Generac Power Systems 00847-1 Operating & Installation Manual

Brand: Generac Power Systems

Model: 00847-1

Category: Power generators

Type: Operating & Installation Manual

POWER SYSTEMS, INC.

APS 6.0 24V DC AIR-COOLED

AUXILIARY POWER SYSTEM

OPERATING & INSTALLATION MANUAL

Model: 00847-1

This Manual Should Remain With The Unit.

Generac®Power Systems, Inc.

INTRODUCTION

READ THIS MANUAL THOROUGHLY

If you do not understand any portion of this manual,

contact Generac or the nearest Generac Authorized

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 you to

special instruction about a particular operation that

may be hazardous if performed incorrectly or care-

lessly. Observe them carefully. Their definitions are as

follows:

After this heading, read instructions that, if not

strictly complied with, will result in personal

injury, death 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.

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.

CONTENTS

This manual contains pertinent owner’s information,

including warranty, electrical diagrams, exploded

views and lists of repair parts, for the model 00847-1.

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 Dealer. Normal maintenance service and

replacement of maintenance parts are the responsibili-

ty of the owner/operator and, as such, are not consid-

ered 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 ensure a

minimum number of problems and keep operating

expenses at a minimum. See a Generac Authorized

Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

simply contact a Generac Authorized Dealer for

assistance. Service technicians are factory-trained

and are capable of handling all service needs.

When contacting a Generac Authorized Dealer or the

factory about parts and service, always supply the

complete model number and serial number of the

unit as given on its data decal, which is located on the

generator.

Model No. ____________ Serial No. ______________



DANGER

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Table of Contents

Generac APS 6.0 DC Auxiliary Power System

Generac®Power Systems, Inc. 1

Introduction ......................Inside Front Cover

Read This Manual Thoroughly ......................IFC

Contents ........................................................IFC

Operation and Maintenance............................IFC

How to Obtain Service ....................................IFC

Safety Rules ......................................................2

Section 1 – General Information..................4

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

1.2 Operation and Maintenance ........................5

1.3 Safety... ........................................................5

1.4 Generator Applicability ................................5

1.5 Specifications ..............................................5

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

1.6.1 Reconfiguring the Fuel System ........6

1.6.2 Recommended Fuel ..........................6

Section 2 – Installation ..................................6

2.1 Installation ..................................................6

2.1.1 Unit Location....................................6

Section 3 – Operation ....................................7

3.1 Operation ....................................................7

3.2 Electrical Connections..................................7

3.2.1 Starting Battery ................................7

3.2.2 DC Output Power ............................8

3.2.3 Alarms and Utility Input ..................8

3.3 Electrical Panel ............................................9

3.4 Electrical Operation ....................................9

3.4.1 Voltage Regulator..............................9

3.4.2 Fine and Course Voltage Adjust......10

3.4.3 Under Frequency Adjust ................10

3.4.4 Current Limit Adjust......................10

3.4.5 Field Set Up Procedure ..................10

3.4.6 Engine Control, Alarm and

Shutdown PCB ..............................11

3.4.7 Manual Operation ..........................11

3.4.8 Automatic Operation ......................11

3.4.9 Off Position ....................................11

3.4.10 Remote Start ..................................11

3.4.11 Remote Stop ..................................11

3.4.12 Alarms............................................11

3.4.13 Start Battery Voltage Alarm ............12

3.4.14 Switch Not In Auto Alarm ..............12

3.4.15 General Failure Alarm ....................12

3.4.16 Engine Run Alarm..........................12

3.4.17 Protective Shutdown Circuits ........12

3.4.18 Utility Source Voltage ....................12

3.4.19 Battery Charger ..............................12

3.4.20 Exercise Timer ..............................12

3.5 Setting the Exerciser ....................................13

3.5.1 Display ............................................13

3.5.2 Exercise Times ................................13

3.6 Push Buttons ............................................13

3.6.1 Up Arrow ↑....................................13

3.6.2 Down Arrow ↓................................13

3.6.3 Time (Time/Alarm Toggle) ..............13

3.6.4 On/Off (Alarm Select Toggle) ..........14

3.6.5 Day ................................................14

3.7 Programming Examples ............................14

3.7.1 Example 1 — Change Time

From Sunday 9:00 AM to

Wednesday 2:00 PM ......................14

3.7.2 Example 2 — Set Exerciser

On for 14 Minutes Mon.-Fri.

at 10:00 AM ..................................14

Section 4 – Maintenance ............................14

4.1 General Maintenance..................................14

4.1.1 25 Hour Break In Period................14

4.1.2 25 Hour Check Up ........................14

4.1.3 Attention Required After

Submersion....................................14

4.1.4 Effects of Moisture and Dirt ..........15

4.1.5 Engine Oil Requirements................15

4.1.6 Battery............................................15

4.1.7 Every Six Months ..........................15

4.2 Engine Protective Devices ..........................16

4.2.1 Automatic Low Oil Pressure

Shutdown ......................................16

4.2.2 High Temperature Switch ................16

4.2.3 Checking Engine Oil Level..............16

4.3 Change Engine Oil......................................16

4.4 Change Oil Filter ........................................17

4.5 Service Engine Air Cleaner ........................17

4.6 Complete Engine Tune Up..........................17

4.7 Inspect Cooling System of Generator ........17

Section 5 – Electrical Data ..........................18

Section 6 – Exploded Views and

Parts Lists ..................................20

Section 7 – Major Features and

Dimensions................................34

Section 8 – Notes ..........................................35

Section 9 – 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 fun-

damental rules or precautions.

Generac cannot possibly anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals

affixed to the unit are, therefore, not all-inclusive. If you

use a procedure, work method or operating technique

Generac does not specifically recommend, you must

satisfy yourself that it is safe for you and others. You

also must make sure the procedure, work method or

operating technique that is chosen does not render the

generator 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 operate or maintain 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 the

installation, initial start-up and maintenance of this

equipment is carried out by a Generac Authorized

Dealer.

