Generac 25/30kW manual

This manual should remain with the unit. 1.6L 25/30kW Models EP A Cer tified Owner's Manual Stationar y Emergency Generator Cover191 Re v . A 04/10 Part No. 0H7230 n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLA TION! DEADL Y EXHA UST FUMES! OUTDOOR INST ALLA[...]

SECTION P AGE INTRODUCTION ........................................................... 1-1 Read this Manual Thoroughly ....................................................... 1-1 Operation and Maintenance .......................................................... 1-1 How to Obtain Ser vice ...........................................................[...]

INTRODUCTION Thank you for purchasing this model of the stationar y emergency generator product line. Ever y effor t was expended to make sure that the infor mation and instr uctions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reser ves the right to change, alter or other wise improve[...]

SAFETY RULES Study these SAFETY RULES carefully before installing, operating or ser vicing this equipment. Become familiar with this Owner ’s Manual and with the unit. The generator can operate safely , effi- ciently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and f[...]

If personnel must stand on metal or concrete while installing, • operating, ser vicing, adjusting or repairing this equipment, place insulative mats over a dr y 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 par ts o[...]

IDENTIFICA TION RECORD DA T A L ABEL Ever y generator set has a DA T A L ABEL that contains impor tant information per tinent to the generator . The data label, which can be found attached to the generator ’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power factor[...]

EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur rent Stationar y Emergency Generator . 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. The u[...]

ENGINE PROTECTIVE DEVICES The Stationar y 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. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically s[...]

FUEL SYSTEM FUEL REQUIREMENTS The Stationar y Emergency Generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (LPV) fuel system Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask[...]

SPECIFICA TIONS ST ANDB Y EMERGENC Y GENERA TOR T ype...................................................................... Synchronous Rotor Insulation ............................................................. Class H Stator Insulation ............................................................ Class H Alternator Output Leads 3-phase ........[...]

WEA THER AND MAINTENANCE KITS T o keep the generator r unning at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32° F . • Extreme Cold Weather Kit ~ Recommended Block Heater Kit for protection in tempera- tures below 32° F . • Scheduled Maintenance Kit ~ Kit includes the recom[...]

AL TERNA TOR AC LEAD 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 th[...]

Figure 7.4 — Stator P ower Winding Connections - 3-phase, 120/208V (6 Lead) E3 E2 00 (NEUTRAL) INTERNAL CONNECTIONS E1 L-L L-N S1 S1 S4 S4 S6 S6 S3 S3 S5 S5 S2 S2 Figure 7.5 — Stator P ower Winding Connections - 3-phase, 120/208V (12 Lead) E3 E2 E1 L-L L-N S7 S1 S10 S4 S12 S6 S9 S3 S5 S11 S2 S8 Figure 7.6 — Stator P ower Winding Connections -[...]

CONTROL P ANEL INTERF ACE USING THE AUTO/OFF/MANUAL SWITCH  With the switch set to AUTO , the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. T o prevent possible injury that might be caused by such sudden star[...]

8-2 CntrlNexus001 Rev . E 12/11 Control P anel ACTIVA TION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- guage. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Display Reads: Press ENTER to begin the activation pro- cess. If ESCAPE is pressed [...]

INST ALLA TION ASSIST ANT Interconnect System Self T est 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. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC termi[...]

SEQUENCE OF AUTOMA TIC OPERA TION Initial Conditions: Generator in Auto ready to r un, load being sup- plied by the Utility Source through the transfer switch. 1. When the utility voltage fails (falls below 60% of nominal), a 10-30 second (programmable) “line interr upt” delay timer is star ted. The factor y set time delay is 10 seconds. If at [...]

CHECK ENGINE MESSAGE The control system has detected an emissions related fault. This fault cannot be cleared using the control panel inter face. The unit will continue to operate in automatic mode. Contact your local ser vicing dealer . UNDER-FREQUENC Y SHUTDOWN AL ARM Af ter star ting, if the generator stays under frequency for more than 30 secon[...]

OVERVOL T AGE AL ARM 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. INTERNAL F AILURE SHUTDOWN ALARM Any internal failure that can be detected such as cor r upted firmware will cause this shutdown alar m. This alarm cannot [...]

