Generac Power Systems 004917 3 Users Manual 0F5093RevB

004917-3 to the manual 0e9dd389-9310-4b21-81ea-63f3bc227ef7

2015-02-09

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Installation and

Owner’s Manual

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

DANGER

This manual should

remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model Number

004917-3

27 kW NG, 30 kW LP Vapor

Not intended for use in life-support applications.

Generac®Power Systems, Inc.

INTRODUCTION

Thank you for purchasing this model of the standby

generator set product line by Generac Power Systems.

Every effort was expended to make sure that the

information and instructions in this manual are both

accurate and current at the time the manual was writ-

ten. However, the manufacturer reserves the right to

change, alter or otherwise improve this product(s) at

any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, con-

tact the nearest Generac Authorized Service Dealer

for starting, operating and servicing procedures.

Throughout this publication, and on tags and

decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular service or

operation that may be hazardous if performed incor-

rectly or carelessly. Observe them carefully. Their defi-

nitions are as follows:

After this heading, read instructions that, if not

strictly complied with, will result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing the

service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates is as follows:

This symbol points out important safety informa-

tion that, if not followed, could endanger personal

safety and/or property of others.

This symbol points out potential 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 start and operate

the unit. This prepares them if they need to operate

the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by a Generac

Authorized Service Dealer. Normal maintenance serv-

ice and replacement of parts are the responsibility of

the owner/operator and, as such, are not considered

defects in materials or workmanship within the terms

of the warranty. Individual operating habits and usage

contribute to the need for maintenance service.

Proper maintenance and care of the generator ensures

a minimum number of problems and keep operating

expenses at a minimum. See the Generac Authorized

Service Dealer for service aids and accessories.

Operating instructions presented in this manual

assume that the standby electric system has been

installed by a Generac Authorized Service Dealer or

other competent, qualified contractor. Installation of

this equipment is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

contact a Generac Authorized Service Dealer for

assistance. Service technicians are factory-trained

and are capable of handling all service needs.

When contacting a Generac Authorized Service

Dealer about parts and service, always supply the

complete model number of the unit as given on the

front cover of this manual or on the DATA CARD

affixed to the unit.



DANGER



AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

Locate us on the web at:

www.generac.com

Table of Contents

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Generac®Power Systems, Inc. 1

INTRODUCTION................................................IFC

SAFETY RULES ....................................................2

Section 1 — GENERAL INFORMATION ............4

1.1 Generator ..............................................................4

1.2 Transfer Switch ....................................................4

1.3 Automatic System Operation ................................4

1.4 Generator AC Connection Systems........................4

1.5 Main Circuit Breaker ............................................4

1.6 Generator Fuel System ..........................................5

1.7 Engine Protective Devices ......................................5

1.8 Unpacking ............................................................6

1.9 Lifting the Generator ............................................6

1.10 Specifications ........................................................7

1.11 Fuel Consumption ................................................7

1.12 Reconfiguring the Fuel System ..............................7

1.13 Torque Specifications ............................................8

1.14 Engine Oil Recommendations ..............................8

1.15 Coolant Recommendations....................................8

1.16 Before Installation ................................................8

Section 2 — INSTALLATION ............................8

2.1 Standby Generator Installation ............................8

2.2 Generator Location................................................9

2.3 Generator Mounting and Support ........................9

2.4 Basic Standby Electric System ..............................9

2.5 Emergency Circuit Isolation Method....................10

2.6 Total Circuit Isolation Method ............................10

2.7 Grounding the Generator ....................................10

2.8 Generator AC Neutral Connections......................10

2.9 Transfer Switch Start Signal Connections ..........11

2.10 Battery Installation ..............................................11

2.11 Preparation Before Start-Up ................................12

Section 3 — OPERATION ................................13

3.1 Using a Standard “GTS” Transfer Switch............13

3.2 Control Console Components..............................13

3.3 Manual Transfer and Startup..............................14

3.4 Engine Governor Adjustments ............................14

3.5 Retransfer and Shutdown....................................15

3.6 Automatic Operation ..........................................15

3.7 Weekly Exercise Cycle..........................................15

Section 4 — MAINTENANCE ..........................16

4.1 Maintenance Performed by Authorized

Service Facilities ..................................................16

4.2 Cooling System....................................................16

4.3 Overload Protection for Engine DC

Electrical System ................................................16

4.4 Checking Fluid Levels ........................................16

4.5 Maintenance Owner/Operator

Can Perform ........................................................17

4.6 Miscellaneous Maintenance ................................18

4.7 Scheduled Maintenance ......................................20

Section 5 — TROUBLESHOOTING ..................23

Section 6 — ELECTRICAL DATA ....................24

Section 7 — EXPLODED VIEWS AND

PARTS LISTS ..............................28

Section 8 — INSTALLATION DIAGRAM ..........44

Section 9 — NOTES ........................................45

Section 10 — WARRANTY .................Back Cover

2 Generac®Power Systems, Inc.

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.

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.

DANGER

IMPORTANT SAFETY INSTRUCTIONS

QUIETSOURCE

™

Liquid-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.

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.

WARNING:

Generac®Power Systems, Inc. 3

• Inspect the generator regularly, and promptly repair

or replace all worn, damaged or defective parts using

only factory-approved parts.

• Before performing any maintenance on the generator,

disconnect its battery cables to prevent accidental

start-up. Disconnect the cable from the battery post

indicated by a NEGATIVE, NEG or (–) first.

Reconnect that cable last.

• Never use the generator or any of its parts as a step.

Stepping on the unit can stress and break parts, and

may result in dangerous operating conditions from

leaking exhaust gases, fuel leakage, oil leakage, etc.

ELECTRICAL HAZARDS

• All generators covered by this manual produce dan-

gerous electrical voltages and can cause fatal electrical

shock. Utility power delivers extremely high and dan-

gerous voltages to the transfer switch as well as the

standby generator. Avoid contact with bare wires, ter-

minals, connections, etc., on the generator as well as

the transfer switch, if applicable. Ensure all appropri-

ate covers, guards and barriers are in place before

operating the generator. If work must be done around

an operating unit, stand on an insulated, dry surface

to reduce shock hazard.

• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• If people 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), Article 250

requires the frame and external electrically conduc-

tive parts of the generator to be connected to an

approved earth ground and/or grounding rods. This

grounding will help prevent dangerous electrical

shock that might be caused by a ground fault condi-

tion in the generator set or by static electricity. Never

disconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables and cord

sets must be adequate to handle the maximum elec-

trical current (ampacity) to which they will be sub-

jected.

• Before installing or servicing this (and related) equip-

ment, make sure that all power voltage supplies are

positively turned off at their source. Failure to do so

will result in hazardous and possibly fatal electrical

shock.

• Connecting this unit to an electrical system normally

supplied by an electric utility shall be by means of a

transfer switch so as to isolate the generator electric

system from the electric utility distribution system

when the generator 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 acceptable preset level. To prevent such automat-

ic start-up and possible injury to personnel, disable

the generator’s automatic start circuit (battery cables,

etc.) before working on or around the unit. Then,

place a “Do Not Operate” tag on the generator control

panel and on the transfer switch.

• In case of accident caused by electric shock, immedi-

ately shut down the source of electrical power. If this

is not possible, attempt to free the victim from the

live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting implement, such

as a dry rope or board, to free the victim from the live

conductor. If the victim is unconscious, apply first aid

and get immediate medical help.

• Never wear jewelry when working on this equipment.

Jewelry can conduct electricity resulting in electric

shock, or may get caught in moving components

causing injury.

FIRE HAZARDS

• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride type

extinguisher. Its fumes are toxic, and the liquid can

deteriorate wiring insulation. Keep the extinguisher

properly charged and be familiar with its use. If there

are any questions pertaining to fire extinguishers,

consult the local fire department.

EXPLOSION HAZARDS

• Properly ventilate any room or building housing the

generator to prevent build-up of explosive gas.

• Do not smoke around the generator. Wipe up any fuel

or oil spills immediately. Ensure that no combustible

materials are left in the generator compartment, or

on or near the generator, as FIRE or EXPLOSION

may result. Keep the area surrounding the generator

clean and free from debris.

• Generac generator sets may operate using one of sev-

eral types of fuels. All fuel types are potentially FLAM-

MABLE and/or EXPLOSIVE and should be handled

with care. Comply with all laws regulating the storage

and handling of fuels. Inspect the unit’s fuel system

frequently and correct any leaks immediately. Fuel

supply lines must be properly installed, purged and

leak tested according to applicable fuel-gas codes

before placing this equipment into service.

• Diesel fuels are highly FLAMMABLE. Gaseous fluids

such as natural gas and liquid propane (LP) gas are

extremely EXPLOSIVE. Natural gas is lighter than air,

and LP gas is heavier than air; install leak detectors

accordingly.

IMPORTANT SAFETY INSTRUCTIONS

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

4 Generac®Power Systems, Inc.

1.1 GENERATOR

This equipment is a liquid-cooled, engine-driven gen-

erator set. The generator is designed to supply elec-

trical power that operates critical electrical loads

during utility power failure. The unit has been facto-

ry-installed in a weather resistant, all aluminum

enclosure and is intended for outdoor installation

only. Use this generator as a source of electrical

power for the operation of 120 and/or 240VAC, sin-

gle-phase loads.

If this generator is used to power electrical load

circuits normally powered by a UTILITY power

source, it is required by code to install a trans-

fer switch. The transfer switch must effectively

isolate the electric system from the utility distri-

bution system when the generator is operating

(NEC 701). Failure to isolate an electrical system

by such means results in damage to the genera-

tor and may also result in injury or even death

to utility power workers due to backfeed of

electrical energy.

1.2 TRANSFER SWITCH

This generator system may include a matched auto-

matic transfer switch which is intended to be used in

conjunction with the Generac generator. It is supplied

in either a NEMA 1 enclosure or a NEMA 3R enclo-

sure. The NEMA 1 enclosure is intended for indoor

use only. The NEMA 3R enclosure is weather proof

and can be used indoors or outdoors. Follow these

rules:

• Install the transfer switch on a firm, sturdy sup-

porting structure.

• To prevent switch distortion, level the switch if nec-

essary. This can be done by placing washers

between the switch enclosure and the mounting

surface.

• Never install the switch where water or any corro-

sive substance might drip onto the enclosure.

• Protect the switch at all times against excessive

moisture, dust, dirt, lint, construction grit and cor-

rosive vapors.

If a transfer switch is not included, one may be pur-

chased separately from a Generac Authorized Dealer.

1.3 AUTOMATIC SYSTEM OPERATION

When this generator, along with a transfer switch, has

been installed and interconnected, a circuit board in

the generator panel constantly monitors UTILITY

power source voltage. Should that voltage drop below

a preset value, and remain at such a low state for a

preset amount of time, the generator cranks and

starts. After the generator starts, the transfer switch

transfers load circuits so the generator can power

them.

When utility source voltage has been restored, the

switch re-transfers back to the UTILITY source volt-

age and the generator then shuts down.

Please reference the transfer switch manual for spe-

cific information.

1.4 GENERATOR AC CONNECTION

SYSTEMS

The generator was shipped from the factory with its

stator AC output leads connected in a single-phase,

three-wire generator AC connection system (Figure

1.1). The stator assembly in this system consists of a

pair of stationary windings, with two leads brought

out of each winding. Each single winding can supply

120VAC, 60 Hertz. When the two windings are con-

nected in series, a 240VAC, 60 Hertz AC output

results. Typically the two HOT leads in the circuit are

wires 11 and 44. The NEUTRAL leads are the junc-

tion of Wires 22 and 33. The NEUTRAL is not

grounded.

Figure 1.1 - Generator AC Connection System

1.5 MAIN CIRCUIT BREAKER

The generator’s main circuit breaker is included with

the unit as shipped from the factory. The breaker for

each unit is described in Figure 1.2.

Section 1 - General Information

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Model Rating Phase Actual Current C/B Rating* Circuit Breaker

004917-3 27,000 NG 1 112.5 150 150A QN2

30,000 LP 1 125.0 150 150A QN2

* Amp Rating of C/B structured under model.

