Generac Power Systems 04358-1 Owner's Manual
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Generac Power Systems 04358-1 Owner's Manual

Generac Power Systems 04358-1 Owner's Manual

Air-cooled auxiliary power system 6.2 kw
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®
POWER SYSTEMS, INC.
Owner's Manual
Air-cooled Auxiliary Power System
Model:
04358-1 (6.2 kW)
DANGER
DEADLY EXHAUST FUMES.
OUTDOOR INSTALLATION ONLY!!

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Summary of Contents for Generac Power Systems 04358-1

  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Air-cooled Auxiliary Power System Model: 04358-1 (6.2 kW) DANGER DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

  • Page 2: Introduction

    Thank you for purchasing this model of the auxiliary operator read this Owner's Manual and thoroughly power system product line by Generac Power Systems understand all instructions before using this equip- Inc. This model is a compact, high performance, air- ment.

  • Page 3: Table Of Contents

    Table of Contents Generac 6.2 kW Auxiliary Power Generator Introduction ......Inside Front Cover Section 3 – Operation ........11 Read This Manual Thoroughly ......IFC Using the Auto/Off/Manual Switch ....11 Installation ............IFC 3.1.1 “Auto” Position........11 Operation and Maintenance......IFC 3.1.2 “Off” Position........11 How to Obtain Service ........IFC 3.1.3 “Manual”...

  • Page 4: General Hazards

    Important Safety Instructions Generac 6.2 kW Auxiliary Power Generator 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 and potential operators of this equipment. WARNING: GENERAL HAZARDS The engine exhaust from this product...

  • Page 5: Electrical Hazards

    Important Safety Instructions Generac 6.2 kW Auxiliary Power Generator ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces • For fire safety, the generator must be installed and dangerous electrical voltages and can cause fatal maintained properly. Installation always must electrical shock.

  • Page 6: Section 1 - General Information Generac 6.2 Kw Auxiliary Power Generator

    Section 1 — General Information Generac 6.2 kW Auxiliary Power Generator ADDITIONAL GENERATOR DANGER FEATURES Only qualified electricians or contractors should Your generator offers additional features that are not attempt such installations, which must comply strictly factory preset: with applicable codes, standards and regulations. 1.

  • Page 7: Your Generator

    Section 1 — General Information Generac 6.2 kW Auxiliary Power Generator YOUR GENERATOR Figure 1.1 – 6.2 kW, V-twin GN-724 Engine AIR FILTER DATE CODE DECAL MODEL DATA DECAL SET EXCERCISE TIMER SWITCH LOCAL CONTROL PANEL ON/OFF/MANUAL ASSEMBLY SWITCH HOUR METER VOLTAGE REGULATOR ENGINE SPEED (Hz) ACCESS PANEL...

  • Page 8: The Battery

    Section 1 — General Information Generac 6.2 kW Auxiliary Power Generator 8. Refit the brass hose fitting to the outlet port of the DANGER demand regulator. Use pipe thread sealant to reseal the threads on the hose fitting to the regu- Do not dispose of the battery in a fire.

  • Page 9: Section 2 - Installation

    Section 2 — Installation Generac 6.2 kW Auxiliary Power Generator INSTALLATION Figure 2.2 — Mounting for Obstructions This section of the manual constitutes as a guideline only. Any installation must be performed by a com- petent, approved and relevant person. The installa- tion must follow any local and or federal codes.

  • Page 10: Section 2 - Installation Generac 6.2 Kw Auxiliary Power Generator

    Section 2 — Installation Generac 6.2 kW Auxiliary Power Generator GENERATOR AC OUTPUT Figure 2.5 – Remote Control Panel Connections The generator is supplied factory wired for customer AC connection. Four wires exit the rear of the local control panel and are configured as follows: •...

  • Page 11: Transfer Switch Connector

    Section 2 — Installation Generac 6.2 kW Auxiliary Power Generator 2.3.2 TRANSFER SWITCH CONNECTOR The regulator is fitted with three switches (Figure 2.7) that allow it to be configured for multiple appli- The following table indicates the required voltages or cations.

  • Page 12: Section 3 - Operation Generac 6.2 Kw Auxiliary Power Generator

    Section 3 — Operation Generac 6.2 kW Auxiliary Power Generator SIGNAL INTERFACE CONNECTOR TABLE Wire # Signal Action Signal Electrical Remotely Position Name Interface Resettable Remote Reset Momentary Low - (Normal) Less than 0.8V High - (Reset) Greater than 2.5V Low Crank Alarm Indication Alarm - TTL open collector sink...