8-7 Control P anel ACTIV A TION RUN LOG ALARM LOG HISTOR Y STA TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA TOR FREQUENCY ENGINE HOURS ENGINE RPM BA TTERY VO LTA G E DEBUG INPUTS OUTPUTS DISPLA YS EDIT LANGU AGE TIME/DA TE EXERCISE TIME/SPEED ESC Press the “ESCAPE” key to jump back up through the menu levels. + / - Use the “+/-” key to navi[...]

ST A TIONARY EMERGENCY GENERA TOR CONTROL AND OPERA TION Refer to the appropriate control panel operator’s manual for this unit. OPERA TING UNIT WITH MANUAL TRANSFER SWITCH If the Stationar y Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only , the fol- lowing procedure applies. A manually ope[...]

GENERAL MAINTENANCE  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 . • The negative battery cable has been removed. • CHECK ENGINE OIL[...]

ENGINE COOLANT Check coolant level in coolant recover y bottle. See the Specifications and Ser vice Schedule sections. Add recommended coolant mixture as necessar y . • P eriodically remove radiator pressure cap (only when engine • has cooled down) to make sure the coolant recover y system is functioning properly . Coolant should be at bottom o[...]

Figure 10.3 – Engine Air Filter AIR FIL TER SP ARK PLUGS Reset the spark plug gap or replace the spark plugs as neces- sar y . 1. Clean the area around the base of the spark plugs to keep dir t and debris out of the engine. Clean by scraping or washing using a wire br ush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove th[...]

SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Y early - Y Inspect Change Clean Fuel Fuel Lines & Connections M X Lubrication Oil Level M X* Oil Y X** Oil Filter Y X** Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y X Enclosure Louvers W X X Engine Air Cleaner Y X X***[...]

T roubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. R eplace fuse.* 2. Loose or corroded or defective 2. Tighten, clean or replace batter y cables. batter y cables as necessar y .* 3. Defective star ter contactor . 3. R eplace contactor .* 4. Defective star ter motor . 4. R e[...]

13-1 EmsnWrnty001 Rev . D 09/11 United States Environmental Protection Agency W arranty Statement (Stationary Emergency Spark -Ignited Generators) W arranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty o[...]

13-2 EmsnWrnty001 Rev . D 09/11 United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark -Ignited Generators) Purchaser's/Owner's Recordkeeping Responsibilities The United States Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac) are pleased to explain your record- kee[...]

Notes[...]

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1 0G4827 1 ASSY RTR 104 KD1 HI EFF ( 18KW) 0G2927 1 RTR- 102-20.0AD1 CP L (2006) (20KW) 0G2827 1 ASS Y RTR 25KW 2P ( 2006) (25KW) 0G3451 1 ASS Y RTR 30KW 2P 10"(2006) 2 0G0 820A 1 HOUS ING BLOWER LG PILOT 3 0G4452 1 BLOW ER HOUSING S CREEN 4 02074 6 4 S CREW PPHM M5- 0.8 X 8 ZINC 5 04922 6 4 W ASHER LOCK M5 6 05171 3 4 W ASHER FLAT M5 7 02212 [...]

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EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-1182-J Page 4 of 8 DATE: 12/16/11 ITEM PART# QTY. DESCR I PTION 1 0H6795 1 CONBOX BACK/SIDES C1 CPL 2 0H6796 1 CONBOX TOP C1 CPL (4)3 0H67330ST0R 1 BRACKET GIMBAL CONTROL PNL RAW 4 0H7115 2 KNOB M6-1.0 CONTROL PANEL 5 022097 2 W ASH ER LOCK M6-1/4 6 022473 4 [...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-1182-J Page 5 of 8 DATE: 12/16/11 ITEM PART# QTY. DESCR I PTION M 022129 6 WASHER LOCK M 8-5/16 N 022145 4 WASHER FLAT 5/16-M 8 ZINC P 045771 2 NUT HEX M8-1 .25 G8 CLEAR ZINC R 058306 2 SCRE W SHC M8- 1.25 X 25 C12.9 S 0F8451 2 LUG SLDLSS 300 MCM- 6 AL/CU T 0[...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-1182-J Page 6 of 8 DATE: 12/16/11 ITEM PART# QTY. DESCR I PTION UL CIRCUIT BRE AKER (CC 2P) A 0H4745 REF CB 0100A 2P 240V E CC LL 0H4746 R EF C B 0125A 2P 240V E CC LL 0H4747 R EF C B 0150A 2P 240V E CC LL B 0H6847 1 COVER CB E CC 2P C1 CONBOX C 051716 2 NUT [...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-1182-J Page 7 of 8 DATE: 12/16/11 ITEM PART# QTY. DESCR I PTION UL CIRCUIT BRE AKER (BQ 2P) A 0D5543 REF CB 0090A 2P 240V S BQ2 LL 0D5544 R EF C B 0100A 2P 240V S BQ2 LL 0A 2077 REF C B 0125A 2P 240V S BQ2 LL B 0H6842 1 COVER CB S BQ2 C1 CONBOX C 0E7890 1 BRK[...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-1182-J Page 8 of 8 DATE: 12/16/11 THIS PAGE LEFT INTENTIONALLY BLANK[...]