Figure 1.2 - Main Circuit Breaker

Generac®Power Systems, Inc. 5

1.6 GENERATOR FUEL SYSTEM

The unit has been factory tested and adjusted using a

natural gas fuel system. If propane (LP) gas is neces-

sary. Refer to Section 1.11, Fuel Consumption.

Fuel pressure for a natural gas set up should be five

inches to 14 inches of water column (0.18 to 0.5

psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11

inches to 14 inches of water column (0.4 to 0.5

psi) at all load ranges.

NOTE:

A seperate gas line and regulator may be needed

to assure proper gas pressure to the generator.

Improper gas pressure can cause hard starting and

affect engine durability.

Gaseous fuels such as natural and LP (propane)

gas are highly explosive. Even the slightest

spark can ignite such fuels and cause an explo-

sion. No leakage of fuel is permitted. Natural

gas, which is lighter than air, tends to collect in

high areas. LP gas is heavier than air and tends

to settle in low areas.

1.7 ENGINE PROTECTIVE DEVICES

The engine has several safety switches which cause

the engine to automatically shut down under the fol-

lowing conditions: low oil pressure, high coolant tem-

perature, engine overspeed, low coolant level or over-

crank (Figure 1.3).

Figure 1.3 - Engine Protective Devices

1.7.1 LOW OIL PRESSURE SWITCH

This switch is normally-closed (N.C.), but is held

open by engine oil pressure during engine running.

Should operating oil pressure drop below about 8-10

psi (55-68 kPa), the switch contacts close, the engine

shuts down automatically, and the low oil pressure

LED is turned ON (Figure 1.4).

NOTE:

The Low Oil Pressure, High Coolant Temperature

and Low Coolant Level are not monitored for the

first 10 seconds of engine run time.

Figure 1.4 - Low Oil Pressure Switch

1.7.2 HIGH COOLANT TEMPERATURE

SWITCH

This normally open (N.O.) thermostatic switch has

sensing tip which is immersed in captive coolant.

Should coolant temperature exceed about 230°F

(110°C), the switch contacts close. This causes the

engine to shut down automatically and turns on the

high coolant temperature/low coolant level LED

(Figure 1.5).

Figure 1.5- High Coolant Temperature Switch

1.7.3 LOW COOLANT LEVEL SWITCH

Should engine coolant level drop below the level of

the high coolant temperature switch, it is possible for

the engine to overheat without automatic shutdown.

To prevent such overheating without automatic shut

down, the engine has a low coolant level sensor. If the

engine coolant drops too low, the engine automatical-

ly shuts down and turns on the high coolant temper-

ature/low coolant level LED (Figure 1.6 on page 6).



PRE

WIT

COO

LAN

TEMPERAT

COO

LAN

LEVEL

WIT

Section 1 - General Information

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

6 Generac®Power Systems, Inc.

Figure 1.6 - Low Coolant Level Sensor

1.7.4 OVERSPEED SHUTDOWN

The engine control board receives AC frequency sig-

nals from an engine run winding in the alternator.

Should AC frequency exceed about 72 Hertz for three

seconds or 75 Hertz instantaniously, the engine shuts

down and the overspeed LED turns on. Should AC

frequency exceed about 72 Hertz, circuit board action

will automatically shutdown the engine (Figure 1.7).

Figure 1.7 - Printed Circuit Board Assembly

1.7.5 RPM SENSOR LOSS

If the engine control board does not receive a proper

rpm signal from the starter during cranking or run-

ning, it shuts down the engine on rpm sensor loss

and flash the overspeed LED.

1.7.6 OVERCRANK SHUTDOWN

The engine control board uses a cyclic cranking

process when attempting to start the engine. The first

crank cycle is a 15-second crank followed by a seven-

second rest. This is followed by five more crank

cycles each with a seven second crank followed by a

seven second rest.

If the engine fails to start after all six attempts, the

start attempt is stopped and the overcrank LED

turned on.

1.7.7 LOW BATTERY

The engine control board continually monitors the

battery voltage and turns on the low battery LED if

the battery voltage falls below 11.0 VDC for one

minute. Low battery voltage is a non-latching alarm,

which will automatically clear if the battery voltage

rises above 11.0 VDC.

The control system will not attempt to start the

engine if there is a low battery condition, however, if

the engine is already running when the low battery

condition occurs, the engine will continue to run as

long as possible.

Battery voltage is NOT monitored during the crank

cycle.

1.7.8 ALARM RESET

If the engine control board shuts down the generator

for any of the above reasons, the engine remains

stopped until the alarm is cleared by placing the

AUTO/OFF/MANUAL switch into the OFF position.

1.7.9 DC FUSE

These fuses are located on the front panel of the con-

trol system. They protect the panel wiring and com-

ponents from damaging overload. Always remove the

15 amp main fuse before working on the generator.

The unit will not start or crank if this fuse is blown.

Replace the fuse with one of the same size, type, and

rating (main AGC-15, battery charger AG4).

1.8 UNPACKING

1.8.1 UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Use

care to avoid damage from dropping, bumping, colli-

sion, etc. Store and unpack cartons with the proper

side up, as noted on the shipping carton.

1.8.2 INSPECTION

After unpacking, carefully inspect the generator for

any damage that may have occurred during ship-

ment. If loss or damage is noted at the time of deliv-

ery, have the person(s) making delivery note all dam-

age on the freight bill or affix their signature under

the consignor’s memo of loss or damage.

1.9 LIFTING THE GENERATOR

When lifting or hoisting equipment is used, be

careful not to touch overhead power lines. The

generators weight of more than 900 pounds

requires proper tools, equipment, and qualified

personnel to be used in all phases of handling

and unpacking.



906

REV

D17

R44

C30

RL1

RL2



Section 1 — General Information

QUIETSOURCE

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Liquid-cooled 30 kW Generators

1.10 SPECIFICATIONS

1.10.1 GENERATOR SPECIFICATIONS

1.10.2 ENGINE SPECIFICATIONS

Make ......................................................................................Ford

Displacement ..................................................................3.0 liters

Cylinder Arrangement ..............................................................V-6

Valve Arrangement ..............................................Overhead Valve

Firing Order ................................................................1-4-2-5-3-6

Number of Main Bearings............................................................4

Compression Ratio............................................................9.3 to 1

No. of Teeth on Flywheel ........................................................164

Ignition Timing at 1800 rpm..............................30 degrees BTDC

Spark Plug Gap ..................................................0.042-0.046 inch

Recommended Spark Plugs

Motor Craft..........................................................AG, SF 32PGM

Oil Pressure....................................................................40-50 psi

Crankcase Oil Capacity........................5.0 U.S. quarts (4.7 liters)

Recommended Engine Oil..........................................SAE 5W-20

Type of Cooling System ..................Pressurized, closed recovery

Cooling Fan ..............................................................Pusher Type

Cooling System Capacity..................3.0 U.S. gallons (11.4 liters)

Recommended Coolant ............................Use a 50-50 mixture of

ethylene glycol base

and de-ionized water.

1.11 FUEL CONSUMPTION

Natural Gas:

% of Load 25% 50% 75% 100%

m3/hr 3.1 5.9 8.5 11.0

ft3/hr 110.3 209.0 299.5 387.0

LP Vapor:

% of Load 25% 50% 75% 100%

m3/hr 1.3 2.4 3.5 4.5

ft3/hr 45.6 86.4 123.8 160.0

NOTE:

Fuel consumption is given at rated maximum con-

tinuous power output when using natural gas rated

at 1000 Btu per cubic foot. LP gas is rated at 2520

Btu per cubic foot. Actual fuel consumption

obtained may vary depending on such variables as

applied load, ambient temperature, engine condi-

tions and other environmental factors.

Fuel pressure for a natural gas set up should be five

inches to 14 inches of water column (0.18 to 0.5

psi) at all load ranges.

Fuel pressure for an LP vapor set up should be 11

inches to 14 inches of water column (0.4 to 0.5

psi) at all load ranges.

1.12 RECONFIGURING THE FUEL

SYSTEM

NOTE:

All models are configured for natural gas from the

factory.

To reconfigure the fuel system from NG to LP vapor,

follow these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet

port (Port 1) of the demand regulator (Figure 1.8).

3. Remove the brass hose fitting from the outlet port

(Port 1) of the demand regulator.

4. Remove pipe plug from Port 2.

5. Install brass hose fitting into Port 2.

6. Install pipe plug into Port 1.

7. Connect carburetor gas hose to brass fitting.

8. Tighten all clamps and plugs.

9. Make sure fuel supply is of the proper pressure

and type for configuration.

10. Reverse the procedure to convert back to natural

gas.

Figure 1.8 — Reconfigure the Fuel System

NG FUEL SYSTEM LP FUEL SYSTEM

Port 1 Port 2

FUEL HOSE

BRASS HOSE

FITTING

HOUSING

PORTS

OUT

PORT 2

PLUG

FUEL HOSE

BRASS HOSE

FITTING

HOUSING

PORTS

PLUG

OUT

PORT 1



Section 1 — General Information

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Generac®Power Systems, Inc. 7

Single-phase

Model 4917-3

Rated Max. Cont. 27 (NG), 30 (LP)

AC Power Output (kW)

Rated voltage (volts) 120/240

No. of Rotor Poles 4

Driven Speed of Rotor 1800

Rotor Excitation System Direct excited brush type

Type of Stator 4 Wire

Rotor/Stator Insulation Class F/H

8 Generac®Power Systems, Inc.

NOTE:

Port 1 is for NG only and Port 2 is for LP vapor

only. No provision for dual fuel has been made.

Serious injury or damage may occur if not con-

figured properly. Please consult an authorized

Generac Service Dealer with any questions.

1.13 TORQUE SPECIFICATIONS

Cylinder Head ............................................15 (+ 90° + 90°) ft.lb.

Intake Manifold ................................................................13 ft.lb.

Exhaust Manifold..............................................................13 ft.lb.

1.14 ENGINE OIL RECOMMENDATIONS

The unit has been filled with 5W-20 engine oil at the

factory. Use a high-quality detergent oil classified “For

Service CC, SD, SE, SF.” Detergent oils keep the

engine cleaner and reduce carbon deposits. Use oil

having the following SAE viscosity rating, based on

the ambient temperature range anticipated before the

next oil change:

NOTE:

5W-30 full synthetic oil is highly recommended in

any element with temperatures above 90°F or

below 30°F.

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

1.15 COOLANT RECOMMENDATIONS

Use a mixture of half low silicate ethylene glycol base

anti-freeze and half de-ionized water. Cooling system

capacity is about 12 U.S. quarts (11.4 liters). Use

only de-ionized water and only low silicate anti-

freeze. If desired, add a high quality rust inhibitor to

the recommended coolant mixture. When adding

coolant, always add the recommended 50-50 mix-

ture.

Do not use any chromate base rust inhibitor

with ethylene glycol base anti-freeze or chromi-

umhydroxide (“green slime”) forms and will

cause overheating. Engines that have been

operated with a chromate base rust inhibitor

must be chemically cleaned before adding eth-

ylene glycol base anti-freeze. Using any high

silicate anti-freeze boosters or additives will

also cause overheating. It is also recommend

that any soluble oil inhibitor is NOT USED for

this equipment.

1.16 BEFORE INSTALLATION

Before installing this equipment, check the ratings of

both the generator and the transfer switch. Read

“Emergency Isolation Method” and “Total Circuit

Isolation Method” in the installation manual (Part No.

079699).

The generator’s rated wattage/amperage capacity

must be adequate to handle all electrical loads that

the unit will power. The critical (essential) loads may

need to be grouped together and wired into a sepa-

rate “emergency” distribution panel.

This generator can be installed in conjunction with a

standard Generac “GTS” type transfer switch, if nec-

essary.

The standard transfer switch has no sensing or con-

trolling circuit boards. Instead, the generator control

console houses a “Printed Circuit Board Assembly”,

which controls all phases of operation, including

engine start up and load transfer.

2.1 STANDBY GENERATOR

INSTALLATION

Connecting this generator to an electrical sys-

tem normally supplied by an electric utility

shall be by means of a transfer switch, so as to

isolate the electric system from the utility distri-

bution system when the generator is operating.

Failure to isolate the electric system by these

means will result in damage to the generator

and may also result in injury or death to utility

workers due to backfeed of electrical energy.

