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! n 4.6L 80kW Models EPA Certified This manual should remain with the unit. Cover199 Rev. A 10/10 Part No.
Table of Contents SECTION PAGE OPERATION ..........................................................................9-1 INTRODUCTION ....................................................................1-1 Stationary Emergency Generator Control and Operation .........9-1 Operating Unit with Manual Transfer Switch...........................9-1 SAFETY RULES ....................................................................1-2 Operating Unit with Automatic Transfer Switch ......................
Safety Instructions THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential nSAVE hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION This symbol points out potential electrical shock hazard. This symbol points out potential fire hazard. Thank you for purchasing this model of the stationary emergency generator product line.
Safety Instructions SAFETY RULES • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. This should be considered prior to installing the generator. The unit should be positioned to direct exhaust gasses safely away from any building where people, animals, etc., will not be harmed.
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 equipment only while standing on such insulative mats. • The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground.
General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit. DATA LABEL Every generator set has a DATA LABEL that contains important information pertinent to the generator.
Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Emergency Generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers.
Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm.
Fuel System FUEL SYSTEM NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems. FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems: • Gas pressure in a building is usually regulated by national, state and local codes.
Specifications SPECIFICATIONS COOLING SYSTEM Type Closed Water Pump ............................................................. Belt Driven Fan Speed .........................................................................1600 Fan Diameter..............................................................26 inches Fan Mode......................................................................... Puller Air Flow (inlet air including alternator and combustion air) ..............................................
Specifications WEATHER AND MAINTENANCE KITS To keep the generator running at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32 °F. • Scheduled Maintenance Kit ~ Kit includes the recommended parts to maintain the generator. Refer to the Service Schedule for regular maintenance intervals. For additional information, or to order any of these kits, please contact an Authorized Service Dealer or Customer Service Representative.
General Information ALTERNATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase are described on the generator data label. The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label.
General Information 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Figure 7.4 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead) INTERNAL CONNECTIONS The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a “Delta” configuration as shown in Figures 7.7 and 7.8.
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 connects AC utility power sense wires into the DC terminal block. If utility voltage is detected, the controller will display a warning message and lock out the generator, preventing damage to the controller. Power to the controller must be removed to clear this warning.
Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Language English Escape Use ARROW keys to scroll to desired language. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER, your generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed.
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 controller will exit the exercise routine and assume full automatic operation. Interconnect System Self Test Feature (follow the on-screen prompts). 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.
Control Panel SEQUENCE OF AUTOMATIC OPERATION MANUAL START Initial Conditions: Generator in Auto ready to run, load being supplied by the Utility Source through the transfer switch. Allows the user to start and run the generator manually. 1. 2. 3. 4. Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode (only if activated).
Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This fault cannot be cleared using the control panel interface. The unit will continue to operate in automatic mode. Contact your local servicing dealer. This is a shutdown alarm. The alarm will activate after five (5) seconds of continuously missing cam pulses. UNDER-FREQUENCY SHUTDOWN ALARM This is a shutdown alarm.
Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an alarm will be issued. If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued. When the generator is shut down due to a latching alarm, the Auto /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message.
8-7 CntrlNexus001 Rev. E 12/11 ENTER +/- ESC ALARM LOG RUN LOG ESC Use the “ENTER” key to select items or enter data. Use the “+/-” key to navigate through the menu. Press the “ESCAPE” key to jump back up through the menu levels.
Operation STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION not crank the engine continuously for longer than 30 seconds, or the heat may nDo damage the starter motor. Refer to the appropriate control panel operator’s manual for this unit. • Let engine stabilize and warm up. • Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to the STANDBY (or EMERGENCY STANDBY) position, i.e.
Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change frequencies. Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows: • • • • Before working on the Stationary Emergency Generator, ensure the following: The AUTO/OFF/MANUAL switch is in the OFF position. The control panel fuse has been removed from the control box. The 120VAC supply to the battery charger is switched OFF.