• 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 not do anything

that might render the unit unsafe or in noncompli-

ance with the aforementioned codes, standards, laws

and regulations.

• The engine exhaust fumes contain carbon monoxide,

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 ventilating

air is critical in any room or building housing the gen-

erator to prevent buildup of explosive gases and to

ensure correct generator operation. Do not alter the

installation or permit even partial blockage of ventila-

tion provisions, as this can seriously affect safe oper-

ation 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 you are

physically or mentally fatigued.

• Inspect the generator regularly, and promptly repair

or replace all worn, damaged or defective parts using

only factory-approved parts.

DANGER

Important Safety Instructions

Generac APS 6.0 DC Auxiliary Power System

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 and potential operators of this equipment.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be

followed during installation and maintenance of the generator and batteries.

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

• 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 electri-

cal shock. Utility power delivers extremely high and

dangerous voltages to the transfer switch as does the

standby generator when it is in operation. Avoid con-

tact with bare wires, terminals, connections, etc.,

while the unit is running. Ensure all appropriate cov-

ers, guards and barriers are in place before operating

the generator. If work must be done around an oper-

ating 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) requires the

frame and external electrically conductive 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 condition 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 to.

• 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 utility electric system while in oper-

ation. 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 automatically 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 automatic

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

rope or board, to free the victim from the live con-

ductor. 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 stor-

age and handling of fuels. Inspect the unit’s fuel sys-

tem 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

Generac APS 6.0 DC Auxiliary Power System

4 Generac®Power Systems, Inc.

1.1 GENERATOR IDENTIFICATION

Section 1 — General Information

Generac APS 6.0 DC Auxiliary Power System

Engine Air Intake

Oil Fill

Oil Check/Dipstick

Oil Drain Hose Oil Filter

Air Filter

(Located Behind Panel)

Air Intake

Terminal Block

Control Board

Air Intake

Voltage Regulator

Control Panel

Fuel Hose

Programmable Exerciser

Exhaust Air Out

DC Output Terminals

Air Intake

Rectifier and

Filter Air Outlet

Muffler

Lifting Point

(use bolt on lifting plates)

Lifting Point

1.2 OPERATION AND MAINTENANCE

It is the operator’s responsibility to perform all safe-

ty checks; to make sure that all maintenance for safe

operation is performed promptly; and to have the

equipment checked by an Authorized Dealer periodi-

cally. We strongly recommend that the operator read

this Owner’s Manual and thoroughly understand all

instructions before using this equipment.

It is the owner/operator’s responsibility for the fol-

lowing:

• Perform all safety checks.

• For safe operation, promptly perform all mainte-

nance.

• Have equipment checked periodically.

1.3 SAFETY

Before attempting to use the generator set, carefully

read GENERAL SAFETY RULES inside the cover of

this Manual. Comply strictly with these RULES to

prevent accidents and damage to equipment and/or

property. We suggest that copying and posting GEN-

ERAL SAFETY RULES in potential hazard areas.

Stress safety to all operators and potential operators

of this equipment.

1.4 GENERATOR APPLICABILITY

This generator has been designed and manufactured

for supplying electrical power. You should not modify

the generator or use it for any application other than

for what it was designed. If there are any questions

pertaining to its application, write or call the factory.

Do not use the unit until a competent authority has

advised you.

1.5 SPECIFICATIONS

Engine

Type ........................................................Generac GT 990

Rated HP..................................................30 at 3600 RPM

Displacement ..........................................................992 cc

Cylinder Block ..............Aluminum With Cast Iron Sleeves

Cooling Method ................................................Air Cooled

Type of Governor ........................Mechanical Fixed Speed

Air Cleaner ............Paper Element with Foam Pre-Cleaner

Starter ......................................................12V DC Electric

Ignition System ............Solid State with Flywheel Magneto

Spark Plug Gap ................................0.030 Inch (0.8 mm)

Recommended Spark Plugs ................Champion RC12YC

Fram Autolite 65

Oil Sump Capacity ......................................1.5 US Quarts

Recommended Oil ....................................5W-30 Synthetic

Generator

Rated kW ......................................................................6.0

Output Voltage......................................27.2V DC Nominal

Output Current..........................................220A Full Load

Stator ..................................................6 Phase - Rectified

Rotor RPM ................................................................3600

Engine RPM ..............................................................2700

Weight ..................................................................550 lbs.

Length ................................................................1355 mm

Width....................................................................980 mm

Height ..................................................................730 mm

1.6 FUEL SYSTEM

The unit has been designed to be mounted above a

propane enclosure. A dividing plate has been sup-

plied to be placed under the unit to separate the gen-

erator from the propane tank. During installation it is

important that this dividing plate be positioned

beneath the generator and bolted into place.

The fuel supply line has been supplied with a bulk-

head fitting which should be attached to the dividing

plate with the locking nut provided (Figure 1.1).

Figure 1.1 — Propane Tank Connection

Once installed the bulkhead fitting will provide a

3/4”-16, 37° JIC fitting to which the propane tank can

be connected. The fuel pressure to the unit must be

regulated to 11-14” WC for the unit to perform as

designed.

With LP gas, use only the vapor withdraw type sys-

tem. This type of system uses the vapor formed above

the liquid fuel in the storage tank.

The engine has been fitted with a carburetion system

which meets the specifications of the 1997 California

Air Resources Board for tamer proof dual fuel sys-

tems. The unit will run on natural gas or propane fuel

and has been factory set to run on LP gas. Should the

primary fuel need to be changed to natural gas, then

the fuel system needs to be reconfigured (Figure 1.2

on page 6).

Section 1 — General Information

Generac APS 6.0 DC Auxiliary Power System

Generac®Power Systems, Inc. 5

6 Generac®Power Systems, Inc.

1.6.1 RECONFIGURING THE FUEL SYSTEM

To reconfigure the fuel system to run on natural gas,

follow these instructions (See Figure 1.2):

1. Loosen the hose clamp holding the fuel hose to

the 1/2” hose fitting.

