Generac 5251 - Manuals - manualsarea.com

Page 2 - INTRODUCTION; is intended exclusively for outdoor; READ THIS MANUAL THOROUGHLY; DANGER; After this heading, read explanatory statements; CONTENTS; Engine; OPERATION AND MAINTENANCE; AUTHORIZED

INTRODUCTION Thank you for purchasing this model of a compact, high performance, air-cooled, engine-driven genera-tor designed to automatically supply electrical power to operate critical loads during a utility power fail-ure. This unit is factory installed in an all-weather, metal enclosure that is...

Page 3 - Table of Contents; Air-cooled Generators; Section 2 – Post Installation Start-up

Table of Contents Air-cooled Generators 1 Introduction ........................Inside Front Cover Read This Manual Thoroughly ........................ IFC Contents .......................................................... IFC Operation and Maintenance ............................ IFC How to Obtain ...

Page 4 - Owner’s Manual; Despite the safe design of this generator,; GENERAL HAZARDS

2 Study these SAFETY RULES carefully before install-ing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused ...

Page 5 - Installation must always; EXPLOSION HAZARDS; STANDARDS INDEX; IMPORTANT SAFETY INSTRUCTIONS

3  ELECTRICAL HAZARDS  All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera-tion. Avoid contact with ba...

Page 6 - outdoor installation only.; SYSTEMS; Section 1 — General Information

DANGER  Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regu-lations. 1.1 UNPACKING/INSPECTION After unpacking, carefully inspect the contents for damage. This standby generator set is ready for installa- ...

Page 9 - CONSUMPTION; Gaseous fuels such as natural gas and liquid

7 1.6 SYSTEM SET LED The “System Set” LED is lit when all of the following conditions are true: 1. The AUTO/OFF/MANUAL switch is set to the AUTO position. 2. The utility voltage being supplied to the unit is being sensed by the PCB. If the utility sense volt-age is not connected to the unit or if it...

Page 10 - Figure 1.4 – Demand Regulator

1.9 RECONFIGURING THEFUEL SYSTEM 1.9.1 7 KW, 410CC ENGINE To reconfigure the fuel system from NG to LP, follow these steps (Figure 1.4): NOTE: The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pres-sure of 10 to 12 inches of water column (0.36 to 0.43 psi) to th...

Page 12 - Figure 1.9 – Generator Clearances; The engine exhaust fumes contain carbon mon-; sure is intended for indoor use only; If the AUTO/OFF/MANUAL switch is not set to its; BATTERY REQUIREMENTS

10 Install the generator as close as possible to the fuel supply, to reduce the length of piping. Install the generator as close as possible to the transfer switch. REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION. The genset must be installed on a level surface. The base frame mus...

Page 13 - Figure 1.10 – Battery Cable Connections

11 Figure 1.10 – Battery Cable Connections NOTE: In areas where temperatures regularly fall below 10° F (-12° C) it is recommended that a pad type battery heater be installed to aid in cold climate starting (see Specifications). NOTE: The generator is equipped with a battery trickle charger that is ...

Page 14 - INITIAL; Never operate the engine with the oil level; Do not attempt manual transfer switch opera-; CHECKS; The transfer switch is now electrically “hot.”; Proceed with caution! Generator power voltage

12 2.1 BEFORE INITIAL START-UP NOTE: These units have been run and tested at the fac-tory prior to being shipped and do not require any type of break-in. Before starting, complete the following: 1. Set the generator’s main circuit breaker to its OFF (or OPEN) position. 2. Set the generator's AUTO/OF...

Page 15 - Section 2 — Post Installation Start-up and Adjustments; TESTS UNDER LOAD

13 Section 2 — Post Installation Start-up and Adjustments Air-cooled Generators 2.4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied, proceed as follows: 1. Set generator’s main circuit breaker to its OFF (or OPEN) position. 2. Turn OFF all breakers on the load cent...

Page 16 - Figure 2.1 — 7kW Fuel Regulator; Do not make any unnecessary adjustments.; A service fee may be charged for this adjustment.; ENGINE GOVERNOR ADJUSTMENT; The engine must be OFF to perform steps 1 and; Figure 2.2 — Engine Governor Adjustment; Unit

14 1. Turn off utility power to the main distribution panel in the house. This can be done by switching the service main breaker to the off or open posi-tion. 2. Allow the generator to start. Before loading the generator, confirm that the No Load Frequency, with the roof open and door off, is set to...

Page 17 - UNITS; Figure 2.3 – Voltage Adjustment Potentiometer; Figure 3.1 – Generator Control Panel; POSITION; With the switch set to AUTO, the engine may

15 4. Connect a frequency meter across the generators AC output leads. 5. Turn the primary adjust screw to obtain a fre- quency reading of 61.5 Hertz. Turn the secondary adjust screw to obtain a frequency of 62.5 Hz. 6. When frequency is correct at no load, check the AC voltage reading. If voltage i...

Page 18 - OPERATION; TRANSFER; Do not attempt to activate the transfer switch

16 3.1.4 CHOKE OPERATION 1. 990 engines have an electric choke in the air box that is automatically controlled by the electronic control board. 2. 530 engines have an electric choke on the divider panel air inlet hose that is automatically con-trolled by the electronic control board. 3. 410 engines ...

Page 19 - Section 3 — Operation; Figure 3.2 – Manual Transfer Switch Operation; SETTING THE EXERCISE TIMER

17 Section 3 — Operation Air-cooled Generators 4. Use the manual transfer handle inside the trans- fer switch to move the main contacts to their STANDBY position, i.e., loads connected to the standby power source (Figure 3.2). 5. To crank and start the engine, set the AUTO/OFF/ MANUAL switch to MANU...

