Generac Power Systems GR-210 Operation And Maintenance Manual
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Generac Power Systems GR-210 Operation And Maintenance Manual

Generac Power Systems GR-210 Operation And Maintenance Manual

Liquid-cooled diesel engine generator set
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GR-210
Operation and
Maintenance Manual
Standby Output 170 kW (213 kVA)
Prime Output 165 kW (206 kVA)
Liquid-cooled
Diesel Engine
Generator Set
Model No. 004066-0 (Trailerized)
004366-0 (w/o Trailer)

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Summary of Contents for Generac Power Systems GR-210

  • Page 1 GR-210 Operation and Maintenance Manual Standby Output 170 kW (213 kVA) Prime Output 165 kW (206 kVA) Liquid-cooled Diesel Engine Generator Set Model No. 004066-0 (Trailerized) 004366-0 (w/o Trailer)

  • Page 2: Introduction

    INTRODUCTION Points out potential explosion hazard. This Owner’s Manual was prepared especially for the purpose of familiarizing personnel with the operation and servicing of the applicable equipment. Points out potential fire hazard. Every effort was expended to make sure that the information and instructions in the Manual are accurate and current at the time the Manual was written.

  • Page 3: Table Of Contents

    Table of Contents GR-210 Generator Set INTRODUCTION ..........Inside Front Cover Low Coolant Level Sensor ............12 DC Control/Latch-Crank Circuit Board ..........13 Read This Manual Thoroughly ......Inside Front Cover Engine Startup ................13 Operation and Maintenance ........Inside Front Cover After Fault Shutdown ..............13 How to Obtain Service ........Inside Front Cover...

  • Page 4: Safety Rules

    Important Safety Instructions GR-210 Generator Set THE MANUFACTURER SUGGESTS THAT THESE RULES FOR SAFE OPERATION BE COPIED AND POSTED IN POTENTIAL HAZARD AREAS. SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT. • Adequate, unobstructed flow of cooling and venti-...
  • Page 5 Important Safety Instructions GR-210 Generator Set For fire safety, the generator must be installed • Operation of the generator set in damp or wet loca- and maintained properly. Installation always must tions can be extremely hazardous. Electrical resist- ance to current is reduced whenever items become comply with applicable codes, standards, laws and regulations.

  • Page 6: Identification Record

    General Information GR-210 Generator Set IDENTIFICATION RECORD • The voltage waveform deviation, total harmonic content of the AC waveform and “telephone influ- ence factor” have been evaluated and are acceptable DATA PLATE according to NEMA MG1-22. Every generator has a DATA PLATE which contains •...

  • Page 7: Installation

    General Information GR-210 Generator Set INSTALLATION • If the electrician has installed a transfer switch and a connection box, use a suitable, approved cord set between the connection box and a suitable genera- STANDBY ELECTRIC SYSTEM tor receptacle, or between the connection box and A standby electric system may be defined as a system in the generator's full capacity terminal studs.

  • Page 8: Emergency Circuit Isolation

    General Information GR-210 Generator Set DANGER! A hazard exists during a power out- Figure 3 - Emergency Circuit Isolation age if the generator is connected to building cir- cuits and no method of positively isolating the generator from the utility supply is provided.

  • Page 9: Preparation Before Use

    General Information GR-210 Generator Set Figure 4 - Total Circuit Isolation Method ENGINE COOLANT Check engine coolant level and add the recommended coolant mixture as required. Refer to “Maintenance” section, page 15. FUEL Fill the fuel tank with the correct recommended diesel Service Disconnec engine fuel (see “Maintenance”...

  • Page 10: 120 Volt, 20 Amp Locking Type Receptacle

    General Information GR-210 Generator Set Figure 7 - 120/208 Volts, 50 Amp Receptacle Use only high quality, well-insulated, 3-wire, grounded cord sets with the 120-volt duplex type receptacles. Cord sets should be rated 15 AC amperes at 135 volts or greater.