2. Remove the hose from the hose fitting.

3. Remove the hose fitting from the regulator cast-

ing.

4. Remove the LP jet which is located below the hose

fitting inside the regulator casting.

5. Remove the natural gas jet from the holding sock-

et on the outside of the regulator casting.

6. Insert the natural gas jet in place of the LP jet and

place the LP jet into the holding socket.

7. Replace the hose fitting onto the regulator casting.

8. Replace the hose into the hose fitting.

9. Tighten the hose clamp to the hose fitting.

10. The unit is now configured to run on natural gas

fuel.

Figure 1.2 — Reconfiguring the Fuel System

1.6.2 RECOMMENDED FUEL

Recommended fuels should have a Btu content of at

least 1000 Btus per cubic foot for natural gas; or at

least 2520 Btus per cubic foot for LP gas. Ask your

fuel supplier for the Btu content of your fuel.

GASEOUS FUELS SUCH AS NATURAL AND LP

(propane) GAS ARE HIGHLY EXPLOSIVE. EVEN

THE SLIGHTEST SPARK CAN IGNITE SUCH

FUELS AND CAUSE AN EXPLOSION. NO LEAK-

AGE OF FUEL IS PERMITTED. NATURAL GAS,

WHICH IS LIGHTER THAN AIR, TENTS TO COL-

LECT IN HIGH AREAS. LP GAS IS HEAVIER

THAN AIR AND TENTS TO SETTLE IN LOW

AREAS.

2.1 INSTALLATION

This Owner’s Manual has been prepared under the

assumption that a competent, qualified technician

installed the generator. We also assume the installer

complied with all applicable codes, standards and

regulations pertaining to installation.

Owner/Operators must make sure to do nothing that

might render the installation unsafe or in noncompli-

ance with applicable codes, standards and instruc-

tions. They should be sure the unit has been installed

to allow adequate ventilation for cooling and exhaust

air.

2.1.1 UNIT LOCATION

The general APS 6.0 24V DC generator has been

designed specifically for use in the telecommunica-

tions industry. The unit is housed in a sound attenu-

ated weatherproof sheet metal enclosure for outside

use only.

During installation it is extremely important that cer-

tain considerations are taken to allow adequate ven-

tilation for cooling and exhaust air and access for

servicing the unit. Figure 2.1 shows the minimum

requirements to allow proper operation of the unit.

Figure 2.1 — Ventilation Requirements

The unit should never be installed up against brick

walls or in tight corners. For proper unit operation, it

is important that the hot exhaust air venting from the

rear of the enclosure does not recirculate into the

engine and control panel intakes. During installation,

ensure all vents and intakes are clear of any foreign

materials that might restrict air flow. This includes

the vents for the rectifier and filter assembly located

on the side of the unit (Figures 2.2 and 2.3).



DANGER



Section 2 — Installation

Generac APS 6.0 DC Auxiliary Power System

Hose Clamp Fuel Hose

1/2” Hose

Fitting

Natural Gas

Jet

12 VDC

Solenoid

THE ENGINE EXHAUST FROM THIS PRODUCT

CONTAINS CHEMICALS KNOWN TO THE STATE

OF CALIFORNIA TO CAUSE CANCER, BIRTH

DEFECTS, OR OTHER REPRODUCTIVE HARM.

THE GENERATOR ENGINE GIVES OFF DEADLY

CARBON MONOXIDE GAS THROUGH ITS

EXHAUST SYSTEM. THIS DANGEROUS GAS, IF

BREATHED IN SUFFICIENT CONCENTRATIONS,

CAN CAUSE UNCONSCIOUSNESS OR EVEN

DEATH. DO NOT OPERATE THE GENERATOR IF

THE EXHAUST SYSTEM IS LEAKING OR HAS

BEEN DAMAGED. SYMPTOMS OF CARBON

MONOXIDE POISONING ARE (a) inability to

think coherently; (b) vomiting; (c) twitching

muscles; (d) throbbing temples; (e) dizziness;

(f) headaches; (g) weakness and sleepiness. IF

YOU FEEL ANY OF THESE SYMPTOMS, MOVE

INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS

PERSIST, GET MEDICAL HELP.

Figure 2.2 — Roof Vents

Figure 2.3 — Rectifier and Filter Assembly Vents

3.1 OPERATION

This section of the manual will describe the operation

of the unit as a whole and in some detail various com-

ponents with which the customer will interface with.

The engine/alternator assembly is housed in its own

section of the enclosure. All service points for the

engine and alternator are accessible from the front of

the enclosure. I.E., oil fill/drain, oil filter, spark plugs,

air filter and for the alternator, brush access (see

Maintenance Section for Service Periods and

Procedures).

The alternator is driven by means of a pulley and

drive belt arrangement. The drive belt and pulleys are

warranted for the life of the generator. Drive belt ten-

sion was properly adjusted before the unit was

shipped from the factory. If there is a suspicion that

drive belt tension is incorrect, contact Generac or the

local service support contractor.

It is important that both air intakes for the engine

and alternator remain free from debris at all times.

3.2 ELECTRICAL CONNECTIONS

The generator has been designed to make all electri-

cal connections to the unit simple and easy.

3.2.1 STARTING BATTERY

A 12V DC automotive type battery with a cold crank-

ing capacity of 525 Amps should be placed in the bat-

tery tray on the right hand side of the control panel

enclosure. Positive and negative cables are provided

for connection to the battery (Figure 3.1).

Figure 3.1 — Battery Cables

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

nel away from batteries.



Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

Generac®Power Systems, Inc. 7

Battery Tray

Battery Cables

8 Generac®Power Systems, Inc.

When replacing the battery, use the following type of

battery: Group 26/26R 12-volt battery with a rating of

525 cold-cranking amps minimum at -17.8º C (0º F).

