Generac Power Systems Stationary emergency generator Owner's Manual
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Generac Power Systems Stationary emergency generator Owner's Manual

Generac Power Systems Stationary emergency generator Owner's Manual

Stationary emergency generator 2.4l 45kw models epa certified with catalyst
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Owner's Manual
Stationary Emergency Generator
NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT
APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST
FUMES! OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
0H7683
No.
Part
2.4L
45kW Models
EPA Certified
with Catalyst
04/10
A
Rev.
Cover196

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  • Page 1 Owner's Manual Stationary Emergency Generator 2.4L 45kW Models NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT EPA Certified APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST with Catalyst FUMES! OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 2: Table Of Contents

    Menu System ...................8-7 Propane Vapor Withdrawal Fuel System ........5-1 OPERATION ..............9-1 LP Liquid Fuel System ..............5-1 Stationary Emergency Generator Control and Operation ....9-1 SPECIFICATIONS ............6-1 Operating Unit with Manual Transfer Switch ........9-1 Stationary Emergency Generator ..........6-1 Engine Start-up and Transfer ............9-1 Engine ..................6-1...

  • 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: General Information

    Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be Stationary Emergency Generator Model and Serial found attached to the generator’s lower connection box, lists the Number unit’s serial number and its rated voltage, amps, wattage capacity,...

  • Page 7: Equipment Description

    Engines that have been operated with a chromate base rust inhibitor The Stationary Emergency Generator incorporates the following must be chemically cleaned before adding eth- alternator features: ylene glycol base anti-freeze. Using any high •...

  • Page 8: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate After a prespecified duration of cranking, this function ends the for long periods of time without an operator on hand to monitor cranking if the engine has failed to start. The overcrank message such engine conditions as coolant temperature, oil pressure or will turn ON.

  • Page 9: Fuel System

    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. the following fuel systems: •...

  • Page 10: Specifications

    Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............Gear Oil Filter ......... Full Flow Spin-on, Cartridge STATIONARY EMERGENCY GENERATOR Crankcase Oil Capacity ...........5.25 U.S. qts. Type..............Synchronous (including filter capacity) Rotor Insulation .............Class H Stator Insulation ............Class H COOLING SYSTEM Telephone Interference Factor (TIF) ........

  • Page 11: Weather And Maintenance Kits

    Specifications WEATHER AND MAINTENANCE KITS Install the previously removed black pipe onto the outlet port of the demand regulator. Use pipe sealant on the pipe To keep the generator running at its peak, the following kits are threads. offered: 10. Reverse steps 1-4 in this procedure to reactivate the demand •...

  • Page 12: General Information

    The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label. The number of lead 3-phase electrical loads. Electric power is produced in the alterna- wires can be identified using the Specifications section and the tor power windings.

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

    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- tor power windings. These windings were connected at the factory INTERNAL CONNECTIONS to the main circuit breaker with a “Delta”...

  • Page 14: Control Panel

    Control Panel CONTROL PANEL INTERFACE Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly USING THE AUTO/OFF/MANUAL SWITCH connects AC utility power sense wires into the DC terminal block.

  • Page 15: Activation Chart

    Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- If the wrong language is chosen, it can be guage. Press ENTER to select. changed later using the “edit” menu. Language English Escape Enter Display Reads: Press ENTER to begin the activation pro-...

  • Page 16: Setting The Exercise Timer

    Control Panel INSTALLATION ASSISTANT • If utility is still lost after the “line interrupt period”, run the engine up to normal RPM and transfer the load. At this time the con- Interconnect System Self Test Feature (follow the on-screen troller will exit the exercise routine and assume full automatic prompts).

  • Page 17: Sequence Of Automatic Operation

    Control Panel MANUAL START SEQUENCE OF AUTOMATIC OPERATION Initial Conditions: Generator in Auto ready to run, load being sup- Allows the user to start and run the generator manually. plied by the Utility Source through the transfer switch. Transfer of the load to the generator will occur if utility is lost while When the utility voltage fails (falls below 60% of nominal), a the unit is running in the manual mode (only if activated).

  • Page 18: Under-Frequency Shutdown Alarm

    Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This This is a shutdown alarm. The alarm will activate after five (5) fault cannot be cleared using the control panel interface. The unit seconds of continuously missing cam pulses.

