Generac Power Systems 004742-0 Owner's Manual
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Generac Power Systems 004742-0 Owner's Manual

Generac Power Systems 004742-0 Owner's Manual

Liquid-cooled, prepackaged standby generators
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®
POWER SYSTEMS, INC.
Owner's Manual
Liquid-cooled, Prepackaged
Standby Generators
Model Numbers
004742-0
004744-0
004746-0
This manual should remain with the unit.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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Summary of Contents for Generac Power Systems 004742-0

  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Liquid-cooled, Prepackaged Standby Generators Model Numbers 004742-0 004744-0 004746-0 This manual should remain with the unit. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 2: Introduction

    DEALER, please call this number: This symbol points out potential explosion hazard. 1-800-333-1322 This symbol points out potential fire hazard. This symbol points out potential electrical shock Locate us on the web at: hazard. www.generac.com...

  • Page 3: Table Of Contents

    Table of Contents Liquid-cooled 15 kW, 20 kW and 25 kW Generators INTRODUCTION ........IFC Section 3 — OPERATION....12 Using a Standard “GTS” Transfer Switch..12 SAFETY RULES ........2 Control Console Components......12 Section 1 — GENERAL Manual Transfer and Startup ......13 INFORMATION....4 Retransfer and Shutdown......13 Generator ............4 Automatic Operation ........13...

  • Page 4: Safety Rules

    Important Safety Instructions Liquid-cooled 15 kW, 20 kW and 25 kW 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: Electrical Hazards

    Important Safety Instructions Liquid-cooled 15 kW, 20 kW and 25 kW 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.

  • Page 6: Section 1 - General Information

    Model 004742-0: Provides 15,000 watts (15 kW) of 1 phase power. Please reference the transfer switch manual for spe- Model 004744-0: Provides 20,000 watts (20 kW) of 1 phase power.

  • Page 7: Engine Protective Devices

    Section 1 - General Information Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 1.2 - Main Circuit Breaker Model Rating Phase Actual Current C/B Rating* % over rating Circuit Breaker 004742-0 15,000 62.5 112% 70A BQ2 004744-0 20,000 83.3 108% 90A BQ2...

  • Page 8: Unpacking

    LED2 personnel to be used in all phases of handling LED1 and unpacking. CUT R83 CR41 2002 GENERAC POWER SYSTEMS, ASSY #076009A FOR 50HZ 1.10 SPECIFICATIONS 1.7.5 PCB OPERATION LED’S 1.10.1 GENERATOR SPECIFICATIONS • LED 1 is RED. This LED will be on when utility sensing is NOT available to the circuit board.

  • Page 9: Fuel Consumption

    Section 1 — General Information Liquid-cooled 15 kW, 20 kW and 25 kW Generators 1.10.2 ENGINE SPECIFICATIONS 1.12 RECONFIGURING THE FUEL SYSTEM Make................Mitsubishi Displacement ..........92 inches (1.5 liters) NOTE: Cylinder Arrangement............4, in-line All models are configured for natural gas from the Valve Arrangement..........Overhead Cam factory.

  • Page 10: Torque Specifications

    Section 2 — Installation Liquid-cooled 15 kW, 20 kW and 25 kW Generators 1.13 TORQUE SPECIFICATIONS 1.16 BEFORE INSTALLATION Before installing this equipment, check the ratings of Cylinder Head ..........15 (+ 90° + 90°) ft.lb. both the generator and the transfer switch. Read Intake Manifold ..............13 ft.lb.

  • Page 11: Generator Location

    Section 2 — Installation Liquid-cooled 15 kW, 20 kW and 25 kW Generators 2.1.1 NFPA STANDARDS • Install the generator as close as possible to the transfer switch. This reduces the length of wiring The following published standards booklets pertain- and conduit.

  • Page 12: Emergency Circuit Isolation Method

    Section 2 — Installation Liquid-cooled 15 kW, 20 kW and 25 kW 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 Liquid-cooled 15 kW, 20 kW and 25 kW Generators 2.10 BATTERY INSTALLATION • Spilled electrolyte is to be washed down with an acid-neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbon- DANGER ate of soda to one gallon (4 liters) of water.

  • Page 14: Section 3 - Operation

    Section 3 — Operation Liquid-cooled 15 kW, 20 kW and 25 kW Generators USING A STANDARD “GTS” 2.11.2 TRANSFER SWITCH TRANSFER SWITCH If this generator is used to supply power to any elec- trical system normally powered by an electric utility, When required, the pre-packaged standby generator the National Electrical Code requires that a transfer can be installed with a standard “GTS”...