Maintenance ENGINE COOLANT CHECK FAN BELT Check coolant level in coolant recovery bottle. See the Specifications and Service Schedule sections. • Inspect fan belts every year. Replace any damaged, deteriorated, worn or otherwise defective belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required. • Check fan belt alignment (see Figure 10.2). • Add recommended coolant mixture as necessary.
Maintenance Figure 10.3 – Engine Air Filter electrolyte fluid is an extremely corronBattery sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water. Air Filter not use any jumper cables or booster battery to crank and start the generator engine.
Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Yearly - Y Inspect M X Oil Level M X* Oil Y X** Oil Filter Y X** Change Clean Fuel Fuel Lines & Connections Lubrication Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y Enclosure Louvers W X Air Cleaner Y X X*** Spark Plugs Y X X*** Remove Corrosion, Ensure Dryness M X X Clean & Tighten Battery Terminals M X X Check Charge Stat
Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 1. Replace fuse.* 2. Tighten, clean or replace battery cables as necessary.* 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery.* Engine cranks but won't start. 1. Out of fuel. 2.
United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators) Warranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine.
United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc.
Notes
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# A B C D E F G H J K A B C D E F G H J K L M N P A B C D E F G H J K L M QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# A B C D E F G H J A B C D E F G H J K L QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: GROUP A THIS PAGE LEFT INTENTIONALLY BLANK REVISION: K-1161-F DATE: 11/6/14 Page 8 of 8
EXPLODED VIEW: EV CPL ALTERNATOR BRUSHLESS GROUP A DRAWING #: 0J0203 APPLICABLE TO: ITEM PART# QTY.
EXPLODED VIEW: EV MTG BASE 6.8L 150KW CPL GROUP C DRAWING #: 0F2975 ITEM (1)1 2 3 4 5 6 7 8 (1)9 10 11 12 13 14 15 (1)16 17 18 19 20 21 22 23 24 25 (1)26 27 28 29 30 PART# QTY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 0F3408 0F3411 058208 022131 050331A 050331 038805U 038804U 045771 022129 027482 075763 0C2454 0F3409 1 1 1 1 1 1 1 1 1 1 1 1 8 1 TRAY BATTERY STRAP BATTERY RETAINMENT BATT 12VDC 24F 625 WASHER FLAT 3/8-M10 ZINC BATT POST COVER RED + BATT POST COVER BLK CABLE BATT BLK #1 X 18.00 CABLE BATT RED #1 X 28.00 NUT HEX M8-1.
EXPLODED VIEW: EV AIR CLEANER GROUP D DRAWING #: 0F3569 ITEM PART# QTY. 0D2513D 0D2513E 0F5419 0F4268 0F4270A 0F6977 037561 047411 022097 057795B 0F4269 022473 0A4256 0G5954 1 1 1 1 1 1 1 4 4 1 1 3 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 REVISION: J-9801-E DATE: 9/19/14 DESCRIPTION AIR CLNR BTM PLT W/CPLR 8.1L PLATE AIR CLEANER W/COUPLER ELEMENT AIR FILTER TOP PLATE VENTURI HOLD DOWN AIR CLEANER PLATED PLATE AIR CLEAN TOP 5.4L/6.8L NUT WING 1/4-20 NYLK SCREW HHC M6-1.0 X 16 G8.
EXPLODED VIEW: COOLSYS/FAN DRIVE 4.6L CP GROUP D DRAWING #: 0J1411 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (4)1 2 3 4 (2)5 6 7 8 9 10 (4)11 (2)12 13 14 15 (2)16 17 18 19 (2)20 21 22 23 (2)24 25 26 0J01150ST0R 1 WELDMENT RADIATOR SUPPORT C5 0F2611 1 RADIATOR 680 X 680 X 70 CPL 0F5254 1 V-BELT 31/64" X 62-3/8" 046526 9 WASHER LOCK M10 059981 4 SCREW HHC M10-1.5 X 30 C10.9 0C2454 2 SCREW THF M6-1 X 16 N WA Z/JS 052250 2 TAPE FOAM 1 X 1 (26.