If an open bottom is used, the engine-genera-

tor is to be installed over non-combustible

materials and should be located such that com-

bustible materials are not capable of accumu-

lating under the generator set.

DANGER

Section 2 — Installation

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Temperature Oil Grade (Recommended)

Above 80° F (27° C) SAE 5W-20

32° to 80° F (-1° to 27° C) SAE 5W-20

Below 32° F (0° C) SAE 5W-20

Generac®Power Systems, Inc. 9

Only qualified, competent installation contractors or

electricians thoroughly familiar with applicable

codes, standards and regulations should install this

standby electric power system. The installation must

comply strictly with all codes, standards and regula-

tions pertaining to the installation.

After the system has been installed, do nothing

that might render the installation in noncompli-

ance with such codes, standards and regula-

tions.

NOTE:

For more information about the installation of a

standby system, order Engine-Generator Standby

Electric Power Systems Installer’s Guide and

Reference Manual (part #046622) from the

Generac Authorized Service Dealer.

2.1.1 NFPA STANDARDS

The following published standards booklets pertain-

ing to standby electric systems are available form the

National Fire Protection Association (NFPA),

Batterymarch Park, Quincy, MA 02269:

NOTE:

It is essential to use the latest version of any stan-

dard to ensure correct and current information.

• NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES.

• NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-

TEMS FOR HEALTH CARE FACILITIES.

• NFPA No. 220, STANDARD TYPES OF BUILDING

CONSTRUCTION

• NFPA No. 68, GUIDE FOR EXPLOSION 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:

NOTE:

It is essential to use the latest version of any stan-

dard to ensure correct and current information.

• Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85 John

Street, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainable

from the Food and Energy Council, 909 University

Avenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTE-

NANCE OF FARM STANDBY ELECTRIC POWER,

available from the American Society of Agricultural

Engineers, 2950 Niles Road, St. Joseph, MI 49085.

• A52.1, AMERICAN NATIONAL STANDARD FOR

CHIMNEYS, FIREPLACES AND VENTING SYS-

TEMS, available from the American National

Standard Institute, 1430 Broadway, New York, N.Y.

10018.

2.2 GENERATOR LOCATION

Install the generator set, in its protective enclosure

outdoors, where adequate cooling and ventilating air

always is available. Consider these factors:

• Install the unit where air inlet and outlet openings

will not become obstructed by leaves, grass, snow,

etc. If prevailing winds will cause blowing or drift-

ing, consider using a windbreak to protect the unit.

• Install the generator on high ground where water

levels will not rise and endanger it.

• This genset must be installed on a level surface.

The base frame must be level within 1/2 inch all

around.

• Allow sufficient room on all sides of the generator

for maintenance and servicing. A good rule is to

allow five feet of space on all sides.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings into

the prevailing winds.

• Install the generator as close as possible to the

transfer switch. This reduces the length of wiring

and conduit.

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping. HOWEVER,

REMEMBER THAT LAWS OR CODES MAY REG-

ULATE THE DISTANCE.

2.3 GENERATOR MOUNTING AND

SUPPORT

Retain the generator compartment to a concrete slab

with 1/4-inch masonry type anchor bolts. Be sure the

bolts are long enough to retain the compartment. The

slab should be at least six inches thick and should

extend beyond the enclosure to a distance of at least

three inches on all sides. See Section 6 for generator

major dimensions.

2.4 BASIC STANDBY ELECTRIC

SYSTEM

Figure 2.1 shows a schematic diagram of a basic

standby electric system. Both the UTILITY power

supply and the STANDBY (GENERATOR) output are

connected to an approved transfer switch. The trans-

fer switch is required by electrical code and serves

the following functions:

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Section 2 — Installation

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

10 Generac®Power Systems, Inc.

• Allows the LOAD circuits to be connected to only

one power supply at a time.

• Prevents electrical backfeed between the generator

and the UTILITY power circuits.

Both the STANDBY and the UTILITY power supplies

to the transfer switch are protected against overload

by a main line circuit breaker.

Figure 2.1 – Basic Standby Electric System

2.5 EMERGENCY CIRCUIT ISOLATION

METHOD

This prevents overloading the generator by keeping

electrical loads below the wattage/amperage capacity

of the generator. If the generator is powering only crit-

ical loads, within the wattage/amperage capacity, dur-

ing utility power outages, consider using the emer-

gency circuit isolation method.

Critical electrical loads 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

panel circuit.

• Have it installed between the building’s main dis-

tribution panel and the emergency distribution

panel.

2.6 TOTAL CIRCUIT ISOLATION

METHOD

When a generator capable of powering all electrical

loads in the circuit is to be installed, use the “Total

Circuit Isolation Method.” It is possible for the gener-

ator to be overloaded when this isolation method is

employed. The following apply to the transfer switch

in this type of system.

• Ampere rating of the transfer switch must equal

the ampere rating of the normal incoming utility

service.

• The transfer switch is installed between the utility

service entrance and the building distribution

panel.

2.7 GROUNDING THE GENERATOR

The National Electrical Code requires the frame and

external electrically conductive parts of this equip-

ment to be properly connected to an approved earth

ground and/or grounding rods. For that purpose, a

GROUND LUG (Figure 2.2) is provided on the gener-

ator mounting base. Consult a qualified electrician

for grounding requirements in the area. Grounding

procedures must meet local regulations.

Do not connect the ground wire to any pipe

that carries a flammable or explosive substance

– FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against

electrical shock in the event of a ground fault condi-

tion in the generator or in connected electrical

devices. In addition, grounding helps dissipate static

electricity that often builds up in ungrounded

devices.

Figure 2.2 – Generator Grounding Lug (typical)

2.8 GENERATOR AC NEUTRAL

CONNECTIONS

Generac uses an UNGROUNDED AC neutral.

Grounding is recommended only at the main service

entrance. If the neutral wire is grounded and one of

the phase loads becomes grounded, the excessive

current opens the load circuit breaker or collapses

the generator field. The actual result depends on the

electrical characteristics of the particular installed

generator.

NDIN

DANGER

Section 2 — Installation

QUIETSOURCE

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Liquid-cooled 30 kW Generators

Generac®Power Systems, Inc. 11

Failure to connect the generator neutral prop-

erly will result in unbalanced line-to-neutral

voltages. Resulting high voltages will cause

equipment damage.

2.9 TRANSFER SWITCH SIGNAL

CONNECTIONS

2.9.1 PRE-PACKAGED ATS

If the generator is to be installed with a pre-packaged

transfer switch, it is necessary to connect the control

wires to the generator and set position two of the

four-position dip switch to OFF.

Setting switch two to OFF allows the control PCB to

perform the ATS control functions.

Control system interconnections consist of N1 and

N2, and leads 23 and 194. Control system intercon-

nection leads must be run in a conduit that is sepa-

rate from the AC power leads. Recommended wire

gauge sizes for this wiring depends on the length of

the wire, as recommended below:

2.9.2 GTS-TYPE ATS

If the generator is to be installed with an automatic

transfer switch, such as a Generac GTS-type switch,

it is necessary to connect the two-wire start control

system.

Connect the two-wire start signal from the automatic

transfer switch to the automatic start connection,

which is located in the middle, on the bottom, inside

the control panel. Match wires 178 and 183 in the

transfer switch to 178 and 183 on the terminal strip

in the control panel. The conductors for the two-wire

start circuit must be in their own conduit. (See

Section 3.1 for further explanation.)

2.10 BATTERY INSTALLATION

Standby generators installed with automatic

transfer switches will crank and start automati-

cally when NORMAL (UTILITY) source voltage is

removed or is below an acceptable preset level.

To prevent such automatic start-up and possible

injury to personnel, do not connect battery

cables until certain that normal source voltage

at the transfer switch is correct and the system

is ready to be placed into operation.

Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture

around the battery for several hours after

charging. The slightest spark can ignite the gas

and cause an explosion. Such an explosion can

shatter the battery and cause blindness or

other injury. Any area that houses a storage

battery must be properly ventilated. Do not

allow smoking, open flame, sparks or any spark

producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caustic

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.

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 represents a risk of high short circuit

current. When working on the battery, always

remove watches, rings or other metal objects,

and only use tools that have insulated handles.

2.10.1 VENTED BATTERIES

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following proce-

dures are to be observed:

• Wear full eye protection and protective clothing,

• Where electrolyte contacts the skin, wash it off

immediately with water,

• Where electrolyte contacts the eyes, flush thor-

oughly and immediately with water and seek med-

ical attention, and



DANGER

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Section 2 — Installation

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

MAXIMUM WIRE LENGTH RECOMMENDED WIRE

SIZE

460 feet (140m) No. 18 AWG.

461 to 730 feet (223m) No. 16 AWG.

731 to 1,160 feet (354m) No. 14 AWG.

1,161 to 1,850 feet (565m) No. 12 AWG.

12 Generac®Power Systems, Inc.

• Spilled electrolyte is to be washed down with an

acid-neutralizing agent. A common practice is to

use a solution of one pound (500 grams) bicarbon-

ate of soda to one gallon (4 liters) of water. The

bicarbonate of soda solution is to be added until

the evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

Lead acid batteries present a risk of fire

because they generate hydrogen gas. The fol-

lowing procedure are to be followed:

• DO NOT SMOKE when near batteries,

• DO NOT cause flame or spark in battery area, and

• Discharge static electricity from body before touch-

ing batteries by first touching a grounded metal

surface.

Servicing of batteries is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

nel away from batteries.

The recommended battery is Group 26, 12VDC, 550

CCA/75 AH minimum. All batteries must be at 100

percent state-of-charge before they are installed on

the generator.

When using maintenance-free batteries, it is not nec-

essary to check the specific gravity or electrolyte level.

Have these procedures performed at the intervals

specified in Section 4, “Maintenance.” A negative

ground system is used. Battery connections are

shown on the wiring diagrams. Make sure all batter-

ies are correctly connected and terminals are tight.

Observe battery polarity when connecting batteries to

the generator set.

NOTE:

Damage will result if the battery connections are

made in reverse.

2.11 PREPARATION BEFORE START-UP

The instructions in this section assume that the

standby generator has been properly installed, serv-

iced, tested, adjusted and otherwise prepared for use

by a competent, qualified installation contractor. Be

sure to read the “Safety Rules” on Pages 2 and 3, as

well as all other safety information in this manual,

before attempting to operate this (and related) equip-

ment.

2.11.1 PRIOR TO INITIAL START-UP

Prior to initially starting the generator, it must

be properly prepared for use. Any attempt to

crank or start the engine before it has been

properly serviced with the recommended types

and quantities of engine fluids (oil, coolant,

fuel, etc.) may result in an engine failure.

Before starting the generator for the first time, the

installer must complete the following procedures. For

follow-up maintenance information and/or service

intervals, please refer to Section 4, “Maintenance.”

2.11.2 TRANSFER SWITCH

If this generator is used to supply power to any elec-

trical system normally powered by an electric utility,

the National Electrical Code requires that a transfer

switch be installed. The transfer switch prevents elec-

trical backfeed between two different electrical sys-

tems (for additional information, see the applicable

transfer switch manual for this unit). The transfer

switch, as well as the generator and other standby

components, must be properly located and mounted

in strict compliance with applicable codes, standards

and regulations.

2.11.3 FUEL SYSTEM

Make sure the fuel supply system to the generator (a)

delivers the correct fuel at the correct pressure and

(b) is properly purged and leak tested according to

code. No fuel leakage is permitted. See

“Specifications” (Section 1.10) for more information.

2.11.4 GENERATOR SET LUBRICATION

Check the engine crankcase oil level before operating

and add oil to the proper level – the dipstick “FULL”

mark. Never operate the engine with the oil level

below the dipstick “ADD” mark. See “Specifications”

(Section 1.10) and “Engine Oil Recommendations”

(Section 1.14).

NOTE:

This engine is shipped from the manufacturer

with 5W-20 oil. This oil should be changed after

30 hours of operation.

2.11.5 ENGINE COOLANT

Have the engine cooling system properly filled with

the recommended coolant mixture. Check the system

for leaks and other problems. See “Specifications”

(Section 1.10) and “Coolant” (Section 1.15).

