Generac Power Systems 004920-0, Owner'S Manual

Page 1: ...WER SYSTEMS INC Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model No 004920 0 ...

Page 2: ... explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and thor oughly understand all instructions before using this equipment Generac also strongly recommends instructing other users to properly...

Page 3: ...System 11 2 5 Emergency Circuit Isolation Method 11 2 6 Total Circuit Isolation Method 11 2 7 Grounding the Generator 11 2 8 Generator AC Neutral Connections 12 2 9 Transfer Switch Start Signal Connections 12 2 10 Battery Installation 12 2 11 Preparation Before Start Up 13 Section 3 OPERATION 14 3 1 Control Console Components 14 3 2 Manual Transfer and Startup 15 3 3 Retransfer and Shutdown 15 3 4...

Page 4: ...that the gener ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient conce...

Page 5: ...nerator is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when NOR MAL UTILITY source voltage is removed or is below an ...

Page 6: ...ntly to the transfer switch door is a RATING DECAL Use the transfer switch only within the specific limits shown on the RATING DECAL and on other decals and labels that may be affixed to the switch This prevents damage to equipment possible injury to personnel and provides long and trouble free life for the equipment When requesting information or ordering parts for this equipment make sure to inc...

Page 7: ...roperly supported of approved insulative qualities protected by approved conduit and of the correct wire gauge size in accordance with applicable codes Tighten terminal lugs to the following torque values as noted inside the transfer switch door Be sure to maintain proper electrical 1 2 inch clear ance between live metal parts and grounded metal STANDBY SUPPLY CUSTOMER UTILITY SUPPLY NORMAL LOAD E...

Page 8: ...ed in Figure 1 4 1 11 GENERATOR FUEL SYSTEM The unit has been factory tested and adjusted using a natural gas liquid fuel system If LP vapor gas is preferred contact an authorized service dealer Refer to Section 1 17 Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu co...

Page 9: ...se about 3 5 for each 1000 feet above sea level and will decrease an additional 1 for each 10 F above 60 F Maximum output power of the generator is limited by maximum engine power Figure 1 9 Control Circuit Board 1 12 5 PCB OPERATION LED S LED 1 is RED This LED will be on when UTILITY sensing is NOT available to the circuit board This LED will function only when the AUTO OFF MANUAL switch is set i...

Page 10: ...placement 92 inches3 1 5 liters Cylinder Arrangement 4 in line Valve Arrangement Overhead Cam Firing Order 1 3 4 2 Number of Main Bearings 5 Compression Ratio 9 to 1 No of Teeth on Flywheel 104 Ignition Timing at 1800 rpm 35 degrees BTDC at 3600 rpm 43 degrees BTDC Spark Plug Gap 0 020 0 025 inch Recommended Spark Plugs Champion RN11YC4 Oil Pressure 30 50 psi Crankcase Oil Capacity 3 25 U S quarts...

Page 11: ... silicate anti freeze If desired add a high quality rust inhibitor to the rec ommended coolant mixture When adding coolant always add the recommended 50 50 mixture Do not use any chromate base rust inhibitor with ethylene glycol base anti freeze or chromiumhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically c...

Page 12: ...ON VENTING NFPA No 70 NATIONAL ELECTRICAL CODE NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following infor mation pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the America...

Page 13: ...s are grouped together and wired into a separate Emergency Distribution Panel Load circuits powered by that panel are with in the wattage amperage capacity of the generator set When this method is used it is difficult to overload the generator The transfer switch must meet the fol lowing requirements It must have an ampere rating equal to the total amperage rating of the emergency distribution pan...

Page 14: ...id 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 Do not dispose of the battery in a fire The bat tery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes The battery re...

Page 15: ...National Electrical Code requires that a transfer switch be installed The transfer switch prevents elec trical backfeed between two different electrical sys tems The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with appli cable codes standards and regulations 2 10 3 FUEL SYSTEM Make sure the fuel supply system to th...

Page 16: ...eter and ammeter 3 1 6 HOURMETER Indicates time the engine generator has operated in hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for the gen erator set 3 1 7 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic opera tion See Automatic Operation Set switch to MANUAL position to crank and start the g...

Page 17: ...n line circuit breaker The UTILITY power source now powers the loads 3 4 AUTOMATIC OPERATION To set the system for fully automatic operation pro ceed as follows Check that LOAD circuits are connected to the UTILITY power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 5 WEEKLY EXERCISE CYCLE The generator will start a...