  • Page 19: Overvoltage Alarm

    Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an When the generator is shut down due to a latching alarm, the Auto alarm will be issued. /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding If the generator voltage rises above 130% for >0.2 seconds, an fault alarm message.

  • Page 20: Menu System Flowchart

    Control Panel 12/11 Rev. CntrlNexus001...

  • Page 21: Operation

    UTILITY.  Do not attempt manual operation until all If the Stationary Emergency Generator has been installed with an power supplies to the transfer switch have been automatic transfer switch, the engine may be started and stopped positively turned off, or extremely dangerous - automatically or manually.

  • Page 22: Maintenance

    Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change fre- quencies. Drain the oil while the engine is still warm from running. This  Before working on the Stationary Emergency means warm up the engine, shut it down and drain immediately as follows: Generator, ensure the following: •...

  • Page 23: Engine Coolant

    EXERCISE SYSTEM qualified service facilities should adjust the governor. Excessively high operating speeds Starts the Stationary Emergency Generator engine once every are dangerous and increase the risk of personal seven days and lets it run for 12 minutes. injury. Low speeds impose a heavy load on the...

  • Page 24: Spark Plugs

    DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. CLEANING THE STATIONARY EMERGENCY GENERATOR Have the state of charge and condition checked. This should Keep the generator as clean and as dry as possible. Dirt and be done with an automotive-type battery hydrometer.

  • Page 25: Service Schedule

    Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Inspect Change Clean Yearly - Y Fuel Fuel Lines & Connections Lubrication Oil Level Oil Filter Cooling Engine Coolant Lines & Connections Engine Coolant Level Engine Coolant Enclosure Louvers Engine...

  • Page 26: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 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 27 Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diag- nosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
  • Page 28 Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the en- gine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emergency stationary ICE in emergency situations.

  • Page 29: Notes

    Notes...
  • Page 31 0F9677 ROTOR-2390-45KD1 CPL 0G0056 ROTOR-2390-35KD1 CPL 0G0959 ROTOR-2390-45KD1 CPL (G2) 0G1155 ROTOR-2390-35KD1 CPL (G2) 0G1931 ROTOR 25KW 3PH DIRECT 390 1800 0G2101 ROTOR 25KW 1PH DIRECT 390 1800 0G3734 RTR-2390-60KD2 CPL 0G6562 RTR 390 35AD1 CPL 0G6564 RTR 390 35KD1 CPL 0F9664 STATOR-390 45K 2P 1PH DIRECT 0G0057...
  • Page 35 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H6266 BACK PANEL CONBOX SUPPORT C2 0H6265 TOP PANEL CONBOX SUPPORT C2 0H6160 COVER WIRE ENTRY CONBOX 057073 JUNCTION BLOCK 3/8-16 056739 RELAY SOLENOID 12VDC PNL MNT (6)6 0H67330ST0R BRACKET GIMBAL CONTROL PNL RAW...
  • Page 36 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (225AF) 0G5250 CB 175A 2 POLE 240V 225AF 0H7356 COVER CB C2 CPL 0F4186AGS0R COVER CB DISH 2P G 225AF 0F8432A INSULATOR CB 2P 225AF 0H7311 STANDOFF CB BOX CONBOX...
  • Page 37 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (KG) 0H5582 CB 0300 3P 600V E KG LL 0H6740 COVER CB E KG C2 CONBOX 0D3700 NUT FLANGE M6-1.0 NYLOK 0H5581A INSULATOR CB E 3P KG 0H6734...
  • Page 38 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (CC (2P & 3P)) 0H4748 CB 0175A 2P 240V E CC LL 0H4915 CB 0150 3P 240V E CC LL 0H7356 COVER CB C2 CPL 0H7432 COVER CB DISH 2P E CC...
  • Page 39 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (VL) 0H7519 CB 0300A 3P 600V S JG-VL LL 0H6738 COVER CB S JG VL C2 CONBOX 040976 SCREW SHC M8-1.25 X 20 C12.9 022129 WASHER LOCK M8-5/16 0H6734...
  • Page 41 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 43 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 45 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 47 0H30830ST03 WELDMENT RADIATOR SUPPORT C2 0F2862 SPRING TENSION CPL 0F2608 RADIATOR 598 X 568 X 49 CPL RH 0F2560 PULLEY V-BELT 4" FLANGED 0F5263 V-BELT 31/64" X 57-3/8" 022131 WASHER FLAT 3/8-M10 ZINC 046526 WASHER LOCK M10 0E2507 PROBE, COOLANT LEVEL 3/8NPTF (1) 5 059981 SCREW HHC M10-1.5 X 30 G10.9...
  • Page 49 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 0E0170A EXHAUST BLANKET 988MM 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G0776A PIPE EXHAUST G2 EMISSIONS 0G0007 DIFFUSER EXHAUST WELDMENT 044149...
  • Page 52 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 45KW GROUP D DRAWING #: 0H7322 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H1619 ENGINE 2.4L G2 CERTIFIED 046526 WASHER LOCK M10 039414 SCREW HHC M8-1.25 X 35 G8.8 0G0149 SCREW SHC M14-1.5 X 35 G10.9 (4)5 0E9868A ALTERNATOR DC W/OUT PULLEY...
  • Page 53 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 45KW GROUP D DRAWING #: 0H7322 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 029333A TIE WRAP UL 7.4"X .19" BLK (2) 70 0H0015 HARN EMISSIONS OVERLAY 2.4L (NOT SHOWN) 045772 NUT HEX M10-1.5 G8 YEL CHR (1) SUPPLIED WITH ENGINE.
  • Page 55 EXPLODED VIEW: FUEL SYSTEM 2.4L 45KW EMSN GROUP E DRAWING #:0H7580A 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 022145 WASHER FLAT 5/16-M8 ZINC 022129...
  • Page 57 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 72 04/07 Rev. BackPg001...
  • Page 73 Owner's Manual Stationary Emergency Generator 2.4L 45kW Models NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT EPA Certified APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST with Catalyst FUMES! OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 74: Exploded Views & Parts Lists Wiring Diagrams & Schematics