  • Page 15: Manual Transfer And Startup

    Section 3 - Operation Liquid-cooled 15 kW, 20 kW and 25 kW Generators 3.2.1 HOURMETER NOTE: This fuse will not remove the + battery input Indicates time the engine-generator has operated, in power from the PCB when it opens. This means hours and tenths of hours.

  • Page 16: Weekly Exercise Cycle

    Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW Generators WEEKLY EXERCISE CYCLE ENGINE HEATER The generator will start and exercise once every 7 This standby generator comes equipped with a block days. During this weekly exercise, the unit runs for heater (Figure 3.3), similar to the block heaters used about 20 minutes and shuts down.

  • Page 17: Cooling System

    Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW Generators E. EVERY 500 OPERATING HOURS CHECKING FLUID LEVELS 1.Service air cleaner. 4.4.1 CHECK ENGINE OIL 2.Check starter. Check engine crankcase oil level (Figure 4.1) at least 3.Check engine DC alternator. every 20 hours of operation, or prior to use.

  • Page 18: Maintenance Owner/Operator Can Perform

    Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW Generators MAINTENANCE OWNER/ DANGER OPERATOR CAN PERFORM Do not attempt to adjust the governor. Only qualified service facilities should adjust the 4.5.1 CHECK ENGINE OIL LEVEL governor. Excessively high operating speeds are Refer to “Checking Fluid Levels”...

  • Page 19: Miscellaneous Maintenance

    Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW Generators Figure 4.4 – Setting the Spark Plug Gap SET PLUG GAP AT 0.5-0.6 mm After refilling the crankcase with oil, always (0.020-0.025 inch) check oil level on dipstick. NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK “ADD”...
  • Page 20 Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW Generators sulfuric solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If any bat- Be sure the Auto/Off/Manual switch is set to tery fluid is spilled, flush the affected area with the OFF position before connecting the battery clear water immediately.

  • Page 21: Scheduled Maintenance

    Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW Generators SCHEDULED MAINTENANCE Following is a recommended maintenance schedule for small standby and residential generator sets. The estab- lished intervals in the schedule are the maximum recommended when the unit is used in an average service appli- cation.
  • Page 22 Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW 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.
  • Page 23 Section 4 — Maintenance Liquid-cooled 15 kW, 20 kW and 25 kW 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.

  • Page 24: Section 5 - Troubleshooting

    Section 5 — Troubleshooting Liquid-cooled 15 kW, 20 kW and 25 kW 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.

  • Page 25: Diagram

    Section 6 — Installation Diagram Liquid-cooled 15 kW, 20 kW and 25 kW Generators Installation Diagram — Drawing No. 0E1533-A...

  • Page 26: Section 7 - Electrical Data

    Section 7 - Electrical Data Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — Control Panel —Drawing No. 0E0345...
  • Page 27 Section 7 - Electrical Data Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L Engine — Drawing No. 0E0343-B...
  • Page 28 Section 7 - Electrical Data Liquid-cooled 15 kW, 20 kW and 25 kW Generators Wiring Diagram — 1.5L — Drawing No. 0E1525 BLACK BLACK BLUE BLUE...
  • Page 29 Section 7 - Electrical Data Liquid-cooled 15 kW, 20 kW and 25 kW Generators Electrical Schematic — 1.5L — Drawing No. 0A7182-C...

