Generac Power Systems 004991-0 Owner's Manual
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Generac Power Systems 004991-0 Owner's Manual

Generac Power Systems 004991-0 Owner's Manual

Liquid-cooled, prepackaged standby generators
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POWER SYSTEMS, INC.
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Number
004991-0
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Number 004991-0 This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • 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 Liquid-cooled Generators INTRODUCTION ..........IFC Section 3 — OPERATION ........12 Using a Standard “GTS” Transfer Switch....12 SAFETY RULES ............2 Control Console Components......13 Section 1 — GENERAL INFORMATION ....4 Manual Transfer and Startup ......14 Generator ..............4 Engine Governor Adjustments ......14 Transfer Switch ............4 Retransfer and Shutdown........14 Automatic System Operation ........4...

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Generac Liquid-cooled Generators 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 Liquid-cooled Generators • Inspect the generator regularly, and promptly repair • Generators installed with an automatic transfer or replace all worn, damaged or defective parts using switch will crank and start automatically when NOR- only factory-approved parts. MAL (UTILITY) source voltage is removed or is below an acceptable preset level.

  • Page 6: Section 1 - General Information

    Figure 1.2. Figure 1.2 - Main Circuit Breaker Model Rating Phase Actual Current C/B Rating* Circuit Breaker 004991-0 37,000 NG 154.2 200A QN2 40,000 LP 166.7 200A QN2 * Amp Rating of C/B structured under model.

  • Page 7: Generator Fuel System

    Section 1 - General Information Generac Liquid-cooled Generators GENERATOR FUEL SYSTEM NOTE: The unit has been factory tested and adjusted using a The Low Oil Pressure, High Coolant Temperature natural gas fuel system. If propane (LP) gas is neces- and Low Coolant Level are not monitored for the sary, contact an authorized service dealer.

  • Page 8: Unpacking

    Section 1 — General Information Generac Liquid-cooled Generators Figure 1.6 - Low Coolant Level Sensor 1.7.7 LOW BATTERY The engine control board continually monitors the battery voltage and turns on the low battery LED if the battery voltage falls below 11.0 VDC for one minute.

  • Page 9: Specifications

    Section 1 — General Information Generac Liquid-cooled Generators 1.10 SPECIFICATIONS NOTE: Fuel consumption is given at rated maximum con- 1.10.1 GENERATOR SPECIFICATIONS tinuous power output when using natural gas rated at 1000 Btu per cubic foot. LP gas is rated Single-phase at 2520 Btu per cubic foot.

  • Page 10: Torque Specifications

    Section 2 — Installation Generac Liquid-cooled Generators 1.16 BEFORE INSTALLATION DANGER Before installing this equipment, check the ratings of both the generator and the transfer switch. Read Serious injury or damage may occur if not con- “Emergency Isolation Method” and “Total Circuit figured properly.

  • Page 11: Generator Location

    Section 2 — Installation Generac Liquid-cooled Generators 2.1.1 NFPA STANDARDS • Where strong prevailing winds blow from one direction, face the generator air inlet openings into The following published standards booklets pertain- the prevailing winds. ing to standby electric systems are available form the •...

  • Page 12: Emergency Circuit Isolation Method

    Section 2 — Installation Generac Liquid-cooled Generators EMERGENCY CIRCUIT ISOLATION Proper grounding helps protect personnel against electrical shock in the event of a ground fault condi- METHOD tion in the generator or in connected electrical This prevents overloading the generator by keeping devices.

  • Page 13: Battery Installation

    Section 2 — Installation Generac Liquid-cooled Generators 2.10.1 VENTED BATTERIES 2.9.2 GTS-TYPE ATS If the generator is to be installed with an automatic transfer switch, such as a Generac GTS-type switch, it is necessary to connect the two-wire start control The electrolyte is a dilute sulfuric acid that is system.

  • Page 14: Section 3 - Operation

    Section 3 — Operation Generac Liquid-cooled Generators 2.11.1 PRIOR TO INITIAL START-UP 2.11.6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals. Belt tension is correct when a force of Prior to initially starting the generator, it must approximately 22 pounds (10 kg), applied midway be properly prepared for use.