  • Page 11: Transfer Switch Terminal

    General Information GR-210 Generator Set CAUTION: Although you can operate single- • Set the voltage adjust dial to “240/416V” for 240 phase loads through the terminal lugs as well as volt, single-phase or 416 volt 3-phase when con- necting for one of these voltages. See “Voltage Adjust the receptacles, DO NOT attempt to connect any 3-phase loads to the receptacles.

  • Page 12: Starting Battery

    General Information GR-210 Generator Set Figure 10 - Transfer Switch Terminals SWITCHES, METERS AND LIGHTS For all the components mentioned in this section, refer to Figure 11. AC VOLTMETER This AC voltmeter indicates the voltages for generator AC output. Also see “Voltage Adjust Dial”.

  • Page 13: Frequency Meter

    Operation GR-210 Generator Set FREQUENCY METER SYSTEM READY LAMP Indicates generator AC output frequency in “Hertz” This lamp goes ON when the unit is running. The lamp (cycles per second). The generator's rated AC frequency will not go ON if a fault has occurred and you have not is 60 Hertz, which is supplied at 1800 rpm.

  • Page 14: Panel Light

    Operation GR-210 Generator Set Figure 12 - Low Oil Pressure Switch PANEL LIGHT The panel light will turn on when the unit is running or cranking. VOLTAGE ADJUST DIAL This potentiometer permits the operator to select the desired output voltage from the alternator. Turning the...

  • Page 15: Dc Control/Latch-Crank Circuit Board

    Operation GR-210 Generator Set DC CONTROL/LATCH-CRANK STARTING THE ENGINE CIRCUIT BOARD • Be sure all necessary cables are connected to the full capacity compression lugs before starting the The circuit board, housed inside the generator control engine (see pages 8-9). ALL electrical loads must be...

  • Page 16: Ground Fault Protection

    Maintenance GR-210 Generator Set MAINTENANCE GROUND FAULT PROTECTION It is the owner's responsibility to perform all safety The generator is equipped with a 120 volt duplex recep- checks; to verify all required maintenance is performed tacle, and a 120V locking type receptacle. Each of these for safe operation;...

  • Page 17: Recommended Engine Fluids

    Maintenance GR-210 Generator Set • Check the unit battery for proper electrolyte fluid SUPPLEMENTAL COOLANT ADDITIVES level, proper state of charge, and condition. The recommended coolant additive is John Deere’s • With engine running, note readings of all gauges and...

  • Page 18: Engine Coolant

    Maintenance GR-210 Generator Set • Never operate the engine with oil below the cross- IMPORTANT: hatching on dipstick. NEVER PERMIT THE ENGINE TO RUN OUT OF • Never overfill the engine crankcase above the dip- FUEL. IF ENGINE RUNS OUT OF FUEL OR IF FUEL stick crosshatching.

  • Page 19: Bleeding The Fuel System

    Maintenance GR-210 Generator Set BLEEDING THE FUEL SYSTEM EVERY 2000 HOURS The fuel system for this engine has a self-bleeding func- • Check and adjust engine valve clearance. tion, so air should not enter the fuel lines unless the • Retorque engine intake manifold bolts.

  • Page 20: Voltage Regulator Adjustment

    Maintenance GR-210 Generator Set WARNING! Do not adjust the engine governed MAJOR REPAIRS speed without proper equipment and know- Proper and regular maintenance of the generator is how. The governed speed was factory set and needed to make sure the generator has a long and trou- should require no additional adjustment.