Page 18: ...ing the transfer switch per form functional tests in the exact order given Before proceeding with functional tests read and be sure all instructions in this section are understood Also read the instructions and information on tags and decals affixed to the transfer switch Note any options and accessories that might be installed or provided with the switch and review their operation Do not attempt ...

Page 19: ...e slowly to allow the spring in the switch box to relax ON now appears in Window A and OFF appears in Window B 3 10 2 CLOSE TO EMERGENCY SOURCE SIDE Before proceeding verify the position of the switch by observing window B in Figure 3 5 on page 18 If window B reads ON the contacts are closed in the EMERGENCY Standby position No further action is required If it reads OFF proceed with Step 1 Step 1 ...

Page 20: ...quency Single phase generator supply Measure across ATS terminal lugs E1 to E2 E1 to NEUTRAL and E2 to NEUTRAL a Frequency 60 62 Hertz b Terminals E1 to E2 240 246 VAC c Terminals E1 to NEUTRAL 120 123 VAC d Terminals E2 to NEUTRAL 120 123 VAC Failure to do so may result in damage to cer tain rotary equipment 8 Set the generator s main circuit breaker CB1 to its OFF or OPEN position 9 Set the AUTO...

Page 21: ... means provided such as a utility main line circuit breaker The UTILITY power source now powers the loads 9 Set the generator s AUTO OFF MANUAL switch to its AUTO position The system is now set for fully automatic operation 4 1 MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES A EVERY THREE MONTHS 1 Check battery state of charge and condition 2 Inspect and test fuel system 3 Check transfer sw...

Page 22: ...r tops of separators DO NOT USE TAP WATER IN BATTERY 4 4 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Specifications Add recommended coolant mixture as necessary Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly Coolant should be at bottom of radiator filler neck If coolant level is low inspect gasket in radiator press...

Page 23: ...for engine oil and filter change frequen cies Drain the oil while the engine is still warm from run ning This means warm up the engine shut it down and drain immediately as follows 1 Remove OIL DRAIN HOSE from its retaining clip 2 Loosen and remove OIL DRAIN HOSE CAP Drain oil completely into suitable container 3 When all oil has drained install and tighten OIL DRAIN HOSE CAP and re install into i...

Page 24: ...nings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Bat...

Page 25: ...OFF MANUAL switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 6 4 BATTERY REPLACEMENT When replacing batteries use the sa...

Page 26: ...removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any po...

Page 27: ...rotection level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check...

Page 28: ...r components and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the...

Page 29: ...rk plugs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant...

Page 30: ...83 6 162 S15 4 0 CAP 0 0 14 BV FL 176 15 1 14 14 0 183 0 229 RED 14 4 13 0 14 4 14 6 13 14 S15 229 14 0 AM 0 67 HZ S16 178 14 S15 176 S15 15E 13 S15 S16 229 14 15 0 S44 178 178 65 S15 S15 64 13 239 15C 0 176 15E S44 14 56 85 4 14 S15 14 14 14 14 14 1 56 85 13 TS1 229 13 4 S15 S16 14 14 183 0 14 1 13 6 85 2 85 S15 13 0 178 85 10 23 T1 162 6 S16 162 BLACK 2 2 TS3 BLUE TR1 S16 RED BLACK T1 4 56 14 19...

Page 31: ... TO 00 NB BRUSH HOLDER 4 RED 1 22 E1 33 S16 E2 1 CB1 44 0 E1 TO 00 11 CT2 120V 11 44 58 0 0 57 AS 11 0 57 S44 DS 15 229 OPEN DOOR LEGEND CT1 CURRENT TRANSFORMER CT2 CURRENT TRANSFORMER DS DOOR SWITCH EC ENGINE CONNECTION F FUSE 15 AMPS F1 FUSE INLINE 7 5 AMP FL FAULT LIGHT CGU GOVERNOR CONTROLLER AM AMP METER AB ALARM BOARD AS ALTERNATOR STATOR BV BATTERY VOLT METER CAP CAPACITOR CB1 CIRCUIT BREAK...