    Menu System ...................8-7 Propane Vapor Withdrawal Fuel System ........5-1 OPERATION ..............9-1 LP Liquid Fuel System ..............5-1 Stationary Emergency Generator Control and Operation ....9-1 SPECIFICATIONS ............6-1 Operating Unit with Manual Transfer Switch ........9-1 Stationary Emergency Generator ..........6-1 Engine Start-up and Transfer ............9-1 Engine ..................6-1...

  • Page 75: Introduction

    Standby Emergency Generator Important 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.
  • Page 76 Standby Emergency Generator Important Safety Instructions WARNING:   GENERAL HAZARDS   The engine exhaust from this product • For safety reasons, the manufacturer recommends that this contains chemicals known to the state equipment be installed, serviced and repaired by a Service of California to cause cancer, birth Dealer or other competent, qualified electrician or installation defects or other reproductive harm.

  • Page 77: Electrical Hazards

    Standby Emergency Generator Important Safety Instructions   ELECTRICAL HAZARDS FIRE HAZARDS   • All stationary emergency generators covered by this manual • Keep a fire extinguisher near the generator at all times. Do NOT produce dangerous electrical voltages and can cause fatal use any carbon tetra-chloride type extinguisher.

  • Page 78: General Information

    Every generator set has a DATA LABEL that contains important information pertinent to the generator. The data label, which can be Stationary Emergency Generator Model and Serial found attached to the generator’s lower connection box, lists the Number unit’s serial number and its rated voltage, amps, wattage capacity,...

  • Page 79: Equipment Description

    Engines that have been operated with a chromate base rust inhibitor The Stationary Emergency Generator incorporates the following must be chemically cleaned before adding ethyl- alternator features: ene glycol base anti-freeze. Using any high sili- •...

  • Page 80: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate After a prespecified duration of cranking, this function ends the for long periods of time without an operator on hand to monitor cranking if the engine has failed to start. The overcrank message such engine conditions as coolant temperature, oil pressure or will turn ON.

  • Page 81: Fuel System

    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. the following fuel systems: •...

  • Page 82: Specifications

    Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ...............Gear Oil Filter ......... Full Flow Spin-on, Cartridge STATIONARY EMERGENCY GENERATOR Crankcase Oil Capacity ...........5.25 U.S. qts. Type..............Synchronous (including filter capacity) Rotor Insulation .............Class H Stator Insulation ............Class H COOLING SYSTEM Telephone Interference Factor (TIF) ........

  • Page 83: Weather And Maintenance Kits

    Specifications WEATHER AND MAINTENANCE KITS Install the previously removed black pipe onto the outlet port of the demand regulator. Use pipe sealant on the pipe To keep the generator running at its peak, the following kits are threads. offered: 10. Reverse steps 1-4 in this procedure to reactivate the demand •...