When using a maintenance-free battery, it is not nec-

essary to check the specific gravity or electrolyte level.

Have these procedures performed at the intervals

specified in the “Service Schedule.” A negative ground

system is used. Battery connections are shown on the

wiring diagrams. Make sure the battery is correctly

connected and terminals are tight. Observe battery

polarity when connecting the battery to the generator

set.

Do not dispose of the battery in a fire. The

battery is capable of exploding.

A battery presents a risk of electrical shock

and high short circuit current. The following

precautions are to be observed when working

on batteries:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery; and

• Disconnect charging source prior to connecting or dis-

connecting battery terminals.

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive.

The following procedures 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, immediately

flush thoroughly with water and seek medical

attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) or water. The bicar-

bonate 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

following procedures are to be followed:

• DO NOT SMOKE when near the battery;

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

• Discharge static electricity from your body before

touching the battery by first touching a grounded

metal surface.

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

you attach the cables and cause an explosion.

3.2.2 DC OUTPUT POWER

The DC output from the unit is taken from two 3/8”

terminals located along the bottom edge of the con-

trol panel. There is sufficient thread on these termi-

nals to add the customer power leads and extra lock

nuts without loosening the factory connections

should these connections become loose, ensure the

cables are routed exactly as supplied from the facto-

ry. A short on either of the output cables could dam-

age components within the unit (Figure 3.2).

Figure 3.2 — DC Output Connections

3.2.3 ALARMS AND UTILITY INPUT

The unit has a number of alarm outputs which can be

monitored via an external source to give information

on the status of the unit (see pages 11 and 12). These

alarm connections are located on the left hand side of

the control panel enclosure. Also on this connection

block are terminals for utility input. The unit

requires a 240V utility input to monitor. During

installation, alarms to be monitored and utility input

connections should be made at this connection block

(Figure 3.3).

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DANGER

Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

Generac®Power Systems, Inc. 9

Figure 3.3 — 12 Position Terminal Block

3.3 ELECTRICAL PANEL

The Electrical Panel, mounted at one end of the

enclosure contains all the electrical components for

proper unit operation (see Figure 3.4).

3.4 ELECTRICAL OPERATION

The engine runs at a speed of 2700 RPM and drives

the alternator at 3600 rpm, producing an AC 6 phase

voltage. This voltage is taken directly from the stator

windings and into two independent 3-phase bridge

rectifiers. The DC output from the rectifier is then fed

into an inductive-capacitive filter assembly designed

to reduce the AC ripple content of the DC output. The

output of the filter is then fed directly to the genera-

tor output terminals.

12 V DC fans assist in cooling both the rectifier and

filter during generator operation. During any inspec-

tion or service of the generator, the operation of both

fans should be checked and replaced if faulty.

The following section describes in some detail most

of the components the user may interface with.

3.4.1 VOLTAGE REGULATOR

A solid state voltage regulator (Figure 3.5). controls

the generator output by supplying an excitation cur-

rent to the rotor. By regulating the rotors excitation

current, the strength of its magnetic field is regulated.

This, in turn, controls the output voltage. To regulate

the field current to the rotor, the voltage regulator

must be connected to the customer DC Bus. This pro-

vides sensing voltage to the regulator. Figure 3.6

shows a simple schematic for the voltage regulator.

Figure 3.5 — Voltage Regulator

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Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

Figure 3.4 — Electrical Panel

Control PCB

12 VDC Fan Current Transformer

Smoothing

Capacitor

3-Phase Bridge

Rectifier

Ground TerminalHour Meter

Voltage

Regulator

10 Generac®Power Systems, Inc.

Figure 3.6 — Voltage Regulator Set Up

The voltage regulator will be set at the factory to pro-

vide the required output voltage. However, should

adjustment be required in the field, the regulator is

fitted with four adjustment potentiometers (Figure

3.7).

Figure 3.7 — Field Adjustment Points

NOTE:

Unnecessary adjustment of these potentiometers

by inexperienced personnel will result in the

impairment of the unit performance. Do not adjust

any pot without clear knowledge of its affect on

the generator.

3.4.2 FINE AND COURSE VOLTAGE ADJUST

These two potentiometers set the required output

voltage.

3.4.3 UNDER FREQUENCY ADJUST

This potentiometer allows the frequency at which the

voltage beings to drop off to be varied. This is one of

the devices built into this generator to protect the

engine from overload and potentially a burnout. If the

engine for some reason begins to overload, it will

slow down. Rather than the voltage regulator increas-

ing the excitation current at a set frequency (to main-

tain constant output voltage), the voltage regulator

will begin to lower the output voltage while maintain-

ing near constant speed (decreasing engine load).

3.4.4 CURRENT LIMIT ADJUST

Another protection device built into the generator is

that the potentiometer allows a maximum current

limit to be set. This is because the generator will be

connected to a bank of batteries. In a state of dis-

charge, the batteries will demand high charge cur-

rents far in excess of the rating of the generator. To

prevent overload, the output current is monitored via

a current transformer. The potentiometer has been

factory set for the output voltage to begin to drop off

at approximately 225 Amps DC in an attempt to

maintain a constant output current.

3.4.5 FIELD SET UP PROCEDURE

The following is the recommended procedure for

checking the output voltage on the generator. This

procedure should be performed after the unit has

been installed on site but BEFORE the unit is con-

nected to the Lucent Technologies Rectifier cabinet.

The voltage set point should be 26.2 VDC.

1. Attach two 12 volt automotive type batteries, con-

nected in series (to provide a 24V supply), to the

output terminals of the generator.

2. Attach a digital voltmeter to the output terminals

of the generator.

3. The voltmeter should be reading approximately

25V. If the batteries are fully charged, and the

voltmeter reads above 26.2V, then it will be nec-

essary to discharge the batteries. When a voltage

between 25V to 25.5V has been achieved, contin-

ue the setup.