2.11.6 BELT TENSION

Check the engine fan belt tension and condition prior

to placing the unit into service and at recommended

intervals. Belt tension is correct when a force of

approximately 22 pounds (10 kg), applied midway

between pulleys, deflects the belt about 3/8- to 5/8-

inch (10 to 16 mm).

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Section 2 — Installation

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Liquid-cooled 30 kW Generators

Generac®Power Systems, Inc. 13

2.11.7 ELECTRICAL SYSTEM

Make sure the generator is properly connected to an

approved earth ground and/or ground rod.

Make sure the generator battery is fully charged,

properly installed and interconnected, and ready for

use.

Check to ensure that there are no loose electrical con-

nections. Restrain any loose wires to keep them clear

of any moving generator set components.

3.1 USING A STANDARD “GTS”

TRANSFER SWITCH

When required, the pre-packaged standby generator

can be installed with an engineered Generac “GTS”

type automatic transfer switch.

In this application, the GTS is responsible for utility

sensing, weekly exercising, and load transferring.

Position two of the four-position dip switch is used to

turn over this control to the GTS.

Pos2 ON — GTS Application

• The control board will NOT monitor utility.

• The control board will NOT perform a weekly exer-

cise. (The five red LEDs will not flash in this

mode.)

• The control board will NOT activate the transfer

output.

• The control board WILL monitor all engine condi-

tions and shut down on all the faults listed in this

document.

Pos2 OFF — ATS Application

• The control board will perform all of the automat-

ic features listed in this document.

• The two-wire start connections should NOT be

used.

GTS Mode Operation

When in GTS mode, the control board will respond

as follows based on the AUTO/OFF/MANUAL switch

position.

OFF — The generator will not start and run in this

position.

MANUAL — The control board will start and run the

generator whenever the switch is in the manual posi-

tion.

AUTO — The control board will monitor the two-wire

start circuit. When a two-wire start is issued the con-

trol board will immediately start and run the genera-

tor. Whe the two-wire start is removed the control

board will immediately stop the generator.

NOTE:

If the generator is installed in conjunction with an

engineered GTS type transfer switch, refer to the

applicable transfer switch manual for exact oper-

ating parameters and timing sequences.

3.2 CONTROL CONSOLE

COMPONENTS

The components of a home standby generator control

console (Figure 3.1) are as follows:

Figure 3.1 - Home Standby Generator Panel

3.2.1 AUTO/OFF/MANUAL SWITCH

Use this three-position switch as follows:

• Set the switch to AUTO for fully automatic opera-

tion. See “Automatic Operation” (Section 3.5).

• Set switch to MANUAL position to crank and start

the generator engine.

• Set switch to OFF position to shut down an oper-

ating engine. With OFF selected, operation will not

be possible.

With switch set to AUTO, engine can crank and

start suddenly without warning. Such automat-

ic start up normally occurs when utility source

voltage drops below a pre-set level. To prevent

possible injury that might be caused by such

sudden starts, set AUTO/OFF/MANUAL switch

to OFF before working on or around the unit.

Then, place a “DO NOT OPERATE” tag on con-

trol console.

DANGER



(

SEE OWNER'S MANUAL FOR COMPLETE LED DETAILS

)

FLA

HIN

RED LED'

= EXER

ER N

FLA

HIN

REEN LED = N

TILITY

TO SET EXERCISER TIME

1) PLACE AUTO/OFF/MANUAL SWITCH TO AUTO POSITION.

(

IN AUTO MODE ONLY

)

SOLID GREEN LED = SYSTEM READY, UTILITY POWER O

OFF

EXER

TIME

LED INDI

RED LED'

= INDIVID

AL FA

0E7194

VER

RAN

O/O

MAN

WIT

A F

USE

MAI

4A F

USE

BATTERY

HAR

EXE

TIME

WIT

RED LED

REEN LE

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Liquid-cooled 30 kW Generators

14 Generac®Power Systems, Inc.

3.2.2 FAULT INDICATOR LED

This LED goes ON when one or more of the following

engine faults occurs and when engine shuts down.

• Low Oil Pressure

• Overcrank

• Low Battery

• Overspeed/RPM Sensor Loss

• High Coolant Temperature/Low Coolant Level

See Section 1.7 for further explanation of engine pro-

tection functions.

3.2.3 15 AMP FUSE

This fuse protects the control console’s DC control

circuit against electrical overload. If the fuse has

melted open because of an overload, engine cranking

and startup cannot occur. If the fuse needs to be

replaced, use only an identical 15-amp replacement

fuse. (Type AGC)

3.2.4 4 AMP INLINE FUSE

This fuse protects the battery charger against electri-

cal overload. If the fuse needs to be replaced, use only

an identical 4 amp replacement fuse (type AG).

NOTE:

This fuse will not remove the + battery input

power from the PCB when it opens. This means

the exercise timer will not be reset.

3.2.5 SET EXERCISE TIME SWITCH

This switch allows programming the generator to

start and exercise automatically. “See Weekly

Exercise Cycle.”

3.2.6 SYSTEM READY LED

The System Ready LED (green) has two main pro-

poses. First, the LED will be ON when the

AUTO/OFF/MANUAL switch is in the AUTO position,

utility is present, and there are no system alarms.

This ON state indicates the system is fully ready for

automatic operation.

The system ready LED will be OFF when the switch

is in the manual or OFF positions.

The system ready LED is also used to indicate the

presence of utility sensing at the PCB when the switch

is either in the AUTO or MANUAL modes. The LED

will flash at the rate of 1/2 second on, 1/2 second off

if the utility sensing level is below the transfer back

threshold.

This secondary function is only available with dip

switch two in the OFF position (standard ATS appli-

cation).

3.3 MANUAL TRANSFER AND

START-UP

To transfer electrical loads to the Standby (EMER-

GENCY) power source side and start the engine man-

ually, refer to the Owner’s Manual of the particular

transfer switch.

3.4 ENGINE GOVERNOR

ADJUSTMENTS

Engine speed governing is also controlled by the

engine control board. Connector J2 on the engine

control board interfaces with a governor driver mod-

ule and the Bosch throttle body. The engine governor

has been set by the factory during final testing of the

generator and, in most cases, should not be adjusted.

If, however, adjustments are necessary, or a new

engine control board is installed in the generator, the

following procedure should be followed (Figure 3.2):

1. Set all three potentiometers (pots) fully counter-

clockwise.

2. Under no load condition, increase the GAIN pot

as much as possible without causeing instability.

3. Apply 1/4, 1/2, 3/4 and full load to the unit.

Decrease the GAIN pot if there is instability at any

load point.

4. Under full load condition, increase the stability

pot until the unit returns to 60 Hertz (or 50 Hertz

in 50 Hertz applications).

Figure 3.2 — Engine Governor Adjustment

PCB# 0E4906 REV.

D17

R44

C30

RL1

RL2

UNUSED

GTS/ATS

50/60 HZ

POSITION 1

50/60 HZ

ON = 50 HZ

OFF = 60 HZ

POSITION 2

GTS/ATS Select

ON = GTS

OFF = ATS (standard mode)

STABILITY

DIFFERENTIAL DIP SWITCH

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Section 3 - Operation

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Liquid-cooled 30 kW Generators

5. Reduce load to 3/4, 1/2, 1/4 and no load.

Decrease the stability pot if there is instability at

any load point.

6. Adjust differential pot to make the recovery to

load changes even faster and minimize load

change undershoot and overshoot. If it is set too

high it may introduce oscillations at some load. It

can be set to zero (full CCW) if a small amount

causes oscillations at some load.

3.5 RETRANSFER AND SHUTDOWN

When utility power source voltage has been restored,

electrical loads may be transferred back to that

source and the generator can be shut down as fol-

lows:

• Verify that utility power supply voltage to the trans-

fer switch has been positively turned OFF, using

whatever means provided (such as utility main line

circuit breaker).

• Set the generator’s main circuit breaker to its OFF

or OPEN position.

• Let the generator engine run at no-load for a few

minutes, to stabilize internal unit temperatures.

• On the generator console, set the AUTO/OFF/

MANUAL switch to OFF. Wait for engine to come to

a complete stop.

• For transfer to UTILITY position, refer to the

Owner’s Manual of the particular transfer switch.

• Turn on the utility power supply to the transfer

switch, using whatever means provided (such as a

utility main line circuit breaker). The utility power

source now powers the loads.

3.6 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.

3.7 WEEKLY EXERCISE CYCLE

The engine control board will start and run the gen-

erator once every seven days for approximately 12

minutes. If utility should fail during this exercise

period, the engine control board will transfer the load

to the generator output and continue to run until util-

ity returns.

On the day, and at the time of day chosen for the gen-

erator to exercise, set the weekly exercise cycle as fol-

lows:

1. Place the AUTO/OFF/MANUAL switch in the

AUTO position.

2. Press and hold the “Set Exercise” switch for three

seconds, then release.

At this time all five red LEDs will flash for approxi-

mately 10 seconds, then the engine will start and run

for it’s 12 minute exercise period, then shut down.

The generator will now start and run each week at the

same time.

If DC power to the control board is lost, the weekly

exercise setting will be lost. This is indicated by all

five red LEDs continually flashing. In this state the

generator will still start and run in manual mode, or

automatically start and run if UTILITY is lost while in

Auto mode, but it will not perform a weekly exercise

cycle.

If a failure occurs while running in this mode, the five

red LEDs will stop flashing, the individual fault LED

will turn on and the engine will shut down. Once the

AUTO/OFF/MANUAL switch has been switch to OFF,

the individual fault LED will turn OFF and the five

red LEDs will begin flashing to show exercise has still

not been set.

Figure 3.2 - “Set Exercise” Switch

BAT.

USE

HAR

EXER

TIME

MAN

USE

MAIN

16 Generac®Power Systems, Inc.

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 switch.

4. Inspect exhaust system.

5. Check engine ignition system.

6. Check fan belts.

B. ONCE EVERY SIX MONTHS

1. Test Engine Safety Devices (low oil pressure, low

coolant level, high coolant temperature).

C. ONCE ANNUALLY

1. Test engine governor. Adjust or repair, if needed.

2. Clean, inspect generator.

3. Flush cooling system.

D. FIRST 100 OPERATING HOURS

1. Change engine oil and oil filter. (After initial

change, service engine oil and filter at 150 oper-

ating hours or 6 months, whichever comes first.)

2. Retorque cylinder head. (See Torque Specs,

Section 1.13.)

3. Retorque intake and exhaust manifold. (See

Torque Specs, Section 1.13.)

E. EVERY 500 OPERATING HOURS

1. Service air cleaner.

2. Check starter.

3. Check engine DC alternator.

4.2 COOLING SYSTEM

Air intake and outlet openings in the generator com-

partment must be open and unobstructed for contin-

ued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to shut down. (See Section 6 for installation drawings

and vent locations.)

The exhaust system parts from this product get

extremely hot and remain hot after shutdown.

High grass, weeds, brush, leaves, etc. must

remain clear of the exhaust. Such materials may

ignite and burn from the heat of the exhaust

system.

4.3 OVERLOAD PROTECTION FOR

ENGINE DC ELECTRICAL SYSTEM

Engine cranking, start up and running are controlled

by a solid state Engine Controller circuit board.

Battery voltage is delivered to that circuit board via a

15 amp fuse. These overcurrent protection devices

will open if the circuit is overloaded.

If a circuit breaker opens or a fuse element

melts, find the cause of the overload before

resetting the circuit breaker or replacing the

fuse.

4.4 CHECKING FLUID LEVELS

4.4.1 CHECK ENGINE OIL

Check engine crankcase oil level (Figure 4.1) at least

every 20 hours of operation, or prior to use.

• Remove oil dipstick and wipe dry with a clean,

lint-free cloth.

• Install oil dipstick, then remove again.

• Oil should be between FULL and ADD marks.

• If oil level is below the dipstick ADD mark, remove

oil fill cap. Add the recommended oil to bring oil

level up to the FULL mark. DO NOT FILL ABOVE

THE “FULL” MARK. See Section 1.14 for recom-

mended oils.

Figure 4.1 - Oil Dipstick and Oil Fill Cap

4.4.2 BATTERY FLUID

Check battery electrolyte fluid at least once weekly.