  • Page 21: Wiring Diagrams/Schematics

    Electrical Data GR-210 Generator Set Wiring Diagram — Control Panel — Drawing No. 090118-B Generac Power Systems, Inc. 19 ®...
  • Page 22 Electrical Data GR-210 Generator Set Schematic — Control Panel — Drawing No. 090119-A 20 Generac Power Systems, Inc. ®...
  • Page 23 Electrical Data GR-210 Generator Set Wiring Diagram — AC Receptacle Panel — Drawing No. 0C4691-E Generac Power Systems, Inc. 21 ®...
  • Page 24 Electrical Data GR-210 Generator Set Schematic — AC Receptacle Panel —Drawing No. 0C4690-C 22 Generac Power Systems, Inc. ®...
  • Page 25 Electrical Data GR-210 Generator Set Wiring Diagram — Diesel Engine — Drawing No. 0A5356 Generac Power Systems, Inc. 23 ®...
  • Page 26 Electrical Data GR-210 Generator Set Schematic — Diesel Engine — Drawing No. 0A5357 24 Generac Power Systems, Inc. ®...
  • Page 27 Electrical Data GR-210 Generator Set Wiring Diagram — Electronic Governor — Drawing No. 090092-A Generac Power Systems, Inc. 25 ®...
  • Page 28 Exploded View and Parts List GR-210 Generator Set Air Cleaner — Drawing No. 0A8313-A ITEM PART NO. QTY. DESCRIPTION 061701 AIR CLEANER W/ELEMENT 0A6288 REDUCER AIR CLEANER 061702 CLAMP AIR CLEANER 0A6289 BRACKET AIR CLEANER 8.1L 057648 CLAMP HOSE #64 3.56 - 4.50 058612 CLAMP HOSE #88 5.12 - 6.00...
  • Page 29 Exploded View and Parts List GR-210 Generator Set Center Lift — Drawing No. 0A9284-C ITEM PART NO. QTY. DESCRIPTION 0A9282 CENTERLIFT, SIDE 8.1 0A9283 CENTER LIFT TOP WELDMENT 059979 SCREW HHC 3/4-10 X 1-1/2 G8 045900 WASHER FLAT 3/4 ZINC...
  • Page 30 Exploded View and Parts List GR-210 Generator Set Trailer — Drawing No. 0A8315 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A8079 TRAILER 8.1L DEERE 040173 CLAMP HOSE #5.5 .62 - .62 035713 SCREW HHC 1/2-13 X 1-1/2 G5...
  • Page 31 Exploded View and Parts List GR-210 Generator Set Muffler — Drawing No. 0A9309-B ITEM PART NO.QTY DESCRIPTION. 0A8189 WELDMENT MUFFLER 8.1L 0A7736 ELBOW MUFFLER 8.1L 0A9208 EXHAUST FLEX 8.1L 083218 CAP RAIN 4.00/4.19 082361 10.5’ INSULATION EXHAUST 0A9307 PIPE EXHAUST 4" OD X 14 LG...
  • Page 32 Exploded View and Parts List GR-210 Generator Set Mounting Base — Drawing No. 0D2270-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A6165 BASE FRM,8.1L JD TLR 044118 BARBED STR 1/2NPT X 5/8 055597 SCREW HHC M12-1.75 X 85 G8.8 057822 CLAMP HOSE #8 .53 - 1.00...
  • Page 33 Exploded View and Parts List GR-210 Generator Set Engine Common Parts — Drawing No. 0A8312-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C1058 SPACER FAN 8.1L 090185 ROD END #10-32 R/H 0C1507 FAN 28" 8.1L JD 022152...
  • Page 34 Exploded View and Parts List GR-210 Generator Set Compartment — Drawing No. 0A8271-C 32 Generac Power Systems, Inc. ®...
  • Page 35 Exploded View and Parts List GR-210 Generator Set Compartment — Drawing No. 0A8271-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A6301 CORNER POST FRONT LH 051713 15 WASHER FLAT M5 0C1876 CORNER POST FRONT RH 029078 PIN COTTER 1/16 X 1/2...
  • Page 36 (REF.) (REF.) STATOR LUG STATOR LUG (REF.) (REF.) LEAD WIRE LEAD WIRE ENLARGED ENLARGED 48, 49, 50, 51, 52, 53, 54, 55, 56 SCROLL DETAIL...
  • Page 37 Exploded View and Parts List GR-210 Generator Set Generator Assembly — Drawing No. 0A7632-J ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A2865A * STATOR ASSEMBLY 520 150KW 0A7821 COLLAR SLIP FIT 116.7MM 0A2865B ** STATOR ASSEMBLY 520 200KW...