  • Page 84: General Information

    The voltage and phase The Stationary Emergency Generator is designed to supply are described on the generator data label. The number of lead 3-phase electrical loads. Electric power is produced in the alterna- wires can be identified using the Specifications section and the tor power windings.

  • Page 85: 3-Phase Alternators ("Delta" Configuration)

    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- tor power windings. These windings were connected at the factory INTERNAL CONNECTIONS to the main circuit breaker with a “Delta”...

  • Page 86: Control Panel

    Control Panel CONTROL PANEL INTERFACE Upon power up, this controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly USING THE AUTO/OFF/MANUAL SWITCH connects AC utility power sense wires into the DC terminal block.

  • Page 87: Activation Chart

    Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- If the wrong language is chosen, it can be guage. Press ENTER to select. changed later using the “edit” menu. Language English Escape Enter Display Reads: Press ENTER to begin the activation pro-...

  • Page 88: Setting The Exercise Timer

    Control Panel INSTALLATION ASSISTANT • If utility is still lost after the “line interrupt period”, run the engine up to normal RPM and transfer the load. At this time the con- Interconnect System Self Test Feature (follow the on-screen troller will exit the exercise routine and assume full automatic prompts).

  • Page 89: Sequence Of Automatic Operation

    Control Panel MANUAL START SEQUENCE OF AUTOMATIC OPERATION Initial Conditions: Generator in Auto ready to run, load being sup- Allows the user to start and run the generator manually. plied by the Utility Source through the transfer switch. Transfer of the load to the generator will occur if utility is lost while When the utility voltage fails (falls below 60% of nominal), a the unit is running in the manual mode (only if activated).

  • Page 90: Under-Frequency Shutdown Alarm

    Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This This is a shutdown alarm. The alarm will activate after five (5) fault cannot be cleared using the control panel interface. The unit seconds of continuously missing cam pulses.

  • Page 91: Overvoltage Alarm

    Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an When the generator is shut down due to a latching alarm, the Auto alarm will be issued. /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding If the generator voltage rises above 130% for >0.2 seconds, an fault alarm message.
  • Page 92 Control Panel 12/11 Rev. CntrlNexus001...

  • Page 93: Operation

    TRANSFER SWITCH  Do not attempt manual operation until all power If the Stationary Emergency Generator has been installed with an supplies to the transfer switch have been posi- automatic transfer switch, the engine may be started and stopped tively turned off, or extremely dangerous - pos- automatically or manually.

  • Page 94: Maintenance

    Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change fre- quencies. Drain the oil while the engine is still warm from running. This  Before working on the Stationary Emergency means warm up the engine, shut it down and drain immediately as follows: Generator, ensure the following: •...

  • Page 95: Engine Coolant

    EXERCISE SYSTEM qualified service facilities should adjust the governor. Excessively high operating speeds Starts the Stationary Emergency Generator engine once every are dangerous and increase the risk of personal seven days and lets it run for 12 minutes. injury. Low speeds impose a heavy load on the...

  • Page 96: Spark Plugs

    DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERIES. CLEANING THE STATIONARY EMERGENCY GENERATOR Have the state of charge and condition checked. This should Keep the generator as clean and as dry as possible. Dirt and be done with an automotive-type battery hydrometer.

  • Page 97: Service Schedule

    Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Inspect Change Clean Yearly - Y Fuel Fuel Lines & Connections Lubrication Oil Level Oil Filter Cooling Engine Coolant Lines & Connections Engine Coolant Level Engine Coolant Enclosure Louvers Engine...