EXPLODED VIEW: EV EXHAUST 4.6L CPL C5 GROUP D DRAWING #: 0J1450 APPLICABLE TO: ITEM PART# QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 26 27 28 29 30 31 0J0675 0J0676 0F4462 0A6765 0F4710 0F7200 080762 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 0F2773C 0D3159 088775 0F4505A 0F5447 022473 0F6214B 0L1789 049813 049721 088510 0C9748 1 1 2 2 6 6 8 1 2 2 4 12 2 2 1 6 2 1 20 2 8 8 12 6 1 0C8566 0D3700 2 2 32 REVISION: K-1591-D DATE: 1/28/15 DESCRIPTION PIPE EXH MANIFOLD 4.
EXPLODED VIEW: EV ENGCOMPRT LH 4.6L G3 GROUP D DRAWING #: 0J4322 APPLICABLE TO: ITEM 1 (1)2 3 4 (1)5 6 (1)7 (1)8 (1)9 (1)10 (1)11 (1)12 13 (1) 14 15 (1)16 (1)17 (1)18 19 (1)20 21 22 23 24 (1)25 (1)26 27 28 29 30 31 32 33 (1)34 35 36 37 38 39 40 41 42 43 44 (2)45 46 47 48 49 50 51 (1)52 53 54 55 (1)56 57 PART# QTY.
EXPLODED VIEW: EV ENGCOMPRT RH 4.6L G3 GROUP D DRAWING #:0J4322A APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 (1)31 (1)32 33 34 35 36 37 38 39 PART# QTY.
EXPLODED VIEW: FUEL SYSTEM NG 4.
EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW GROUP E DRAWING #:0H3919 APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART# 0G9239D 057822 0H3894 082121A 0H3921 0H4537 026915 0A8064 064346 031015 030131 039130 065908 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766B 097962 022097 042568 049811 0D3700 063831 REVISION: J-8381-C DATE: 4/22/14 QTY.
REPLACEMENT SHEET METAL PARTS ORDERING GUIDE Parts listed in the manual Bill of Material on the EV drawings/Manuals are listed in the unfinished form with the default material – usually steel or plain six or seven digit number. 0XXXXXXST0R or 0XXXXXX Base number Suffix1 Raw After entering serial number or model number of the unit to search/order replacement sheet metal parts follow steps below to identify/verify correct part number: 1. 2. 3.
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EXPLODED VIEW: EV ENCLOSURE C5 EMISSION GROUP F DRAWING #: 0J0204 APPLICABLE TO: ITEM PART# QTY.
BackPg001 Rev.
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! n 4.6L 80kW Models EPA Certified This manual should remain with the unit. Cover199 Rev. A 10/10 Part No.
Table of Contents SECTION PAGE OPERATION ..........................................................................9-1 INTRODUCTION ....................................................................1-1 Stationary Emergency Generator Control and Operation .........9-1 Operating Unit with Manual Transfer Switch...........................9-1 SAFETY RULES ....................................................................1-2 Operating Unit with Automatic Transfer Switch ......................
Safety Instructions THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential nSAVE hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. INTRODUCTION This symbol points out potential electrical shock hazard. This symbol points out potential fire hazard. Thank you for purchasing this model of the stationary emergency generator product line.
Safety Instructions SAFETY RULES • The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. For that reason, adequate ventilation must be provided. This should be considered prior to installing the generator. The unit should be positioned to direct exhaust gasses safely away from any building where people, animals, etc., will not be harmed.
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 equipment only while standing on such insulative mats. • The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground.
General Information IDENTIFICATION RECORD NOTE: For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit. DATA LABEL Every generator set includes DATA LABEL that contains important information pertinent to the generator.
Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Emergency Generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers.
Engine Protective Devices ENGINE PROTECTIVE DEVICES OVERCRANK SHUTDOWN The Stationary Emergency Generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant temperature, oil pressure or rpm.