4. Start the unit in the manual mode. The engine

will start and stabilize. After a delay of between

15 to 45 seconds, the voltage regulator will turn

on. This will be apparent in a sudden engine

sound change, and the voltmeter will be reading a

higher voltage than previously. This voltage is fac-

tory set at 26.2V. Confirm this, and if the voltage

is correct, shut the unit down and continue the

installation. If the voltage set point is low or high,

proceed as follows.

5. Using a combination of both the fine and coarse

voltage adjust potentiometers, readjust the out-

put voltage to 26.2V. Use caution during the

adjustment as the coarse potentiometer is very

sensitive and a small change will result in a

large voltage change.

6. If for some reason the voltage is mistakenly

turned too low and the voltmeter is again reading

battery voltage, slowly turn the voltage pots up

until the change in engine sound is heard.

Continue to adjust the voltage as described

above.

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Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

Generac®Power Systems, Inc. 11

Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

7. Once the output voltage has been set, shut the

unit down and allow to stop. Re-start the unit and

double check that the output voltage is set to

26.2V.

8. The unit can now be connected to the Lucent

Rectifier box.

3.4.6 ENGINE CONTROL, ALARM AND

SHUTDOWN P.C.B.

The control panel performs all the start/stop and

shutdown functions of the generator both in manual

and automatic modes (Figure 3.8).

Figure 3.8 — Control Panel

3.4.7 MANUAL OPERATION

Select manual on the Manual/Off/Auto switch. The

engine generator will crank and start. In the manual

mode, all alarm and shutdown functions are opera-

tional.

3.4.8 AUTOMATIC OPERATION

Select auto on the Manual/Off/Auto switch. In Auto

mode, a printed circuit board on the control panel

constantly monitors utility power source voltage.

Should that voltage drop below a preset level

(approximately 130V) and remain at such a low state

for a period of time, the engine will crank and start.

The time interval between utility fail and engine start,

(Delay on Start), can be field selected by changing the

position of a series of dip switches mounted on the

printed circuit board (Figure 3.9).

Figure 3.9 — Dip Switches

Each unit has been factory set with a 2 minute delay

on start as a standard. Depending on the battery

bank capacity and the load requirements, this time

may need to be adjusted.

When the utility voltage returns to a pre-set level

(approximately 153V) and remains at that high level,

the printed circuit board will keep the engine running

for a duration of approximately 5 minutes as a cool

down period. During automatic operation, all alarm

and shutdown functions are operational.

3.4.9 OFF POSITION

With the manual/off/auto switch in the off position.

The unit will remain stationary indefinitely.

3.4.10 REMOTE START

When the Auto/Off/Manual switch is in the Auto posi-

tion, application of 12 VDC to this contact point will

start the engine. The engine will continue to run as

long as 12 VDC is present.

3.4.11 REMOTE STOP

When the Auto/Off/Manual switch is in the Auto posi-

tion, application of 12 VDC to this contact point will

prevent the engine from starting and running.

As long as 12 VDC is maintained, the unit will run.

This contact point can also be used to remotely reset

alarm faults.

3.4.12 ALARMS

The control panel provides a number of status alarm

outputs which can be monitored by the operator. The

alarm signals from the control panel are located on a

12 position terminal block mounted on the left hand

side of the electrical enclosure (Figure 3.10).



Only Switch 1 ON = 2 min. delay

Only Switch 2 ON = 5 min. delay

Only Switch 3 ON = 10 min. delay

Only Switch 4 ON = 15 min. delay

All Switches OFF - 20 min. delay

12 Generac®Power Systems, Inc.

Figure 3.10 — 12 Position Terminal Block

NOTE:

PCB alarms marked with “*1” relay contact clo-

sure to ground. These contacts can be used to

switch DC voltage up to 30 VDC at 1 amp current.

3.4.13 START BATTERY VOLTAGE ALARM

This status signal indicates a low or overcharged

engine start battery. A low condition would be 10V

DC or lower, and an overload would be 14.5V DC or

higher. This alarm contact is normally open.

3.4.14 SWITCH NOT IN AUTO ALARM

This signal indicates that the Manual/Off/Auto switch

is not in the auto position and will not start in the

event of utility failure.

3.4.15 GENERAL FAILURE ALARM

This alarm signal indicates a forced shutdown due to

an engine fault (see Protective Shutdown Circuits,

Page 13). This alarm contact is normally open.

3.4.16 ENGINE RUN ALARM

This status signal indicates that the engine generator

is running and producing an output. This alarm con-

tact is normally open.

3.4.17 PROTECTIVE SHUTDOWN CIRCUITS

The printed circuit board on the control panel moni-

tors a number of inputs from the engine. Should a

problem in the operation of the engine arise, the cir-

cuit board will shutdown the unit to prevent cata-

strophic failure. The protection circuits include the

following:

• Low oil pressure shutdown - below 10 PSI

• High engine temperature shutdown - above 284º F

• Overspeed shutdown - above 3225 RPM

• Overcrank shutdown - allows the unit to attempt

to start in cycles for approximately 90 seconds

then locks out the starter.

3.4.18 UTILITY SOURCE VOLTAGE

The control panel requires a 240V input to monitor

the utility voltage.

• N2 - 240V AC

• N1 - 240V AC

• Ground Utility

3.4.19 BATTERY CHARGER

The control panel circuit board also contains an

engine start battery charger. This charger only oper-

ates while utility voltage is present. The charger pro-

vides a 1.5A maximum trickle charge. This charger is

only to keep the battery voltage floating while the

engine is stationary. During engine running periods,

the battery is charged via a winding in the stator

through a regulator at a maximum charge current of

7.5 A.

3.4.20 EXERCISE TIMER

In order to maintain system reliability and to perform

secondary functions such as engine lubrication and

battery charging, the unit is fitted with an electronic

programmable timer which, once programmed, will

exercise the generator at customer specific intervals

(Figure 3.11). For information on the programming of

the timer, see the separate Operating Instructions

supplied with each unit.