Page 32: ...BLACK GREEN WHITE GRD BATTERY 12 V 1 12 56 GRD 16 13 0 BLACK SM CC RED ACTUATOR CONNECTOR ACTUATOR GOVERNOR DC VR DC A DIS FS 85 85 85 13 14 0 48 49 48 85 85 85 56 0 13 14 14 14 RED 14 14 0 0 0 0 0 16 0 6 5 4 3 8 11 12 10 9 1 2 3 5 FS2 14 0 0 0 WLS WATER LEVEL SENSOR SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH LOS LOW OIL PRESSURE SWITCH FS FUEL SOLENOID DCA DC ALTERNATOR EH ENGINE HEATER CC CON...

Page 33: ...H ISC IGNITION SYSTEM CONTACT GRD GROUND EH ENGINE HEATER DCA DC ALTERNATOR CC CONTROL CONTACTOR FS2 FUEL SOLENOID 2 12V BATTERY FED CIRCUIT TO 120V 15A UTILITY 0 BLACK GREEN WHITE EH 0 CC 16 RED SM TO CONTROL PANEL TERMINAL STRIP 14 56 85 DC A 14 56 14 CC FS 0 0 85 WTS LOS WLS GRD BLACK 0 LEGEND 13 49 49 13 CONTROL UNIT TO CONTROL PANEL GOVERNOR GOVERNOR ACTUATOR ACTUATOR CONNECTOR 49 49 14 14 13...

Page 34: ...05 E1 E1 A 7 1 3 6 N1A N2A E2 N2A N1A E1 N1A F4 F3 F2 F1 TB T1A T2A 194 23 23 194 23 194 N1 N2 T1 T2 N1A N1A N2A 00 00 NEUTRAL BLOCK 205 126 N2A N2A Y Z A B ATS Y ATS Z NB N2A 1 2 4 5 6 7 B2 T1 B1 A2 T2 A1 T1 T2 ATS X E1 N1 E2 N2 ATS UTILITY 1 OPTIONAL NEUTRAL LOAD 2 UTILITY 2 CUSTOMER CONTROL CONNECTIONS LOAD 1 23 194 UTILITY CONNECTION GENERATOR CONNECTION CUSTOMER LOAD CONNECTION ...

Page 35: ...ERATION 6 9 TR 1 7 TR E1 E1 N2A N2A N1A E2 205 126 TR 23 194 23 194 NOTE ALL CONTACTS SHOWN WITH TRANSFER SWITCH IN UTILITY POSITION B A F2 N2 N1 F1 N1A N2A T2 F4 T1 F3 T2A T1A 126 N1A ATS Y ATS Z A B A B TB A B A B 00 00 NB ATS X ATS X A2 NO NC B2 M2 COM A1 M1 COM NO NC B1 TD2 T1 E1 T2 NC COM NO COM E2 T2 N1 NC COM NO COM T1 TD1 N2 C AUX AUX ATS Section 6 Electrical Data Generac Liquid cooled 20 ...

Page 36: ...R LOCK M8 5 16 8 045771 4 NUT HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8 1 25 X 60 G8 8 ITEM PART NO QTY DESCRIPTION 11 021991 1 EARTH STRAP 13 0D9335 2 PANEL SUPPORT 14 0D9336 2 PANEL BRACKET 15 0C2454 16 SCREW TH FRM M6 1 X 16 N WA Z JS 16 047411 1 SCREW HHC M6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK M6 1 4 18 022473 1 WASHER FLAT 1 4 M6 ZINC 19 055414 1 LUG SLDLSS 2...

Page 37: ...3121 3 SCREW HHC 10 32 X 1 2 13 051716 3 NUT HEX M5 0 8 G8 YEL CHR ITEM PART NO QTY DESCRIPTION 14 022152 3 WASHER LOCK 10 15 0912970064 3 ASSMBLY BASE DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT 10 STL 17 0912970063 3 GRD WIRE ASS Y 99HSB 18 022264 6 WASHER LOCK 8 M4 19 067035 6 SCREW PPHM 8 32 X 5 16 20 022127 1 NUT HEX 1 4 20 STEEL 21 0C2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FL...

Page 38: ...LITY A ON N1 0A9949 T 0A9949 T 19 20 21 26 8 9 36 35 33 34 32 2 PLS TYP 27 27 47 48 A A 49 46 45 47 23 12 11 10 13 18 14 16 17 15 1 22 A 34 39 38 3 44 36 34 25 24 28 31 30 29 32 33 32 34 33 35 37 35 2 PLS TYP 2 PLS 42 35 43 TYP 45 46 48 6 TO RETAIN COVER 7 5 OF COVER MOUNT ON INSIDE 40 41 2 4 ENCLOSURE GROUND LUG ASSEMBLY DETAIL A A BOTTOM VIEW 0A9957X 0C7907H T FRONT VIEW 0C7907H S RIGHT SIDE VIE...