Page 20 - Figure 3.3 – Low Oil Pressure and; Oil Filter

18 Low speed exercise will be handled as follows: 1. The standard start sequence will be initiated.2. The unit will run at 2,400 RPM.3. If utility is lost during exercise, the controller will do the following: • Wait 10 seconds for utility to return.• If utility returns within 10 seconds, continue t...

Page 21 - BATTERY; Figure 4.1 – Generator Control Panel; Remove the dipstick and wipe it dry with a clean; the; Oil Dipstick and Fill; Section 4 — Maintenance

19 3.6.5 RPM SENSOR FAILURE During cranking, if the board does not see a valid RPM signal within three (3) seconds, it will shut down and latch out on RPM sensor loss. During running, if the RPM signal is lost for one full second the board will shut down the engine, wait 15 seconds, then re-crank th...

Page 22 - CHANGING THE ENGINE OIL; Any attempt to crank or start the engine before; Figure 4.5 – Oil Drain Hose and Filter

20 Figure 4.3 — Oil Dipstick and Fill, 10kW Oil Dipstick Oil Fill Figure 4.4 — Oil Dipstick and Fill, 13kW and 16kW Oil Dipstick Oil Fill 4.3 CHANGING THE ENGINE OIL 4.3.1 OIL CHANGE INTERVALS See the "Service Schedule" section. 4.3.2 ENGINE OIL RECOMMENDATIONS Use all season SAE 5W-30 synth...

Page 23 - box and around edges.; Figure 4.6 — 7 kW, Engine Air Cleaner Location; GENERATORS; Figure 4.7 — 10kW Engine Air Cleaner; Air Filter; Air Cleaner; Clean the area around the base of the spark

21 4.4 CHANGING THE ENGINE AIR CLEANER 4.4.1 7, 13, AND 16KW GENERATORS See Figures 1.1 and 1.2, for the location of the air cleaner. Use the following procedures (Figure 4.6, 7kW; Figure 4.8, 13/16kW): 1. Lift the roof and remove the door.2. Turn the two screws counterclockwise to loosen.3. Remove ...

Page 24 - Figure 4.9 – Setting the Spark Plug Gap; MAINTENANCE; To check valve clearance:

22 3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 inch) for 7 and 10kW; and 1.02 mm (0.040 inch) for 13/16 kW by carefully bending the ground electrode (Figure 4.9). Figure 4.9 – Setting the Spark Plug Gap 4.6 BATTERY MAINTENANCE The battery should be inspect...

Page 25 - SYSTEM; Figure 4.11 – Cooling Vent Locations; The exhaust from this product gets extremely; ATTENTION AFTER SUBMERSION; must

Remove spark plug wires and position wires away from plugs. Remove spark plugs.Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a larg...

Page 27 - SERVICE SCHEDULE; ATTENTION: It is recommended that all service work

25 Section 4 — Maintenance Air-cooled Generators 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Authorized Dealer. SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dea...

Page 28 - TROUBLESHOOTING GUIDE; Problem Cause; *Contact the nearest Authorized Dealer for assistance.; Section 5 — Troubleshooting

5.1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary. 3. Defective starter contactor. (7 ...

Page 29 - Section 6 — Notes

Page 32 - Section 7 — Mounting Dimensions

30 Section 7 — Mounting Dimensions Air-cooled GeneratorsDrawing No. 0F9424

Page 33 - Section 8 — Electrical Data

31 NEUTRALCONNECTIONINSIDE SWITCH XB NO C1 COM XA VR1 NC NC COM C2 VR2 NO TR 194 23 1 7 4 7 9 3 6 9 F2 CIRCUIT 10 BLACK (MAIN 1) 12Vdc TRANSERCOIL RED (MAIN 2) NEUTRAL (WHITE) NEUTRAL (WHITE) 23 OPEN F1 N2 N1 194 23 BLACK RED N2 N1 194 240VAC TO TO GENERATOROUTPUT PANEL MAIN DISTRIBUTION LC-CIRCUIT ...

Page 44 - Material

42 Section 9 — Exploded Views and Parts Lists Air-cooled GeneratorsEnclosure – Drawing No. 0F9431-C SHEET METAL PAINT/MATERIAL CODE LEGEND The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the correct ...

Page 45 - Section 9 — Exploded Views and Parts Lists

43 ITEM PART NO. QTY. DESCRIPTION 1 0F9653 1 PAD, 24 X 48” WITH MOUNTING HOLES 2 045771 4 NUT HEX M8-1.25 3 022129 4 WASHER LOCK 5/16 022129 5 WASHER LOCK 5/16 (7KW) 4 022145 8 WASHER FLAT 5/16 5 043107 4 SCREW HHC M8-1.25 X 25 6 090388 15 SCREW TAPTITE M6-1.0 X 12 7 0D3700 24 NUT, LOCKING FLANGE M6...

Page 63 - ITEM PART

61 Section 9 — Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine – Drawing No. 0F9422-B ITEM PART NO. QTY. DESCRIPTION 1 0F8186 1 ADAPTOR, ENGINE 2 0F5540H 1 STATOR 3 0C9934H 1 ROTOR 4 0F7774A 1 CARRIER, REAR BEARING 5 0C8096 1 FAN, 8” CURVED BLADE 6 0F6591 1 MUFFLER 7 0F8078 1...

Page 70 - CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT

68 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System Warranty on your new engine. * In California, new utility, and lawn and garden...

Page 71 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Section 10 – Warranty

69 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/de...

Page 72 - GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR; WARRANTY SCHEDULE; THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Part No. 0G0492 Revision A (06/16/06) Printed in U.S.A. Section 10 – Warranty Air-cooled Generators GENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOW For a period of two (2) years from the date of sale, or start-up by Authorized/Certified Genera...