Fluid should cover separators in all battery cells. If

fluid level is low, add distilled water to cover tops of

separators. DO NOT USE TAP WATER IN BATTERY.



DIP

FIL

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Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Generac®Power Systems, Inc. 17

4.4.3 ENGINE COOLANT

Check coolant level in coolant recovery bottle. See

Specifications, Section 1.10.

• 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 pressure cap. Replace cap, if necessary.

To have pressure cap tested, contact an authorized

Generac Service Dealer. Inspect cooling system

and coolant recovery system for leaks.

4.5 MAINTENANCE OWNER/

OPERATOR CAN PERFORM

4.5.1 CHECK ENGINE OIL LEVEL

Refer to “Checking Fluid Levels” in Section 4.4.

4.5.2 CHECK BATTERY

• Check battery fluid level each week as outlined

under “Check Fluid Levels”.

• Check battery cables for condition, tightness, cor-

rosion or damage. Clean, tighten or replace as

necessary.

4.5.3 EXERCISE SYSTEM

Start the generator engine at least once every seven

days and let it run at least 20 minutes. See Section

3.6, “Weekly Exercise Cycle”.

4.5.4 INSPECT COOLING SYSTEM

• Inspect engine cooling system at least once each

month.

• Check hoses for damage, deterioration, leaks, etc.

Correct any discrepancies found.

• Check hose clamps for tightness.

4.5.5 CHECK ENGINE COOLANT LEVEL

See “Checking Fluid Levels” in Section 4.4.

4.5.6 PERFORM VISUAL INSPECTION

Complete a thorough visual inspection of the entire

engine-generator monthly. Look for obvious damage,

loose, missing or corroded nuts, bolts and other fas-

teners. Look for fuel, oil or coolant leaks.

4.5.7 INSPECT EXHAUST SYSTEM

Inspect the exhaust system at least once every three

months. Check all exhaust system pipes, mufflers,

clamps, etc. for condition, tightness, leaks, security,

damage.

4.5.8 CHECK FAN BELT

• Inspect fan belts every three months. Replace any

damaged, deteriorated, worn or otherwise defec-

tive belt.

• Check fan belt tension. Thumb pressure, exerted

midway between pulleys, should deflect about 3/8

to 5/8 inch. Adjust belt tension as required.

4.5.9 INSPECT ENGINE GOVERNOR

Visually inspect electronic governor.

Do not attempt to adjust the governor. Only

qualified service facilities should adjust the

governor. Excessively high operating speeds are

dangerous and increase the risk of personal

injury. Low speeds impose a heavy load on the

engine when adequate engine power is not

available and may shorten engine life. Correct

rated frequency and voltage are supplied only

at the proper governed speed. Some connected

electrical load devices may be damaged by

incorrect frequency and/or voltage. Only quali-

fied service technicians should adjust the gov-

erned speed.

4.5.10 CHANGING ENGINE OIL

Refer to maintenance performed by authorized service

facilities for engine oil and filter change frequencies.

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 its retaining

clip.

4. Turn OIL FILTER (Figure 4.2) counterclockwise

and remove. Dispose of old filter.

5. Apply light coating of new engine oil to seal of new

oil filter. Install FILTER and tighten by hand only.

DO NOT OVERTIGHTEN.

6. Remove OIL FILL CAP. Add recommended oil (see

SPECIFICATIONS). DO NOT FILL ABOVE THE

DIPSTICK “FULL” MARK. Crankcase oil capacity

is 4.0 U.S. quarts (3.8 liters).

After refilling the crankcase with oil, always

check oil level on dipstick. NEVER OPERATE

ENGINE WITH OIL BELOW THE DIPSTICK “ADD”

MARK.



DANGER



Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

18 Generac®Power Systems, Inc.

7. Start engine and check for oil leaks.

Figure 4.2 - Oil Filter

4.5.11 CHANGING THE ENGINE AIR CLEANER

To replace the engine air cleaner, (part number

059402), remove the air cleaner cover and replace

the air filter making sure it is positioned properly

before reattaching the cover (Figure 4.3).

Figure 4.3 – Engine Air Cleaner

See the “Service Schedule,” Section 6, for air cleaner

maintenance.

4.5.12 SPARK PLUGS

Reset the spark plug gap or replace the spark plugs

as necessary. See Section 6.

1. Clean the area around the base of the spark plugs

to keep dirt and debris out of the engine. Clean by

scraping or washing using a wire brush and com-

mercial solvent. Do not blast the spark plugs to

clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is

questionable. See the “Service Schedule,” Section

6, for recommended inspection.

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 1.06-1.16 mm (0.042-

0.046 inch) by carefully bending the ground elec-

trode (Figure 4.4).

Figure 4.4 – Setting the Spark Plug Gap

4.5.13 COOLANT CHANGE

Every year, have Authorized Service Facility drain,

flush and refill the cooling system. See SPECIFICA-

TIONS (Section 1.10) for cooling system recommen-

dations.

4.6 MISCELLANEOUS MAINTENANCE

4.6.1 CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible.

Dirt and moisture that accumulates on internal gen-

erator windings have an adverse effect on insulation

resistance.

Periodically clean generator exterior surfaces. A soft

brush may be used to loosen caked on dirt. Use a

vacuum system or dry, low pressure air to remove

any accumulations of dirt. The generator is housed

inside an all-weather enclosure, clean the enclosure

with a soft, damp cloth or sponge and water.

Once each year, have the generator cleaned and

inspected by an Authorized Service Dealer. That deal-

er will use dry, low pressure air to clean internal

windings. Parts inside the control console should be

cleaned and inspected at this time as well.

Finally, have the insulation resistance of stator and

rotor windings checked. If insulation resistances are

excessively low, the generator may require drying.



IL FILTE

Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

SET PLUG GAP AT 1.06-1.16 mm

(0.042-0.046 inch)

Generac®Power Systems, Inc. 19

4.6.2 BATTERY

All lead-acid storage batteries discharge when not in

use. Refer to specific instructions and warnings 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.

• Battery electrolyte fluid is an extremely caustic

sulfuric solution that can cause severe burns. DO

NOT permit fluid to contact eyes, skin, clothing,

painted surfaces, wiring insulation, etc. If any bat-

tery fluid is spilled, flush the affected area with

clear water immediately.

• Always wear safety glasses, rubber apron and

gloves when handling a battery.

• Batteries give off explosive hydrogen gas while

charging. The gas can form an explosive mixture

around the battery for several hours after charging.

Any spark, heat or flames can ignite the gas and

cause an explosion which can shatter the battery,

causing blindness or other serious injury.

4.6.3 BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule,” Section 6. The following procedure

should be followed for inspection:

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

Storage batteries give off explosive hydrogen

gas. This gas can form an explosive mixture

around the battery for several hours after

charging. The slightest spark can ignite the gas

and cause an explosion. Such an explosion can

shatter the battery and cause blindness or

other injury. Any area that houses a storage

battery must be properly ventilated. Do not

allow smoking, open flame, sparks or any spark

producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caustic

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 the fluid is spilled, flush

the affected area immediately with clear water.

Do not use any jumper cables or booster bat-

tery to crank and start the generator engine. If

the battery has completely discharged, remove

it from the generator for recharging.

Be sure the AUTO/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 same number and

the type of battery that follows:

NOTE:

The BCI number should be located directly

on the battery.



DANGER



Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

BCI Group No. CCA

26/26R 525 @ 0 deg. F

27 600 @ 0 deg. F

PERIODIC REPLACEMENT PARTS

Part Name Generac’s Part Number

Oil Filter # 0E7180

Radiator Cap # 046627

Air Cleaner # 0C8127

Spark Plug # 0E7079

20 Generac®Power Systems, Inc.

Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

4.7 SCHEDULED MAINTENANCE

Following is a recommended maintenance schedule for Generac small standby and residential generator sets. The

established intervals in the schedule are the maximum recommended when the unit is used in an average service

application. They will need to be decreased (performed more frequently) if the unit is used in a severe application.

Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to deter-

mine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1An early inspection of the generator set to ensure it is ready to operate when required and to identify any poten-

tial problem areas.

Performed monthly or following each 10 hours of operation of the unit and requires approximately .5 man-

hours per unit to complete.

This inspection may be performed by the end user providing the following safety steps are taken to prevent

the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance:

• Disable the generator set from starting and/or connecting to the load by setting the control panel

AUTO-OFF-MANUAL switch to the “OFF” position.

• Remove the control panel fuse.

• Turn off the battery charger.

• Remove the negative battery cable.

The battery charger must be turned off BEFORE 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.

2A break-in service inspection of the generator set to ensure it is ready to operate and carry the load when

required, and to identify any potential problem areas.

Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of

the unit and requires approximately 2.5 man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

3An operational inspection of the generator set to ensure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5

man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

4A mid-level inspection of the generator set to ensure it is ready to operate and carry the load when required,

and to identify any potential problem areas.

Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0

man-hours per unit to complete.

This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge

to accomplish and should be performed only by an authorized Generac Service Dealer.

Generac®Power Systems, Inc. 21

Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4

Tasks Recom- Task Required Task Required Task Task

mended Comp. to be done Comp. to be done Comp. Required Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-

monthly Initials) Break-in Initials) annually Initials) Annually Initials)

1. Disable the unit from

operating per the first page

warning.

2. Check the engine oil level.

Adjust as necessary.

3. Check the engine coolant

level. Adjust as necessary.

4. Check the engine coolant

thermal protection level.

Correct as necessary.

5. Check the natural gas or LP

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 the unit wiring for

loose connections,

corrosion, and damage.

Correct as necessary.

10. Check the engine

accessory drive belts for

wear, weather cracking,

and damage. Replace as

necessary.

11. Visually inspect the unit

looking for leaks, wear or

damage, loose connections

or components, and

corrosion. Correct as

necessary.

12. Test the engine and

transfer switch safety

devices. Correct and/or

adjust as necessary.

22 Generac®Power Systems, Inc.

Section 4 — Maintenance

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Maintenance Level 1 Level 2 Level 3 Level 4

Tasks Recom- Task Required Task Required Task Task

mended Comp. to be done Comp. to be done Comp. Required Comp.

to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date-

monthly Initials) Break-in Initials) annually Initials) Annually Initials)

13. Initiate an automatic start

and transfer of the unit to

site load and exercise it for

at least 1 hour looking for

leaks, loose connections

or 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 engine fuel

filter(s) on diesel engine

driven units and re-prime

the fuel system.

19. Check the engine spark

plugs on gas engine driven

units. Clean and re-gap or

replace as necessary.

20. Perform a 5 minute no-load

operational run of the unit

looking for any post service

problems.

21. Return the unit to standby

setup for operation when

required.

Generac®Power Systems, Inc. 23

Section 5 — Troubleshooting

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

TROUBLESHOOTING POINTS

PROBLEM CAUSE CORRECTION

Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse.

2. Loose or corroded or defective 2. Tighten, clean or replace

battery cables. battery cables as necessary.

3. Defective starter contactor. 3. Replace contactor.

4. Defective starter motor. 4. Replace starter motor.

5. Dead or Defective Battery. 5. Remove, change or replace battery.

6. 4 amp fuse blown. 6. Replace fuse.

Engine cranks, but won't start 1. Out of fuel. 1. Replenish fuel.

2. Fuel solenoid (FS) is defective 2. Replace solenoid.

3. Open Wire #14 from Engine Control 3. Reconnect wire.

circuit board.

4. Spark plugs defective. 4. Clean, regap or replace plugs.

Engine starts hard, runs rough. 1. Flame arrestor (air cleaner) plugged or 1. Clean or replace as needed.

damaged.

2. Plugged fuel line. 2. Unclog fuel line.

3. Defective spark 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.

7. Defective Low Coolant Level Switch 7. Replace Switch.

AUTO/OFF/MANUAL Switch at, 1. Defective AUTO/OFF/MANUAL switch 1. Replace switch.

OFF engine continues to run 2. Open/disconnected wire #15A between 2. Reconnect/close wire.

AUTO/OFF/MANUAL switch and Control

Module circuit board.

3. Defective Control Module circuit board 3. Replace board.

No AC output from generator. 1. Check main line circuit breaker. 1. Reset to ON or CLOSED.

