Generac 004709-0, 005852-0

PART II –

INSTALLATION

INSTRUCTIONS

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!

Contents

Main Table of Contents Part Owners Manual Part II Installation Instructions INTRODUCTION Introduction n n n GENERAL HAZARDS ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS 1 1.1 GENERATOR IDENTIFICATION 2 3 13 12 7 n 1.5.2 FUEL CONSUMPTION 1.5.3 ENGINE OIL REQUIREMENTS 1.5.4 ENGINE 1.5.5 GENERATOR 2.1 GENERATOR CONTROL PANEL Figure 2.1 Generator Control Panel 2.1.1 FUEL PRIMER 2.1.2 START/STOP SWITCH 2.1.3 FUSE 2.5 STARTING THE GENERATOR 2.6 STOPPING THE GENERATOR 2.7 APPLYING LOADS TO GENERATOR 2.7.1 LETTING THE ENGINE STABILIZE 2.8 DO NOT OVERLOAD THE GENERATOR 2.9 PROTECTION SYSTEMS 2.9.1 LOW OIL PRESSURE SWITCH 2.9.2 HIGH TEMPERATURE SWITCH Figure 2.2 Low Oil Pressure and High Temperature Switches 2.10 ADDITIONAL INFORMATION 2.10.1 ATTENTION REQUIRED AFTER SUBMERSION 2.10.2 OPERATION IN HIGH GRASS OR BRUSH 2.10.3 EFFECTS OF MOISTURE AND DIRT 3.1 CHECKING THE ENGINE OIL LEVEL 3.3 MAINTAINING THE ENGINE AIR CLEANER Figure 3.1 Oil Maintenance Features QUIETPACT 40G Oil Dipstick/Oil Fill Oil Drain Oil Filter 3.3.1 CLEANING THE FOAM PRECLEANER 3.4 CLEAN AIR INTAKE Figure 3.3 Cleaning Air Intake Figure 3.4 Setting the Spark Plug Gap 3.5 CHECKING THE ENGINE SPARK PLUG 3.6 FUEL FILTER n RETAINING SCREW P/N 056892 SPARK ARRRESTOR SCREEN P/N 089680 TAILPIPE P/N 0E0683 3.8 CLEANING THE GENERATOR 3.10 MAJOR SERVICE MANUAL 3.11 EXERCISING THE GENERATOR 3.12 OUT OF SERVICE PROCEDURE 3.12.1 REMOVAL FROM SERVICE 3.12.2 RETURN TO SERVICE 3.14 RV GENERATOR SERVICE INTERVAL Notes Page NOTICE TO INSTALLER n n GENERAL HAZARDS ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS 1.1 PURPOSE AND SCOPE OF THE MANUAL 1.2 SAFETY 1.3 STANDARDS BOOKLETS 1.4 EQUIPMENT DESCRIPTION 1.5 GENERATOR ENGINE OPERATING SPEED Page 2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION 2.1.2 GENERATOR SUPPORT Figure 2.1 Typical Horizontal Support Frame 2.1.3 SUSPENDED MOUNTING 2.2 GENERATOR COMPARTMENTS 2.2.1 COMPARTMENT SIZE Figure 2.4 Clearances 2.2.2 COMPARTMENT CONSTRUCTION Figure 2.5 Typical Compartment Construction Page 2.3 COOLING AND VENTILATING AIR 2.3.1 GENERATOR AIRFLOW Figure 2.9 Airflow Through Engine/Generator 2.3.2 TESTING THE INSTALLATION 2.4 GASOLINE FUEL SYSTEM 2.5 EXHAUST SYSTEM 2.5.1 SPARK ARRESTOR Figure 2.11 - Spark Arrestor Figure 2.12 Spark Arrestor Installation 2.5.2 EXHAUST SYSTEM SAFETY 2.6 ELECTRICAL CONNECTIONS 2.6.1 ELECTRICAL JUNCTION BOX 2.6.2 WIRING 2.6.3 GENERATOR AC CONNECTIONS Figure 2.13 Generator AC Output Leads 2.7 BATTERY INSTALLATION 2.7.1 RECOMMENDED BATTERY Page 2.7.2 BATTERY CABLES 2.7.3 BATTERY CABLE CONNECTIONS Figure 2.16 Connecting Battery Cables 2.7.4 BATTERY COMPARTMENT 2.8 OPTIONAL ACCESSORIES Figure 2.17 Remote Panel Plug-in Receptacle 2.8.1 REMOTE START/STOP PANEL 3.1 POST INSTALLATION TESTS Post Installation Start-up Adjustments 3.2 BEFORE INITIAL START-UP 3.3 INITIAL START 3.4 TESTING UNDER LOAD 3.5 INSTALLATION CHECKLIST Post Installation Start-up Adjustments TROUBLESHOOTING GUIDE Troubleshooting Problem Cause Correction Page Electrical Data Electrical Schematic/Wiring Diagram Drawing No. 0D8063-D Electrical Data SM BATTERY FILTER MTG AC CONNECTION Page Enclosure Drawing No. 0D8352-N Exploded Views & Parts Lists Page Generator Drawing No. 0D8353-M Exploded Views & Parts Lists Page Control Panel Drawing No. 0D8354-H Exploded Views & Parts Lists Page GN-220 H/SH Engine Drawing No. 0D8355-AG Part 1 Exploded Views & Parts Lists Page GN-220 H/SH Engine Drawing No. 0D8355-AG Part 2 Exploded Views & Parts Lists CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURERS EMISSION CONTROL SYSTEM WARRANTY COVERAGE: PURCHASERS/OWNERS WARRANTY RESPONSIBILITIES: 1-800-333-1322 EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING: NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. WARRANTY SCHEDULE COMMERCIAL APPLICATIONS WARRANTY SCHEDULE CONSUMER/PERSONAL APPLICATIONS THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: GENERAC POWER SYSTEMS, INC. P.O. BOX 297 WHITEWATER, WI 53190