Fuel System FUEL SYSTEM NATURAL GAS FUEL SYSTEM Natural gas is supplied in its vapor state. In most cases, the gas distribution company provides piping from the main gas distribution line to the standby generator site. The following information applies to natural gas fuel systems. FUEL REQUIREMENTS The Stationary Emergency Generator may be equipped with one of the following fuel systems: • Gas pressure in a building is usually regulated by national, state and local codes.
Specifications SPECIFICATIONS COOLING SYSTEM Type Closed Water Pump ............................................................. Belt Driven Fan Speed .........................................................................1600 Fan Diameter..............................................................26 inches Fan Mode......................................................................... Puller Air Flow (inlet air including alternator and combustion air) ..............................................
Specifications WEATHER AND MAINTENANCE KITS To keep the generator running at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32 °F. • Scheduled Maintenance Kit ~ Kit includes the recommended parts to maintain the generator. Refer to the Service Schedule for regular maintenance intervals. For additional information, or to order any of these kits, please contact an Authorized Service Dealer or Customer Service Representative.
General Information ALTERNATOR AC LEAD CONNECTIONS ALTERNATOR POWER WINDING CONNECTIONS The electrical wires in the unit’s AC connection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. The voltage and phase are described on the generator data label. The number of lead wires can be identified using the Specifications section and the power output rating on the generator data label.
General Information 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Figure 7.4 — Stator Power Winding Connections - 3-phase, 120/208V (6 Lead) INTERNAL CONNECTIONS The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alternator power windings. These windings were connected at the factory to the main circuit breaker with a "Delta" configuration as shown in Figures 7.7 and 7.8.
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 connects AC utility power sense wires into the DC terminal block. If utility voltage is detected, the controller will display a warning message and lock out the generator, preventing damage to the controller. Power to the controller must be removed to clear this warning.
Control Panel ACTIVATION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Language English Escape Use ARROW keys to scroll to desired language. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER, your generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed.
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 controller will exit the exercise routine and assume full automatic operation. Interconnect System Self Test Feature (follow the on-screen prompts). 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.
Control Panel SEQUENCE OF AUTOMATIC OPERATION MANUAL START Initial Conditions: Generator in Auto ready to run, load being supplied by the Utility Source through the transfer switch. Allows the user to start and run the generator manually. 1. 2. 3. 4. Transfer of the load to the generator will occur if utility is lost while the unit is running in the manual mode (only if activated).
Control Panel Figure 1 – Generator Control Panel CHECK ENGINE MESSAGE MISSING CAM PULSE ALARM The control system has detected an emissions related fault. This fault cannot be cleared using the control panel interface. The unit will continue to operate in automatic mode. Contact your local servicing dealer. This is a shutdown alarm. The alarm will activate after five (5) seconds of continuously missing cam pulses. UNDER-FREQUENCY SHUTDOWN ALARM This is a shutdown alarm.
Control Panel OVERVOLTAGE ALARM ALARM CANCEL If the generator voltage rises above 110% for >3 seconds, an alarm will be issued. If the generator voltage rises above 130% for >0.2 seconds, an alarm will be issued. When the generator is shut down due to a latching alarm, the Auto /Off/ Manual switch must be set to the off position and the ENTER key pressed to unlatch any active fault and clear the corresponding fault alarm message.
8-7 CntrlNexus001 Rev. E 12/11 ENTER +/- ESC ALARM LOG RUN LOG ESC Use the “ENTER” key to select items or enter data. Use the “+/-” key to navigate through the menu. Press the “ESCAPE” key to jump back up through the menu levels.
Operation STATIONARY EMERGENCY GENERATOR CONTROL AND OPERATION not crank the engine continuously for longer than 30 seconds, or the heat may nDo damage the starter motor. Refer to the appropriate control panel operator’s manual for this unit. • Let engine stabilize and warm up. • Check all applicable instrument and gauge readings. When certain that all readings are correct, move the transfer switch manual handle to the STANDBY (or EMERGENCY STANDBY) position, i.e.
