Generac 004917-5 owner manual General Hazards

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IMPORTANT SAFETY INSTRUCTIONS

QUIETSOURCELiquid-cooled 30 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 – This manual contains important instructions that should be

!followed during installation and maintenance of the generator and batteries.

!

!

!WARNING: !

The engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

!

WARNING:

!

 

 

 

This product contains or emits chemicals

 

 

known to the state of California to cause

 

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The gen- erator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible cir- cumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If using a procedure, work method or operating technique that Generac does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique chosen does not render the genera- tor unsafe.

DANGER

Despite the safe design of this generator,

!operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or main- tain this equipment.

Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot

!during operation. Exercise care near running gen- erators.

! GENERAL HAZARDS !

For safety reasons, Generac recommends that this equipment be installed, serviced and repaired by a Generac Authorized Service Dealer or other compe- tent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations.

Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure 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 concentrations, can cause unconsciousness or even death. For that reason, ade- quate ventilation must be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people, animals, etc., will not be harmed. This exhaust system must be installed properly, in strict compliance with applicable codes and standards.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilat- ing air is critical to prevent buildup of explosive gases and to ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.

Keep the area around the generator clean and unclut- tered. Remove any materials that could become haz- ardous.

When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

2 Generac® Power Systems, Inc.

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Contents Installation Authorized Service Dealer Location ‹ Operation and Maintenance‹ HOW to Obtain Service IntroductionTable of Contents General Hazards Electrical Hazards Transfer Switch GeneratorAutomatic System Operation Generator AC Connection Systems‹ 1.7.2 High Coolant Temperature Switch ‹ 1.7.1 LOW OIL Pressure Switch‹ 1.7.3 LOW Coolant Level Switch Generator Fuel SystemUnpacking Lifting the GeneratorSpecifications Reconfiguring the Fuel System‹ 1.10.1 Generator Specifications ‹ 1.10.2 Engine SpecificationsTorque Specifications Before InstallationEngine OIL Recommendations Coolant RecommendationsGenerator Location Generator Mounting SupportBasic Standby Electric System ‹ 2.1.1 Nfpa StandardsEmergency Circuit Isolation Method Total Circuit Isolation MethodGrounding the Generator Generator AC Neutral ConnectionsTransfer Switch Signal Connections Battery Installation‹ 2.9.1 PRE-PACKAGED ATS ‹ 2.9.2 GTS-TYPE ATSPreparation Before START-UP Using AN Engineered GTS Transfer Switch ‹ 3.2.1 AUTO/OFF/MANUAL SwitchControl Console Components ‹ 2.11.7 Electrical SystemManual Transfer START-UP Engine Governor Adjustments ‹ 3.2.2 Fault Indicator LED‹ 3.2.5 SET Exercise Time Switch ‹ 3.2.4 4 AMP Inline FuseAutomatic Operation Retransfer and ShutdownWeekly Exercise Cycle Checking Fluid Levels Overload Protection for Engine DC Electrical SystemCooling System ‹ 4.5.2 Check Battery ‹ 4.4.3 Engine Coolant‹ 4.5.1 Check Engine OIL Level ‹ 4.5.3 Exercise SystemMiscellaneous Maintenance ‹ 4.5.11 Changing the Engine AIR Cleaner‹ 4.6.1 Cleaning the Generator ‹ 4.5.13 Coolant Change‹ 4.6.3 Battery Maintenance ‹ 4.6.2 Battery‹ 4.6.4 Battery Replacement Scheduled Maintenance Service Maintenance Interval InformationLevel Maintenance Level Troubleshooting Points Problem Cause CorrectionCustomer Connection PCB J2 BCW LOS WLS HCT Starter Carrier Bolt Boot Battery Cable Battery Post Cover BaclkBattery Post Cover RED + Hold Down BatteryDetail Assy Wire 14AWG 7.5 #0 GRN/YEL Duct Intake MID ALDuct Discharge RH AL Duct Discharge LH ALGenerac Power Systems, Inc Assy 2A 12V UL Battery Control BOX HSBDecal AVR Cover Cover Front Panel HSBLiquid-cooled 30 No F6836-A Wire SET 3.0L Ford not Not SHOWN-USED to Hold OIL Drain AssemblyCoil Ignition 3.0L Ford Bracket DC ALT 3.0L FordFrame Tank Coolant Recovery Radiator R-IN,L-OUTVenturi 3.0L Ford HSB Side Support Radiator HSBTo B Weldment Mounting Base Flange Fuel InletAssy Regulator 3.0L NG or LPV Washer Flat 5/16 ZincLocktight Rotor 390 15KW 1P Direct HSB 2.5L Ford Rotor 390 20KW 1P Direct HSB 2.5L FordRotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 39030AD1 HSB TecumExhaust Flange 2 Pipe Pipe Muffler OUTWasher Lock 3/8 SS Gasket Exhaust RingPlate AIR Cleaner Adapter Element AIR CleanerCover AIR Cleaner Adapter Carburetor W/PVC ConnInstallation Diagram Quietsource Liquid-cooled 30 kW Generators This Warranty Shall not Apply to the Following