2. Check circuit breaker & fuses. 2. Reset and replace, if necessary.

3. Transfer switch set to NORMAL position 3. Set to GENERATOR position.

4. Generator internal failure. 4. Contact an Authorized Generac

facility.

5. Thermal circuit breaker open. 5. Auto-reset - Wait five minutes and

attempt restart.

BRUSH ASSEMLY

(

GENERATOR

)

MATI

LTA

E RE

LAT

BULKHEAD CONNECTOR 1

(

ENGINE

)

CIRCUIT BREAKER

(

EXCITATION

)

FUSE, BAT. POWER

(

15A AGC TYPE

)

CIRCUIT BREAKER

(

OUTPUT

)

DIODE

[

FIELD BOOST

]

BATTERY

HAR

F1 -

B2 -

B1 -

AVR -

BA -

END

TRAL BL

OCK

TERMINAL BL

TRANSFORMER 1

(

56 VA 240/16 VAC

)

TRANSFORMER 2

(

6 VA 240/16 VAC

)

INTER

NNE

T. TERMINAL BL

OCK

FUSE, B/C

(

4A AGC TYPE

)

O/O

MAN

WIT

ET EXER

WIT

TB1

TR1

TR2 -

LEGEND

{

CONT.

F2 -

RL1 -

NB -

RELAY 1

B/C

CUS

MER

NNE

TRA

- REM

TART

TILITY FR

M T

TILITY FR

M T

- REM

TART

RAN

FER RELAY

RAN

FER RELAY

TRAN

FER

WIT

183

14A

L LI

TED

NLE

ALL WIRE

ARE 1

300

224

THERWI

E N

TED A

SIZE

(

AWG

)

TAT

TR1

183

224A

224

14A

224

TR2

TB1

AVR

RL1

24 Generac®Power Systems, Inc.

Section 6 - Electrical Data

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Wiring Diagram — Engine — Drawing No. 0E6199-F

Generac®Power Systems, Inc. 25

LEGEND

[

CONT.

-2

-1

IM -

ELE

VERN

R A

GROUND

(

SENSING/LOW AMP

)

GROUND

(

POWER/HIGH AMP

)

HAR

E ALTERNAT

TARTER

NTA

CONNECTOR 1

(

ENGINE

)

DRIVER ELE

VERN

LEN

12VD

BATTER

ND1

ND2

END

ALT -

BAT -

JUNCTION 2

(

ON PCB

)

IL PRE

SSU

WIT

IGNITION MODULE

(

ON DISTRIBUTOR

)

COO

LANT TEMP

WIT

JUNCTION BLOCK

(

RUN POWER

)

COO

LANT LEVEL

WIT

JUNCTION 1

(

ON PCB

)

TARTER M

NITI

ALT

224

14A

RED

BLK

ND2

L LI

TED

NLE

ALL WIRE

ARE 1

300

THERWI

E N

TED A

BAT

SIZE

(

AWG

)

771

GOV

771

Section 6 - Electrical Data

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Wiring Diagram — Engine — Drawing No. 0E6199-F

26 Generac®Power Systems, Inc.

Section 6 - Electrical Data

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Electrical Schematic — Engine — Drawing No. 0E6200-B

MATI

LTA

E RE

LAT

BRUSH ASSEMLY

(

GENERATOR

)

CIRCUIT BREAKER

(

EXCITATION

)

PLA

ED PHA

E EX

ITATI

DPE -

ALTERNAT

TAT

ALTERNAT

R R

BATTERY

HAR

DIODE

[

FIELD BOOST

]

CIRCUIT BREAKER

(

OUTPUT

)

BATTERY

HAR

E WINDIN

AR -

END

AVR -

BA -

B2 -

B1 -

TR2 -

TRANSFORMER 2

(

6 VA 240/16 VAC

)

FUSE, BAT. POWER

(

15A AGC TYPE

)

SWITCH

SET EXERCISE

SWITCH

AUTO/OFF/MANUA

FUSE, B/C

(

4A AGC TYPE

)

TERMINAL BLOCK

INTERCONNECT.

TRANSFORMER 1

(

56 VA 240/16 VAC

)

TRAL BL

OCK

LEGEND

{

CONT.

RL1 -

TR1

NB -

F2 -

F1 -

RELAY 1

TRAN

FER

WIT

CUS

MER

NNE

V 1-PHA

DPE

NNE

183

224A

TR1

224

TR2

AVR

RL1

14A

224

14A

15E

15A

ULKHEAD CONNECTOR

(

BC1

)

FF P

ITI

Generac®Power Systems, Inc. 27

Section 6 - Electrical Data

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Electrical Schematic — Engine — Drawing No. 0E6200-B

IM -

LEGEND

[

CONT.

CONNECTOR (C1)

SWITCH

HIGH COOLANT TEM

RANKIN

NTA

HAR

E ALTERNAT

CONNECTOR 1

(

ENGINE

)

DRIVER ELE

VERN

LEN

ID F

ELE

VERN

R A

END

ALT -

CONTACTOR

STARTER MOTO

IGNITION MODULE

(

ON DISTRIBUTOR

)

WIT

H L

IL PRE

SSU

SENSOR

COOLANT LEVE

NITI

TARTER M

14A

224

GOV

14A

1-1

224

1-1

771

ALT

771

449

12V BATTERY

(

)

RED

BLA

(

)

CONTACTOR

WIRE

ARNE

INE

FOO

BLOCK

INE

TARTER

INE

EAR BEARIN

ARRIER

28 Generac®Power Systems, Inc.

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Mounting Base — Drawing No. 0E6266-E

ITEM PART NO. QTY. DESCRIPTION

1 0E5822 1 BASEFRAME, WELDMENT 3.0L FORD

2 052860 4 NUT FLANGED HEX M12-1.75

3 052251 4 DAMPENER VIBRATION 40 BLUE

4 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZNC

5 052252 4 DAMPENER VIBRATION

6 052259 4 WASHER FLAT M12

7 052891 4 SCREW HHC M12-1.75 X 80 G8.8

8 0536210213 1 ASSY GRNDWIRE 11"/3/8 & 5/16 LUG

9 074906 1 SCREW HHTT M6-1.0 X 20 BP

10 047411 1 SCREW HHC M6-1.0 X 16 BP

11 055414 1 LUG SLDLSS #2-#8 X 17/64 CU

12 026850 2 WASHER SHAKEPROOF EXT 1/4 STL

13 022097 1 WASHER LOCK M6-1/4

14 022473 2 WASHER FLAT M6-1/4 ZINC

15 049813 1 NUT HEX M6 -1.0 G8 YEL CHR

16 0A1694 4 1-1/2" BUTTON PLUG

17 052213 1 SCREW HHC M10-1.25 X 20 G8.8

18 025507 3 WASHER SHAKEPROOF EXT 7/16 STL

20 027482 2 WASHER SHAKEPROOF EXT 5/16 STL

21 022129 1 WASHER LOCK M8-5/16

22 045771 1 NUT HEX M8-1.25 G8 YEL CHR

23 * 051756 1 SCREW HHC M10-1.5 X 20 G8.8

24 * 046526 1 WASHER LOCK M10

25 * 022131 1 WASHER FLAT 3/8-M10 ZINC

26 * 055934M 1 CLAMP VINYL .75 X .343 Z

30 077483 REF. BATT 12VDC 75-AH 26

058665 REF. BATT 12VDC 90-AH 27F

31 038804D 1 CABLE BATT RED #4 X 20.00

32 038805AA 1 CABLE BATT BLK #4 X 30"

33 021991 1 EARTH STRAP

34 049814 1 SCREW HHC M10-1.5 X 25 G8.8

35 046526 2 WASHER LOCK M10

36 022131 1 WASHER FLAT 3/8 ZINC

37 075763 1 BOOT BATTERY CABLE

38 050331 1 BATTERY POST COVER BACLK -

39 050331A 1 BATTERY POST COVER RED +

40 0A4010 2 SCREW HHC M8-1.25 X 60 G8.8 FT

41 052858 2 NUT TOP LOCK FL M8-1.25

42 061902 1 HOLD DOWN BATTERY

43 059473 1 HOLD DOWN BATTERY

44 049820 2 NUT HEX LOCK M8-1.25 NY INS

* NOT SHOWN-USED TO HOLD DOWN I/N 32

Section 8 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Mounting Base — Drawing No. 0E6266-E

Generac®Power Systems, Inc. 29

30 Generac®Power Systems, Inc.

TATE

AM I

N NEAR

IDE

TATE

AM I

N FAR

H DETAIL

EE LAT

DETAIL

"B"

"A"

RE A

WN.

UIRE INSULATION.

YPI

F R

F PANEL THAT

ADIAT

(

2-PLCS

)

"B"

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Compartment — Drawing No. 0E8519-B

Generac®Power Systems, Inc. 31

ITEM PART NO. QTY. DESCRIPTION

1 0E8418 1 DUCT INTAKE MID AL

2 0E8414 1 DUCT DISCHARGE RH AL

3 0E8413 1 DUCT DISCHARGE LH AL

4 0C2454 62 SCREW TH-FRM M6-1 X 16 N WA Z/JS

5 0E8402 1 BAFFLE REAR BOTTOM

6 0E5902 1 POST CORNER LH REAR HSB AL

7 0E5903 1 POST CORNER RH REAR HSB AL

8 0E8387 1 BAFFLE REAR TOP

9 0E5912 2 DOOR SIDE HSB AL

10 0E5911 1 SUPPORT RH SIDE HSB AL

11 089961 2 FOAM STRIP 3/4" WIDE X 3/16" THK (40" LG)

12 0A2115 4 WASHER NYLON .257

13 0E8404 1 BRACKET STIFFENER RH FRONT

14 0D2538A 1 HINGE LIFT OFF TYPE B KNUCKLE

15 0D2538 1 HINGE LIFT OFF TYPE B PIN

16 043116 8 SCREW HHC M6-1.0 X 12 G8.8

17 022097 12 WASHER LOCK M6-1/4

18 022473 12 WASHER FLAT 1/4-M6 ZINC

19 0E7570 2 GAS SPRING

20 0E7571 4 BALL STUD GAS SPRING MOUNT

21 070015 4 NUT HEX 5/16-18 LOCK

22 0E7662 4 SCREW WING M6-1.00 X 25

23 0D2537A 1 HINGE LIFT OFF TYPE A KNUCKLE

24 0D2537 1 HINGE LIFT OFF TYPE A PIN

25 0D2023 2 TRIM VINYL SELF GRIPPING (91" LG)

26 0E7869 2 BRACKET STIFFENING BACK

27 0E8001 1 MUFFLER BOX

28 0E5913 1 ROOF HSB AL

29 0E5915 1 BRACE FRONT TOP HSB AL

30 0D3037A 1 LATCH 1/4 TURN NONLOCKING

31 0C7781 2 PAWL DOOR HSB

32 0E5910 1 SUPPORT LH SIDE HSB AL

33 0E8052 1 MUFFLER BOX TOP

34 0D3037 1 LATCH QUARTER TURN LOCKING

35 0E5900 1 POST CORNER LH FRONT HSB AL

36 0E5901 1 POST CORNER RH FRONT HSB AL

37 0E5916 1 BRACE FRONT BOTTOM HSB AL

38 0E8415 1 DUCT DISCHARGE MID AL

39 026850 4 WASHER SHAKEPROOF EXT 1/4 STL

40 0912970063 2 ASSY GRD WIRE 99HSB

41 0912970064 2 ASSEMBLY,BASE-DOOR GROUND WIRE

42 049813 2 NUT HEX M6 X 1.0 G8 YEL CHR

43 0E8416 1 DUCT INTAKE LH AL

44 0E8417 1 DUCT INTAKE RH AL

45 0E8665 1 BRACKET STIFFENER LH FRONT

46 0D2023 1 TRIM VINYL SELF GRIPPING (165.5"LG)