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

    Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Mounting Base — Drawing No. 0E0768-B...
  • Page 31 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Mounting Base — Drawing No. 0E0768-B ITEM PART NO. QTY. DESCRIPTION 0D8656 BASE MOUNTING 1.5L STNRD & ACSTC 027482 WASHER SHAKEPROOF EXT 5/16 STL 070936 DAMPENER VIBRATION 070936C...
  • Page 32 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Standard Compartment — Drawing No. 0E0771-H...
  • Page 33 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Standard Compartment — Drawing No. 0E0771-H ITEM PART NO. QTY. DESCRIPTION 0D8666 (A) ROOF ACSTC&STND CMPRTMNT 1.5L 0D8664C (G) DUCT CENTER 1.5L 0D8657 (A) SUPPORT RADIATOR 1.5L MITSU 0D8660 (A) BRACE SIDE 1.5L MITSU...
  • Page 34 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Acoustic Compartment — Drawing No. 0E0772-L...
  • Page 35 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Acoustic Compartment — Drawing No. 0E0772-L ITEM PART NO. QTY. DESCRIPTION 0D8666 (A) ROOF ACSTC & STND CMPRTMNT 1.5L 0D8664C (G) DUCT CENTER 1.5L 0D8657 (A) SUPPORT RADIATOR 1.5L MITSU 0D8660 (A)
  • Page 36 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Control Panel — Drawing No. 0E0778-G...
  • Page 37 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Control Panel — Drawing No. 0E0778-G ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D9322 PANEL BACK & BOTTOM GUARDIAN 0C2267 SCREW HHTT M5-0.8 X 12 BP 0D9332 PANEL LH SIDE GUARDIAN &...
  • Page 38 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Engine — Drawing No. 0E1228-H...
  • Page 39 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Engine — Drawing No. 0E1228-H ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0A4531 ENGINE-1.5L 0A5110 PIPE WATER-INLET 022473 WASHER FLAT 1/4 ZINC 0A7006 O-RING 1-1/16 X 1-5/16 X 1/8 0A45310258...
  • Page 40 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Radiator — Drawing No. 0E0769-K...
  • Page 41 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Radiator — Drawing No. 0E0769-K ITEM PART NO. QTY. DESCRIPTION 0D8657 SUPPORT RADIATOR 1.5L MITSU 0A5734 RADIATOR 1.5L 0A6237 VENTURI 1.5L MODINE 0A6238 GUARD FAN 1.5L MODINE 084918 HEATER ENGINE 0500W 120V 051520N...
  • Page 42 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Fuel System — Drawing No. 0E0774-F "C" "C" "D" PORT "OUT 1" (NATURAL GAS) "D" PORT "OUT 2" L.P. VAPOR...
  • Page 43 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Fuel System — Drawing No. 0E0774-F ITEM PART NO. QTY. DESCRIPTION --------- WELDMENT MOUNTING BASE 075580 FLANGE FUEL INLET 0E1006 ASSY REGULATOR 1.5L N.G.OR LPV 039253 SCREW HHC M8-1.25 X 20 G8.8 022145...
  • Page 44 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Alternator — Drawing No. 0A9348-G...
  • Page 45 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Alternator — Drawing No. 0A9348-G ITEM PART NO. QTY. DESCRIPTION 098671 ASSY ROTOR 10KW 098681 ASSY ROTOR 15KW 098675 ASSY ROTOR 20KW 098936 ASSY ROTOR 25KW 0A5336A HOUSING BLOWER 0A1659...
  • Page 46 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Battery — Drawing No. 0E0770-B STARTER SOLENOID TO ENGINE BLOCK ITEM PART NO. QTY. DESCRIPTION 077483 BATT 12VDC 75-AH 26 (NOT INCLUDED) 038804D CABLE BATT RED #4 X 20.00 038805B CABLE BATT BLK #4 X 23.00 0742600131...
  • Page 47 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Muffler — Drawing No. 0E0773-A ITEM PART NO. QTY. DESCRIPTION 0A4355 MANIFOLD EXHAUST 1.5L 0E2844 NIPPLE TOE 1.5NPTX5.5 BLK IRON 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH 0E0109...
  • Page 48 Section 8 - Exploded Views and Parts Liquid-cooled 15 kW, 20 kW and 25 kW Generators Governor Assembly — Drawing No. 0E1331-B ITEM (13) NEOPRENE COATING WIRE HARNESS SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN. "A" TO "A" INTAKE MANIFOLD (REF.) CARBURETOR ARM (REF.)

  • Page 49: Section 9 - Notes

    Section 9 - Notes Liquid-cooled 15 kW, 20 kW and 25 kW Generators...