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1 0G3418 1 RADIATOR SUP PORT LH SIDE 1.6L 2 0G3421 1 VENTURI 1. 6L 3 0G3419 1 RADIATOR SUP PORT RH SIDE 1.6L 4 0E9837B 1 RA DIATOR 1.6L CHY 5 0G3553 1 FAN COOL 450MM DIA 7 BLADE 6 0 E3257 2 S CREW HWHTF M6 -1.0 X 16 7 0G4080 1 HOSE LOWER RADIATOR 1.6L 8 099502 6 CLAMP HOSE #24 B1.06-2.00 9 0G4070 1 HOSE REAR CO OLANT 1.6L 10 0G4072 1 TUBE ENGINE CO[...]

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EXPLODED VIEW: MO UNTING BASE 1.6L DRAWING #: 0G3531 GROUP C APPLICABLE TO: REVISION: H-5975-B Page 2 of 2 DATE: 2/5/10 ITEM PART# QTY. DESCR I PTION 1 0G3343 1 MOUNTING BASE 1 .6L 2007 C1 2 027 482 1 WASHER SHAKEPROOF EXT 5/16 STL 3 070 936 2 DAMPENER VIBRATION 4 070936C 2 VIB. ISO. 70-7 5 DURO 5 039 253 12 SCREW HHC M8-1.25 X 20 G8.8 6 022 145 16[...]

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1 0F3408C 1 BATTE RY TRAY, C1 & C2 2 0F3411 1 STRAP BATTERY RETAINMENT 3 02550 7 1 WASHER SHAKEPR OO F EXT 7/16 STL 4 05998 0 1 SCREW HHC M10-1.5 X 25 G10.9 5 04652 6 1 WASHER LOCK M10 6 07748 3 REF BATTERY 12VDC 75-AH 26 7 050331A R EF BATTERY POST COVE R RED + 8 05033 1 REF BATTERY POST COVE R BLK - 9 038805J 1 CA B LE B AT TERY BLACK #1 X 30[...]

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EXPLODED VIEW: E NGINE COMMON PARTS 1.6L DRAWING #: 0H7219 GROUP D APPLICABLE TO: REVISION: H-8414-C Page 2 of 2 DATE: 3/1/11 ITEM PART# QTY. DESCR I PTION 1 0H1734 R EF ENGINE GENERAC 1.6L G11 CERT 2 0G0834A 1 ENGINE PLATE 1 .6L 6MM (TO BE USED W ITH PLATE SPACER P/N 0G2070A.) 3 0G0820A REF HOUSING BLOWER LG PILOT 4 0G7461 1 STARTER MOTOR 12V 5 0G[...]

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EXPLODED VIEW: FUE LSYS NG/LPV 1.6L CPL DRAWING #: 0H6671 GROUP E APPLICABLE TO: REVISION: H-9610-B Page 2 of 2 DATE: 9/9/11 ITEM PART# QTY. DESCR I PTION 1 037 561 1 NUT W ING 1/4-20 NYL K 2 0A 5547 1 COVER AIR CLEANER 3 062 522 1 STUD TH 1/4-20 X 3 G2 ZNC FULL 4 022 127 1 NUT HEX 1/4-20 STEEL 5 059402 1 FILTE R ELEMENT 6 091 526 4 SCREW PPHM M5-0[...]