Maintenance GENERAL MAINTENANCE Refer to the Service Schedule for engine oil and filter change frequencies. Drain the oil while the engine is still warm from running. This means warm up the engine, shut it down and drain immediately as follows: • • • • Before working on the Stationary Emergency Generator, ensure the following: The AUTO/OFF/MANUAL switch is in the OFF position. The control panel fuse has been removed from the control box. The 120VAC supply to the battery charger is switched OFF.
Maintenance ENGINE COOLANT CHECK FAN BELT Check coolant level in coolant recovery bottle. See the Specifications and Service Schedule sections. • Inspect fan belts every year. Replace any damaged, deteriorated, worn or otherwise defective belt. • Check fan belt tension. Thumb pressure, exerted midway between pulleys, should deflect about 3/8 to 5/8 of an inch. Adjust belt tension as required. • Check fan belt alignment (see Figure 10.2). • Add recommended coolant mixture as necessary.
Maintenance Figure 10.3 – Engine Air Filter electrolyte fluid is an extremely corronBattery sive sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water. Air Filter not use any jumper cables or booster battery to crank and start the generator engine.
Service Schedule SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Yearly - Y Inspect M X Oil Level M X* Oil Y X** Oil Filter Y X** Change Clean Fuel Fuel Lines & Connections Lubrication Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y Enclosure Louvers W X Air Cleaner Y X X*** Spark Plugs Y X X*** Remove Corrosion, Ensure Dryness M X X Clean & Tighten Battery Terminals M X X Check Charge Stat
Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 1. Replace fuse.* 2. Tighten, clean or replace battery cables as necessary.* 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery.* Engine cranks but won't start. 1. Out of fuel. 2.
United States Environmental Protection Agency Warranty Statement (Stationary Emergency Spark-Ignited Generators) Warranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new stationary emergency engine.
United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark-Ignited Generators) Purchaser's/Owner's Record Keeping Responsibilities The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc.
Notes
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM PART# QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM 64 65 PART# QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM A B C D E F G H J K A B C D E F G H J K L M N P A B C D E F G H J K L M PART# QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS GROUP A DRAWING #: 0H9370 APPLICABLE TO: ITEM A B C D E F G H J A B C D E F G H J K L PART# QTY.
EXPLODED VIEW: EV CONBOX C5 NEXUS DRAWING #: 0H9370 APPLICABLE TO: GROUP A THIS PAGE LEFT INTENTIONALLY BLANK REVISION: K-3487-G DATE: 8/4/15 Page 8 of 8
EXPLODED VIEW: EV CPL ALTERNATOR BRUSHLESS GROUP A DRAWING #: 0J0203 APPLICABLE TO: ITEM PART# QTY.
EXPLODED VIEW: EV MTG BASE 6.8L 150KW CPL GROUP C DRAWING #: 0F2975 ITEM (1)1 2 3 4 5 6 7 8 (1)9 10 11 12 13 14 15 (1)16 17 18 19 20 21 22 23 24 25 (1)26 27 28 29 30 PART# QTY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 0F3408 0F3411 058208 022131 050331A 050331 038805U 038804U 045771 022129 027482 075763 0C2454 0F3409 1 1 1 1 1 1 1 1 1 1 1 1 8 1 TRAY BATTERY STRAP BATTERY RETAINMENT BATT 12VDC 24F 625 WASHER FLAT 3/8-M10 ZINC BATT POST COVER RED + BATT POST COVER BLK CABLE BATT BLK #1 X 18.00 CABLE BATT RED #1 X 28.00 NUT HEX M8-1.
EXPLODED VIEW: EV AIR CLEANER GROUP D DRAWING #: 0F3569 ITEM PART# QTY. 0D2513D 0D2513E 0F5419 0F4268 0F4270A 0F6977 037561 047411 022097 057795B 0F4269 022473 0A4256 0G5954 1 1 1 1 1 1 1 4 4 1 1 3 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 REVISION: J-9801-E DATE: 9/19/14 DESCRIPTION AIR CLNR BTM PLT W/CPLR 8.1L PLATE AIR CLEANER W/COUPLER ELEMENT AIR FILTER TOP PLATE VENTURI HOLD DOWN AIR CLEANER PLATED PLATE AIR CLEAN TOP 5.4L/6.8L NUT WING 1/4-20 NYLK SCREW HHC M6-1.0 X 16 G8.