  • Page 50: Section 10 - Warranty

    Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
  • Page 51 Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or “grey market”...
  • Page 52 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.
  • Page 54 098671 ASSY ROTOR 10KW 098681 ASSY ROTOR 15KW 098675 ASSY ROTOR 20KW 098936 ASSY ROTOR 25KW 0A5336A HOUSING BLOWER 0A1659 SCREEN AIR OUTLET 071912 SCREW PPHM M5-0.8 X 8 SS 049226 WASHER LOCK M5 051713 WASHER FLAT M5 022129 WASHER LOCK M8-5/16 098672 ASSY STATOR 10KW A 098673...
  • Page 56 0D9322 PANEL BACK & BOTTOM GUARDIAN 0D9332 PANEL LH SIDE GUARDIAN & SPRN 0D9325A PANEL FRONT CONTROL GUARDIAN W/ SILKSC 0D9330 PANEL RH SIDE C-PANEL SML BRK 0C1457 HOURMETER 064009 LIGHT 12VDC .02A LED RED PILOT 032300 HOLDER FUSE 022676 FUSE 15A X AGC15 0E4494 SWITCH ROC DPDT ON-OFF-ON...
  • Page 58 0D8656 BASE MOUNTING 1.5L STNRD & ACSTC 027482 WASHER SHAKEPROOF EXT 5/16 STL 070936 DAMPENER VIBRATION 070936C VIB. ISO. 70-75 DURO 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 YEL CHR 071956 WASHER FLAT M8 051730...
  • Page 60 0D8657 SUPPORT RADIATOR 1.5L MITSU 0A5734 RADIATOR 1.5L 0A6237 VENTURI 1.5L MODINE 0A6238 GUARD FAN 1.5L MODINE 084918 HEATER ENGINE 0500W 120V 084918A HEATER BLOCK 1000W 120V 051520N TUBING 5/8 ID X 12 048031C CLAMP HOSE BAND 1/4 099502 CLAMP HOSE #24 B1.06 - 2.00 083709 CLAMP WIRE HOSE .573 - .551 052250...
  • Page 62 077483 BATT 12VDC 75-AH 26 (NOT INCLUDED) 038804D CABLE BATT RED #4 X 20.00 038805B CABLE BATT BLK #4 X 23.00 0742600131 ASSY,WIRE#16 RED 1.6 022131 WASHER FLAT 3/8 ZINC 046526 WASHER LOCK M10 052213 SCREW HHC M10-1.25 X 20 G8.8 075763 BOOT, BATTERY CABLE 0D8668...
  • Page 64 0A4531 ENGINE-1.5L 0A5275 V-BELT 3/8 X 32-1/8 1.5L 022473 WASHER FLAT 1/4 ZINC 0A5586 V-BELT 3/8 X 28.9 1.5L 0A45310258 GASKET-EXHAUST MANIFOLD 0A4814 SPACER PULLEY 0A4355 MANIFOLD-EXHAUST 0A45310244 FILTER OIL 0E2632 HEAT SHIELD EXH 1.5L 0C1852 ADAPTER DRAIN OIL 022097 WASHER LOCK M6-1/4 0912970066 GROUND WIRE (STARTER)
  • Page 65 ITEM (13) NEOPRENE COATING WIRE HARNESS SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN. "A" TO "A" INTAKE MANIFOLD (REF.) CARBURETOR ARM (REF.)
  • Page 66 098290 ASM MOTOR STEPPER 098941A HOUSING GOVERNOR CONNECTOR 098958A CONNECTOR INTERFACE ASSEMBLY 098942A COVER CONNECTOR HOUSING 098225 SCREW FHM #2 X 5/8 SELF TAP 043146 SCREW HHC M6-1.0 X 10 G8.8 022097 WASHER LOCK M6-1/4 084543A SCREW PHM M3-0.5 X 12MM 098783 LEVER STEPPER MOTOR 037398...
  • Page 68 --------- WELDMENT MOUNTING BASE 075580 FLANGE FUEL INLET 0E1006 ASSY REGULATOR 1.5L N.G.OR LPV 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 YEL CHR 0A7040 BRACKET-RAD HOSE 032552 BARBED EL 90 5/16 X 1/8 NPT 029032...
  • Page 70 0D8666 (A) ROOF ACSTC&STND CMPRTMNT 1.5L 0D8664C (G) DUCT CENTER 1.5L 0D8657 (A) SUPPORT RADIATOR 1.5L MITSU 0D8660 (A) BRACE SIDE 1.5L MITSU 0A7568 (A) DOORWELDMENT 1.5EPS 0D8659 (A) CORNER POST REAR RH SIDE 1.5L 0D8662 (A) DOOR REAR COMPARTMENT 1.5L 0D8661 (A) BRACE REAR 1.5L MITSU 0D8658 (A)
  • Page 72 0D8666 (A) ROOF ACSTC & STND CMPRTMNT 1.5L 0D8664C (G) DUCT CENTER 1.5L 0D8657 (A) SUPPORT RADIATOR 1.5L MITSU 0D8660 (A) BRACE SIDE 1.5L MITSU 0A7568 (A) DOOR WELDMENT 1.5 EPS 0D8659 (A) CORNER POST REAR RH SIDE 1.5L 0D8662 (A) DOOR REAR COMPARTMENT 1.5L 0D8661 (A) BRACE REAR 1.5L MITSU...
  • Page 74 0A4355 MANIFOLD EXHAUST 1.5L 0E2844 NIPPLE TOE 1.5 NPT X 5.5 BLK IRON 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH 0E0109 PIPE EXHAUST 1.5L STNDRD & ACSTC 0C1318 FLEX PIPE EXHAUST 0D8657 SUPPORT RADIATOR 1.5L MITSU 027837 SCREW RHM 1/4-20 X 2-1/4 0D9437 MUFFLER 1.5L ACOUSTIC&STANDARD...
  • Page 78 EC-3 N.C. EC-4 EC-5 225A BLUE 225A BLUE 2 WIRE START FOR STANDARD GENERAC TRANSFER SWITCH CONNECTION USE BLUE WIRE FOR 240V L-L SYSTEMS YELLOW WIRE FOR 208V L-L SYSTEMS YELLOW INSULATE UNUSED WIRE ORANGE ALTERNATE TR1 YELLOW (RED) (BLUE)

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004744-0004746-0

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