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EXPLODED VIEW: E V ENCLOSURE C1 CPL DRAWING #: 0G3534 GROUP F ITEM PART# QT Y. DESCRIPTION REVISION: -A- Page 2 of 2 DATE: 11/14/11 (2) 1 0G33370AL0R 1 ROOF 1.6L C1 (2) 2 0J14640AL0R 1 REAR INTAKE WRAP C1 (1) 3 077992 10 NUT HEX LOCK M6-1.0 SS NY I NS (2) 4 0J14630AL0R 2 DOOR LEFT/RIGHT SIDE C1 6 0F4487A 1 ASSY ACCESS COVER 7 022127 1 NUT HEX 1/4-2[...]

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1 0F7 366 1 MUFFLER C1 2 0F7 647 1 MUFFLER SADDLE 3 0F8 095 1 PIPE EX HAUST OUTLET 4 0G3576 1 EXHAUS T PIPE LOWER 1.6L 5 0E3257 4 SCREW HW HTF M6-1.0 X 1 6 6 0F7 644 2 MUFFLER STRAP 7 0C611 9 1 BOLT U 5 /16- 18 X 2-1/4 8 036434 3 BO LT U 5/16-18 X 2. 09 9 036449 3 S ADDLE 2 INCH 10 022129 6 W ASHER LOCK M 8 - 5 /16 11 022259 6 NUT HEX 5/16-18 STE E[...]

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BackPg001 Re v . A 04/07[...]

This manual should remain with the unit. 1.6L 25/30kW Models EP A Cer tified Owner's Manual Stationar y Emergency Generator Cover191 Re v . A 04/10 P ar t No . 0H7230 n NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICA TIONS. ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLATION! DEADL Y EXHAUST FUMES! OUTDOOR INST ALL[...]

SECTION P AGE INTRODUCTION ........................................................... 1-1 Read this Manual Thoroughly ....................................................... 1-1 Operation and Maintenance .......................................................... 1-1 How to Obtain Ser vice ...........................................................[...]

INTRODUCTION Thank you for purchasing this model of the stationar y emergency generator product line. Ever y effor t was expended to make sure that the infor mation and instr uctions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reser ves the right to change, alter or other wise improve[...]

SAFETY RULES Study these SAFETY RULES carefully before installing, operating or ser vicing this equipment. Become familiar with this Owner ’s Manual and with the unit. The generator can operate safely , effi- ciently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and f[...]

If personnel must stand on metal or concrete while installing, • operating, ser vicing, adjusting or repairing this equipment, place insulative mats over a dr y 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 par ts o[...]

IDENTIFICA TION RECORD DA T A L ABEL Ever y generator set has a DA T A L ABEL that contains impor tant information per tinent to the generator . The data label, which can be found attached to the generator ’s lower connection box, lists the unit’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power factor[...]

EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur rent Stationar y Emergency Generator . 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. The u[...]

ENGINE PROTECTIVE DEVICES The Stationar y 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. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically s[...]

FUEL SYSTEM FUEL REQUIREMENTS The Stationar y Emergency Generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (LPV) fuel system Recommended fuels should have a Btu content of at least 1,000 Btu's per cubic foot for natural gas; or at least 2,520 Btu's per cubic foot for LP gas. Ask[...]

SPECIFICA TIONS ST ANDB Y EMERGENC Y GENERA TOR T ype...................................................................... Synchronous Rotor Insulation ............................................................. Class H Stator Insulation ............................................................ Class H Alternator Output Leads 3-phase ........[...]

WEA THER AND MAINTENANCE KITS T o keep the generator r unning at its peak, the following kits are offered: • Cold Weather Kit ~ Recommended for climates with temperatures below 32° F . • Extreme Cold Weather Kit ~ Recommended Block Heater Kit for protection in tempera- tures below 32° F . • Scheduled Maintenance Kit ~ Kit includes the recom[...]

AL TERNA TOR AC LEAD 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 th[...]

Figure 7.4 — Stator P ower Winding Connections - 3-phase, 120/208V (6 Lead) E3 E2 00 (NEUTRAL) INTERNAL CONNECTIONS E1 L-L L-N S1 S1 S4 S4 S6 S6 S3 S3 S5 S5 S2 S2 Figure 7.5 — Stator P ower Winding Connections - 3-phase, 120/208V (12 Lead) E3 E2 E1 L-L L-N S7 S1 S10 S4 S12 S6 S9 S3 S5 S11 S2 S8 Figure 7.6 — Stator P ower Winding Connections -[...]