  • Page 15: Control Console Components

    Section 3 - Operation Generac Liquid-cooled Generators AUTO — The control board will monitor the two-wire 3.2.2 FAULT INDICATOR LED start circuit. When a two-wire start is issued the con- This LED goes ON when one or more of the following trol board will immediately start and run the genera- engine faults occurs and when engine shuts down.

  • Page 16: Manual Transfer And Startup

    Section 3 — Operation Generac Liquid-cooled Generators MANUAL TRANSFER AND RETRANSFER AND SHUTDOWN When utility power source voltage has been restored, START-UP electrical loads may be transferred back to that To transfer electrical loads to the Standby (EMER- source and the generator can be shut down as follows: GENCY) power source side and start the engine man- •...

  • Page 17: Section 4 - Maintenance

    Section 4 — Maintenance Generac Liquid-cooled Generators If a failure occurs while running in this mode, the five E. EVERY 500 OPERATING HOURS red LEDs will stop flashing, the individual fault LED 1. Service air cleaner. will turn on and the engine will shut down. Once the 2.

  • Page 18: Maintenance Owner/Operator Can Perform

    Section 4 — Maintenance Generac Liquid-cooled Generators Figure 4.1 - Oil Dipstick and Oil Fill Cap 4.5.4 INSPECT COOLING SYSTEM • Inspect engine cooling system at least once each month. Oil Dipstick Oil Fill • Check hoses for damage, deterioration, leaks, etc. Correct any discrepancies found.

  • Page 19: Miscellaneous Maintenance

    Section 4 — Maintenance Generac Liquid-cooled Generators 4.5.10 CHANGING ENGINE OIL 4.5.12 SPARK PLUGS Refer to maintenance performed by authorized serv- Reset the spark plug gap or replace the spark plugs ice facilities for engine oil and filter change frequen- as necessary.
  • Page 20 Section 4 — Maintenance Generac Liquid-cooled Generators Finally, have the insulation resistance of stator and DANGER rotor windings checked. If insulation resistances are excessively low, the generator may require drying. Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture 4.6.2 BATTERY around the battery for several hours after charging.

  • Page 21: Scheduled Maintenance

    Section 4 — Maintenance Generac Liquid-cooled Generators SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 22 Section 4 — Maintenance Generac Liquid-cooled Generators Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi-...
  • Page 23 Section 4 — Maintenance Generac Liquid-cooled Generators Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom- Task Required Task Required Task Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done (Date- 3 months/ (Date- Semi-...

  • Page 24: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Generac Liquid-cooled Generators TROUBLESHOOTING POINTS 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.

  • Page 25: Section 6 - Intallation Diagram

    Section 6 — Installation Diagram Generac Liquid-cooled Generators Installation Diagram — Drawing No. 0E8422-A Generac ® Power Systems, Inc. 23...

  • Page 26: Section 7 - Electrical Data

    Section 7 - Electrical Data Generac Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115 225A 224A STATOR NEUTRAL TRANSFER SWITCH CUSTOMER CONNECTION LEGEND {CONT.]: LEGEND: F2 - FUSE, B/C (4A AGC TYPE) AVR - AUTOMATIC VOLTAGE REGULATOR ICT - INTERCONNECT.
  • Page 27 Section 7 - Electrical Data Generac Liquid-cooled Generators Wiring Diagram — Engine — Drawing No. 0E8115 PCB J2 PCB J1 GND1 DIST FRONT LEGEND [CONT.]: LEGEND: HCT - HIGH COOLANT TEMP SWITCH ALT - D.C. CHARGE ALTERNATOR IC - IGNITION COIL BAT - 12VDC BATTERY IM -...
  • Page 28 Section 7 - Electrical Data Generac Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116 LEGEND {CONT.]: LEGEND: F1 - FUSE, BAT. POWER (15A AGC TYPE) AR - ALTERNATOR ROTOR F2 - FUSE, B/C (4A AGC TYPE) AS - ALTERNATOR STATOR ICT - TERMINAL BLOCK, INTERCONNECT.
  • Page 29 Section 7 - Electrical Data Generac Liquid-cooled Generators Electrical Schematic — Engine — Drawing No. 0E8116 PCB J2 PCB J1 12V BATTERY ( + ) BLACK GND1 DIST LEGEND [CONT.]: FRONT LEGEND: HCT - HIGH COOLANT TEMP SWITCH ALT - D.C.