Generac strongly suggests that the unit be exercised

for a minimum of 30 minutes at least every seven

days.

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Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

Figure 3.11 — Exercise Timer

3.5 SETTING THE EXERCISER

3.5.1 DISPLAY

3.5.1.1 Current Time

The current time is selected with the time/alarm

push-button and is displayed in 12:00 hour format

on four 7-segment LED displays. The colon flashes at

a rate of 0.5 seconds on/off to indicate normal oper-

ation and display of the current time.

3.5.1.2 Exercise Time

The exercise time is selected with the time/alarm

push-button, the exercise time for the selected day is

displayed in a similar format to current time, except

that the colon does not flash but is always ON to indi-

cate the exercise time is being displayed.

To change the exercise day being displayed, use the

“day” push-button when in this mode.

3.5.1.3 PM (Time)

A single LED indicates PM (ON) time or AM (OFF).

3.5.1.4 Day of Week

The day of the week is indicated on the seven indi-

vidual day LEDs which represent Sunday through

Saturday.

3.5.1.5 Exercise ON

A single LED indicates that the relay output is

switched ON (exercise period).

3.5.1.6 Power Saving

To minimize the power consumption of the unit, it

will switch to a “dim” display mode if no keyboard

activity is noted for five minutes. The display bright-

ness is reduced to 50% of normal, but returns to

100% when any key is pressed.

3.5.1.7 Default Times

When the exerciser is first powered up, or if power is

removed from the unit and the battery backup has

expired, the default times will revert to:

Current Time 9:00 am

Current Day Sunday

Sun.-Sat. Exercise 9:00 am

Exercise Period 20 minutes

3.5.2 EXERCISE TIMES

The exercise times may be set individually on a day

by day basis. Exercise periods can overlap days, i.e.,

if a time is set for 11:55 pm Sunday for 20 minutes,

it will turn off at 12:15 am Monday.

The exercise period is globally programmable (com-

mon to all days), and is limited from 10-59 minutes.

3.6 PUSH BUTTONS

3.6.1 UP ARROW ↑↑

The up arrow is used to step the time forward in

increments of one second. This feature has auto-

acceleration, if the button is held on, the step incre-

ments will progressively increase to allow fast search-

ing of a required time. As soon as the button is

released, it will revert to normal speed.

3.6.2 DOWN ARROW ↓↓

The down arrow is used to step the time backward in

increments of one second. It also has auto-acceleration.

3.6.3 TIME (TIME/ALARM TOGGLE)

This toggles the display between normal current time

and exercise time. When in exercise time mode the

following happens:

1. The colon stops flashing to indicate exercise time

mode.

2. The Sun LED flashes to indicate it is initially

selected. The rate of flashing is either:

a. 50:50% on/off to indicate exercise time is

enabled.

b. 90:10% on/off to indicate exercise time is not

enabled.

3. All other days that have exercise time enabled to

ON are indicated by LED on. Days that are dis-

abled are set to LED off.



✧ ✧

✧ ✧ ✧ ✧ ✧



Generac®Power Systems, Inc. 13

Section 3 — Operation

Generac APS 6.0 DC Auxiliary Power System

9 V Battery

(not supplied)

If the display is inadvertently left in this mode with no

keyboard activity for more than five minutes, it will

revert back to normal (current time) display.

3.6.4 ON/OFF (ALARM SELECT TOGGLE)

When in exercise mode, this button will toggle the

exercise enable/disable status of the displayed day.

The rate of flashing will change as above.

3.6.5 DAY

This is used to step forward through the days in

either current time or exercise time.

1. In current time mode, the days will step through

seven states indicating Sunday to Saturday.

2. In exercise time mode, the days will step through

seven states indicating Sunday to Saturday and

will then display state eight - all days LEDs flash-

ing on/off together which represents the global

exercise time period. In this mode, the exercise

period may be changed using the up/down arrows

but the on time is limited to between 10 and 59

minutes.

3.7 PROGRAMMING EXAMPLES

3.7.1 EXAMPLE 1 - CHANGE TIME FROM

SUNDAY 9:00 AM TO WEDNESDAY

2:00 PM

1. Ensure the current time is displayed by flashing

colon. If colon is not flashing, then press and

release the “time” push-button once.

2. Press and hold the “up arrow” push-button until

the time steps to almost 2:00 pm, note the pm

LED will now be on.

3. Repeatedly press and release the “up arrow”

push-button until the exact time is obtained. If

you go past 2:00 pm, use the “down arrow” to

step back to the required time.

3.7.2 EXAMPLE 2 - SET EXERCISER ON FOR

14 MINUTES MON-FRI AT 10:00 AM

1. Press and release the “time” push-button once to

display the exercise time for Sunday, indicated by

a static (ON) colon and a flashing “Sun” LED. If

the colon is still flashing, repeat this step.

2. The “Sun” LED should be flashing on/off 50:50

approximately four times/second. This means

that the exercise time is correctly set to ON for

Sunday. If it is ON but briefly flashes OFF once

every two seconds, this indicates the exercise

time is set to OFF. If ON, press and release the

on/off push-button once to toggle this state to

OFF.

3. Press and release the “day” button to advance

from Sunday to Monday, indicated by the “Mon”

LED flashing.

4. Press and release the on/off push-button once to

toggle the exercise state from OFF to ON. This

will be indicated by the “Mon” LED now flashing

on/off 50:50 approximately 4 times/second.

5. Repeat steps 3 and 4 for Tuesday through

Saturday ensuring the correct on/off exercise sta-

tus for each day.

6. Press and release the “day” button once more and

the display will now show “0:20” which is the

exercise period in minutes. This is common for

all days and this display mode is indicated by all

seven “day” lights flashing simultaneously.

7. Use the up/down arrows to change the exercise

period to 14 minutes.

8. Press and release the “time” push-button once to

return the display mode to the current time.