CONTROL P ANEL INTERF ACE USING THE AUTO/OFF/MANUAL SWITCH  With the switch set to AUTO , the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage drops below a preset level or during the normal exercise cycle. T o prevent possible injury that might be caused by such sudden star[...]

8-2 CntrlNexus001 Rev . E 12/11 Control P anel ACTIVA TION CHART CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired lan- guage. Press ENTER to select. If the wrong language is chosen, it can be changed later using the “edit” menu. Display Reads: Press ENTER to begin the activation pro- cess. If ESCAPE is pressed [...]

INST ALLA TION ASSIST ANT Interconnect System Self T est 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. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC termi[...]

SEQUENCE OF AUTOMA TIC OPERA TION Initial Conditions: Generator in Auto ready to r un, load being sup- plied by the Utility Source through the transfer switch. 1. When the utility voltage fails (falls below 60% of nominal), a 10-30 second (programmable) “line interr upt” delay timer is star ted. The factor y set time delay is 10 seconds. If at [...]

CHECK ENGINE MESSAGE The control system has detected an emissions related fault. This fault cannot be cleared using the control panel inter face. The unit will continue to operate in automatic mode. Contact your local ser vicing dealer . UNDER-FREQUENC Y SHUTDOWN AL ARM Af ter star ting, if the generator stays under frequency for more than 30 secon[...]

OVERVOL T AGE AL ARM 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. INTERNAL F AILURE SHUTDOWN ALARM Any internal failure that can be detected such as cor r upted firmware will cause this shutdown alar m. This alarm cannot [...]

8-7 Control P anel ACTIV A TION RUN LOG ALARM LOG HISTOR Y STA TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA TOR FREQUENCY ENGINE HOURS ENGINE RPM BA TTERY VO LTA G E DEBUG INPUTS OUTPUTS DISPLA YS EDIT LANGU AGE TIME/DA TE EXERCISE TIME/SPEED ESC Press the “ESCAPE” key to jump back up through the menu levels. + / - Use the “+/-” key to navi[...]

ST A TIONARY EMERGENCY GENERA TOR CONTROL AND OPERA TION Refer to the appropriate control panel operator’s manual for this unit. OPERA TING UNIT WITH MANUAL TRANSFER SWITCH If the Stationar y Emergency Generator was installed in conjunction with a transfer switch capable of manual operation only , the fol- lowing procedure applies. A manually ope[...]

GENERAL MAINTENANCE  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 . • The negative battery cable has been removed. • CHECK ENGINE OIL[...]

ENGINE COOLANT Check coolant level in coolant recover y bottle. See the Specifications and Ser vice Schedule sections. Add recommended coolant mixture as necessar y . • P eriodically remove radiator pressure cap (only when engine • has cooled down) to make sure the coolant recover y system is functioning properly . Coolant should be at bottom o[...]

Figure 10.3 – Engine Air Filter AIR FIL TER SP ARK PLUGS Reset the spark plug gap or replace the spark plugs as neces- sar y . 1. Clean the area around the base of the spark plugs to keep dir t and debris out of the engine. Clean by scraping or washing using a wire br ush and commercial solvent. Do not blast the spark plugs to clean. 2. Remove th[...]

SERVICE SCHEDULE System / Component Frequency Procedure Weekly - W Monthly - M Y early - Y Inspect Change Clean Fuel Fuel Lines & Connections M X Lubrication Oil Level M X* Oil Y X** Oil Filter Y X** Cooling Engine Coolant Lines & Connections M X Engine Coolant Level M X Engine Coolant Y X Enclosure Louvers W X X Engine Air Cleaner Y X X***[...]

T roubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. Control panel 7.5 amp fuse blown. 1. R eplace fuse.* 2. Loose or corroded or defective 2. Tighten, clean or replace batter y cables. batter y cables as necessar y .* 3. Defective star ter contactor . 3. R eplace contactor .* 4. Defective star ter motor . 4. R e[...]