  • Page 30: Section 8 - Exploded Views And Parts Lists

    Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-A 28 Generac ® Power Systems, Inc.
  • Page 31 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Mounting Base — Drawing No. 0E8084-A ITEM PART NO. QTY. DESCRIPTION 0E7331 WELDMENT MTG BASE 3.9L CRYSLR 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...
  • Page 32 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Enclosure — Drawing No. 0E8439-E 30 Generac ® Power Systems, Inc.
  • Page 33 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Enclosure — Drawing No. 0E8439-E ITEM PART NO. QTY. DESCRIPTION 0E8411 INTAKE DUCT HSB 0E8042 DUCT DISCHARGE RH FRONT 0E8041 DUCT DISCHARGE LH FRONT 0C2454 SCREW TH-FRM M6-1 X 16 N WA Z/JS 0E7807 BAFFLE REAR BOTTOM 0E7808...
  • Page 34 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Control Panel — Drawing No. 0E7118-G 32 Generac ® Power Systems, Inc.
  • Page 35 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Control Panel — Drawing No. 0E7118-G ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7195 CONTROL BOX HSB 0D4698 * REF. BLOCK TERM 20A 6 X 3 X 1100V 0E7196 COVER FRONT PANEL HSB 0E7252...
  • Page 36 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Engine — Drawing No. 0E8121-C 34 Generac ® Power Systems, Inc.
  • Page 37 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Engine — Drawing No. 0E8121-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E5048A FLEXPLATE 3.9L HSB 050873A PLUG PIPE 1/4 CSK W/ VIBRA SL 0E7477 MACHINING, 3.9L ENGINE 031919 PLUG STD PIPE 3/8 COUNTER- ADAPTOR...
  • Page 38 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Radiator — Drawing No. 0E8102-D 36 Generac ® Power Systems, Inc.
  • Page 39 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Radiator — Drawing No. 0E8102-D ITEM PART NO. QTY. DESCRIPTION 0D7825A RADIATOR COPPER BRASS 0D7174C VENTURI,3.9L CRYSLR HSB 22"FAN 0E7640 RADIATOR SUPPORT L/H SIDE 0E7924 HOSE LOWER RADIATOR 0D7850 RADIATOR HOSE, UPPER 0D8252 FAN GUARD, TOP 0D8251...
  • Page 40 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Fuel System — Drawing No. 0E8122-E 38 Generac ® Power Systems, Inc.
  • Page 41 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Fuel System — Drawing No. 0E8122-E ITEM PART NO. QTY. DESCRIPTION 033212 SCREW HHC 5/16-18 X 1-1/4 G5 075580 FLANGE FUEL INLET 0E8365 ASSY REG. 3.9L N/G-LPV 1800RPM 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129...
  • Page 42 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Alternator — Drawing No. 0E5146-B 40 Generac ® Power Systems, Inc.
  • Page 43 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Alternator — Drawing No. 0E5146-B ITEM PART NO. QTY. DESCRIPTION 0E5093A ROTOR 390 30KW 1P DIRECT HSB 0E7413A ROTOR 390 40KW 1P DIRECT HSB 0E5094A STR-390--35AD1 HSB (382MM LONG)(3.0LFORD) 0E7412A STR-390--40AD HSB (433MM LONG)(3.9L CHRYSLER) 0E5706 REAR BEARING CARRIER 390/DRCT...
  • Page 44 Section 8 - Exploded Views and Parts Generac Liquid-cooled Generators Muffler — Drawing No. 0E8068-E COMPARTMENT TO EXHAUST MANIFOLD TO EXHAUST MANIFOLD ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E8616 MUFFLER 7" X 9" X 21" 2.5" IN & 052860 NUT TOP LOCK FL M12-1.75 052891...

  • Page 45: Section 9 - Notes

    Section 9 - Notes Generac Liquid-cooled Generators Generac ® Power Systems, Inc. 43...
  • Page 46 Section 9 - Notes Generac Liquid-cooled Generators 44 Generac ® Power Systems, Inc.
  • Page 47 Section 9 - Notes Generac Liquid-cooled Generators Generac ® Power Systems, Inc. 45...

  • Page 48: Section 10 - Warranty

    FOR GENERAC RESIDENTIAL AND LIGHT COMMERCIAL UNITS For a period of two (2) years or two thousand (2,000) hours of operation from the date of sale, which ever occurs first, Generac Power Systems, Inc. will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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