  • Page 13: Section 3 - Operation

    Section 3 — Operation Generac 6.2 kW Auxiliary Power Generator 3. Turn OFF all electrical loads. Start-up and initial 3.1.2 “OFF” POSITION adjustment will be done under a “no-load” condi- This switch position shuts down the engine. This tion. position also prevents automatic operation. 4.

  • Page 14: Protection Systems

    Section 3 — Operation Generac 6.2 kW Auxiliary Power Generator 2. Hold down the set timer switch until the genera- 3.3.3 OVERCRANK tor starts (approximately 10 seconds) and This feature prevents the generator from damaging then release. itself when it continually attempts to start and another 3.

  • Page 15: Governor Adjustment Procedure

    Section 4 — Maintenance Generac 6.2 kW Auxiliary Power Generator GOVERNOR ADJUSTMENT CHECKING THE ENGINE OIL PROCEDURE LEVEL 1. Loosen the governor clamp bolt. For oil capacities, see “Specifications,” Section 1.7 (Page 5). For engine oil recommendations, see 2. It is very important that this procedure for resetting the governor is followed correctly.

  • Page 16: Oil Change Procedure

    Section 4 — Maintenance Generac 6.2 kW Auxiliary Power Generator 5. Start the engine and check for leaks. Figure 4.3 – Engine Oil Filter Any attempt to crank or start the engine before it has been properly serviced with the recom- mended oil may result in an engine failure.

  • Page 17: Battery Maintenance

    Section 4 — Maintenance Generac 6.2 kW Auxiliary Power Generator 3. Check the spark plugs gap using a wire feeler • Wear full eye protection and protective clothing; gauge. Adjust the gap to 0.76 mm (0.030 inch) • Where electrolyte contacts the skin, wash it off by carefully bending the ground electrode immediately with water;...

  • Page 18: Drive Belt

    Section 4 — Maintenance Generac 6.2 kW Auxiliary Power Generator Without sufficient cooling and ventilating airflow, the 6. Attach a tag to the engine indicating the viscosity engine/generator quickly overheats, which causes it and classification of the oil in the crankcase. to quickly shut down.

  • Page 19: Service Schedule

    Section 4 — Maintenance Generac 6.2 kW Auxiliary Power Generator 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by your nearest Generac Authorized Service Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer...

  • Page 20: Section 5 - Troubleshooting Generac 6.2 Kw Auxiliary Power Generator

    Section 5 — Troubleshooting Generac 6.2 kW Auxiliary Power Generator TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary. 3.

  • Page 21: Section 6 - Notes

    Section 6 — Notes Generac ® Power Systems, Inc. 19...
  • Page 22 Section 6 — Notes 20 Generac ® Power Systems, Inc.
  • Page 23 Section 6 — Notes Generac ® Power Systems, Inc. 21...

  • Page 24: Section 7 - Electrical Data Generac 6.2 Kw Auxiliary Power Generator Electrical Schematic - Drawing No. 0D2832-C

    Section 7 — Electrical Data Generac 6.2 kW Auxiliary Power Generator Electrical Schematic – Drawing No. 0D2832-C 225A DIAGRAM KEY 224A BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RECTIFIER CB1 - MAIN OUTPUT BREAKER (6.2kW=25A) CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION D - DIODE VOLTAGE REGULATOR...
  • Page 25 Section 7 — Electrical Data Generac 6.2 kW Auxiliary Power Generator Electrical Schematic – Drawing No. 0D2832-C 225A L.E.D - FAULT INDICATORS 224A 4 - LED Test 3 - Test Mode 2 - Remote Not Auto 1 No Function PRINTED CIRCUIT BOARD AUTO MANUAL SIGNAL INTERFACE...
  • Page 26 Section 7 — Electrical Data Generac 6.2 kW Auxiliary Power Generator Electrical Schematic – Drawing No. 0D1130-C DIAGRAM KEY REMOTE PANEL BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RECTIFIER CB1 - MAIN OUTPUT BREAKER 25A CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION 225A D - DIODE BATTERY...
  • Page 27 Section 7 — Electrical Data Generac 6.2 kW Auxiliary Power Generator Electrical Schematic – Drawing No. 0D1130-C P.C.B. SIGNAL INTERFACE CONNECTIONS PIN # OVERCRANK ALARM LOW OIL PRESSURE ALARM GAS HAZARD ALARM DOOR OPEN CONTACT (N0) UTILITY FROM T/SW UTILITY FROM T/SW TRANSFER RELAY COIL C - REMOTE START NO - REMOTE START...