Page 39: ...0 NATL 26 072252 1 GROMMET 1 37 X 06 X 1 00 27 038057 2 GROMMET 7 8 X 1 16 X 3 4 28 0C8884 1 XFER SW W 200A600V2P 29 074908 3 SCREW HHTT M5 0 8 X 10 BP 30 022152 3 WASHER LOCK 10 31 051713 3 WASHER FLAT M5 32 0A9949 6 LUG SLDLSS 400 4X1 4 20 CU7AL 33 0C4896 6 SCREW FHM M8 1 25 X 20MM CR 34 067989 12 NUT LOCK FL M8 1 25 YEL CHR 35 026902 7 SCREW HHTT 8 32 X 1 4 CZ 36 0E3513 2 BUSBAR 200A UTIL CUST ...

Page 40: ...52 53 49 41 20 1 50 30 43 42 45 44 61 4 56 TO A A NOTES 1 DOOR SWITCH ITEM 72 WILL BE PUT TO THE RIGHT OF THE CB IN THE UPPER RIGHT SCREWDRIVER HOLE FOR THE 3RD POLE WHICH WILL BE LEFT OPEN FOR THIS SYSTEM 2 RELAY SOLENOID TO BE REMOTELY MOUNTED TO SIDE OF RIGHT SIDE PANEL SUPPORT AS SHOWN ON BOTTOM LEFT OF PAGE Section 7 Exploded Views and Parts Generac Liquid cooled 20 kW Generator Control Panel...

Page 41: ... 5 8 SS 34 0A8955 2 SCREW PHM M6 1 0 X 20MM 35 022097 3 WASHER LOCK M6 1 4 36 022473 2 WASHER FLAT 1 4 M6 ZINC ITEM PART NO QTY DESCRIPTION 37 0C2212 10 SCREW PHTT M4 0 7 X 16 ZYC 38 023762 2 WASHER SHAKEPROOF EXT 10 STL 39 0C2267 14 SCREW HHTT M5 0 8 X 12 BP 40 023897 15 WASHER FLAT 10 ZINC 41 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 42 042907 4 SCREW HHC M8 1 25 X 16 G8 8 43 022129 4 WASHER LOCK ...

Page 42: ... 14 11 19 17 18 20 26 21 20 25 22 24 57 33 11 14 9 24 72 10 11 10 14 1 24 35 34 36 44 45 14 71 12 46 11 10 49 47 70 11 10 6 69 56 55 67 59 52 58 64 63 65 62 60 7 Section 7 Exploded Views and Parts Generac Liquid cooled 20 kW Generator Engine Drawing No 0E1228 E 40 Generac Power Systems Inc ...

Page 43: ...1 BARBED EL 90 3 8 NPT X 5 8 41 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD ITEM PART NO QTY DESCRIPTION 42 061012 1 PLUG STD PIPE 1 8 SCKT HD 43 039253 4 SCREW HHC M8 1 25 X 20 G8 8 44 0A5110 1 PIPE WATER INLET 45 0A7006 1 O RING 1 1 16 X 1 5 16 X 1 8 46 025507 2 WASHER SHAKEPROOF EXT 7 16 STL 47 022500B 2 SPACER 41 X 75 X 25 ST ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1 8 50 0...

Page 44: ...R INLET MIDWAY UP ENGINE BLOCK 14 TUBE ON BLOCK TO THERMOSTAT 31 10 23 26 8 20 WATER INLET 8 19 8 8 6 ADAPTER 12 24 7 16 7 7 15 13 TO ENGINE BYPASS 33 34 11 12 Section 7 Exploded Views and Parts Generac Liquid cooled 20 kW Generator Radiator Drawing No 0E0769 G 42 Generac Power Systems Inc ...

Page 45: ...4 20 X 5 8 18 056892 4 SCREW CRIMPTITE 10 24 X 3 8 19 0A6284 1 HOSE LOWER RADIATR 20 0A6258 1 HOSE UPPER RADIATR 21 029032 1 HOSE 9 32 ID 36 LG 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 4 NUT HEX 1 4 20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE 38 87 28 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS 29 076749 1 TANK COOLANT RECOVERY 30 0E072...