  • Page 98: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 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 99 Emission Control System Warranty on your new stationary emergency engine. If during the warranty period, any emission control system or component on your engine is found defective in materials or workmanship, Generac will repair your engine at no cost to you for diag- nosis, replacement parts and labor provided it be done by a Generac Authorized Warranty Service Facility.
  • Page 100 Emergency stationary internal combustion engines (ICE) may be operated for the purpose of maintenance checks and readiness testing, provided that the tests are recommended by Federal, State or local government, Generac, or the insurance company associated with the en- gine. Maintenance checks and readiness testing of such units is limited to 100 hours per year. There is no time limit on the use of emergency stationary ICE in emergency situations.
  • Page 101 Stationary Emergency Generator Notes...
  • Page 103 0F9677 ROTOR-2390-45KD1 CPL 0G0056 ROTOR-2390-35KD1 CPL 0G0959 ROTOR-2390-45KD1 CPL (G2) 0G1155 ROTOR-2390-35KD1 CPL (G2) 0G1931 ROTOR 25KW 3PH DIRECT 390 1800 0G2101 ROTOR 25KW 1PH DIRECT 390 1800 0G3734 RTR-2390-60KD2 CPL 0G6562 RTR 390 35AD1 CPL 0G6564 RTR 390 35KD1 CPL 0F9664 STATOR-390 45K 2P 1PH DIRECT 0G0057...
  • Page 107 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H6266 BACK PANEL CONBOX SUPPORT C2 0H6265 TOP PANEL CONBOX SUPPORT C2 0H6160 COVER WIRE ENTRY CONBOX 057073 JUNCTION BLOCK 3/8-16 056739 RELAY SOLENOID 12VDC PNL MNT (6)6 0H67330ST0R BRACKET GIMBAL CONTROL PNL RAW...
  • Page 108 MANUFACTURING: FOR CORRECT MATERIAL AND COLOR REFER TO AS400 BOM. • CUSTOMER: FOR CORRECT MATERIAL AND COLOR OF REPLACEMENT PARTS REFER TO “REPLACEMENT SHEET • METAL PARTS ORDERING GUIDE-0H7169” INCLUDED IN THE MANUAL OR AVAILABLE ON THE GENERAC WEBSITE REVISION: H-8120-D DATE: 1/19/11 PAGE 5 OF 8...
  • Page 109 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (KG) 0H5582 CB 0300 3P 600V E KG LL 0H6740 COVER CB E KG C2 CONBOX 0D3700 NUT FLANGE M6-1.0 NYLOK 0H5581A INSULATOR CB E 3P KG 0H6734...
  • Page 110 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION UL CIRCUIT BREAKER (QN) 0E7284 CB 0175A 2P 240V S QN2 LL 0H7356 COVER CB C2 CPL 0H7429 COVER CB DISH 2P S QN 0E3664 BASE, QN CIRCUIT BREAKER 0H7311...
  • Page 111 EXPLODED VIEW: CONBOX C2 CPL GROUP A DRAWING #: 0H7326 APPLICABLE TO: THIS PAGE LEFT INTENTIONALLY BLANK REVISION: H-8120-D DATE: 1/19/11 PAGE 8 OF 8...
  • Page 113 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 115 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 117 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 119 0H30830ST03 WELDMENT RADIATOR SUPPORT C2 0F2862 SPRING TENSION CPL 0F2608 RADIATOR 598 X 568 X 49 CPL RH 0F2560 PULLEY V-BELT 4" FLANGED 0F5263 V-BELT 31/64" X 57-3/8" 022131 WASHER FLAT 3/8-M10 ZINC 046526 WASHER LOCK M10 0E2507 PROBE, COOLANT LEVEL 3/8NPTF (1) 5 059981 SCREW HHC M10-1.5 X 30 G10.9...
  • Page 121 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 0E0170A EXHAUST BLANKET 988MM 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0G0776A PIPE EXHAUST G2 EMISSIONS 0G0007 DIFFUSER EXHAUST WELDMENT 044149...
  • Page 124 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 45KW GROUP D DRAWING #: 0H7322 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 0H1619 ENGINE 2.4L G2 CERTIFIED 046526 WASHER LOCK M10 039414 SCREW HHC M8-1.25 X 35 G8.8 0G0149 SCREW SHC M14-1.5 X 35 G10.9 (4)5 0E9868A ALTERNATOR DC W/OUT PULLEY...
  • Page 125 EXPLODED VIEW: ENGINE COMMON PRT 2.4L G2 45KW GROUP D DRAWING #: 0H7322 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION 029333A TIE WRAP UL 7.4"X .19" BLK (2) 70 0H0015 HARN EMISSIONS OVERLAY 2.4L (NOT SHOWN) 045772 NUT HEX M10-1.5 G8 YEL CHR (1) SUPPLIED WITH ENGINE.
  • Page 127 EXPLODED VIEW: FUEL SYSTEM 2.4L 45KW EMSN GROUP E DRAWING #:0H7580A 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 022145 WASHER FLAT 5/16-M8 ZINC 022129...
  • Page 129 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 144 04/07 Rev. BackPg001...

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