4.1 GENERAL MAINTENANCE

4.1.1 25 HOUR BREAK IN PERIOD

The first 25 hours of operation is the break-in period

for the generator. Properly breaking in the generator

is essential to reducing oil consumption and enhanc-

ing engine performance. During this 25-hour break

in period, follow this procedure:

• Run the unit at varying electrical loads, to help seat

engine piston rings properly.

• Check engine oil level frequently during the break-

in period. Add oil if needed. It is normal for the

generator engine to consume more oil than is nor-

mal until the piston rings have properly seated.

• After operating the unit for 25 hours, complete the

tasks recommended under “25-Hour Check Up.”

4.1.2 25 HOUR CHECK UP

After the 25-hour break-in period, contact an author-

ized service facility for the following maintenance:

• Change engine crankcase oil and oil filter.

• Inspect cooling and ventilation openings.

• Check engine carburetor adjustments.

• Check engine ignition system.

• Inspect entire electrical system.

• Inspect the engine exhaust system.

4.1.3 ATTENTION REQUIRED AFTER

SUBMERSION

If the generator has been submerged in water, it must

NOT be started or operated. Following any submer-

sion in water, have an authorized Generac Service

Facility thoroughly clean and dry the generator.



Section 4 — Maintenance

Generac APS 6.0 DC Auxiliary Power System

14 Generac®Power Systems, Inc.

4.1.4 EFFECTS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible.

Protect the unit against excessive dust, dirt, corrosive

vapors, etc. Permitting dirt and moisture to accumu-

late on generator windings will have an adverse effect

on the insulation resistance of those windings.

When moisture is allowed to remain in contact with

windings, some of the moisture will be retained in

voids and cracks in the insulation. This causes a

reduced insulation resistance and will eventually

cause problems. Dirt will make the problem worse,

since dirt tends to hold moisture in contact with

windings. Salt (as from sea air) will also worsen the

problem since it tends to absorb moisture from the

air. Salt and moisture, when combined, form a good

electrical conductor.

4.1.5 ENGINE OIL RECOMMENDATIONS

Use a high quality detergent oil that meets or exceeds

API Service SF, SF/CC or SF/CD requirements for

gasoline engines.

The PRIMARY recommended oil is a synthetic oil

such as MOBILE Formula 5W-30. Synthetic oil pro-

motes easier starts in cold weather and provides

maximum protection in hot weather.

Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in an engine fail-

ure. The engine crankcase must be properly

filled with the recommended oil.

4.1.6 BATTERY

All lead-acid storage batteries will discharge when

not in use. The generator battery should be inspect-

ed as follows:

4.1.7 EVERY SIX MONTHS

Have battery state of charge and condition checked.

This should be done with automotive type battery

hydrometer.

Inspect battery posts and cables for tightness, corro-

sion. Clean and/or tighten as needed.

Also check battery fluid level, and, if necessary, fill

with DISTILLED WATER ONLY. DO NOT USE TAP

WATER IN BATTERY.

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

nel away from batteries.

When replacing the battery, use the following type of

battery: Group 26/26R 12-volt battery with a rating of

525 cold-cranking amps minimum at -17.8º C (0º F).

When using a maintenance-free battery, it is not nec-

essary to check the specific gravity or electrolyte level.

Have these procedures performed at the intervals

specified in the “Service Schedule.” A negative ground

system is used. Battery connections are shown on the

wiring diagrams. Make sure the battery is correctly

connected and terminals are tight. Observe battery

polarity when connecting the battery to the generator

set.

Do not dispose of the battery in a fire. The

battery is capable of exploding.

A battery presents a risk of electrical shock

and high short circuit current. The following

precautions are to be observed when working

on batteries:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery; and

• Disconnect charging source prior to connecting or dis-

connecting battery terminals.

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive.

The following procedures 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, immediately

flush thoroughly with water and seek medical

attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) or water. The bicar-

bonate 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

following procedures are to be followed:

DANGER

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Section 4 — Maintenance

Generac APS 6.0 DC Auxiliary Power System

Generac®Power Systems, Inc. 15

16 Generac®Power Systems, Inc.

• DO NOT SMOKE when near the battery;

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

• Discharge static electricity from your body before

touching the battery by first touching a grounded

metal surface.

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

you attach the cables and cause an explosion.

4.2 ENGINE PROTECTIVE DEVICES

Unlike an automobile engine, the generator may have

to run for long periods of time with no operator in the

vicinity to monitor engine conditions. For that rea-

son, the engine is equipped with several devices

which protect it against such potentially damaging

conditions as (a) low oil pressure and (b) high tem-

perature.

4.2.1 AUTOMATIC LOW OIL PRESSURE

SHUTDOWN

The engine is equipped with a normally closed (N.C.)

contacts oil pressure switch (Figure 18). Engine oil

pressure holds the switch open during cranking and

operating. Should oil pressure drop below about 10

psi, switch contacts close and the engine shuts down.

4.2.2 HIGH TEMPERATURE SWITCH

Switch (Figure 4.1) contacts close if temperature

should exceed about 285 F (140 C) to initiate an

engine shutdown.

Figure 4.1 — Engine Protective Devices

4.2.3 CHECKING ENGINE OIL LEVEL

To check the engine oil level, proceed as follows

(Figure 4.2):

1. Remove dipstick and wipe it dry with a clean

cloth.

2. Install and tighten dipstick cap, then remove

again. Oil level should be at the dipstick “full”

mark. If necessary add oil to the “full” mark only.

DO NOT FILL ABOVE THE “FULL” MARK.

3. Install and tighten the dipstick.

Figure 4.2 — Oil Dipstick and Filler Tube

Never operate the engine with oil level below

the ADD mark on dipstick. Doing this could

damage the engine.