  • Page 28: Section 8 - Exploded Views And Parts Lists Generac 6.2 Kw Auxiliary Power Generator Gn-724 Engine - Drawing No. 0C2474-A

    Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator GN-724 Engine – Drawing No. 0C2474-A 26 Generac ® Power Systems, Inc.
  • Page 29 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator GN-724 Engine – Drawing No. 0C2474-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 153-C1198 MAGNETO ARMATURE C1198 GN-724 ENGINE (NOT PICTURED 154-C1198 SCREW (MAGNETO ARMATURE) COMPLETE) 100-C1198 CYLINDER ASSEMBLY...
  • Page 30 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator GN-724 Engine Accessories and Sheet Metal – Drawing No. 0C5446-B 28 Generac ® Power Systems, Inc.
  • Page 31 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator GN-724 Engine Accessories and Sheet Metal – Drawing No. 0C5446-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION C1350A WRAPPER, VALLEY C1676 GOVERNOR LEVER C1351A WRAPPER, CYLINDER #1 C1679...
  • Page 32 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Remote Panel Assembly – Drawing No. 0D2706-A 30 Generac ® Power Systems, Inc.
  • Page 33 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Remote Panel Assembly – Drawing No. 0D2706-A ITEM PART NO. QTY. DESCRIPTION 0D2528 REMOTE PANEL, ENCLOSURE 0A1801 ASSEMBLY, ENGINE BATTERY CHARGER 0C3291 COVER, REMOTE PANEL 0C2174 RELAY, 12V 25A 075210A TERMINAL BLOCK...
  • Page 34 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Alternator – Drawing No. 0C3555-G 32 Generac ® Power Systems, Inc.
  • Page 35 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Alternator – Drawing No. 0C3555-G ITEM PART NO. QTY. DESCRIPTION 075995 LOWER BEARING CARRIER 073163H ROTOR ASSEMBLY 0C4507H STATOR ASSEMBLY 073159 BALL BEARING 031971 BALL BEARING 072379B UPPER BEARING CARRIER 077006...
  • Page 36 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Mounting Base Assembly – Drawing No. 0C9446-B 34 Generac ® Power Systems, Inc.
  • Page 37 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Mounting Base Assembly – Drawing No. 0C9446-B ITEM PART NO. QTY. DESCRIPTION C1753A ALTERNATOR PULLEY C7387 SKID MOUNT C1112 V-BELT 75224G ENGINE PULLEY 38353 RUBBER MOUNT C7386 SKID, RUBBER MOUNT A9827...
  • Page 38 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Enclosure – Drawing No. 0E2814 42 35 EGULATOR ASSEMBLY Y POWER HEAD GROUND WIRE 37 32 58 8 8 8 36 Generac ® Power Systems, Inc.
  • Page 39 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Enclosure – Drawing No. 0E2814 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E2987 ENCLOSURE BASE 022097 M6- 1/4", LOCK WASHER 0C7542 ENCLOSURE DOOR 028238 U BOLT 0E2645...
  • Page 40 Section 8 — Exploded Views and Parts Lists Generac 6.2 kW Auxiliary Power Generator Regulator Assembly – Drawing No. 0E2893 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D5694 CASTING, TWIN REGULATOR HOUSING 0C4643A INLET, TWIN REG 11.11 DIA. 075475 SCREW PPHM M4-0.7 X 10 0C6066...

  • Page 41: Section 9 - Installation Drawing Generac 6.2 Kw Auxiliary Power Generator Installation Drawing - Drawing No. 0C9387-D

    Section 9 — Installation Drawing Generac 6.2 kW Auxiliary Power Generator Installation Drawing – Drawing No. 0C9387-D Generac ® Power Systems, Inc. 39...

  • Page 42: Section 10 - Warranty Generac 6.2 Kw Auxiliary Power Generator

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to 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. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.

  • Page 43: Emission Control System Warranty

    Section 10 – Warranty Generac 6.2 kW Auxiliary Power Generator EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall con- tinue for 24 consecutive months thereafter.
  • Page 44 Generac Service Facility. • A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non-Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no war- ranty coverage shall apply.

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