13-1 EmsnWrnty001 Rev . D 09/11 United States Environmental Protection Agency W arranty Statement (Stationary Emergency Spark -Ignited Generators) W arranty Rights, Obligations and Coverage The United States Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty o[...]

13-2 EmsnWrnty001 Rev . D 09/11 United States Environmental Protection Agency Compliance Requirements (Stationary Emergency Spark -Ignited Generators) Purchaser's/Owner's Recordkeeping Responsibilities The United States Environmental Protection Agency (EP A) and Generac Power Systems, Inc. (Generac) are pleased to explain your record- kee[...]

Notes[...]

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1 0G 4 827 1 A SSY RT R 10 4 K D1 H I EF F ( 1 8KW ) 0G 2 927 1 R T R- 1 02 - 20. 0A D 1 C PL ( 20 06 ) (2 0K W ) 0G 2 827 1 A SS Y RT R 25 K W 2 P ( 2006 ) ( 25 K W) 0G 3 451 1 A SS Y RT R 30 K W 2 P 10" ( 20 06 ) 2 0G 0 820 A 1 H O U SI N G BL OWE R L G PIL O T 3 0G 4 452 1 BLO WER HOUSI N G S CR E E N 4 02074 6 4 SC REW PPH M M 5-0 . 8 X 8 [...]

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EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-6101-L Page 4 of 8 DATE: 8/12/13 ITEM PART# QTY. DESCR I PTION 1 0H6795 1 CONBOX BACK/SIDES C1 CPL 2 0H6796 1 CONBOX TOP C1 CPL (4)3 0H67330ST0R 1 BRACKET GIMBAL CONTROL PNL RAW 4 0H7115 2 KNOB M6-1.0 CONTROL PANEL 5 022 097 2 WASHER LOCK M6-1 /4 6 022 473 4 [...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-6101-L Page 5 of 8 DATE: 8/12/13 ITEM PART# QTY. DESCR I PTION M 022129 6 WASHER LOCK M 8-5/16 N 022145 4 WASHER FLAT 5/16-M 8 ZINC P 045771 2 NUT HEX M8-1 .25 G8 CLEAR ZINC R 058306 2 SCRE W SHC M8- 1.25 X 25 C12.9 S 0F8451 2 LUG SLDLSS 300 MCM- 6 AL/CU T 0G[...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-6101-L Page 6 of 8 DATE: 8/12/13 ITEM PART# QTY. DESCR I PTION UL CIRCUIT BRE AKER (CC 2P) A 0H4745 REF CB 0100A 2P 240V E CC LL 0H4746 R EF C B 0125A 2P 240V E CC LL 0H4747 R EF C B 0150A 2P 240V E CC LL B 0H6847 1 COVER CB E CC 2P C1 CONBOX C 051716 2 NUT H[...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-6101-L Page 7 of 8 DATE: 8/12/13 ITEM PART# QTY. DESCR I PTION UL CIRCUIT BRE AKER (BQ 2P) A 0D5543 REF CB 0090A 2P 240V S BQ2 LL 0D5544 R EF C B 0100A 2P 240V S BQ2 LL 0A 2077 REF C B 0125A 2P 240V S BQ2 LL B 0H6842 1 COVER CB S BQ2 C1 CONBOX C 0E7890 1 BRKT[...]

EXPLODED VIEW: CO NNECTION BOX C1 CPL DRAWING #: 0H7234 GROUP A APPLICABLE TO: REVISION: J-6101-L Page 8 of 8 DATE: 8/12/13 ITEM PART# QTY. DESCR I PTION G 0J 78230 AS0R 1 SHIELD CB HANDLE CONBOX H 029289 1 TAPE ELEC 1/2 FOAM J 036261 4 RIVET POP .125 X .2 K 0K4772 1 DECAL SER VICE DISCONNECT[...]

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1 0G3418 1 RADIATOR SUP PORT LH SIDE 1.6L 2 0G3421 1 VENTURI 1. 6L 3 0G3419 1 RADIATOR SUP PORT RH SIDE 1.6L 4 0E9837B 1 RA DIATOR 1.6L CHY 5 0G3553 1 FAN COOL 450MM DIA 7 BLADE 6 0 E3257 2 S CREW HWHTF M6 -1.0 X 16 7 0G4080 1 HOSE LOWER RADIATOR 1.6L 8 099502 6 CLAMP HOSE #24 B1.06-2.00 9 0G4070 1 HOSE REAR CO OLANT 1.6L 10 0G4072 1 TUBE ENGINE CO[...]