4.3 CHANGE ENGINE OIL

Change engine oil after the first 25 hours of opera-

tion. Thereafter, change oil every 100 operating

hours. Change oil more frequently if operating con-

sistently under heavy load or at high ambient tem-

peratures. To change oil, proceed as follows:

1. Run engine until it is thoroughly warmed up, then

shut OFF the engine.

2. Immediately after the engine shuts OFF, pull OIL

DRAIN HOSE (Figure 4.2) free of its retaining

clip. Remove CAP from hose and drain oil into

suitable container.

3 When oil has drained, install cap onto end of oil

drain hose. Retain hose in clip.

4. Refill with proper recommended oil (see Page 15).



Section 4 — Maintenance

Generac APS 6.0 DC Auxiliary Power System

Oil Fill

Oil Level

Dipstick

Oil Drain

Hose

Oil Filter

Generac®Power Systems, Inc. 17

4.4 CHANGE OIL FILTER

Change engine oil filter every 200 operating hours (or

every second oil change), as follows:

1. Remove old oil filter by turning counterclock-

wise(Figure 4.4).

2. Apply a light coating of clean engine oil to gasket

of new filter.

3. Screw new filter on by hand until its gasket con-

tacts the oil filter adapter lightly. Then, tighten fil-

ter an additional 3/4 to one turn.

4. Start engine and check for leaks.

Figure 4.4 — Engine Oil Filter

4.5 SERVICE FOAM PRE-CLEANER

AND ENGINE AIR CLEANER

• Clean and oil the FOAM PRE-CLEANER (Figure

4.5) every three months or every 100 operating

hours, whichever comes first. Service more fre-

quently if operating under extremely dusty or dirty

conditions.

• Annually, or every 250 hours of operation, clean

the AIR FILTER ELEMENT. Replace the air filter

element every 500 hours or sooner if extremely

dirty.

1. To remove the foam pre-cleaner and air filter ele-

ment, loosen and remove the plastic wing bolt

and the air box cover. Slide the foam pre-clean-

er off the air filter element.

2. Replace foam pre-cleaner or wash it in kerosene

or in liquid detergent and water. Wrap foam pre-

cleaner in cloth and squeeze dry.

3. Saturate foam pre-cleaner in engine oil. Squeeze

to remove excess oil.

4. Clean the air filter element by blowing air from

the inside, out.

5. Return the air filter and the foam pre-cleaner

into the air box and secure with retaining nut.

6. Replace air box cover and secure plastic wing

bolt.

Figure 4.5 — Engine Air Cleaner Assembly

DO NOT oil the PAPER FILTER. DO NOT use

any petroleum solvents, such as kerosene, to

clean the filter. DO NOT use air pressure to

clean or dry paper filter.

4.6 COMPLETE ENGINE TUNE UP

• Annually, an authorized service technician should

tune up the engine. This annual tune up should

include the following tasks:

• Remove engine air cleaner and inspect. Clean or

replace as necessary.

• Check engine oil level.

• Clean the engine and generator.

• Check engine intake manifold for damaged gas-

kets.

• Inspect engine governor springs for damage.

Replace any damaged components.

• Check governed speed and adjust governor, if nec-

essary.

• Check engine for evidence of oil leaks.

• Check for proper ignition spark using an appro-

priate engine spark tester.

• Check valves for lash adjustment.

• Clean spark plugs, inspect and reset plug gaps.

Replace plugs if necessary.

• Check exhaust muffler and engine exhaust mani-

fold for restrictions, damage.

• Run engine and check operation. Adjust load block

if necessary.

4.7 INSPECT COOLING SYSTEM OF

GENERATOR

At least quarterly, inspect air inlet and outlet open-

ings in the generator compartment. All air openings

must be clean and unobstructed.

AIR B

RETAININ

AIR FILTER

AM PRE

LEANE

PLASTIC

AIR B

WING

RETAININ

Section 4 — Maintenance

Generac APS 6.0 DC Auxiliary Power System

MAN

B = EN

INE

NTR

LLER

REM

TE ALARM B

ENERAL FAIL

RE ALAR

INE R

N ALAR

W F

EL ALAR

TILIT

RD -

TILIT

REM

TART +12

REM

P +12

TART BATT. V

LTA

E ALAR

WIT

H N

T IN A

ALAR

TB2

TB3 = TERMINAL STRIP

POWER CONNECTION

T =

RRENT TRAN

RME

F1 = 1

A F

USE

D2 = DIODE

IGNITIO

B1 = 1

IT BREAKE

B2 =

IT BREAKE

DB1 = DI

DE BRID

DB2 = DI

DE BRID

= HI

H TEMP

WIT

HRM = H

R METE

TARTER

NTA

TB1 = TERMINAL BL

OCK

M =

TARTER M

TILITY INP

TEP D

WN TRAN

RME

= RE

HM 2

WAT

P = L

IL PRE

SSU

WIT

TB2 = ALARM

NN. TERMINAL

TRI

R =

TARTER

NTA

R RELA

R2 = RE

R 1

HM 2

WAT

B1 =

N BL

OCK

B2 =

N BL

OCK

IM1 = I

NITI

N MA

NET

- #1

IM2 = I

NITI

N MA

NET

- #2

P1 =

PARK PL

- #1

P2 =

PARK PL

- #2

W =

TART

WIT

= F

LEN

CUS

MER P

WER TAKE

APA

FAN

TRAN

S-

RME

277

FAN

TB1

NTR

L PANE

HRM

277

BATT.

HAR

M K III PR

RAMMABL

EXER

TIME

DAY

18 Generac®Power Systems, Inc.

Section 5 — Electrical Data

Generac APS 6.0 DC Auxiliary Power System

Wiring Diagram – Drawing No. 0E3498-A

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Generac Power Systems 00847-1 Operating & Installation Manual

Brand: Generac Power Systems

Model: 00847-1

Category: Power generators

Type: Operating & Installation Manual

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Generac Power Systems 00847-1 Operating & Installation Manual

Generac Power Systems 00847-1 Operating & Installation Manual

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