRAWING #: 0J3109 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0F2608C RAD RH-IN/OUT DEAERATN BAFFEL (1)2 0J06450ST0R RAD SUPPORT LH 4.5L G17 A-GRP (1)3 0J06460ST0R RAD SUPPORT RH 4.5L G17 A-GRP (1)4 0J06470ST0R ASSY VENTURI 4.5L G17 A-GRP (1)5...
  • Page 63 EXPLODED VIEW: EV AIR CLEANER STD D4.5L G17 GROUP D DRAWING #: 0J5072 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0A5260A HOSE 3"ID X 3.0"LG 066212 CLAMP HOSE #52 2.81-3.75 0H2371 AIR INTAKE TUBE 0F1922 AIR CLEANER 3"IN X 6.75"OD 024200 SCREW RHM 1/4-20 X 2-1/2 0C4071 MOUNTING BAND...
  • Page 65 EXPLODED VIEW: EV FLEX EXHAUST 4.5L G17 GROUP F DRAWING #: 0J5281 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 055978 BOLT U 3/8-16 X 3.25 0A5215C FLEX PIPE 3" 0H5480 ASSY 4.5L OPEN EXHAUST PIPE 0J5096 PIPE EXHAUST ELBOW D4.5L G17 096694 V-BAND CLAMP EXH ELB REVISION: -A-...
  • Page 67 EXPLODED VIEW: EV LOOSE EXHAUST 4.5L G17 GROUP F DRAWING #: 0J5282A APPLICABLE TO: 0062900 ITEM PART# QTY. DESCRIPTION 0J5282A61R – EXHAUST PARTS 0E7611 MUFFLER OPENSET 60KW VZW 059936 ELBOW 90D 3NPT 0E4264 BOLT U 3/8-16 X 3.50" W/SADDLE 0J5234 EXHAUST ADAPTER 3"OD TO 3.5"ID 059940 RAIN CAP 3.50 / 3.69...
  • Page 97 047290 (1) HOSE 3/8 ID SINGLE BRAID (24”LG) 047290 (2) HOSE 3/8 ID SINGLE BRAID (42”LG) 0C7649 CLAMP HOSE .38-.87 036865 DRAINCOCK 41.8LG BRASS 065852 SPRING CLIP HOLDER .37-.62 086292 SCREW DRILLTITE #10-16 X 3/4 (1) USED IN RADIATOR DRAIN HOSE KIT P/N 0G9064 (2) USED IN RADIATOR DRAIN HOSE KIT P/N 0G9064A...
  • Page 99 EXPLODED VIEW: EV, NEUTRAL BLOCK 0-250A GROUP H DRAWING #: 0J1047 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION NEUTRAL BLOCK (250A) 057073 JUNCTION BLOCK 3/8-16 0H9690 NEUTRAL, BRACKET (60-100A) 0F8451 LUG SLDLSS 300 MCM-6 AL/CU 0C2266 SCREW PHTT M5-0.8 X 16 ZP 022131 WASHER FLAT 3/8-M10 ZINC 022237...
  • Page 101 EXPLODED VIEW: EV KIT 12/24V RUN RELAY GROUP H DRAWING #: 0J1171 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0C3211E RELAY PNL 12VDC DPDT 8PIN 0C3211F RELAY 24VDC DPDT 8 PIN (1)2 0J0400 DECAL, HV CONNECTION RUN RELAY 0C3211H SPRING RELAY RETAINING (1)4 0J5462 SCREW THTT M4-0.7 X 16 ZP...
  • Page 103 EXPLODED VIEW: EV 4.5L 50KW G17 ENGINE Y01 GROUP H DRAWING #: 0J4086A APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H6298 WASHER 0H6299 THREADED UNION 0H6297 SWIVEL COUPLING 0H6295 BANJO BOLT M12-1.5 X 25 0H6296 ELBOW COUPLING 048031E CLAMP HOSE BAND .66 0D7532 HOSE DIESEL 3/8"...
  • Page 105 EXPLODED VIEW: EV ANN MTG FOR O/S UNIT Y02 GROUP H DRAWING #: 0J7227 ITEM PART# QTY. DESCRIPTION 0J2330037R KIT ANN 57.6 BAUD SURF RAP/RRP (1)2 0J17540ST0R MOUNT REM ANN 390S REAR 049813 NUT HEX M6-1.0 G8 CLEAR ZINC 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC...
  • Page 107 EXPLODED VIEW: EV SPILL FILL ASSY 5G CUST MNT GROUP H DRAWING #:0J7606A ITEM PART# QTY. DESCRIPTION (1)1 0J7600 ADPTR FUEL FILL 2"NPT MALE ALM 0G4085 DUST CAP 2" TIGHT FILL (1)3 024310 PLUG STD PIPE 1/2 STEEL SQ HD 0G5835DST03 SPILL FILL 5GAL 2"NPT CUST MNT (1) APPLY PIPE SEALANT TO THREADS.
  • Page 108 Notes...
  • Page 109 Notes...
  • Page 110 Notes...
  • Page 112 GENERAC POWER SYSTEMS, INC. 211 MURPHY DR. • P .O. BOX 310 EAGLE, WI 53119 Part No. 0J9129 Rev. A (04/12)

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