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EXPLODED VIEW: MO UNTING BASE 1.6L DRAWING #: 0G3531 GROUP C APPLICABLE TO: REVISION: H-5975-B Page 2 of 2 DATE: 2/5/10 ITEM PART# QTY. DESCR I PTION 1 0G3343 1 MOUNTING BASE 1 .6L 2007 C1 2 027 482 1 WASHER SHAKEPROOF EXT 5/16 STL 3 070 936 2 DAMPENER VIBRATION 4 070936C 2 VIB. ISO. 70-7 5 DURO 5 039 253 12 SCREW HHC M8-1.25 X 20 G8.8 6 022 145 16[...]

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1 0F3408C 1 BATTE RY TRAY, C1 & C2 2 0F3411 1 STRAP BATTERY RETAINMENT 3 02550 7 1 WASHER SHAKEPR OO F EXT 7/16 STL 4 05998 0 1 SCREW HHC M10-1.5 X 25 G10.9 5 04652 6 1 WASHER LOCK M10 6 07748 3 REF BATTERY 12VDC 75-AH 26 7 050331A R EF BATTERY POST COVE R RED + 8 05033 1 REF BATTERY POST COVE R BLK - 9 038805J 1 CA B LE B AT TERY BLACK #1 X 30[...]

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EXPLODED VIEW: E NGINE COMMON PARTS 1.6L DRAWING #: 0H7219 GROUP D APPLICABLE TO: REVISION: H-8414-C Page 2 of 2 DATE: 3/1/11 ITEM PART# QTY. DESCR I PTION 1 0H1734 R EF ENGINE GENERAC 1.6L G11 CERT 2 0G0834A 1 ENGINE PLATE 1 .6L 6MM (TO BE USED W ITH PLATE SPACER P/N 0G2070A.) 3 0G0820A REF HOUSING BLOWER LG PILOT 4 0G7461 1 STARTER MOTOR 12V 5 0G[...]

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EXPLODED VIEW: FUE LSYS NG/LPV 1.6L CPL DRAWING #: 0H6671 GROUP E APPLICABLE TO: REVISION: -A- Page 2 of 2 DATE: 1/21/10 ITEM PART# QTY. DESCR I PTION 1 037 561 1 NUT W ING 1/4-20 NYL K 2 0A 5547 1 COVER AIR CLEANER 3 062 522 1 STUD TH 1/4-20 X 3 G2 ZNC FULL 4 022 127 1 NUT HEX 1/4-20 STEEL 5 059402 1 FILTE R ELEMENT 6 091 526 4 SCREW PPHM M5-0.8 X[...]

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EXPLODED VIEW: E V ENCLOSURE C1 CPL DRAWING #: 0G3534 GROUP F ITEM PART# QT Y. DESCRIPTION REVISION: J-1720-K Page 2 of 2 DATE: 3/23/12 (2) 1 0G33370AL0R 1 ROOF 1.6L C1 (2) 2 0J14640AL0R 1 REAR INTAKE WRAP C1 (1) 3 077992 10 NUT HEX LOCK M6-1.0 SS NY I NS (2) 4 0J14630AL0R 2 DOOR LEFT/RIGHT SIDE C1 6 0F4487A 1 ASSY ACCESS COVER 7 022127 1 NUT HEX 1[...]

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1 0F7 366 1 MUFFLER C1 2 0F7 647 1 MUFFLER SADDLE 3 0F8 095 1 PIPE EX HAUST OUTLET 4 0G3576 1 EXHAUS T PIPE LOWER 1.6L 5 0E3257 4 SCREW HW HTF M6-1.0 X 1 6 6 0F7 644 2 MUFFLER STRAP 7 0C611 9 1 BOLT U 5 /16- 18 X 2-1/4 8 036434 3 BO LT U 5/16-18 X 2. 09 9 036449 3 S ADDLE 2 INCH 10 022129 6 W ASHER LOCK M 8 - 5 /16 11 022259 6 NUT HEX 5/16-18 STE E[...]

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