EXPLODED VIEW: COOLSYS/FAN DRIVE 4.6L CP GROUP D DRAWING #: 0J1411 APPLICABLE TO: ITEM PART# QTY. DESCRIPTION (4)1 2 3 4 (2)5 6 7 8 9 10 (4)11 (2)12 13 14 15 (2)16 17 18 19 (2)20 21 22 23 (2)24 25 26 0J01150ST0R 1 WELDMENT RADIATOR SUPPORT C5 0F2611 1 RADIATOR 680 X 680 X 70 CPL 0F5254 1 V-BELT 31/64" X 62-3/8" 046526 9 WASHER LOCK M10 059981 4 SCREW HHC M10-1.5 X 30 C10.9 0C2454 2 SCREW THF M6-1 X 16 N WA Z/JS 052250 2 TAPE FOAM 1 X 1 (26.
EXPLODED VIEW: EV EXHAUST 4.6L CPL C5 GROUP D DRAWING #: 0J1450 APPLICABLE TO: ITEM PART# QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 26 27 28 29 30 31 0J0675 0J0676 0F4462 0A6765 0F4710 0F7200 080762 0F2809 0F2981A 0F2962 0C2454 022097 0F2830 0F2773C 0D3159 088775 0F4505A 0F5447 022473 0F6214B 0L1789 049813 049721 088510 0C9748 1 1 2 2 6 6 8 1 2 2 4 12 2 2 1 6 2 1 20 2 8 8 12 6 1 0C8566 0D3700 2 2 32 REVISION: K-1591-D DATE: 1/28/15 DESCRIPTION PIPE EXH MANIFOLD 4.
EXPLODED VIEW: EV ENGCOMPRT LH 4.6L G3 GROUP D DRAWING #: 0J4322 APPLICABLE TO: ITEM 1 (1)2 3 4 (1)5 6 (1)7 (1)8 (1)9 (1)10 (1)11 (1)12 13 (1) 14 15 (1)16 (1)17 (1)18 19 (1)20 21 22 23 24 (1)25 (1)26 27 28 29 30 31 32 33 (1)34 35 36 37 38 39 40 41 42 43 44 (2)45 46 47 48 49 50 51 (1)52 53 54 55 (1)56 57 PART# QTY.
EXPLODED VIEW: EV ENGCOMPRT RH 4.6L G3 GROUP D DRAWING #:0J4322A APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 (1)31 (1)32 33 34 35 36 37 38 39 PART# QTY.
EXPLODED VIEW: FUEL SYSTEM NG 4.
EXPLODED VIEW: FUEL SYSTEM LP VAPOR 4.6L 80KW GROUP E DRAWING #:0H3919 APPLICABLE TO: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART# 0G9239D 057822 0H3894 082121A 0H3921 0H4537 026915 0A8064 064346 031015 030131 039130 065908 022304 052645 0G3167 0F3691C 0H39430ST03 059057 022195 045773 0F3885 086133E 0F0960 086133D 0G7104 0E4392 0E4390 0H3766B 097962 022097 042568 049811 0D3700 063831 REVISION: K-2798-D DATE: 5/13/15 QTY.
REPLACEMENT SHEET METAL PARTS ORDERING GUIDE Parts listed in the manual Bill of Material on the EV drawings/Manuals are listed in the unfinished form with the default material – usually steel or plain six or seven digit number. 0XXXXXXST0R or 0XXXXXX Base number Suffix1 Raw After entering serial number or model number of the unit to search/order replacement sheet metal parts follow steps below to identify/verify correct part number: 1. 2. 3.
EXPLODED VIEW: EV ENCLOSURE C5 EMISSION GROUP F DRAWING #: 0J0204 APPLICABLE TO: ITEM PART# QTY.
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