  • Page 38 LOOSE WIRES #90126W WIRE NO. WIRE SIZE WIRE P/N LENGTH LUG A LUG B 55199A 5.50 STRIP .5" 58355 BOARD TO BE ORIENTED WIRE HARNESS TO BE SUCH THAT THE 15 PIN ROUTED AS SHOWN 15 14 HEADER IS POSITIONED AS SHOWN VIEW A SECTION A-A...
  • Page 39 Exploded View and Parts List GR-210 Generator Set Control Panel — Drawing No. 0A8519-A ITEM PART NO.QTY. DESCRIPTION ITEM PART NO.QTY. DESCRIPTION 070042 METER FREQUENCY 55-65 HZ 089532 PANEL CONTROL FRONT 055406 GUAGE COOLANT TEMPERATURE W/SILKSCREEN 055405 GUAGE OIL PRESSURE...
  • Page 40 CIRCUIT BREAKER 600A 600V 3P 055920 SWITCH SPST SPADE PNL MNT (GR-160 & 190) 032990 BUMPER RUBBER 081531U CIRCUIT BREAKER 700A 600V 3P (GR-210) 065511 PLUG BUTTON 1/2" (NOT SHOWN) 064828 DECAL TRANS SW CONN 0A2081 HASP LUG BOX DOOR 029333 TIE WRAP 7.4"...
  • Page 41 Exploded View and Parts List GR-210 Generator Set Connection Panel — Drawing No. 0D3450-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 070013 SCREW HHC 5/16-18 X 3/4 SS VIB 090427 WASHER FLAT #10 SS 070006 WASHER LOCK M8 SSTL...
  • Page 42 Exploded View and Parts List GR-210 Generator Set Radiator Assembly — Drawing No. 0A8316-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A6485 RADIATOR, 8.1L 040173 CLAMP, HOSE #5.5 .62-.62 0A6296 VENTURI, 8.1L 029032 HOSE, 9/32 ID 0A6298 FAN GUARD, 8.1L...
  • Page 43 Exploded View and Parts List GR-210 Generator Set Block Heater — Drawing No. 0D3593 ITEM PART NO. QTY. DESCRIPTION 084918C HEATER ENGINE 1800W 120V 050967 20" HOSE 5/8 ID RIA 250F 050967 24" HOSE 5/8 ID RIA 250F 042568 SCREW HHC M6-1.0 X 20 G8.8...
  • Page 44 Exploded View and Parts List GR-210 Generator Set Battery Charger — Drawing No. 091237-F ITEM PART NO. QTY. DESCRIPTION 079535 ASSEMBLY BATTERY CHARGER 10A12V 062059 ASSEMBLY BATTERY CHARGER 2A/12V 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4 ZINC 022127 NUT HEX 1/4-20 STEEL 027831 MOUNT VIBR .50 X 1.0 X 1/4-20...

  • Page 45: Warranties

    Warranty GR-210 Generator Set EMISSION SYSTEM WARRANTY (NON-ROAD DIESEL) EMISSIONS CONTROL SYSTEM CERTIFICATION LABEL WARNING: Statutes providing severe penalties for tampering with emissions controls may apply at the user's location. The emissions warranty described below applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB);...
  • Page 46 Warranty GR-210 Generator Set CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (CALIFORNIA ONLY) Your Warranty Rights and Obligations The California Air Resources Board (CARB) and John Deere are pleased to explain the emission control system on your new engine. In California, new heavy-duty engines must be designed, built, and equipped to meet the State's stringent anti-smog standards.
  • Page 47 Warranty GR-210 Generator Set OWNER'S WARRANTY RESPONSIBILITIES: As the heavy-duty engine owner, you are responsible for the performance of the required maintenance as outlined in this Operation and Maintenance Manual. John Deere recommends that you retain all receipts covering maintenance on your heavy-duty engine, but John Deere cannot deny warranty solely for the lack of receipts or for your failure to ensure the per- formance of all scheduled maintenance.
  • Page 48 For a period of 1 (one) year or 1,500 (one thousand five hundred) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

This manual is also suitable for:

004066-0004366-0

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