50 * 0E8441 1 KIT INSULATION 3.0L HSB

51 0E7829A 1 AI ROOF PANEL 1

52 0E7829B 2 AI DOOR PANEL

53 0E7829P 4 AI CORNER POST PANEL 1

54 0E7829R 2 AI CORNER POST PANEL 2

55 0E7829S 1 AI SUPPORT LH PANEL

56 0E7829T 1 AI SUPPORT RH PANEL

57 0E7829N 2 AI ROOF PANEL 2

58 0E7829U 2 AI BRACE PANEL

59 078115 8 WASHER SELF LOCKING DOME

* ALL ITEMS NOTATED WITH "AI" ARE COMPONENTS OF 0E8441

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Compartment — Drawing No. 0E8519-B

32 Generac®Power Systems, Inc.

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Control Panel — Drawing No. 0E7118-K

Generac®Power Systems, Inc. 33

ITEM PART NO. QTY. DESCRIPTION

1 0E7195 1 CONTROL BOX HSB

2 0E7196 1 COVER FRONT PANEL HSB

3 0E7197 1 COVER TOP PANEL HSB

4 0E7193 1 DECAL WARNINGS HSB

5 0E7194 1 DECAL CONTROLS HSB

6 0E4494 1 SWITCH ROC DPDT ON-OFF-ON

7 082573 1 SWITCH ROCKER DPST 125V SPD

8 032300 2 HOLDER FUSE

9 022676 1 FUSE 15A X AGC15

10 067682B 1 FUSE 4A SLO BLO GLASS

11 060015 1 FITTING CONDUIT 90D 3/8"

12 054199 1 DECAL DANGER HIGH VOLTAGE

13 0C2657 1 TRANSFRMR 16V 6VA

14 099076 1 TRANSFORMER 16V 56VA

15 040213 2 PCB SUPPORT SNAP-IN 1/4"

16 0E9668 1 ASSY PCB HSB CONTROLLER

17 067680 1 ASSY VOLTAGE REGULATOR 60HZ

18 0E6875A 1 RELAY 12VDC C FORM W/DIODE

19 0E6881 * REF. SOCKET RELAY

20 0C5139 * REF. CONN DEUTSCH RECEPT GY/FLN

21 0C5142 * REF. CONN DEUTSCH RECEPT WDGE

BLKHD

22 0E3161 1 ASSY BOSCH GOV DRIVER

23 054450 1 CIRCT BRK 5.5 X 1 ETA 46-500-P

24 0D5070A 1 ASSY 2A 12V UL BATTERY

CHARGER

25 0E2514 1 FITTING CONDUIT STR 1-1/2"

26 0A9457 1 DECAL NEUTRAL

27 0E7539 1 DECALCUSTOMER CNNCTN XFER

28 046357 * REF. BLOCK TERM 20A 6 X 6 X 1100V

29 0D3719B 1 DECAL CUSTOMER CNNCTN

30 057073 1 JUNCTION BLOCK 3/8-16

31 0E7283 1 CB 0150A2P240V S QN2 LL

0E3628 1 CB 0200A2P240V S QN2 LL

32 0E3664 1 BASE QN CIRCUIT BREAKER

33 0E7539A 1 DECAL TB1 HSB CONTROL PANEL

34 0D4698 * REF. BLOCK TERM 20A 6 X 3 X 1100V

35 0E7252 1 BRACKET CB 221.5 X 102

36 0C1229 1 DECAL WARNING ELECTRICAL

SHOCK

ITEM PART NO. QTY. DESCRIPTION

37 0C1127 1 DECAL AVR COVER

38 0A1441B 1 COVER PLATE, AVR

39 0E7128 1 HARNESS CNTRL PNL (NOT

SHOWN)

40 0E7358 8 SCREW PPPH HI-LO #4-24 X 3/8

41 074908 6 SCREW HHTT M5-0.8 X 10 BP

42 0C5141 1 CONN DEUTSCH GASKET 8/12 POS

43 0C2699 11 SCREW PHTT #6-32 X 3/8 ZYC

44 0C2323 4 SCREW PHTT #6-32 X 5/8 ZYC

45 022155 15 WASHER LOCK #6

46 0C2265 4 SCREW PHTT M4-0.7 X 12 ZYC

47 022264 4 WASHER LOCK #8-M4

49 020911 2 SCREW PPHM M5-0.8 X 30 ZINC

50 066849 2 SCREW HHTT M5-0.8 X 16

51 022152 4 WASHER LOCK #10

52 023897 3 WASHER FLAT #10 ZINC

53 051716 2 NUT HEX M5-0.8 G8 YEL CHR

54 090388 2 SCREW HHTT M6-1.0 X 12 ZINC

55 042568 4 SCREW HHC M6-1.0 X 20 G8.8

56 022097 8 WASHER LOCK M6-1/4

57 022473 6 WASHER FLAT 1/4-M6 ZINC

58 0441140187 2 WIRE ASSY 3" X (2) 3/16" TABS

59 070370 2 WASHER MICA .203

60 023762 1 WASHER SHAKEPROOF EXT #10

STL

61 055444 1 HEATSINK

62 030468 1 WASHER STEP NYLON .20

63 049939 1 RECTIFIER MSC 12A 600V 1N1206R

64 022158 1 NUT HEX #10-32 STEEL

65 022985 1 WASHER FLAT #6 ZINC

66 038750 2 SCREW HHC M6-1.0 X 30 G8.8

67 0A2115 4 WASHER NYLON .257

68 0C2454 4 SCREW THF M6-1 X 16 N WA Z/JS

69 0F6146 1 HANG TAG 2 WIRE START (NOT

SHOWN)

* ITEMS INCLUDED AS PART OF I/N 39

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Control Panel — Drawing No. 0E7118-K

WIRE

GROUND

REAR

PPE

BAFFLE

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Engine — Drawing No. 0E8170-N

34 Generac®Power Systems, Inc.

ITEM PART NO. QTY. DESCRIPTION

1 0E6202 1 ENGINE 3.0L FORD (RD) (MAKE)

2 0E8824 2 STAMPING ENG FOOT 3.0L FORD

3 0E8963 1 PULLEY CRANKSHAFT 3.0L FORD

4 0E9020 1 BRACKET DC ALT 3.0L FORD

5 0A1232 1 D.C. ALTERNATOR ASSY

6 0A7801B 1 PULLEY POLY-V 82 OD.

7 0A5610 1 BRACKET ALTERNATOR

8 0E6308 1 PULLEY WATERPUMP 3.0L FORD

(RD)

9 ** 0E7804 1 HARN IGNITION 3.0L FORD (NOT

SHOWN)

10 0D3488F 1 BELT SERPENTINE 38.35

11 0E7996 1 CLUTCH COOLING FAN FORD

12 0E8006 1 FAN 18" 7 BLADE STEEL ECS

14 035606 1 SENSOR HI COOLANT SHUTDOWN

15 0E0561 1 ASSY WATER LEVEL SENSOR C/E

16 0E6729 1 STARTER DELCO-REMY 12V

17 0E6703 1 COVER FLYWHEEL ACCESS 3.0L

HSB

18 0E6667 1 ENGINE ADAPTER 3L FORD

19 0E5048 1 FLEXPLATE 3.0L FORD

20 035579 1 BUSHING REDUCER 1/4 TO 1/8

21 0A8584 1 SWITCH OIL PRESSURE 10PSI

2POL

24 083896 6 WASHER LOCK 1/4-M6 SS

25 084929 6 WASHER FLAT 1/4 SS

26 055597 1 SCREW HHC M12-1.75 X 85 G8.8

27 077996 1 CAP HOSE

28 057823 1 CLAMP HOSE #10 .56-1.06

29 056739 1 RELAY SOLENOID 12VDC PNL MNT

30 047411 6 SCREW HHC M6-1.0 X 16 G8.8

31 022097 6 WASHER LOCK M6-1/4

32 022473 6 WASHER FLAT 1/4-M6 ZINC

33 047411 4 SCREW HHC M6-1.0 X 16 G8.8

34 040976 4 SCREW SHC M8-1.25 X 20 G12.9

35 022129 24 WASHER LOCK M8-5/16

36 022145 22 WASHER FLAT 5/16-M8 ZINC

37 045771 1 NUT HEX M8-1.25 G8 YEL CHR

38 051756 6 SCREW HHC M10-1.5 X 20 G8.8

39 049821 16 SCREW SHC M8-1.25 X 30 G12.9

40 059980 4 SCREW HHC M10-1.5 X 25 G10.9

41 0D5417 REF. SCREW HHC M10-1.0 X 25 G10.9

42 046526 18 WASHER LOCK M10

43 022131 11 WASHER FLAT 3/8-M10 ZINC

44 059982 4 SCREW SHC M12-1.75 X 45 G10.9

45 098780 2 SCREW HHC M12-1.75 X 65 G8.8

46 051769 3 WASHER LOCK M12

ITEM PART NO. QTY. DESCRIPTION

47 049808 2 WASHER FLAT M12

48 051430 6 WASHER SHAKEPROOF INT 1/2

49 045773 3 NUT HEX M12-1.75 G8 YEL CHR

50 0E6203C 1 COIL IGNITION 3.0L FORD

51 0E6679 2 BRACKET IGN COIL 3.0L FORD

53 049226 7 WASHER LOCK M5

54 091526 3 SCREW PPHM M5-0.8 X 12 ZNC

55 093278 4 SCREW HHTT M5-0.8 X 25 BP

56 0E6517 1 HARNESS ENGINE 3.0L FORD HSB

(NOT SHOWN)

57 0E7163 2 GASKET EXHAUST 3.0L FORD

58 0E5527 2 MANIFOLD EXHAUST 3.0L FORD

60 0E7202 2 HEAT SHIELD 260 X 80 HOT

61 085296 6 SCREW HHC 1/4-20 X 1/2 SS

62 0E6203D 1 WIRE SET 3.0L FORD (NOT

SHOWN)

63 057772 1 WASHER NYLON .565

64 057765 1 ADAPTER M14-1.50 X 3/8 NPT

65 043790 1 BARBED EL 90 3/8 NPT X 3/8

66 069860C 1 HOSE OIL DRAIN ASSY 21"

67 057822 2 CLAMP HOSE #8 .53-1.00

68 069811 1 CAP HEX 1/4 NPT BRASS

69 026925 1 PLUG STD PIPE 3/8 STEEL SQ HD

70 * 065852 1 SPRING CLIP HOLDER .37-.62

71 * 0A2111 1 SCREW SWAGE 10-32 X 5/16 Z/YC

72 057073 1 JUNCTION BLOCK 3/8-16

73 066849 2 SCREW HHTT M5-0.8 X 16

74 022152 2 WASHER LOCK #10

75 0E7880 2 CLIP SPARK PLUG 3P SCREW-

MOUNT (NOT SHOWN)

76 0E7880A 4 CLIP SPARK PLUG 2P SCREW-

MOUNT (NOT SHOWN)

77 0E7880B 1 CLIP SPARK PLUG 3P FREEHANG

(NOT SHOWN)

78 055934C 1 CLAMP VINYL .5 X .406 Z

79 027482 1 WASHER SHAKEPROOF EXT 5/16

STL

80 0E8940 1 SPACER FLEXPLATE HSB

81 0A7387 2 SCREW HHC M10-1.5 X 40 G10.9

82 022097 4 WASHER LOCK M6-1/4

83 022473 4 WASHER FLAT 1/4-M6 ZINC

84 055934H 2 CLAMP VINYL .62 X .406 Z

85 0F5966 1 REFLECTIVE HEAT SHIELD 3.0L FD

86 022985 3 WASHER FLAT #6 ZINC

87 036261 3 RIVET POP .125 X .275 SS

* NOT SHOWN-USED TO HOLD OIL DRAIN ASSEMBLY.