Page 46: ... P VAPOR PORT OUT 2 41 40 3 11 14 9 C 12 14 16 17 8 43 D 7 2 40 21 39 38 28 30 34 24 25 6 6 41 26 37 35 22 13 11 NATURAL GAS OUT 1 PORT 41 3 5 27 15 D Section 7 Exploded Views and Parts Generac Liquid cooled 20 kW Generator Fuel System Drawing No 0E5470 A ...

Page 47: ... STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0D8492M 1 DECAL EMISSION 3GNXS1 472CH 10 15KW NATURAL GAS 0D8492N 1 DECAL EMISSION 3GNXS1 472LH 10 15KW LP VAPOR UNITS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0E0590 1 VENTURI 18MM 33 ...

Page 48: ... 36 13 3 12 5 9 15 14 17 To Blower Housing 32 23 24 35 1 21 28 7 22 33 10 29 16 30 18 2 6 19 20 31 21 4 To Engine Crankshaft 26 Section 7 Exploded Views and Parts Generac Liquid cooled 20 kW Generator Alternator Drawing No 0A9348 F ...

Page 49: ...OLDER BRUSH 11 075476 4 SCREW PPHM M4 0 7 X 16 12 0A5601 1 COVER REAR BEARING CARRIER 13 075554B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 097146 1 FAN RING GEAR ASSEM 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A5061 1 SPACER FLEX PLATE 19 0A4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12 1 75 X 40 G8 8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10 1 5 X 35 ...

Page 50: ...0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH 48 Generac Power Systems Inc ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 ...

Page 51: ...42600133 1 ASSY WIRE 16 RED 1 5 5 022131 1 WASHER FLAT 3 8 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC M10 1 25 X 20 G8 8 8 075763 3 BOOT BATTERY CABLE 9 0D8668 1 BRACKET BATTERY HOLD DOWN 1 5 13 050331A 1 BATTERY POST COVER RED 14 050331 1 BATTERY POSTCOVER BLACK 15 0C2454 2 SCREW TH FRM M6 1X16 N WA Z JS 16 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5 16 S...

Page 52: ...61 1 NIPPLE TOE 2NPT X 4 5 BLK IRON 5 059939 1 RAIN CAP 2 37 I D 6 075546E 1 EXHAUST FLEX PIPE PRO SOL 7 036434 1 BOLT U 5 16 18 X 2 09 8 022259 2 NUT HEX 5 16 18 STEEL 9 022129 6 WASHER LOCK M8 5 16 10 036449 1 SADDLE 2 INCH 11 076032 1 CHANNEL MUFFLER SUP 12 039253 4 SCREW HHC M8 1 25 X 20 G8 8 13 045771 4 NUT HEX M8 1 25 G8 YEL CHR 14 0C3683 1 GUARD MUFFLER 1 5L 15 0A7215 4 SCREW SW 1 4 20 X 5 ...

Page 53: ...Generac Power Systems Inc 51 Section 8 Installation Diagram Generac Liquid cooled 20 kW Generator Installation Diagram Drawing No 0E5498 ...

Page 54: ...erac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem...

Page 55: ...to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Wa...

Page 56: ...ated part s adjustments loose leaking clamps installation and start up 4 Use of Non Generac replacement part s will void the warranty in its entirety 5 Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 6 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime...

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Page 58: ...HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8 1 25 X 60 G8 8 11 021991 1 EARTH STRAP 13 0D9335 2 PANEL SUPPORT 14 0D9336 2 PANEL BRACKET 15 0C2454 16 SCREW TH FRM M6 1 X 16 N WA Z JS 16 047411 1 SCREW HHC M6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK M6 1 4 18 022473 1 WASHER FLAT 1 4 M6 ZINC 19 055414 1 LUG SLDLSS 2 8 X 17 64 CU 20 049813 5 NUT HEX M6 X 1 0 G8 YEL CHR 21 02...