** NOT SHOWN

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Engine — Drawing No. 0E8170-N

Generac®Power Systems, Inc. 35

INE

FRAME

WATER

"A"

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Radiator — Drawing No. 0E8528-B

36 Generac®Power Systems, Inc.

ITEM PART NO. QTY. DESCRIPTION

1 0E9947 1 RADIATOR R-IN,L-OUT 658X489X49

2 0E6340 1 VENTURI 3.0L FORD HSB

3 0E8531 2 SIDE SUPPORT RADIATOR HSB

4 0E6398 1 TUBE LOWER RAD 3.0L FORD HSB

5 0E6397 1 HOSE UPPER RAD 3.0LFORD HSB

6 080713 1 BRACKET COOLANT TANK

7 076749 1 TANK COOLANT RECOVERY

8 049814 4 SCREW HHC M10-1.5 X 25 G8.8

9 022131 8 WASHER FLAT 3/8-M10 ZINC

10 046526 4 WASHER LOCK M10

11 045772 4 NUT HEX M10-1.5 G8 YEL CHR

12 035685 4 CLAMP HOSE #28 1.32-2.25

13 0E8562 1 FAN GUARD HSB

14 058443 4 SCREW CRIMPTITE 1/4-20 X 5/8

15 0C2454 9 SCREW TH-FRM M6-1 X 16 N WA Z/JS

17 048031C 1 CLAMP HOSE BAND 1/4

18 029032 1 HOSE 9/32 ID (30" LG)

20 046627 1 CAP RADIATOR

21 069811 1 CAP HEX 1/4 NPT BRASS

22 065852 1 SPRING CLIP HOLDER .37-.62

23 0A2111 1 SCREW SWAGE 10-32 X 5/16 Z/YC

24 052250 2 TAPE FOAM 1 X 1 (27" LG)

25 035461 1 BARBED STR 1/4 NPT X 3/8

26 0C7649 1 CLAMP HOSE .38-.87

27 069860C 1 HOSE OIL DRAIN ASSY 21"

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Radiator — Drawing No. 0E8528-B

Generac®Power Systems, Inc. 37

38 Generac®Power Systems, Inc.

"B"

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Fuel System — Drawing No. 0E8190-C

Generac®Power Systems, Inc. 39

ITEM PART NO. QTY. DESCRIPTION

1 * --------- 1 WELDMENT MOUNTING BASE

2 075580 1 FLANGE FUEL INLET

3 0E7691 1 ASSY REGULATOR 3.0L NG OR LPV

4 039253 2 SCREW HHC M8-1.25 X 20 G8.8

5 022145 2 WASHER FLAT 5/16 ZINC

6 022129 4 WASHER LOCK M8-5/16

7 045771 2 NUT HEX M8-1.25 G8 YEL CHR

8 042907 2 SCREW HHC M8-1.25 X 16 G8.8

9 0C2454 2 SCREW TH-FRM M6-1 X 16 N WA Z/JS

10 026307 1 ELBOW 90D STREET 3/4

11 0E1056 1 FUEL HOSE ASSY NAT.GAS/L.P.V.

12 0E6584 1 BRACKET REGULATOR 3.0L FORD HSB

13 057823 2 CLAMP HOSE #10 .56 - 1.06

14 059194 1 HOSE 5/8 ID LPG & NG (20" LG)

15 044117 1 BARBED STR 3/8 NPT X 5/8

16 0D1509 1 DECAL INLET PRESSURE

17 050279 1 DECAL FUEL INLET NG

18 0E6123 1 INTAKE ADAPTER 3.0L FORD-BOSCH

19 0E6586 1 GASKET BOSCH 32

20 0E4395 1 ACTUATOR BOSCH 32 GOVERNOR

21 057753B 1 HOSE 1.5 ID X 2 LG 20R4

25 047487 4 SCREW SHC M6-1.0 X 18 G12.9

26 022097 8 WASHER LOCK M6-1/4

27 051751 4 SCREW HHC M6-1.0 X 50 G8.8

28 035685 2 CLAMP HOSE #28 1.32-2.25

29 057823 4 CLAMP HOSE #10 .56-1.06

30 047290 1 HOSE 3/8 ID SINGLE BRAID (305mm [12"] LONG)

31 047290 1 HOSE 3/8 ID SINGLE BRAID (432mm [17"] LONG)

32 0A4121 1 VALVE PCV

33 0E6609 1 GROMMET ROCKER COVER 3.0LFORD

34 049099 1 BARBED EL 90 3/8 X 3/8 PLST

35 ** 055934M 1 CLAMP VINYL .75 X .343 Z

36 ** 047411 1 SCREW HHC M6-1.0 X 16 G8.8

37 ** 022097 1 WASHER LOCK M6-1/4

38 ** O22473 1 WASHER FLAT 1/4-M6 ZINC

39 0E9295A 1 ASSY THROTTLE 27MM

40 0E6382A 1 VENTURI HOLDER W/32MM ACTUATOR

41 0E7121 1 O-RING 47.625 ID X 2.38 WIDTH

42 0E6376A 1 VENTURI, 27 ID THROTTLE W/CHOK

43 0F2119 1 O-RING 45.63 ID X 2.62 WIDTH

* SHOWN IN OTHER VIEW

** NOT SHOWN-USED TO HOLD #31 IN PLACE

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Fuel System — Drawing No. 0E8190-C

40 Generac®Power Systems, Inc.

LOC

KTI

LOC

KTI

EAD

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Alternator — Drawing No. 0F5092-A

Generac®Power Systems, Inc. 41

ITEM PART NO. QTY. DESCRIPTION

1 0F1659A 1 ROTOR 390 15KW 1P DIRECT HSB (2.5L FORD)

0F1657A 1 ROTOR 390 20KW 1P DIRECT HSB (2.5L FORD)

0F1655A 1 ROTOR 390 25KW 1P DIRECT HSB (2.5L FORD)

0F5073A 1 ROTOR 390__30AD1 HSB TECUM

0E7413A 1 RTR 390 40KW 1P DIRECT HSB

2 0F1660A 1 STR 390 15AD HSB (382MM LONG) (2.5L FORD)

0F1658A 1 STR 390 20AD HSB (382MM LONG) (2.5L FORD)

0F1656A 1 STR 390 25AD HSB (382MM LONG) (2.5L FORD)

0F5074A 1 STR-390__30AD1 HSB TECUM

0E7412A 1 STR-390--40AD HSB (433MM LONG)

3 0E5706 1 REAR BEARING CARRIER 390/DRCT

4 0E5048 REF FLEXPLATE 3.0L FORD

0E5048B REF FLEXPLATE 2.5L FORD

0E5048A REF FLEXPLATE HSB 3.9L CHRYSLER

5 0E6668 1 FLYWHEEL ASSY 3.0L HSB LG GEAR

6 0E6076 1 REVCOR FAN 10.75 X 2 W/PRESS DIS

7 046526 8 WASHER LOCK M10

8 051755 4 SCREW HHC M10-1.5 X 16 G8.8

9 04576100BK 4 STUD M14-2.0 X 490 G5 ZINC (3.0L FORD & 2.5L FORD)

04576100BF 4 STUD M14-2.0 X 540 G5 ZINC

10 043123 4 WASHER LOCK M14

11 051779 4 NUT HEX M14-2.0 G8 YEL CHR

12 0E7587 1 ASSY BRUSH HOLDER 390/HSB

13 023365 1 WASHER SHAKEPROOF INT #8

14 0C3993 4 SCREW HHTT M4-0.7 X 25 BP

15 057192 4 SCREW SHC M10-1.5 X 30 G12.9

16 0A2602 1 WASHER FLAT .688 ID X 3.25 OD

17 042558 1 KEY SQ 3/8 X 1 STEEL

18 0A2601 1 SCREW HHC M16-2.0 X 45 G8.8

19 022264 4 WASHER LOCK #8-M4

20 038150 4 WASHER FLAT #8 ZINC

21 077043F 1 CONDUIT FLEX 1-1/4" (30" LG - 3.0L FORD & 3.9L CHRYSLER)

077043F 1 CONDUIT FLEX 1-1/4" (18" LG - 2.5L FORD)

ROTOR REPLACEMENT PARTS

30 047248 1 BALL BEARING-45 MM

31 070892 1 SLIP RING -MACHINED-

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Alternator — Drawing No. 0F5092-A

ITEM PART NO. QTY. DESCRIPTION

1 0E8616 1 MUFFLER 7" X 9" X 21" 2.5" IN &

OUT

2 0E8727 1 PIPE MUFFLER OUT

3 0E8822 1 WYE PIPE 2-1/2"

4 0E8821 2 EXHAUST ELBOW HSB (2"-2-1/2")

5 0E6465 1 EXHAUST PIPE LH 3.0L FORD HSB

6 0E6465A 1 EXHAUST PIPE RH 3.0L FORD HSB

7 0E5914 1 BRACKET MUFFLER 3.0L FORD

HSB

8 0E8726 2 STRAP MUFFLER

9 0E0170 2 EXHAUST BLANKET 750MM

10 036797 2 BOLT U 5/16-18 X 2.25

11 080762 4 BOLT U 3/8-16 X 2.62

ITEM PART NO. QTY. DESCRIPTION

12 0E8816 2 EXHAUST FLANGE 2" PIPE

13 085917 4 WASHER LOCK 3/8 SS

14 0D2611 4 SCREW HHC 3/8-16 X 1-3/4 SS

15 039253 2 SCREW HHC M8-1.25 X 20 G8.8

16 022145 5 WASHER FLAT 5/16-M8 ZINC

17 022129 7 WASHER LOCK M8-5/16

18 045771 3 NUT HEX M8-1.25 G8 YEL CHR

19 0C2454 4 SCREW TH-FRM M6-1 X 16 N WA

Z/JS

20 039288 1 SCREW HHC M8-1.25 X 55 G8.8

21 044149 2 GASKET EXHAUST RING

22 022259 4 NUT HEX 5/16-18 STEEL

MANIF

MPARTMEN

MANIF

42 Generac®Power Systems, Inc.

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Muffler — Drawing No. 0E8766-C

Generac®Power Systems, Inc. 43

ITEM PART NO. QTY. DESCRIPTION

1 0E5193 1 PLATE AIR CLEANER ADAPTER

2 0E8200 1 TUBE AIR INTAKE 3.0L FORD

3 0E8201 1 BRACKET AIR INTAKE 3.0L FORD

4 036434 1 BOLT U 5/16-18 X 2.09

5 0E0519A 1 ADAPTER CARBURETOR W/PVC

CONN

6 0C8127 1 ELEMENT AIR CLEANER

7 0A5547 1 COVER - AIR CLEANER

8 062974 1 STUD TH 1/4-20 X 4-1/2 G2 ZNC

9 022127 1 NUT HEX 1/4-20 STEEL

10 037561 1 NUT WING 1/4-20 NYLK

ITEM PART NO. QTY. DESCRIPTION

11 049226 8 WASHER LOCK M5

12 049815 4 SCREW HHC M5-0.8 X 16 G8.8

13 052619 4 SCREW HHC M5-0.8 X 20 G8.8

14 051713 4 WASHER FLAT M5

15 051716 4 NUT HEX M5-0.8 G8 YEL CHR

16 022131 2 WASHER FLAT 3/8-M10

17 046526 2 WASHER FLAT M10

18 051755 2 SCREW HHC M10-1.5 X 16 G8.8

19 022145 2 WASHER FLAT 5/16-M8 ZINC

20 022129 2 WASHER LOCK M8-5/16

21 022259 2 NUT HEX 5/16-18 STEEL

Section 7 - Exploded Views and Parts

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Air Cleaner — Drawing No. 0E8189-A

44 Generac®Power Systems, Inc.

Section 8 — Installation Diagram

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Installation Diagram — Drawing No. 0E8696

Generac®Power Systems, Inc. 45

Section 9 — Notes

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

Part No. 0F5093 Revision B (05/05/05) Printed in U.S.A.

Section 10 – Warranty

QUIETSOURCE

™

Liquid-cooled 30 kW Generators

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR QUIETSOURCE™

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource

generator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its

option, repair or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty

Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by

the nearest Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are

to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Quietsource prepackaged emergency

automatic standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase

and maintenance is required):

Engine - All Components

Alternator - All Components

Transfer System - All Components

All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat

Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Quietsource generators that utilize non-Generac replacement parts.

• Quietsource generators utilizing non-Generac automatic transfer switches.

• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by

Generac Power Systems.

• Any Quietsource generators used as rental or trailer mounted applications.

• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where

utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with

all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty

will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,

freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or

replacement of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit

warranty period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC

MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some

states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO

EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH

DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of

incidental or consequential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC®POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190 Revision (2.05)

Generac Power Systems 004917 3 Users Manual 0F5093RevB

004917-3 to the manual 0e9dd389-9310-4b21-81ea-63f3bc227ef7

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