Page 59: ...2 45 44 61 4 56 TO A A NOTES 1 DOOR SWITCH ITEM 72 WILL BE PUT TO THE RIGHT OF THE CB IN THE UPPER RIGHT SCREWDRIVER HOLE FOR THE 3RD POLE WHICH WILL BE LEFT OPEN FOR THIS SYSTEM 2 RELAY SOLENOID TO BE REMOTELY MOUNTED TO SIDE OF RIGHT SIDE PANEL SUPPORT AS SHOWN ON BOTTOM LEFT OF PAGE 0 0 0 79 13 0 14 14 14 15A 15A 15 85 229 56 4 68 69 85 150 194 LOAD 1 LOAD 2 23 UTILITY 1 UTILITY 2 P N 0E1454 18...

Page 60: ...0 PCB 33 080882 8 SCREW PPH TAPPING 6 X 5 8 SS 34 0A8955 2 SCREW PHM M6 1 0 X 20MM 35 022097 3 WASHER LOCK M6 1 4 36 022473 2 WASHER FLAT 1 4 M6 ZINC 37 0C2212 10 SCREW PHTT M4 0 7 X 16 ZYC 38 023762 2 WASHER SHAKEPROOF EXT 10 STL 39 0C2267 14 SCREW HHTT M5 0 8 X 12 BP 40 023897 15 WASHER FLAT 10 ZINC 41 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 42 042907 4 SCREW HHC M8 1 25 X 16 G8 8 43 022129 4 WA...

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Page 62: ...EW TH FRM M6 1 X 16 N WA Z JS 12 033121 3 SCREW HHC 10 32 X 1 2 13 051716 3 NUT HEX M5 0 8 G8 YEL CHR 14 022152 3 WASHER LOCK 10 15 0912970064 3 ASSEMBLY BASE DOOR GROUND WIRE 16 023762 3 WASHER SHAKEPROOF EXT 10 STL 17 0912970063 3 GRD WIRE ASS Y 99HSB 18 022264 6 WASHER LOCK 8 M4 19 067035 6 SCREW PPHM 8 32 X 5 16 20 022127 1 NUT HEX 1 4 20 STEEL 21 0C2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WA...

Page 63: ...29 33 32 31 18 20 10 19 L P VAPOR PORT OUT 2 41 40 3 11 14 9 C 12 14 16 17 8 43 D 42 44 45 23 7 6 2 40 21 39 36 38 28 30 34 24 25 6 6 41 26 37 35 22 13 11 NATURAL GAS OUT 1 PORT 41 3 C 5 4 27 15 D ...

Page 64: ...OID GAS FUEL 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0D8492M 1 DECAL EMISSION 3GNXS1 472CH 10 15KW NATURAL GAS 0D8492N 1 DECAL EMISSION 3GNXS1 472LH 10 15KW LP VAPOR UNITS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0...

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Page 66: ...39 1 BARBED EL 90 3 8 NPT X 5 8 41 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 42 061012 1 PLUG STD PIPE 1 8 SCKT HD 43 039253 5 SCREW HHC M8 1 25 X 20 G8 8 44 0A5110 1 PIPE WATER INLET 45 0A7006 1 O RING 1 1 16 X 1 5 16 X 1 8 46 025507 2 WASHER SHAKEPROOF EXT 7 16 STL 47 022500B 2 SPACER 41 X 75 X 25 ST ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1 8 50 042574 1 ADAPTOR 1 8 NPTF T...

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Page 68: ...IER REAR 10 075591 1 ASSY HOLDER BRUSH 11 075476 4 SCREW PPHM M4 0 7 X 16 12 0A5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 097146 1 FAN RING GEAR ASSEM 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A5061 1 SPACER FLEX PLATE 19 0A4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12 1 75 X 40 G8 8 21 051769 6 WASHER LOCK M12 22 049541 4 SCR...

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Page 70: ...TUBING 5 8 ID X 18 LG 17 058443 6 SCREW CRIMPTITE 1 4 20 X 5 8 18 056892 4 SCREW CRIMPTITE 10 24 X 3 8 19 0A6284 1 HOSE LOWER RADIATR 20 0A6258 1 HOSE UPPER RADIATR 21 029032 1 HOSE 9 32 ID 36 LG 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 4 NUT HEX 1 4 20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE 38 87 28 0C2454 4 SCREW TH FRM M6 1 X 16 ...

Page 71: ...ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 6 7 9 10 10 5 4 INTAKE MANIFOLD REF 6 12 7 A 2 3 1 16 7 15 COATING WIRE HARNESS 14 ...

Page 72: ... 8 7 022097 5 WASHER LOCK M6 1 4 8 084543A 1 SCREW PHM M3 0 5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1...